www.siemens.com/drives
Operating Instructions
Installation Instructions
Electric motor
SIMOTICS HV M
Type 1RN76308PR900CG0-Z
Edition 07/2018
03.07.2018 13:28
V3.00
Electric motor
SIMOTICS HV M
Type 1RN76308PR900CG0-Z
Introduction
1
Operating Instructions
Installation Instructions
Safety information
Description
Preparations for use
Assembly
Electrical connection
Commissioning
Operation
2
3
4
5
6
7
8
Maintenance
Spare parts
Disposal
Service and Support
Technical data and drawings
Quality documents
Additional documents
9
10
11
A
B
C
D
Edition 07/2018
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: MUSTER
Ⓟ 07/2018 Subject to change
Copyright © Siemens AG 2017.
All rights reserved
Table of contents
1 Introduction.................................................................................................................................................11
1.1 About these instructions.........................................................................................................11
1.2 Compiling personal documents..............................................................................................12
2 Safety information.......................................................................................................................................13
2.1 Information for those responsible for the plant.......................................................................13
2.2 The five safety rules...............................................................................................................13
2.3 Qualified personnel................................................................................................................14
2.4 Safe handling.........................................................................................................................14
2.5 Electrostatic sensitive devices...............................................................................................16
2.6 Interference immunity.............................................................................................................17
2.7 Electromagnetic fields when operating electrical power engineering installations.................17
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 Cooling water quality..............................................................................................................23
4.4 Insufficient cooling water quality............................................................................................24
4.5 Interlock circuit for the external fan motor..............................................................................24
4.6 Interlock circuit for anti-condensation heating........................................................................25
4.7 Space requirements...............................................................................................................25
4.8 Noise emission.......................................................................................................................25
4.9 Voltage and frequency fluctuations during line operation......................................................25
4.10 Phase synchronization during supply system switching........................................................26
4.11 System-inherent frequencies.................................................................................................26
4.12 Torsional loading of the shaft assembly.................................................................................26
4.13 Switching high-voltage motors...............................................................................................26
4.14 Thermal protection ................................................................................................................27
4.15 Transport and storage............................................................................................................27
4.15.1 Transport markings................................................................................................................27
4.15.2 Checking the delivery.............................................................................................................28
4.15.3 Checking the load handling attachments...............................................................................28
4.15.4 Lifting and transportation........................................................................................................29
4.15.5 Storage...................................................................................................................................32
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Operating Instructions 07/2018 5
Table of contents
4.15.6 Protection against corrosion...................................................................................................34
4.15.7 Protecting the cooling water circuit during storage................................................................34
4.16 Converter operation...............................................................................................................35
4.16.1 Rotational speed limit values.................................................................................................35
4.16.2 Insulated bearings when operating the converter..................................................................36
4.16.3 Reducing bearing currents.....................................................................................................38
5 Assembly....................................................................................................................................................39
5.1 Preparations for installation....................................................................................................39
5.1.1 Requirements for installation..................................................................................................39
5.1.2 Parts delivery.........................................................................................................................40
5.1.3 Insulation resistance and polarization index..........................................................................40
5.1.4 Testing the insulation resistance and polarization index........................................................41
5.1.5 Preparing the mating faces....................................................................................................44
5.1.6 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 anti-corrosion protection.......................................................................................45
5.2.4 Mounting the output elements................................................................................................47
5.2.5 Lifting and transportation........................................................................................................48
5.2.6 Putting the machine down......................................................................................................50
5.2.7 Draining condensation...........................................................................................................51
5.2.8 Roughly aligning the machine................................................................................................51
5.3 Installing the machine............................................................................................................52
5.3.1 Safety instructions for installation...........................................................................................52
5.3.2 Selecting bolts........................................................................................................................53
5.3.3 Preconditions for smooth, vibration-free operation................................................................53
5.3.4 Aligning and attaching the machine to the driven machine....................................................53
5.4 Connecting the supply lines...................................................................................................55
5.4.1 Surfaces for mounted parts or cable fixing elements.............................................................55
5.4.2 Connecting the cooling water supply.....................................................................................55
5.5 Complete the installation work...............................................................................................57
6 Electrical connection...................................................................................................................................59
6.1 Preparation.............................................................................................................................59
6.1.1 Selecting cables.....................................................................................................................59
6.1.2 Route the cable with an appropriate loop so that water can drip off......................................60
6.1.3 Terminal designation..............................................................................................................60
6.1.4 Terminal box..........................................................................................................................61
6.1.5 Connecting the grounding conductor.....................................................................................61
6.1.6 Radio-frequency grounding for converter operation...............................................................62
6.2 Inserting and routing the cables.............................................................................................63
6.2.1 Connecting the machine for a specific direction of rotation....................................................63
6.2.2 Inserting the cable into the terminal box................................................................................63
6.2.3 Connecting cables with cable lugs.........................................................................................64
6.2.4 Minimum air clearances.........................................................................................................64
6.2.5 Connecting aluminum conductors..........................................................................................65
6.2.6 Internal equipotential bonding................................................................................................65
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6 Operating Instructions 07/2018
Table of contents
6.2.7 Stepless mating face for sealing in the terminal box cover....................................................65
6.2.8 Performing connection operations.........................................................................................66
6.3 Connecting the auxiliary circuits.............................................................................................66
6.3.1 Selecting cables.....................................................................................................................66
6.3.2 Bringing cables into the auxiliary terminal box and routing them...........................................67
6.3.3 Degree of protection of the auxiliary terminal box..................................................................67
6.3.4 Connecting an external fan motor..........................................................................................68
6.3.5 Connecting temperature monitoring for the stator winding....................................................68
6.3.6 Internal equipotential bonding in the auxiliary terminal box...................................................69
6.3.7 Terminating the connection work (auxiliary circuit)................................................................70
7 Commissioning...........................................................................................................................................71
7.1 Prior to commissioning ..........................................................................................................71
7.2 Commissioning an external fan..............................................................................................73
7.3 Greasing the roller bearings prior to commissioning..............................................................73
7.4 Overvoltages when switching high-voltage motors................................................................74
7.5 Test run..................................................................................................................................75
8 Operation....................................................................................................................................................77
8.1 Safety instructions in operation..............................................................................................77
8.2 Switching on with the anti-condensation heating active.........................................................78
8.3 Switching on the machine......................................................................................................79
8.4 Regreasing roller bearings.....................................................................................................79
8.5 Switching off...........................................................................................................................79
8.6 Switching off...........................................................................................................................79
8.7 Switching on again after an emergency switching-off............................................................80
8.8 Stoppages..............................................................................................................................80
8.8.1 Avoidance of condensation or formation of condensation within the machine.......................80
8.8.2 Avoidance of frost and corrosion damage to the air-to-water heat exchanger.......................80
8.8.3 Avoidance of damage to roller bearings during stoppages....................................................81
8.8.4 Measuring the insulation resistance after an extended stoppage..........................................81
8.9 Decommissioning the machine..............................................................................................82
8.10 Re-commissioning the machine.............................................................................................82
8.11 Faults.....................................................................................................................................82
8.11.1 Inspections in the event of faults............................................................................................82
8.11.2 Electrical faults.......................................................................................................................83
8.11.3 Mechanical faults...................................................................................................................83
8.11.4 Roller bearing faults...............................................................................................................84
8.11.5 Cooling system faults.............................................................................................................85
8.11.6 Cooling system faults.............................................................................................................85
9 Maintenance...............................................................................................................................................87
9.1 Inspection and maintenance..................................................................................................87
9.1.1 Safety instructions for inspection and maintenance...............................................................87
9.1.2 Inspections in the event of faults............................................................................................88
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Operating Instructions 07/2018 7
Table of contents
9.1.3 First service after installation or repair...................................................................................89
9.1.4 General inspection.................................................................................................................90
9.1.5 Servicing the air-to-water heat exchanger.............................................................................90
9.1.6 Assessing the roller bearings.................................................................................................91
9.1.7 Regreasing intervals and types of grease for operating roller bearings.................................91
9.1.8 Removing spent grease.........................................................................................................94
9.1.9 Cleaning cooling air ducts and passages...............................................................................95
9.1.10 Cleaning the air-to-water heat exchanger..............................................................................95
9.1.11 Servicing the external fan.......................................................................................................95
9.1.12 Maintaining the anti-condensation heating.............................................................................96
9.1.13 Maintaining terminal boxes....................................................................................................96
9.1.14 Measuring the insulation resistance during the course of maintenance work........................97
9.1.15 Touch up any damaged paintwork.........................................................................................97
9.2 Corrective Maintenance.........................................................................................................98
9.2.1 Prepare servicing work...........................................................................................................98
9.2.2 Top enclosure........................................................................................................................99
9.2.2.1 Air-to-water heat exchanger...................................................................................................99
9.2.2.2 Removing the top enclosure................................................................................................100
9.2.2.3 Mounting the top enclosure..................................................................................................101
9.2.3 Roller bearings.....................................................................................................................102
9.2.3.1 Removing roller bearings.....................................................................................................102
9.2.3.2 Removing the labyrinth sealing ring.....................................................................................103
9.2.3.3 Remove V ring for roller bearing seal...................................................................................104
9.2.3.4 Installing the labyrinth sealing ring.......................................................................................105
9.2.3.5 Fitting V ring for roller bearing seal......................................................................................105
9.2.3.6 Installing felt rings for the inner bearing seal........................................................................106
9.2.4 Seal the motor......................................................................................................................107
10 Spare parts...............................................................................................................................................109
10.1 Ordering data.......................................................................................................................109
10.2 Ordering spare parts via the Internet...................................................................................110
10.3 Stator and rotor....................................................................................................................111
10.4 Top enclosure......................................................................................................................112
10.5 Roller bearings, DE..............................................................................................................113
10.6 Roller bearings, NDE...........................................................................................................114
10.7 Main terminal box, type 9-103A 732.60...............................................................................115
10.8 Auxiliary terminal box 1XB9014...........................................................................................116
11 Disposal....................................................................................................................................................117
11.1 RoHS - restricting the use of certain hazardous substances...............................................117
11.2 Preparing for disassembly....................................................................................................117
11.3 Dismantling the machine......................................................................................................118
11.4 Disposal of components.......................................................................................................118
SIMOTICS HV M 1RN76308PR900CG0-Z
8 Operating Instructions 07/2018
Table of contents
A Service and Support.................................................................................................................................121
B Technical data and drawings....................................................................................................................123
B.1 Tightening torques for screw and bolt connections..............................................................123
B.2 Maximum weights of the coupling........................................................................................124
C Quality documents....................................................................................................................................127
D Additional documents...............................................................................................................................129
Index.........................................................................................................................................................131
Tables
Table 3-1 Machine design ..........................................................................................................................19
Table 3-2 Machine version with type of protection Ex ec or Ex nA ............................................................20
Table 4-1 Power limits.................................................................................................................................27
Table 5-1 Stator winding insulation resistance at 40° C..............................................................................42
Table 6-1 Terminal designations using the 1U1-1 as an example..............................................................60
Table 6-2 Determining the cross-section of the grounding conductor.........................................................61
Table 6-3 Minimum air clearances..............................................................................................................64
Table 8-1 Electrical faults .......................................................................................................................83
Table 8-2 Mechanical faults .....................................................................................................................83
Table 8-3 Rolling bearing faults ..............................................................................................................84
Table 8-4 Cooling system faults ...............................................................................................................85
Table 8-5 Cooling system faults .............................................................................................................85
Table 9-1 Criteria for selecting roller bearing greases.................................................................................91
Table 9-2 Roller bearing greases for vertical and horizontal types of construction ....................................92
Table 9-3 Alternative greases with NLGI class 2 for motors of horizontal construction..............................93
Table 10-1 Spare parts for the stator and rotor...........................................................................................111
Table 10-2 Spare parts for the top enclosure..............................................................................................112
Table 10-3 Spare parts for roller bearings, DE............................................................................................113
Table 10-4 Spare parts for roller bearings, NDE.........................................................................................114
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%........................................123
Figures
Figure 4-1 Rotor transport lock with two screws in the bearing housing......................................................31
Figure 4-2 Schematic representation of a single drive.................................................................................36
Figure 4-3 Schematic representation of a tandem drive...............................................................................37
Figure 5-1 Balancing type on the drive-end side..........................................................................................47
Figure 5-2 Schematic representation of alignment of the machine to the driven machine...........................54
Figure 5-3 Areas for mounting parts.............................................................................................................55
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Table of contents
Figure 6-1 Water drip loop............................................................................................................................60
Figure 6-2 High-frequency grounding...........................................................................................................62
Figure 9-1 Top enclosure fastening ...........................................................................................................101
Figure 9-2 Mounting the top enclosure.......................................................................................................102
Figure 9-3 Dismantling the labyrinth ring....................................................................................................104
Figure 9-4 Remove the V ring.....................................................................................................................104
Figure 9-5 Position the set screws for the labyrinth sealing ring on the outer bearing cover.....................105
Figure 9-6 Install the V ring.........................................................................................................................106
Figure 10-1 Stator and rotor.........................................................................................................................111
Figure 10-2 Top enclosure............................................................................................................................112
Figure 10-3 Roller bearings, DE...................................................................................................................113
Figure 10-4 Roller bearings, NDE.................................................................................................................114
Figure 10-5 Terminal box 9-103A 732.60.....................................................................................................115
Figure 10-6 Auxiliary terminal box 1XB9014 .............................................................................................116
SIMOTICS HV M 1RN76308PR900CG0-Z
10 Operating Instructions 07/2018
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 121) if you have any suggestions on how to improve
this document.
Machine-specific data
Technical data for the machine and all of the necessary drawings, documents for verifying the
qualitative implementation of the machine and, where relevant, additional documents on the
components, are provided in the separate Appendixes to the Operating Instructions.
1
● Technical data and drawings
● Quality documents
● Additional documents
Text format features
The warning notice system is explained on the rear of the inside front. Carefully comply with
all of the safety-relevant information in these instructions and attached to the product itself.
In addition, you will find the following text format features in these instructions:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
● Lists are formatted as bulleted lists.
Note
The note provides you with additional information about the product itself, handling the product
- and the relevant documentation.
in the order given.
– Lists on the second level are hyphenated.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 11
Introduction
1.2 Compiling personal documents
1.2 Compiling personal documents
On the Internet pages in Industry Online Support you have the possibility of compiling personal
documents using the function Documentation (https://support.industry.siemens.com/My/ww/
en/documentation)
Using the "Documentation" function, from Product Support manuals, you can compile your
own "Documentation". However, you can also include other Product Support content such as
FAQs or characteristics in the documentation that you compile.
In the "Documentation" function, you have the option of creating your own compiled documents
in your own structure and managing them. You can delete or shift individual chapters or topics.
Further, using the note function you can import your own content. The compiled
"documentation" can be exported as PDF, for example.
Using the "Documentation" function, you can efficiently compile your own plant or system
documentation. The "Documentation" compiled in a specific language can also be
automatically exported in one of the other available languages.
The full functionality is only available for registered users.
SIMOTICS HV M 1RN76308PR900CG0-Z
12 Operating Instructions 07/2018
Safety information
2.1 Information for those responsible for the plant
This machine has been designed for use in industrial plants in accordance with Directive
2006/42/EC ("Machinery Directive"). Commissioning in the European Community is forbidden
until the plant into which the machine will be installed has been shown to conform with this
directive. Please observe the country-specific regulations when using the machine outside the
European Community.
Follow the local and industry-specific safety and setup regulations.
The persons responsible for the plant must ensure the following:
● Planning and configuration work and all work carried out on and with the machine is only
to be done by qualified personnel.
● The operating instructions must always be available for all work.
● The technical data as well as the permissible installation, connection and operating
conditions are always consequentially taken into account.
● The specific setup and safety regulations as well as regulations on the use of personal
protective equipment are observed.
Note
2
Use the services and support provided by the local service center (Page 121) 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.
2.2 The five 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.
Five 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 13
Safety information
2.3 Qualified personnel
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
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 13) 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 87) chapter of the operating instructions.
SIMOTICS HV M 1RN76308PR900CG0-Z
14 Operating Instructions 07/2018
Safety information
2.4 Safe handling
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.
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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 15
Safety information
2.5 Electrostatic sensitive devices
WARNING
Noise emissions
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 Electrostatic sensitive devices
Material damage due to electrostatic discharge
Electronic modules contain components that can be destroyed by electrostatic discharge.
These components can be damaged or destroyed if they are not handled correctly. To protect
equipment against damage, follow the instructions given below.
● Only touch electronic modules if you absolutely have to work on them.
● The body of the person concerned must have been electrostatically discharged and
grounded immediately before any electronic modules are touched.
● Electronic modules should not be brought into contact with electrically insulating materials,
such as:
– Plastic film
– Plastic parts
– Insulating table supports
– Clothing made of synthetic fibers
● Always place electrostatic sensitive devices on conductive bases.
● Always pack, store and transport electronic modules or components in conductive
packaging, such as:
– Metallized plastic or metal containers
– Conductive foam material
– Domestic aluminum foil
SIMOTICS HV M 1RN76308PR900CG0-Z
16 Operating Instructions 07/2018
The necessary ESD protective measures for electrostatic sensitive devices are illustrated once
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again in the following drawings:
a = conductive floor surfaceb = ESD table c = ESD shoes
d = ESD overall e = ESD wristband f = cabinet ground connection
2.6 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.
Safety information
2.6 Interference immunity
2.7 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 M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 17
Safety information
2.7 Electromagnetic fields when operating electrical power engineering installations
SIMOTICS HV M 1RN76308PR900CG0-Z
18 Operating Instructions 07/2018
Description
Applications
3
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 123) 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.
WARNING
Risk of explosion
This machine is not designed for use in hazardous areas. An explosion can occur if the
machine is operated in these areas. This can result in death, serious injury or material damage.
● Never operate this machine in hazardous areas.
Machine design
The regulations and standards used as the basis to design and test this machine are stamped
on the rating plate.
The machine design basically complies with the subsequent standards. Please refer to the EU
Declaration of Conformity for the versions of the harmonized standards referenced.
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
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 19
Description
See also
Rating plate
Rotor
Quality documents (Page 127)
Additionally, the following standards apply to these explosion-protected machines:
Table 3-2 Machine version with type of protection Ex ec or Ex nA
Characteristic Standard
Type of protection Ex ec (previously Ex nA) IEC / EN 60079‑0
IEC / EN 60079-7 (previously
-15)
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 rotor is designed as a squirrel-cage rotor. The number and design of the shaft extensions
are shown and described in the technical data.
Cooling
The cooling system is designed as a closed, internal cooling circuit. The mounted cooler is an
air-to-water heat exchanger with a pipe system. The heat lost from the machine is dissipated
via the surface of the cooling pipes to the cooling liquid flowing in the pipes. External fans
facilitate the circulation of the cooling air in the primary circuit.
External fan
The machine is fitted with an external fan. For IC 666, there are two external fans. The electrical
connection data are stamped on the rating plate of the external fan.
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.
See also
Technical data and drawings (Page 123)
SIMOTICS HV M 1RN76308PR900CG0-Z
20 Operating Instructions 07/2018
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.
Description
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 21
Description
SIMOTICS HV M 1RN76308PR900CG0-Z
22 Operating Instructions 07/2018
Preparations for use
Good planning and preparation of machine applications are essential in terms of keeping
installation simple and avoiding errors, ensuring safe operation, and allowing access to the
machine for servicing and corrective maintenance.
This chapter outlines what you need to consider when configuring your plant in relation to this
machine and the preparations you need to make before the machine is delivered.
4.1 Safety-related aspects to consider when configuring the plant
A number of residual risks are associated with the machine. These are described in the chapter
titled "Safety information" (Page 13) and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.
4.2 Observing the operating mode
Observe the machine's operating mode. Use a suitable control system to prevent overspeeds,
thus protecting the machine from damage.
4
4.3 Cooling water quality
● The specifications for the cooling water temperatures and cooling water quantities can be
found on the rating plate and in the Appendix "Technical data".
● In the case of a heat exchanger built for chemical purification (closed cooling-water circuit),
the cooling water quality recommended in the operating instructions provided by the
exchanger's manufacturer must be observed.
● For internally cooled motors, which are designed for pipe connection and/or operation with
separately driven/external fans. Connect the pipes and/or adequately dimensioned,
separately-driven/external fans with a suitable type of construction.
● Please refer to the operating instructions provided by the heat exchanger manufacturer
(Page 129).
See also
Technical data and drawings (Page 123)
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 23
Preparations for use
4.4 Insufficient cooling water quality
4.4 Insufficient cooling water quality
NOTICE
Corrosion due to insufficient cooling water quality
The materials used in the cooler are selected to match the cooling water quality for which the
air-water cooler was ordered. The cooler cannot be simply used without taking any other
measures if other water conditions apply. If the cooling water quality is unsuitable, the air-towater heat exchanger may suffer corrosion and fail.
● The chemical composition of the cooling water must comply with the configuration
specifications.
● If the cooling water quality fails to satisfy the quality stated on the order, please contact
the Service Center.
● Please observe the recommended water quality in the operating instructions for the airwater cooler.
NOTICE
Overheating of the machine as a result of additives in the cooling water
Additives for antifreeze or corrosion protection can have a negative impact on the heat
transporting properties. The machine can overheat.
● Only operate the machine with the contractually agreed cooling water quality.
See also
Service and Support (Page 121)
4.5 Interlock circuit for the external fan motor
Interlock circuit for the external fan motor
For machines with external fans, install an interlock circuit that prevents the main machine
being switched on if the external fan is not operational.
See also
Connecting an external fan motor (Page 68)
SIMOTICS HV M 1RN76308PR900CG0-Z
24 Operating Instructions 07/2018
4.6 Interlock circuit for anti-condensation heating
4.6 Interlock circuit for anti-condensation heating
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine.
● Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
● Only switch on the anti-condensation heating after the machine has been switched off.
See also
Switching on with the anti-condensation heating active (Page 78)
4.7 Space requirements
Ensure that there is sufficient space where the motor is to be installed so that when required,
the air-to-water exchanger can be removed and installed.
Preparations for use
4.8 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.
4.9 Voltage and frequency fluctuations during line operation
If nothing else is stamped on the rating plate, the permissible voltage fluctuation is ±5 % and
the permissible frequency fluctuation is ±2 %, corresponding to range A 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. Such actions can avoid thermal ageing leading to a reduction in the service life of
the machine.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 25
Preparations for use
4.10 Phase synchronization during supply system switching
4.10 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.
4.11 System-inherent frequencies
Excessively high vibration levels and system resonances can damage the machine set.
● Configure and match the system consisting of the foundation and machine set in such a
way that no system resonances can arise and result in the permissible vibration levels being
exceeded.
● The vibration limit values according to DIN ISO 10816-3 must not be exceeded.
4.12 Torsional loading of the shaft assembly
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.
4.13 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).
SIMOTICS HV M 1RN76308PR900CG0-Z
26 Operating Instructions 07/2018
Preparations for use
4.14 Thermal protection
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
See also
Prior to commissioning (Page 71)
4.14 Thermal protection
The machine is equipped with measuring equipment to directly monitor the motor temperature
to protect the machine against overheating during operation. Plan a corresponding circuit for
monitoring. You will find more information in the Technical Data in the "Explanatory text for the
machine dimension drawing".
4.15 Transport and storage
Observe the following when carrying out any work on the machine:
N
Power limit
● 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.
4.15.1 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).
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 27
Preparations for use
4.15 Transport and storage
Note the symbols which appear on the packing. These have the following meanings:
Top Fragile material Keep dry Keep cool Center of
4.15.2 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.
4.15.3 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.
gravity
Do not use
hand hook
Attach here
● 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
28 Operating Instructions 07/2018
4.15.4 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.
● 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
Preparations for use
4.15 Transport and storage
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 29
Preparations for use
4.15 Transport and storage
● When lifting the machine, refer to the information on the lifting plate or in the "Technical
Data and Drawings":
– Comply with the specified spreading angles.
– Do not exceed the maximum lifting acceleration and lifting speed specified on the lifting
plate. Lift the machine without jerking it.
Acceleration a ≤ 0.4 g (≈ 4 m/s2)
Velocity v ≤ 20 m/min
● Use only the attachment points provided on the stator frame for lifting, such as lifting eyes
or ring bolts or the lifting eyebolts on the bearing shield.
Transport for a different type of construction
The machine or the machine set may be lifted and transported only using the load handling
attachments at the intended positions. Otherwise, the machine may tip over, slip in the
direction of lifting or fall.
This can result in death, serious injury or material damage.
1. Use only the attachment points (eyebolts, etc.) on the stator frame.
2. Use suitable rope guiding or spreading devices. You will find the weight of the motor
on the rating plate.
WARNING
WARNING
Center of gravity is not at the center.
If the center of gravity of a load is not located centrally between the attachment points,
the motor can tip over or slip out of the lifting equipment and fall when it is being transported
or lifted. This can result in death, serious injury or material damage.
1. Always take account of the center of gravity when transporting or lifting the motor. The
center of gravity of the machine is specified in the dimension drawing.
2. Comply with the handling instructions on the machine when transporting it. If the center
of gravity is not located centrally between the attachment points, position the hoisting
hook above the center of gravity.
3. Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
NOTICE
Risk of corrosion and reduction of the degree of protection
Empty holes can corrode; the degree of protection may then be no longer guaranteed.
● Do not remove the factory-fitted load suspension device. In operation, the loadsuspension device must remain screwed in.
● If you do remove the load-suspension device, then seal the holes so that they are
airtight.
SIMOTICS HV M 1RN76308PR900CG0-Z
30 Operating Instructions 07/2018
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.
The rotor is locked in the bearing housing using two screws
When delivered, the rotor is locked in the bearing housing ① using two M12 screws. The
maximum tightening torque is 20 Nm.
If you wish to remove the rotor transport lock, rotate the set screws out by about 15 mm, and
secure using a lock nut.
Preparations for use
4.15 Transport and storage
Figure 4-1 Rotor transport lock with two screws in the bearing housing
● 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 31
Preparations for use
4.15 Transport and storage
4.15.5 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.
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%.
– 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.
≤ 0.2 mm/s).
eff
– Covers or tarpaulins must not trail on the floor around the machine.
SIMOTICS HV M 1RN76308PR900CG0-Z
32 Operating Instructions 07/2018
Storing outdoors
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.
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.
Preparations for use
4.15 Transport and storage
● Inspect the machine regularly.
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 32)", 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 33
Preparations for use
4.15 Transport and storage
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.
4.15.6 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.
4.15.7 Protecting the cooling water circuit during storage
Anti-freeze protection
When supplied, the machine is not filled with cooling water, so that there is no risk of frost
damage.
SIMOTICS HV M 1RN76308PR900CG0-Z
34 Operating Instructions 07/2018
Protecting the cooling circuit against corrosion
You protect the cooling circuit against corrosion when the machine has already been in
operation and is then placed in storage or put out of operation. Also observe the information
in the operating instructions supplied by the manufacturer of the cooler.
1. Completely drain the cooling ducts. To be completely certain, use compressed air to clean
the cooling water ducts so that they are completely empty.
2. Flush the cooling water ducts with a corrosion-protection emulsion to avoid the buildup of
rust.
See also
Additional documents (Page 129)
4.16 Converter operation
Preparations for use
4.16 Converter operation
4.16.1 Rotational speed limit values
Danger as a result of resonance within certain speed ranges
At over-critical speeds, machines encounter resonance within certain speed ranges. Such
vibrations can reach impermissibly high levels. This can result in death, serious injury or
material damage.
● The controller must ensure that those speed ranges are blocked when the converter is in
operation. Refer to the "Electrical Data" section in the appendix for details of the blocked
speed ranges.
● The blocked speed ranges must be run through rapidly.
Machine damage due to excessively high speeds
Excessive rotational speed can lead to serious damage to the machine. This can result in
death, serious injury or material damage.
● Avoid operation above the permissible speed by using the appropriate control function.
● Observe the speeds stamped on the rating plate and specified in Chapter "Electrical data"
in the appendix.
In the case of converter operation, the motor is designed for operation with square-law load
characteristics. The motor overload must not exceed 110 % of the rated torque. The safety is
reduced for higher overloads. This can result in shaft breakage. Parts and components that
are flung off may result in death, serious injury or material damage.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 35
Preparations for use
4.16 Converter operation
4.16.2 Insulated bearings when operating the converter
Operation with a medium-voltage converter with insulated coupling and insulated bearings
If the machine is fed from a 3-level voltage-source DC link converter without a sine-wave filter,
then shaft grounding is fitted at the NDE. The shaft grounding can be implemented as a
grounding device or incorporated in the tachometer. The DE and NDE bearings are insulated.
● Comply with the plates on the machine relating to bearing insulation and possible bridging
options.
● Use an insulated coupling to connect the motor to the driven machine. Otherwise, the
bearing insulation at the DE is bypassed. The consequence of that would be a circulating
current through the motor shaft and the surrounding grounding system.
WARNING
Defective shaft grounding
If the shaft grounding does not function correctly, the shaft can be at a high voltage level that
does not decay quickly enough when the machine comes to a standstill. This can lead to
death or serious injury as a result of electric shock, or bearing damage caused by current
flowing through the bearing.
● Regularly check the shaft grounding and maintain it at the maintenance intervals.
● Observe the operating instructions for the shaft grounding.
① Driving machine ④ Insulated bearings
② Motor ⑤ Insulated tachometer fitting
③ Insulated coupling ⑥ Shaft grounding
Figure 4-2 Schematic representation of a single drive
36 Operating Instructions 07/2018
SIMOTICS HV M 1RN76308PR900CG0-Z
Tandem operation
Preparations for use
4.16 Converter operation
WARNING
Bridging the bearing insulation
Bridging an insulated bearing can result in an electric current flowing through the machine
enclosure and possibly through the coupling to the driven machine. When touched, this can
lead to death or serious injury as a result of electric shock, and bearing damage caused by
current flowing through the bearing.
● Use insulated couplings.
● Do not bridge the bearing insulation on the insulated bearing while the machine is
operational.
● Be sure not to damage the bearing insulation when carrying out installation work, e.g.
when drilling holes, etc.
● Keep the insulation points clean.
● Observe the labels on the machine relating to the bearing insulation.
See also
If you connect two motors in series in "tandem operation", fit an insulated coupling between
the motor and the driven machine. It is not necessary to fit an insulated coupling between the
motors acting in tandem operation.
① Driving machine ④ Insulated bearings
② Motor ⑤ Insulated tachometer fitting
③ Insulated coupling ⑥ Shaft grounding
Figure 4-3 Schematic representation of a tandem drive
Additional documents (Page 129)
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 37
Preparations for use
4.16 Converter operation
4.16.3 Reducing bearing currents
Reducing bearing currents
Taking the following actions will reduce the bearing currents:
● Grounding: In addition to grounding the machines via the solid protective ground conductor,
supplement the high-frequency grounding using braided flat copper straps or highfrequency stranded conductors. Ensure that the contacts are made over a large area. Solid
copper cables are not suitable for high-frequency grounding because of the skin effect. Use
equipotential bonding conductors between the motor and the driven machine and motor
and converter.
● Selecting and connecting the cable: As far as possible, use symmetrically arranged,
shielded connection cables with a common outer shield to improve the EMC characteristics.
The cable shielding, made up of as many strands as possible, must have good electrical
conductivity. Braided shields made of copper or aluminum are very suitable.
– The shield must be connected at both ends to the motor and the converter; unshielded
cable ends must be kept as short as possible.
– To ensure good discharging of high-frequency currents, provide contacting over a large
surface area: with 360° contacting at the converter, at the motor for instance with EMC
screw fastenings at the cable entries.
Measures to further reduce bearing currents
To specifically reduce and prevent damage caused by bearing currents, you must consider
the system as a whole, which comprises the motor, converter, and driven machine. The
following precautions help to reduce bearing currents:
● Setting up a properly interconnected grounding system in the system as a whole, with low
impedance for high-frequency currents
● Use iron cores mounted above the motor connecting cable at the converter output. The
iron cores reduce the common-mode components. The sales representative is responsible
for selection and dimensioning.
● Limit the voltage rate of rise by using an output filter to dampen harmonic components in
the output voltage
● The operating instructions for the converter are not part of this documentation. Refer to the
configuration information for the converter.
See also
Insulated bearings when operating the converter (Page 36)
SIMOTICS HV M 1RN76308PR900CG0-Z
38 Operating Instructions 07/2018
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.
5.1 Preparations for installation
5
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 123).
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)
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 39
Assembly
5.1 Preparations for installation
NOTICE
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 Parts delivery
If the machine has been shipped in separate parts, you must mount the separately delivered
components, such as top enclosure, terminal box or separate fan, onto the motor at the final
site of installation. For further information, please refer to section "Repair (Page 98)".
Contact the Service Center (Page 121) if you require support.
5.1.3 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 41)
SIMOTICS HV M 1RN76308PR900CG0-Z
40 Operating Instructions 07/2018
5.1.4 Testing the insulation resistance and polarization index
WARNING
Hazardous voltage at the terminals
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.
Assembly
5.1 Preparations for installation
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 M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 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
N
V
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)
U
= rated voltage, see the rating plate
rated
U
= DC measuring voltage
meas
R
= minimum insulation resistance at a reference temperature of 40 °C
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)
R
=
K
·
T
(40-T)/10
R
T
(2)
C
K
= (0.5)
T
U
meas
V
R
Insulation resistance converted to 40° C reference temperature
C
K
Temperature coefficient according to equation (2)
T
R
Measured insulation resistance for measuring/winding temperature
T
T
in °C
40 Reference temperature in °C
10 Halving/doubling of the insulation resistance with 10 K
T
Measuring/winding temperature in °C
R
MΩ
C
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.
SIMOTICS HV M 1RN76308PR900CG0-Z
42 Operating Instructions 07/2018
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 =
R
insul 10 min
Many measuring devices display these values automatically following the measurement.
/
R
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
/ 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 121).
● 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
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 43
Assembly
5.1 Preparations for installation
5.1.5 Preparing the mating faces
● Ensure that the foundation faces are flat and free of contaminations.
Note
Shims
To establish a defined mounting surface, you can order shims (option L31) from our Service
Center.
● Check the dimensions of the mounting-foot holes.
See also
Technical data and drawings (Page 123)
Removing anti-corrosion protection (Page 45)
Lifting and transportation (Page 48)
Service and Support (Page 121)
5.1.6 Do not bridge the bearing insulation
The machine is fitted with an insulated bearing cartridge. The bearing cover and the bearing
cartridge are insulated from the bearing shield and the motor enclosure with insulating parts.
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.
SIMOTICS HV M 1RN76308PR900CG0-Z
44 Operating Instructions 07/2018
5.2 Lift the machine to where it will be installed, and position it
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 motor
If you are not familiar with the prescribed measures and procedures, make use of the services
offered by the Service Center (Page 121).
5.2.3 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 45
Assembly
5.2 Lift the machine to where it will be installed, and position it
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.
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.
SIMOTICS HV M 1RN76308PR900CG0-Z
46 Operating Instructions 07/2018
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 5-1 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 47
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.
See also
Maximum weights of the coupling (Page 124)
5.2.5 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.
● 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.
SIMOTICS HV M 1RN76308PR900CG0-Z
48 Operating Instructions 07/2018
Assembly
5.2 Lift the machine to where it will be installed, and position it
● 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
● 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
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.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 49
Assembly
5.2 Lift the machine to where it will be installed, and position it
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.
● 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.
5.2.6 Putting the machine down
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, ...
● There is no condensation present within the machine.
Setting down the machine
● Set down the machine slowly and carefully at the installation location to avoid any impact.
SIMOTICS HV M 1RN76308PR900CG0-Z
50 Operating Instructions 07/2018
See also
Removing anti-corrosion protection (Page 45)
5.2.7 Draining condensation
Under the following conditions it is possible that condensation may accumulate within the
machine:
● Wide fluctuations in the ambient temperature, such as direct sunlight combined with high
atmospheric humidity
● Intermittent operation or load fluctuations during operation
NOTICE
Damage due to condensate
If the stator winding is damp, its insulation resistance will be reduced. This can result in
voltage flashovers that can seriously damage the windings. Condensate can also cause
rust to form within the machine.
Assembly
5.2 Lift the machine to where it will be installed, and position it
Ensure that condensate can drain away.
Ensure that condensate can drain away
In the bearing shields on the DE and NDE, water drainage holes are situated below or opposite
the regreasing devices. They are sealed with screw plugs. Depending on the type of
installation, the water drainage holes are located at the bottom.
1. Regularly remove the screw plugs to allow the condensate to drain away.
2. Replace them when you have finished.
NOTICE
The degree of protection is reduced
Nominally the degree of protection of the machine is reduced to IP44 when the screw plug is
removed.
5.2.8 Roughly aligning the machine
Requirement
The transmission element such as a coupling half has already been pulled on.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 51
Assembly
5.3 Installing the machine
Roughly aligning the machine
● For horizontal positioning, push the motor sideways across the foundation. When doing so,
ensure that the axial position is maintained.
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.
See also
Tightening torques for screw and bolt connections (Page 123)
SIMOTICS HV M 1RN76308PR900CG0-Z
52 Operating Instructions 07/2018
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 123)
5.3.3 Preconditions for smooth, vibration-free operation
Preconditions for smooth, vibration-free operation:
● Stable foundation design
Assembly
5.3 Installing the machine
● 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 Aligning and attaching the machine to the driven machine
1. Refer to any instructions for aligning the driven machine and those of the coupling
manufacturer.
2. Align the machines with coupling output to the driven machine in such a manner that the
center lines of the shafts are parallel with no offset. This ensures that no additional forces
affect their bearings during operation.
3. For the vertical positioning (x→0) place thin shims under the machine feet. The number of
shims should be kept as low as possible, i.e. stack as few as possible. This also prevents
the machine being subjected to any stress/distortion. Use the existing tapped holes for the
forcing-off bolts to raise the machine.
4. When positioning the machine, ensure that a uniform axial gap (y→0) is maintained around
the coupling.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 53
'
[
\
Assembly
5.3 Installing the machine
5. Fix the machine to the foundation. The choice of fixing elements depends on the foundation
and is the plant operator's responsibility.
Figure 5-2 Schematic representation of alignment of the machine to the driven machine
6. When aligning, make allowance for the thermal expansion of the machine when the
temperature increases. The information is provided under "Technical specifications".
See also
Technical data and drawings (Page 123)
Details about the alignment accuracy can be found in the Section "Information about the
machine dimension drawing".
NOTICE
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.
● Contact the Service Center, if necessary.
54 Operating Instructions 07/2018
SIMOTICS HV M 1RN76308PR900CG0-Z
See also
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+
Service and Support (Page 121)
5.4 Connecting the supply lines
5.4.1 Surfaces for mounted parts or cable fixing elements
The surfaces on the enclosure are marked to which you can attach components or cables.
If you drill through the side panel, then seal the holes so that they are airtight.
Assembly
5.4 Connecting the supply lines
Figure 5-3 Areas for mounting parts
Shaft height Height H Panel/wall thickness T
800 1065 15
710 910 12
630 760 10
5.4.2 Connecting the cooling water supply
Documentation
Please refer to the operating instructions provided by the manufacturer of the heat exchanger
in Chapter "Additional documents (Page 129)". For the operating data of the air-to-water heat
exchanger, refer to the rating plate on the machine or the information about the dimension
drawing in the appendix.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 55
Assembly
5.4 Connecting the supply lines
Connection
The arrangement, type and size of the connecting flanges are specified in the dimension
drawing. When required, you can move the cooler and the cover to the other side.
1. For the pipes, select materials with the required chemical composition in accordance with
the water conditions. You must also consider the pressure load and compatibility with the
materials from which the cooler is made.
2. Route and support the water pipes so that the connecting flanges are not exposed to
excessive stress or strain or vibration loads.
3. Arrange the pipes so that the cooler can be removed when the machine has been fully
assembled. The amount of space required to do this is shown on the machine dimension
drawing.
4. Remove the flange cover plate. Insert the gaskets correctly.
5. Connect the cooling water pipes to the flanges.
6. Before connecting the pipes, flush them in order to remove any deposits and foreign bodies
that might otherwise enter the cooler. If there is a possibility of the cooling water containing
dirt and foreign bodies, install suitable filters in the cooling-water feed pipe.
Filling and venting the cooler
1. After making the flange connections, open the vent plug and fill the cooler with water until
all the air inside the cooler is expelled.
2. Firmly close the venting screw. Perform a pressure test to ensure that the cooling water
supply has no leaks.
Do not exceed the maximum pressure. The maximum pressure data is stamped on the
cooler type plate or is specified in the operating instructions of the cooler.
After conversion work
When reinstalling components after conversion work has been performed, you must ensure
that a proper seal is in place between the upper part of the enclosure and the cooler and/or
between the top enclosure and the cover.
The machine is not operated immediately
If the machine is not subsequently put into operation, then appropriately prepare for the nonoperational period.
See also
Technical data and drawings (Page 123)
Transport and storage (Page 27)
SIMOTICS HV M 1RN76308PR900CG0-Z
56 Operating Instructions 07/2018
5.5 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.
Assembly
5.5 Complete the installation work
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 57
Assembly
5.5 Complete the installation work
SIMOTICS HV M 1RN76308PR900CG0-Z
58 Operating Instructions 07/2018
Electrical connection
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.
Material damage as a result of connection parts coming loose
If you use fixing elements made from the wrong material or apply the wrong tightening torque,
this could impair current transfer or cause connecting parts to become loose. This could result
in material damage to the machine or even in total failure, which could in turn lead indirectly
to material damage to the system.
● Tighten the screwed connections to the specified tightening torques.
● Observe any specifications regarding the materials from which fixing elements must be
made.
6
● When performing servicing, check the fastenings.
See also
Tightening torques for screw and bolt connections (Page 123)
6.1 Preparation
6.1.1 Selecting cables
Take the following criteria into account when selecting the connecting cables:
● Rated current
● Rated voltage
● If required, service factor
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Configuration notes
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 59
;
;
Electrical connection
6.1 Preparation
● Requirements according to IEC/EN 60204‑1
● Dimensioning for bundled cable routing, e.g. according to DIN VDE 0298 Part 4 or
IEC 60364-5-52
6.1.2 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
6.1.3 Terminal designation
According to IEC / EN 60034‑8, the following basic definitions apply to the terminal
designations for 3-phase machines:
Table 6-1 Terminal designations using the 1U1-1 as an example
1 U 1 - 1 Designation
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 designations
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60 Operating Instructions 07/2018
6.1.4 Terminal box
The type designation of the terminal box for connecting the power cables can be found in the
technical data. An illustration can be found in Chapter "Spare parts" (Page 109).
The maximum conductor cross-section that can be connected and the permissible cable
external diameter are listed in the "Technical data and drawings" section. The connecting
cables can be sealed and secured at every entry point into the terminal box, using the sealing
insert supplied.
See also
Technical data and drawings (Page 123)
6.1.5 Connecting the grounding conductor
The grounding conductor cross-section of the machine must be in full conformance with the
installation specifications and to EN 60204-11.
Electrical connection
6.1 Preparation
Table 6-2 Determining the cross-section of the grounding conductor
External conductor cross-section S Cross-section of the grounding conductor [mm²]
S ≤ 16 mm² S
16 mm² < S ≤ 35 mm² 16 mm²
S > 35 mm² S/2
There is a hexagon bolt with flat and spring washer on the stator frame at the designated
connecting point for the grounding conductor. This is suitable for connecting multi-core
conductors with cable lugs or straps with appropriate conductor ends.
When connecting the grounding conductor, ensure the following:
● The connecting surface is bare and protected against corrosion using a suitable substance,
e.g. acid-free Vaseline, zinc dust primer etc.
● The flat and spring washers are located under the bolt head.
SIMOTICS HV M 1RN76308PR900CG0-Z
Operating Instructions 07/2018 61
Electrical connection
6.1 Preparation
● The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not
● The minimum required screw-in depth and the tightening torque for the clamping bolt are
exceeded
listed in the table below. The screw-in depth and tightening torque differ 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
M6 > 9 mm 8 Nm
M8 > 12 mm 20 Nm
M10 > 15 mm 40 Nm
Tightening torque of bolts with ground terminals
6.1.6 Radio-frequency grounding for converter operation
In converter operation, the converter emits RF alternating currents. To establish and RFspecific optimal connection between motor terminal box and motor enclosure, you can use
flexible braided copper flat cables with low impedance and a broad frequency range.
Establish the radio-frequency ground connection with flat cables. Alternatively you can
establish the radio-frequency ground connection with cable lugs.
① Hexagon bolt ⑤ Hexagon nut
② Spring washer ⑥ Radio-frequency grounding cable
③ Terminal Board ⑦ Cable lug
④ Grounding conductor
Figure 6-2 High-frequency grounding
You find further information in the "Operation with converter (Page 35)" section.
SIMOTICS HV M 1RN76308PR900CG0-Z
62 Operating Instructions 07/2018
6.2 Inserting and routing the cables
6.2 Inserting and routing the cables
6.2.1 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
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
rotation is clockwise.
Electrical connection
● If you interchange two connections, e.g. you connect L1, L2, L3 to V, U, W, the resulting
rotation will be counter-clockwise.
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.
According to IEC
6.2.2 Inserting 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.
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Electrical connection
6.2 Inserting and routing the cables
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.
6.2.3 Connecting cables with cable lugs
1. Select the cable lugs according to the required cable cross-section and stud size.
The cable cross section that can be connected is determined by the type of cable lug. The
range of external diameters for the connecting cable is limited by the cable entry that is
used. The data are listed under "Technical data". Connect only one conductor per cable
lug.
2. Insulate the conductor ends in such a way that the remaining insulation reaches almost up
to the cable lug.
3. Fasten the cable lug to the end of the conductor correctly, e.g. by squeezing.
4. Insulate the cable lug sleeves where necessary to ensure minimum air clearances
(Page 64) are maintained.
5. Place the cable lug on the bolt as shown in the schematic diagram below. Take note of the
arrangement of any disconnecting link used, and tighten the contact and fastening nut to
the appropriate tightening torque. When doing this, restrain the bolts so they do not twist.
6.2.4 Minimum air clearances
When making electrical connections, maintain minimum air clearances for bare electrically live
components. The rated voltage can be found on the rating plate.
Table 6-3 Minimum air clearances
Rated voltage Minimum air clearance
Up to 6.6 kV 60 mm
Up to 11 kV 100 mm
Up to 13.8 kV 140 mm
Minimum air clearances for bare electrically live parts
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6.2.5 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
6.2 Inserting and routing the cables
See also
The five safety rules (Page 13)
6.2.6 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.
6.2.7 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
6.3 Connecting the auxiliary circuits
6.2.8 Performing connection operations
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, dirt and foreign
bodies.
– All gaskets and seals are intact
– 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.
2. Close the terminal box.
See section "Tightening torques for screw and bolt connections (Page 123)" for the
tightening torque of the fixing bolts for the cover.
6.3 Connecting the auxiliary circuits
6.3.1 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, cable crosssection as defined by required length of cable, etc.
● Requirements according to IEC/EN 60204‑1
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6.3 Connecting the auxiliary circuits
6.3.2 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 can be found the "Information about
the machine dimension drawing ".
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.
Electrical connection
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.
6.3.3 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.
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Electrical connection
6.3 Connecting the auxiliary circuits
6.3.4 Connecting an external fan motor
Connect the separate fan motor in accordance with the associated terminal connection
diagram located in the external fan terminal box and in accordance with any data provided on
rating plates.
1. When working on the external fan motor, refer to the operating instructions.
2. Check:
– The line voltage and line frequency match the details on the rating plate;
– the cross-sections of the designated connecting cables are matched to the rated current
of the motor (with due consideration for the relevant installation directives).
3. Connect the protective conductor to the protective conductor terminal.
4. Establish the other electrical connections as per the circuit diagram.
5. If the separate fan is supplied with a connector already attached, check whether the pin
allocation of the connector matches the pin allocation of the socket.
6. Complete the work at the external fan terminal box. For this, proceed as described in the
"Completing connection work in the auxiliary terminal box" (Page 70) section.
Check direction of rotation
The direction of rotation of the external fan must match the arrow indicating the direction of
rotation. The fan impeller is visible through the air inlet opening in the fan cover on the external
fan motor.
● If the direction of rotation is wrong, then interchange two line cables in the external fan
motor terminal box.
See also
Interlock circuit for the external fan motor (Page 24)
6.3.5 Connecting temperature monitoring for the stator winding
The stator winding is monitored for thermal loading by temperature sensors embedded in the
stator winding.
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Electrical connection
6.3 Connecting the auxiliary circuits
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”.
6.3.6 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.
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Electrical connection
6.3 Connecting the auxiliary circuits
6.3.7 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 123)" 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 121) 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:
7
See also
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.
Testing the insulation resistance and polarization index (Page 41)
● 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.
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Commissioning
7.1 Prior to commissioning
Electrical connection
● The grounding and equipotential bonding connections have been made correctly.
● The machine is connected so that it rotates in the direction specified.
● 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. Refer to the "Technical data and drawings" section for
more information.
● The values for "Alarm" and "Shut down" at the monitoring equipment are set to the values
listed in the "Explanatory text for the machine dimension drawing" section.
● All brakes and backstops are operating correctly.
See also
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.
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 26)
Converter operation
● If the design of the motor requires connection to a particular converter type, the rating plate
will contain corresponding additional information.
● The converter is correctly parameterized. The parameterization data is specified on the
rating plate of the machine. Information about the parameters is available in the operating
instructions for the converter.
● Any supplementary motor monitoring devices and equipment have been correctly
connected and are functioning correctly.
● In continuous operation, the motor cannot exceed the specified upper speed limit n
undershoot the lower speed limit n
The permissible acceleration time to the limit speed n
min
.
depends on the parameter
min
max
or
assignment.
● The bearing insulation should be implemented as shown on the plates.
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Cooling
● Check that the machine cooling is available for commissioning.
Cooling water supply
● The cooling water supply is connected and ready for operation.
● The cooling water supply is switched on. The data can be found on the rating plate.
● Cooling water is available in the configured quality and quantity.
7.2 Commissioning an external fan
An external fan is suitable for use only in unidirectional operation; refer to the specification of
the direction of rotation on the fan cowl or on the fan unit. The external fan ensures that the
machine is cooled irrespective of the machine speed or direction of rotation.
If the cooling air is in open circulation, it must have only weak, chemically abrasive properties
and only a low dust content.
Commissioning
7.2 Commissioning an external fan
Checks before the first test run
Before the first test run, carry out the following checks:
● The external fan is correctly fitted and aligned.
● The rotor runs freely.
● All of the retaining elements and electrical connections are securely tightened.
● The grounding and equipotential bonding connections to the mains have been correctly
made.
● The air flow is not impeded or shut off by flaps, covers or similar.
● All protection measures have been taken to prevent accidental contact with moving or live
parts.
Performing the test run
1. Switch the external fan motor on and off briefly.
2. Compare the the direction of rotation of the external fan with the arrow indicating the
direction of rotation. If the direction of rotation and the arrow do not match, then switch two
of the three phases of the external fan motor.
7.3 Greasing the roller bearings prior to commissioning
The following information assumes that the specified storage conditions have been complied
with.
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Commissioning
7.4 Overvoltages when switching high-voltage motors
General specifications
● Pay attention to the instructions on the lubricant plate.
● Regrease in portions. The shaft must rotate so that the new grease can be distributed in
the bearings.
Regreasing the roller bearings prior to commissioning
● If the period between delivery and commissioning is more than a year and less than four
years:
– Re-grease the roller bearings with twice the amount of grease specified on the lubricant
plate.
– Check the bearing temperature, as far as possible.
Regreasing roller bearings before commissioning
You must regrease the roller bearings under the following conditions:
● If the machine has been in storage for more than four years.
● If the machine has not been stored in accordance with the specifications in the "Storage"
section.
Procedure
1. Remove the bearing, regreasing pipes, grease nipples and the bearing cap.
2. Flush out the old grease.
3. Check the bearings before regreasing. If necessary, install new bearings.
4. Lubricate the bearings and reinstall the bearing components.
See also
Regreasing intervals and types of grease for operating roller bearings (Page 91)
Transport and storage (Page 27)
Stoppages (Page 80)
7.4 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.
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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7.5 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.
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.
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.
Commissioning
7.5 Test run
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.
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Commissioning
7.5 Test run
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.
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Operation
8.1 Safety instructions in 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 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.
Qualified personnel
Ensure that only qualified personnel in the sense of these operating instructions work at the
machine or close to the machine.
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.
8
● 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.
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
8.2 Switching on with the anti-condensation heating active
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.
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.
Damage caused by condensation
Humidity in the air can condense for intermittent duty or load fluctuations. Condensate can
collect. Moisture can have a negative impact on the winding insulation or result in damage,
such as corrosion.
● Ensure that any condensation can freely flow away.
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.
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See also
Interlock circuit for anti-condensation heating (Page 25)
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
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.
Operation
8.3 Switching on the machine
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.
See also
Transport and storage (Page 27)
8.5 Switching off
Do not immediately switch off the separately-driven (external) fan after switching off the
machine. First wait for the machine to cool down. This will prevent the accumulation of residual
heat.
8.6 Switching off
● Switch off the water-cooling system after switching off the machine. Condensation can form
inside the machine if cooling water flows while the machine is at a standstill.
● Only switch off the water cooling system once the machine has cooled down. This will
prevent the accumulation of residual heat.
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Operation
8.7 Switching on again after an emergency switching-off
8.7 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
8.8 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.
8.8.1 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.
8.8.2 Avoidance of frost and corrosion damage to the air-to-water heat exchanger
● For avoidance of frost and corrosion damage completely drain the water from the air-towater cooler. Then blow air through it to dry it.
● If the cooler cannot be drained because standby capability is required at short notice,
protect the cooling circuit against frost and corrosion damage. To do this, add suitable
additives to the cooling water.
NOTICE
Diminished heat conduction
These additives may affect the heat transport capability. Operate the motor only with the
contractually agreed water quality.
For avoidance of deposits, the cooling water circuit must then be kept running. So as to be
certain of excluding the possibility of formation of condensation within the machine, the anticondensation heating should also remain switched on.
● Comply with the cooler manufacturer's instructions for cooling system servicing in the
operating instructions.
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8.8.3 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.
● During recommissioning, refer to the information in Chapter "Commissioning".
See also
Commissioning (Page 71)
Greasing the roller bearings prior to commissioning (Page 73)
Operation
8.8 Stoppages
8.8.4 Measuring the insulation resistance after an extended stoppage
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 41)
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Operation
8.9 Decommissioning the machine
8.9 Decommissioning the machine
NOTICE
Damage as a result of an extended period out of service
If the machine is going to be out of service for longer than six months, then take the necessary
measures for preservation and storing. Otherwise damage to the machine will result.
Record the decommissioning steps. This log will be useful upon recommissioning.
See also
Protection against corrosion (Page 34)
Protecting the cooling water circuit during storage (Page 34)
Storage (Page 32)
8.10 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 71)
Decommissioning the machine (Page 82)
8.11 Faults
8.11.1 Inspections in the event of faults
Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.
Correct the cause of the fault as described in the respective remedial measures section. Repair
any damage to the machine.
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Operation
8.11 Faults
8.11.2 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.
8.11.3 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.
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Operation
8.11 Faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults Remedial measures
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)
8.11.4 Roller bearing faults
Damage to rolling bearings can be difficult to detect in some cases. If in doubt, replace the
rolling bearing. Use other bearing designs only after consulting the manufacturer.
Table 8-3 Rolling 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.
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
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8.11.5 Cooling system faults
The following table shows the possible causes of and remedial measures for faults on forcedventilated machines.
Table 8-4 Cooling system faults
↓ High temperature rise with load
Possible causes of faults Remedial measures
X Wrong direction of rotation of the external fan Check the electrical connections to the external fan.
X External fan is not running Check the external fan and its connections.
X Reduced air flow Check the air ducts; clean the machine.
8.11.6 Cooling system faults
The following table shows the possible causes of and remedial measures for faults on watercooled machines.
Operation
8.11 Faults
Table 8-5 Cooling system faults
↓ High temperature rise
↓ Water leaking
Possible causes of faults Remedial measures
X Reduced cooling Check the cooling water flow, increase the amount of cooling water if
necessary
X Cooling water flow rate too low Clean the air-to-water heat exchanger.
X Inlet temperature too high Set the correct upstream temperature.
X Cooling water supply switched off Switch on the cooling water supply.
X Cooling water contains frost or anti-corro‐
sion additives
X X Defective cooling water pipes / defective
cooling water connection
Use cooling water of the agreed quality.
Locate the leaky section and seal it or consult the manufacturer.
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Operation
8.11 Faults
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Maintenance
Through careful and regular maintenance, inspections, and overhauls you can detect faults at
an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 13)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
Note
Please contact the service center (Page 121), if you require support with service, maintenance
or repair.
9
down in EN 50110‑1 regarding safe operation of electrical equipment.
9.1 Inspection and maintenance
9.1.1 Safety instructions for inspection and maintenance
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 roller bearings.
● When performing maintenance work, comply with the five safety rules (Page 13).
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Maintenance
9.1 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.
9.1.2 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.
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Immediately perform an inspection after such faults.
9.1.3 First service after installation or repair
● Check after approx. 500 operating hours, but after not more than one year:
Maintenance
9.1 Inspection and maintenance
Check When the
motor is
running
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.
X
At stand‐
still
● Further checks may be required if so specified in operating instructions of components
(Page 129) 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.
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Maintenance
9.1 Inspection and maintenance
9.1.4 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
motor is
running
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 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
(*) This check can be made at standstill or when running.
X
At stand‐
still
X
X
X
● If you detect any deviations during the inspection, you must rectify them immediately. They
may otherwise cause damage to the machine.
Checking the cooling system
● With the machine stopped, check the condition of the cooling system:
– The cooling system is in good condition.
– The pressure drop between entry and exit has not increased appreciably.
9.1.5 Servicing the air-to-water heat exchanger
At every inspection, check to see whether there is leakage water in the top enclosure.
1. Remove the appropriate stopper in the top enclosure.
2. If water flows through the opening, then determine the cause and deal with it. This may be
condensate.
3. Replace the stopper in the top enclosure.
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9.1 Inspection and maintenance
9.1.6 Assessing the roller bearings
To assess the roller 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 roller bearing can be assessed by analyzing the bearing vibration. The measured
values provide an indication and can be assessed by specialists. Contact the Service Center.
9.1.7 Regreasing intervals and types of grease for operating roller bearings
The specified grease data applies to the data specified on the rating plate and for high-quality
grease in accordance with the specifications in these operating instructions. Because these
greases exceed significantly the requirements according to DIN 51825 and ISO 6743‑9, they
permit the specified relubrication intervals.
Initial lubrication
The grease specified on the lubricant plate is selected according to the operating conditions
known at the time of ordering and should be used for initial lubrication.
Maintenance
Grease selection criteria
High quality ISO‑L‑X BDEA3 lubricating grease according to ISO 6743-9 and K3K‑20
lubricating grease according to DIN 51825 with lithium soap as a thickener and an upper
service temperature of at least +130° C / +266° F are permissible for standard applications
without special requirements.
When selecting the lubricating grease, ensure that the technical data of the grease is suitable
for the application.
The lubricating grease must satisfy the criteria listed in the table below and must match the
operating conditions. If different special lubricating greases are stated on the lubricant plate,
then different criteria apply.
Table 9-1 Criteria for selecting roller bearing greases
Criteria Standard Property, characteristic value Unit
Type of base oil - Mineral oil -
Thickener - Lithium Consistency in accordance with
NLGI class
Operating temperature range - At least -20° C ... +130° C °C
Dropping point DIN ISO 2176 At least +180° C °C
Basic oil viscosity DIN 51562-1
DIN 51818
● "3" for vertical and horizontal types of
construction
● "2" alternatively for horizontal type of
construction with reduced lubrication interval
● Approx. 100 mm²/s at 40 °C
● Approx. 10 mm²/s at 100 °C
-
mm²/s
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Maintenance
9.1 Inspection and maintenance
Criteria Standard Property, characteristic value Unit
Additives -
FE9 test: A/1500/6000 DIN 51821-1/-2 F10 ≥50 h at +130 °C
Behavior in the presence of water DIN 51807 0 or 1 at a test temperature of +90° C Corrosive effect on copper DIN 51811 0 or 1 at a test temperature of +120° C Korr.°
Corrosion resistance (EMCOR) DIN 51802 /
ISO 11007
Solid matter content, particle sizes >
25 µm
Suitability of bearings
Speed parameter nxdm
DIN 51813 <10 mg/kg mg/kg
- Suitable for the built-in motor bearings, seals and
● Anti-Oxidation (AO), Anti-Wear (AW)
● No solid lubricants
● Alternatively: Extreme-pressure (EP) only after
prior consultation with grease and bearing
manufacturers
F50 ≥100 h at +130 °C
0 - 0 Korr.°
these speeds
-
H
mm/min
Note
Deviating operating conditions and characteristics
Only use the grease type that is specified on the lubricant plate.
● If the operating conditions differ from those mentioned, other greases may only be used
after prior consultation with the manufacturer.
Note
Use of other greases
If greases other than those named on the lubricant plate are used, it cannot be guaranteed
that they are compatible with the complete system.
● If you use greases that satisfy only the minimum requirements of DIN 51825 or ISO 6743-9,
then reduce the lubrication intervals by half or adapt them as appropriate.
● If in doubt, consult the manufacturer.
Recommended greases for roller bearings
For standard applications, the following high-quality greases are recommended for roller
bearings for vertical and horizontal motor constructions due to their technical properties:
Table 9-2 Roller bearing greases for vertical and horizontal types of construction
Manufacturer Grease type
Shell Gadus S2 V100 3
ExxonMobil Unirex N3
Esso
BP Energrease LS3
Fuchs Renolit H443 HD88
Lubcon Turmoplex 3
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Maintenance
9.1 Inspection and maintenance
Manufacturer Grease type
Addinol LM 3 EP
FAG Arcanol Multi 3
For motors of horizontal construction you can alternatively use greases with NLGI class 2.
However, this reduces the lubrication interval by 20%.
Table 9-3 Alternative greases with NLGI class 2 for motors of horizontal construction
Manufacturer Grease type
Shell Gadus S2 V100 2
ExxonMobil
Esso
BP Energrease LS2
Castrol Longtime PD2
Lubcon Turmogrease L 802 EP plus
Shell Retinax LX2
FAG Arcanol Multi 2
Unirex N2
NOTICE
Diminished lubrication properties by mixing greases
The lubrication properties will be impaired if you mix different greases. This can result in
material damage.
● Avoid mixing greases. Only the manufacturer can provide a guarantee for the miscibility
of particular greases.
Lubrication data
Regreasing data are stated on the lubricant plate of the machine:
● Regreasing intervals in operating hours
● Regreasing amount in grams
● Grease type
Regrease the roller bearing at the latest every 12 months irrespective of the actual number of
operating hours.
NOTICE
Damage to roller bearings
The regreasing intervals for roller bearings are different from the servicing intervals for the
machine. The roller bearings may be damaged if the relubrication intervals are not adhered
to.
● Pay attention to the instructions on the lubricant plate.
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Maintenance
9.1 Inspection and maintenance
Grease replacement intervals
The grease replacement intervals in these operating instructions or the regreasing intervals
indicated on the plate apply to the following conditions:
● Normal load
● Operation at speeds in accordance with rating plate
● Low-vibration operation
● Neutral ambient air
● High-quality roller bearing greases
In the case of unfavorable operating conditions, reduce the relubrication intervals after prior
consultation with the manufacturer.
Regreasing roller bearings
Pay attention to the instructions on the lubricant plate.
1. Rotate the shaft when regreasing, so that the new grease can be distributed throughout
the bearing.
Motors that are operated with converters: Regrease the bearings at a low to medium speed
(n
= 250 rpm, n
min
= 3600 rpm) to ensure an even distribution of grease.
max
WARNING
Rotating components
The shaft must rotate to allow the grease to be distributed. This can result in death, serious
injury or material damage.
● When regreasing, pay attention to all rotating components.
2. Clean the grease nipple before regreasing. Gradually press in an appropriate type and
amount of grease, as stamped on the lubricant plate and specified in these operating
instructions.
The roller bearing temperature rises sharply at first, then drops to the normal value again
when the excess grease is displaced out of the bearing.
3. The used grease collects outside each bearing in a spent grease chamber.
Lubricating roller bearings prior to commissioning
When properly stored prior to commissioning for a longer period of time, normally the grease
in the bearings does not deteriorate within two years. Please note the information regarding
long-term storage.
When commissioning, the bearings must be relubricated with twice the amount of lubricating
grease. When doing this, the shaft must rotate so that the grease is replaced in the bearings.
9.1.8 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
9.1 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.
9.1.9 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.
9.1.10 Cleaning the air-to-water heat exchanger
● Clean the air-to-water heat exchanger in accordance with the operating instructions of the
heat exchanger manufacturer. These instructions specify the conditions to be complied with
and describe the available cleaning methods.
Instructions of the heat exchanger manufacturer (Page 129)
9.1.11 Servicing the external fan
WARNING
Injury caused by rotating parts or live (under voltage) parts
Live electrical parts are dangerous. Contact with them can cause death, serious injury or
material damage.
● Before carrying out any maintenance work on the external fan, disconnect it from the
mains, particularly before opening the terminal box.
● Make sure that the device cannot be switched back on.
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Maintenance
9.1 Inspection and maintenance
Servicing the external fan
However, dirt and dust deposits on the impeller and the motor, particularly in the gap between
the impeller and the inlet nozzle can impair its function.
● Remove the dirt and dust deposits regularly; the intervals depend on how dirty the
surrounding area is.
● Make sure that the impeller is cleaned evenly, as irregular deposits can lead to an
imbalance.
● The full air flow can only be achieved when air can freely flow through the impeller.
● There must be a clearance of at least 1 x air intake diameter in the axial direction.
● A uniform gap must be maintained between the impeller and the air intake assembly.
Servicing the external fan motor
● Perform an occasional visual inspection of the external fan motor and check it electrically
and mechanically every time the roller bearings are replaced.
● Replace the permanently lubricated rolling bearing on the external fan motor after
40,000 operating hours or five years at the latest.
9.1.12 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 121).
9.1.13 Maintaining terminal boxes
Requirement
The machine is de-energized.
Checking the terminal box
● Terminal boxes must be regularly checked for tightness, undamaged insulation, and tight
terminal connections.
● If dust or humidity have infiltrated the terminal box, this should be cleaned and dried
(particularly the insulators).
Check all the seals and sealing surfaces and address the cause of the leakiness.
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Maintenance
9.1 Inspection and maintenance
● Check the insulators, connectors and cable connections in the terminal box.
● Replace any damaged components.
WARNING
Short-circuit hazard
Short-circuits can occur as a result of damaged components. This can result in death,
serious injury or material damage.
Replace damaged components.
9.1.14 Measuring the insulation resistance during the course of maintenance work
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 41)
9.1.15 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 121) before you repair any paint damage. They will provide
you with more information about the correct paint system and methods of repairing paint
damage.
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Maintenance
9.2 Corrective Maintenance
9.2 Corrective 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.
If the motor has to be transported, please observe the information and instructions in the
chapter "Transport (Page 27)".
9.2.1 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.
● Immediately replace damaged components.
● Contact the Service Center (Page 121), if necessary.
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9.2.2 Top enclosure
Note
Removing the air-water radiator
The air-water radiator is very heavy. To make removal of the top enclosure easier, remove it
and then refit it after the operation is complete.
9.2.2.1 Air-to-water heat exchanger
Disassembly
1. Please observe the instructions of the heat exchanger manufacturer.
Air-water heat exchanger instructions (Page 129).
2. Shut off the feed and return pipes and use the discharge device to empty the heat
exchanger.
Maintenance
9.2 Corrective Maintenance
3. Undo the water lines and the connections for the leakage electrodes, flow meters, etc.,
where fitted.
4. Release the tensioning straps on the air-to-water heat exchanger.
5. Slide the heat exchanger slightly out of the top enclosure. The lifting eyes are then
accessible; attach a lifting gear to them to pull the heat exchanger out further. Use suitable
strap guiding or spreading devices for this.
6. There are two holes on the guide strip of the air-to-water heat exchanger for points at which
to secure it. Secure the heat exchanger with an additional sling rope and pull it out as far
as the center. Suspend the heat exchanger from the attachment point on the guide strip.
7. Pull the air-to-water heat exchanger out beyond the second hole and suspend it from there.
8. When the heat exchanger has been pulled all the way out, suspend it from the lifting eyes
at the rear and put it down carefully.
WARNING
The connecting flanges on the air-to-water heat exchanger are not suitable for lifting or
supporting.
The connecting flanges are not strong enough to bear heavy loads. The heat exchanger
can fall. This can result in death, serious injury or material damage.
● Do not stand the heat exchanger on the connecting flanges for the cooling water pipes.
● Do not suspend the heat exchanger from them.
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Maintenance
9.2 Corrective Maintenance
Assembly
1. Using the hoisting lugs, lift the air-to-water heat exchanger and push it into the top
enclosure. Secure it with an additional attachment with the hole on the guide strip. The
guide strip on the heat exchanger stops it from sliding sideways when it is pushed in.
2. When the air-to-water heat exchanger is fully in, tighten the tensioning straps. When
securing, ensure that the tensioning straps and the spherical disks are arranged correctly.
3. Connect the water pipes and the connections for the leakage water electrodes (if fitted).
Bleed the heat exchanger via the depressurization device.
4. Open the feed and return pipes.
9.2.2.2 Removing the top enclosure
You will find the weight of the top enclosure in the Technical Specifications and Drawings in
the Appendix (Page 123).
1. Use only the welded lifting eyes to hoist and transport the top enclosure. Remove the
warning plates on the lifting eyes and put them to one side for later refitting.
Prerequisite
● Remove all built-on or connecting parts which will prevent the top enclosure from being
safely disassembled.
● Before lifting off the top enclosure, loosen the equipotential bonding conductor and the
fixing bolts on the stator housing.
SIMOTICS HV M 1RN76308PR900CG0-Z
100 Operating Instructions 07/2018
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