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SIMOTICS HV C
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Siemens SIMOTICS HV C, 1NB1402-2AA84-4CA0-Z Operating And Installation Instructions

www.siemens.com/drives
For employment in zone 1 or zone 2 (IEC/EN 60079-10-1)
Operating Instructions Installation Instructions
Induction motor
SIMOTICS HV C
Type 1NB1402-2AA84-4CA0-Z
II 2G Ex db e IIB T4 Gb
Edition 06/2018
26.06.2018 15:34 V3.00
Induction motor
SIMOTICS HV C Type 1NB1402-2AA84-4CA0-Z
For employment in zone 1 or zone 2 (IEC/EN 60079-10-1)
0102
II 2G Ex db e IIB T4 Gb
Introduction
1
Operating Instructions Installation Instructions
Safety information
Description
Preparations for use
Assembly
Electrical connection
Commissioning
Operation
2
3
4
5
6
7
8
Maintenance
Spare parts
Disposal
Service and Support
Technical data and drawings
Quality documents
Additional documents
9
10
11
A
B
C
D
Edition 06/2018
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.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE indicates that property damage can result if proper precautions are not taken.
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.
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:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical 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 ambient conditions must be complied with. The information in the relevant documentation must be observed.
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.
Siemens AG Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY
Document order number: EXAMPLE Ⓟ 06/2018 Subject to change
Copyright © Siemens AG 2018. All rights reserved

Table of contents

1 Introduction.................................................................................................................................................11
1.1 About these instructions.........................................................................................................11
1.2 Compiling personal documents..............................................................................................12
2 Safety information.......................................................................................................................................13
2.1 Information for those responsible for the plant.......................................................................13
2.2 The 5 safety rules...................................................................................................................14
2.3 Qualified personnel................................................................................................................14
2.4 Safe handling.........................................................................................................................14
2.5 Use in hazardous zones and areas........................................................................................16
2.6 Electrostatic sensitive devices...............................................................................................17
2.7 Electromagnetic compatibility.................................................................................................18
2.8 Interference immunity.............................................................................................................18
2.9 Influence on the line power supply through a strongly irregular torque..................................18
2.10 Electromagnetic fields when operating electrical power engineering installations.................18
3 Description..................................................................................................................................................19
4 Preparations for use...................................................................................................................................23
4.1 Safety-related aspects to consider when configuring the plant..............................................23
4.2 Observing the operating mode...............................................................................................23
4.3 Ensure adequate cooling.......................................................................................................23
4.4 Interlock circuit for anti-condensation heating........................................................................23
4.5 Noise emission.......................................................................................................................24
4.6 Voltage and frequency fluctuations during line operation......................................................24
4.7 Phase synchronization during supply system switching........................................................24
4.8 System-inherent frequencies.................................................................................................24
4.9 Torsional loading of the drive train due to faults in the electrical supply................................25
4.10 Switching high-voltage motors...............................................................................................25
4.11 Machines without final paint coating......................................................................................26
4.12 Thermal protection.................................................................................................................26
4.13 Transport and storage............................................................................................................27
4.13.1 Transport markings................................................................................................................27
4.13.2 Checking the delivery.............................................................................................................27
4.13.3 Attaching the rotor shipping brace.........................................................................................28
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4.13.4 Checking the load handling attachments...............................................................................28
4.13.5 Lifting and transportation........................................................................................................29
4.13.6 Securing the rotor...................................................................................................................31
4.13.7 Working on the underside of the machine..............................................................................33
4.13.8 Storage...................................................................................................................................33
4.13.9 Storing machines together with the driven machine..............................................................35
4.13.10 Storage for longer than two years..........................................................................................37
4.13.11 Protection against corrosion...................................................................................................38
4.14 Converter operation...............................................................................................................38
4.14.1 Tandem operation..................................................................................................................38
5 Assembly....................................................................................................................................................39
5.1 Preparations for installation....................................................................................................40
5.1.1 Requirements for installation..................................................................................................40
5.1.2 Insulation resistance and polarization index..........................................................................40
5.1.3 Testing the insulation resistance and polarization index........................................................41
5.1.4 Prepare the mating faces for a flange connection..................................................................44
5.1.5 Do not bridge the bearing insulation......................................................................................44
5.2 Lift the machine to where it will be installed, and position it...................................................45
5.2.1 Checking the load handling attachments...............................................................................45
5.2.2 Preconditions for correct alignment and secure attachment .................................................45
5.2.3 Removing the rotor shipping brace........................................................................................46
5.2.4 Mounting the output elements................................................................................................47
5.2.5 Lifting the machine.................................................................................................................48
5.2.6 Working on the underside of the machine..............................................................................50
5.2.7 Removing anti-corrosion protection.......................................................................................50
5.2.8 Setting down the machine......................................................................................................51
5.3 Installing the machine............................................................................................................52
5.3.1 Safety instructions for installation...........................................................................................52
5.3.2 Selecting bolts........................................................................................................................52
5.3.3 Preconditions for smooth, vibration-free operation................................................................53
5.3.4 Recommended alignment accuracy.......................................................................................53
5.3.5 Aligning the machine to the driven machine and mounting it.................................................53
5.3.6 Axial and radial forces at the second shaft extension............................................................54
5.4 Complete the installation work...............................................................................................54
6 Electrical connection...................................................................................................................................55
6.1 Safety instructions..................................................................................................................55
6.2 Preparation.............................................................................................................................55
6.2.1 Selecting cables.....................................................................................................................55
6.2.2 Route the cable with an appropriate loop so that water can drip off......................................56
6.2.3 Terminal designation..............................................................................................................56
6.2.4 Routing the cable into the terminal box..................................................................................57
6.2.5 Terminal boxes with type of protection "Ex d/Ex db" .............................................................57
6.2.6 Terminal boxes with type of protection "Ex e/Ex eb" .............................................................58
6.2.7 Connecting the grounding conductor.....................................................................................59
6.3 Inserting and routing the cables.............................................................................................60
6.3.1 Connecting the machine for a specific direction of rotation....................................................60
6.3.2 Tightening torques for cable glands ......................................................................................61
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6.3.3 Cable ends with wire end sleeves..........................................................................................62
6.3.4 Connecting aluminum conductors..........................................................................................63
6.3.5 Internal equipotential bonding................................................................................................63
6.3.6 Stepless mating face for sealing in the terminal box cover....................................................63
6.3.7 Finishing connection work......................................................................................................64
6.4 Connecting the auxiliary circuits.............................................................................................64
6.4.1 Selecting cables.....................................................................................................................64
6.4.2 Selecting cables.....................................................................................................................65
6.4.3 Bringing cables into the auxiliary terminal box and routing them...........................................65
6.4.4 Degree of protection of the auxiliary terminal box..................................................................66
6.4.5 Connecting temperature monitoring for the stator winding....................................................66
6.4.6 Intrinsically safe circuits for sensors or probes......................................................................66
6.4.7 Installing intrinsically safe circuits..........................................................................................67
6.4.8 Internal equipotential bonding in the auxiliary terminal box...................................................68
6.4.9 Terminating the connection work (auxiliary circuit)................................................................68
7 Commissioning...........................................................................................................................................69
7.1 Prior to commissioning ..........................................................................................................69
7.2 Insulation resistance and polarization index..........................................................................71
7.3 Greasing the roller bearings prior to commissioning..............................................................71
7.4 Test run..................................................................................................................................72
7.5 Overvoltages when switching high-voltage motors................................................................73
8 Operation....................................................................................................................................................75
8.1 Safety instructions for operation.............................................................................................75
8.2 Switching on with the anti-condensation heating active.........................................................77
8.3 Switching on the machine......................................................................................................77
8.4 Regreasing roller bearings.....................................................................................................77
8.5 Switching on again after an emergency switching-off............................................................78
8.6 Stoppages..............................................................................................................................78
8.6.1 Avoidance of condensation or formation of condensation within the machine.......................78
8.6.2 Avoidance of damage to roller bearings during stoppages....................................................79
8.6.3 Measuring the insulation resistance after an extended stoppage..........................................79
8.7 Decommissioning the machine..............................................................................................80
8.8 Re-commissioning the machine.............................................................................................80
8.9 Faults.....................................................................................................................................80
8.9.1 Inspections in the event of faults............................................................................................80
8.9.2 Electrical faults.......................................................................................................................81
8.9.3 Mechanical faults...................................................................................................................82
8.9.4 Roller bearing faults...............................................................................................................82
9 Maintenance...............................................................................................................................................85
9.1 Safety instructions for maintenance.......................................................................................85
9.2 Maintenance for machines with type of protection "Ex d/Ex db" ...........................................85
9.3 Inspection and maintenance..................................................................................................86
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9.3.1 Safety instructions..................................................................................................................86
9.3.1.1 Working on machines with type of protection "Ex d/Ex db"....................................................88
9.3.1.2 Static charging when cleaning...............................................................................................88
9.3.2 Inspections in the event of faults............................................................................................88
9.3.3 First service after installation or repair...................................................................................89
9.3.4 General inspection.................................................................................................................89
9.3.5 Assessing the rolling bearings...............................................................................................90
9.3.6 Alternative types of grease for the operation of roller bearings..............................................90
9.3.7 Removing spent grease.........................................................................................................91
9.3.8 Cleaning cooling air ducts and passages...............................................................................92
9.3.9 Maintaining the anti-condensation heating.............................................................................92
9.3.10 Maintaining terminal boxes....................................................................................................93
9.3.11 Measuring the insulation resistance during the course of maintenance work........................93
9.3.12 Touch up any damaged paintwork.........................................................................................93
9.3.13 Repainting..............................................................................................................................94
9.4 Corrective Maintenance.........................................................................................................94
9.4.1 Safety instructions for repair work..........................................................................................94
9.4.2 Prepare servicing work...........................................................................................................96
9.4.3 Checking all screw connections.............................................................................................97
9.4.4 Fan cover...............................................................................................................................97
9.4.5 External fan............................................................................................................................98
9.4.6 Internal fan.............................................................................................................................98
9.4.7 Bearings.................................................................................................................................99
9.4.7.1 Gamma ring...........................................................................................................................99
9.4.8 Seal the motor......................................................................................................................100
10 Spare parts...............................................................................................................................................101
10.1 Ordering data.......................................................................................................................101
10.2 Ordering spare parts via the Internet...................................................................................101
10.3 Main terminal box, type 9-103 472.60..................................................................................103
10.4 Auxiliary terminal box type 9-106A 202.05...........................................................................104
10.5 Auxiliary terminal box type 9-106B 122.06...........................................................................105
11 Disposal....................................................................................................................................................107
11.1 RoHS - restricting the use of certain hazardous substances...............................................107
11.2 Preparing for disassembly....................................................................................................107
11.3 Dismantling the machine......................................................................................................108
11.4 Disposal of components.......................................................................................................108
A Service and Support.................................................................................................................................111
B Technical data and drawings....................................................................................................................113
B.1 Tightening torques for screw and bolt connections..............................................................113
C Quality documents....................................................................................................................................115
C.1 Declaration of incorporation of partly completed machinery................................................115
C.2 Declaration of conformity.....................................................................................................131
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Table of contents
D Additional documents...............................................................................................................................149
Index.........................................................................................................................................................151
Tables
Table 3-1 Machine design ..........................................................................................................................20
Table 3-2 Machine version with type of protection Ex db............................................................................20
Table 4-1 Power limits.................................................................................................................................25
Table 5-1 Stator winding insulation resistance at 40° C..............................................................................42
Table 5-2 Recommended alignment accuracy............................................................................................53
Table 6-1 Terminal markings using the 1U1-1 as an example....................................................................56
Table 6-2 Tightening torques for standard cable glands [Nm] ................................................................62
Table 6-3 Electrical data..............................................................................................................................67
Table 8-1 Electrical faults .......................................................................................................................81
Table 8-2 Mechanical faults .....................................................................................................................82
Table 8-3 Roller bearing faults ...............................................................................................................82
Table 10-1 Spare parts, terminal box 9-103 472.60....................................................................................103
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%........................................113
Figures
Figure 5-1 Schematic diagram: Bearing insulation.......................................................................................44
Figure 5-2 Balancing type on the drive-end side..........................................................................................47
Figure 6-1 Water drip loop............................................................................................................................56
Figure 10-1 Terminal box 9-103 472.60.......................................................................................................103
Figure 10-2 Auxiliary terminal box 9-106A 202.05........................................................................................104
Figure 10-3 Auxiliary terminal box 9-106B 122.06........................................................................................105
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SIMOTICS HV C 1NB1402-2AA84-4CA0-Z
10 Operating Instructions 06/2018

Introduction

In the following text, the motor is referred to as "electrical machine" – or abbreviated, just "machine".

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, problem-free machine operation and long service life.
Please contact the service center (Page 111) if you have any suggestions on how to improve this document.
Machine-specific data
Technical data for the machine and all of the necessary drawings, documents for verifying the qualitative implementation of the machine and, where relevant, additional documents on the components, are provided in the separate Appendixes to the Operating Instructions.
1
● Technical data and drawings
● Quality documents
● Additional documents
Text format features
The warning notice system is explained on the rear of the inside front. Always follow the safety instructions and notices in these instructions.
In addition to the safety-related warning notices which you must read, you will find the text in these instructions is formatted in the following way:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
● Lists are formatted as bulleted lists.
Note
A Note is an important item of information about the product, handling of the product or the relevant section of the document. Notes provide you with help or further suggestions/ideas.
in the order given.
– Lists on the second level are hyphenated.
SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 11
Introduction

1.2 Compiling personal documents

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.
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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12 Operating Instructions 06/2018

Safety information

2.1 Information for those responsible for the plant

This machine has been designed for use in industrial plants in accordance with Directive 2006/42/EC ("Machinery Directive"). Commissioning in the European Community is forbidden until the plant into which the machine will be installed has been shown to conform with this directive. Please observe the country-specific regulations when using the 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 permissible installation, connection and operating conditions are always consequentially taken into account.
● The specific setup and safety regulations as well as regulations on the use of personal protective equipment are observed.
Note
2
Use the services and support provided by the local Service Center (Page 111) for planning, installation, commissioning and service work.
In the individual chapters of this document, you will find warning and safety instructions that must be observed without fail, for your own safety, to protect other people and to avoid material damage.
Observe the following safety instructions for all activities on and with the machine.
This machine has been designed and built in accordance with Directives GB 3836.1 ("Explosive atmospheres – Equipment – General requirements") and GB 3836.2 ("Equipment protection by flameproof enclosures "d""), and is designed for use in hazardous zones in industrial plants and systems.
Commissioning in the European Community in accordance with directive 2006/42/EU ("Machine Directive") is forbidden until the plant into which the machine will be installed has been shown to conform with this directive. Please observe the country-specific regulations when using the machine outside the European Community.
Risk of explosion with commissioning prior to determining the conformity
If the machine is commissioned prior to determining the plant conformance, the explosion protection of the plant is not guaranteed. An explosion can result that can lead to death, serious injury or material damage.
● Only commission the machine if it has been absolutely confirmed that the plant or system is in full conformance with the valid directive.
SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 13
Safety information

2.2 The 5 safety rules

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.

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
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Safety information
2.4 Safe handling
WARNING
Live parts
Electric machines contain live parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed or if the machine is not handled, operated, or maintained properly.
● Always observe the “five safety rules" (Page 14) when carrying out any work on the machine.
● Only remove covers in the manner described in the operating instructions.
● Operate the machine properly.
● Regularly and professionally maintain the machine according to the instructions provided in the "Maintenance" (Page 86) chapter of the operating instructions.
WARNING
Rotating parts
Electric machines contain dangerous rotating parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed or if the machine is not handled, operated, or maintained properly.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.
● Regularly and correctly maintain the machine.
● Secure free shaft extensions and other rotating part such as couplings and pulley belts so that they cannot be touched.
WARNING
Hot surfaces
Electric machines have hot surfaces. Touching hot surfaces can result in severe burns.
● Allow the machine to cool before starting work on the machine.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.
CAUTION
Hazardous substances
Chemical substances required for the setup, operation and maintenance of machines can present a health risk.
● 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.
SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 15
Safety information

2.5 Use in hazardous zones and areas

CAUTION
Flammable substances
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.
During operation, the machine's noise emission levels can exceed those permitted at the workplace, which can cause hearing damage.
● Take steps to reduce noise, such as introducing covers and protective insulation or adopting hearing protection measures, so that the machine can be operated safely within your system.
2.5 Use in hazardous zones and areas
Electrical systems in hazardous zones must be assembled, installed, and operated by the applicable responsible persons in accordance with the applicable rules and regulations.
Note
Basic requirements relating to electrical plants and systems in operation in hazardous zones is provided in Standard GB 3836.15.
Ignition hazards
The operating company – together with the responsible authorities – must fully evaluate the operational risks, the local operating conditions and the monitoring methods that are required. The operating company must comply with all of the necessary measures. Regarding this topic, the machine manufacturer cannot provide any generally applicable recommendations. Please observe the information in these operating instructions.
Note
Basic information on assessing sources of ignition caused by electrical equipment and their operation in hazardous zones is provided in Standard GB 3836.
If a third-party certification is available for the machine, then carefully comply with the technical data defined in it and any special conditions.
The certificate must be available before commissioning.
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2.6 Electrostatic sensitive devices
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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
Safety information

2.6 Electrostatic sensitive devices

● 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:
a = conductive floor surfaceb = ESD table c = ESD shoes d = ESD overall e = ESD wristband f = cabinet ground connection
Risk of explosion due to electrostatic discharge
Electrostatic discharge poses a potential ignition source. Dangerous electrostatic charges can occur, for example as a result of mechanical friction, flowing air that contains particles - or persons that are not appropriately grounded, e.g. when carrying out maintenance or cleaning work.
SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 17
Safety information

2.7 Electromagnetic compatibility

In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious injury or material damage.
● Avoid carrying out work specified above on non-metallic parts, e.g. foam rubber for noise dampeners/attenuators.
● Please comply with ESD protective measures.
2.7 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.

2.8 Interference immunity

By selecting suitable signal cables and evaluation units, companies operating complete plants and systems must ensure that the interference immunity of the machine is not diminished.

2.9 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.

2.10 Electromagnetic fields when operating electrical power engineering installations

Interference to electronic devices caused by electrical power equipment
Electrical power equipment generate electric 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.
● It is forbidden for people with pacemakers to enter the vicinity of the machine.
● 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.
● Do not carry any magnetic or electronic data media.
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18 Operating Instructions 06/2018

Description

Applications
This electrical machine is designed for driving rotating machines in industrial environments and also for energy conversion. It is characterized by a high level of safety, long lifetime, and overall reliability.
For details of the machine supplied and the permissible operating conditions, refer to the "Technical data and drawings" (Page 113) section in the Appendix of these Operating Instructions.
The machine was designed in accordance with the ordering party's specification and may only be used for the contractually agreed purpose.
Type of protection Ex db
This machine has Ex db type of protection according to GB 3836.2. Therefore, it may be operated in hazardous areas of Zone 1 in accordance with GB 3836.14.
DANGER
3
Machine design
Explosion hazard from hybrid mixtures
Hybrid mixtures are mixtures of flammable dusts with explosive gas/air atmospheres which can together create a dangerous explosive atmosphere if they occur at the same time. Changes can arise in the safety characteristics here, such as a change in the zonal classification, increase in the explosion pressure, reduction in the minimum ignition energy and a reduction in the maximum temperatures to be observed.
An explosion can result. This can result in death, serious injury or material damage.
● For this reason, the relative characteristics must be considered both for gas (zones 0, 1 and 2) and for dust (zones 20, 21 and 22) where hybrid mixtures arise. It is necessary for a competent assessor to determine in the individual case whether the parameters determining ignition are unfavorably affected in a particular hybrid mixture.
● Motors with dual plates for G (“Gas”) and D (“Dust”) may only be used where these two occur after prior examination of the properties of the hybrid mixtures by the user.
The regulations and standards used as the basis to design and test this machine are stamped on the rating plate.
SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 19
Description
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.
Table 3-1 Machine design
Feature Standard Rating and performance IEC/EN 60034‑1
Degree of protection IEC/EN 60034‑5 Cooling IEC/EN 60034‑6 Type of construction IEC/EN 60034‑7 Terminal markings and direction of rotation IEC/EN 60034‑8 Noise emission IEC/EN 60034‑9 Starting characteristics, rotating electrical machines IEC/EN 60034‑12* Vibration severity grades IEC/EN 60034‑14 Vibration limits DIN ISO 10816-3
* For machines in line operation only
See also
Rating plate
Line operation
Quality documents (Page 115)
The following standards additionally apply for explosion-protected machines:
Table 3-2 Machine version with type of protection Ex db
Characteristic Standard Type of protection Ex db GB 3836.1
GB 3836.2
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.
The motor is supplied from the line system.
If you connect the machine to a converter, the machine can be damaged. Operate the machine only on the electrical supply system.
Cooling
The cooling system is designed as a closed, internal cooling circuit. The heat lost from the machine is dissipated to the ambient air via the machine's surface. A shaft-mounted fan moves the cooling air in the primary circuit. Movement of the cooling air in the secondary circuit is driven by a shaft-mounted fan.
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Rotor
The rotor has a squirrel cage rotor manufactured out of die-cast aluminum or a brazed copper rotor. The rotor is dynamically balanced with half feather key as standard. With a different balancing status the corresponding balancing status is appropriately marked using an adhesive sticker.
Terminal boxes
In the terminal box, additional connecting terminals are available if required 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.
Supplementary devices
Temperature sensors are integrated in the stator winding to monitor the winding temperature. Various supplementary devices can be integrated or mounted, depending on the order. These include, for example, anti-condensation heating to prevent condensation or temperature sensors for monitoring bearings.
Description
Monitoring equipment
Monitoring equipment is provided corresponding to what has been ordered. This monitoring equipment can be damaged by electrostatic discharge. Observe the ESD protective measures (Page 17).
Anti-condensation heating
The machine is fitted with anti-condensation heating. The connection data is listed on an additional plate on the machine.
Paint finish
The machine is painted according to the instructions in your order.
Suitability test of the paint system for hazardous areas Proof is available for the electrostatic suitability with explosion-proof machines for the paint
systems ordered by default. Such evidence is not available for paint systems that are non­standard or specifically requested by customers. Take into consideration that the provided evidence is not valid for repaintings.
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Description
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Preparations for use

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 13) 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

4.3 Ensure adequate cooling

Ensure that the machine is sufficiently cooled by the cooling air flow at the installation site:
● Ensure that the cooling air can flow in and out unobstructed. The full air flow provided by the fan is only possible if air can freely enter the impeller. In the axial direction, ensure a clearance of at least 1 x air intake diameter.
● Make sure that the machine does not draw in the hot discharged air again.
● For machines with a vertical type construction with an air intake from above, ensure that the air inlets are protected against the ingress of foreign bodies and water.

4.4 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.
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Preparations for use

4.5 Noise emission

See also
Switching on with the anti-condensation heating active (Page 77)
4.5 Noise emission
Excessive sound pressure levels can lead to hearing impairment or hearing loss.
● When assessing the noise level of the system, make due allowance for the noise emissions from the machine.
● If necessary, take suitable noise protection measures for personnel.

4.6 Voltage and frequency fluctuations during line operation

Unless stated otherwise on the rating plate, the permissible voltage fluctuation is ±10 % and the permissible frequency fluctuation is ±2 % in accordance with range B in IEC / EN 60034-1. Permissible fluctuations that go beyond this are stamped on the rating plate.
Under operating conditions a machine may sometimes have to be operated outside the limits of range A.
● 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 machine.
● 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.

4.7 Phase synchronization during supply system switching

Damage to the machine may be caused when switching to another supply system with different phasing.
● The phasing must be synchronized during switching. Use appropriate means to synchronize the phasing.

4.8 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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Preparations for use

4.9 Torsional loading of the drive train due to faults in the electrical supply

4.9 Torsional loading of the drive train due to faults in the electrical supply
In the event of faults in the electrical connection, such as line switching operations with a residual field or short circuit at the terminals, excessive air gap torques can occur. These excessive air gap torques can lead to additional mechanical torsional loads on the shaft assembly.
If the configuration does not correctly recognize the mechanical torsional loadings of the shaft assembly, this can lead to serious damage to the machine. This can result in death, serious injury or material damage.
● When planning the system, make due allowance for the maximum air gap torques that can
occur. This data can be found in the "Electrical data".
The system planner is responsible for the entire drive train.

4.10 Switching high-voltage motors

If vacuum circuit breakers and vacuum contactors are used, then what are known as multiple restrikes can occur when the machine is switched off. This depends on various factors, such as:
● Arc-extinguishing principle of the switch
● Machine size
● Length of the power supply cable
● System capacitance, etc.
A surge suppressor to ground is installed in the switchgear between the circuit breaker and the cable termination for each of the three conductors. The level of protection for the machine windings is sufficient when the limiter is correctly selected (machine rated voltage / response voltage).
Example This current limit corresponds to the following upper power limits, depending on the relationship
between the starting current IA and rated current IN and on the voltage dip (up to approximately 20%) while the machine is starting up:
Table 4-1 Power limits
Rated voltage V
3 kV 750 kW 6 kV 1500 kW
10 kV 2500 kW
N
Power limit
See also
Prior to commissioning (Page 69)
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Preparations for use

4.11 Machines without final paint coating

4.11 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.

4.12 Thermal protection

The machine is optionally equipped with temperature sensors, e.g. Pt100, PTC thermistor, ....
Thermal motor protection by directly monitoring the winding temperature is permissible if this is certified and test data specified on the rating plate. Temperature sensors for directly monitoring the temperature guarantee explosion protection in conjunction with function tested tripping devices with type of protection marking II (2) G.
● Direct temperature monitoring for line (DOL) operation: Motors operating with duty type S1 either require a circuit breaker or the temperature must be directly monitored (temperature sensor and associated tripping device). Evaluate the temperature sensors.
● Direct temperature monitoring for inverter operation: The temperature must be directly monitored (temperature sensor and associated tripping device). Evaluate the temperature sensors.
● If you have to perform a continuity test of the temperature sensors, do not apply a voltage >2.5 V. If no test data is specified on the rating plate, this means that the winding protection is only intended as an additional protection.
● For pole-changing motors, use a direct temperature monitoring sensor as stated on the rating plate, e.g. PTC thermistor according to DIN 44081/44082, for each speed level in addition to the separate, mutually interlocked motor protection relays.
Every machine must be protected against an inadmissible temperature rise. Observe the following:
● Protect every machine according to IEC/EN 60079–14 using a current-dependent, delayed circuit breaker with phase failure protection according to IEC/EN 60947 or a similar device in all phases.
● Set the protective device (e.g. circuit breaker) to the rated current. The value is stamped on the rating plate.
● For windings in a delta connection, protect the winding in such a way that the tripping device or relay is connected in series with the winding phases. When selecting and setting the tripping unit, define the rated value of the phase current. The phase current is 0.58 times the rated machine current. Any thermal machine protection via direct temperature monitoring to be used in addition to the machine circuit breaker is specified on the rating plate if required.
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4.13 Transport and storage
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 13)
● 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.

4.13.1 Transport markings

The packing differs depending on the transport type and size. If not otherwise contractually agreed, the packaging corresponds to the packing guidelines for International Standards for Phytosanitary Measures (ISPM).
Note the symbols which appear on the packing. These have the following meanings:
Preparations for use

4.13 Transport and storage

Top Fragile material Keep dry Keep cool Center of

4.13.2 Checking the delivery

The components are assembled on an individual basis. When you take receipt of the delivery, please check immediately whether the scope of the delivery matches up with the accompanying documents. No claims relating to defects/items missing from the delivery will be accepted if they are submitted at a later date.
● Report any apparent transport damage to the delivery agent immediately.
● Immediately report any apparent defects/missing components to your contact partner.
These Operating Instructions are part of the scope of delivery; keep them in a location where they can be easily accessed.
gravity
Do not use
hand hook
Attach here
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Preparations for use
4.13 Transport and storage

4.13.3 Attaching the rotor shipping brace

Bearing damage caused by shocks and vibration during storage
Improper storage can result in damage to bearings caused by shocks and vibration.
● On machines that have been supplied with a rotor shipping brace, secure the rotor as described in the notes on transportation.
● Protect the motor against severe radial shocks and vibration. The rotor shipping brace cannot completely absorb these shocks and vibrations.
Bearing damage caused by vibration during transport
If the customer has already mounted parts, such as coupling, belt pulley etc., the bearing can be damaged during transport.
● In this case, make sure that the customer uses a rotor shipping brace.

4.13.4 Checking the load handling attachments

Inspect the load handling attachments such as the load trestles, lifting eyes and ring bolts and also the lifting gear, before lifting the machine:
● Inspect the load handling attachments on the machine for possible damage. Replace any load suspension equipment that is found to be damaged.
● Before use, check that the load suspension equipment is correctly attached.
● When lifting the machine, use only approved and undamaged lifting gear of sufficient rated capacity. Check the lifting gear prior to its use.
WARNING
The machine can be dropped
If the load handling attachments and lifting gear are damaged or not correctly secured, the machine may be dropped during lifting. This can result in death, serious injury or material damage.
● Inspect the load handling attachments and lifting gear before use.
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WARNING
Danger if the machine falls
The lifting lugs on the machine are designed only for the weight of the machine. If a machine set is lifted and transported on a single machine, this can lead to mechanical failure of the lifting lug. The machine or machine set may fall. This can result in death, serious injury or material damage.
● Do not lift machine sets by attaching lifting tackle to the individual machines.
● Use only the equipment provided, e.g. the openings or lugs on the base plates, for transporting machine sets. Note the maximum capacity of the lifting lug.

4.13.5 Lifting and transportation

● Persons driving cranes and fork-lift trucks must hold appropriate licenses.
● If the motor is packed, depending on the weight, size and on-site conditions, lift crates and transport frames using a fork-lift truck or a crane with slings. Use a crane or fork-lift truck suitable for the load.
Preparations for use
4.13 Transport and storage
● When lifting the machine, use only approved and undamaged sling guides and spreaders of sufficient rated capacity. Check this equipment before using it. The weight of the machine is shown on the rating plate.
● If adapter flange and adapter plates are also supplied, then lift them and transport these parts separately. The load suspension equipment for the motor is not rated for lifting the motor with mounted adapter flange is or adapter plates
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Preparations for use
4.13 Transport and storage
● When lifting the machine, refer to the information on the lifting plate or in the "Technical Data and Drawings":
– Comply with the specified spreading angles.
– Do not exceed the maximum lifting acceleration and lifting speed specified on the lifting
plate. Lift the machine without jerking it. Acceleration a ≤ 0.4 g (≈ 4 m/s2) Velocity v ≤ 20 m/min
● Use only the attachment points provided on the stator frame for lifting, such as lifting eyes or ring bolts or the lifting eyebolts on the bearing shield.
Transport for a different type of construction
The machine or the machine set may be lifted and transported only using the load handling attachments at the intended positions. Otherwise, the machine may tip over, slip in the direction of lifting or fall.
This can result in death, serious injury or material damage.
1. Use only the attachment points (eyebolts, etc.) on the stator frame.
2. Use suitable rope guiding or spreading devices. You will find the weight of the motor on the rating plate.
WARNING
WARNING
Center of gravity is not at the center.
If the center of gravity of a load is not located centrally between the attachment points, the motor can tip over or slip out of the lifting equipment and fall when it is being transported or lifted. This can result in death, serious injury or material damage.
1. Always take account of the center of gravity when transporting or lifting the motor. The center of gravity of the machine is specified in the dimension drawing.
2. Comply with the handling instructions on the machine when transporting it. If the center of gravity is not located centrally between the attachment points, position the hoisting hook above the center of gravity.
3. Be aware of the possibility of different loads on the sling ropes or lifting straps and the carrying capacity of the lifting equipment.
NOTICE
Risk of corrosion and reduction of the degree of protection
Empty holes can corrode; the degree of protection may then be no longer guaranteed.
● Do not remove the factory-fitted load suspension device. In operation, the load­suspension device must remain screwed in.
● If you do remove the load-suspension device, then seal the holes so that they are airtight.
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