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

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For employment in zone 1 or zone 2 (IEC/EN 60079-10-1)

0102

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

Operating Instructions Installation Instructions

Safety information

Description

Preparations for use

Assembly

Electrical connection

Commissioning

Operation

Maintenance

Spare parts

Disposal

Service and Support

Technical data and drawings

Quality documents

Additional documents

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

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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Table of contents

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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Table of contents

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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Table of contents

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

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 9

Table of contents

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.

● 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

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

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

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.

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z

16 Operating Instructions 06/2018

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.

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z

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

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.

4.3 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

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

Power limit

See also

Prior to commissioning (Page 69)

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Preparations for use

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

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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WARNING

Lifting equipment can break at low temperatures

At low temperatures, the material of the lifting equipment can become brittle. When lifting and transporting, the lifting equipment can tear off and the motor might be dropped.

This can result in death, serious injury, or material damage.

● Only lift the machine using the lifting equipment at temperatures that are not below -20 °C.

● Alternatively, warm up the lifting equipment or lift the machine in a different way.

4.13.6 Securing the rotor

The machine is equipped with a rotor shipping brace. This protects the bearings against damage due to shock and vibration when it is being transported or placed into storage.

NOTICE

Preparations for use

4.13 Transport and storage

Bearing damage caused by vibration and shock during transport

The machine can be damaged if it is jolted during transport. This can result in material damage.

● Always transport the machine with the rotor shipping brace supplied. The rotor shipping brace must be attached during the transport.

● Do not remove the rotor shipping brace until you are ready to push on the output element.

● 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.

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཰

ཱ

Preparations for use

4.13 Transport and storage

Alternative rotor bracing

● If you transport the machine after the output transmission element has been pulled on, then you must axially fix the rotor in another way.

Roller bearing or journal bearing machine with coupling

Machine with journal bearings without a coupling with shaft clamp lock

Machine with journal bearings without a coupling

Roller bearing machine without coupling (sleeve

①, shaft screw and washer ②)

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Preparations for use

4.13 Transport and storage

● Machines with an oil-injection interference fit and a center hole ≥ M56 have an adapter

installed between the shaft and the shipping brace.

● Tighten the shaft screw ② on the rotor shipping brace to the following torques.

Thread in the shaft extension Tightening torque M20 80 Nm

M24 150 Nm M30 230 Nm M36 350 Nm M42 450 Nm

Tightening torques for other rotor shipping brace types

● The thread in the shaft extension indicates the rotor weight. This indirectly specifies the

required preload force when axially fixing the rotor.

Thread in the shaft extension Preload M20 20 kN

M24 30 kN M30 40 kN M36 50 kN M42 60 kN

Axial preload force for other rotor shipping brace types

4.13.7 Working on the underside of the machine

● 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 secure

and raised position.

4.13.8 Storage

You must correctly store the machine if you do not install and use it after it has been delivered.

NOTICE

Bearing seizure damage if incorrectly stored

If storage conditions are inappropriate there is a risk of bearing seizure damage. Resulting damage can include scoring (brinelling) and corrosion.

● Follow the storage guidelines.

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Preparations for use

4.13 Transport and storage

Preconditions and preparations

● Only store goods in undamaged packaging. Unpack the goods if the packaging is damaged. Correctly store the goods corresponding to the type.

● Repair any damage to the packaging before putting the equipment into storage insofar as this is necessary to ensure proper storage conditions.

General instructions for storage

Wherever possible, store the machine in a storage room. The place of storage must satisfy the following general conditions:

● Select a sufficiently sized dry and horizontal place of storage that is above flood level and free of vibration (v

– The place of storage must be well ventilated as well as free of dust and frost. Provide

protection against extreme weather conditions. Ensure that the temperature remains stable in the range from 10 °C to 50 °C – or 50 °F to 120 °F. If there is a risk of condensation, the room temperature should be approx. 10 K above the outside temperature. The temperature should not fall below ‑20° C.

– The relative humidity of the air should be less than 60%.

≤ 0.2 mm/s).

eff

Storing outdoors

– The floor of the place of storage must be sufficiently strong. The maximum permissible

floor loading or storage compartment loading may not be exceeded.

– The ambient air must not contain any harmful gases.

● Protect the machine from shocks and humidity.

● Position machines, devices and crates on pallets, wooden beams or foundations that protect them against rising damp and water.

● Ensure that the air circulation under the equipment is not impeded.

– Place wooden spacer blocks between the covers and the machine.

– Covers or tarpaulins must not trail on the floor around the machine.

When storing the machines outside, the storage location must comply with the following conditions:

● The ground must be sufficiently strong. Prevent the machine from sinking into the ground.

● Covers or tarpaulins used to protect the equipment against the weather must not make contact with the surfaces of the equipment. Otherwise air circulation under the stored items will be prevented.

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Protection against humidity

If a dry storage space is not available, protect the machine as follows against humidity:

● Wrap the machine in humidity-absorbent material.

● Wrap the machine in plastic film:

– Place a humidity meter inside the plastic film.

– Place desiccant within the plastic film.

– Pack the machine air-tight.

● Inspect the machine regularly.

● Store the machines in a dry, dust-free room where the temperature is controlled. Special

packing is therefore not necessary. In all other cases, pack the machines in a plastic film with a substance that absorbs moisture, e.g. Branogel, or in hermetically sealed welded foil. Use a protective cover to protect against sun and rain.

● Store the machines only in vibration-free rooms in order to avoid consequential damage to

the bearings due to vibration at standstill.

Preparations for use

4.13 Transport and storage

The materials used are specially designed for the temperature range required by the customer. The relevant temperature limits are specified on the rating plate.

WARNING

Risk of explosion due to damaged sealing materials

Storing the machine at temperatures that do not fall within the specified limits can damage the material of the seals and cause them to fail. As a result, a potentially explosive gaseous atmosphere can enter the machine and be ignited during commissioning. Explosions can occur. This can result in death, serious injury or material damage.

● Do not store the machine in conditions that lie outside the specified temperature limits.

4.13.9 Storing machines together with the driven machine

● Before mounting the machines, grease the free parts of the shaft extension, as well as all

other bare metal parts, such as mounting foot surfaces, flange surfaces, terminal box and cover contact surfaces. Attach caps filled with roller bearing grease to the shaft output gland to provide protection against dust and humidity.

● Fill the terminal boxes of the machines with a substance that will absorb moisture, e.g.

Branogel.

● Store the machines in a dry, dust-free room where the temperature is controlled.

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Preparations for use

4.13 Transport and storage

Long-term storage

If you are storing a machine for more than six months, you must check its condition every six months. Store the machine in accordance with the specifications in Section "Storage (Page 33)", and if possible, packed.

● Check the motor for damage.

● Carry out any necessary maintenance work.

● Make sure that the storage conditions are such that condensation cannot form in the motor.

● If the machine is not sealed in plastic film, continually and slightly heat the machine, e.g. with anti-condensation heating (if available), and ensure that the air circulates in the storage room.

Storage for longer than three months

Lubricate the machine after every two years of storage.

1. Unpack the machine.

2. Remove the rotor shipping brace, if one is fitted.

3. When stored for longer than two years, lubricate with twice the grease quantity in accordance with the lubricant plate. This ensures that the grease is evenly distributed and covers all surfaces. Corrosion damage is avoided.

NOTICE

Rolling bearing damage due to unchanged resting position

Roller bearings can be damaged when kept in the same or almost the same position.

● Every three months, manually rotate the rotor through five revolutions.

● Make sure that the resting position of the rotor after the rotor has been turned over is different from its previous position. Use the feather key as a reference point, if present.

4. Replace the corrosion protection.

5. Reattach the rotor shipping brace, if present.

6. Pack the machine again.

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4.13.10 Storage for longer than two years

DANGER

Loss of type of protection "Ex d" as a result of incorrect storage or commissioning

This can result in death, serious injury, or material damage. An explosion can occur.

Only authorized technical personnel from the manufacturer or authorized by the manufacturer or permitted to work on machines with type of protection "Ex d".

Preserving the machine before it is stored

● Protect the machine against moisture and humidity.

– Only store the machine in a dry and dust-free room. The relative humidity of the air must

be less than 60 %.

– Place desiccants (drying agents) in all of the terminal boxes.

– Place an adequate amount of desiccant in the machine itself.

– Wrap the machine in a barrier layer foil so that it is airtight, e.g. using composite

aluminum foil.

Preparations for use

4.13 Transport and storage

– Place a humidity meter inside the foil.

– Regularly check the air humidity within the foil using the humidity meter. If the relative

humidity within the packaging exceeds 50%, then replace the desiccant and the barrier layer foil.

● Preserve parts of the motor shaft, journal bearings and enclosure that can possibly corrode using Tectyl 506-EH from the Valvoline company.

● Close all journal bearing openings and check to ensure that they are correctly sealed.

When in storage – check at least every two years

● Replace the desiccant (moisture absorbing material) in the terminal boxes and in the journal bearings.

● Open the journal bearings and check the anticorrosion protection applied to the shaft and to the journal bearings. Apply Tectyl 506-EH from the Valvoline company with a dry film thickness of 100 up to 150 µm to parts that are not correctly protected.

● Close all journal bearing openings and check to ensure that they are correctly sealed.

● Completely package the machine again, also see "Preserving the machine before it is stored".

Preparing for commissioning and commissioning Commissioning may only be carried out by appropriately trained personnel of the manufacturer

or those authorized by the manufacturer. Contact the Service Center regarding this topic.

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Preparations for use

4.14 Converter operation

4.13.11 Protection against corrosion

If the machine is stored in dry conditions, then apply the subsequently listed anti-corrosion measures:

● Storage up to six months: Apply a coat of corrosion protective compound to all accessible bare metal parts such as the exposed shaft extension, flange or machine feet.

● Storage for longer than six months: Apply a coat of long-term anti-corrosion agent to all accessible bare parts.

● Inspect the machine regularly and if necessary, apply an additional coating of corrosion protection.

Document all preservation measures taken so that they can be reversed before the machines are put back into service.

4.14 Converter operation

4.14.1 Tandem operation

If you connect two motors in series for "tandem operation", install an insulated coupling between the motors; this coupling should satisfy series of standards GB 25286 or the regulations that apply in the country where the equipment is installed.

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Assembly

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.

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 warranty.

Explosion hazard when making modifications to the machine

Substantial modifications to the machine are not permitted – or may only be performed by the manufacturer. Otherwise an explosion can occur in an explosive atmosphere. This can result in death, serious injury or material damage.

● If necessary, please contact the service center.

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Assembly

5.1 Preparations for installation

5.1.1 Requirements for installation

The following requirements must be satisfied prior to starting installation work:

● Staff have access to the relevant installation instructions and operating instructions.

● The machine is unpacked and ready for mounting at the installation location.

Note Further Information

Further machine-specific information for installation can be found in Chapter "Technical data and drawings" (Page 113).

Note Measure the insulation resistance of the winding before starting installation work

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.

See also

Insulation resistance and polarization index (Page 40)

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 in 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 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

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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 41)

5.1.3 Testing the insulation resistance and polarization index

WARNING

Hazardous voltage at the terminals

Assembly

5.1 Preparations for installation

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

– Attach the connection cable.

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.

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 41

Assembly

5.1 Preparations 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

U ≤ 1000 500 ≥ 5 1000 ≤ U ≤ 2500 500 (max. 1000) 100 2500 < U ≤ 5000 1000 (max. 2500)

5000 < U ≤ 12000 2500 (max. 5000)

U > 12000 5000 (max. 10000)

= rated voltage, see the rating plate

rated

= DC measuring voltage

meas

= minimum insulation resistance at a reference temperature of 40 °C

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)

(40-T)/10

(2)

= (0.5)

meas

Insulation resistance converted to 40° C reference temperature

Temperature coefficient according to equation (2)

Measured insulation resistance for measuring/winding temperature

in °C 40 Reference temperature in °C 10 Halving/doubling of the insulation resistance with 10 K

Measuring/winding temperature in °C

MΩ

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.

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42 Operating Instructions 06/2018

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.

● 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 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 =

insul 10 min

Many measuring devices display these values automatically following the measurement.

insul 1 min

Assembly

5.1 Preparations for installation

For insulation resistances > 5000 MΩ, the measurement of the PI is no longer meaningful and consequently not included in the assessment.

/ R

(10 min)

(1 min)

≥ 2 Insulation in good condition < 2 Dependent on the complete diagnosis of the insulation

NOTICE

Damage to insulation

If the critical insulation resistance is reached or undershot, this can damage the insulation and cause voltage flashovers.

● Contact the service center (Page 111).

● 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.

Assessment

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Assembly

5.1 Preparations for installation

5.1.4 Prepare the mating faces for a flange connection

● Clean the flange before installation, and make sure that the flange face is flat and free of contaminations.

● Check the geometry of the flange.

See also

Technical data and drawings (Page 113)

Removing anti-corrosion protection (Page 50)

5.1.5 Do not bridge the bearing insulation

The machine is fitted with an insulated bearing seat. The insulation is located between the rotor and bearing. The insulation means that the motor (housing, stator, shaft) represents an open conductor loop.

NOTICE

Bridged bearing insulation

It is not permissible that the insulation is bridged when instruments are mounted, such as vibration measuring systems, relubrication equipment, etc. Circulating currents in the motor cause bearing damage at the drive and non-drive end.

● Only connect lubrication tubes, shock-pulse measurement sensor, bearing cover, etc. with other motor parts or the motor ground with the appropriate insulation.

Cylindrical roller bearing: Insulated shaft Deep-groove ball bearing: Insulated bearing

Figure 5-1 Schematic diagram: Bearing insulation

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5.2 Lift the machine to where it will be installed, and position it

5.2.1 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.

Assembly

5.2.2 Preconditions for correct alignment and secure attachment

To align the machine correctly and fasten it securely, you require detailed specialist knowledge of the following necessary measures:

● Preparing the foundation

● Select and mount the coupling

● Measure the radial and axial eccentricity

● Position the machine

If you are not familiar with the prescribed measures and procedures, make use of the services offered by the Service Center (Page 111).

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Assembly

5.2 Lift the machine to where it will be installed, and position it

5.2.3 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.

Note Machines with an oil-injection interference fit and a center hole ≥ M56

An adapter is installed between the shaft and the rotor shipping brace on machines with an oilinjection interference fit and a center hole ≥ M56. Remove this adapter together with the rotor shipping brace.

See also

Securing the rotor (Page 31)

NOTICE

Removing the rotor shipping brace in the horizontal position.

See also

Dismantling the rotor shipping brace when the machine is in a horizontal position could damage the bearings.

● Only remove the rotor shipping brace when the machine is in a vertical position.

NOTICE

Turning the motor over without rotor shipping brace

Failure to fit the rotor shipping brace can result in damage to the bearings while the machine is being turned onto its side.

● Fix the rotor in place before you turn the machine into a horizontal position.

Securing the rotor (Page 31)

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5.2.4 Mounting the output elements

Balance quality

The rotor is dynamically balanced. For shaft extensions with featherkeys, 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

● "F" means balancing with a whole feather key.

Figure 5-2 Balancing type on the drive-end side

Assembly

5.2 Lift the machine to where it will be installed, and position it

Pushing on the power output elements

● Prerequisites:

– The coupling and/or the output element must be appropriately dimensioned for the

operating case at hand. The balance quality must satisfy the following requirements.

– 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 transmission 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 output element must be pulled on in one continuous operation using the front thread holes in the shaft or pulled on by hand.

– Do not strike it with a hammer, as this would damage the bearings.

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Assembly

5.2 Lift the machine to where it will be installed, and position it

Shaft extensions with feather key

To maintain the balancing quality, you have the following options:

● If the output 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 output element. Alternatively, ensure that the weights are compensated to achieve the appropriate 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 for all 2-pole machines and 4-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. The number of poles of the machine is specified on the rating plate (in the designation of the motor type).

WARNING

The feather key can fall out

The feather keys are only locked against falling out during shipping. If a machine with two shaft extensions does not have an output element on one shaft extension, the feather key can fall out during operation.

Death or serious injury can result.

● If the machine is to be operated without output elements, secure the feather key on the free shaft extension so that it cannot be flung out.

● To avoid imbalance, for balancing type "H", reduce the weight of the feather key to 60 % of the original weight.

5.2.5 Lifting the machine

● Persons driving cranes and fork-lift trucks must hold appropriate licenses.

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Assembly

5.2 Lift the machine to where it will be installed, and position it

● 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.

WARNING

Transport for a different type of construction

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

Center of gravity is not at the center.

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.

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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Assembly

5.2 Lift the machine to where it will be installed, and position it

Note Store the rotor locking device

Be sure to store the rotor locking device. It must be remounted for possible disassembly and transport.

5.2.6 Working on the underside of the machine

● 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 secure and raised position.

5.2.7 Removing anti-corrosion protection

Machined, bare metal surfaces of machine parts and small components such as screws, bolts, wedges, feather keys, and dowel pins, are treated with an anti-corrosion agent.

Carefully remove the anti-corrosion agent and immediately start the installation work.

Bright surfaces on machine parts

● Use petroleum, petroleum ether, or a similar solvent or detergent to remove the anticorrosion coating from the machined surfaces of machine parts and from small components.

NOTICE

Paintwork damage

Make sure that the cleaning agent or solvent does not come into contact with any painted surfaces, as this could damage the lacquer.

● Use a suitable solvent to soften thick layers of anti-corrosion agent. Then push off the softened layers using a piece of hardwood (approximately 10 x 10 x 1 cm). Do not sand the protective coating down or scrape it off.

NOTICE

Do not use metal tools.

Do not use metal objects such as scrapers, spatulas, or plates to remove the anti-corrosion protection,

as this could damage the surfaces of the machine parts.

● Lightly oil the depreserved surfaces.

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Thread and fastening parts

● Remove the anti-corrosion protection from bolts and tapered pins.

● Use the appropriate tap or cutting die to shave the tapped holes of machine parts and

threads of screws, etc. See the drawings for the relevant male and female thread dimensions.

● Use dry compressed air to purge the shaved tapped holes.

● Lightly oil the depreserved threads.

Burrs and pressure marks

● Check the machine parts, as well as fastening and fixing elements, for burrs or pressure

marks. Use a smoothing file to carefully remove any such burrs/pressure marks.

● Only whetstones may be used to smooth finished surfaces.

5.2.8 Setting down the machine

Assembly

5.2 Lift the machine to where it will be installed, and position it

Requirements

The following preconditions must be satisfied before setting down the machine at the installation location:

● The mating faces must be clean.

● The anti-corrosion protection paint has been removed from the mating faces, such as the

machine mounting feet, flange, ...

Setting down the machine

Set down the machine slowly and carefully at the installation location to avoid any impact.

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Assembly

5.3 Installing the machine

5.3.1 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.

5.3.2 Selecting bolts

● Use fixing bolts with the appropriate property class to ensure that the machine is securely fastened and torque can be adequately transmitted.

● 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 line system transfer operations in phase opposition, etc. Values for the foundation forces can be found in the "Technical Data and Drawings" section.

See also

Technical data and drawings (Page 113)

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5.3.3 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.

● Maintaining the vibration velocity according to ISO 10816‑3

5.3.4 Recommended alignment accuracy

The alignment accuracy required depends essentially on the configuration of the overall machine train. Observe the required alignment accuracy of the coupling manufacturer in all cases when aligning the machine.

Table 5-2 Recommended alignment accuracy

Assembly

5.3 Installing the machine

Speed

rpm

750 0.09 0.09 1500 0.06 0.05 3000 0.03 0.025

Parallel offset

mm per 100 mm coupling diameter

5.3.5 Aligning the machine to the driven machine and mounting it

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.

Note

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.

Angular offset

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.

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Assembly

5.4 Complete the installation work

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.

5.3.6 Axial and radial forces at the second shaft extension

Large output masses and their centers of gravity outside the shaft extensions can cause vibration. This can result in damage to bearings, the shaft, or components in the shaft assembly.

● Comply with permissible loads for the forces on the shaft extensions in accordance with the configuration data.

● If necessary, contact the Service Center.

See also

Service and Support (Page 111)

5.4 Complete the installation work

1. Check that all of the screw connections are correctly tightened.

2. Once you have completed the installation work, remove all objects – such as tools, cloths, deposits of dirt and moisture, etc. – from the machine.

3. Clean the machine to remove any dirt that may have accumulated as a result of the installation work.

4. Protect all exposed rotating parts against contact by persons. Cover any open shaft ends, couplings and belt drives, etc.

5. Make sure that there are no loose parts on or in rotating machine elements. Observe any feather keys that may be located in free shaft ends.

Record all of the installation work that was carried out.

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Electrical connection

6.1 Safety instructions

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.

Risk of explosion by fixing elements becoming 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. Fastening elements can work loosely, so that the minimum air clearances are no longer maintained. Sparking formation may occur, in an explosive atmosphere it can lead to an explosion. This could result in death, serious injury or material damage to the machine or even in failure, which could in turn lead indirectly to material failure of 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.

See also

Tightening torques for screw and bolt connections (Page 113)

6.2 Preparation

6.2.1 Selecting cables

Take the following criteria into account when selecting the connecting cables:

● Rated current

● Rated voltage

● Where necessary, the service factor

● System-dependent conditions, such as ambient temperature, routing type, cable length etc.

● Configuration notes

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 55

;

Electrical connection

6.2 Preparation

● Requirements according to IEC/EN 60204‑1

● Requirements according to GB 3836.15

6.2.2 Route the cable with an appropriate loop so that water can drip off

● In case of high humidity or when installed outside, water drops can move along the cable jacket and enter the motor through the cable entry and cable gland. If you route the cable with an appropriate loop then water doesn't enter the terminal box, but simply drips off.

Figure 6-1 Water drip loop

6.2.3 Terminal designation

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

1 U 1 - 1 Marking x Index for pole assignment for pole-changing machines where applicable. A lower

index signifies a lower speed. Special case for split winding. x Phase designation U, V, W x Index for winding start (1) or end (2) or if there is more than one connection per

winding x Additional indices for cases in which it is obligatory to connect parallel power feed

cables to several terminals with otherwise identical markings

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6.2.4 Routing the cable into the terminal box

Normally the cable entry plate is supplied drilled. The number and size of the cable entry tapped holes is provided in the machine dimension drawing.

Inserting the cable into the terminal box

1. Only use cable entries that are suitable for the cable.

2. Only use suitable cable entries and cables for the prevailing ambient temperature.

3. Ensure that the power cables are strain relieved where they enter the terminal box.

4. Carefully connect the cable and ensure a reliable protective conductor connection.

5. Tighten the glands and the elements for the strain relief with the torque specified by the manufacturer.

6. Check the cable glands and cables to ensure that they are correctly sealed and firmly seated.

7. Correctly close and seal threads or holes that are not being used ensuring that the IP degree of protection is maintained. The IP degree of protection is specified on the rating plate.

Electrical connection

6.2 Preparation

Rotating the terminal box

Depending on the particular version, the terminal box can be rotated. It can then be rotated through increments of 90° corresponding to the connection direction.

If necessary, contact your Service Center (Page 111).

6.2.5 Terminal boxes with type of protection "Ex d/Ex db"

With terminal boxes of protection type "Ex d" or "Ex db", the type and size of the cable entry threads and the type of protection are stated on the terminal box.

● The cable entries must be suitable for the cables.

● The cable entries and cables must be suitable for the ambient temperature.

WARNING

Explosion hazard when non-approved components are used

If cable entries, pipe or conduit systems, and filler plugs of a simple design are used with terminal boxes with type of protection "Ex d" or "Ex db", this can result in an explosion during operation. This can result in death, serious injury, or material damage.

● Use only filler plugs with type of protection "Ex d/Ex db" that have been tested and certified in accordance with IEC / EN 60079-1 to plug holes that will not be used.

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 57

Electrical connection

6.2 Preparation

6.2.6 Terminal boxes with type of protection "Ex e/Ex eb"

WARNING

Risk of explosion due to damaged seals of the pressure relief flap

If the seal of the pressure relief flap (preset rupture point) in the lower section of the terminal box is damaged, then the explosion type of protection is no longer guaranteed. An explosion can occur in operation. This can result in death, serious injury or material damage.

● Only use original spare parts when repairing the damaged seal.

WARNING

Risk of explosion if components are used that have not been approved

If, for terminal boxes, type of protection "Ex e" or "Ex eb", cables and cable glands as well as simple screw plugs are used, then there is a risk of explosion in operation. This can result in death, serious injury or material damage.

● Use only cable entries that have been tested and certified in accordance with IEC / EN 60079–7.

● Use only screw plugs that have been tested and certified in accordance with IEC / EN 60079–7 to close openings that are not to be used.

WARNING

Risk of explosion as a result of an incorrectly drilled cable entry plate

For terminal boxes, type of protection "Ex e" or "Ex eb", machining threads in an undrilled cable entry plate, can diminish the strength of the cable entry plate. Sparks can occur in an explosive atmosphere that can result in an explosion. This can result in death, serious injury or material damage.

● Carefully ensure that the cable entry plate is still adequately strong after machining the threads.

Drill holes in the cable entry plate

If you drill holes in the cable entry plate of terminal boxes for types of protection "Increased safety "e"" or "Intrinsic safety "i"", then document the data about these holes in the motor documentation:

● Number and size of the holes

● Type of thread, e.g. metric or NPT

Data regarding the installation of pipes and accessories is provided in GB3836.15.

● If you are using cable glands, use only certified cable glands with strain relief. Comply with the installation and operation conditions specified in the certificate for these cable glands and check that they have been complied with.

● Correctly close unused threads or holes, maintaining the IP degree of protection. The IP degree of protection is stamped on the rating plate.

● Replace any unused cable glands by certified screw plugs.

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6.2.7 Connecting the grounding conductor

The grounding conductor cross-section of the machine must be in full conformance with the installation specifications and to IEC 60034-1.

Electrical connection

6.2 Preparation

External conductor cross-section S

mm²

4 4

6 6 10 10 16 16 25 25 35 25 50 25 70 35 95 50

120 70 150 70 185 95 240 120 300 150 400 185

Grounding conductor cross-section

mm²

There is a hexagon bolt with a flat washer and a spring washer on the stator frame at the designated connecting point for the grounding conductor.

The grounding conductor can be connected as follows:

● With stranded cables with cable lugs

● With flat cables with cable end designed accordingly

Connecting the grounding conductor

● Use the connecting terminals designated for the grounding conductor in the terminal box.

● 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 screw head.

SIMOTICS HV C 1NB1402-2AA84-4CA0-Z Operating Instructions 06/2018 59

Electrical connection

6.3 Inserting and routing the cables

● Check that the maximum permissible clamping thickness of 10 mm for the cable lug or strap is not exceeded.

● Fasten the clamping screw according to the following table. Screw-in depth and tightening torque are different depending on whether cable lugs or ground terminals are used.

Screw Screw-in depth Tightening torque

M12 x 25 > 16 mm 38 Nm M16 x 35 > 20 mm 92 Nm

Tightening torque of bolts with cable lugs

Screw Screw-in depth Tightening torque

Tightening torque of bolts with ground terminals

M6 > 9 mm 8 Nm M8 > 12 mm 20 Nm

M10 > 15 mm 40 Nm

6.3 Inserting and routing the cables

6.3.1 Connecting the machine for a specific direction of rotation

The technical data stipulate the following 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

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Direction of rotation

If the machine has one shaft extension or two shaft extensions with different diameters, the direction of rotation when looking at the front of the single or the thicker shaft extension is defined as follows:

● If you connect line cables with a phase sequence of L1, L2, L3 at U, V, W, the resulting

● If you interchange two connections, e.g. you connect L1, L2, L3 to V, U, W, the resulting

Electrical connection

6.3 Inserting and routing the cables

rotation is clockwise.

rotation will be counter-clockwise.

According to IEC Clockwise U V W Counter-clockwise V U W

Direction of rotation of the motor when looking at DE

Machines that must run only in one specific direction of rotation are marked as follows.

– On the rating plate with a direction of rotation arrow

– With terminal designations in the required phase sequence

The machine can malfunction or be damaged if it is operated other than how it was originally ordered or with the incorrect direction of rotation.

Changing the direction of rotation

If you want to operate the machine in the opposite direction to the direction stated in the order, please consult your contact partner at Siemens.

Directions of rotation, which may be required for an application in a particular plant or system, are not shown on the rating plate. Please take these requirements into consideration when connecting up the machine.

NOTICE

Machine damage due to incorrect direction of rotation

The machine will not be adequately cooled if it is operated other than how it was originally ordered or with the incorrect direction of rotation. This can result in machine damage.

● Observe the direction of rotation data on the nameplate.

6.3.2 Tightening torques for cable glands

● Tighten the cable gland and the parts of terminal box intended to act as a strain relief to the appropriate torque as specified by the manufacturer after inserting the feeder cables. The tightening torques depend on the cable gland used and the cable or wire used.

● Tighten the standard cable glands supplied with the motor in accordance with the following table.

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Electrical connection

6.3 Inserting and routing the cables

Table 6-2 Tightening torques for standard cable glands [Nm]

Nominal size Cable gland for Ex e II

Type HSK-M

Union nut Connection thread Union nut / connection

M12 x 1.5 5 7 7.5 M16 x 1.5 5 7 12.5 17 M20 x 1.5 5 7 20 23 M25 x 1.5 7 10 30 29 M32 x 1.5 7 10 55 33 M40 x 1.5 7 10 75 41 M50 x 1.5 7 10 100 50 M63 x 1.5 7 10 135 75 M75 x 1.5 - - 175 100

Cable gland for Ex e / Ex d IIC

Type ADE 1F, ADE 4F R... / B...

thread

6.3.3 Cable ends with wire end sleeves

1. Preferably use end sleeves instead of soldering cable ends.

2. Before connecting, attach the end sleeves so as to form a technically correct, currentcarrying crimped joint at the end of the conductor.

Union nut / connection

thread

WARNING

Risk of explosion due to excessive temperature rise

If the end of the conductor is not correctly enclosed by the end sleeve, but is trapped by it, this can lead to overheating. The temperature class of the machine can be exceeded. This can trigger ignition of an explosive mixture. This can result in death, serious injury or material damage.

● Insert only one conductor end into each end sleeve. Attach the end sleeve correctly.

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6.3.4 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.

NOTICE

Aluminum flow due to contact pressure

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.

Electrical connection

6.3 Inserting and routing the cables

See also

The 5 safety rules (Page 14)

6.3.5 Internal equipotential bonding

The equipotential bonding between the ground terminal in the terminal box and the motor frame is established via the terminal box fixing bolts and via defined equipotential bonding surfaces. The contact points for the equipotential bonding connection underneath the bolt heads are bare metal and protected against corrosion.

The standard cover fixing screws are sufficient as equipotential bonding between the terminal box cover and terminal box enclosure.

6.3.6 Stepless mating face for sealing in the terminal box cover

The sealing face of the terminal box cover is formed by the terminal box enclosure and the cable entry element. Therefore make sure these parts are correctly aligned, so as to ensure the seal and hence the degree of protection.

Align the cable entry support and the cable entry plate to the terminal box enclosure so that the sealing surface between the terminal box and the terminal box cover form a flat face. There must be no steps in the sealing area.

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Electrical connection

6.4 Connecting the auxiliary circuits

6.3.7 Finishing connection work

1. Before closing the terminal box, please check that:

– The electrical connections in the terminal box are tight and in full compliance with the

specifications above

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

– The inside of the terminal box is clean and free of any cable debris

– All gaskets and seals are intact

– Unused cable glands must be replaced with certified closures or closed with other

suitable closure types. Comply with the installation and operation conditions specified in the certificate for these plug elements and check that they have been complied with.

– The pressure relief device is intact Depending on the type of terminal box being used,

the pressure relief device can be implemented either by sealing the slots or by using a pressure relief diaphragm.

WARNING

Damaged pressure relief device

Water and foreign bodies can penetrate the enclosure if the pressure relief device is damaged: The degree of protection of the terminal box is no longer guaranteed, a shortcircuit can occur, which can result in death, serious injury or material damage.

● Do not operate the machine with a damaged pressure relief device.

● Any damage may only be repaired after prior discussion with the person responsible for the safety of the plant or system and only using original parts. Any damage may only be repaired after prior discussion with the person responsible for the safety of the installation and only by using original parts.

2. Close the terminal box. See section "Tightening torques for screw and bolt connections (Page 113)" for the tightening torque of the fixing bolts for the cover.

6.4 Connecting the auxiliary circuits

6.4.1 Selecting cables

Take the following criteria into account when selecting the connecting cables for the auxiliary circuits:

● Rated current

● Rated voltage

● System-dependent conditions, such as ambient temperature, routing type, etc.

● Requirements according to IEC/EN 60204‑1

● Requirements according to GB 3836.15

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6.4 Connecting the auxiliary circuits

6.4.2 Selecting cables

Take the following criteria into account when selecting the connecting cables for the auxiliary circuits:

● Rated current

● Rated voltage

● System-dependent conditions, such as ambient temperature, routing type, cable cross-

section as defined by required length of cable, etc.

● Requirements according to IEC/EN 60204‑1

● Requirements according to IEC/EN 60079‑14

6.4.3 Bringing cables into the auxiliary terminal box and routing them

The type designations of the mounted auxiliary terminal boxes, their arrangement, and the relevant connection terminals are documented in the "Technical data and drawings" section. The information required to connect the auxiliary circuits is provided in the terminal diagram located on the inside of the terminal box cover and in the "Technical specifications" section. The connectable cable cross-sections and the dimensions are listed in "Technical Data".

Electrical connection

Adapting the cable glands

A plate is bolted to the terminal box enclosure via a rectangular cutout through which the connecting cables enter. Normally, this plate is supplied without threaded holes for the cable glands. This enables you to adapt the number and size of the cable glands to the rated conditions.

Degree of protection Use only cable glands that are suitable for the degree of protection of the auxiliary terminal

box.

Introducing and routing the cables

1. Open the auxiliary terminal box and undo the cable entry plate screws.

2. Drill the required number of holes or threads in the required size of the cable gland into the

cable entry plate.

3. Mark the cables if necessary for subsequent assignment.

4. Pull the cables through the cable glands and the entry plate, and connect the cables.

5. Fit the cable entry plate.

6. Make sure that the seal on the screwed sockets for the cable glands satisfies the degree

of protection.

See also

Technical data and drawings (Page 113)

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Electrical connection

6.4 Connecting the auxiliary circuits

6.4.4 Degree of protection of the auxiliary terminal box

Normally the cable entry plate is supplied undrilled. In special versions the cable entry plate can be supplied with tapped holes for connection of cable entries and conductor entries. This requires derating of the IP degree of protection of the auxiliary terminal box.

1. Close the openings for operation, using suitable sealing elements such as sealing plugs, threaded adapters, cable or conductor entries.

6.4.5 Connecting temperature monitoring for the stator winding

The stator winding is monitored for thermal loading by temperature sensors embedded in the stator winding.

The connecting cables of the temperature sensors are routed to the main or auxiliary terminal box, depending on the version. The connection and assignment of the terminals is specified in the circuit diagram.

WARNING

Hazard due to electric shock

The installation of the temperature sensors for the winding monitoring with respect to the winding is implemented according to the requirements for basic insulation. The temperature sensor connections are located in terminal boxes, safe to touch, and have no protective separation. This is the reason that in the case of a fault, a hazardous voltage can be present at the measuring sensor cable. When touched, this can result in death, severe bodily injury and material damage.

● When connecting the temperature sensor to external temperature monitoring devices, when required, apply additional measures to fully comply with the requirements set out in IEC 60664-1 or IEC 61800-5-1 "Hazard due to electric shock”.

6.4.6 Intrinsically safe circuits for sensors or probes

Observe standard GB 3836.15 when selecting and routing connecting cables.

NOTICE

Intrinsically safe circuits for sensors or probes

If blue connection terminals are installed for sensors, you must connect them to certified intrinsically safe circuits. This can otherwise result in damage.

Ensure that you also observe the additional requirements in GB 3836.15 for intrinsically safe equipment and the associated connecting cables.

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NOTICE

Connecting the temperature sensors

Temperature sensors may be connected only to intrinsically safe circuits with certified evaluation devices. The maximum permissible input currents and powers according to the prototype test certificate may not be exceeded. This can otherwise result in damage.

If shielded, intrinsically safe temperature sensors are fitted or mounted, they must be connected using the blue connecting terminals. The cable shield is grounded just once; multiple grounding is not permitted.

6.4.7 Installing intrinsically safe circuits

There must be potential equalization along the entire length of the intrinsically safe electrical circuits when intrinsically safe circuits are involved.

A stranded wire is used as the potential equalizing cable. A copper braided strip is used to ensure potential equalization between the cable entry plate and the terminal box enclosure.

Electrical connection

6.4 Connecting the auxiliary circuits

Table 6-3 Electrical data

Non-intrinsically safe electric circuit Vm = 700 V alternating voltage Intrinsically safe power circuit in "fail-safe" type of protection Ex ib IIB/IIC, only connected to certified intrinsically safe circuits that are galvan‐

ically isolated from ground. Maximum values for total:

IIB IIC

e.g. with T4: Vi = 28 V Vi = 24 V Ii = 300 mA Ii = 170 mA Pi = 1.3 W Pi = 1.3 W The effective internal inductance and capacitance are negligibly small.

The intrinsically safe circuits are safely galvanically isolated from all non-intrinsically safe circuits up to a peak value for the rated voltage of 1000 V. Please refer to the additional plate on the machine for the maximum values for "intrinsically safe power circuits".

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Electrical connection

6.4 Connecting the auxiliary circuits

6.4.8 Internal equipotential bonding in the auxiliary terminal box

The equipotential bonding between the PE terminals in the relevant auxiliary terminal box enclosure and the machine enclosure is established via a fixing bolt in each auxiliary terminal box enclosure. The contact point underneath the bolt head is bare metal and protected against corrosion.

WARNING

Ineffective equipotential bonding

If the equipotential bonding connection fails, parts of the machine may become live. If you touch them, you will receive an electric shock. This can result in death, serious injury or material damage.

● When performing any installation work you must always take care to ensure that all equipotential bonding connections remain effective.

6.4.9 Terminating the connection work (auxiliary circuit)

1. Before closing the auxiliary terminal box, please check that:

– The cables are connected in accordance with the terminal diagram.

– The cables are freely arranged so that they cannot come into contact with the machine,

and the cable insulation cannot be damaged.

– The inside of the terminal box is clean and free of any cable debris, dirt and foreign

bodies.

– The cable glands are firmly tightened, are suitable with respect to the degree of

protection, type of cable routing, permissible cable diameter, etc., and have been mounted in full compliance with specifications and regulations

– The threads in the connection plate are sealed using cable and conductor entries, thread

adapters or sealing plugs that achieve the respective degree of protection.

– Unused cable entries are sealed. The sealing elements are firmly screwed in, and can

only be released using a tool.

– All of the seals/gaskets and sealing surfaces of the terminal box are in good condition

– The screws of all of the screw clamps are fully tightened, even if they are not being used.

2. Close the auxiliary terminal box using the cover supplied for this purpose. See section "Tightening torques for screw and bolt connections (Page 113)" for the tightening torque of the fixing bolts for the cover.

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Commissioning

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.

Note Service Center

Please contact the Service Center (Page 111) if you require commissioning support.

7.1 Prior to commissioning

Once the system has been correctly installed, you should check the following prior to commissioning:

Note 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.

● The machine is undamaged.

● The machine has been correctly installed and aligned, the transmission elements are

correctly balanced and adjusted.

● 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..

● Moving parts such as the coupling move freely.

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

Electrical connection

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

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

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Commissioning

7.1 Prior to commissioning

● Appropriately configured control and speed monitoring functions ensure that the motor cannot exceed the permissible speeds specified in the technical data. See also the systemspecific documentation.

● The minimum insulation resistance values are within tolerance.

● Minimum air clearances have been maintained.

● Any supplementary motor monitoring devices and equipment have been correctly connected and are fully functional.

● The values for "Warning" and "Shutdown" are set at the monitoring devices.

● All brakes and backstops are operating correctly.

See also

Technical data and drawings (Page 113)

● The bearing insulation should be implemented as shown on the plates.

Switching overvoltages When high-voltage machines with starting current IA ≤ 600 A are switched off while starting or

after they have been blocked, then in individual cases inadmissibly high switching overvoltages for the stator winding insulation can occur through multiple restrikes.

See also

The peak voltages which arise as a result can damage the winding insulation.

● If you are using vacuum circuit breakers and vacuum contactors, use an appropriate surge suppressor, such as the Siemens 3EF (zinc oxide varistor with spark gap).

● An additional RC arrester (resistor and capacitor connected in series) makes sense at unfavorable operating points/under unfavorable line supply conditions.

Switching high-voltage motors (Page 25)

Current transformer

● Ensure that the secondary circuit of the current transformer is protected against accidental opening during operation.

Cooling

● Check that the machine cooling is available for commissioning.

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7.2 Insulation resistance and polarization index

● 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:

Commissioning

"Testing the insulation resistance and polarization index" (Page 41)

7.3 Greasing the roller bearings prior to commissioning

● Regrease the roller bearings prior to commissioning if the machine has been out of

operation for more than a year. The shaft must rotate so that the new grease can be distributed across the bearings.

● Regrease the roller bearings prior to commissioning in the following circumstances:

– When the machine has been in storage in favorable conditions, e.g. in dry rooms that

are free of dust and vibrations. This applies to the period between delivery and commissioning, or longer periods of stoppage.

– If the machine has been in storage in unfavorable conditions for more than two years.

Note

Pay attention to the instructions on the lubricant plate.

● If the machine is equipped with grease removal valves, after relubricating, remove the

grease used by completely withdrawing the valve mounted at the bearing several times. The machine must be operational while doing this.

● If the machine is equipped with grease collection chambers, unscrew the grease collection

chambers after the interval specified on the plate with the motor stationary and remove the spent bearing grease. If this is not done, the grease will clog and the bearings will overheat.

● Continually check the bearing temperature rise. When using the specified grease quality,

for a maximum room temperature of 40 °C, the maximum bearing temperature rise is 80 K.

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Commissioning

7.4 Test run

Avoiding mechanical damage to bearings

Regularly inspect all machines for any mechanical damage. Especially observe that the bearing replacement intervals and relubrication intervals, respectively grease change intervals or oil change intervals specified by the machine manufacturer are maintained.

Replace the bearings once they have reached their nominal service life or verify that they are mechanically in good working order as part of an inspection.

● Where bearings are sealed for life, there is a guarantee that the rated service life is achieved only well after expiry of the service life of the grease in the bearing.

● The theoretical nominal service life of the bearings can be taken from the data sheet of the machine if this was specified – or was specifically defined for mechanical design reasons for a particular application.

● Where machines are subject to externally applied forces (e. g. the force on a drive belt or axial forces arising from the driven machine), at the full loadings listed on the technical specification the rated service life of the bearings is at least 20,000 hours.

● For all other machines, the rated service life of the bearings is at least 40,000 hours.

● For bearings with external oil supply, monitor the lubrication system to ensure that it is operating correctly.

7.4 Test run

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. Allow the machine to run down before switching it on again.

NOTICE

Avoiding mechanical damage to the cylindrical roller bearing

Under all circumstances maintain the minimum load on cylindrical roller bearings of 50% corresponding to what is specified in the catalog.

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.

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Commissioning

7.5 Overvoltages when switching high-voltage motors

3. If it runs perfectly, connect a load.

NOTICE

Thermal overload of motors connected directly to the line supply

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, ...

NOTICE

Serious damage to the machine

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.

7.5 Overvoltages when switching high-voltage motors

When commissioning high-voltage motors or switchgear for high voltage motors from 3 kV and above, surge voltages can occur while starting. This can damage the machine.

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Commissioning

7.5 Overvoltages when switching high-voltage motors

These consequences are independent of the motor size and quenching principle of the switch used, i.e. they can also occur when using minimum oil,SF6- or air-blast switches.

● Avoid shutting down the machine during startup by, for instance, checking for errors in the starting control or for excessively sensitive protection settings.

● Keep shutdowns during startup for checking the direction of rotation or other tests to an absolute minimum.

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Operation

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.

8.1 Safety instructions for operation

Risk of explosion when the bridging across the insulated bearing is removed

If the machine was factory-fitted with bridging of the insulated drive-end bearing, this bridging must not be removed. The consequence of doing so would be to allow potential differences to develop between the rotor and the grounded machine. This can cause the generation of sparks, which especially in an explosive atmosphere can ignite the surrounding gas. Explosions can occur. There is also a risk of an electric shock. Death, serious injury, or material damage will result.

● Do not disconnect the bridging of the bearing insulation at the drive end during operation.

● Comply with the plates on the machine relating to bearing insulation and possible bridging

options.

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.

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Operation

8.1 Safety instructions for operation

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.

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.

This 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 systemspecific safety conditions.

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.

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8.2 Switching on with the anti-condensation heating active

NOTICE

Excessive machine temperature

If the anti-condensation heating is operated while the machine is running, this can increase the temperatures inside the machine. This can result in material damage.

● 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.

See also

Interlock circuit for anti-condensation heating (Page 23)

Operation

8.3 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.

NOTICE

Thermal overload of motors connected directly to the line supply

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.

8.4 Regreasing roller bearings

Refer to the regreasing instructions for the roller bearings on the lubricant plate.

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Operation

8.5 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

8.6 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.

Measures for machines ready to operate during longer non-operational periods

● For longer periods when the machine is not being used, either energize it at regular intervals (roughly once a month), or at least spin the rotor.

● Please refer to the section "Switching on" (Page 77) before switching on to recommission the motor.

NOTICE

Damage due to improper storage

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

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

● When recommissioning the motor after a long period out of service, carry out the measures recommended in the chapter entitled "Commissioning (Page 69)".

8.6.1 Avoidance of condensation or formation of condensation within the machine

● If the controller does not do this automatically, switch on any anti-condensation heating during stoppages. This will avoid the formation of condensation.

● Observe the specifications on the anti-condensation heating plate in this regard.

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WARNING

Explosion hazard

If the anti-condensation heating is switched on directly after the machine is switched off, the temperature class or the maximum surface temperature of the machine can be exceeded.

In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious injury or material damage.

● Only switch on the anti-condensation heating after the motor has been switched off. Carefully comply with the data on the anti-condensation heating plate.

8.6.2 Avoidance of damage to roller bearings during stoppages

Extended stoppages at the identical or almost identical resting position of the rotor in the roller 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.

Operation

8.6 Stoppages

● During recommissioning, refer to the information in Chapter "Commissioning".

See also

Commissioning (Page 69)

8.6.3 Measuring the insulation resistance after an extended stoppage

● 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?

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Operation

8.7 Decommissioning the machine

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 41)

8.7 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.

See also

Protection against corrosion (Page 38)

Securing the rotor (Page 31)

Storage (Page 33)

8.8 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.

See also

Commissioning (Page 69)

Decommissioning the machine (Page 80)

8.9 Faults

8.9.1 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.

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Operation

8.9 Faults

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.

8.9.2 Electrical faults

Note

If you are operating the motor with a converter, the operating instructions of the converter must also be observed if electrical faults occur.

Table 8-1 Electrical faults

↓ 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.

X X X X Interrupted phase in the feeder cable af‐

ter switching on X Mains voltage too low, frequency too high Check the power supply conditions. X Mains voltage too high, frequency too low Check the power supply conditions.

X X X X X Stator winding incorrectly connected Check the winding connection in the terminal box.

X X X X Winding short circuit or phase short cir‐

cuit in stator winding

X Incorrect direction of rotation Check the connection.

Check the switches and cables.

Determine the winding resistances and insulation resistances. Carry out repair work after consulta‐ tion with the manufacturer.

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Operation

8.9 Faults

8.9.3 Mechanical faults

Table 8-2 Mechanical faults

↓ Grinding noise ↓ Radial vibrations

↓ Axial vibrations

Possible causes of faults Remedial measures

X Rotating parts grind Establish the cause and realign the parts. X Stator or coupling not balanced. Disconnect the stator or coupling and rebalance.

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 its length. X Rotor out of true, 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. X X Resonance of the overall system com‐

prising motor and foundation

X X Changes in foundation Establish the cause of the changes and eliminate them if necessary;

(1)

Take any changes into account when warming up the machine.

Stabilize the foundation following consultation.

realign the machine.

(1)

8.9.4 Roller bearing faults

Damage to roller bearings can be difficult to detect in some cases. If in doubt, replace the bearing. Use other bearing designs only after consulting the manufacturer.

Table 8-3 Roller bearing faults

↓ Bearing overheats ↓ Bearing "whistles"

↓ Bearing "knocks"

Possible causes of faults Remedial measures X High coupling pressure Align the machine more accurately. X Belt tension too high Reduce the drive belt tension. 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.

X X Bearing corroded Replace the bearing. Check the seals.

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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. X Brinelling or scoring Replace the bearing. Avoid any vibration at standstill

Operation

8.9 Faults

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Operation

8.9 Faults

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Maintenance

9.1 Safety instructions for maintenance

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 at the place of installation

● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.

Comply with standard GB 3836.16 when carrying out all service and maintenance work on the machine.

9.2 Maintenance for machines with type of protection "Ex d/Ex db"

Maintenance and repair for machines, type of protection "Ex d/Ex db"

The machine marking based on IEC / EN 60079–0 was supplemented by the "X" symbol.

● Maintain the special conditions for repairs. The gap dimensions for the electric machine do not comply with the standardized values in IEC / EN 60079–1. For repair work, obtain the gap dimensions of the electrical machine from the manufacturer.

● Perform maintenance, repair and modification work on explosion-protected machines in strict compliance with the corresponding national health and safety legislation, the safety instructions and descriptions in the general maintenance instructions.

Work influencing explosion protection must be carried out by the manufacturer or by a specialist workshop for electrical machinery authorized by the manufacturer. This includes the following operations, for example:

● Repairs to the stator or rotor windings and to the terminals

● Repairs to the ventilation system

● Repairs to the bearings

● Dismantling machines with flameproof enclosures

● Connection work carried out in the terminal box

The operations must be identified by an additional repair plate carrying the following information:

● Date

● Company carrying out repair

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Maintenance

9.3 Inspection and maintenance

● Type of repair

● Reference number of the repair technician regarding repair work

Testing after repair shall be carried out in accordance with EU directives.

WARNING

Risk of explosion when altering the ignition gap geometry

Changing ignition gap geometries (gap dimensions) as part of repair work according to the minimum specifications of IEC / EN 60079–1 is not permissible.

This can result in death, serious injury or material damage.

● Obtain the gap dimensions of the electrical machine from the manufacturer for the repair or restoration of ignition gap geometries.

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.).

Note

Please contact the service center (Page 111), if you require support with service, maintenance or repair.

9.3 Inspection and maintenance

9.3.1 Safety instructions

WARNING

Rotating and live parts

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 14).

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Maintenance

9.3 Inspection and maintenance

WARNING

Machine damage

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.

CAUTION

Dust disturbances when working with compressed air

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.).

NOTICE

Damage to insulation

If metal swarf enters the winding head when cleaning with compressed air, this can damage the insulation. Clearance and creepage distances can be undershot. This may cause damage to the machine extending to total failure.

When cleaning with compressed air, ensure there is adequate extraction.

NOTICE

Machine damage caused by foreign bodies

Foreign bodies such as dirt, tools or loose components, such as screws etc., can be left by accident inside the machine after maintenance is performed. These can cause short circuits, reduce the performance of the cooling system or increase noise in operation. They can also damage the machine.

● When carrying out maintenance work, make sure that no foreign bodies are left in or on

the machine.

● Securely attach all loose parts again once you have completed the maintenance

procedures.

● Carefully remove any dirt.

Note

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

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Maintenance

9.3 Inspection and maintenance

9.3.1.1 Working on machines with type of protection "Ex d/Ex db"

For explosion-protected machines with type of protection "Ex d" or "Ex db" in accordance with IEC / EN 60079–0 and IEC / EN 60079–1, observe the following:

● Machined contact and fitting surfaces on the following components must not be reworked or painted:

– Stator frame

– Bearing end shields, bearing cover

– Motor shaft

– Gland plate

– Terminal box base, terminal box cover

– Cable entry plates for additional terminal boxes, if available

● Keep these surfaces clean and protect them against corrosion by applying a thin coating of grease. It is not permissible that any seals are fitted between the surfaces that guarantee that flame is not transmitted.

9.3.1.2 Static charging when cleaning

Risk of explosion due to static charging

If you clean the motor, plastic components may become statically charged and ignite a potentially explosive atmosphere. An explosion can occur. This can result in death, serious injury or material damage.

● When cleaning ensure that there is absolutely no explosive atmosphere present.

● Clean the plastic parts and components so that absolutely no static charging occurs

● Do not use compressed air for cleaning.

9.3.2 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.

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9.3.3 First service after installation or repair

● Check after approx. 500 operating hours, but after not more than one year:

Maintenance

9.3 Inspection and maintenance

Check When the

The electrical parameters are maintained. X The permissible bearing temperatures are not exceeded. X The smooth running characteristics and machine running noise have not

deteriorated. The foundation has no cracks or indentations. (*) X X

(*) You can perform these checks while the motor is at standstill or, if required, while running.

● Further checks may be required if so specified in operating instructions of components

(Page 149) or in accordance with the plant-specific conditions.

● If you find any deviations during the inspection, you must rectify them immediately. They

may otherwise damage the motor.

9.3.4 General inspection

● Check that the installation conditions are observed. Perform the following checks after

approx. 16 000 operating hours or at the latest after two years:

Checking When the

The electrical parameters are maintained X The permissible bearing temperatures are not exceeded X The smooth running characteristics and machine running noise have not

deteriorated The foundation has no cracks or indentations. (*) X X The machine is aligned within the permissible tolerance ranges. X All the fixing bolts/screws for the mechanical and electrical connections

have been securely tightened All the potential connections, grounding connections and shield supports

are correctly seated and properly bonded The winding insulation resistances are sufficiently high (Page 40) X Any bearing insulation is fitted as shown on the plates and labels X The CABLES and insulating parts and components are in good condition

and there is no evidence of discoloring Condensation can freely flow away. X

motor is running

At stand‐ still

(*) This check can be made at standstill or when running.

● If you detect any deviations during the inspection, you must rectify them immediately. They

may otherwise cause damage to the machine.

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Maintenance

9.3 Inspection and maintenance

9.3.5 Assessing the rolling bearings

To assess the rolling bearings, it is generally not necessary to dismantle the machines. The motor only has to be dismantled if the bearings are to be replaced.

The state of a rolling bearing can be assessed by analyzing the bearing vibration. The measured values provide an indication and can be assessed by specialists. In this case, please contact the Service Center.

See also

Service and Support (Page 111)

WARNING

Explosion hazard due to overheating of the roller bearings

If the roller bearings are not regularly regreased, local overheating may be possible, and, as a consequence, an explosion in an explosive atmosphere. This can result in death, serious injury, or material damage.

● Regrease the roller bearings regularly according to the lubrication plate.

● Implement bearing temperature monitoring if not yet in existence.

9.3.6 Alternative types of grease for the operation of roller bearings

In the following table, you will find a list of approved alternative types of grease.

Filling with oil for the first time Alternative permissible greases Shell Gadus S2 V100 3 Aral Aralub HL3

BP Energrease LS3 Castrol Optimol Olista Longtime 3 Exxon Mobil Beacon EP3 Mobilux EP3 OMV Signum L3

SKF LGMT 3 Shell Gadus S5 V42P 2.5 Aeroshell Gadus S7

Shell Gadus S5 V100 2 Exxon Mobil Mobilith SHC 100

Currently no comparable grease with Dm*n≥1,000,000 is known.

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Maintenance

9.3 Inspection and maintenance

Filling with oil for the first time Alternative permissible greases Esso Unirex N3 Exxon Mobil Mobilgrease XHP 103

Shell Gadus S5 V100 2

Shell Gadus S3 T100 2 BP Energrease SY2202

Castrol Firetemp XT2 Chevron Grease SRI2 Klüber Petamo GHY 133N SKF LGHP 2 Exxon Mobil Polyrex EM

Observe the following when changing over to an alternative type of grease that is permitted according to the table:

Bearings with permanent lubrication:

● Completely remove the old grease from the bearing before regreasing it.

● Fill roller bearings completely with grease and cavities in the bearing cover only up to one third.

Bearings with regreasing:

If complete replacement of grease and cleaning of the bearing is not possible, keep the operating time to a minimum when different greases are mixed. To do this, thoroughly grease the bearing when the machine is running with about twice the amount of grease until spent grease has been removed from the greasing ducts. Then regrease 4x at intervals of ¼ of the normal greasing interval. During this time, very carefully monitor the bearing locations involved. Then resume the normal greasing intervals.

NOTICE

Damage due to mixing grease types

If you mix greases and oils with different soap or oil bases, then the lubricating properties may no longer be guaranteed.

Mixing low-temperature grease with normal temperature grease can cause lumps to form in the lubricant. The consequence can be damage to the roller bearings due to overheating.

Never mix greases that have different thickening agents and different base oils.

9.3.7 Removing spent grease

If the specifications on the lubricant plate are observed, the spent grease chamber will provide capacity for a calculated service life of at least 40 000 operating hours, approx. five years. When the spent grease chamber is full, the spent grease must be removed prior to

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Maintenance

9.3 Inspection and maintenance

relubrication. This is indicated by the fact that during relubrication, oil or grease escapes at the bearing cover.

● To remove the spent grease, loosen the outer bearing cap.

NOTICE

Removing spent grease

If the spent grease is not removed, then the roller bearings become too hot and can seize up as the grease distribution mechanism is disturbed.

WARNING

Working on the locating bearing

If the motor is in a vertical position, the rotor can fall out while work is being performed on the locating bearing. This can result in death, serious injury or material damage.

Support or reduce the load on the rotor when carrying out work with the machine in a vertical position.

9.3.8 Cleaning cooling air ducts and passages

The cooling ducts must be free of any pollution in order that the machine is adequately cooled.

● Regularly clean the grids, ducts, ribs, pipes etc. to remove dust and pollution.

● Regularly clean the cooling air passages through which the ambient air flows, e.g. using dry compressed air.

NOTICE

Motor overheating caused by dirt

The frequency of the cleaning intervals depends on the local degree of fouling. The machine will overheat if the cooling air ducts are polluted and the cooling air cannot flow without obstruction.

● Regularly check for dirt.

● Clean the cooling air ducts through which the ambient air flows.

9.3.9 Maintaining the anti-condensation heating

The anti-condensation heating is maintenance-free. If it is defective, it can be replaced. In this case, please contact the Service Center (Page 111).

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Maintenance

9.3 Inspection and maintenance

9.3.10 Maintaining terminal boxes

● For terminal boxes with type of protection "Ex d" or "Ex db", regularly inspect the cable

entries inside the terminal box according to IEC / EN 60079-17. Retighten the screw fastenings if necessary.

9.3.11 Measuring the insulation resistance during the course of maintenance work

● 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 41)

9.3.12 Touch up any damaged paintwork

If the paint is damaged, it must be repaired in order to protect the unit against corrosion.

Note Paint system

Contact the Service Center (Page 111) before you repair any damage to paint. They will provide you with more information about the correct paint system and methods of repairing paint damage.

Complete overpainting

The paint applied must conform to the requirements to avoid electrostatic charging, see EN 60079-0.

The repair of painted surfaces of the non-conductive paint coating up to a nominal coating thickness of 350 μm was investigated and is acceptable.

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Maintenance

9.4 Corrective Maintenance

9.3.13 Repainting

WARNING

Explosion hazard caused by incorrect painting

The paint coat can become electrostatically charged where there is a thick coat. Electrostatic discharges can occur. There is a risk of explosion if potentially explosive mixtures are also present at this moment. This can result in death, serious injury or material damage.

You must comply with one of the following requirements when you repaint painted surfaces:

● Limit the total paint coating thickness according to the explosion protection group:

– IIB: Total paint coating thickness ≤ 2 mm

– IIC: Total paint coating thickness ≤ 0.75 mm for machines of Group II (gas)

– III: Total paint coating thickness ≤ 0.45 mm for Group III machines (dust)

According to tests, paint repair work up to the total paint coating thickness of the nonconductive paint coating listed has also been investigated and is harmless.

● Limit the surface resistance of the paint used:

– IIB, IIC, III: Surface resistance ≤ 1 GΩ for machines of groups II and III (gas and dust)

● Breakdown voltage ≤ 4 kV for machines, Groups II and III (gas and dust)

● Limiting the charge transfer:M

– IIB: Limit value for the highest transferred charge < 25 nC

– IIC: Limit value for the highest transferred charge < 10 nC for Group II machines (gas)

– III: Limit value for the highest transferred charge < 200 nC for Group III machines (dust)

● Incapability, dangerous charge to be saved:

– IIB: Limit value for the maximum capacity ≤ 10 pF

– IIC: Limit value for the maximum capacity ≤ 3 pF for Group II machines (gas)

– III: Limit value for the maximum capacity ≤ 10 pF for Group III machines (dust)

9.4 Corrective Maintenance

9.4.1 Safety instructions for repair work

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.

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If the motor has to be transported, please observe the information and instructions in the chapter "Transport (Page 27)".

Risk of explosion as a result of inadmissible repair work

Repairs are only permissible within the scope of the work described in these operating instructions. Otherwise an explosion can occur in an explosive atmosphere. This can result in death, serious injury or material damage.

● For repairs to go beyond this scope, please contact the Service Center.

See also

Service and Support (Page 111)

Maintenance and repair for machines, type of protection "Ex d/Ex db"

The machine marking based on IEC / EN 60079–0 was supplemented by the "X" symbol.

● Maintain the special conditions for repairs. The gap dimensions for the electric machine do

not comply with the standardized values in IEC / EN 60079–1. For repair work, obtain the gap dimensions of the electrical machine from the manufacturer.

Maintenance

9.4 Corrective Maintenance

● Perform maintenance, repair and modification work on explosion-protected machines in

strict compliance with the corresponding national health and safety legislation, the safety instructions and descriptions in the general maintenance instructions.

● Repairs to the stator or rotor windings and to the terminals

● Repairs to the ventilation system

● Repairs to the bearings

● Dismantling machines with flameproof enclosures

● Connection work carried out in the terminal box

The operations must be identified by an additional repair plate carrying the following information:

● Date

● Company carrying out repair

● Type of repair

● Reference number of the repair technician regarding repair work

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Maintenance

9.4 Corrective Maintenance

Testing after repair shall be carried out in accordance with EU directives.

WARNING

Risk of explosion when altering the ignition gap geometry

Changing ignition gap geometries (gap dimensions) as part of repair work according to the minimum specifications of IEC / EN 60079–1 is not permissible.

This can result in death, serious injury or material damage.

● Obtain the gap dimensions of the electrical machine from the manufacturer for the repair or restoration of ignition gap geometries.

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.

9.4.2 Prepare servicing work

● The drawings and parts lists do not contain any detailed information about the type and dimensions of fixing elements and components. For this reason, you should establish this information when dismantling them and make a note of it for the purpose of reassembly.

● Document the type, dimensions and arrangement of the parts so that you will be able to reassemble the machine to its original state.

● Use suitable tools to disassemble the machine.

● Take measures to prevent parts from dropping down before you dismantle them, e.g. by replacing fastening elements with extra-long screws, threaded bolts or similar. This ensures that the part is supported after it is pulled off.

● The centerings in the shaft extensions have reset threads. Use lifting gear which is suitable for the rotor weight and direction of loading.

Danger when a rotor falls

Eyebolts in accordance with DIN 580 are unsuitable for suspending the rotor. The rotor can fall off. This can result in death, serious injury or material damage.

● Use lifting gear which is suitable for the rotor weight and direction of loading.

Machine damage caused by improper repair work

Improper servicing work can damage the machine. This can cause damages and/or faults which can result in eventual or immediate death, serious injury, or property damage.

● Properly assemble or disassemble the machine.

● Use only suitable tools and equipment.

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● Immediately replace damaged components.

● If necessary, contact the Service Center (Page 111).

9.4.3 Checking all screw connections

● Check that all the bolts for attaching the bearing shields, bearing covers, gland plates, and

terminal boxes are present and properly tightened.

● Replace damaged bolts with identical bolts that are in perfect condition.

Bolt grade Stainless steel bolts A4-80

WARNING

Incorrectly repairing the anti-condensation heating

If the anti-condensation heating is not correctly repaired, e.g. if unauthorized or untested spare parts are used, this can result in explosions during operation in a potentially explosive atmosphere. This can result in death, serious injury or material damage.

● Only appropriately trained specialists in the service center (Page 111) are authorized to repair anti-condensation heating systems. The anti-condensation heating must then be subject to a routine test, which requires extensive specialist knowledge.

● Only use authorized and tested spare parts.

Maintenance

9.4 Corrective Maintenance

9.4.4 Fan cover

The fan cowl is fixed on the machine enclosure with screws.

Disassembly

1. Secure the fan cowl against falling before you start working.

2. Loosen the fixing screws that secure the fan cowl on the enclosure.

3. Observe existing retaining components and retain them for the reassembly.

Assembly

Proceed in the reverse order to assemble the fan cowl.

1. Position the fan cowl and tighten the fixing screws.

2. Ensure that the retaining components are undamaged and correctly installed.

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Maintenance

9.4 Corrective Maintenance

9.4.5 External fan

To remove the external fan or to replace it, remove the protective grille and other components that are at the end of the fan cover.

Disassembling

1. Secure the components so that they cannot fall before you start any work.

2. Loosen the fixing screws that are used to attach the components and the fan cover.

3. Observe existing fixing components and keep them for the reassembly.

Assembly

Mount the components in the inverse sequence.

1. Position the components and tighten the fixing screws.

2. Ensure that the fixing components are undamaged and correctly installed.

9.4.6 Internal fan

The internal fan is located on the rotor inside the machine. If the internal fan is defective or must be replaced, please contact the Service Center (Page 111).

WARNING

Risk of explosion by a rubbing fan impeller

Sparking can occur if the fan impeller comes into contact with the air guidance nozzle. In an explosive atmosphere, this can be ignited and cause an explosion. This can result in death, serious injury or material damage.

● After any inspection and work carried out on the fan, check that the gap between the air inlet nozzle and the fan impeller is radially approximately 2 mm around the complete circumference.

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WARNING

Rotor can fall out

If the motor is in a vertical position, the rotor can fall out while work is being performed on the locating bearing. This can result in death, serious injury or damage.

● Support or unload the rotor when carrying out work with the machine in a vertical position.

9.4.7 Bearings

Work influencing explosion protection must be carried out by the manufacturer or by a specialist workshop for electrical machinery authorized by the manufacturer.

See also

Safety instructions for repair work (Page 94)

Maintenance

9.4 Corrective Maintenance

9.4.7.1 Gamma ring

Depending on the particular version, a Gamma ring is installed as sealing ring.

The Gamma ring comprises an elastic, sealing sleeve and a metal housing, which are not firmly connected with one another. The metal housing acts as thrower ring, provides protection and maintains the sleeve at the correct position. The sleeve is kept in the housing through the radial lift that is applied and the associated preload condition. The Gamma ring is mounted on the shaft with a press fit, and requires no additional fastening.

Mounting the Gamma ring

1. Grease the sealing lip of the sleeve. It is not permissible that grease is applied between the sleeve and the housing.

2. Press the Gamma ring onto the shaft by applying constant and uniform pressure. When required, use an appropriate mounting tool. Position the Gamma ring so that there is a play of 1 mm with respect to the flat surface of the bearing cover.

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Maintenance

9.4 Corrective Maintenance

9.4.8 Seal the motor

Extreme caution and attention to cleanliness are vital to installation.

● Clean all bare joints between parts such as housings, bearing shields and bearing bushes etc., and remove old sealant material.

● Smear bare joints between parts with non-hardening, permanently flexible sealant, such as "Hylomar M". Follow the manufacturer's application and safety instructions when doing this.

● Check all sealing elements, such as those on the terminal boxes, for elasticity, aging or damage, and renew them if they are no longer effective.

Replace the seals if necessary with original parts or with tested sealing elements. The seals must be fully bonded to the motor and the air intake housing. It is impermissible to have gaps and holes where seals make contact.

● Surfaces whose mating faces are sealed using liquid sealant can be resealed by applying the original liquid sealant (Hylomar M).

● Surfaces whose mating faces are sealed using sealings that adhere to one side only can be resealed with the original sealing using the original adhesives (Loctite).

See also

If you are installing covers that are sealed with liquid gasket, proceed as follows to maintain the IP degree of protection of the machine before closing it again:

1. Use only approved liquid sealants.

2. Clean the sealing surfaces according to the technical data sheet of the liquid sealant. The sealing surfaces must be clean and dry before reassembly.

3. Apply the liquid gasket as a continuous bead with a diameter of approx. 3 mm.

4. Assemble the components after the solvent has had a chance to vaporize, while still assembling within the specified assembly time.

5. Retighten the fixing screws of the cover after the liquid sealant has set.

Note

If you have any questions, contact the Service Center.

Service and Support (Page 111)

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

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Introduction

1.1 About these instructions

1.2 Compiling personal documents

Safety information

2.1 Information for those responsible for the plant

2.2 The 5 safety rules

2.3 Qualified personnel

2.4 Safe handling

2.5 Use in hazardous zones and areas

2.6 Electrostatic sensitive devices

2.7 Electromagnetic compatibility

2.8 Interference immunity

2.9 Influence on the line power supply through a strongly irregular torque

2.10 Electromagnetic fields when operating electrical power engineering installations

Description

Preparations for use

4.1 Safety-related aspects to consider when configuring the plant

4.2 Observing the operating mode

4.3 Ensure adequate cooling

4.4 Interlock circuit for anti-condensation heating

4.5 Noise emission

4.6 Voltage and frequency fluctuations during line operation

4.7 Phase synchronization during supply system switching

4.8 System-inherent frequencies

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

4.10 Switching high-voltage motors

4.11 Machines without final paint coating

4.12 Thermal protection

4.13.1 Transport markings

4.13 Transport and storage

4.13.2 Checking the delivery

4.13.3 Attaching the rotor shipping brace

4.13.4 Checking the load handling attachments

4.13.5 Lifting and transportation

4.13.6 Securing the rotor

4.13.7 Working on the underside of the machine

4.13.8 Storage

4.13.9 Storing machines together with the driven machine

4.13.10 Storage for longer than two years

4.14 Converter operation

4.13.11 Protection against corrosion

4.14.1 Tandem operation

Assembly

5.1 Preparations for installation

5.1.1 Requirements for installation

5.1.2 Insulation resistance and polarization index

5.1.3 Testing the insulation resistance and polarization index

5.1.4 Prepare the mating faces for a flange connection

5.1.5 Do not bridge the bearing insulation

5.2 Lift the machine to where it will be installed, and position it

5.2.1 Checking the load handling attachments

5.2.2 Preconditions for correct alignment and secure attachment

5.2.3 Removing the rotor shipping brace

5.2.4 Mounting the output elements

5.2.5 Lifting the machine

5.2.6 Working on the underside of the machine

5.2.7 Removing anti-corrosion protection

5.2.8 Setting down the machine

5.3 Installing the machine

5.3.1 Safety instructions for installation

5.3.2 Selecting bolts

5.3.3 Preconditions for smooth, vibration-free operation

5.3.4 Recommended alignment accuracy

5.3.5 Aligning the machine to the driven machine and mounting it

5.4 Complete the installation work

5.3.6 Axial and radial forces at the second shaft extension

Electrical connection

6.1 Safety instructions

6.2 Preparation

6.2.1 Selecting cables

6.2.2 Route the cable with an appropriate loop so that water can drip off

6.2.3 Terminal designation

6.2.4 Routing the cable into the terminal box

6.2.5 Terminal boxes with type of protection "Ex d/Ex db"

6.2.6 Terminal boxes with type of protection "Ex e/Ex eb"