Siemens SIMOTICS GP series, SIMOTICS DP series, SIMOTICS SD series Operating Instructions Manual
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SIMOTICS GP, SD, DP
Low-Voltage Motors
Standard motors SH 63 ... 355
Operating Instructions
12/2018
A5E38483075A
Introduction
1
Safety information
2
Description
3
Preparing for use
4
Assembly
5
Electrical connection
6
Commissioning
7
Operation
8
Maintenance
9
Spare parts
10
Disposal
11
Service & support
A
Technical data
B
Quality documents
C
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Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E38483075A
Ⓟ
Copyright © Siemens AG 2008 - 2018.
All rights reserved
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
may
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.
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Legal information
Warning notice system
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.
indicates that death or severe personal injury
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.
result if proper precautions are not taken.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
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.
Proper use of Siemens products
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
maintenance are required to ensure that the products operate safely and without any problems. The permissible
Trademarks
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.
Disclaimer of Liability
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.
12/2018 Subject to change
Page 5
Table of contents
1 Introduction ............................................................................................................................................. 9
1.1 About these instructions............................................................................................................ 9
1.2 Compiling personal documents ................................................................................................ 9
2 Safety information ................................................................................................................................. 11
2.1 Information for those responsible for the plant or system ....................................................... 11
2.2 The 5 safety rules ................................................................................................................... 11
2.3 Qualified personnel ................................................................................................................. 12
2.4 Safe handling .......................................................................................................................... 12
2.5 Electrostatic sensitive devices ................................................................................................ 14
2.6 Interference immunity ............................................................................................................. 15
2.7 Influence on the line power supply through a strongly irregular torque .................................. 15
2.8 Interference voltages when operating the converter .............................................................. 15
2.9 Special designs and construction versions ............................................................................. 15
3 Description ............................................................................................................................................ 17
3.1 Area of application .................................................................................................................. 17
3.2 Rating plates ........................................................................................................................... 19
3.3 Installation ............................................................................................................................... 20
3.3.1 Cooling and ventilation............................................................................................................ 21
3.3.1.1 General ................................................................................................................................... 21
3.3.1.2 Machines with a fan ................................................................................................................ 21
3.3.1.3 Machines without a fan (optional) ........................................................................................... 23
3.3.2 Bearings .................................................................................................................................. 23
3.3.3 Balancing ................................................................................................................................ 24
3.3.4 Types of construction/method of installation .......................................................................... 24
3.3.5 Degree of protection ............................................................................................................... 25
3.3.6 Environmental conditions ........................................................................................................ 25
3.3.7 Optional built-on and built-in accessories ............................................................................... 26
3.3.8 Terminal box ........................................................................................................................... 26
3.3.9 Paint finish .............................................................................................................................. 26
4 Preparing for use .................................................................................................................................. 27
4.1 Safety-related aspects to consider when configuring the plant .............................................. 27
4.2 Observing the operating mode ............................................................................................... 27
4.3 Machines without final paint coating ....................................................................................... 27
4.4 Delivery ................................................................................................................................... 28
4.5 Transport and storage............................................................................................................. 28
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Table of contents
4.5.1 Storage ................................................................................................................................... 30
4.5.2 Securing the rotor................................................................................................................... 32
4.5.3 Commissioning after storage ................................................................................................. 34
4.5.3.1 Insulation resistance and polarization index .......................................................................... 34
4.5.3.2 Lubricating the rolling bearings .............................................................................................. 34
4.5.3.3 Regreasing rolling bearings after storage periods of up to two years ................................... 34
4.5.3.4 Releasing the rotor shipping brace before commissioning .................................................... 34
4.6 Ensure adequate cooling ....................................................................................................... 35
4.7 Interlock circuit for anti-condensation heating ....................................................................... 37
4.8 Noise emission ....................................................................................................................... 37
4.9 Voltage and frequency fluctuations during line operation ...................................................... 37
4.10 Rotational speed limit values ................................................................................................. 38
4.11 System-inherent frequencies ................................................................................................. 38
4.12 Electromagnetic compatibility ................................................................................................ 39
4.13 Converter operation ............................................................................................................... 40
4.13.1 Parameterizing the converter ................................................................................................. 40
4.13.2 Converter input voltage .......................................................................................................... 40
4.13.3
Reducing bearing currents during operation with converter (low voltage) ............................ 41
4.13.4 Insulated bearings when operated with a converter .............................................................. 42
4.13.5 Tandem operation .................................................................................................................. 43
4.13.6 Speed limits for converter operation ...................................................................................... 44
5 Assembly .............................................................................................................................................. 45
5.1 Preparing for installation ........................................................................................................ 45
5.1.1 Requirements for installation ................................................................................................. 45
5.1.2 Insulation resistance .............................................................................................................. 46
5.1.2.1 Insulation resistance and polarization index .......................................................................... 46
5.1.2.2 Testing the insulation resistance and polarization index ....................................................... 47
5.2 Installing the machine ............................................................................................................ 49
5.2.1 Preparing the assembly area ................................................................................................. 49
5.2.2 Safety instructions for installation .......................................................................................... 50
5.2.3 Lift the machine to where it will be mounted and position it .................................................. 50
5.2.4 Balancing ............................................................................................................................... 51
5.2.4.1 Mounting and withdrawing output transmission elements ..................................................... 52
5.2.5 Machines with type of construction IM B15, IM B9, IM V8 and IM V9 ................................... 52
5.2.6 Foot mounting ........................................................................................................................ 53
5.3 Aligning and fixing the machine ............................................................................................. 53
5.3.1 Measures for alignment and mounting .................................................................................. 54
5.3.2 Flatness of the supporting surfaces for conventional motors ................................................ 55
5.3.3 Machine frame mounting feet (special design) ...................................................................... 55
5.4 Installing the machine ............................................................................................................ 55
5.4.1 Preconditions for smooth, vibration-free operation ................................................................ 55
5.4.2 Aligning the machine to the driven machine and mounting ................................................... 55
5.4.2.1 Selecting bolts ........................................................................................................................ 55
5.4.2.2 Horizontal types of construction with mounting feet .............................................................. 56
5.4.2.3 Horizontal types of construction with flange .......................................................................... 56
5.4.2.4 Vertical types of construction with flange ............................................................................... 57
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5.4.3 Removing the rotor shipping brace ......................................................................................... 57
5.4.4 Mounting the output elements ................................................................................................ 58
5.4.5 Axial and radial forces............................................................................................................. 59
6 Electrical connection ............................................................................................................................. 61
6.1 Connected parts can become loose ....................................................................................... 62
6.2 Connecting the machine ......................................................................................................... 62
6.2.1 Selecting cables ...................................................................................................................... 62
6.2.2 Terminal box ........................................................................................................................... 63
6.2.2.1 Terminal marking .................................................................................................................... 63
6.2.2.2 Circuit diagram inside the terminal box cover ......................................................................... 64
6.2.2.3 Direction of rotation ................................................................................................................. 64
6.2.2.4 Cable entry .............................................................................................................................. 64
6.2.2.5 Versions .................................................................................................................................. 65
6.2.2.6 Protruding connection cables ................................................................................................. 65
6.2.2.7 Connecting protruding cables ................................................................................................. 66
6.2.2.8 Connection with/without cable lugs ......................................................................................... 66
6.2.2.9 Minimum air clearances .......................................................................................................... 66
6.2.3 Cable glands ........................................................................................................................... 67
6.2.3.1 Mounting position of sheet metal nuts in screw-type connections ......................................... 67
6.3 Tightening torques .................................................................................................................. 68
6.3.1 Cable entries, sealing plugs and thread adapters .................................................................. 68
6.4 Connecting the grounding conductor ......................................................................................
68
6.4.1 Minimum surface area of grounding conductor ...................................................................... 69
6.4.2 Grounding connection type ..................................................................................................... 69
6.5 Connecting the temperature sensor/anti-condensation heater .............................................. 70
6.5.1 Connecting optional integrated devices and equipment ......................................................... 70
6.6 Conductor connection ............................................................................................................. 71
6.6.1 Type of conductor connection ................................................................................................. 71
6.6.2 Connecting aluminum conductors .......................................................................................... 72
6.7 Connecting converters ............................................................................................................ 72
6.8 Final checks ............................................................................................................................ 73
7 Commissioning ..................................................................................................................................... 75
7.1 Measures before commissioning ............................................................................................ 75
7.1.1 Checks to be carried out prior to commissioning .................................................................... 75
7.1.2 Mechanical checks .................................................................................................................. 76
7.1.3 Insulation resistance and polarization index ........................................................................... 77
7.1.4 Testing the insulation resistance and polarization index ........................................................ 78
7.1.5 Testing the cooling of the machine ......................................................................................... 80
7.1.6 Commissioning an external fan .............................................................................................. 80
7.1.7 Further documents .................................................................................................................. 81
7.1.8 Setpoint values for monitoring the bearing temperature ......................................................... 82
7.2 Switching on ............................................................................................................................ 82
7.2.1 Measures required for commissioning and test operation ...................................................... 82
8 Operation .............................................................................................................................................. 85
8.1 Safety instructions for operation ............................................................................................. 85
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Table of contents
8.1.1 Safety instructions relating to ventilation and cooling ............................................................ 88
8.1.1.1 Safety instruction for forced ventilation (option) ..................................................................... 88
8.1.1.2 Safety instructions when operating machines with fan .......................................................... 89
8.1.1.3 Machines with fan for the textile industry ............................................................................... 89
8.1.2 Switching on with the anti-condensation heating active ........................................................ 89
8.2 Switching on the machine ...................................................................................................... 90
8.3 Switch off the external fan ...................................................................................................... 90
8.4 Switching on again after an emergency switching-off............................................................ 90
8.5 Stoppages .............................................................................................................................. 90
8.5.1 Avoidance of damage to rolling bearings during stoppages .................................................. 92
8.5.2 Decommissioning the machine .............................................................................................. 92
8.5.3 Re-commissioning the machine ............................................................................................. 92
8.6 faults ....................................................................................................................................... 92
8.6.1 Inspections in the event of faults............................................................................................ 92
8.6.2 Electrical faults ....................................................................................................................... 93
8.6.3 Mechanical faults ................................................................................................................... 94
8.6.4 Rolling bearing faults ............................................................................................................. 94
Faults at the external fan ....................................................................................................... 95
8.6.5
8.7 Deactivating ........................................................................................................................... 95
9 Maintenance ......................................................................................................................................... 97
9.1 Preparation and notes ............................................................................................................ 97
9.1.1 North American market (optional) .......................................................................................... 97
9.1.2 Touch up any damaged paintwork ......................................................................................... 98
9.2 Inspection and maintenance .................................................................................................. 98
9.2.1 Safety instructions for inspection and maintenance .............................................................. 98
9.2.2 Inspections in the event of faults............................................................................................ 99
9.2.3 First inspection after installation or repair ............................................................................ 100
9.2.4 General inspection ............................................................................................................... 100
9.2.5 Assessing the rolling bearings ............................................................................................. 101
9.2.6 Maintenance intervals .......................................................................................................... 101
9.2.7 Re-greasing .......................................................................................................................... 102
9.2.8 Cleaning ............................................................................................................................... 103
9.2.9 Cleaning the fan cover of machines for the textile industry ................................................. 103
9.2.10 Drain condensate ................................................................................................................. 104
9.2.11 Insulation resistance and polarization index ........................................................................ 104
9.2.12 Servicing the external fan .................................................................................................... 105
9.3 Corrective maintenance ....................................................................................................... 105
9.3.1 Rolling bearings ...................................................................................................................
106
9.3.1.1 Bearing bushes .................................................................................................................... 108
9.3.1.2 Installing rolling bearings ..................................................................................................... 108
9.3.2 Mounting dimension "x" ....................................................................................................... 110
9.3.3 Fan ....................................................................................................................................... 110
9.3.3.1 Metal fan disassembly ......................................................................................................... 111
9.3.3.2 Mounting fans....................................................................................................................... 112
9.3.3.3 Mounting the fan cover ........................................................................................................ 113
9.3.4 Canopy; mounting a rotary pulse encoder under the canopy .............................................. 113
9.3.5 Screw lock washers ............................................................................................................. 113
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9.3.6 Links ...................................................................................................................................... 114
9.3.7 Reassembly: Miscellaneous information .............................................................................. 114
9.3.8 Optional add-on units ............................................................................................................ 114
9.3.8.1 Mounting a brake .................................................................................................................. 115
9.3.9 O-ring seal ............................................................................................................................ 115
10 Spare parts ......................................................................................................................................... 117
10.1 Parts order ............................................................................................................................ 117
10.2 Data matrix code on the machine ......................................................................................... 117
10.3 Ordering data ........................................................................................................................ 117
10.4 Ordering spare parts via the Internet .................................................................................... 118
10.5 Replacing rolling bearings .................................................................................................... 118
10.6 Insulated rolling bearings ...................................................................................................... 118
10.7 Parts groups definition .......................................................................................................... 118
10.8 Ordering example ................................................................................................................. 119
10.9 Machine parts ....................................................................................................................... 120
10.10 Standardized parts ................................................................................................................ 122
10.11 Exploded drawings ................................................................................................................ 123
10.11.1 1LA,1LP,1PP6 SH63 ... 90 ................................................................................................... 123
10.11.2 1LA,1LP,1PP6 SH100 ... 160 ............................................................................................... 124
10.11.3 1LA5180 ... 225 ..................................................................................................................... 125
10.11.4 1LE1,1FP1 SH80 ... 160 aluminum ...................................................................................... 126
10.11.5 1LE1 SH180 ... 200 aluminum .............................................................................................. 127
10.11.6 1LE1 SH71 ... 90 cast iron .................................................................................................... 128
10.11.7 1LE1, 1FP1 SH100 ... 200 cast iron .....................................................................................
129
10.11.8 1LE1 SH225 ... 315 cast iron ................................................................................................ 130
10.11.9 1LG4/6 SH180 ... 315 ........................................................................................................... 131
10.11.10 Terminal box gk330, gt320, gk430, gt420 ............................................................................ 132
10.11.11 Terminal box gk431, gt421, gt520, gt540 ............................................................................. 133
10.11.12 Terminal box 1LG4/6 gt620, gt640, gt791 ............................................................................ 134
11 Disposal .............................................................................................................................................. 135
11.1 Country-specific legislation - LV machines ........................................................................... 135
11.2 RoHS - restricting the use of certain hazardous substances ................................................ 135
11.3 Information according to Article 33 of the REACH regulation .............................................. 135
11.4 Preparing for disassembly .................................................................................................... 136
11.5 Dismantling the machine ...................................................................................................... 136
11.6 Disposal of components........................................................................................................ 136
A Service & support ................................................................................................................................ 139
A.1 Siemens Industry Online Support ......................................................................................... 139
A.2 Further documents ................................................................................................................ 140
B Technical data .................................................................................................................................... 141
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Table of contents
B.1 Tightening torques ............................................................................................................... 141
B.1.1 Tightening torques for screw and bolt connections ............................................................. 141
B.1.2 Terminal board and grounding ............................................................................................. 142
B.1.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers ..................... 142
B.1.4 Additional connecting terminals for monitoring equipment and anti-condensation
heating ................................................................................................................................. 142
C Quality documents ............................................................................................................................... 143
C.1 Quality documents SIMOTICS in SIOS ............................................................................... 143
Index ................................................................................................................................................... 145
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1
Note
The note provides you with additional information about the product itself, handling the
product
1.1 About these instructions
These instructions describe the machine and explain how to handle it, from initial delivery to
final disposal of the equipment. Keep these instructions for later use.
Read these operating instructions before you handle the machine and follow the instructions
to become familiar with its design and operating principles and thus ensure safe, problemfree machine operation and long service life.
Safety instructions and handling-related warning notes are provided in these instructions.
When carrying out any activity at or with the machine, carefully comply with all of these notes
for your own safety, to protect other people and to avoid material damage.
Please contact the Service Center if you have any suggestions on how to improve this
document.
Text format features
You can find the following text format features in these instructions:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
in the order given.
● Lists are formatted as bulleted lists.
– Lists on the second level are hyphenated.
- and the relevant documentation.
1.2 Compiling personal documents
On the Internet pages in Industry Online Support you have the possibility of compiling
personal documents using the function Documentation
(https://support.industry.siemens.com/My/ww/en/documentation
Using the "Documentation" function, from Product Support manuals, you can compile your
own "Documentation". However, you can also include other Product Support content such as
FAQs or characteristics in the documentation that you compile.
)
In the "Documentation" function, you have the option of creating your own compiled
documents in your own structure and managing them. You can delete or shift individual
chapters or topics. Further, using the note function you can import your own content. The
compiled "documentation" can be exported as PDF, for example.
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Introduction
1.2 Compiling personal documents
Using the "Documentation" function, you can efficiently compile your own plant or system
documentation. The "Documentation" compiled in a specific language can also be
automatically exported in one of the other available languages.
The full functionality is only available for registered users.
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2
Note
Use the services and support provided by the local service center for planning,
installation, commissioning and service work.
2.1 Information for those responsible for the plant or system
This electric machine has been designed and built in accordance with the specifications
contained in Directive 2014/35/EU ("Low-Voltage Directive") and is intended for use in
industrial plants. Please observe the country-specific regulations when using the electric
machine outside the European Community. Follow the local and industry-specific safety and
setup regulations.
The persons responsible for the plant must ensure the following:
● Planning and configuration work and all work carried out on and with the machine is only
to be done by qualified personnel.
● The operating instructions must always be available for all work.
● The technical data as well as the specifications relating to the permissible installation,
connection, ambient and operating conditions are taken into account at all times.
● The specific setup and safety regulations as well as regulations on the use of personal
protective equipment are observed.
2.2 The 5 safety rules
For your own personal safety and to prevent material damage when carrying out any work,
always observe the safety-relevant instructions and the following five safety rules according
to EN 50110-1 "Working in a voltage-free state". Apply the five safety rules in the sequence
stated before starting work.
5 safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.
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Safety information
2.3 Qualified personnel
2.3 Qualified personnel
All work at the machine must be carried out by qualified personnel only. For the purpose of
this documentation, qualified personnel is taken to mean people who fulfill the following
requirements:
● Through appropriate training and experience, they are able to recognize and avoid risks
and potential dangers in their particular field of activity.
● They have been instructed to carry out work on the machine by the appropriate person
responsible.
2.4 Safe handling
Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
● General safety regulations applicable in the country where the machine is deployed.
● Manufacturer-specific and application-specific regulations
● Special agreements made with the operator
● Separate safety instructions supplied with the machine
● Safety symbols and instructions on the machine and its packaging
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum clearance and creepage distances may be
violated when coming close to live parts. Touching or coming close to them can result in
death, serious injury or material damage.
● Ensure that all live parts are suitably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer
guaranteed if covers are removed. Touching rotating parts can result in death, serious injury
or material damage.
● Ensure that all rotating parts are reliably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
● Only remove covers when the rotating parts have come to a complete standstill.
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Safety information
2.4 Safe handling
Risk of burns due to hot surfaces
Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
● Never touch machine parts during operation.
● Allow the machine to cool before starting work on the machine.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Health hazard due to chemical substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk.
● Observe the product information provided by the manufacturer.
Flammable substances hazard
Chemical substances required for the setup, operation and maintenance of machines may
be flammable. These substances can ignite if handled incorrectly. They can cause burns and
property damage.
Noise emissions
● Observe the product information provided by the manufacturer.
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
● Ensure that nobody is in the area of increased noise emissions during machine operation.
● Take steps to reduce noise so that the machine can be operated safely within your
system. The following measures may help to reduce noise.
– Covers
– Noise insulation
– Hearing protection measures
Prevention of hearing damage
If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
Observe the permissible sound pressure level in accordance with ISO 1680. The maximum
permissible sound pressure level is 70 dB (A).
Electrical power equipment generate electromagnetic fields during operation. Potentially
lethal malfunctions can occur in medical implants, e.g. pacemakers, in the vicinity of
electrical power equipment. Data may be lost on magnetic or electronic data carriers.
● Protect the personnel working in the plant by taking appropriate measures, such as
erecting identifying markings, safety barriers and warning signs and giving safety talks.
● Observe the nationally applicable health and safety regulations.
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Safety information
a = conductive floor surface
b = ESD table
c = ESD shoes
d = ESD overall
e = ESD wristband
f = cabinet ground connection
2.5 Electrostatic sensitive devices
● It is forbidden for people with pacemakers to be close to the machine.
● Do not carry any magnetic or electronic data media.
2.5 Electrostatic sensitive devices
Material damage due to electrostatic discharge
Electronic modules contain components that can be destroyed by electrostatic discharge.
These components can be damaged or destroyed if they are not handled correctly. To
protect equipment against damage, follow the instructions given below.
● Only touch electronic modules if you absolutely have to work on them.
● The body of the person concerned must have been electrostatically discharged and
grounded immediately before any electronic modules are touched.
● Electronic modules should not be brought into contact with electrically insulating
materials, such as:
– Plastic film
– Plastic parts
– Insulating table supports
– Clothing made of synthetic fibers
● Always place electrostatic sensitive devices on conductive bases.
● Always pack, store and transport electronic modules or components in conductive
packaging, such as:
– Metallized plastic or metal containers
– Conductive foam material
– Domestic aluminum foil
The necessary ESD protective measures for electrostatic sensitive devices are illustrated
once again in the following drawings:
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Safety information
Note
Before carry out any work on the machine, determine the machine version.
If there are any deviations or uncertainty, contact the manufacturer, specifying the type
designation and serial number (see th
2.6 Interference immunity
Electromagnetic compatibility
This machine is designed in accordance with IEC/EN 60034, and when used as prescribed it
satisfies the requirements of European Directive 2014/30/EU on Electromagnetic
Compatibility.
2.6 Interference immunity
By selecting suitable signal cables and evaluation units, ensure that the interference
immunity of the machine is not diminished.
2.7 Influence on the line power supply through a strongly irregular
torque
A strongly irregular torque, for example with the drive of a reciprocating motor, forces a nonsinusoidal motor current. The emerging harmonics can have an impermissible influence on
the line power supply via the connection lines.
2.8 Interference voltages when operating the converter
Interference voltages when operating the converter
When a converter is in operation, the emitted interference varies in strength depending on
the converter (manufacturer, type, interference suppression measures undertaken). On
machines with integrated sensors (e.g. PTC thermistors), interference voltages caused by
the converter may occur on the sensor lead. This can cause faults which can result in
eventual or immediate death, serious injury or material damage.
● Comply with the EMC information provided by the manufacturer of the converter. This is
how you prevent the limit values stipulated by IEC/EN 61000-6-3 for the drive system
(consisting of the machine and converter) from being exceeded.
● You must put appropriate EMC measures in place.
2.9 Special designs and construction versions
e rating plate), or contact the Service Center.
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Safety information
2.9 Special designs and construction versions
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3
Note
Machine directive
Low
with the current Machinery Directive. Commissioning is prohibited until it has been absolutely
identified that the end product is in conformance with this Directive. Please observe the
EN
Note
IE2 marking
Since January 1, 2017, according to REGULATION (EC) No. 640/2009, low
with power ratings above 0.75
This is mandatory within the European Economic Area (EEA). Customers ar
responsible in ensuring the correct use.
When connecting the machine to a converter, carefully observe the rules and notes in
Chapter "Connecting a converter."
3.1 Area of application
The rotating electrical motors of this series are used as industrial drives. They are designed
for a wide range of drive applications both for line operation as well as in conjunction with
frequency converters.
They are characterized by their high power density, extreme robustness, long service life
and outstanding reliability.
Intended use of the machines
These machines are intended for industrial installations. They comply with the harmonized
standards of the series EN / IEC 60034 (VDE 0530). It is prohibited to use these motors in
hazardous zones if the marking on the motor rating plate does not explicitly permit line or
converter operation. If other/more wide-ranging demands (e.g. protection so that they cannot
be touched by children) are made in special cases – i.e. use in non-industrial installations –
these conditions must be ensured by the customer.
-voltage motors are components designed for installation in machines in accordance
/ IEC 60204-1 standard.
Use of machines without CE marking
Machines without CE marking are intended for operation outside the European Economic
Area (EEA). Do not use any machines without a CE marking in the EEA!
-voltage motors
kW up to 375 kW – and with efficiency IE2 – have this label.
e solely
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Description
WARNING
Risk of explosion
Never
3.1 Area of application
Use of machines without EAC marking
EAC machines are appropriately marked on the rating plate, and are intended for operation
within the Eurasian customs union.
Within the Eurasian customs union, do not use machines without the appropriate EAC
marking.
This machine is not designed for use in hazardous areas. An explosion can occur if the
machine is operated in these areas. This can result in death, serious injury or material
damage.
•
operate this machine in hazardous areas.
Operating a machine with a converter
Implement all machines of the overall machine-converter system according to UL-File
E227215 assuming that the machines are only to be operated with a converter and are
supplied with UL certificate.
The company operating the equipment is responsible for implementing this in the actual
application.
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Page 21
Description
Item
Description
Item
Description
General data
Electrical data
2
Machine type
33
Rated voltage V
3
Serial number (incl. date of manufacture YY.MM )
34
Winding connections
4
Standards
35
Frequency Hz
5
Additional details (optional)
36
Rated power kW
6
Customer data (optional)
37
Rated current A
7
Country of origin
38
Power factor cosφ
8
Production location
39
Rated speed rpm
9
Identification number of testing agency (optional)
40
Efficiency class
10
Regulations (optional)
41
Efficiency
49
Company logo
42
Torque Nm (optional)
52
Marine regulation
43
Bemessungsleistung hp (optional)
53
Machine family type
44
Service factor (optional)
Mechanical data
45
Starting current ratio (optional)
11
Frame size
46
Operating mode (optional)
12
Type of construction
47
NEMA data (optional)
13
Degree of protection
48
Anti-condensation heating (optional)
terization (optional)
15
Temperature class
51
Converter data
16
Ambient temperature range (optional)
17
Installation altitude (only if higher than 1000 m)
19
Bearing sizes
20
Relubrication data/specifications (optional)
21
Brake data (optional)
22
Mechanical speed limit
24
Feather key arrangement
3.2 Rating plates
3.2 Rating plates
Rating plate
The rating plate shows the identification data and the most important technical data. The
data on the rating plate and the contractual agreements define the limits of proper usage.
Data on the rating plate
1 Type of machine 31 Electrical data
14 Machine weight kg 50 CODE: Motor code number for converter parame-
18 Vibration severity grade
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Description
3.3 Installation
3.3 Installation
Machine design
The regulations and standards used as the basis to design and test this machine are
stamped on the rating plate.
The machine design basically complies with the subsequent standards. Please refer to the
EU Declaration of Conformity for the versions of the harmonized standards referenced.
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Page 23
Description
Feature
Standard
EAC
Dimensioning and operating behavior
EN / IEC 60034-1
GOST R IEC 60034-1
Degree of protection
EN / IEC 60034-5
GOST IEC 60034-5
Cooling
EN / IEC 60034-6
GOST R IEC 60034-6
Type of construction
EN / IEC 60034-7
GOST R IEC 60034-7
Terminal designations and direction of rotation
EN / IEC 60034-8
GOST 26772
Noise emission
EN / IEC 60034-9
GOST IEC 60034-9
chines
Vibration severity grades
EN / IEC 60034-14
GOST IEC 60034-14
induction motors
IEC standard voltages
IEC 60038
GOST R IEC 61800-1
3.3 Installation
The regulations and standards used as the basis for designing and testing this machine are
stamped on the rating plate. The machine design basically complies with the following
standards:
Table 3- 1 Applicable general regulations
Procedure for determining the losses and the efficiency of rotating electrical machines and inspections
Starting characteristics of rotating electrical ma-
Efficiency classification of three-phase squirrel-cage
3.3.1 Cooling and ventilation
3.3.1.1 General
The machines of this series have a closed primary (internal) cooling circuit and an open
secondary cooling circuit (surface cooling). The surface cooling varies depending on the
version.
EN / IEC 60034-2-1
EN / IEC 60034-2-2
EN / IEC 60034-2-3
EN / IEC 60034-12 GOST R IEC 60034-12
EN / IEC 60034-30-1 GOST IEC 60034-30-1
GOST R IEC 60034-2-1
GOST R IEC 60034-2-2
GOST IEC 60034-2-3
3.3.1.2 Machines with a fan
Self-ventilation (standard): Cooling method IC 411 according to EN / IEC 60034-6
Located at the ND end of the stator housing is an air intake cowl that guides the external air
on its way to the motor. The external air is drawn in through openings in the air intake cowl
and flows axially across the outer cooling ribs of the motor frame. The fan wheel for the
external flow of cooling air is attached to the machine shaft.
The fan wheels are bidirectional.
Check the cooling effect below rated speed in the case of frequent switching or braking – or
if the speed is controlled continually below the rated speed.
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Description
3.3 Installation
Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
Cooling that does not depend on the speed is achieved by means of a unit that is
independent of the motor operating state (forced ventilation). This unit is closed to the
outside by a fan cover. It has its own main drive with fan impeller which creates the cooling
air flow required for cooling the motor.
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Description
3.3 Installation
3.3.1.3 Machines without a fan (optional)
Surface cooling by free convection: Cooling method IC 410 according to EN / IEC 60034-6
Figure 3-1 IC410
Surface cooling by relative movement of cooling air: Cooling method IC 418 according to
EN / IEC 60034-6
Figure 3-2 IC418
3.3.2 Bearings
In order to support the machine shaft and maintain its position in the non-moving part of the
machine, only 2 rolling bearings are used. One rolling bearing performs the function of a
location bearing that transfers axial and radial forces from the rotating machine shaft to the
non-moving part of the machine. The second rolling bearing is implemented as floating and
support bearing in order to allow thermal expansion inside the machine and transfer radial
forces.
The nominal (calculated) useful life of the bearings according to ISO 281 is at least 20,000
hours with utilization of the permissible radial/axial forces. However, the achievable useful
life of the bearings can be significantly longer in the case of lower forces (e.g. operation with
self-aligning couplings).
Rolling bearings with permanent lubrication are maintenance-free.
The machine is equipped with grease-lubricated rolling bearings.
● In the standard version, the bearings of machines up to shaft height 250 are permanently
lubricated.
● The bearings of machines from shaft height 280 and above are equipped with a
relubrication system.
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Description
Basic type of construction code
Diagram
Other methods of installation
Diagram
Basic type of construction code
Diagram
Other methods of installation
Diagram
3.3 Installation
3.3.3 Balancing
As standard, the motor is balanced dynamically with a half feather key (code "H").
Vibration level "A" is standard and, if ordered as an option, vibration level B is specified on
the rating plate.
See also
Balancing (Page 51)
3.3.4 Types of construction/method of installation
The type of construction of the machine is stated on the rating plate.
Table 3- 2 Type of construction
IM B3 (IM 1001)
IM V6 (IM 1031)
IM B6 (IM 1051)
IM B7 (IM 1061)
IM B8 (IM 1071)
IM B5 (IM 3001)
IM V5 (IM 1011)
IM V1 (IM 3011)
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IM V3 (IM 3031)
Page 27
Description
Basic type of construction code
Diagram
Other methods of installation
Diagram
Basic type of construction code
Diagram
Ambient temperature
-20 °C to +40 °C
Installation altitude
≤ 1000 m
Air with normal oxygen content, usually
21 % (V/V)
3.3 Installation
IM B14 (IM 3601)
IM V19 (IM 3631)
IM B35 (IM 2001)
IM B34 (IM 2101)
3.3.5 Degree of protection
The machine has a type of protection as stamped on the rating plate, and can be installed in
dusty or humid environments.
IM V18 (IM 3611)
3.3.6 Environmental conditions
Limit values for the standard version
Relative humidity for ambient temperature
40 °C
The standard machines are not suitable for use in corrosive atmospheres, atmospheres with
a high salt content, or outdoor applications.
Limit values for the special versions
If the environmental conditions are different from the details listed here, then the values on
the rating plate or in the catalog will apply.
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T
amb
Max. 55 %
25
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Description
Note
Further documents
Observe all of the other documents provided with this m
3.3 Installation
3.3.7 Optional built-on and built-in accessories
Machines can be equipped with the following integrated components/devices:
● Temperature sensors integrated in the stator winding in order to monitor the temperature
and protect the stator winding from overheating.
● Anti-condensation heating for machines whose windings are subject to a risk of
condensation due to the climatic conditions.
Machines can be equipped with the following mounted components/devices:
● Brake
● Rotary pulse encoder
● External fan (forced ventilation)
● Measuring nipple for SPM shock pulse measurement for bearing monitoring
● Backstop
Supplementary devices
Depending on the order, various supplementary devices can be installed or mounted. These
include sensors for bearing temperature monitoring or winding monitoring, for example.
3.3.8 Terminal box
As an option, additional connecting terminals are available in the terminal box for monitoring
equipment. For larger machines, an additional terminal box can be optionally mounted. You
can see the number of available terminals in the circuit diagrams.
3.3.9 Paint finish
Paint finish
The machine is painted according to the instructions in your order.
achine.
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4
Good planning and preparation of machine applications are essential in terms of keeping
installation simple and avoiding errors, ensuring safe operation, and allowing access to the
machine for servicing and corrective maintenance.
This chapter outlines what you need to consider when configuring your plant in relation to
this machine and the preparations you need to make before the machine is delivered.
4.1 Safety-related aspects to consider when configuring the plant
A number of residual risks are associated with the machine. These are described in the
chapter titled "Safety information" (Page 11) and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.
4.2 Observing the operating mode
Observe the machine's operating mode. Use a suitable control system to prevent
overspeeds, thus protecting the machine from damage.
4.3 Machines without final paint coating
For machines, which are only delivered with primer, you must paint them to comply with the
applicable guidelines for the specific application. The primer alone does not provide
adequate corrosion protection.
The paint applied must conform to the requirements to avoid electrostatic charging, see
EN 60079-0.
Please contact the Service Center for recommendations relating to the paint finish.
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WARNING
Risk of dropping and swinging when transported suspended
4.4 Delivery
4.4 Delivery
Checking the delivery for completeness
The drive systems are put together on an individual basis. When you take receipt of the
delivery, please 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.
Archive the safety and commissioning notes provided in the scope of delivery as well as the
optionally available operating instructions so that these documents are always easily
accessible.
The rating plate optionally enclosed as a loose item with the delivery is provided to enable
the motor data to be attached on or near the machine or installation.
4.5 Transport and storage
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
If you transport the motor suspended from cables or ropes, the cables or ropes can break,
e.g. as a result of damage. Further, if not adequately attached, the motor can swing. This
can result in death, serious injury, or material damage.
• Use additional, suitable lifting equipment for transport and during installation.
• Two cables alone must be able to carry the complete load.
• Prevent the lifting equipment from sliding by appropriately securing it.
• When using 2-cable lifting equipment, ensure that the maximum angle of inclination is
≤45° according to ISO 3266 (DIN 580).
• Align the eyebolts so that the cables used for lifting are aligned with the planes of the
eyebolts.
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WARNING
Toppling over or slipping of the motor
WARNING
Danger to life as a result of a machine falling
Note
When lifting the machines for transpor
basic construction type.
moisture
heat
4.5 Transport and storage
The motor can slide or topple over if it is not correctly lifted or transported. This can result in
death, serious injury, or material damage.
• Use all the lifting eyes on the machine.
• When using the lifting eyes on the machine, do not attach any additional loads or
weight. The lifting eyes are only designed for the weight of the machine itself.
• Any eyes that are screwed in must be tightly fastened.
• Eyebolts must be screwed in right up to their supporting surface.
• Comply with the permissible eyebolt loads.
• When necessary, use suitably dimensioned lifting equipment, for example hoisting
straps (EN1492-1) and load restraints (EN12195-2).
● Never remain under or in the immediate vicinity of the machine when it is lifted.
If the lifting gear or load handling attachments were to fail, the machine could fall. This
can result in death, serious injury or material damage.
• In order to gain easy and safe access to the underside of the machine, place it in a
The type of construction of the machine is stated on the rating plate.
If any transport locks are in place, remove them before commissioning. Store the transport
locks or disable them. Use the transport locks when transporting the motors again or
reactivate the transport locks.
The machines are packed in different ways depending on how they are transported and their
size. If not otherwise contractually agreed, the packaging corresponds to the packing
guidelines according to ISPM (International Standards for Phytosanitary Measures).
Comply with the images shown on the packaging. Their meaning is as follows:
secure and raised position.
t, only lift them in a position that corresponds to their
Up Fragile
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goods
Protect
against
Protect
against
Center of
gravity
Hand hooks
forbidden
Attach
here
29
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Preparing for use
NOTICE
Damage to the motor
4.5 Transport and storage
4.5.1 Storage
Storing outdoors
Damage can occur if incorrectly stored.
Take all precautions to protect the motor under extreme climatic conditions, e.g. salt-laden
and/or dusty, moist/humid atmospheres.
Choose a dry storage location which is safe from flooding and free from vibration. Repair any
damage to the packaging before putting the equipment into storage if this is necessary to
ensure proper storage conditions. In order to ensure protection against ground moisture,
locate machines, equipment and crates on pallets, wooden beams or foundations. Prevent
equipment from sinking into the ground. Do not impede air circulation under the stored items.
Covers or tarpaulins used to protect the equipment against the weather must not come into
contact with the surfaces of the equipment. Use wooden spacer elements to ensure that air
can circulate freely around the equipment.
Storing indoors
The storage rooms must provide protection against extreme weather conditions. They must
be dry, free from dust, frost and vibration and well ventilated.
Bare metal surfaces
For transport, the bare surfaces (shaft ends, flange surfaces, centering edges) should be
coated with an anti-corrosion agent which will last for a limited amount of time (<6 months).
Apply suitable anti-corrosion measures for longer storage times.
Condensation drain hole
Open any condensation drain holes to drain the condensation depending on the
environmental conditions, every six months at the latest.
Storage temperature
Permissible temperature range: -20 °C to +50 °C
Maximum permissible air humidity: 60%
For machines that have a special design regarding the ambient temperature in the operating
state or the installation altitude, other conditions could apply regarding the storage
temperature. In this case, refer to the machine rating plate for data on the ambient
temperature and installation altitude.
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NOTICE
Storage
4.5 Transport and storage
Storage time
Turn the shaft once every year to avoid bearing brinelling. Prolonged storage periods reduce
the useful life of the bearing grease (aging).
Open bearings
● For open bearings, e.g. 1Z, check the status of the grease when stored for longer than 12
months.
● Replace the grease if it is identified that the grease has lost its lubricating properties or is
polluted. The consistency of the grease will change if condensation is allowed to enter.
Closed bearings
● For closed bearings, replace the DE and NDE bearings after a storage time of 48 months.
The motor can be damaged if you use it or store it unprotected outdoors.
• Protect the motor against intensive solar radiation, rain, snow, ice and dust. Use a
superstructure or additional cover, for example.
• If required, contact the service center, or technically coordinate outdoors use.
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NOTICE
Motor damage due to vibrations
supplied in the horizontal position from the manufacturing plant.
4.5 Transport and storage
4.5.2 Securing the rotor
Depending on the version, the machine is fitted with a rotor shipping brace. This protects the
bearings against damage due to shock and vibration during transport or storage.
Not using the rotor shipping brace can cause damage to the machine if it is jolted during
transport or storage. Material damage can result.
• If the machine is fitted with a rotor shipping brace, this should always be used when
transporting the machine. The rotor shipping brace must be attached during the
transport.
• Protect the motor against strong radial shocks and vibration when storing, as the rotor
shipping brace cannot completely absorb these forces.
• Do not remove the rotor shipping brace until you are ready to push on the output
element.
• If the customer already has mounted parts, such as a coupling or belt pulley, the
bearings can be damaged during transport. In this case, make sure that the customer
uses a rotor shipping brace.
• For machines with a vertical type of construction:
– Do not remove the rotor shipping brace until the machine is in a vertical position.
– If a machine has to be transported in a horizontal position, the rotor must be fixed in
position before the machine is turned onto its side. Vertical machines can be
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①
Sleeve
②
Shaft screw and washer
Thread in the shaft extension
Tightening torque
M16
40 Nm
M20
80 Nm
M24
150 Nm
M30
230 Nm
Tightening torques for other rotor shipping brace types
Thread in the shaft extension
Preload
M16
13 kN
M20
20 kN
M24
30 kN
M30
40 kN
Axial preload force for other rotor shipping brace types
4.5 Transport and storage
Alternative rotor bracing
● If you transport the machine after the output element has been pulled on, then you must
axially fix the rotor in another way.
Figure 4-1 Axial fastening of the rotor
● The thread in the shaft extension indicates the rotor weight. This indirectly specifies the
required preload force when axially fastening the rotor.
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
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4.5 Transport and storage
4.5.3 Commissioning after storage
4.5.3.1 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"
4.5.3.2 Lubricating the rolling bearings
If you correctly store the machine for a longer period of time, it can be assumed that within a
period of two years, the grease in the bearings will not deteriorate.
● For motors with thermal class 155, for normal ambient temperatures, use a lithium-soap
rolling bearing grease with a melting point of at least 180° C.
● For machines with thermal class 180, and for certain special machines, use the special
grease specified on the machine lubricant plate.
4.5.3.3 Regreasing rolling bearings after storage periods of up to two years
● For machines with regreasing systems, briefly lubricate both bearings after
commissioning with the machine running as a precautionary measure.
● Grease type, grease quantity and relubrication intervals for the regreasing system are
stamped on the rating plate attached to the machine.
4.5.3.4 Releasing the rotor shipping brace before commissioning
If one is being used, release the rotor shipping brace before commissioning.
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WARNING
Overheating and failure of the motor
WARNING
Damage caused by small parts falling in
4.6 Ensure adequate cooling
4.6 Ensure adequate cooling
Death, severe injury or material damage can occur if you do not carefully observe the
following points.
• Do not obstruct ventilation.
• Prevent the air expelled by neighboring equipment from being immediately sucked in
again.
• For machines with a vertical type construction with air entry from above, prevent the
ingress of foreign bodies and water in the air entry openings (standard IEC / EN 60079-
0).
• If the shaft extension is facing upwards, liquid must be prevented from entering by
moving along the shaft.
Material damage and injury can occur if the fan is destroyed and therefore the motor
overheats.
• For types of construction with the shaft extension facing downwards, prevent small parts
from falling into the fan cover by providing suitable covers (standard IEC / EN 60079-0).
• Ensure that the cooling air flow is not reduced as a result of covers and that the
minimum air clearances are maintained.
For machines with external fans, install an interlock circuit that prevents the main machine
being switched on if the external fan is not operational.
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Preparing for use
Incorrect
Correct
Minimum dimension "x" for the distance between neighboring modules and the air intake of the ma-
chine
4.6 Ensure adequate cooling
Table 4- 1 Air guidance
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Shaft height
X
mm
63 ... 71
15
112
25
132
30
160
40
180 ... 200
90
225 ... 250
100
280 ... 315
110
355
140
4.7 Interlock circuit for anti-condensation heating
Table 4- 2 Minimum dimension "X" for the distance between adjacent modules and the air intake of
the machine
80 ... 100 20
4.7 Interlock circuit for anti-condensation heating
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine.
● Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
● Only switch on the anti-condensation heating after the machine has been switched off.
See also
Switching on with the anti-condensation heating active (Page 89)
4.8 Noise emission
Prevention of hearing damage
If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
Observe the permissible sound pressure level in accordance with ISO 1680. The maximum
permissible sound pressure level is 70 dB (A).
4.9 Voltage and frequency fluctuations during line operation
Unless otherwise stated on the rating plate, the permissible voltage/frequency fluctuation is
corresponds to Zone B in IEC / EN 60034-1. Permissible fluctuations that go beyond this are
indicated on the rating plate.
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4.10 Rotational speed limit values
Operate the machine in continuous operation in Zone A. Prolonged operation in Zone B is
not recommended:
● Exceeding the permissible tolerances for voltage and frequency can lead to an
impermissibly high temperature rise of the winding. This can result in long-term damage
to the winding.
● Limit exceptions of this sort with regard to the values that arise, how often, and for how
long they occur.
● Where possible and within a reasonable time take corrective actions such as reducing the
power. In this way you can avoid that the service life of the machine is reduced as a
result of thermal aging.
4.10 Rotational speed limit values
Danger as a result of resonance within certain speed ranges
At over-critical speeds, machines encounter resonance within certain speed ranges. Such
vibrations can reach impermissibly high levels. This can result in death, serious injury or
material damage.
● The controller must ensure that those speed ranges are blocked when the converter is in
operation. Please note the data on the blocked speed ranges specified in the Electrical
Data.
● The blocked speed ranges must be run through rapidly.
Machine damage due to excessively high speeds
Excessive rotational speed can lead to serious damage to the machine. This can result in
death, serious injury or material damage.
● Avoid operation above the permissible speed by using the appropriate control function.
● Observe the speeds stamped on the rating plate and in the Electrical Data.
4.11 System-inherent frequencies
Excessively high vibration levels and system resonances can damage the machine set.
● Configure and match the system consisting of the foundation and machine set in such a
way that no system resonances can arise and result in the permissible vibration levels
being exceeded.
● The vibration values according to DIN ISO 10816-3 must not be exceeded.
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Note
If the torque levels are very unequal (e.g. when a reciprocating compressor is being driven),
a non
impermissible effect on the supply system and cause impermissible interference emissions
as a result.
Note
Converter
•
•
•
•
•
4.12 Electromagnetic compatibility
4.12 Electromagnetic compatibility
-sinusoidal machine current will be induced whose harmonics can have an
If operated with a frequency converter, the emitted interference varies in strength,
depending on the design of the converter (type, interference suppression measures,
manufacturer).
Avoid that the specified limit values stipulated for the drive system (consisting of the
motor and converter) are exceeded.
You must observe the EMC information from the manufacturer of the converter.
The most effective method of shielding is to conductively connect a shielded machine
supply cable to the metal terminal box of the machine (with a metal screw connection)
over a large surface area.
On machines with integrated sensors (e.g. PTC thermistors), disturbance voltages
caused by the converter may occur on the sensor cable.
When used in accordance with their intended purpose and operated on an electrical supply
system with characteristics according to EN 50160, the enclosed machines comply with the
requirements of the EC Directive concerning electromagnetic compatibility.
Immunity to interference
The machines fulfill the requirements of interference immunity in conformity with EN /
IEC 61000-6-2. If machines with integrated sensors (e.g. PTC thermistors) are used, the
operating company must ensure sufficient interference immunity by selecting a suitable
sensor signal lead (possibly with shielding, connected in the same way as the machine
feeder cable) and a suitable evaluation unit.
When operating the machines from a converter at speeds higher than the rated speed, then
the mechanical speed limits must be carefully observed (safe operating speed
EN / IEC 60034-1).
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Preparing for use
NOTICE
Material damage caused by an excessively high supply voltage
4.13 Converter operation
4.13 Converter operation
4.13.1 Parameterizing the converter
● If the design of the motor requires connection to a particular converter type, the rating
plate will contain corresponding additional information.
● Correctly parameterize the converter. Parameterizing data can be taken from the
machine rating plates.
You can find parameter data here:
– In the operating instructions for the converter.
– In the SIZER engineering tool
– In the SINAMICS Configuration Manuals.
– For explosion-protected machines, also in the declaration of compliance with the order
2.1.
● Do not exceed the specified maximum speed limit
n
rating plate
or on the supplementary plate for converter operation as the highest
max
speed.
● Check that the machine is cooled sufficiently for commissioning purposes.
4.13.2 Converter input voltage
The insulation system of SIMOTICS machines always complies with the requirements of
stress category C (IVIC C = high stress). If voltage peaks higher than those specified
according to IVIC C can occur, then please contact your Siemens partner:
● For a line supply voltage (converter input voltage) up to max. 480 V, and when controlled
from a SINAMICS G/SINAMICS S converter with uncontrolled/controlled infeed: Comply
with the guidelines for configuring motor and converter.
● For line voltages (converter input voltages) higher than 480 V, motors, which are ordered
for converter operation, have an appropriate insulation system.
● Operation with a converter from another manufacturer: Comply with the permissible
voltage peaks according to IEC 60034-18-41 in accordance with stress category C,
dependent on the particular line voltage (converter input voltage) and the motor insulation
system.
n
. You can either find this on the
max
The insulation system will be damaged if the supply voltage is too high for the insulation
system. This can completely destroy the machine.
• Comply with the peak voltages as laid down in the guidelines above.
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Preparing for use
Concentric copper or aluminum shield
Steel armor
4.13 Converter operation
See also
Download Center
(http://w3app.siemens.com/mcms/infocenter/content/en/Pages/order_form.aspx
)
4.13.3 Reducing bearing currents during operation with converter (low voltage)
Taking the following actions will reduce the bearing currents:
● Ensure that the contacts are made over a large area. Solid copper cables are not suitable
for high-frequency grounding because of the skin effect.
Equipotential bonding conductors:
Use equipotential bonding conductors:
● between motor and driven machine
● between motor and converter
● between the terminal box and the RF grounding point at the motor enclosure.
Selecting and connecting the cable:
As far as possible, use symmetrically arranged, shielded connection cables. The cable
shielding, made up of as many strands as possible, must have good electrical conductivity.
Braided shields made of copper or aluminum are very suitable.
● The shield is connected at both ends, at the motor and converter.
● To ensure good discharging of high-frequency currents, provide contacting over a large
surface area:
– as contact established through 360° at the converter
– at the motor, for instance with EMC glands at the cable entries.
● If the cable shield is connected as described, then it ensures the specified equipotential
bonding between the motor enclosure and converter. A separate RF equipotential
bonding conductor is then not necessary.
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Preparing for use
①
Driving machine
④
Insulated bearings
②
Motor
⑤
Insulated tachometer fitting
③
Coupling
4.13 Converter operation
● If the cable shield is not connected due to special secondary conditions, or not
adequately connected, then the specified equipotential bonding is not provided. In this
particular case, use a separate RF equipotential bonding conductor:
– Between the motor enclosure and protective ground rail of the converter.
– Between motor enclosure and driven machine
– Use braided flat copper straps or high-frequency cables with finely-stranded
conductors for the separate RF equipotential bonding cable.
– Ensure that the contacts are made over a large area.
Measures to reduce bearing currents
To specifically reduce bearing currents, you must consider the system as a whole, which
comprises the motor, converter, and driven machine. The following measures support you
when reducing bearing currents and help to avoid damage:
● In the overall system, set up a properly meshed grounding system with low impedance.
● Use the common-mode filter (damping cores) at the converter output. The Siemens sales
representative is responsible for selection and dimensioning.
● Limit the rise in voltage by using output filters. Output filters dampen the harmonic content
in the output voltage.
● The operating instructions for the converter are not part of this documentation. Refer to
the configuration information for the converter.
4.13.4 Insulated bearings when operated with a converter
If the machine is operated from a low-voltage converter, insulated bearings are fitted at the
NDE and an insulated encoder with insulated bearings (option).
Comply with the plates on the machine relating to bearing insulation and possible bridges.
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Figure 4-2 Schematic representation of a single drive
Page 45
Preparing for use
NOTICE
Bearing damage
①
Driving machine
④
Insulated bearings
②
Motor
⑤
Insulated tachometer fitting
③
Coupling
⑥
Insulated coupling
NOTICE
Bearing damage
4.13 Converter operation
The bearing insulation must not be bridged. Bearing currents can damage bearings.
• Do not bridge the bearing insulation for subsequent installation work, such as the
installation of an automatic lubrication system or a non-insulated vibration sensor.
• Please contact the service center if necessary.
Tandem operation
If you connect two motors in series in "tandem operation", install an insulated coupling
between the motors.
Figure 4-3 Schematic representation of a tandem drive
Bearing currents can flow if the coupling between the motors of the tandem drive is not
insulated. This can damage the DE bearings of both motors.
• Use an insulated coupling to link the motors.
4.13.5 Tandem operation
If you connect two motors in series in "tandem operation", locate a coupling between the
motors; this coupling should satisfy the Directive 2014/34/EU or the regulations that apply in
the country where the equipment is installed.
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4.13 Converter operation
4.13.6 Speed limits for converter operation
Observe the information on the rating plate regarding the speed limits for converter
operation.
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5
Note
Note also the technical data on the rating plates on the motor enclosure.
NOTICE
Damage to the motor
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
Loss of conformity with European directives
In the delivery state, the machine corresponds to the requirements of the European
directives. Unauthorized changes or modifications to the machine lead to the loss of
conformity with European Directives and the loss of the associated warranty.
5.1 Preparing for installation
5.1.1 Requirements for installation
The following requirements must be satisfied prior to starting installation work:
● Staff have access to the operating and installation instructions.
● The machine is unpacked and ready for mounting at the installation location.
● Measure the insulation resistance of the winding before starting any installation work. If
the insulation resistance lies below the specified value, take appropriate remedial
measures. These remedial measures may necessitate the machine being removed again
and transported.
To avoid material damage, before commissioning, check whether the correct direction of
rotation of the machine has been set on the customer side, e.g. by decoupling from the
driven load.
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5.1 Preparing for installation
Damage to mounted parts and components as a result of high temperatures
The motor components get very hot during operation. High temperatures can damage parts
mounted by customers, such as cables manufactured out of materials that are not heat
resistant.
● Temperature-sensitive parts must not come into contact with or be attached to
components mounted on the machine.
● Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the particular application.
5.1.2 Insulation resistance
5.1.2.1 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 47)
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WARNING
Hazardous voltage at the terminals
– Attach the connection cable.
5.1 Preparing for installation
5.1.2.2 Testing the insulation resistance and polarization index
During and immediately after measuring the insulation resistance or the polarization index
(PI) of the stator winding, hazardous voltages may be present at some of the terminals.
Contact with these can result in death, serious injury or material damage.
• If any power cables are connected, check to make sure line supply voltage cannot be
delivered.
• Discharge the winding after measurement until the risk is eliminated, e.g. using the
following measures:
– Connect the terminals with the ground potential until the recharge voltage drops to a
non-hazardous level
Measure the insulation resistance
1. Before you begin measuring the insulation resistance, please read the operating manual
for the insulation resistance meter you are going to use.
2. Short-circuit the ends of the temperature sensor cables before applying the test voltage. If
the test voltage is connected to only one temperature sensor terminal, the temperature
sensor will be destroyed.
3. Make sure that no power cables are connected.
4. Measure the winding temperature and the insulation resistance of the winding in relation
to the machine enclosure. The winding temperature should not exceed 40° C during the
measurement. Convert the measured insulation resistances in accordance with the
formula to the reference temperature of 40° C. This thereby ensures that the minimum
values specified can be compared.
5. Read out the insulation resistance one minute after applying the measuring voltage.
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U
N
V
U
meas
V
R
C
MΩ
U ≤ 1000
500
≥ 5
2500 < U ≤ 5000
1000 (max. 2500)
U > 12000
5000 (max. 10000)
U
U
R
C
= minimum insulation resistance at a reference temperature of 40 °C
R
C
Insulation resistance converted to 40° C reference temperature
K
Temperature coefficient according to equation (2)
T
in °C
40
Reference temperature in °C
10
Halving/doubling of the insulation resistance with 10 K
T
Measuring/winding temperature in °C
5.1 Preparing for installation
Limit values for the stator winding insulation resistance
The following table specifies the measuring voltage and limit values for the insulation
resistance. These values correspond to IEEE 43-2000 recommendations.
Table 5- 1 Stator winding insulation resistance at 40° C
1000 ≤ U ≤ 2500 500 (max. 1000) 100
5000 < U ≤ 12000 2500 (max. 5000)
= rated voltage, see the rating plate
rated
= DC measuring voltage
meas
Conversion to the reference temperature
When measuring with winding temperatures other than 40° C, convert the measuring value
to the reference temperature of 40° C according to the following equations from IEEE 43-
2000.
(1)
R
=
K
·
R
T
(40-T)/10
T
C
(2)
K
= (0.5)
T
In this case, doubling or halving the insulation resistance at a temperature change of 10 K is
used as the basis.
● The insulation resistance halves every time the temperature rises by 10 K.
● The resistance doubles every time the temperature falls by 10 K.
For a winding temperature of approx. 25° C, the minimum insulation resistances are 20 MΩ
(U ≤ 1000 V) or 300 MΩ (U > 1000 V). The values apply for the complete winding to ground.
Twice the minimum values apply to the measurement of individual assemblies.
● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ, or
possibly even higher values. An insulation resistance value close to the minimum value
could be due to moisture and/or dirt accumulation. The size of the winding, the rated
voltage and other characteristics affect the insulation resistance and may need to be
taken into account when determining measures.
T
R
Measured insulation resistance for measuring/winding temperature
T
● Over its operating lifetime, the motor winding insulation resistance can drop due to
ambient and operational influences. Calculate the critical insulation resistance value
depending on the rated voltage by multiplying the rated voltage (kV) by the specific
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R
(10 min)
/ R
(1 min)
Assessment
≥ 2
Insulation in good condition
NOTICE
Damage to insulation
5.2 Installing the machine
critical resistance value. Convert the value for the current winding temperature at the time
of measurement, see above table.
Measuring the polarization index
1. To determine the polarization index, measure the insulation resistances after one minute
and ten minutes.
2. Express the measured values as a ratio:
PI =
R
insul 10 min
Many measuring devices display these values automatically following the measurement.
For insulation resistances > 5000 MΩ, the measurement of the PI is no longer meaningful
and consequently not included in the assessment.
/
R
insul 1 min
< 2 Dependent on the complete diagnosis of the insulation
If the critical insulation resistance is reached or undershot, this can damage the insulation
and cause voltage flashovers.
• Contact the service center.
• If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
Limit values of the anti-condensation heating insulation resistance
The insulation resistance of the anti-condensation heating with respect to the machine
housing should not be lower than 1 MΩ when measured at 500 V DC.
5.2 Installing the machine
5.2.1 Preparing the assembly area
1. Prepare a suitable assembly area (e.g. assembly stands). Make sure that the assembly
area has sufficient clearance from the floor for the DE shaft end. The necessary data is
provided in the machine dimension drawing.
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2. Refer to the shipping documents to check that all motor components are available for
assembly.
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Assembly
5.2 Installing the machine
5.2.2 Safety instructions for installation
Injury and material damage caused by inappropriate fastening material
If screws of an incorrect property class have been selected or if they have been fastened to
an incorrect tightening torque, they may break or become loose. This will cause the machine
to move, which could damage the bearings. The rotor could smash into the machine
enclosure and machine parts could be flung out of place. This can result in death, serious
injury or material damage.
● Comply with the required property classes for screwed connections.
● Tighten the screwed connections to the specified tightening torques.
Injury and material damage caused by incorrect machine alignment
If the machine has not been properly aligned, this will mean the fastening parts are subjected
to stress/distortion. Screws may become loose or break, the machine will move, machine
parts could be flung out of place. This can result in death, serious injury or material damage.
● Carefully align the machine to the driven machine.
Material damage caused by improper handling
Mounting parts such as temperature sensors or speed sensors are attached to the machine
and could be ripped off or destroyed as a result of improper handling. This could lead to
machine malfunctions, extending even to total loss of the machine.
● Where necessary, use suitable steps when performing installation work on the machine.
● Do not stand on cables or attachments during installation. Do not use attachments as
steps.
5.2.3 Lift the machine to where it will be mounted and position it
● For vertical installation, use all of the eyebolts provided and when necessary, hoisting
straps (DIN EN 1492-1) and/or lashing straps (DIN EN 12195-2) to stabilize the position
of the motor.
● Prevent foreign bodies from falling into the fan cover. For vertical machine installation
with the shaft end facing downwards, attach a protective canopy.
● If the shaft extension is facing upwards, the user must prevent liquid from moving along
the shaft and entering the motor.
● Clean bare metal surfaces with anti-corrosion agent using white spirit to ensure proper
installation and / or machine mounting.
● Do not obstruct the ventilation! Do not draw in the discharged air directly – also from
adjacent equipment.
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CAUTION
Risk of injury due to Incorrect installation or removal
5.2 Installing the machine
● Avoid exposing them to direct, intense solar radiation, rain, snow, ice, or also dust for
extended periods. Attach a covering structure or an additional cover when using or
storing outdoors.
● Do not exceed the permissible axial and radial forces.
5.2.4 Balancing
The rotor is dynamically balanced. For shaft extensions with feather keys, the balancing type
is specified using the following coding on the face of the drive end of the shaft:
● "H" means balancing with a half feather key (standard)
● "F" means balancing with a whole feather key
● "N" means balancing without a featherkey.
If the required touch protection measures for drive output elements are not observed this
can result in physical injury and material damage.
• The general touch protection measures for drive output elements must be observed.
• Drive output elements may only be pushed on or pulled off with the correct equipment.
• The feather keys are only locked against falling out during shipping. If you commission a
machine without a drive output element, the feather keys must be secured to prevent
them from being thrown out.
The featherkey data on the shaft and transmission element must indicate the correct type of
balancing in each case and must be correctly mounted.
The balancing quality corresponds to vibration severity grade "A" for the complete machine;
vibration severity grade "B" is possible as an option, i.e. in order to ensure the desired
balancing quality, it must be ensured that the featherkey data on the hub and machine shaft
complement each other in the case of a shorter or longer output transmission element.
Align the offset at the coupling between electrical machines and the driven machines so that
the maximum permissible vibration values according to ISO 10816-3 are not exceeded.
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Mounting output transmission elements
5.2 Installing the machine
5.2.4.1 Mounting and withdrawing output transmission elements
Withdrawing output transmission elements
● When mounting output transmission elements (coupling, gear wheel, belt pulley etc. ) use
the thread at the shaft end.
If possible, heat up the output transmission elements as required.
● Use a suitable device when withdrawing output elements.
● When mounting or withdrawing, do not apply any blows, for example with a hammer or
similar tool, to the parts to be mounted or withdrawn.
● Only transfer radial or axial forces specified in the catalog to the motor bearings via the
shaft extension.
5.2.5 Machines with type of construction IM B15, IM B9, IM V8 and IM V9
Types of construction without bearings on the drive side
These machines do not have their own bearing system for the machine shaft at the drive end
(DE). The machine shaft is accepted by the (hollow) shaft or coupling of the system or driven
machine.
● Using the centering edge, the machine is aligned with respect to enclosures, flanges or
driven machines.
● Note that the temperature of the motor and motor shaft increases during operation. The
thermal expansion of the machine shaft must be compensated by the customer by
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NOTICE
Damage to the motor
Note
Only authorized retrofit partners must be employed to relocate the bolted on mounting feet at
the machine enclosure.
5.3 Aligning and fixing the machine
applying suitable measures.
Use the spring washers provided to locate the NDE bearing without any play.
Material damage can occur if the following notes are not carefully observed:
• The IM B3 bearing shield with integrated distance ring mounted at the drive end (DE) is
only used transport lock. A warning label is attached to this bearing shield.
• The spacer ring is not a roller bearing.
• Remove the bearing shield and the spacer ring.
• Remove the transport lock before commissioning.
5.2.6 Foot mounting
After attaching the mounting feet, you must note the following in order to avoid stressing and
deforming the machine.
● Ensure that the foot mounting surfaces are aligned in one plane and are parallel to the
machine shaft.
● Post-machine the foot mounting surfaces or use thin shims, for example.
● Professionally touch up damaged painted surfaces.
● Observe the information provided in Chapter Aligning and mounting (Page 53)
5.3 Aligning and fixing the machine
Observe the following when aligning and mounting:
● Ensure a flat and uniform contact surface for foot and flange mounting.
● When mounting on the wall, support the machine from below, e.g. using a bracket, or bolt
it.
● Precisely align the machine when couplings are used.
● Ensure that the mounting surfaces are clean and free of any dirt.
● Remove any anti-corrosion protection using white spirit.
● Avoid installation-related resonances with the rotating frequency and twice the line
frequency.
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5.3 Aligning and fixing the machine
● Note any unusual noise when the rotor is manually turned.
● Check the direction of rotation with the motor uncoupled.
● Avoid rigid couplings.
● Repair any damage to the paint, this must be done immediately and correctly.
5.3.1 Measures for alignment and mounting
The following measures are required in order to compensate any radial offset at the coupling
and to horizontally adjust the electrical machine with respect to the driven load:
● Vertical positioning
For vertical mounting positions, avoid deforming the machines by placing shims under the
mounting feet. Keep the number of shims low; only use a few stacked shims.
● Horizontal positioning
To position the machine horizontally, shift it sideways on the foundation and ensure that
the axial position is maintained (angularity error).
● When positioning the motor, ensure that a uniform axial gap is maintained around the
coupling.
● Smooth running
Preconditions for smooth, vibration-free operation:
– Stable foundation design free of any shock or vibration.
– A precisely aligned coupling.
– A well-balanced drive output element (coupling, belt pulleys, fans, ...)
Maintain the maximum permissible vibration values in operation according to ISO 10816-
3.
Avoid inadmissible vibration caused by imbalance, for example (drive output element),
external vibration or any resonance over the complete speed range.
It may be necessary to completely balance the machine with the drive output element or
the system resonance frequency must be shifted.
● Foot mounting/flange mounting
– Use the specified thread size laid down in EN 50347 when flanging the machine to a
foundation or a machine flange.
– Mount the machine at all the foot or flanged holes provided. The choice of fixing
elements depends on the foundation and is the plant operator's responsibility. Comply
with the required property classes for screwed connections and materials for fixing
elements.
– Select the correct screw length for IM B14 flanges.
– Ensure that the screw heads are in full contact with the flange surface. Use additional
flat washers (ISO 7093), especially for elongated foot mounting holes.
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Shaft height
Flatness
[mm]
≤ 132
0.10
≥ 180
0.20
5.4 Installing the machine
5.3.2 Flatness of the supporting surfaces for conventional motors
160 0.15
5.3.3 Machine frame mounting feet (special design)
Please note that when the terminal box is mounted at the NDE (option H08), dimension C
can deviate from EN 50347.
To comply with dimension C according to EN 50347, for machines with double or triple holes
at the NDE, use the appropriate screw bore.
5.4 Installing the machine
5.4.1 Preconditions for smooth, vibration-free operation
Preconditions for smooth, vibration-free operation:
● Stable foundation design
● Precise alignment of the machine
● Correct balancing of parts to be fitted to the shaft end.
● Vibration values in compliance with ISO 10816-3
5.4.2 Aligning the machine to the driven machine and mounting
5.4.2.1 Selecting bolts
● Unless specified otherwise, use fixing screws with at least strength class 8.8 to ISO 898-1
to ensure that the machine is securely mounted and to transmit the torque-generated
forces.
● When selecting the bolts and the design of the foundation, take into account the
maximum forces occurring in the case of a fault such as short circuit or system transfers
in phase opposition, etc.
Request the foundation force values from the Service Center if required.
See also
Tightening torques for screw and bolt connections (Page 141)
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Assembly
Note
Machine expansion
When aligning, make allowance for the thermal expansion of the machine when the
temperature increases.
5.4 Installing the machine
5.4.2.2 Horizontal types of construction with mounting feet
1. Refer to any instructions for aligning the driven machine and those of the coupling
manufacturer.
2. Align the machines with coupling output to the driven machine in such a manner that the
center lines of the shafts are parallel with no offset. This ensures that no additional forces
affect their bearings during operation.
3. For the vertical positioning (x→0) place thin shims under the machine feet. The number of
shims should be kept as low as possible, i.e. stack as few as possible. This also prevents
the machine being subjected to any stress/distortion. If available, use the existing tapped
holes for the forcing-off bolts to somewhat raise the machine.
4. When positioning the machine, ensure that a uniform axial gap (y→0) is maintained
around the coupling.
5. Fix the machine to the foundation. The choice of fixing elements depends on the
foundation and is the plant operator's responsibility.
5.4.2.3 Horizontal types of construction with flange
The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Procedure
The machine axis must be horizontal when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw three studs into tapped holes spaced about 120° apart around the driven machine
flange. The studs act as positioning aids.
3. Position the machine so that its axis is aligned with that of the driven machine, but not yet
quite touching. Advance the machine slowly towards the driven machine; advancing too
quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Move the machine fully up against the mating flange so that it is fully in contact.
6. Fix the machine using the flange fixing bolts, finishing by replacing the studs.
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5.4 Installing the machine
5.4.2.4 Vertical types of construction with flange
The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Procedure
The machine axis must be vertical when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw in two studs into tapped holes on opposite sides of the driven machine flange. The
studs act as positioning aids.
3. Lower the machine slowly toward the driven machine and into the centering, so that the
flanges do not quite touch. Lowering too quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Lower the machine completely onto the mating flange so that it is fully in contact; then
remove the studs.
6. Fix the machine using the flange fixing bolts.
5.4.3 Removing the rotor shipping brace
If a rotor shipping brace is attached to the machine, remove it at the last possible moment,
for example, when you are ready to push on the output or drive element.
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
Details about the alignment accuracy can be found in the Section "Information about the
machine dimension drawing".
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Assembly
5.4 Installing the machine
5.4.4 Mounting the output elements
Balance quality
The rotor is dynamically balanced. For shaft ends with feather keys, the balancing type is
specified using the following coding on the rating plate:
● "H" means balancing with a half feather key
● "F" means balancing with a whole feather key
● "N" means balancing without a featherkey.
Figure 5-1 Balancing type on the drive-end side
Pushing on the power output elements
● Requirements:
– The coupling and/or the output element must be appropriately dimensioned for the
operating case at hand.
– Comply with the coupling manufacturer's instructions.
– Make sure that the balancing type of the transmission element correctly matches the
type of balance of the rotor.
– Use only ready drilled and balanced transmission elements. Check the hole diameters
and the balancing status before pulling them on. Thoroughly clean the shaft extension.
● Pulling on:
– Warm up the drive output elements to expand them before pulling them on. Select the
temperature difference for the heating process to suit the coupling diameter, fit and
material. See the coupling manufacturer's instructions.
– Power output elements may only be pushed on or pulled off with the correct
equipment. The transmission element must be pulled on in one continuous operation
via the front thread holes in the shaft or pushed on by hand.
– Do not use a hammer, as this will damage the bearings.
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Assembly
5.4 Installing the machine
Shaft extensions with feather key
To maintain the balancing quality, you have the following options:
● If the transmission element is shorter than the feather key with balancing type "H", then
you must machine off the section of feather key protruding from the shaft contour and
transmission element in order to maintain the balance quality.
● If the transmission element is drawn up on to the shoulder of the shaft, you must ensure
that the part of the coupling groove where the feather key is not inserted is taken into
consideration when balancing the coupling.
The following applies to all four-pole machines with a frequency ≥ 60 Hz:
● The feather key must be shortened if the coupling hub is shorter than the feather key.
● The center of gravity of the coupling half should be within the length of the shaft end.
● The coupling used must be prepared for system balancing.
Danger as a result of a feather key being flung out
Rotating parts are dangerous. The feather keys are only locked against falling out during
shipping. If a machine with 2 shaft extensions does not have an output element on one shaft
extension, the feather key can be flung out during operation. Rotating parts can result in
death, serious injury or material damage.
● Do not operate the machine unless the transmission elements have been pulled on.
● On shaft extensions without drive output element, take suitable measures to ensure that
the feather key cannot be flung out. For balancing type "H", shorten the feather key by
about half.
5.4.5 Axial and radial forces
You can obtain the permissible values for axial and radial forces by contacting the Service
Center or referring to the machine catalog.
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Assembly
5.4 Installing the machine
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6
DANGER
Hazardous voltages
nly
Note
Service Center
If you require support when electrically connecting up the machine, please contact
Service Center
See also
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
Tightening torques (Page 141)
Death, injury or material damage can occur. Note the following safety information before
connecting-up the machine:
• Only qualified and trained personnel should carry out work on the machine while it is
stationary.
• Disconnect the machine from the power supply and take measures to prevent it being
reconnected. This also applies to auxiliary circuits.
• Check that the machine really is in a no-voltage condition.
• Establish a safe protective conductor connection before starting any work.
• If the incoming power supply system displays any deviations from the rated values in
terms of voltage, frequency, curve form or symmetry, such deviations will increase the
temperature and influence electromagnetic compatibility.
• Operating the machine on a line supply system with a non-grounded neutral point is o
permitted over short time intervals that occur rarely, e.g. the time leading to a fault being
eliminated (ground fault of a cable, EN 60034-1).
the
(Page 139).
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Electrical connection
6.1 Connected parts can become loose
6.1 Connected parts can become loose
Material damage as a result of connection parts coming loose
If you use fixing elements made from the wrong material or apply the wrong tightening
torque, this could impair current transfer or cause connecting parts to become loose. This
could result in material damage to the machine or even in total failure, which could in turn
lead indirectly to material damage to the system.
● Tighten the screwed connections to the specified tightening torques.
● Observe any specifications regarding the materials from which fixing elements must be
made.
● When performing servicing, check the fastenings.
6.2 Connecting the machine
6.2.1 Selecting cables
Take the following criteria into account when selecting the connecting cables:
● Rated current
● Rated voltage
● If required, service factor
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Configuration notes
● Requirements according to IEC/EN 60204-1
● Dimensioning for bundled cable routing, e.g. according to DIN VDE 0298 Part 4 or
IEC 60364-5-52
● Observe the information in EN / IEC 60034-1 (VDE 0530-1) regarding operation at the
limits of A and B zones, especially in respect of temperature increase and deviation of the
operating data from the rated data stamped on the rating plate. Do not exceed these
limits.
● Connect up so that a permanently safe electrical connection is guaranteed (no protruding
wire ends); use the assigned cable-end fittings (e.g. cable lugs, end sleeves).
Connect up the line supply voltage and arranged the disconnecting link in accordance
with the circuit diagram provided in the terminal box.
● Select the connecting cables in accordance with DIN VDE 0100 taking into account the
rated current and the installation-specific conditions – e.g. ambient temperature, routing
method etc. - according to DIN VDE 0298 and/or EN / IEC 60204-1.
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Electrical connection
DANGER
Hazardous voltage
NOTICE
Damage to the terminal box
1 U 1 - 1
Marking
index signifies a lower speed. Special case for split winding.
winding
feed cables to several terminals with otherwise identical markings
6.2 Connecting the machine
The technical specifications stipulate the following that have to be taken into account with
respect to the motor connection:
● Direction of rotation
● The number and arrangement of the terminal boxes.
● The circuit and connection of the motor winding
6.2.2 Terminal box
Electric motors have high voltages. When incorrectly handled, this can result in death or
severe injury.
Switch off the machine so that it is in a no-voltage condition before you open the terminal
box.
If you incorrectly carry out work on or in the terminal box, this can result in material
damage. You must observe the following to avoid damaging the terminal box:
• Ensure that the components inside the terminal box are not damaged.
• It must be ensured that there are no foreign bodies, dirt or moisture in the terminal box.
• Close the terminal box using the original seal so that it is dust tight and water tight.
• Use O-rings or suitable flat gaskets to seal entries in the terminal box (DIN 42925) and
other open entries.
• Please observe the tightening torques for cable entries and other screws.
6.2.2.1 Terminal marking
According to IEC / EN 60034-8, the following basic definitions apply to the terminal markings
for 3-phase machines:
Table 6- 1 Terminal markings using the 1U1-1 as an example
x Index for pole assignment for pole-changing machines where applicable. A lower
x Phase designation U, V, W
x Index for winding start (1) or end (2) or if there is more than one connection per
x Additional indices for cases in which it is obligatory to connect parallel power
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Electrical connection
Clockwise rotation
U V W
T1 T2 T3
Direction of rotation of the motor when looking at DE
NOTICE
Damage to the terminal box
6.2 Connecting the machine
6.2.2.2 Circuit diagram inside the terminal box cover
Data on the connection and connecting the machine winding can be found in the circuit
diagram in the cover of the terminal box.
6.2.2.3 Direction of rotation
The standard motors are suitable for clockwise and counter-clockwise rotation.
For defined directions of rotation (direction of rotation arrow), appropriately connect the line
power cables.
● If you connect the line cables with phase sequence L1, L2, L3 at U, V, W or according to
NEMA at T
● If you interchange two connections, e.g. L1, L2, L3 at V, U, W or according to NEMA at
T
T1 T3 , then the machine rotates counter-clockwise.
2
T2 T3 , then the machine rotates in the clockwise direction.
1
According to IEC According to NEMA
Counter-clockwise
rotation
6.2.2.4 Cable entry
Knockout openings
To avoid damaging the terminal box:
• Knockout openings in the terminal box must be knocked out using appropriate methods.
• Do not damage the terminal box, the terminal board, the cable connections etc. inside
the terminal box.
V U W T2 T1 T3
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Electrical connection
Note
The screw
(diameter armoring, brai
For the screw
protection (water and dust)
rating plate.
WARNING
Risk of short-circuit and voltage hazard
CAUTION
Damage to connecting cables that are freely led out
6.2 Connecting the machine
Assembly and laying of cables
Screw the screw-type connection into the housing or fasten with a nut.
-type connections must have been matched to the connecting cables used
d, shield).
-type connections, comply or exceed the requirements relating to IP degree of
- as well as the temperature range in operation stamped on the
6.2.2.5 Versions
The terminal box can be turned 4x90 degrees on the terminal base of the machine's housing
in the case of a terminal board with 6 terminal studs (standard design).
6.2.2.6 Protruding connection cables
A short circuit can occur if connecting cables are clamped and crushed between parts of
the enclosure and the cover plate.
This can result in death, severe injury and material damage.
• During disassembly and particularly when installing the cover plate, make sure that the
connecting cables are not clamped between enclosure parts and the cover plate.
You must observe the following note to avoid damaging connecting cables that are freely
led out:
• It must be ensured that there are no foreign bodies, dirt, or moisture in the terminal base
of the machine enclosure.
• Use O-rings or suitable flat gaskets to seal entries in cover plates (DIN 42925) and other
open entries.
• Seal the terminal base of the machine enclosure using the original seal of the cover
plate to prevent dust and water from entering.
• Please observe the tightening torques for cable entries and other screws.
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Electrical connection
Note
The direct contact between the cable lug surfaces and the contact nuts or contact screws
ensure that the connection can conduct current.
Rms value of the alternating voltage
Minimum air clearance
mm
≤ 250 V
3.0
≤ 500 V
3.0
≤ 630 V
5.5
≤ 1000 V
8.0
Values apply at an installation altitude of up to 2000
When determining the required minimum air clearance, the voltage value in the table may be in-
eral use.
6.2 Connecting the machine
6.2.2.7 Connecting protruding cables
In the case of connection cables brought out of the machine, no terminal board is installed
on the terminal base of the machine housing. The connection cables are directly connected
to stator winding terminals at the factory.
The connection cables are color-coded or labeled. The customer directly connects individual
cables in the control cabinet for their system in accordance with the labeling.
6.2.2.8 Connection with/without cable lugs
In the case of terminals with terminal clamps, distribute the conductors in such a way that the
clamping heights on both sides of the fillet are about the same. This method of connection
requires that you must bend a single conductor in a U shape or use a cable lug. The same
applies to the inner and outer terminals of the ground conductor.
When connecting up using cable lugs, select their size corresponding to the required cable
cross-section and the stud size. An inclined arrangement is only permitted provided the
required air clearances and creepage distances are carefully maintained.
Remove insulation from the ends of the conductors so that the remaining insulation almost
reaches the cable lug.
6.2.2.9 Minimum air clearances
After proper installation, verify that the minimum air clearances between non-insulated parts
are maintained. Be aware of any protruding wire ends.
Table 6- 2 Minimum air clearance dependent on rms value of the alternating voltage
creased by a factor of 1.1, so that the rated input voltage range is taken into account during gen-
U
rms
U
rms
m.
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Electrical connection
①
②
Nut
O ring
①
②
Nut
O ring
②
③
O ring
Mounting position of metal
nuts
6.2 Connecting the machine
6.2.3 Cable glands
Cable glands with (sheet metal) nuts (EN 50262)
Cable glands with reductions and (sheet metal) nuts (EN 50262)
6.2.3.1 Mounting position of sheet metal nuts in screw-type connections
-sheet
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Electrical connection
②
O ring
6.3 Tightening torques
Cable glands with connecting thread in the terminal box (EN 50262)
6.3 Tightening torques
Note the information in Chapter Tightening torques (Page 141).
6.3.1 Cable entries, sealing plugs and thread adapters
Note the following when mounting:
● Avoid damaging the cable jacket.
● Adapt the tightening torques to the cable jacket materials.
Observe the documentation for tightening torques of the cable entries and sealing plugs for
direct mounting at the machine as well as additional glands (e.g. adapters).
6.4 Connecting the grounding conductor
The machine's grounding conductor cross-section must comply with EN / IEC 60034-1.
Please also observe installation regulations such as those specified in EN / IEC 60204-1.
Basically, there are two ways of connecting a grounding conductor to the machine.
● Internal grounding with a connection in terminal box at the location intended for this
purpose and marked accordingly.
● External grounding with connection at the stator housing at the locations intended for this
purpose and marked accordingly.
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Electrical connection
Minimum cross-section of the phase conductor
for installation
S
[mm²]
Minimum cross-section of the associated ground-
ing connection
[mm²]
S ≤ 25
S
S > 50
0.5 S
Enclosure grounding method
Conductor cross-
section
mm²
6.4 Connecting the grounding conductor
6.4.1 Minimum surface area of grounding conductor
Table 6- 3 Minimum cross-sectional area of grounding conductor
25 < S ≤ 50 25
6.4.2 Grounding connection type
Connection of an individual conductor under the
external grounding bracket.
Connection is made using a DIN cable lug under
the external grounding bracket. DIN 46 234
Internal ground terminal
When making connections, ensure the following:
● Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
● Arrange the flat washer and spring washer under the bolt head.
● Locate the cable lug under the clamping bracket.
● Use the terminals designated for the grounding conductor in the terminal box.
… 10
… 25
● Observe the tightening torque for the locking screw.
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Electrical connection
Terminal block connection
Terminal board connection
6.5 Connecting the temperature sensor/anti-condensation heater
External ground terminal
When making connections, ensure the following:
● Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
● Position the cable lug between the contact bracket and the grounding bracket; do not
remove the contact bracket pressed into the enclosure!
● Arrange the flat washer and spring washer under the bolt head.
● Use the marked connection location for the grounding conductor on the stator housing.
● Observe the tightening torque for the locking screw.
6.5 Connecting the temperature sensor/anti-condensation heater
6.5.1 Connecting optional integrated devices and equipment
In addition to the current-dependent overload protective device located in the connecting
cables, use the optionally available integrated devices and equipment, for example,
temperature sensor, anti-condensation heating.
Depending on the terminal box version, connect the auxiliary circuits to the terminal block or
to the terminal board.
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Electrical connection
Shaft height
Max. connectable conductor cross-section
[mm²]
2.5 with cable lug
100 ... 112
4.0
132
6.0
160 ... 180
16.0
200
25.0
225
35.0 with cable lug
250 ... 280
120.0
315
240.0
Terminal board
Conductor
cross-
section
[mm²]
Connection with cable lug
①
④ Cover plate
6.6 Conductor connection
6.6 Conductor connection
Cross-sections that can be connected depending on the size of the terminal (possibly
reduced due to size of cable entries)
Table 6- 4 Max. conductor connection
63 ... 90 1.5
6.6.1 Type of conductor connection
DIN 46 234
Bend down the cable lug for the
connection.
... 25
Connection of an individual conductor with terminal clamp
Connection of two conductors of
approximately the same thickness
with terminal clamp
Connecting bar
② Line supply cable
③ Motor connecting cable
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... 25
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Electrical connection
NOTICE
Aluminum flow due to contact pressure
NOTICE
Excessively high supply voltage
6.7 Connecting converters
6.6.2 Connecting aluminum conductors
If you are using aluminum conductors, then comply with the following:
● Use only cable lugs that are suitable for connecting aluminum conductors.
● Immediately before inserting the aluminum conductor, remove the oxide layer from the
contact areas on the conductor and/or the mating piece. Do this using a brush or file.
● Then grease the contact areas immediately using neutral Vaseline. This prevents a new
oxide layer from forming.
Aluminum flows following installation due to the contact pressure. The connection using
clamping nuts can loosen as a result. The contact resistance increases, obstructing the
current from being conducted. This can result in fire and material damage to the
machine – or even in total failure, as well as material damage to the plant or system due
to machine failure.
• Retighten the clamping nuts after approximately 24 hours and then again after
approximately four weeks. Make sure that the terminals are de-energized before you
tighten the nuts.
6.7 Connecting converters
Material damage can occur if the supply voltage is too high for the insulation system.
SIMOTICS machines can be operated with SINAMICS G converters and SINAMICS S
converters (uncontrolled and controlled infeed) when maintaining the permissible peak
voltages.
Carefully observe the values in the following tables.
Rise times t
The insulation system of SIMOTICS machines corresponds to the specifications laid down
in IEC 60034-18-41 according to voltage stress category C (IVIC C = high stress).
> 0.1 µs.
r
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Electrical connection
Rated motor voltage
V
Maximum peak voltage at the motor terminals
Û
dependent on the rise time t
Vpk
Vpk
μs
V
1500
1100
0.5
900
900
0.1
Rated motor voltage
V
Maximum peak voltage at the motor terminals
Û
dependent on the rise time tr
Vpk
Vpk
μs
V
1600
1400
0.5
1000
1000
0.1
2200
1800
0.5
1000
1000
0.1
6.8 Final checks
Table 6- 5 Maximum voltage peaks at the motor terminals for line (DOL) motors, converter operation possible
Û
phase-to-phase
≤ 500 V
Table 6- 6 Maximum voltage peaks at the motor terminals for motors specifically designed for converter operation (e.g.
VSD 10)
Û
phase-to-phase
≤ 500 V
> 500 V to 690 V
max
Û
phase-to-ground
max
Û
phase-to-ground
Rise time tr
Rise time tr
r
DC link UDC
750
DC link UDC
750
1080
See also
Further documents (Page 140)
6.8 Final checks
Before closing the terminal box/terminal base of the machine enclosure, check the following:
● Establish the electrical connections in the terminal box in accordance with the information
in this documentation.
● Maintain the air clearances between non-insulated parts as described in Chapter
Minimum air clearances. (Page 66)
● Avoid protruding wire ends.
● In order not to damage the cable insulation, freely arrange the connecting cables.
● Connect the machine corresponding to the specified direction of rotation.
● Keep the inside of the terminal box clean and free from trimmed-off ends of wire.
● Ensure that all seals and sealing surfaces are undamaged and clean.
● Correctly and professionally close unused openings in the terminal boxes. Observe the
information in this documentation.
● Observe the information on torques in this documentation.
See also
Tightening torques for screw and bolt connections (Page 141)
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Electrical connection
6.8 Final checks
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7
Note
Service Center
Plea
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
se contact the Service Center if you require commissioning support.
7.1 Measures before commissioning
Risk of losing the IP degree of protection as a result of damaged shaft sealing rings
This can result in death, serious injury, or material damage.
● Replace damaged components immediately.
7.1.1 Checks to be carried out prior to commissioning
The following list of checks to be performed prior to commissioning does not claim to be
complete. It may be necessary to perform further checks and tests in accordance with the
specific situation on-site.
Once the system has been correctly installed, you should check the following prior to
commissioning:
● The machine is undamaged.
● The machine has been properly installed and aligned.
● The output transmission elements are set correctly for their type,
e.g. alignment and balancing of couplings, belt forces in the case of a belt drive, tooth
forces and tooth-flank backlash in the case of geared output, radial and axial clearance in
the case of coupled shafts.
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● All fixing screws, connection elements, and electrical connections have been tightened to
the specified tightening torques.
● The operating conditions match the data provided in accordance with the technical
documentation, such as degree of protection, ambient temperature, etc..
75
Page 78
Commissioning
7.1 Measures before commissioning
● Moving parts, for example the coupling, move freely.
● All touch protection measures for moving and live parts have been taken.
● Screwed-in lifting eyes are removed after installation or secured to prevent them from
becoming loose.
● Before commissioning, attach the covers to guarantee the correct air guidance.
● Ensure that all condensation drain holes are always located at the lowest part of the
machine.
Second shaft extension
If the second shaft extension is not used:
● Carefully secure the feather key to prevent it from being thrown out, and for balancing
type "H" (standard type), ensure its weight is reduced to approximately 60 % of the
original value.
● Using covers, carefully secure the unused shaft extension so that it cannot be touched.
7.1.2 Mechanical checks
● Rotate the rotor to ensure that it does not touch the stator.
● Ensure that the bearing insulation is not bridged/jumpered.
● Using the appropriately designed and adjusted control and speed monitoring functions
ensure that the permissible speeds specified on the rating plate cannot be exceeded.
● Ensure that any supplementary equipment used to monitor the motor is correctly
connected and is functioning.
Electrical connection
● Carefully check the grounding and potential bonding connections.
● Connect the machine corresponding to the specified direction of rotation.
● Using the appropriate open-loop control and speed monitoring functions, carefully ensure
that no higher speeds can be achieved than are permitted and specified in the technical
data. For this purpose, compare the data on the rating plate or, if necessary, the systemspecific documentation.
● Comply with the minimum insulation resistances.
● Comply with the minimum air clearances.
● Correctly connect possibly available machine monitoring devices and equipment - and
carefully ensure that they are functioning correctly.
● Check the correct functioning of the brakes or backstops.
● Set the values for "Alarm" and "Shutdown" at the monitoring devices.
● Carefully ensure that temperature-sensitive parts and components, e.g. cables are not in
contact with the machine enclosure.
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Commissioning
7.1 Measures before commissioning
Converter operation
● If the motor design requires connection to a specific converter type, carefully check the
supplementary data on the rating plate/supplementary plate.
● Ensure that the converter is correctly parameterized. Depending on the design, you will
find some parameterization data on the rating plate of the machine. Further information is
provided in the converter documentation. If necessary, contact the Service Center.
● Check that the supplementary equipment and devices to monitor the machine are
correctly connected and are functioning correctly.
● In continuous operation, carefully ensure that the motor cannot exceed the specified
upper speed limit n
or fall below the lower speed limit n
max
min
.
The permissible acceleration time to the limit speed n
assignment.
7.1.3 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
depends on the parameter
min
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"
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Commissioning
WARNING
Hazardous voltage at the terminals
– Attach the connection cable.
7.1 Measures before commissioning
7.1.4 Testing the insulation resistance and polarization index
During and immediately after measuring the insulation resistance or the polarization index
(PI) of the stator winding, hazardous voltages may be present at some of the terminals.
Contact with these can result in death, serious injury or material damage.
• If any power cables are connected, check to make sure line supply voltage cannot be
delivered.
• Discharge the winding after measurement until the risk is eliminated, e.g. using the
following measures:
– Connect the terminals with the ground potential until the recharge voltage drops to a
non-hazardous level
Measure the insulation resistance
1. Before you begin measuring the insulation resistance, please read the operating manual
for the insulation resistance meter you are going to use.
2. Short-circuit the ends of the temperature sensor cables before applying the test voltage. If
the test voltage is connected to only one temperature sensor terminal, the temperature
sensor will be destroyed.
3. Make sure that no power cables are connected.
4. Measure the winding temperature and the insulation resistance of the winding in relation
to the machine enclosure. The winding temperature should not exceed 40° C during the
measurement. Convert the measured insulation resistances in accordance with the
formula to the reference temperature of 40° C. This thereby ensures that the minimum
values specified can be compared.
5. Read out the insulation resistance one minute after applying the measuring voltage.
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Commissioning
U
N
V
U
meas
V
R
C
MΩ
U ≤ 1000
500
≥ 5
2500 < U ≤ 5000
1000 (max. 2500)
U > 12000
5000 (max. 10000)
U
U
R
C
= minimum insulation resistance at a reference temperature of 40 °C
R
C
Insulation resistance converted to 40° C reference temperature
K
Temperature coefficient according to equation (2)
T
in °C
40
Reference temperature in °C
10
Halving/doubling of the insulation resistance with 10 K
T
Measuring/winding temperature in °C
7.1 Measures before commissioning
Limit values for the stator winding insulation resistance
The following table specifies the measuring voltage and limit values for the insulation
resistance. These values correspond to IEEE 43-2000 recommendations.
Table 7- 1 Stator winding insulation resistance at 40° C
1000 ≤ U ≤ 2500 500 (max. 1000) 100
5000 < U ≤ 12000 2500 (max. 5000)
= rated voltage, see the rating plate
rated
= DC measuring voltage
meas
Conversion to the reference temperature
When measuring with winding temperatures other than 40° C, convert the measuring value
to the reference temperature of 40° C according to the following equations from IEEE 43-
2000.
(1)
R
=
K
·
R
T
(40-T)/10
T
C
(2)
K
= (0.5)
T
In this case, doubling or halving the insulation resistance at a temperature change of 10 K is
used as the basis.
● The insulation resistance halves every time the temperature rises by 10 K.
● The resistance doubles every time the temperature falls by 10 K.
For a winding temperature of approx. 25° C, the minimum insulation resistances are 20 MΩ
(U ≤ 1000 V) or 300 MΩ (U > 1000 V). The values apply for the complete winding to ground.
Twice the minimum values apply to the measurement of individual assemblies.
● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ, or
possibly even higher values. An insulation resistance value close to the minimum value
could be due to moisture and/or dirt accumulation. The size of the winding, the rated
voltage and other characteristics affect the insulation resistance and may need to be
taken into account when determining measures.
T
R
Measured insulation resistance for measuring/winding temperature
T
● Over its operating lifetime, the motor winding insulation resistance can drop due to
ambient and operational influences. Calculate the critical insulation resistance value
depending on the rated voltage by multiplying the rated voltage (kV) by the specific
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Commissioning
R
(10 min)
/ R
(1 min)
Assessment
≥ 2
Insulation in good condition
NOTICE
Damage to insulation
7.1 Measures before commissioning
critical resistance value. Convert the value for the current winding temperature at the time
of measurement, see above table.
Measuring the polarization index
1. To determine the polarization index, measure the insulation resistances after one minute
and ten minutes.
2. Express the measured values as a ratio:
PI =
R
insul 10 min
Many measuring devices display these values automatically following the measurement.
For insulation resistances > 5000 MΩ, the measurement of the PI is no longer meaningful
and consequently not included in the assessment.
/
R
insul 1 min
< 2 Dependent on the complete diagnosis of the insulation
If the critical insulation resistance is reached or undershot, this can damage the insulation
and cause voltage flashovers.
• Contact the service center.
• If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
Limit values of the anti-condensation heating insulation resistance
The insulation resistance of the anti-condensation heating with respect to the machine
housing should not be lower than 1 MΩ when measured at 500 V DC.
7.1.5 Testing the cooling of the machine
Cooling
● Check that the machine cooling is available for commissioning.
7.1.6 Commissioning an external fan
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The external fan ensures that the machine is cooled irrespective of the machine speed or
direction of rotation. The external fan is only suitable for one direction of rotation.
Page 83
Commissioning
Note
Use these operating instructions f
Note
Further documents
Observe all of the other documents provided with this machine.
7.1 Measures before commissioning
Checks before the first test run
Before the first test run, carry out the following checks:
● The external fan is correctly fitted and aligned.
● The rotor runs freely.
● All of the retaining elements and electrical connections are securely tightened.
● The grounding and equipotential bonding connections to the mains have been correctly
made.
● The air flow is not impeded or shut off by flaps, covers or similar.
● If the cooling air is in open circulation, it has only weak, chemically abrasive properties
and a low dust content.
● All protection measures have been taken to prevent accidental contact with moving or live
parts.
Performing the test run
1. Switch the external fan motor on and off briefly.
2. Compare the direction of rotation of the external fan with the specified direction of
rotation. The direction of rotation of the external fan is indicated with an arrow on the fan
cover specifying the direction of rotation or with a terminal designation on the rating plate
of the external fan unit.
Depending on the version, the fan impeller is visible through the air inlet opening in the
fan cover on the external fan motor.
3. If the direction of rotation is wrong, then interchange two line cables in the external fan
motor terminal box.
7.1.7 Further documents
or motors with external fans.
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Commissioning
Set value
Temperature
Alarm
115 °C
Shutting down
120 °C
Set value
Temperature
Alarm
T
+ 5 K ≤ 115 °C
Shutting down
T
+ 10 K ≤ 120 °C
7.2 Switching on
7.1.8 Setpoint values for monitoring the bearing temperature
Prior to commissioning
If the machine is equipped with bearing thermometers, set the temperature value for
disconnection on the monitoring equipment before the first machine run.
Table 7- 2 Set values for monitoring the bearing temperatures before commissioning
Normal operation
Determine the maximum operating temperature of the bearings T
the temperature, bearing load and influences of the plant on the motor in °C. Set the values
for shutdown and warning corresponding to the operating temperature T
Table 7- 3 Set values for monitoring the bearing temperatures
operation
operation
7.2 Switching on
7.2.1 Measures required for commissioning and test operation
After installation or inspection, carry out a test run:
1. Start up the machine without a load. To do this, close the circuit breaker and do not
switch off prematurely. Check whether it is running smoothly.
Switching the machine off again while it is starting up and still running at slow speed
should be kept to a bare minimum, for example for checking the direction of rotation or for
checking in general.
taking into account
operation
.
op
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Allow the machine to run down before switching it on again.
2. If the machine is running smoothly and evenly, switch on the cooling equipment. Continue
to observe the machine for a while in no-load operation.
Page 85
Commissioning
NOTICE
Thermal overload of motors connected directly to the line supply
NOTICE
Serious damage to the machine
7.2 Switching on
3. If it runs perfectly, connect a load.
In addition to the load torque, the ramp-up (accelerating) time is essentially influenced
by the moment of inertia to be accelerated. While ramping up when connected to the
line supply, the inrush (starting) current is a multiple of the rated current. This can result
in thermal overload. This can damage the motor.
As a consequence, when ramping up, observe the following:
• Monitor the ramp-up time and number of consecutive starts.
• Comply with the limit values and/or ramp-up conditions specified in the catalog or the
order documentation.
4. During the test run, check and document the following:
– Check whether it is running smoothly.
– Document the voltage, current and power values. As far as possible, document the
corresponding values of the driven machine.
– If this is possible using the available measuring equipment, check the bearing and
stator winding temperatures until they have reached steady-state values.
– Check the machine for noise or vibrations on the bearings or bearing shields as it
runs.
5. In case of uneven running or abnormal noise, switch off the machine. As the machine
runs down, identify the cause.
– If the mechanical operation improves immediately after the machine is switched off,
then the cause is magnetic or electrical.
– If the mechanical running does not improve immediately after switching the machine
off, then the cause is mechanical.
- Imbalance of the electrical machine or the driven machine
- The machine set has not been adequately aligned
- The machine is being operated at the system resonance point. System = motor, base
frame, foundation, ...
If the vibration values in operation are not maintained in accordance with DIN ISO
10816-3, then the machine can be mechanically destroyed.
• During operation, observe the vibration values in accordance with
DIN ISO 10816-3.
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Commissioning
7.2 Switching on
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8
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
8.1 Safety instructions for operation
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer
guaranteed if covers are removed. Touching rotating parts can result in death, serious injury
or material damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● Only remove the covers when the rotating parts have come to a complete standstill.
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum air and creepage distances may be fallen
below (violated) when coming close to active parts. Touching or coming close can result in
death, serious injury or material damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and in a no-voltage
condition.
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Operation
8.1 Safety instructions for operation
Faults in operation
Any changes with respect to the normal condition can indicate that the machine is not
functioning correctly.
● Higher power consumption, temperatures or vibration levels.
● Unusual noise or smells.
● Monitoring devices respond.
These changes can cause faults which can result in eventual or immediate death, serious
injury or material damage.
● Immediately inform the service personnel.
● If you are in doubt, immediately switch off the machine, carefully observing the system-
specific safety conditions.
Damage caused by condensation
Humidity in the air can condense for intermittent duty or load fluctuations. Condensate can
collect. Moisture can have a negative impact on the winding insulation or result in damage,
such as corrosion.
● Ensure that any condensation can freely flow away.
Risk of burn injuries as a result of hot surfaces
Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
● Never touch machine parts during operation.
● Allow the machine to cool down before starting work.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Hazardous substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk. Poisoning, skin damage, cauterization of the respiratory tract, and
other health damage may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.
Substances that can be easily ignited and are flammable
Chemical substances required for the setup, operation and maintenance of machines may
be flammable. Burns and other damage to health and material may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.
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Operation
DANGER
Hazardous voltages
NOTICE
Damage to the machine or premature bearing failure
WARNING
Faults in operation
8.1 Safety instructions for operation
Switching on the machine
Electrical machines are at hazardous voltage levels. Contact with these can result in death,
serious injury or material damage.
Operating the machine on a line supply system with a non-grounded neutral point is only
permitted for short periods of time that occur rarely, e.g. the time leading to a fault being
eliminated. Cable ground fault EN / IEC 60034-1.
The bearings can be damaged if the following is not observed.
• It is absolutely crucial that you maintain the permissible vibration values to avoid
damage to the machine or its destruction.
• In operation, observe the vibration values in accordance with ISO 10816-3.
• Under all circumstances maintain the minimum radial load of cylindrical roller bearings
of 50% corresponding to what is specified in the catalog.
• Take the appropriate measures to reduce bearing currents. Observe the Chapter
Converter operation.
Changes with respect to normal operation indicate that there is an impaired function. This
can cause faults which can result in eventual or immediate death, severe injury or material
damage.
For instance, observe the following signs that could indicate a malfunction:
• Higher power drawn than usual
• Higher temperatures than usual
• Unusual noises
• Unusual smells
• Response of monitoring equipment
Immediately contact the maintenance personnel if you identify any irregularities. If you are
in doubt, immediately switch off the machine, being sure to observe the system-specific
safety conditions.
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Operation
NOTICE
Risk of corrosion due to condensation
CAUTION
Machine overheating
WARNING
Risk of burning
8.1 Safety instructions for operation
If the machine and/or ambient temperatures fluctuate, this can result in condensation inside
the machine.
• If available, remove the drain plugs or drain screws to drain the water depending on the
ambient and operating conditions.
• If available, re-attach the drain plugs or drain screws.
If the motor is equipped with drain plugs, then the water can drain away by itself.
Switching on the machine with anti-condensation heating (optional)
Minor injury or material damage can occur if you do not observe the following:
• If available, switch off the anti-condensation heating each time before switching on.
8.1.1 Safety instructions relating to ventilation and cooling
8.1.1.1 Safety instruction for forced ventilation (option)
Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
Operating the machine without external fan results in overheating. This may result in death,
personal injury and material damage.
• Never commission the machine without an external fan.
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Operation
CAUTION
Risk of injury when touching the fan
8.1 Safety instructions for operation
8.1.1.2 Safety instructions when operating machines with fan
There is a risk of injury at machines equipped with a fan cover (e.g. on machines in the
textile industry), as the fan is not completely touch protected.
• Do not touch the rotating fan.
• Do not put your fingers into the larger air discharge openings.
• Prevent manual intervention by using suitable measures, e.g. appropriate housings or a
protective grating.
8.1.1.3 Machines with fan for the textile industry
In order to guarantee an essentially unobstructed flow of cooling air containing fluff, remains
of materials or similar dirt, machines used in the textile industry have a larger air discharge
cross-section between the edge of the cover and the cooling ribs of the machine frame.
These machines have a warning sticker on the fan cover.
8.1.2 Switching on with the anti-condensation heating active
Excessively high machine temperature when heating is switched on
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine. Material damage can result.
● Make sure that the anti-condensation heating is switched off before the machine is
switched on.
● Only operate anti-condensation heating when the machine is switched off.
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Operation
NOTICE
Thermal overload of motors connected directly to the line supply
8.2 Switching on the machine
8.2 Switching on the machine
1. If at all possible, run the machine without load and check that it is running smoothly.
2. If it runs perfectly, connect a load.
In addition to the load torque, the ramp-up (accelerating) time is essentially influenced
by the moment of inertia to be accelerated. While ramping up when connected to the
line supply, the inrush (starting) current is a multiple of the rated current. This can result
in thermal overload. This can damage the motor.
As a consequence, when ramping up, observe the following:
• Monitor the ramp-up time and number of consecutive starts.
• Comply with the limit values and/or ramp-up conditions specified in the catalog or the
order documentation.
3. If this is possible using the available measuring equipment, check the bearing and stator
winding temperatures.
8.3 Switch off the external fan
Do not immediately switch off the separately-driven (external) fan after switching off the
machine. First wait for the machine to cool down. This will prevent the accumulation of
residual heat.
8.4 Switching on again after an emergency switching-off
● Check the machine before recommissioning the driven machine after an Emergency Off.
● Eliminate all the causes that have led to the emergency off
8.5 Stoppages
The stoppage is a shutdown for a period of time, during which the machine is stopped but
remains at the location of use.
Under normal ambient conditions, e. g. the stopped machine is not exposed to any vibration,
no increased level of corrosion, etc. in general, the following measures are necessary during
stoppages.
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Operation
Note
•
•
•
NOTICE
Restricted motor function
NOTICE
Dry running bearings
8.5 Stoppages
Longer non-operational periods
For longer non-operational periods (> 1 month), either operate the machine or at least
turn the rotor regularly, approximately once per month.
Please refer to the section "Switching on" before switching on to recommission the motor.
Remove any machine rotor locking devices before you turn the rotor.
If not used for longer periods of time, material damage or complete motor failure can occur.
If the motor is out of service for a period of more than 12 months, then environmental
effects can damage the motor.
• Apply suitable corrosion protection, preservation, packing and drying measures.
Switching on the anti-condensation heater
Switch on any anti-condensation heating while the machine is not being operated.
Taking the machine out of service
Details regarding the necessary measures, Chapter Preparing for use (Page 27).
Lubricating before recommissioning
Bearings can be damaged if they do not have sufficient grease.
• Re-grease the bearings if they have been out of service for more than one year. The
shaft must rotate so that the grease can be distributed in the bearings. Observe the data
on the lubricant plate.
Chapter Rolling bearings (Page 106).
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Operation
8.6 faults
8.5.1 Avoidance of damage to rolling bearings during stoppages
Extended stoppages at the identical or almost identical resting position of the rotor in the
rolling bearings can result in damage, such as brinelling or corrosion.
● During stoppages, regularly start up the machine for a brief period once a month. As a
minimum, turn the rotor several times.
If you have uncoupled the machine from the driven machine and secured the rotor with a
rotor shipping brace, then remove this before turning the rotor over or starting up the
machine.
Make sure that the resting position of the rotor after the rotor has been turned over is
different from its previous position. Use the fitted key or the coupling halves as reference
markers.
● During recommissioning, refer to the information in Chapter "Commissioning".
8.5.2 Decommissioning the machine
● Record the decommissioning steps. This log will be useful upon recommissioning.
● If the machine is going to be out of service for longer than six months, then take the
necessary measures for preservation and storage. Otherwise, the machine could be
damaged as a result of not being operated.
8.5.3 Re-commissioning the machine
When you re-commission the machine, proceed as follows:
● Study the record made when the machine was decommissioned, and reverse the
measures that were taken for conservation and storage.
● Perform the measures listed in the "Commissioning" section.
8.6 faults
8.6.1 Inspections in the event of faults
Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.
Correct the cause of the fault as described in the respective remedial measures section.
Repair any damage to the machine.
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Operation
Note
If you are operating the motor with a converter, the operating instructions of the converter
must also be observed if electrical faults occur.
↓ Motor fails to start
↓ Motor accelerates sluggishly
↓ Rumbling noise during startup
↓ Rumbling noise during operation
↓ High temperature rise during no-load operation
↓ High temperature rise with load
↓ High temperature rise of individual winding sections
Possible causes of faults
Remedial measures
X X X X
Overload
Reduce the load.
X
Interrupted phase in the supply cable
Check the switches and cables.
after switching on
high
low
box.
after
consultation with the manufacturer.
X
Incorrect direction of rotation
Check the connection.
8.6 faults
8.6.2 Electrical faults
Table 8- 1 Electrical faults
X X X X Interrupted phase in the feeder cable
X Mains voltage too low, frequency too
X Mains voltage too high, frequency too
X X X X X Stator winding incorrectly connected Check the winding connection in the terminal
X X X X Winding short circuit or phase short
circuit in stator winding
Check the switches and cables.
Check the power supply conditions.
Check the power supply conditions.
Determine the winding resistances and insulation resistances. Carry out repair work
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Operation
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults
Remedial measures
Disconnect the rotor or coupling and rebalance.
its length.
X
Rotor out of round, shaft bent
Consult the manufacturing plant.
X X
Poor alignment
Align the machine set; check the coupling.
X
Coupled machine not balanced
Rebalance the coupled machine.
X
Shocks from coupled machine
Investigate the coupled machine.
X X
Uneven running of gear unit
Fix the gearing.
prising motor and foundation
sary; realign the machine.
Take any changes into account when warming up the machine.
↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
Possible causes of faults
Remedial measures
X
High coupling pressure
Align the machine more accurately.
X
Bearing contaminated
Clean or replace the bearing. Check the seals.
X
High ambient temperature
Use a suitable high-temperature grease.
X X
Insufficient lubrication
Grease the bearings as instructed.
X X
Bearing canted
Contact the service center.
X X
Insufficient bearing play
Contact the service center.
X
Excessive bearing play
Contact the service center.
8.6 faults
8.6.3 Mechanical faults
Table 8- 2 Mechanical faults
X Rotating parts grind Establish the cause and realign the parts.
X Rotor or coupling not balanced.
If the machine has two shaft ends, and a transmission element is
only fitted to one end, secure the fitted key at the other end to
prevent it from being thrown out. If the rotor has balance type "H"
(standard type), the fitted key must be cut back to roughly half of
(1)
X X Resonance of the overall system com-
X X Changes in foundation Establish the cause of the changes and eliminate them if neces-
(1)
Stabilize the foundation following consultation.
8.6.4 Rolling bearing faults
Damage to rolling bearings can be difficult to detect in some cases. If in doubt, replace the
rolling bearing. Use other bearing designs only
Table 8- 3 Rolling bearing faults
X Belt tension too high Reduce the drive belt tension.
after consulting the manufacturer.
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Operation
X X
Bearing corroded
Replace the bearing. Check the seals.
X
Too much grease in bearing
Remove surplus grease.
X
Wrong grease in the bearing
Use the correct grease.
X
Friction marks on raceway
Replace the bearing.
↓ High temperature rise with load
Possible causes of faults
Remedial measures
X
External fan is not running
Check the external fan and its connections.
X
Reduced air flow
Check the air ducts; clean the machine.
8.7 Deactivating
X Brinelling or scoring Replace the bearing. Avoid any vibration at standstill
8.6.5 Faults at the external fan
The following table shows the possible causes of and remedial measures for faults on
forced-ventilated machines.
Table 8- 4 Cooling system faults
X Wrong direction of rotation of the external fan Check the electrical connections to the external fan.
8.7 Deactivating
Commission any devices provided for protection against condensation after switching off the
machine.
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Operation
8.7 Deactivating
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9
Note
Please contact the service center, if you require support with service, maintenance or repair.
Underwriters Laboratories
Canadian Stand
Canadian Standard Association Energy Efficiency Verification
Through careful and regular maintenance, inspections, and overhauls you can detect faults
at an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
9.1 Preparation and notes
9.1.1 North American market (optional)
When making changes or repairs, maintain the corresponding design standards! These
machines are labeled on the rating plate with the following markings.
ard Association
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Maintenance
Note
Paint system
Contact the Service
with more information about the correct paint system and methods of repairing paint
damage.
WARNING
Rotating and live parts
WARNING
Machine damage
CAUTION
Dust disturbances when working with compressed air
9.2 Inspection and maintenance
9.1.2 Touch up any damaged paintwork
If the paint is damaged, it must be repaired in order to protect the unit against corrosion.
Center before you repair any damage to paint. They will provide you
9.2 Inspection and maintenance
9.2.1 Safety instructions for inspection and maintenance
Electric machines contain live and rotating parts. Fatal or serious injuries and substantial
material damage can occur if maintenance work is performed on the machine when it is not
stopped or not de-energized.
• Perform maintenance work on the machine only when it is stopped. The only operation
permissible while the machine is rotating is regreasing the rolling bearings.
• When performing maintenance work, comply with the five safety rules (Page 11).
If the machine is not maintained it can suffer damage. This can cause faults which can
result in eventual or immediate death, serious injury or material damage.
Perform regular maintenance on the machine.
When cleaning with compressed air, dust, metal chips, or cleaning agents can be whirled
up. Injuries can result.
When cleaning using compressed air, make sure you use suitable extraction equipment
and wear protective equipment (safety goggles, protective suit, etc.).
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