www.siemens.com/drives
Low-voltage motor
SIMOTICS HT Series HT-direct
Type 1FW4...1......A
Operating Instructions
Installation Instructions
Edition 11/2018
13.11.2018 16:25
V5.00
Low-voltage motor
SIMOTICS HT Series HT-direct
Type 1FW4...1......A
Operating Instructions
Installation Instructions
Edition 11/2018
Introduction 1
Safety information 2
Description 3
Preparations for use 4
Assembly 5
Electrical connection 6
Start-up 7
Operation 8
Maintenance 9
Spare parts 10
Disposal 11
Service and Support A
Technical data B
Quality documents C
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: A5E37543838-04
Ⓟ 11/2018 Subject to change
Copyright © Siemens AG 2018.
All rights reserved
Table of contents
1 Introduction.................................................................................................................................................11
1.1 Compiling personal documents..............................................................................................11
2 Safety information.......................................................................................................................................13
2.1 Information for those responsible for the plant or system......................................................13
2.2 The 5 safety rules...................................................................................................................13
2.3 Qualified personnel................................................................................................................14
2.4 Safe handling.........................................................................................................................14
2.5 Working on machines with permanent magnets....................................................................15
2.6 Electrostatic sensitive devices...............................................................................................17
2.7 Interference immunity.............................................................................................................18
2.8 Interference voltages when operating the converter..............................................................18
2.9 Electromagnetic fields when operating electrical power engineering installations.................18
3 Description..................................................................................................................................................21
4 Preparations for use...................................................................................................................................27
4.1 Safety-related aspects to consider when configuring the plant..............................................27
4.2 Observing the operating mode...............................................................................................27
4.3 Cooling water quality..............................................................................................................27
4.4 Cooling water inlet temperature (water-cooled motor)...........................................................28
4.5 Interlock circuit for anti-condensation heating (option)...........................................................31
4.6 Thermal motor protection.......................................................................................................31
4.7 Noise emissions.....................................................................................................................31
4.8 Rotational speed limit values.................................................................................................31
4.9 System-inherent frequencies.................................................................................................32
4.10 Torsional loading of the drive train due to faults in the electrical supply................................32
4.11 Transport................................................................................................................................32
4.11.1 Safety instructions for transport.............................................................................................32
4.11.1.1 Transporting the machine set.................................................................................................33
4.11.2 Checking the delivery.............................................................................................................33
4.11.3 Securing the rotor...................................................................................................................34
4.11.4 Protecting cooling water ducts...............................................................................................36
4.11.5 Transporting a motor that has already been in operation......................................................36
4.11.6 Lifting and transportation........................................................................................................37
4.12 Storage...................................................................................................................................38
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 5
4.13 Converter operation...............................................................................................................41
4.13.1 Converter input voltage..........................................................................................................41
4.13.2 Reducing bearing currents.....................................................................................................41
4.13.3 Insulated bearings when operating the converter..................................................................42
5 Assembly....................................................................................................................................................45
5.1 Safety instructions when mounting........................................................................................45
5.1.1 Safety instructions for installation...........................................................................................45
5.2 Preparations for installation....................................................................................................46
5.2.1 Requirements for installation..................................................................................................46
5.2.2 Insulation resistance and polarization index..........................................................................46
5.2.3 Testing the insulation resistance and polarization index........................................................47
5.2.4 Preparing the mating faces....................................................................................................50
5.3 Lift the machine to where it will be installed, and position it...................................................50
5.3.1 Preconditions for correct alignment and secure attachment .................................................50
5.3.2 Checking the load handling attachments...............................................................................51
5.3.3 Removing the rotor shipping brace........................................................................................51
5.3.4 Removing the rotor shipping brace from machines with vertical type of construction............51
5.3.5 Removing anti-corrosion protection.......................................................................................52
5.3.6 Only operate with a flexible coupling......................................................................................52
5.3.7 Mounting the output elements................................................................................................53
5.3.8 Lifting and transporting the machine......................................................................................54
5.3.9 Putting the machine down......................................................................................................56
5.3.10 Roughly aligning the machine................................................................................................56
5.4 Installing the machine............................................................................................................56
5.4.1 Selecting fixing screws...........................................................................................................57
5.4.2 Preconditions for smooth, vibration-free operation................................................................57
5.4.3 Connection cables..................................................................................................................57
5.4.4 Aligning the machine to the driven machine and mounting (IM B3).......................................57
5.4.5 Aligning the machine to the driven machine and mounting (IM V1).......................................59
5.4.6 Axial and radial forces............................................................................................................60
5.5 Connecting the cooling water supply.....................................................................................60
5.6 Insulated bearings..................................................................................................................61
6 Electrical connection...................................................................................................................................63
6.1 Safety instructions relating to the electrical connection.........................................................63
6.2 Basic rules..............................................................................................................................63
6.3 Preparation.............................................................................................................................64
6.3.1 Terminal designation..............................................................................................................64
6.3.2 Selecting cables.....................................................................................................................65
6.3.3 Connecting the machine for a specific direction of rotation....................................................65
6.3.4 Connecting the grounding conductor.....................................................................................66
6.4 Inserting and routing the cables.............................................................................................68
6.4.1 Circuit diagram.......................................................................................................................68
6.4.2 Terminal box..........................................................................................................................69
6.4.3 Introducing the cables into the terminal box and routing them...............................................69
6.4.4 Connecting cables with cable lugs.........................................................................................70
6.4.5 Use of aluminum conductors..................................................................................................71
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6Operating Instructions 11/2018
6.4.6 Using single-stranded cables.................................................................................................71
6.4.7 Minimum air clearances.........................................................................................................72
6.4.8 Internal equipotential bonding................................................................................................72
6.4.9 Finishing connection work......................................................................................................73
6.5 Connecting the auxiliary circuits.............................................................................................73
6.5.1 Selecting cables.....................................................................................................................73
6.5.2 Introducing cables into the auxiliary terminal box and routing them......................................74
6.5.3 Connecting temperature monitoring for the stator winding....................................................74
6.5.4 Internal equipotential bonding in the auxiliary terminal box...................................................75
6.5.5 Terminating the connection work (auxiliary circuit)................................................................76
6.6 Converter operation...............................................................................................................76
6.6.1 Operation on a converter with a low pulse frequency............................................................77
6.6.2 Converter operation on a grounded network..........................................................................77
7 Start-up.......................................................................................................................................................79
7.1 Safety instructions for commissioning....................................................................................79
7.2 Checks to be carried out prior to commissioning ..................................................................80
7.3 Greasing the roller bearings prior to commissioning..............................................................81
7.4 Setting the converter pulse frequency....................................................................................82
7.5 Test run..................................................................................................................................82
7.6 Measure the insulation resistance and polarization index for the commissioning..................84
7.7 Switching on the machine......................................................................................................84
7.8 Set values for temperature monitoring of the bearing thermometer.......................................85
7.9 Setting values for temperature monitoring (slot thermometer)...............................................85
7.10 Switching off the machine......................................................................................................85
7.11 Avoidance of condensation or formation of condensation within the machine.......................85
8 Operation....................................................................................................................................................87
8.1 Safety instructions for operation.............................................................................................87
8.2 Switching on the machine......................................................................................................89
8.3 Stoppages..............................................................................................................................90
8.3.1 Prolonged outage periods......................................................................................................90
8.3.2 Avoidance of frost and corrosion damage in the cooling system...........................................91
8.3.3 Avoidance of condensation or formation of condensation within the machine.......................91
8.3.4 Avoidance of damage to roller bearings during stoppages....................................................91
8.3.5 Measuring the insulation resistance after an extended non-operational period.....................92
8.4 Switching off the machine......................................................................................................92
8.5 Switching on again after an emergency switching-off............................................................92
8.6 Decommissioning the machine..............................................................................................92
8.7 Re-commissioning the machine.............................................................................................93
8.8 Faults.....................................................................................................................................93
8.8.1 Inspections in the event of faults............................................................................................93
8.8.2 Electrical faults water-cooled machines.................................................................................93
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Operating Instructions 11/2018 7
8.8.3 Mechanical faults...................................................................................................................94
8.8.4 Rolling-contact bearing faults.................................................................................................95
8.8.5 Water cooling faults................................................................................................................96
9 Maintenance...............................................................................................................................................97
9.1 Inspection and maintenance..................................................................................................97
9.1.1 Safety instructions for inspection and maintenance...............................................................97
9.1.2 Inspections in the event of faults............................................................................................98
9.1.3 First service after installation or repair ..................................................................................99
9.1.4 General inspection...............................................................................................................100
9.1.5 Measuring the insulation resistance during the course of maintenance work......................100
9.1.6 Servicing and maintaining the anti-condensation heating....................................................101
9.1.7 Roller bearing.......................................................................................................................101
9.1.8 Regreasing intervals and types of grease for operating rolling bearings.............................101
9.1.9 Touch up any damaged paintwork.......................................................................................102
9.1.10 Maintaining terminal boxes..................................................................................................103
9.2 Corrective Maintenance.......................................................................................................103
9.2.1 Prepare servicing work.........................................................................................................104
9.2.2 Anti-condensation heating....................................................................................................104
9.2.3 Changing the bearings.........................................................................................................104
9.2.4 Replacing the speed encoder..............................................................................................105
10 Spare parts...............................................................................................................................................109
10.1 Ordering data.......................................................................................................................109
10.2 Ordering spare parts via the Internet...................................................................................109
10.3 Anti-condensation heating....................................................................................................110
11 Disposal....................................................................................................................................................111
11.1 Introduction..........................................................................................................................111
11.2 RoHS - restricting the use of certain hazardous substances...............................................111
11.3 Information according to Article 33 of the REACH regulation..............................................111
11.4 Preparing for disassembly....................................................................................................112
11.5 Working on machines with permanent magnets..................................................................112
11.6 Disposing of permanent magnets........................................................................................113
11.7 Disposal of components.......................................................................................................114
A Service and Support.................................................................................................................................117
B Technical data..........................................................................................................................................119
B.1 Tightening torques for screw and bolt connections..............................................................119
C Quality documents....................................................................................................................................121
Index.........................................................................................................................................................123
Tables
Table 3-1 Machine design ........................................................................................................................22
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SIMOTICS HT Series HT-direct 1FW4...1......A
8Operating Instructions 11/2018
Table 4-1 Derating factors...........................................................................................................................29
Table 4-2 Coolant flow rate and maximum permissible water pressure......................................................29
Table 4-3 Chemical requirements of the cooling water quality....................................................................29
Table 5-1 Stator winding insulation resistance at 40° C..............................................................................48
Table 5-2 Permissible deviations for aligning the machine with flexible coupling.......................................58
Table 6-1 Terminal designations using the 1U1-1 as an example..............................................................64
Table 6-2 Determining the cross-section of the grounding conductor.........................................................66
Table 6-3 Tightening torques of bolts (cable lug)........................................................................................66
Table 6-4 Bolt tightening torques (ground terminals) ...............................................................................66
Table 6-5 Minimum air clearance dependent on rms value of the alternating voltage Urms.........................72
Table 7-1 Guidelines for setting the tripping temperature of bearing thermometers...................................85
Table 7-2 Guidelines for setting the tripping temperature of winding thermometers...................................85
Table 8-1 Electrical faults .........................................................................................................................94
Table 8-2 Mechanical faults ......................................................................................................................94
Table 8-3 Roller bearing faults ...............................................................................................................95
Table 8-4 Cooling system faults .............................................................................................................96
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%........................................119
Figures
Figure 3-1 1FW4 water-cooled motor...........................................................................................................21
Figure 3-2 Rating plate diagram...................................................................................................................23
Figure 4-1 Example of a cooling circuit.........................................................................................................30
Figure 4-2 Axial fastening of the rotor...........................................................................................................35
Figure 4-3 Schematic representation of a single drive.................................................................................43
Figure 5-1 Balancing type on the drive-end side..........................................................................................53
Figure 5-2 Schematic diagram: Aligning the machine to the driven machine...............................................58
Figure 6-1 Water drip loop............................................................................................................................64
Figure 6-2 High-frequency grounding...........................................................................................................67
Figure 6-3 Neutral point connection..............................................................................................................68
Figure 6-4 Terminal box 1XB1631................................................................................................................69
Figure 6-5 Connection with cable lug and fixing screw (schematic diagram)...............................................70
Figure 9-1 Detailed view of the speed encoder..........................................................................................105
Figure 9-2 Replacing a speed encoder.......................................................................................................106
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Operating Instructions 11/2018 9
Table of contents
SIMOTICS HT Series HT-direct 1FW4...1......A
10 Operating Instructions 11/2018
Introduction 1
In the following text, the motor is referred to as "electrical machine" – or abbreviated, just
"machine".
These operating instructions are valid for water-cooled synchronous motors in the 1FW4
series. The serial number of the motor can be found on the rating plate.
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.
Safety instructions and handling-related warning notes are provided in these instructions.
When carrying out any activity at or with the machine, carefully comply with all of these notes
for your own safety, to protect other people and to avoid material damage.
Please contact the Service Center (Page 117) if you have any suggestions on how to improve
this document.
Text format features
You can find the following text format features in these instructions:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
in the order given.
● Lists are formatted as bulleted lists.
– Lists on the second level are hyphenated.
Note
The note provides you with additional information about the product itself, handling the product
- and the relevant documentation.
1.1 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.
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 11
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.
Introduction
1.1 Compiling personal documents
SIMOTICS HT Series HT-direct 1FW4...1......A
12 Operating Instructions 11/2018
Safety information 2
2.1 Information for those responsible for the plant or system
This electric machine has been designed and built in accordance with the specifications
contained in Directive 2014/35/EU ("Low-Voltage Directive") and is intended for use in
industrial plants. Please observe the country-specific regulations when using the electric
machine outside the European Community. Follow the local and industry-specific safety and
setup regulations.
The persons responsible for the plant must ensure the following:
● Planning and configuration work and all work carried out on and with the machine is only
to be done by qualified personnel.
● The operating instructions must always be available for all work.
● The technical data as well as the specifications relating to the permissible installation,
connection, ambient and operating conditions are taken into account at all times.
● The specific setup and safety regulations as well as regulations on the use of personal
protective equipment are observed.
Note
Use the services and support provided by the local service center (Page 117) for planning,
installation, commissioning and service work.
2.2 The 5 safety rules
For your own personal safety and to prevent material damage when carrying out any work,
always observe the safety-relevant instructions and the following five safety rules according
to EN 50110‑1 "Working in a voltage-free state". Apply the five safety rules in the sequence
stated before starting work.
5 safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 13
2.3 Qualified personnel
All work at the machine must be carried out by qualified personnel only. For the purpose of
this documentation, qualified personnel is taken to mean people who fulfill the following
requirements:
● Through appropriate training and experience, they are able to recognize and avoid risks
and potential dangers in their particular field of activity.
● They have been instructed to carry out work on the machine by the appropriate person
responsible.
2.4 Safe handling
Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
● General safety regulations applicable in the country where the machine is deployed.
● Manufacturer-specific and application-specific regulations
● Special agreements made with the operator
● Separate safety instructions supplied with the machine
● Safety symbols and instructions on the machine and its packaging
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum clearance and creepage distances may be
violated when coming close to live parts. Touching or coming close to them can result in death,
serious injury or material damage.
● Ensure that all live parts are suitably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules".
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer guaranteed
if covers are removed. Touching rotating parts can result in death, serious injury or material
damage.
● Ensure that all rotating parts are reliably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules".
● Only remove covers when the rotating parts have come to a complete standstill.
Safety information
2.3 Qualified personnel
SIMOTICS HT Series HT-direct 1FW4...1......A
14 Operating Instructions 11/2018
Risk of burns due to hot surfaces
Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
● Never touch machine parts during operation.
● Allow the machine to cool before starting work on the machine.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Health hazard due to chemical substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk.
● Observe the product information provided by the manufacturer.
Flammable substances hazard
Chemical substances required for the setup, operation and maintenance of machines may be
flammable. These substances can ignite if handled incorrectly. They can cause burns and
property damage.
● Observe the product information provided by the manufacturer.
See also
The 5 safety rules (Page 13)
Inspection and maintenance (Page 97)
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
● Ensure that nobody is in the area of increased noise emissions during machine operation.
● Take steps to reduce noise so that the machine can be operated safely within your system.
The following measures may help to reduce noise.
– Covers
– Noise insulation
– Hearing protection measures
2.5 Working on machines with permanent magnets
On machines with permanent magnets, the magnetic field is guided in an assembled state in
the magnetic circuit of the machine. This means that no magnetic fields, which may be to your
health, are detectable outside the machine.
Safety information
2.5 Working on machines with permanent magnets
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 15
WARNING
Strong magnetic field when the machine is open
A strong magnetic field is always present inside the machine. If the housing is open, e.g.
when maintenance openings are open or when working inside the machine, magnetic objects
can be suddenly attracted by this magnetic field. This can result in death, serious injury or
material damage.
● Working in the vicinity of the rotor is only permitted in exceptional circumstances.
Unambiguous access rules must be established in accordance with the magnetic fields
prevailing in the workplace. Clearly mark the boundaries of the areas where standing is
permitted.
● People who need to use electronic or magnetic medical aids such as pacemakers, hearing
aids, implants or similar devices, are at particularly high risk. Such persons must undergo
an industrial medicine assessment.
● Observe the following measures.
Personal protective measures
● Ensure that you never wear or carry any of the following objects and that they are kept a
safe distance from the machine:
– All kinds of magnetic metal parts such as, keys, glasses, tools, knives, scissors, tape
measures, etc.
– Magnetic jewelry such as rings, chains, needles, watches, etc.
– Electronic devices and data carriers such as service cards, check cards, credit cards,
calculators, cell phones, etc.
– Wallets or other iron-containing objects
– Electrically conductive foreign bodies
● Do not use any magnetic tools or lifting devices.
● Wear only occupational safety items without magnetic metal parts, e.g. occupational safety
shoes with non-magnetic protective caps and soles.
● Keep your shoes and clothing free from chips and waste containing iron.
● Exercise caution when installing accessories. Ensure that no parts fall into the inside of the
machine.
● Do not perform any cutting at the machine, e.g. manufacturing threaded holes. Any
exceptions require written approval from the manufacturer.
Safety information
2.5 Working on machines with permanent magnets
SIMOTICS HT Series HT-direct 1FW4...1......A
16 Operating Instructions 11/2018
Danger due to induced voltages
Electrical voltages are induced in the stator when rotating the rotor. Touching the stator
connections can result in death or severe physical injury.
● Before starting any work at the machine, carefully ensure that the system is secured to
prevent the rotor accidentally turning in compliance with the regulations.
● If you must rotate the rotor, then ensure that each phase is grounded.
2.6 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
Safety information
2.6 Electrostatic sensitive devices
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 17
The necessary ESD protective measures for electrostatic sensitive devices are illustrated once
again in the following drawings:
6HDWLQJSRVLWLRQ6WDQGLQJSRVLWLRQ6WDQGLQJVHDWLQJSRVLWLRQEEDFDIIIIIDFFHGGHG
a = conductive floor surfaceb = ESD table c = ESD shoes
d = ESD overall e = ESD wristband f = cabinet ground connection
2.7 Interference immunity
By selecting suitable signal cables and evaluation units, ensure that the interference immunity
of the machine is not diminished.
2.8 Interference voltages when operating the converter
Interference voltages when operating the converter
When a converter is in operation, the emitted interference varies in strength depending on the
converter (manufacturer, type, interference suppression measures undertaken). On machines
with integrated sensors (e.g. PTC thermistors), interference voltages caused by the converter
may occur on the sensor lead. This can cause faults which can result in eventual or immediate
death, serious injury or material damage.
● Comply with the EMC information provided by the manufacturer of the converter. This is
how you prevent the limit values stipulated by IEC/EN 61000-6-3 for the drive system
(consisting of the machine and converter) from being exceeded.
● You must put appropriate EMC measures in place.
2.9 Electromagnetic fields when operating electrical power engineering
installations
Electrical power equipment generate electromagnetic fields during operation. Potentially lethal
malfunctions can occur in medical implants, e.g. pacemakers, in the vicinity of electrical power
equipment. Data may be lost on magnetic or electronic data carriers.
● Protect the personnel working in the plant by taking appropriate measures, such as erecting
identifying markings, safety barriers and warning signs and giving safety talks.
● Observe the nationally applicable health and safety regulations.
Safety information
2.7 Interference immunity
SIMOTICS HT Series HT-direct 1FW4...1......A
18 Operating Instructions 11/2018
● It is forbidden for people with pacemakers to be close to the machine.
● Do not carry any magnetic or electronic data media.
Safety information
2.9 Electromagnetic fields when operating electrical power engineering installations
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 19
Safety information
2.9 Electromagnetic fields when operating electrical power engineering installations
SIMOTICS HT Series HT-direct 1FW4...1......A
20 Operating Instructions 11/2018
Description 3
Area of application
The series 1FW4 motors are multi-pin, permanent-magnet synchronous motors with full-shaft
rotors. The motors are liquid or air cooled. The operating behavior is comparable to that of
electrically excited synchronous motors.
Motors of the 1FW4 series are used together with converters as slow running direct drives,
e.g. in the following sectors:
● Pulp and paper industry
● Steel industry
● Plastics industry
● Marine
● Crushers
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.
Figure 3-1 1FW4 water-cooled motor
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 21
Machine design
The regulations and standards used as basis for designing and testing 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
Dimensions and operation characteristics IEC / EN 60034-1
Degree of protection IEC / EN 60034-5
Cooling IEC / EN 60034-6
Type of construction IEC / EN 60034-7
Terminal markings and direction of rotation IEC/EN 60034-8
Noise emission IEC / EN 60034-9
Mechanical vibrations IEC / EN 60034-14
IEC‑standard voltages IEC/DIN IEC 60038
Vibration limit values DIN ISO 10816-3
See also
Quality documents (Page 121)
Rating plate
The rating plate shows the identification data and the most important technical data. The data
on the rating plate and the contractual agreements define the limits of proper usage.
Description
SIMOTICS HT Series HT-direct 1FW4...1......A
22 Operating Instructions 11/2018
Rating plate
①Motor type: Three-phase motor ⑪Maximum operating speed [rpm]
②Motor type: Synchronous motor, order num‐
ber
⑫Operating mode
③Serial number ⑬Required amount of cooling water [l/min] at
the maximum cooling water inlet tempera‐
ture [°C]
④Type ⑭Maximum water pressure [bar]
⑤Temperature class ⑮Rotors, standards and regulations
⑥Degree of protection ⑯Rated power [kW]
⑦Rated torque [Nm] ⑰Rated current [A]
⑧Rated speed [rpm] ⑱Rated frequency [Hz]
⑨Induced voltage ⑲Rated voltage [V]
⑩Motor weight [t]
Figure 3-2 Rating plate diagram
Degree of protection
The machine is available with degree of protection IP55.
Ambient conditions
The standard machines are not suitable for use in corrosive atmospheres, atmospheres with
a high salt content, or outdoor applications.
Description
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 23
Water cooling
The cooling system is designed as a closed, internal cooling circuit. A shaft-mounted fan
ensures circulation of the cooling air. The machine has cooling type IC71W according to IEC /
EN 60034‑6.
Cooling power
To ensure adequate cooling of the machine, it is essential to adhere to the specified cooling
water rate, temperature and cooling water quality.
Drive
The machine is designed for operation with SINAMICS converters and has been type-tested
for use with these converters. No liability is assumed in respect of damage to the motor or
converter and no warranty is issued in respect of the drive function if you operate the motor
with a different converter.
As far as the SINAMICS Motor Modules are concerned, special control software has been
developed for these motors. The converter module is selected depending on many influencing
parameters, e.g.:
● Torque
● Speed
● Overload
● Duty cycles
● Control precision
● Capable of energy recovery
More detailed information is provided in Catalog D86.2 "SIMOTICS HT‑direct". For more
complex questions, contact your Siemens sales representative.
Anti-condensation heating (option)
The machine is fitted with anti-condensation heating. The connection data is listed on an
additional plate on the machine.
Rotor shipping brace
Depending on the order, the machine is fitted with a rotor shipping brace.
Supplementary devices
Temperature sensors are integrated in the stator winding to monitor the winding temperature.
Various supplementary devices can be integrated or mounted, depending on the order. These
include, for example, anti-condensation heating to prevent condensation or temperature
sensors for monitoring bearings.
Description
SIMOTICS HT Series HT-direct 1FW4...1......A
24 Operating Instructions 11/2018
Rolling-contact bearing design for "Increased degree of protection" (option)
Improved sealing of the bearing units to prevent dust and water from getting in can be achieved
by positioning a grease chamber ahead of the actual bearing unit. Although the same grease
is used in both cases for reasons of convenience, a distinction is made here between
"lubricating grease" and "sealing grease" because of their different functions.
Layout
The spent lubricating grease collects in the space between the bearing housing and the outer
bearing cap. The latter also forms the sealing grease chamber with the labyrinth sealing ring
(optional). The second lubricating nipple containing the grease duct for pressing in the sealing
grease is also located in the outer bearing cap. The chamber is sealed off from the space
where the lubricating grease collects by a V-ring or a V-ring and felt ring combination which
prevents the sealing grease in the chamber from penetrating into the lubricating grease
collecting space. During operation, the sealing grease in the chamber slowly runs out via the
labyrinth and seals it, additionally removing dust from inside and around the outside of the
labyrinth ring.
Description
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 25
Description
SIMOTICS HT Series HT-direct 1FW4...1......A
26 Operating Instructions 11/2018
Preparations for use 4
Good planning and preparation of machine applications are essential in terms of keeping
installation simple and avoiding errors, ensuring safe operation, and allowing access to the
machine for servicing and corrective maintenance.
This chapter outlines what you need to consider when configuring your plant in relation to this
machine and the preparations you need to make before the machine is delivered.
4.1 Safety-related aspects to consider when configuring the plant
A number of residual risks are associated with the machine. These are described in the chapter
titled "Safety information" (Page 13) and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.
4.2 Observing the operating mode
Observe the machine's operating mode. Use a suitable control system to prevent overspeeds,
thus protecting the machine from damage.
4.3 Cooling water quality
● The cooling water must circulate in a closed cooling circuit.
● Avoid fluctuations in the oxygen content of the cooling water.
● The cooling system is maintenance-free provided cooling water of the specified quality is
used.
Note
Order-specific agreements
Observe any order-specific agreements regarding the cooling water specification. These
might deviate from the named cooling water specification.
Cooling water specification
Characteristic Specified as Measured value German unitary proce‐
dure
Currently
ISO / alterna‐
tive
pH 7.5 - 10 DIN 38404-5 (Z) ISO 10523
Conductivity <600 µS/cm DIN 38404-8 (Z) ISO 7888
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 27
Chloride Cl <150 mg/l DIN 38405-1 ISO 9297
Manganese Mn <0.05 mg/l DIN 38406-2 ISO 6333 /
ISO 11885
Fluoride F <0.05 mg/l DIN 38405-4 ISO 10359-1
Sulfate SO42- <150 mg/l DIN 38405-5 ISO 10304
Copper Cu = Total copper <0.1 mg/l DIN 38406-7 ISO 8288 /
ISO 11885
Silicic acid SiO2<25 mg/l F1 (DIN 38407-1) ISO 16264
Free carbon dioxide CO20 mg/l G1 (DIN 38408-1) -
Total salts <1000 mg/l DIN 38409-1 -
Nitrate NO3-<20 mg/l DIN 38405-9 ISO 7890-1
(Z) /
ISO 10304
Suspended matter <10 mg/l DIN 38409-2 ISO 11923
Permanganate consump‐
tion
O <12 mg/l H4 (DIN 38409-5) ISO 8467
Total hardness Mg+Ca <12 °DH DIN 38409-6 ISO 6059
Carbonate hardness HCO3-<12 °DH DIN 38404-10 ISO 9963-1
Ammonium content N ISO 11732 /
NH4+ ISO 14911
<10 mg/l DIN 38406-5 ISO 11732 /
ISO 14911
Iron content Fe = Total iron <0.2 mg/l DIN 38406-1 ISO 6332 /
ISO 11885
4.4 Cooling water inlet temperature (water-cooled motor)
The motor has two cooling circuits that can be used to achieve intensive, effective cooling.
● The fan inside the motor provides air circulation between DE and NDE. This cools, in
particular, the stator winding overhang, the magnetic rotor and the bearings.
● The motor housing is designed with a water-cooling system. This allows a high power
density. The coolant flows through a duct that runs in a spiral from the DE to the NDE in
the cooling jacket. The coolant inlet is on the DE, the coolant outlet is on the NDE. Seen
from the shaft end, connection is possible from the right and from the left.
Close the duct provided for cooling on the cooling circuit. The cooling duct geometry is
designed so that the stator power losses are dissipated. Forced air ventilation prevents local
temperature peaks inside the motor. This also draws off the low magnetic losses in the rotor
via the stator.
Ambient and coolant inlet temperature
To prevent the formation of condensation, the coolant inlet temperature for a stationary motor
and still operational cooling system must be higher than the ambient temperature.
Tcooling water ≥ Tambient + 2 °C
The motor is designed in accordance with EN 60034‑1 for operation up to a coolant
temperature of 25 °C, maintaining all motor data. If you operate the motor with a higher coolant
Preparations for use
4.4 Cooling water inlet temperature (water-cooled motor)
SIMOTICS HT Series HT-direct 1FW4...1......A
28 Operating Instructions 11/2018
inlet temperature and/or an ambient temperature > +40°C, then you must reduce the torque.
Note the derating factors shown in the table below.
Table 4-1 Derating factors
Coolant inlet temperature up to 25 °C 30 °C 35 °C 40 °C 45 °C
Ambient temperature up to 40 °C 45 °C 50 °C 55 °C 60 °C
Derating factor kT1.0 0.97 0.95 0.92 0.89
Cooling volumetric flow and water pressure
Table 4-2 Coolant flow rate and maximum permissible water pressure
Type Cooling volumetric flow
l/min
Max. permissible water
pressure 1
MPa
Thread sizes for water
connections
1FW440. 30 0.5 G¾
1FW445. 50 0.5 G1
1FW4503 / 1FW4505 65 0.5 G1½
1FW4507 / 1FW4508 80 0.5 G1½
1A maximum pressure drop of approximately 0.1 MPa occurs in the water jacket.
Cooling water quality
The cooling water must meet the following prerequisites:
● Chemically neutral reaction
● Water cleaned by solids
● Max. particle size of particles carried: ≦ 0.1 mm
● No salt water
NOTICE
Damage due to sea water
The cooling system is made of St37 steel. This material is not resistant to sea water.
● Do not use seawater to cool the motor.
Table 4-3 Chemical requirements of the cooling water quality
Contents and chemical composition Value
pH value 6.0 to 8.0
Total hardness < 170 ppm
Chloride < 40 ppm
Sulphate < 50 ppm
Nitrate < 10 ppm
Preparations for use
4.4 Cooling water inlet temperature (water-cooled motor)
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 29
Contents and chemical composition Value
Iron < 0.2 ppm
Ammonia < 10 ppm
Dissolved solids < 340 ppm
Conductivity < 500 µS/cm
Mix additives in with the cooling water in appropriate quantities to protect against corrosion
and inhibit the growth of algae. The type and quantity of additive should be taken from the
respective manufacturer's specifications for these additives and the particular ambient
conditions.
Cooling unit
The use of a correspondingly dimensioned cooling unit ensures the coolant inlet temperature
of 25°C. You can operate several motors and/or the converter on one cooling unit.
Use a closed cooling cooling circuit. This will prevent deposits in the cooling circuit, cooling is
then permanently guaranteed.
The cooling unit is not part of the motor's scope of delivery.
ཱཱཱིིུུྲྀཷླྀ
①Filter1 ⑥Coolant temperature sensing
②Flow quantity display ① ⑦Compressor/cooling unit
③Flow regulating valve ① ⑧Motor
④Pump ⑨Cooling unit
⑤Cooling-medium reservoir
1 These components are not absolutely necessary.
Figure 4-1 Example of a cooling circuit
Preparations for use
4.4 Cooling water inlet temperature (water-cooled motor)
SIMOTICS HT Series HT-direct 1FW4...1......A
30 Operating Instructions 11/2018
4.5 Interlock circuit for anti-condensation heating (option)
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
Avoidance of condensation or formation of condensation within the machine (Page 91)
4.6 Thermal motor protection
The machine is equipped as standard with two KTY 84 temperature sensors, optionally with
six PT100 to directly monitor the motor temperature to protect the machine against overload
in operation. Plan a corresponding circuit for monitoring.
4.7 Noise emissions
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
● Ensure that nobody is in the area of increased noise emissions during machine operation.
● Take steps to reduce noise so that the machine can be operated safely within your system.
The following measures may help to reduce noise.
– Covers
– Noise insulation
– Hearing protection measures
4.8 Rotational speed limit values
Excessive rotational speed can lead to serious damage to the machine and the converter. This
can result in death, serious injury or material damage.
● The converter control must ensure that operation at impermissible speeds is prevented.
● Please note the speed data specified in the Electrical Data.
Preparations for use
4.5 Interlock circuit for anti-condensation heating (option)
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 31
4.9 System-inherent frequencies
Excessively high vibration levels and system resonances can damage the machine set.
● Configure and match the system consisting of the foundation and machine set in such a
way that no system resonances can arise and result in the permissible vibration levels being
exceeded.
● The vibration values according to DIN ISO 10816-3 must not be exceeded.
4.10 Torsional loading of the drive train due to faults in the electrical supply
In the event of faults in the electrical connection during operation, excessive air gap torques
can lead to additional mechanical torsional load on the line shaft.
Risk of torsional stress on the drive train
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, consider the configuration data. The system planner is
responsible for the entire drive train.
Note
More information about this may be found in the catalog.
4.11 Transport
4.11.1 Safety instructions for transport
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.
Preparations for use
4.9 System-inherent frequencies
SIMOTICS HT Series HT-direct 1FW4...1......A
32 Operating Instructions 11/2018
Danger due to induced voltages
Electrical voltages are induced in the stator when rotating the rotor. Touching the stator
connections can result in death or severe physical injury.
● Before starting any work at the machine, carefully ensure that the system is secured to
prevent the rotor accidentally turning in compliance with the regulations.
● If you must rotate the rotor, then ensure that each phase is grounded.
4.11.1.1 Transporting the machine set
Danger if the machine falls
The attachment points on the machine are designed for the weight of the machine only. If a
machine set is lifted and transported at a single machine, this can fracture the attachment
point. The machine or machine set may fall. This can result in death, serious injury or material
damage.
● Do not lift machine sets by attaching lifting tackle to the individual machines.
● Use only the equipment provided, e.g. the openings or lugs on the base plates, for
transporting machine sets. Note the maximum capacity of the lifting lug.
4.11.2 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. Subsequent claims cannot be recognized.
● 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.
Preparations for use
4.11 Transport
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 33
4.11.3 Securing the rotor
Depending on the version, the machine is fitted with a rotor shipping brace. This protects the
bearings against damage due to shock and vibration during transport or storage.
NOTICE
Motor damage due to vibrations
Not using the rotor shipping brace can cause damage to the machine if it is jolted during
transport or storage. Material damage can result.
● If the machine is fitted with a rotor shipping brace, this should always be used when
transporting the machine. The rotor shipping brace must be attached during the transport.
● Protect the motor against strong radial shocks and vibration when storing, as the rotor
shipping brace cannot completely absorb these forces.
● Do not remove the rotor shipping brace until you are ready to push on the output element.
● If the customer already has mounted parts, such as a coupling or belt pulley, the bearings
can be damaged during transport. In this case, make sure that the customer uses a rotor
shipping brace.
● For machines with a vertical type of construction:
– Do not remove the rotor shipping brace until the machine is in a vertical position.
– If a machine has to be transported in a horizontal position, the rotor must be fixed in
position before the machine is turned onto its side. Vertical machines can be supplied
in the horizontal position from the manufacturing plant.
Preparations for use
4.11 Transport
SIMOTICS HT Series HT-direct 1FW4...1......A
34 Operating Instructions 11/2018
Alternative rotor bracing
● If you transport the machine after the output element has been pulled on, then you must
axially fix the rotor in another way.
ཱ
①Sleeve ②Shaft screw and washer
Figure 4-2 Axial fastening of the rotor
Thread in the shaft extension Tightening torque
M20 80 Nm
M24 150 Nm
M30 230 Nm
Tightening torques for other rotor shipping brace types
● The thread in the shaft extension indicates the rotor weight. This indirectly specifies the
required preload force when axially fastening the rotor.
Thread in the shaft extension Preload
M20 20 kN
M24 30 kN
M30 40 kN
Axial preload force for other rotor shipping brace types
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
Preparations for use
4.11 Transport
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 35
4.11.4 Protecting cooling water ducts
Protecting the cooling-water ducts during storage
The cooling water ducts are not filled with cooling water when the motor is supplied. To avoid
corrosion, the cooling water ducts are treated with a rust protection agent in the factory.
NOTICE
Corrosion
If the cooling water has been drained, you must flush the cooling circuit with a rust protection
agent if the motor is going to sit idle for a long period of time.
Otherwise material damage will occur.
NOTICE
Foreign bodies in the cooling circuit
Foreign bodies in the cooling system can cause blockages in individual circuits. Water-cooled
components can overheat and the motor fails.
● Ensure that no foreign bodies can enter the cooling system.
● Do not remove the protective cover until you are ready to make the final water connections.
NOTICE
Temperatures below 0 °C
Damage may be caused to the cooling circuit if the cooling water freezes at temperatures
below 0°C. Drain the water from the cooling system before you transport and store the motor.
● Drain the cooling water ducts.
● Blow out the cooling water ducts with compressed air.
4.11.5 Transporting a motor that has already been in operation
If you have already operated the motor and now want to transport it, proceed as follows:
1. Allow the motor to cool down.
2. Remove the connections provided by the customer.
3. Drain the cooling-water system and purge it carefully with air.
4. Fit the rotor shipping brace, if present.
5. Only use the eyebolts on the bearing shields - for example - to transport and lift the motor.
Preparations for use
4.11 Transport
SIMOTICS HT Series HT-direct 1FW4...1......A
36 Operating Instructions 11/2018
4.11.6 Lifting and transportation
To safely lift and transport the machine, the following requirements must be met:
● Personnel operating cranes and fork-lift trucks must be appropriately qualified.
● If the machine 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 the lifting equipment prior to its use. The weight of the
machine is shown on the rating plate.
● When lifting the machine, refer to the information on the lifting plate.
– 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
WARNING
Transport for a different type of construction
If you do not transport or lift the machine in a position appropriate for its construction, the
machine can tip, slip into the lifting equipment or fall down. This can result in death, serious
injury or material damage.
● Use only the load carrying device on the stator frame for lifting.
● Use the load carrying device appropriate for the machine position.
● Only use suitable rope guiding or spreading devices.
WARNING
Center of gravity not centered
If the center of gravity of a load is not located centrally between the attachment points, the
machine 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.
● Comply with the handling instructions on the machine when transporting it.
● Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
● Always take account of the center of gravity when transporting or lifting the machine. If
the center of gravity is not located centrally between the attachment points, then position
the hoisting hook above the center of gravity.
Preparations for use
4.11 Transport
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 37
● Never remain under or in the immediate vicinity of the machine when it is lifted.
WARNING
Danger to life as a result of a machine falling
If the lifting gear or load handling attachments were to fail, the machine could fall. This
can result in death, serious injury or material damage.
● In order to gain easy and safe access to the underside of the machine, place it in a
secure and raised position.
4.12 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.
Preparations for use
4.12 Storage
SIMOTICS HT Series HT-direct 1FW4...1......A
38 Operating Instructions 11/2018
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 (veff ≤ 0.2 mm/s).
– 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.
– Covers or tarpaulins must not trail on the floor around the machine.
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.
● Inspect the machine regularly.
Preparations for use
4.12 Storage
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 39
Storage for longer than three months
Lubricate the machine after every two years of storage.
1. Unpack the machine.
2. Remove the rotor shipping brace, if one is fitted.
3. When stored for longer than two years, lubricate with twice the grease quantity in
accordance with the lubricant plate. This ensures that the grease is evenly distributed and
covers all surfaces. Corrosion damage is avoided.
NOTICE
Rolling bearing damage due to unchanged resting position
Roller bearings can be damaged when kept in the same or almost the same position.
● Every three months, manually rotate the rotor through five revolutions.
● Make sure that the resting position of the rotor after the rotor has been turned over is
different from its previous position. Use the feather key as a reference point, if present.
4. Replace the corrosion protection.
5. Reattach the rotor shipping brace, if present.
6. Pack the machine again.
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 38)", 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.
Preparations for use
4.12 Storage
SIMOTICS HT Series HT-direct 1FW4...1......A
40 Operating Instructions 11/2018
4.13 Converter operation
4.13.1 Converter input voltage
The insulation system of SIMOTICS machines always complies with the requirements of stress
category C (IVIC C = high stress). If voltage peaks higher than those specified according to
IVIC C can occur, then please contact your Siemens partner:
● For a line supply voltage (converter input voltage) up to max. 480 V, and when controlled
from a SINAMICS G/SINAMICS S converter with uncontrolled/controlled infeed: Comply
with the guidelines for configuring motor and converter.
● For line voltages (converter input voltages) higher than 480 V, motors, which are ordered
for converter operation, have an appropriate insulation system.
● Operation with a converter from another manufacturer: Comply with the permissible voltage
peaks according to IEC 60034-18-41 in accordance with stress category C, dependent on
the particular line voltage (converter input voltage) and the motor insulation system.
NOTICE
Material damage caused by an excessively high supply voltage
The insulation system will be damaged if the supply voltage is too high for the insulation
system. This can completely destroy the machine.
● Comply with the peak voltages as laid down in the guidelines above.
4.13.2 Reducing bearing currents
If you want to prevent damage due to bearing currents, you must take the entire system into
account, i.e., the motor, converter and driven machine. The following measures help to prevent
bearing currents:
● In addition to grounding the motors via the grounding conductor, supplement the RF
grounding with braided flat copper cables or RF stranded conductors. Ensure that contact
is established across the largest possible surface area. Solid copper cables are not suitable
for RF grounding because of the skin effect.
● Use symmetrically constructed, shielded connection cables to connect the motor to a
converter. The cable shielding, made up of as many strands as possible, must have good
electrical conductivity. Braided shields made of copper or aluminum are well suited.
Connect the shielding at both ends on the motor and on the converter. Keep unshielded
cable ends as short as possible.
Preparations for use
4.13 Converter operation
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 41
/3(3(3(/////
3(///
Concentric copper or aluminum shield Steel armor
● To ensure that high-frequency currents are appropriately discharged, establish a contact
through the largest possible surface area at both ends. Establish a 360° contact of the cable
shielding on the motor housing and on the protective grounding bar of the converter. On
the motor end for example, this can be done using EMC screw joints at the cable entry
ports. On the converter end, you can use EMC-shielded clips, for example.
● In the overall system, set up a properly meshed grounding system with low impedance for
high-frequency currents.
● No potential difference between the motor, converter, and working machine.
– Use equipotential bonding cables between the terminal box and the‑ high-frequency
grounding point on the motor enclosure.
– Use a separate high-frequency equipotential bonding cable between the motor
enclosure and the protective grounding bar of the converter.
– Use a separate high-frequency equipotential bonding cable between the motor
enclosure and the driven machine.
● Use the common-mode filter (damping cores) at the converter output. The Siemens sales
representative is responsible for selection and dimensioning.
● Limit the rise in voltage by using output filters. Output filters dampen the harmonic content
in the output voltage.
● Use the motor reactors.
● Preferably use an IT line supply with an insulated neutral point.
Note
Converter documentation
The operating instructions for the converter are not part of this documentation. Refer also
to the configuration/engineering information for the converter.
4.13.3 Insulated bearings when operating the converter
If the machine is operated from a low-voltage converter, insulated bearings are fitted at the
NDE and an insulated encoder with insulated bearings (option).
Comply with the plates on the machine relating to bearing insulation and possible bridges.
Preparations for use
4.13 Converter operation
SIMOTICS HT Series HT-direct 1FW4...1......A
42 Operating Instructions 11/2018
①Driven machine ④Insulated bearings
②Motor ⑤Insulated tachometer mounting
③Coupling
Figure 4-3 Schematic representation of a single drive
NOTICE
Bearing damage
The bearing insulation must not be bridged. Damage may be caused to the bearings if there
is a flow of current.
● Also when performing subsequent installation work, e.g. installing an automatic lubrication
system or a non-insulated vibration sensor, ensure the bearing insulation is not bridged.
● Contact your Service Center, if necessary.
See also
Service and Support (Page 117)
Preparations for use
4.13 Converter operation
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 43
Preparations for use
4.13 Converter operation
SIMOTICS HT Series HT-direct 1FW4...1......A
44 Operating Instructions 11/2018
Assembly 5
5.1 Safety instructions when mounting
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.
5.1.1 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.
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 45
Damage to mounted parts and components as a result of high temperatures
The motor components get very hot during operation. High temperatures can damage parts
mounted by customers, such as cables manufactured out of materials that are not heat
resistant.
● Temperature-sensitive parts must not come into contact with or be attached to components
mounted on the machine.
● Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the particular application.
Loss of conformity with European directives
In the delivery state, the machine corresponds to the requirements of the European directives.
Unauthorized changes or modifications to the machine lead to the loss of conformity with
European Directives and the loss of the associated warranty.
5.2 Preparations for installation
5.2.1 Requirements for installation
The following requirements must be satisfied prior to starting installation work:
● Staff have access to the operating and installation instructions.
● The machine is unpacked and ready for mounting at the installation location.
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.
5.2.2 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
Assembly
5.2 Preparations for installation
SIMOTICS HT Series HT-direct 1FW4...1......A
46 Operating Instructions 11/2018
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 47)
5.2.3 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.
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.
Assembly
5.2 Preparations for installation
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 47
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
meas
V
R
C
MΩ
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 = rated voltage, see the rating plate
U
meas = DC measuring voltage
R
C = minimum insulation resistance at a reference temperature of 40 °C
Conversion to the reference temperature
When measuring with winding temperatures other than 40° C, convert the measuring value to
the reference temperature of 40° C according to the following equations from IEEE 43-2000.
(1)
R
C =
K
T ·
R
T
R
CInsulation resistance converted to 40° C reference temperature
K
TTemperature coefficient according to equation (2)
R
TMeasured insulation resistance for measuring/winding temperature
T
in °C
(2)
K
T = (0.5) (40-T)/10
40 Reference temperature in °C
10 Halving/doubling of the insulation resistance with 10 K
T
Measuring/winding temperature in °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.
Assembly
5.2 Preparations for installation
SIMOTICS HT Series HT-direct 1FW4...1......A
48 Operating Instructions 11/2018
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 /
R
insul 1 min
Many measuring devices display these values automatically following the measurement.
For insulation resistances > 5000 MΩ, the measurement of the PI is no longer meaningful and
consequently not included in the assessment.
R(10 min) / R(1 min) Assessment
≥ 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 117).
● 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.
Assembly
5.2 Preparations for installation
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 49
5.2.4 Preparing the mating faces
Prepare the foundation faces dependent on the machine type:
● Mounting on a foundation
– Ensure that the foundation faces are flat and free of contaminations.
– Check the dimensions of the mounting-foot holes.
● Flange connection
– Clean the flange before installation. Ensure that the flange surfaces are flat and perfectly
clean.
– Check the geometry of the flange.
● Wall mounting
– Ensure that the wall faces are flat and free of contaminations.
– Check the dimensions of the mounting-foot holes.
– Support the machine from below, e.g. using a wall bracket or by bolting it.
5.3 Lift the machine to where it will be installed, and position it
5.3.1 Preconditions for correct alignment and secure attachment
Detailed specialist knowledge of the following measures is required in order to correctly align
and securely fit the equipment.
● Preparing the foundation
● Selecting and mounting the coupling
● Measuring the concentricity and axial eccentricity tolerances
● Positioning the machine
If you are not familiar with the prescribed measures and procedures, then you can make use
of the services offered by the local Service Center (Page 117).
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
50 Operating Instructions 11/2018
5.3.2 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.
5.3.3 Removing the rotor shipping brace
If a rotor shipping brace is attached to the machine, remove it at the last possible moment,
for example, when you are ready to push on the output or drive element.
Note
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
5.3.4 Removing the rotor shipping brace from machines with vertical type of
construction
NOTICE
Removing the rotor shipping brace in the horizontal position.
Dismantling the rotor shipping brace when the machine is in a horizontal position could
damage the bearings.
● Only remove the rotor shipping brace when the machine is in a vertical position.
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 51
NOTICE
Turning the motor over without rotor shipping brace
Failure to fit the rotor shipping brace can result in damage to the bearings while the machine
is being turned onto its side.
● Fix the rotor in place before you turn the machine into a horizontal position.
5.3.5 Removing anti-corrosion protection
Machined, bright 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 just before starting the installation work.
Bright surfaces on machine parts
● Remove the anti-corrosion coating from the machined surfaces of machine parts and from
small components. To do this, use petroleum, petroleum ether - or a similar solvent or
cleaning agent.
NOTICE
Paintwork damage
Painted surfaces can be damaged if they come into contact with detergents or solvents.
● 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
Damage to the machine surface
Metal objects, such as scrapers, spatulas or pieces of metal, are not suitable to remove
the anti-corrosion protection.
These could damage the surfaces of the machine parts.
● Lightly oil the depreserved surfaces.
5.3.6 Only operate with a flexible coupling
It is only permissible to operate the machine using a flexible coupling.
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
52 Operating Instructions 11/2018
WARNING
Insufficient screw locking
Vibration and shock loads can loosen the screws. The machine or components may fall down.
This can result in death, serious injury or material damage.
● Lock the screwed connections with a screw-locking compound, e.g. Loctite 243.
5.3.7 Mounting the output elements
Type of balancing
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
Pushing on the power output elements
Prerequisites
● The coupling and/or the output element must be appropriately dimensioned for the
operating case at hand.
● Comply with the coupling manufacturer's instructions.
● Make sure that the balancing type of the transmission element correctly matches the type
of balance of the rotor.
● Use only ready drilled and balanced transmission elements. Check the hole diameters and
the balancing status before pulling them on. Thoroughly clean the shaft extension.
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 53
Fitting
● 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 transmission element must be pulled on in one continuous operation via the front thread
holes in the shaft or pushed on by hand.
● Do not strike it with a hammer, as this would damage the bearings.
Shaft extensions with feather key
To maintain the balancing quality, you have the following options:
● If the transmission element is shorter than the feather key with balancing type "H", then you
must machine off the section of feather key protruding from the shaft contour and
transmission element in order to maintain the balance quality.
● If the transmission element is drawn up on to the shoulder of the shaft, you must ensure
that the part of the coupling groove where the feather key is not inserted is taken into
consideration when balancing the coupling.
Danger when feather keys are flung out
The feather key is only secured to prevent it falling out during transport. The feather key may
be flung out if the motor is operated without fitted transmission elements, such as coupling,
etc.
This can result in death, serious injury or material damage.
● Only operate the motor with the transmission element pulled on.
● For test operation or when commissioning without transmission element, carefully secure
the feather key using a suitable locking element. When doing this, take into account the
type of balancing of the motor.
5.3.8 Lifting and transporting the machine
To safely lift and transport the machine, the following requirements must be met:
● Personnel operating cranes and fork-lift trucks must be appropriately qualified.
● If the machine 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.
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
54 Operating Instructions 11/2018
● When lifting the machine, use only approved and undamaged sling guides and spreaders
of sufficient rated capacity. Check the lifting equipment prior to its use. The weight of the
machine is shown on the rating plate.
● When lifting the machine, refer to the information on the lifting plate.
– 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
WARNING
Transport for a different type of construction
If you do not transport or lift the machine in a position appropriate for its construction, the
machine can tip, slip into the lifting equipment or fall down. This can result in death, serious
injury or material damage.
● Use only the load carrying device on the stator frame for lifting.
● Use the load carrying device appropriate for the machine position.
● Only use suitable rope guiding or spreading devices.
WARNING
Center of gravity not centered
If the center of gravity of a load is not located centrally between the attachment points, the
machine 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.
● Comply with the handling instructions on the machine when transporting it.
● Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
● Always take account of the center of gravity when transporting or lifting the machine. If
the center of gravity is not located centrally between the attachment points, then position
the hoisting hook above the center of gravity.
Note
Place the machine in a secure and raised position
In order to obtain easy and safe access to the underside of the machine, place it in a secure
and raised position.
DANGER
Standing under suspended loads
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.
● Never remain under or in the immediate vicinity of the machine when it is raised.
Assembly
5.3 Lift the machine to where it will be installed, and position it
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 55
5.3.9 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.
5.3.10 Roughly aligning the machine
Requirement
The transmission element such as a coupling half has already been pulled on.
Roughly aligning the machine
● For horizontal positioning, push the motor sideways across the foundation. When doing so,
ensure that the axial position is maintained.
5.4 Installing the machine
Note
Service Center
For any installation work that is required, contact the Service Center (Page 117) or commission
service engineers trained by Siemens and authorized for this task.
Assembly
5.4 Installing the machine
SIMOTICS HT Series HT-direct 1FW4...1......A
56 Operating Instructions 11/2018
5.4.1 Selecting fixing screws
● Unless specified otherwise, use mounting bolts with at least strength class 8.8 to ISO 898‑1.
In this way you guarantee that the machine is securely mounted and the forces can be
transferred through the torque.
● Take into account the maximum forces occurring in the case of a fault such as short circuit
or system transfers in phase opposition.
– When selecting the bolts
– When designing the foundation
5.4.2 Preconditions for smooth, vibration-free operation
Preconditions for smooth, vibration-free operation:
● Stable foundation design
● Precise alignment of the machine
● Correct balancing of parts to be fitted to the shaft end.
● Maintaining the vibration velocity according to ISO 10816‑3
5.4.3 Connection cables
Observe the following when installing connection cables:
● Connection cables must not be damaged.
● Connection cables must not be under tension.
● Connection cables must not be touched by rotating parts.
Observe the technical data in these operating instructions and on the rating plate.
5.4.4 Aligning the machine to the driven machine and mounting (IM B3)
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 at the operating temperature do not have any parallel or angular
offset. This ensures that no additional forces affect their bearings during operation.
If the thermal change of the motor and the driven machine is different, couple in the cold
state with an appropriate alignment offset. The alignment offset to be set in the cold state
must be determined and specified by the system specialist.
Assembly
5.4 Installing the machine
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 57
3. For the vertical positioning (x→0), place thin shims over a large surface area 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.
The balance state of the shaft (full-key or half-key balancing) and alignment errors primarily
influence the service life of the bearing, especially for high motor speeds or when using
rigid couplings.
4. When positioning the machine, ensure that a uniform axial gap (y→0) is maintained around
the coupling.
5. Fix the machine to the foundation. The choice of fixing elements depends on the foundation
and is the plant operator's responsibility.
'
[
\
①Plates placed under the motor for alignment
②Laser alignment
Figure 5-2 Schematic diagram: Aligning the machine to the driven machine
Table 5-2 Permissible deviations for aligning the machine with flexible coupling
Max. speed nmax Max. parallel offset x Max. angular offset y
nmax ≤ 1500 rpm xmax = 0.08 mm ymax = 0.08 mm / 100 mm ∅ D
1500 rpm < nmax ≤ 3600 rpm xmax = 0.05 mm ymax = 0.05 mm / 100 mm ∅ D
Assembly
5.4 Installing the machine
SIMOTICS HT Series HT-direct 1FW4...1......A
58 Operating Instructions 11/2018
Note
Machine expansion
When performing alignment, make allowance for the thermal expansion of the machine due
to rising temperature.
See also
Tightening torques for screw and bolt connections (Page 119)
5.4.5 Aligning the machine to the driven machine and mounting (IM V1)
The standard flange is provided with a centering. The choice of fit for the mating flange on the
driven machine is the system manufacturer's or the plant operator's responsibility.
Note
If the machine is not fitted with a standard flange, align the machine to suit the driven machine.
Procedure
The machine axis must be vertical when it is lifted and the flange must be parallel to the mating
flange, so as to avoid seizing and stressing. Otherwise damage to the centering will result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw in two studs into tapped holes on opposite sides of the driven machine flange. The
studs act as positioning aids.
3. Lower the machine slowly toward the driven machine and into the centering, so that the
flanges do not quite touch. Lowering too quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Lower the machine completely onto the mating flange so that it is fully in contact; then
remove the studs.
6. Fix the machine using the flange fixing bolts.
See also
Tightening torques for screw and bolt connections (Page 119)
Alignment accuracy
The coaxial characteristic of the shafts of electrical machines and driven machine may not
exceed 0.05 mm in diameter.
Assembly
5.4 Installing the machine
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 59
5.4.6 Axial and radial forces
You can obtain the permissible values for axial and radial forces by contacting the Siemens
Service Center (Page 117) or referring to the machine catalog.
NOTICE
Damage to bearings or the shaft
Large output masses and their centers of gravity outside the shaft extensions can lead to
resonance in operation. This can result in damage to the bearings and shaft.
Ensure that the permissible loads for the forces on the shaft extension are adhered to in
accordance with the catalog data or configuration data.
5.5 Connecting the cooling water supply
The size of the connecting threads is described in the "Technical data" section.
1. For the pipes, select materials with the required chemical composition in accordance with
the water conditions. 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, strain or vibration loads.
3. Remove the flange cover plate.
4. Insert the gaskets correctly.
5. Rinse out the water circuit before you connect the cooling water supply to the motor. This
removes deposits and foreign bodies.
6. Should there be a possibility of the cooling water containing dirt and foreign bodies, install
suitable filters in the cooling-water feed pipe.
7. Connect the cooling circuit to the machine.
Filling the cooling circuit
1. Fill the cooling circuit with water until the air has been completely forced out of the cooling
circuit.
2. Perform a pressure check to see whether the cooling water supply is airtight. Do not exceed
the maximum pressure. The maximum permissible pressure is specified in the technical
data.
3. If you don't immediately commission the machine, then appropriately prepare for the non-
operational period.
See also
Stoppages (Page 90)
Assembly
5.5 Connecting the cooling water supply
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60 Operating Instructions 11/2018
5.6 Insulated bearings
The motor is fitted with electrically insulated bearings on the non-drive end.
NOTICE
Bearing damages
The bearing insulation must not be bridged. Damage may be caused to the bearings if there
is a flow of current.
Assembly
5.6 Insulated bearings
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 61
Assembly
5.6 Insulated bearings
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62 Operating Instructions 11/2018
Electrical connection 6
6.1 Safety instructions relating to the 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.
● 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.
● When performing servicing, check the fastenings.
Note
Service Center
If you require support when electrically connecting up the machine, please contact the Service
Center (Page 117).
6.2 Basic rules
The following generally applies to electrical connections:
● Ensure that there is a safe and reliable PE ground connection before starting any work.
● The connecting cables can be sealed and secured at every cable entry point into the
terminal box.
● Lay the connecting cables and in particular the PE conductor in the terminal box in an open
arrangement so that chafing of the cable insulation is prevented.
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 63
● Connect the machine in such a way that a permanent, safe electrical connection is
maintained. Avoid protruding wire ends.
● Lay and secure external auxiliary cables separately from the main cable. Elements with
cable ties may be present for this purpose.
● 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
6.3 Preparation
6.3.1 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
Electrical connection
6.3 Preparation
SIMOTICS HT Series HT-direct 1FW4...1......A
64 Operating Instructions 11/2018
6.3.2 Selecting cables
Take the following criteria into account when selecting the connecting cables:
● Rated current
● Rated voltage
● If required, service factor
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Configuration notes
● Requirements according to IEC/EN 60204‑1
● Dimensioning for bundled cable routing, e.g. according to DIN VDE 0298 Part 4 or
IEC 60364-5-52
6.3.3 Connecting the machine for a specific 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 the power cables in the phase sequence L1, L2, L3 to U, V, W, the resulting
rotation will be clockwise.
● If you interchange two connections, e.g. L1, L2, L3 to W, V, U, the resulting rotation will be
counter-clockwise.
● On machines which are only allowed to run in one direction, the rating plate shows an arrow
which indicates the permitted direction of rotation, and it also specifies the terminal
connections in the required phase sequence.
NOTICE
Incorrect direction of rotation
The machine will not be adequately cooled if it is operated other than how it was originally
ordered or with the incorrect direction of rotation. This can result in machine damage.
Observe the direction of rotation data on the nameplate.
Electrical connection
6.3 Preparation
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6.3.4 Connecting the grounding conductor
The grounding conductor cross-section of the machine must be in full conformance with the
installation specifications and to IEC / EN 60204-1.
Table 6-2 Determining the cross-section of the grounding conductor
External cable 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 a flat washer and a spring washer on the stator frame at the
designated connecting point for the grounding conductor. This can be used for connecting
stranded conductors with cable lugs or ribbon cables with an appropriately shaped conductor
end.
When making connections, ensure the following:
● The connecting surface is bare and protected against corrosion using a suitable substance,
e.g. acid-free Vaseline.
● The flat and spring washers are located under the bolt head.
● The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not
exceeded.
● The minimum required screw-in depth and the tightening torque for the clamping bolt as
given in the table below are observed. Screw-in depth and tightening torque are different
depending on whether cable lugs or ground terminals are used.
Table 6-3 Tightening torques of bolts (cable lug)
Bolt Screw-in depth Tightening torque
M12 x 25 > 16 mm 38 Nm
M16 x 35 > 20 mm 92 Nm
Table 6-4 Bolt tightening torques (ground terminals)
Bolt Screw-in depth Tightening torque
M6 > 9 mm 8 Nm
M8 > 12 mm 20 Nm
M10 > 15 mm 40 Nm
M12 > 18 mm 70 Nm
M16 > 20 mm 170 Nm
Connecting the grounding conductor in the terminal box
In the terminal box, use the connection terminals designated for the ground conductor.
Electrical connection
6.3 Preparation
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66 Operating Instructions 11/2018
Connecting the radio-frequency ground for forced-ventilated motors
1, 5 Hexagon bolt 4 Grounding conductor
2 Spring washer 6 High-frequency grounding cable
3 Terminal Board 7 Cable lug
Figure 6-2 High-frequency grounding
● Connecting using flat ribbon cables is recommended.
● Connection with cable lugs is possible.
High-frequency grounding for water-cooled motors
For water-cooled motors, a radio-frequency ground is required between the terminal box and
the housing due to the steel housing.
Electrical connection
6.3 Preparation
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Operating Instructions 11/2018 67
6.4 Inserting and routing the cables
6.4.1 Circuit diagram
For the machine, the neutral point is formed internally. A separate neutral point circuit must
not therefore be wired in the main terminal box by the servicing or commissioning personnel.
Figure 6-3 Neutral point connection
Data on the connection and connecting the motor winding can be found in the circuit diagram
in the cover of the terminal box.
Electrical connection
6.4 Inserting and routing the cables
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68 Operating Instructions 11/2018
6.4.2 Terminal box
Figure 6-4 Terminal box 1XB1631
The connecting cables are inserted via cable glands with 4 x M80 x 2 threaded holes into the
terminal box. The cable glands are not included in the standard scope of supply.
For more information, see:
● Introducing the cables into the terminal box and routing them (Page 69)
● Connecting cables with cable lugs (Page 70)
6.4.3 Introducing the cables into the terminal box and routing them
The connection cables are inserted into the terminal box via an exchangeable cable entry plate
or cable entry support . The cable entry plate is drilled by default. The cable glands are not
included in the standard scope of supply.
The cable entry can be turned by 180°.
Insert the cable into the terminal box
1. Unscrew the cable entry plate.
2. Drill the required number of holes or tapped holes in the required size into the cable entry
plate, if necessary. Ensure that the cable entry plate can be assembled after drilling and
that it features sufficient stiffness.
3. Fit the required cable glands.
4. Route the cables through the cable glands.
5. Fit the cable entry plate to the terminal box with the assembled cables.
6. Connect the ends of the cables to the terminals in accordance with the circuit diagram. The
circuit diagram is located in the cover of the terminal box.
Refer to the "Connecting cables..." section for more information.
Electrical connection
6.4 Inserting and routing the cables
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Operating Instructions 11/2018 69
6.4.4 Connecting cables with cable lugs
1. Select the cable lugs according to the required cable cross-section and fixing screw or stud
size. Information about the maximum cross-section for the respective standard terminal
box design can be found in the catalog.
A sloped/angular arrangement of the supply cables is only permitted provided the required
minimum air clearances are met.
2. Remove the insulation from the conductor ends so that the remaining insulation reaches
almost up to the cable lug ①. Connect only one conductor per cable lug.
3. Fasten the cable lug to the end of the conductor correctly, e.g. by squeezing.
Figure 6-5 Connection with cable lug and fixing screw (schematic diagram)
4. Insulate the cable lug sleeves where necessary to ensure minimum air clearances and the
creepage distance are maintained.
5. Place the cable lug on the terminal support. If you are using a disconnecting link, check its
positioning.
6. Tighten the fixing element ② with the corresponding tightening torque:
Fixing element Tightening torque
Fastening screw M12 20 Nm
Fixing screws M16 40 Nm
Fixing nuts M12 20 Nm
See also
Tightening torques for screw and bolt connections (Page 119)
Electrical connection
6.4 Inserting and routing the cables
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70 Operating Instructions 11/2018
6.4.5 Use of 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.
6.4.6 Using single-stranded cables
NOTICE
High temperatures from induced eddy currents
With high currents and where several single-stranded cables are used instead of multiple-
stranded cables, high temperatures can result in the cable entry area due to induced eddy
currents. This can result in material damage or even a machine failure.
● After commissioning, ensure that the temperature limits of the connected power cables
are not exceeded during operation. This temperature effect can be reduced by altering
the conditions at the entry points or by using modified cable entry plates after consultation
with the manufacturing plant.
● Use a cable entry plate made of non-ferrous metal.
Electrical connection
6.4 Inserting and routing the cables
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Operating Instructions 11/2018 71
6.4.7 Minimum air clearances
After proper installation, verify that the minimum air clearances between non-insulated parts
are maintained. Be aware of any protruding wire ends.
Table 6-5 Minimum air clearance dependent on rms value of the alternating voltage Urms
Rms value of the alternating voltage Vrms Minimum air clearance
≤ 500 V 8 mm
≤ 630 V 10 mm
≤ 800 V 12 mm
≤ 1000 V 14 mm
≤ 1250 V 18 mm
Values apply at an installation altitude of up to 2000 m.
When determining the required minimum air clearance, the voltage value in the table may be increased
by a factor of 1.1, so that the rated input voltage range is taken into account during general use.
6.4.8 Internal equipotential bonding
The internal equipotential bonding between the grounding terminal in the box enclosure and
the motor frame is established through the terminal box retaining bolts. The contact locations
underneath the bolt heads are bare metal and protected against corrosion.
The standard cover fixing screws are sufficient for equipotential bonding between the terminal
box cover and terminal box housing.
Note
Connecting points are available at the frame or bearing end shield to connect an external
protective conductor or potential bonding connector.
Electrical connection
6.4 Inserting and routing the cables
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72 Operating Instructions 11/2018
6.4.9 Finishing connection work
1. Before closing the terminal box, please check that:
– The electrical connections in the terminal box have been made in accordance with the
specifications above and tightened with the correct tightening torque.
Remove the used bolts and fastening elements.
– The machine is connected in such a way 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 of the seals and sealing surfaces of the terminal box are intact and in a good condition.
– Unused cable entries are closed and their plugs are tightly screwed in place, i.e. they
can only be released using a tool.
– The connecting cables are freely routed. The cable insulation cannot be damaged in
operation.
2. Close the terminal box using the cover fixing screws, see Chapter Tightening torques for
screw connections. (Page 119)
6.5 Connecting the auxiliary circuits
The type designations of the mounted auxiliary terminal boxes, their arrangement, and the
relevant connection terminals are documented in the "Technical data" section. The information
required to connect anti-condensation heating and the auxiliary circuits is provided in the
connection diagram, located on the inside of the terminal box cover, and in the "Technical
data" section. The terminals are suitable for conductor cross-sections up to 4 mm2.
6.5.1 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 cross-
section as defined by required length of cable, etc.
● Requirements according to IEC/EN 60204‑1
Electrical connection
6.5 Connecting the auxiliary circuits
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Operating Instructions 11/2018 73
6.5.2 Introducing cables into the auxiliary terminal box and routing them
The required data for connecting the auxiliary circuits is located on the terminal diagram on
the inside of the respective auxiliary terminal or terminal box cover.
● In some cases a terminal strip is installed in the main terminal box for the auxiliary circuit
connections.
● The required stripped length on conductors for auxiliary terminals differs according to
terminal type (6 to 9 mm). When the length is correct, the conductor should reach the stop
in the terminal and at the same time the conductor insulation should reach the contact part
of the terminal.
Adapting the cable glands
A plate is bolted to the terminal box enclosure via a rectangular cutout through which the
connecting cables enter. The plate is generally delivered with threaded holes and cable glands.
1. Open the auxiliary terminal box and undo the cable entry plate screws. Depending on the
terminal box version, the cable entry plate is below a steel screening plate.
2. For the undrilled version, 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 cable 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.
6.5.3 Connecting temperature monitoring for the stator winding
The stator winding is monitored for thermal loading by temperature sensors embedded in the
stator winding.
Electrical connection
6.5 Connecting the auxiliary circuits
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74 Operating Instructions 11/2018
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”.
6.5.4 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.
Electrical connection
6.5 Connecting the auxiliary circuits
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Operating Instructions 11/2018 75
6.5.5 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 119)" for the tightening torque of
the fixing bolts for the cover.
6.6 Converter operation
WARNING
Dangerous voltage via the converter
As long as the feeding converter is switched on, or the DC link of the converter is not
discharged, there can be a voltage at the motor terminals even when the rotor is not moving.
The voltage is up to 1000 V, depending on the converter type.
Ensure that the five safety rules (Page 13) are followed before working on the motor.
Electrical connection
6.6 Converter operation
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76 Operating Instructions 11/2018
6.6.1 Operation on a converter with a low pulse frequency
NOTICE
Increased motor temperature
If the pulse frequency is less than the rated pulse frequency, then increased motor losses
occur. This results in a higher motor temperature.
● Reduce the power to prevent exceeding the temperature class and to avoid consequential
premature thermal aging of the insulation.
● Contact the Service Center if necessary.
6.6.2 Converter operation on a grounded network
NOTICE
Damage resulting from protective conductor currents
When the machine is operated on a converter with current limiter, but without ground-fault
monitoring, protective conductor currents of up to 1.7 times the external conductor current
can arise if there is a ground fault on the output side. Neither the PE conductors of normally
rated multi-core connecting cables nor the PE connecting points of normal terminal boxes
are suitable for this purpose. Material damage can result.
● Use an appropriately sized PE conductor.
● Connect the PE conductor to the grounding terminal on the motor enclosure.
Electrical connection
6.6 Converter operation
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Operating Instructions 11/2018 77
Electrical connection
6.6 Converter operation
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78 Operating Instructions 11/2018
Start-up 7
7.1 Safety instructions for 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 117) if you require commissioning support.
Danger to life as a result of the converter voltage
As long as the feeding converter is switched on, or the DC link of the converter is not
discharged, there can be a voltage at the motor terminals even when the rotor is not moving.
Depending on the converter type, the voltage is up to 1000 V. When coming into contact, this
can result in death, serious injury, and material damage.
● Maintain the five safety rules (Page 13)at all times when operating the machine.
Danger to life as a result of voltage at the motor terminals when the rotor is rotating
There is always a magnetic flux in the motor due to the permanent magnets in the rotor. With
each rotation of the rotor, a voltage occurs at the motor terminals. As a result of this, there is
also a voltage at the converter output terminals via the connecting cable. Contact with them
can cause death, serious injury or material damage.
● When working on the drive system, you must prevent any rotational movement of the motor
shaft.
Damage caused by the short-circuit current
When the permanent magnet rotor is a driven, a voltage ("rotor voltage") is induced in the
stator winding, that can be measured at the motor terminals. If a cable or converter short-circuit
simultaneously occurs, then a short-circuit current is driven by the induced rotor voltage. This
can result in material damage.
● Use cables that are short-circuit proof.
● Alternatively, use a circuit breaker close to the motor to protect the cable against a short
circuit.
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Operating Instructions 11/2018 79
7.2 Checks to be carried out prior to commissioning
The following list of checks to be performed prior to commissioning does not claim to be
complete. It may be necessary to perform further checks and tests in accordance with the
specific situation on-site.
Once the system has been correctly installed, you should check the following prior to
commissioning:
● The machine is undamaged.
● The machine has been properly installed and aligned.
● The output transmission elements are set correctly for their type,
e.g. alignment and balancing of couplings, belt forces in the case of a belt drive, tooth forces
and tooth-flank backlash in the case of geared output, radial and axial clearance in the case
of coupled shafts.
● 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, for example the coupling, move freely.
● All touch protection measures for moving and live parts have been taken.
● Screwed-in lifting eyes are removed after installation or secured to prevent them from
becoming loose.
● For test operation or when commissioning without output element, carefully secure the
feather key using a suitable security element. When doing this, take into account the
balancing type of the motor.
Second shaft extension
If the second shaft extension is not used:
● Carefully secure the feather key to prevent it from being thrown out, and for balancing type
"H" (standard type), ensure its weight is reduced to approximately 60 % of the original value.
● Using covers, carefully secure the unused shaft extension so that it cannot be touched.
Electrical connection
● Carefully check the grounding and potential bonding connections.
● Connect the machine corresponding to the specified direction of rotation.
● Using the appropriate open-loop control and speed monitoring functions, carefully ensure
that no higher speeds can be achieved than are permitted and specified in the technical
data. For this purpose, compare the data on the rating plate or, if necessary, the system-
specific documentation.
● Comply with the minimum insulation resistances.
● Comply with the minimum air clearances.
● Correctly connect possibly available machine monitoring devices and equipment - and
carefully ensure that they are functioning correctly.
Start-up
7.2 Checks to be carried out prior to commissioning
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80 Operating Instructions 11/2018
● Check the correct functioning of the brakes or backstops.
● Set the values for "Alarm" and "Shutdown" at the monitoring devices.
● Carefully ensure that temperature-sensitive parts and components, e.g. cables are not in
contact with the machine enclosure.
See also
Set values for temperature monitoring of the bearing thermometer (Page 85)
Setting values for temperature monitoring (slot thermometer) (Page 85)
Converter operation
● If the motor design requires connection to a specific converter type, carefully check the
supplementary data on the rating plate/supplementary plate.
● Ensure that the converter is correctly parameterized. Depending on the design, you will
find some parameterization data on the rating plate of the machine. Further information is
provided in the converter documentation. If necessary, contact the Service Center.
● Check that the supplementary equipment and devices to monitor the machine are correctly
connected and are functioning correctly.
● In continuous operation, carefully ensure that the motor cannot exceed the specified upper
speed limit nmax or fall below the lower speed limit nmin.
The permissible acceleration time to the limit speed nmin depends on the parameter
assignment.
● The bearing insulation should be implemented as shown on the plates.
● If the machine can be driven by the mechanical system, then protect the converter DC link
voltage against overvoltage conditions: Limit the field-weakening operation to 120%.
The machine will be destroyed if it is directly connected to the line supply. Only operate the
machine using a converter.
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.
7.3 Greasing the roller bearings prior to commissioning
The following information assumes that the specified storage conditions have been complied
with.
Start-up
7.3 Greasing the roller bearings prior to commissioning
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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.
Contact the Service Center.
See also
Transport (Page 32)
Service and Support (Page 117)
7.4 Setting the converter pulse frequency
● At the converter, set a minimum pulse frequency of 2.5 kHz in operation. This means that
the guaranteed machine parameters can be maintained.
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.
Start-up
7.4 Setting the converter pulse frequency
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3. If it runs perfectly, connect a load.
NOTICE
Thermal overload of motors connected directly to the line supply
In addition to the load torque, the ramp-up (accelerating) time is essentially influenced by
the moment of inertia to be accelerated. While ramping up when connected to the line
supply, the inrush (starting) current is a multiple of the rated current. This can result in
thermal overload. This can damage the motor.
As a consequence, when ramping up, observe the following:
● Monitor the ramp-up time and number of consecutive starts.
● Comply with the limit values and/or ramp-up conditions specified in the catalog or the
order documentation.
4. During the test run, check and document the following:
– Check whether it is running smoothly.
– Document the voltage, current and power values. As far as possible, document the
corresponding values of the driven machine.
– If this is possible using the available measuring equipment, check the bearing and stator
winding temperatures until they have reached steady-state values.
– Check the machine for noise or vibrations on the bearings or bearing shields as it runs.
5. In case of uneven running or abnormal noise, switch off the machine. As the machine runs
down, identify the cause.
– If the mechanical operation improves immediately after the machine is switched off, then
the cause is magnetic or electrical.
– If the mechanical running does not improve immediately after switching the machine off,
then the cause is mechanical.
- Imbalance of the electrical machine or the driven machine
- The machine set has not been adequately aligned
- The machine is being operated at the system resonance point. System = motor, base
frame, foundation, ...
NOTICE
Serious damage to the machine
If the vibration values in operation are not maintained in accordance with DIN ISO 10816-3,
then the machine can be mechanically destroyed.
● During operation, observe the vibration values in accordance with DIN ISO 10816‑3.
Start-up
7.5 Test run
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7.6 Measure the insulation resistance and polarization index for the
commissioning
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 47)
7.7 Switching on the machine
● After starting the motor, observe it for a while to see if it is running smoothly and check the
monitoring devices.
● Monitor operation and the monitoring devices regularly and record the values you read off.
NOTICE
Motor damage caused by impermissible speeds
The motor is designed for a certain speed range. If a motor is operated at impermissible
speeds damage to the winding, bearings, or complete destruction of the motor can be the
result.
● Ensure that the speeds specified on the rating plate are not exceeded by appropriately
configuring controller and speed monitoring components.
See also
Description (Page 21)
Start-up
7.6 Measure the insulation resistance and polarization index for the commissioning
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84 Operating Instructions 11/2018
7.8 Set values for temperature monitoring of the bearing thermometer
Before the first machine run, set the tripping temperatures of the monitoring system.
Table 7-1 Guidelines for setting the tripping temperature of bearing thermometers
Set value Temperature
Prior to commissioning For shutdown T0 = 110 °C
During operation For warning T1 = T + 5 K (max. 115 °C)
For shutdown T2 = T + 10 K (max. 120 °C)
T = temperature in steady state (°C)
7.9 Setting values for temperature monitoring (slot thermometer)
Before the first machine run, set the tripping temperatures of the monitoring system.
The tripping temperatures of winding thermometers differ depending on the temperature class
of the machine. The temperature class can be found on the rating plate.
Table 7-2 Guidelines for setting the tripping temperature of winding thermometers
Set value Temperature class F/B Temperature class F/F
Prior to commis‐
sioning
for shutdown T0 = 120°C T0 = 140°C
During operation for warning T1 = T + 10 K (max. 135°C) T1 = T + 10 K (max. 150℃)
for shutdown T2 = T + 15 K (max. 140°C) T2 = T + 15 K (max. 155℃)
T = temperature in steady state (°C)
7.10 Switching off the machine
● Do not switch off the water-cooling system immediately after switching off the machine.
Wait for the machine to cool. This will prevent the accumulation of residual heat.
7.11 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.
Start-up
7.8 Set values for temperature monitoring of the bearing thermometer
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Start-up
7.11 Avoidance of condensation or formation of condensation within the machine
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Operation 8
8.1 Safety instructions for operation
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 13)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110‑1 regarding safe operation of electrical equipment.
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer guaranteed
if covers are removed. Touching rotating parts can result in death, serious injury or material
damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● Only remove the covers when the rotating parts have come to a complete standstill.
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum air and creepage distances may be fallen
below (violated) when coming close to active parts. Touching or coming close can result in
death, serious injury or material damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and in a no-voltage
condition.
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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 system-
specific safety conditions.
Damage caused by condensation
Humidity in the air can condense for intermittent duty or load fluctuations. Condensate can
collect. Moisture can have a negative impact on the winding insulation or result in damage,
such as corrosion.
● Ensure that any condensation can freely flow away.
Risk of burn injuries as a result of hot surfaces
Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
● Never touch machine parts during operation.
● Allow the machine to cool down before starting work.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Danger to life as a result of voltage at the motor terminals when the rotor is rotating
There is always a magnetic flux in the motor due to the permanent magnets in the rotor. With
each rotation of the rotor, a voltage occurs at the motor terminals. As a result of this, there is
also a voltage at the converter output terminals via the connecting cable. Contact with them
can cause death, serious injury or material damage.
● When working on the drive system, you must prevent any rotational movement of the motor
shaft.
Operation
8.1 Safety instructions for operation
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Damage caused by the short-circuit current
When the permanent magnet rotor is a driven, a voltage ("rotor voltage") is induced in the
stator winding, that can be measured at the motor terminals. If a cable or converter short-circuit
simultaneously occurs, then a short-circuit current is driven by the induced rotor voltage. This
can result in material damage.
● Use cables that are short-circuit proof.
● Alternatively, use a circuit breaker close to the motor to protect the cable against a short
circuit.
Damage due to overheating
If the cooling water supply fails or if the motor is operated for a short time without water cooling,
the motor will overheat. This can result in material damage, or even destroy the machine
completely.
● Never operate the motor without the cooling water supply switched on.
● Monitor the permissible water intake temperatures.
Risk of burns from hot steam
If the cooling water supply fails, the motor will overheat. If cooling water enters the hot machine,
hot steam will suddenly be generated, which escapes under high pressure. The cooling water
system can burst. This can result in death, serious injury or material damage.
● Do not connect the cooling water supply until the machine has cooled down.
8.2 Switching on the machine
1. If at all possible, run the machine without load and check that it is running smoothly.
2. If it runs perfectly, connect a load.
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.
3. If this is possible using the available measuring equipment, check the bearing and stator
winding temperatures.
Operation
8.2 Switching on the machine
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Excessively high machine temperature when heating is switched on
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine. Material damage can result.
● Make sure that the anti-condensation heating is switched off before the machine is switched
on.
● Only operate anti-condensation heating when the machine is switched off.
8.3 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.
8.3.1 Prolonged outage periods
If the machine is out of operation for longer than one month, start up the machine regularly,
that is, approximately once a month. Alternatively, as a minimum, turn the rotor.
If the machine is to be taken out of operation for more than 12 months, suitable anti-corrosion,
preservation, packaging, and drying measures must be taken.
See also
Protecting cooling water ducts (Page 36)
Operation
8.3 Stoppages
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8.3.2 Avoidance of frost and corrosion damage in the cooling system
● For avoidance of frost and corrosion damage, completely drain the water from the cooling
system. Then blow air through the cooling system to dry it.
If the cooling system 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
Impairment of the heat transport
Additives such as anti-freeze and corrosive inhibitor can impair the heat transport.
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 anti-
condensation heating should also remain switched on (if fitted).
8.3.3 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.
● Do not switch on the anti-condensation heating for at least two hours after the motor has
been switched off. This prevents damage to the winding insulation.
8.3.4 Avoidance of damage to roller bearings during stoppages
Extended stoppages at the identical or almost identical resting position of the roller bearings
can lead to damage such as brinelling or corrosion, for example.
● During stoppages, regularly start the machine up for a brief period once a month. As a
minimum, rotate 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 the machine
up.
Make sure that the resting position of the roller bearings after the rotor has been turned
over is different from what it previously had been. Use the fitted key or the coupling halves
as reference markers.
● During re-commissioning, refer to the information in the "Commissioning" section.
See also
Start-up (Page 79)
Operation
8.3 Stoppages
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8.3.5 Measuring the insulation resistance after an extended non-operational period
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 47)
8.4 Switching off the machine
● Do not switch off the water-cooling system immediately after switching off the machine.
Wait for the machine to cool. This will prevent the accumulation of residual heat.
See also
Avoidance of condensation or formation of condensation within the machine (Page 91)
8.5 Switching on again after an emergency switching-off
● Check the machine before recommissioning the driven machine after an Emergency Off.
● Eliminate all the causes that have led to the emergency off
8.6 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.
Operation
8.4 Switching off the machine
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Record the decommissioning steps. This log will be useful upon recommissioning.
8.7 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
Start-up (Page 79)
8.8 Faults
8.8.1 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.
8.8.2 Electrical faults water-cooled machines
Note
When operating the machine with a converter, also refer to the operating instructions of the
frequency converter if electrical faults occur.
Operation
8.7 Re-commissioning the machine
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Table 8-1 Electrical faults
↓ Motor fails to start
↓ Motor accelerates sluggishly
↓ Humming noise when starting
↓ Humming noise in operation
↓ High temperature rise during no-load operation
↓ High temperature rise under load
↓ High temperature rise of individual winding sections
Possible causes of faults Remedial measures
X X Rotor (partially) demagnetized Contact the Service Center.
X X X X Overload Reduce the load.
X Interruption of a phase in the feeder
cable
Check the frequency converters and feeder cables.
X X X X Interrupted phase in the feeder ca‐
ble after switching on
Check the frequency converters and feeder cables.
X X X X Winding short circuit or inter-phase
short circuit in stator winding
Determine the winding resistances and insulation re‐
sistances. Contact the Service Center.
X Converter output voltage too high,
frequency too low
Check the settings at the frequency converter and
perform the automatic motor identification.
X X Cooling water not connected
Cooling water supply switched off
Water connection / pipes defective
Check the cooling water connection. Switch on the
cooling water supply.
Find the leak and seal it. Contact the Service Center.
X X Cooling water flow rate too low
Inlet temperature too high
Increase the cooling water flow.
Set the correct upstream temperature.
8.8.3 Mechanical faults
Table 8-2 Mechanical faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults Remedial measures
X Rotating parts are grinding Establish the cause and realign the parts.
X Rotor not balanced Contact the Service Center.
X Rotor out of true, shaft bent Contact the Service Center.
X X Poor alignment Align the machine set and check the coupling. 1)
X Coupled machine not balanced Rebalance the coupled machine.
X Shocks from coupled machine Examine the coupled machine.
X X Resonance with the foundation Stabilize the foundation after prior discussion.
X X Changes in foundation Determine the cause of the changes and, if necessa‐
ry, rectify. Realign the machine.
1) Take into account possible changes which may occur during overheating.
Operation
8.8 Faults
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8.8.4 Rolling-contact bearing faults
Damage to roller bearings can be difficult to detect in some cases. If in doubt, replace the roller
bearing. Contact the Service Center.
Table 8-3 Roller bearing faults
↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
Possible causes of fault Remedial measures
X High coupling pressure Align the machine more accurately.
X Ambient temperature higher than 40 °C Use high-temperature grease.
X X Insufficient lubrication Grease the bearings as instructed.
X Too much grease in bearing Remove surplus grease. Contact the Service Center, if necessary.
X Wrong grease in the bearing Use the correct grease.
X Belt tension too high * Reduce the drive belt tension.
X Bearing contaminated
Contact the Service Center.
X X Bearing canted
X X Insufficient bearing play
X X Bearing corroded
X Friction marks on raceway
X Brinelling or scoring
X Excessive bearing play
X Mechanical wear of bearing elements
* Only in special version
See also
Service and Support (Page 117)
Operation
8.8 Faults
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8.8.5 Water cooling faults
The following table shows the possible causes of and remedial measures for faults on water-
cooled machines.
Table 8-4 Cooling system faults
↓ Overheating
↓ Water leaking
Possible causes of faults Remedial measures
X Reduced cooling ● Check the cooling water flow, increase the amount of cooling water
if necessary.
● Clean the cooling system, e.g. by briefly increasing the cooling
water flow rate or by adding suitable cleaning agents.
X Cooling water flow rate too low Consult the manufacturer. If the specified cooling water quality is ob‐
served, the cooling system is maintenance-free.
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 too many or unsuit‐
able antifreeze and corrosion-protection
agents
Use cooling water of the agreed quality.
X Leaks in the cooling system Consult the manufacturer.
X Defective cooling water connection Find the leak and seal it.
Operation
8.8 Faults
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Maintenance 9
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
Please contact the service center (Page 117), if you require support with service, maintenance
or repair.
9.1 Inspection and maintenance
9.1.1 Safety instructions for inspection and maintenance
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.
● Take the machine out of operation.
● Switch off the machine and ensure that it is in a no-voltage condition. Carefully comply with
the "5 safety rules" (Page 13).
● Only open the terminal box when the motor is stationary 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.
● Before carrying out any repair work on the machine, take it out of operation, and carefully
lock it out so that it cannot be switched on again.
● Only remove the covers when the rotating parts have come to a complete standstill.
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Risk of burn injuries due to hot surfaces
In operation, the temperature of individual machine parts can increase - and only decrease
slowly after switching off. You can burn yourself if you touch hot surfaces.
● Allow the machine to cool before starting any maintenance and service work on the machine.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Damage if the machine is not maintained
The machine can be damaged if it is not appropriately maintained. This can cause faults which
can result in eventual or immediate death, serious injury or material damage.
● Maintain the machine at the specified maintenance intervals.
Damage from foreign bodies in the machine
Foreign bodies such as dirt, tools or loose components 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
motor.
● Ensure that no foreign bodies are left in or on the motor.
● Securely attach all loose parts once you have completed the work.
● Carefully remove any dirt.
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.
Immediately perform an inspection after such faults.
Maintenance
9.1 Inspection and maintenance
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9.1.3 First service after installation or repair
● Check after approx. 500 operating hours, but after not more than one year:
Check When the
motor is
running
At stand‐
still
The electrical parameters are maintained. X
The permissible bearing temperatures are not exceeded (Page 85). X
The smooth running characteristics and machine running noise have not
deteriorated.
X
The foundation has no cracks or indentations. (*) X X
(*) You can perform these checks while the motor is at standstill or, if required, while running.
● Further checks may be required if so specified in operating instructions of components 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.
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.
Maintenance
9.1 Inspection and maintenance
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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
At stand‐
still
The electrical parameters are maintained X
The permissible bearing temperatures are not exceeded (Page 85) X
The smooth running characteristics and machine running noise have not
deteriorated
X
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
X
All the potential connections, grounding connections and shield supports
are correctly seated and properly bonded
X
The winding insulation resistances are sufficiently high (Page 47) 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
X
Condensation can freely flow away. X
(*) This check can be made at standstill or when running.
● If you detect any deviations during the inspection, you must rectify them immediately. They
may otherwise cause damage to the machine.
9.1.5 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:
Maintenance
9.1 Inspection and maintenance
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"Testing the insulation resistance and polarization index" (Page 47)
9.1.6 Servicing and maintaining the anti-condensation heating
The anti-condensation heating is maintenance-free. If it is defective, then contact the
Service Center (Page 117).
9.1.7 Roller bearing
Inspecting roller bearings
WARNING
Hazard due to magnetic fields
Do not disassemble the bearing. Do not remove the rotor. If it becomes necessary to remove
the rotor with permanent magnets or change a bearing at the machine site, please contact a
Siemens Service Center (Page 117).
NOTICE
Different intervals for regreasing and inspection
The required relubrication intervals for roller bearings are not the same as the servicing
intervals. It is essential to adhere to them. The bearings may be damaged if the relubrication
intervals are not adhered to.
Note
Lubrication data
Information on regreasing (e.g. grease type, grease quantity and relubrication intervals) is
given on the lubrication plate on the machine.
9.1.8 Regreasing intervals and types of grease for operating rolling bearings
Grease types
"Lubcon Thermogrease DSV 2 EP" grease is used for initial lubrication of the bearings. The
amount of grease for the initial lubrication is 25% to 35% of the free bearing volume.
"Shell Gadus S3 V220C" grease is suitable and has been tested.
Maintenance
9.1 Inspection and maintenance
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Operating Instructions 11/2018 101
These greases have lithium soap as the thickening agent and mineral oil as the base oil. They
exceed the standard requirements of DIN 51825 in several important respects and are,
therefore, compatible with the specified relubrication intervals.
Note
Damage due to mixing grease types
Mixing greases and oils which are based on different types of soap or oil can degrade their
lubrication properties. Mixing low-temperature grease with normal temperature grease can
cause lumps to form in the lubricant. The consequence can be damage to the roller bearings
due to overheating.
Never mix greases that have different thickening agents and different base oils.
Regreasing
The regreasing intervals are specified on the lubricant plate of the machine. If the specified
number of operating hours is not reached within three years, regrease the bearings at the main
inspection.
If you use other KP2N greases, some of which only meet the minimum requirements per DIN
51825, halve the regreasing intervals.
1. Clean the lubricating nipple and press in suitable grease. The shaft should rotate so that
the new grease can be distributed throughout the bearing. The bearing temperature rises
sharply at first, then drops to the normal value again after the excess grease has been
displaced out of the bearing.
The used grease collects outside the bearing.
After several regreasing operations, remove the spent grease depending on the specified
relubrication intervals. To do this, loosen the outer bearing cover.
9.1.9 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 117) before you repair any damage to paint. They will provide
you with more information about the correct paint system and methods of repairing paint
damage.
Maintenance
9.1 Inspection and maintenance
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9.1.10 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.
● 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.
9.2 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.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110‑1 regarding safe operation of electrical equipment.
WARNING
Strong magnetic field when the machine is open
A strong magnetic field is always present inside the machine. If the housing is open, e.g.
when maintenance openings are open or when working inside the machine, magnetic objects
can be suddenly attracted by this magnetic field. This can result in death, severe injury or
material damage.
● Repairs are only permissible within the scope of the work described in these operating
instructions.
● For repairs that go beyond this scope, please contact the Service Center.
Maintenance
9.2 Corrective Maintenance
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Operating Instructions 11/2018 103
See also
Service and Support (Page 117)
If the motor has to be transported, please observe the information and instructions in the
chapter "Transport (Page 32)".
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.
See also
Service and Support (Page 117)
9.2.2 Anti-condensation heating
The anti-condensation heater is mounted directly on the winding. The anti-condensation heater
cannot be removed without causing damage to the winding. A new anti-condensation heater
may only be installed by Siemens Service Center (Page 117) specialists.
9.2.3 Changing the bearings
We recommend that the roller bearings are replaced after approx. 60,000 operating hours,
however, at the latest after 10 years.
NOTICE
Rotor removal or bearing change
Improper handling can lead to irreparable damage to the motor.
If it is necessary to remove the rotor or change the bearings, then under all circumstances
please contact the Service Center (Page 117).
Maintenance
9.2 Corrective Maintenance
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9.2.4 Replacing the speed encoder
ཱཱིི
①Touch protection ③Speed encoder
②Torque arm ④Shaft journal
Figure 9-1 Detailed view of the speed encoder
To remove the speed encoder, proceed as follows:
1. Unscrew the speed encoder cover.
2. Detach the electrical connection.
– Carefully withdraw the cable out of its holder.
– Withdraw the connector.
Maintenance
9.2 Corrective Maintenance
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Operating Instructions 11/2018 105
3. Remove the torque arm of the speed encoder.
4. Withdraw the speed encoder from the shaft using a pressure screw. The procedure
depends on the mounted speed encoder.
Speed encoder "Heidenhain EQN 425"
– Remove screw M5x50.
– Screw in a grub screw (M5x50) and a screw (M6x70) one after the other. This releases
the speed encoder from the shaft journal taper.
– Remove the speed encoder.
Speed encoder "Hübner-Berlin HOG10, HOG11 andHMG111"
– Remove screw M6x25.
– Screw in the screw M8x60. This releases the speed encoder hollow shaft from the shaft
journal.
– Remove the speed encoder.
Figure 9-2 Replacing a speed encoder
Maintenance
9.2 Corrective Maintenance
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106 Operating Instructions 11/2018
Mounting the speed encoder
1. Removing the coupling at the DE.
2. Screw a suitable lever into the tapped hole on the face of the shaft extension. You can use
the centering hole at the end of the shaft for this purpose.
3. Rotate the rotor using the lever. The required torque is approximately 200 Nm.
Measure the radial runout of the shaft journal. The radial runout must be less than 0.1 mm
when the rotor turns.
4. If the height of the shaft journal is more than 0.1 mm, dismantle the contact guard with the
outer bearing cover. Adjust the shaft journal using the three grub screws in such a way that
the height of the shaft journal is less than 0.1 mm when rotating the rotor. Install the outer
bearing cover with contact guard.
5. Mount the new speed encoder.
6. Mount the torque arm of the speed encoder.
7. Insert the connector into the socket.
8. Press the cable into the holder provided for it.
9. Screw on the speed encoder cover. Take care that you do not catch the cable as you screw
it in.
Note
Identifying the position of the rotor
After replacing the speed encoder, perform a rotor position identification routine (automatic
encoder adjustment) using the converter Motor Module.
Maintenance
9.2 Corrective Maintenance
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Maintenance
9.2 Corrective Maintenance
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108 Operating Instructions 11/2018
Spare parts 10
10.1 Ordering data
In addition to the exact part designation, please specify the machine type and serial number
in all orders for spare parts. Ensure that the spare part designation matches that on the spare
parts list and make sure you use the appropriate part number as well.
Example
● Bearing shield, drive end (Part 5.00)
● Machine type
● Serial number
The machine type and serial number can be found on the rating plate. The serial number is
also stamped on the end face of the shaft extension at the drive end.
Note
The graphical representations in this chapter show schematic diagrams of the basic versions.
They are used for spare parts definitions. The supplied version may differ in details from these
representations.
10.2 Ordering spare parts via the Internet
You can use "Spares on Web" to determine the order numbers for motor
spare parts quickly and easily.
.
See also
Spares on Web (https://www.sow.siemens.com/)
Guide for Spares on Web (http://support.automation.siemens.com/WW/news/en/25248626)
You can use commercially available, standard components, but ensure that they have the
same construction type, dimensions, strength class etc.
SIMOTICS HT Series HT-direct 1FW4...1......A
Operating Instructions 11/2018 109
NOTICE
Rotor removal or bearing change
Improper handling can lead to irreparable damage to the motor.
If it is necessary to remove the rotor or change the bearings, then under all circumstances
please contact the Service Center (Page 117).
Rolling bearings
When ordering rolling bearings, in addition to the bearing identification code, the
supplementary specifying code is also necessary for the bearing version. Both of these codes
are stamped on the lubricant plate and specified in the motor documentation, or can also be
taken from the installed bearings.
Always replace the rolling bearings with the identical bearings.
If insulated rolling bearings are fitted, use insulated rolling bearings of the same type as spare
parts. This will prevent any bearing damage being caused by bearing currents.
10.3 Anti-condensation heating
The anti-condensation heater is mounted directly on the winding. The anti-condensation heater
cannot be removed without causing damage to the winding. A new anti-condensation heater
may only be installed by Siemens Service Center (Page 117) specialists.
Spare parts
10.3 Anti-condensation heating
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110 Operating Instructions 11/2018
Disposal 11
11.1 Introduction
Protecting the environment and preserving its resources are corporate goals of the highest
priority for us. Our worldwide environmental management system to ISO 14001 ensures
compliance with legislation and sets high standards in this regard. Environmentally friendly
design, technical safety and health protection are always firm goals even at the product
development stage.
Recommendations for the environmentally friendly disposal of the machine and its components
are given in the following section. Be sure to comply with local disposal regulations.
Country-specific legislation
The machine uses materials that can be recovered or recycled. Correctly separating materials
helps to simply recycle important materials.
● When disposing of the machine or of waste that is created during the individual phases of
its life cycle, please observe the statutory requirements applicable in the country of use.
● Please contact your local authorities for more information about disposal.
11.2 RoHS - restricting the use of certain hazardous substances
In compliance with RoHS ("Restriction of certain Hazardous Substances" ) we replace
substances that are damaging to the environment by those that are not based on state-of-the-
art technology. In doing so, safety in operation and handling will take priority at all times.
11.3 Information according to Article 33 of the REACH regulation
This product contains one or several subproducts in which the following substance – belonging
to the "list of candidates" – exists in a concentration exceeding 0.1 percent by weight.
● CAS No. 7439-92-1, lead
Based on the currently available information, we assume that this substance does not
represent any risk when correctly used, including its disposal.
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11.4 Preparing for disassembly
Disassembly of the machine must be carried out and/or supervised by qualified personnel with
appropriate expert knowledge.
1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in
terms of the quality of dismantling the machine and provision of the components.
2. Follow the five safety rules (Page 13).
3. Disconnect all electrical connections and remove all cables.
4. Remove all liquids such as oil and cooling liquids. Collect the liquids separately and dispose
of them in a professional manner.
5. Detach the machine fixings.
6. Transport the machine to a suitable location for disassembly.
11.5 Working on machines with permanent magnets
On machines with permanent magnets, the magnetic field is guided in an assembled state in
the magnetic circuit of the machine. This means that no magnetic fields, which may be to your
health, are detectable outside the machine.
WARNING
Strong magnetic field when the machine is open
A strong magnetic field is always present inside the machine. If the housing is open, e.g.
when maintenance openings are open or when working inside the machine, magnetic objects
can be suddenly attracted by this magnetic field. This can result in death, serious injury or
material damage.
● Working in the vicinity of the rotor is only permitted in exceptional circumstances.
Unambiguous access rules must be established in accordance with the magnetic fields
prevailing in the workplace. Clearly mark the boundaries of the areas where standing is
permitted.
● People who need to use electronic or magnetic medical aids such as pacemakers, hearing
aids, implants or similar devices, are at particularly high risk. Such persons must undergo
an industrial medicine assessment.
● Observe the following measures.
Disposal
11.4 Preparing for disassembly
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112 Operating Instructions 11/2018
Personal protective measures
● Ensure that you never wear or carry any of the following objects and that they are kept a
safe distance from the machine:
– All kinds of magnetic metal parts such as, keys, glasses, tools, knives, scissors, tape
measures, etc.
– Magnetic jewelry such as rings, chains, needles, watches, etc.
– Electronic devices and data carriers such as service cards, check cards, credit cards,
calculators, cell phones, etc.
– Wallets or other iron-containing objects
– Electrically conductive foreign bodies
● Do not use any magnetic tools or lifting devices.
● Wear only occupational safety items without magnetic metal parts, e.g. occupational safety
shoes with non-magnetic protective caps and soles.
● Keep your shoes and clothing free from chips and waste containing iron.
● Exercise caution when installing accessories. Ensure that no parts fall into the inside of the
machine.
● Do not perform any cutting at the machine, e.g. manufacturing threaded holes. Any
exceptions require written approval from the manufacturer.
11.6 Disposing of permanent magnets
If the entire motor is melted down, no special action is required for the permanent magnets.
Remove all cables before the melting process.
Demagnetizing the motor
If the motor is disassembled and dismantled, the permanent magnets must be demagnetized.
To do this, the motor is heated up to 350 °C so that during and after disposal, the rotors do
not represent any danger. The disposal must be carried out by an authorized waste disposal
company.
Note
Removing the permanent magnet rotor
Injury and material damage can occur if the permanent magnet rotor is incorrectly removed.
Only authorized workshops and waste disposal companies are permitted to remove the rotor.
Disposal
11.6 Disposing of permanent magnets
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Demagnetizing the rotors
Waste disposal companies that are authorized to demagnetize rotors use a specially designed
disposal furnace. The insides of the disposal furnace consist of non-magnetic material. The
rotors are put in the furnace in a solid, heat-resistant container made of non-magnetic material
and left in the furnace during the entire demagnetization procedure. Demagnetization is
achieved by heating the rotor in the furnace until the permanent magnets have reached a
temperature of 350 °C.
NOTICE
Emissions
Exhaust gas that is released must be collected and rendered harmless without damaging the
environment.
Note
Authorized waste disposal companies
Information regarding authorized waste disposal companies and workshops can be obtained
from the Siemens Service Center (Page 117).
11.7 Disposal of components
Components
The machines consist mainly of steel and various proportions of copper and aluminum. Metals
are generally considered to be unlimitedly recyclable.
Sort the components for recycling according to whether they are:
● Iron and steel
● Aluminum
● Non-ferrous metal, e.g. windings
The winding insulation is incinerated during copper recycling.
● Insulating materials
● Cables and wires
● Electronic waste
Process materials and chemicals
Sort the process materials and chemicals for recycling according to whether they are for
example:
● Oil
● Grease
● Cleaning substances and solvents
Disposal
11.7 Disposal of components
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114 Operating Instructions 11/2018
● Paint residues
● Anti-corrosion agent
● Coolant additives such as inhibitors, antifreeze or biocides
Dispose of the separated components according to local regulations or via a specialist disposal
company. The same applies for cloths and cleaning substances which have been used while
working on the machine.
Packaging material
● If necessary, contact a suitable specialist disposal company.
● Wooden packaging for sea transport consists of impregnated wood. Observe the local
regulations.
● The foil used for water-proof packaging is an aluminum composite foil. It can be recycled
thermally. Dirty foil must be disposed of via waste incineration.
Disposal
11.7 Disposal of components
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Disposal
11.7 Disposal of components
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116 Operating Instructions 11/2018
Service and Support A
Technical questions or additional information
If you have any technical questions or require additional information, please
contact www.siemens.com/yourcontact (www.siemens.com/yourcontact).
Please have the following data ready:
● Type
● Serial number
You can find this data on the rating plate.
Contact person
If you wish to request on-site service or order spare parts, please contact
your local office. This office will contact the responsible service center on
your behalf. You can find your contact person in the relevant contact data‐
base:
Technical Support (https://support.industry.siemens.com/cs/ww/en/sc/
2090)
Siemens Support for on the move
With the "Siemens Industry Online Support" App, you can access more than
300,000 documents for Siemens Industry products – any time and any‐
where. The App supports you in the following areas:
● Resolving problems when executing a project
● Troubleshooting when faults develop
● Expanding a system or planning a new system
Further, you have access to the Technical Forum and other articles that our
experts have drawn-up:
● FAQs
● Application examples
● Manuals
● Certificates
● Product announcements and many more
The app is available for Apple iOS, Android and Windows Phone.
SIMOTICS HT Series HT-direct 1FW4...1......A
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Service and Support
SIMOTICS HT Series HT-direct 1FW4...1......A
118 Operating Instructions 11/2018
Technical data B
B.1 Tightening torques for screw and bolt connections
Bolt locking devices
● Refit nuts or bolts that are mounted together with locking, resilient, and/or force-distributing
elements with identical, fully-functional elements when re-assembling. Always renew keyed
elements.
● When screwing together threads secured with a liquid adhesive, use a suitable medium
such as Loctite 243.
● Always use suitable securing devices or removable adhesives (e.g., Loctite 243) when
installing fixing bolts with a clamping length of less than 25 mm. The clamping length is
taken as the distance between the head of the bolt and the point at which the bolt is screwed
in.
Tightening torques
The bolted connections with metal contact surfaces, such as end shields, bearing cartridge
parts, terminal box parts bolted onto the stator frame, should be tightened to the following
torques, depending on the thread size:
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%.
Case M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48 M56
A1.2 2.5 4 8 13 20 40 52 80 150 - - - - Nm
B1.3 2.6 4.5 11 22 38 92 180 310 620 1080 1700 2600 4200 Nm
C3 5 8 20 40 70 170 340 600 1200 2000 3100 4700 7500 Nm
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Applications
The above-mentioned tightening torques apply for the following applications:
● Case A
Applies to electrical connections in which the permissible torque is normally limited by the
bolt materials and/or the current carrying capacity of the insulators, with the exception of
the busbar connections in case B.
● Case B
Applies to bolts screwed into components made from materials with lower property class
(e. g. aluminum) and to bolts with property class 8.8 according to ISO 898-1.
● Case C
Applies to bolts with property class 8.8, A4-70 or A4-80 according to ISO 898-1, however
only to bolts screwed into components made from materials with higher property class, e.g.
cast iron, steel or cast steel.
Note
Non-standard tightening torques
Different tightening torques for electrical connections and bolted connections for parts with
flat seals or insulating parts are specified in the relevant sections and drawings.
Technical data
B.1 Tightening torques for screw and bolt connections
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120 Operating Instructions 11/2018
Quality documents
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122 Operating Instructions 11/2018
Index
"
"Siemens Industry Online Support" App, 117
5
5 safety rules, 13
A
Additive, 30
Aligning, 56, 59
Accuracy, 59
Prerequisites, 50
Aluminum conductors, 71
Ambient temperature, 28
Anti-condensation heating, 31, 85, 90, 91, 101
installation, 104, 110
Insulation resistance, 49
Anti-corrosion protection, 30, 66
Anti-freeze protection, 91
Area of application, 21
Auxiliary circuits, 73
Auxiliary terminal box, 73
close, 76
Axial force, 60
Axial gap, 58
B
Bearing currents, 41
Bearing damages, 61
Bearing insulation, 42, 61, 81
Bearing seizure damage, 38
Bolt locking device, 119
C
Cable entry plate, 69
Cable lug, 66
Center of gravity, 37, 55
Centering flange, 59
Circuit diagram, 68
Claims, 33
Common-mode filters, 42
Compressor, 30
Condensation, 28
Connecting cables
Selection of, 65, 73
Connecting terminals, 73
Connection cables, 57
Converter, 24, 81
Converter documentation, 42
Coolant inlet temperature, 28
Coolant supply, 28
Coolant temperature sensing, 30
Cooling circuit, 28
Cooling power, 24
Cooling system
Faults, 96
Cooling unit, 30
Cooling volumetric flow, 29
Cooling water
Connection, 60
Cooling water ducts, 36
Protect, 36
Cooling water inlet temperature, 23
Cooling water quality, 29
Cooling water quantity, 23
Cooling water specification, 27
Cooling water supply, 60, 81
Cooling-medium reservoir, 30
Correct usage, 22
Corrosion, 36
Corrosion protection, 36, 91
Removing, 52
D
Damage during transportation, 33
Damping cores, 42
DC link of the converter, 81
De-energizing
Anti-condensation heating, 91
Degree of protection, 23
Increased, 25
Delivery, 33
Demagnetization
Rotor, 114
Derating factors, 29
Direct drive, 21
Direction of rotation, 65
Disassembly
Disposal, 112
Machine, 104
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Disposal
Chemicals, 114
Components, 114
E
Electromagnetic fields, 18
EMC-shielded clips, 42
Emergency off, 92
Emitted interference, 18
Environmental requirements, 23
Equipotential bonding, 72, 75
Equipotential bonding connection, 75
ESD guidelines, 17
F
Faults
Cooling system, 96
Electrical, 94
Inspection, 93, 98
Mechanical, 94
Roller bearings, 95
Faults in operation, 88
Filling, 60
Filter, 30, 60
Fixing, 63
Flammable substances, 15
Flange connection, 50
Flexible coupling, 52
Flow quantity display, 30
Flow regulating valve, 30
Foreign bodies in the cooling circuit, 36
Frost danger, 36
Full-shaft rotor, 21
G
General inspection, 100
Geometry of the flange, 50
Grounding clamp, 66
Grounding conductor
Cross section, 66
Grounding system, 42
H
Hazardous substances, 15
Hearing damage, 15, 31
High-frequency grounding, 41, 67
Hot surfaces, 15
I
Increased degree of protection, 25
Induced eddy currents, 71
Induced voltage, 23
Insert cable, 69
Inspection
Faults, 93, 98
Installation
Initial inspection, 99
Installing, 57
Insulated bearings, 42
Insulation resistance, 46, 84, 92, 100
Anti-condensation heating, 49
measure, 47
Interference immunity, 18
Interference voltages, 18
Interlocking circuit
Anti-condensation heating, 31
L
Lifting, 37, 55
Live parts, 14
Long-term storage, 40
Low-Voltage Directive, 13
M
Machine
Aligning to the driven machine, 57
Mounting, 57
setting down, 56
Machine design, 22
IEC, 22
Machine expansion, 59
Machine type, 109
Magnetic fields, 16, 104, 110, 112
Magnetic losses, 28
Minimum air clearances, 72
More information, 117
Motor type, 23
Motor weight, 23
Mounting the speed encoder, 107
Mounting-foot hole dimensions, 50
Index
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124 Operating Instructions 11/2018
N
Neutral point, 68
Noise emissions, 15, 31
O
On-site service, 117
Operating mode, 23, 27
Operating speed, 23
Order number, 23
Output element, 53
Overspeed, 27
P
Paint system, 102
Paintwork damage, 102
Permanent magnet, 16, 112, 113
Permanent-magnet synchronous motor, 21
Polarization index, 46, 49, 84, 92, 100
Positioning, 58
potential difference, 42
Power density, 28
Precision alignment, 58
Preload
Rotor bracing, 35
Preparations for assembly, 46
Property class, 57
Protective conductor, 77
Protective grounding conductor, 41
Pulse frequency, 82
Pump, 30
Q
Qualified personnel, 14
R
Radial force, 60
Rated current, 23
Rated frequency, 23
Rated speed, 23
Rated torque, 23
Rated voltage, 23
Rating plate, 22
REACH regulation, 111
Re-commissioning, 93
Regreasing intervals, 102
Removing the speed encoder, 105
Repair
Initial inspection, 99
Residual risks, 27
Restriction of certain Hazardous Substances, 111
RF equipotential bonding cable, 42
RF grounding point, 42
Risk of explosion, 21
RoHS, 111
Roller bearings
Faults, 95
Regreasing, 82
Rolling bearings
Replacement, 110
Rotating parts, 14
Rotor, 113
Demagnetizing, 114
Rotor shipping brace, 24, 34, 51
Remove, 51
S
Safety instructions
Flammable substances, 15
Hazardous substances, 15
Hot surfaces, 15
Live parts, 14
Rotating parts, 14
Screw-in depth, 66
Sea water, 29
Sealing grease, 25
Selection of bolts, 57
Serial number, 11, 23, 109
Shaft assembly, 32
Siemens Industry Online Support
App, 117
Spare parts, 117
Spare parts ordering, 109
Spares on Web, 109
Speed, 31
Standard flange, 59
Stator winding
Temperature monitoring, 74
Stoppages, 90, 91
Roller bearings, 91
Storage, 39
Storage location, 39
Strap, 66
Supplementary devices, 24
Surface of the foundations, 50
Index
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Switching off
Anti-condensation heating, 85
Switching on, 82, 89
Synchronous motor, 21
System resonances, 32
T
Technical Support, 117
Temperature class, 23
Temperature monitoring
Stator winding, 74
Terminal box, 66
Closing, 73
Maintaining, 103
Terminal designation, 64
Terminal diagram, 74
Test pressure, 60
Test run, 82
Thermal motor protection, 31
Tightening torques, 63, 66
Bolted connection, 119
Torsional loadings, 32
Transporting, 37, 55
Turning the machine on to its side, 52
Type, 23
Type of balancing, 53
V
Vibration values, 32, 83
Voltage via the converter, 76
W
Wall face, 50
Wall mounting, 50
Water cooling
Switching off, 85, 92
Water drip loop, 64
Water pressure, 23, 29
Water-cooling, 28
Index
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126 Operating Instructions 11/2018
Further Information
www.siemens.com/drives
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
