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SIMOTICS XP
Low-voltage motors
1LA5/6/7/9, 1LG4/6, 1MA6/7,
1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions
For use in Zone 1 (IEC/EN/GOST 60079-10-1)
For use in Zone 2 (IEC/EN/GOST 60079
-10-1)
For use in Zone 21 (IEC/EN/GOST 60079
-10-2)
For use in Zone 22 (I
EC/EN/GOST 60079-10-2)
12/2018
A5E44455710A
Introduction
1
Safety information
2
Description
3
Preparing for use
4
Assembly
5
Electrical connection
6
Commissioning
7
Operation
8
Maintenance
9
Spare parts
10
Disposal
11
Service and support
A
Technical data
B
Quality documents
C
Document order number: A5E44455710A
Ⓟ
11/2018 Subject to change
Copyright © Siemens AG 2018.
All rights reserved
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.
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Operating Instructions, 12/2018, A5E44455710A 3
Table of contents
1 Introduction ............................................................................................................................................. 9
1.1 About these instructions............................................................................................................ 9
1.2 Compiling personal documents ................................................................................................ 9
2 Safety information ................................................................................................................................. 11
2.1 Information for those responsible for the plant or system ....................................................... 11
2.2 The 5 safety rules ................................................................................................................... 11
2.3 Qualified personnel ................................................................................................................. 12
2.4 Safe handling .......................................................................................................................... 12
2.5 Use in hazardous areas .......................................................................................................... 14
2.6 Electrostatic sensitive devices ................................................................................................ 15
2.7 Electromagnetic compatibility ................................................................................................. 16
2.8 Interference immunity ............................................................................................................. 16
2.9 Influence on the line power supply through a strongly irregular torque .................................. 17
2.10 Interference voltages when operating the converter .............................................................. 17
2.11 Special designs and construction versions ............................................................................. 17
2.12 Special conditions for explosion-proof machines ................................................................... 17
3 Description ............................................................................................................................................ 19
3.1 Area of application .................................................................................................................. 19
3.2 Rating plates ........................................................................................................................... 21
3.3 Installation ............................................................................................................................... 22
3.3.1 Regulations ............................................................................................................................. 23
3.3.2 Cooling and ventilation............................................................................................................ 24
3.3.2.1 Machines with a fan ................................................................................................................ 24
3.3.2.2 Machines without a fan (optional) ........................................................................................... 24
3.3.3 Bearings .................................................................................................................................. 24
3.3.4 Balancing ................................................................................................................................ 25
3.3.5 Types of construction/method of installation .......................................................................... 25
3.3.6 Degree of protection ............................................................................................................... 27
3.3.7 Environmental conditions ........................................................................................................ 27
3.3.8 Optional built-on and built-in accessories ............................................................................... 28
3.3.9 Class ....................................................................................................................................... 29
3.3.9.1 Zone 1, type of protection increased safety Ex "e" or "eb" ..................................................... 29
3.3.9.2 Zone 2, type of protection increased safety Ex "ec" or Non sparking "nA" ............................ 30
3.3.9.3 Zone 21 with type of protection Ex tb IIIC Db (equipment dust explosion protection
provided by the enclosure "t") ................................................................................................. 31
3.3.9.4 Zone 22 with type of protection Ex tc IIIB Dc (equipment dust explosion protection
provided by the enclosure "t") ................................................................................................. 32
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4 Operating Instructions, 12/2018, A5E44455710A
3.3.10 Terminal box .......................................................................................................................... 32
3.3.11 Paint finish .............................................................................................................................. 33
4 Preparing for use .................................................................................................................................. 35
4.1 Safety-related aspects to consider when configuring the plant ............................................. 35
4.2 Observing the operating mode ............................................................................................... 35
4.3 Machines without final paint coating ...................................................................................... 35
4.4 Delivery .................................................................................................................................. 36
4.5 Transport and storage ............................................................................................................ 36
4.5.1 Storage ................................................................................................................................... 38
4.5.2 Securing the rotor................................................................................................................... 40
4.5.3 Commissioning after storage ................................................................................................. 42
4.5.3.1 Insulation resistance and polarization index .......................................................................... 42
4.5.3.2 Lubricating the rolling bearings .............................................................................................. 42
4.5.3.3 Regreasing rolling bearings after storage periods of up to two years ................................... 42
4.5.3.4 Releasing the rotor shipping brace before commissioning .................................................... 42
4.6 Ensure adequate cooling ....................................................................................................... 43
4.7 Thermal protection ................................................................................................................. 44
4.8 Interlock circuit for anti-condensation heating ....................................................................... 45
4.9 Noise emission ....................................................................................................................... 46
4.10 Voltage and frequency fluctuations during line operation ...................................................... 46
4.11 Rotational speed limit values ................................................................................................. 47
4.12 System-inherent frequencies ................................................................................................. 47
4.13 Electromagnetic compatibility ................................................................................................ 47
4.14 Converter operation ............................................................................................................... 48
4.14.1 Parameterizing the converter ................................................................................................. 48
4.14.2 Converter input voltage .......................................................................................................... 49
4.14.3 Reducing bearing currents for converter operation ............................................................... 49
4.14.4 Insulated bearings when operated with a converter .............................................................. 51
4.14.5 Tandem operation .................................................................................................................. 52
4.14.6 Speed limits for converter operation ...................................................................................... 52
5 Assembly .............................................................................................................................................. 53
5.1 Preparing for installation ........................................................................................................ 53
5.1.1 Requirements for installation ................................................................................................. 53
5.1.2 Insulation resistance .............................................................................................................. 54
5.1.2.1 Insulation resistance and polarization index .......................................................................... 54
5.1.2.2 Testing the insulation resistance and polarization index ....................................................... 55
5.2 Mounting and installed the machine ...................................................................................... 57
5.2.1 Preparing the assembly area ................................................................................................. 57
5.2.2 Balancing ............................................................................................................................... 58
5.2.2.1 Mounting and withdrawing output transmission elements ..................................................... 59
5.2.3 Machines with type of construction IM B15, IM B9, IM V8 and IM V9 ................................... 60
5.2.4 Foot mounting ........................................................................................................................ 61
5.3 Alignment and fastening ........................................................................................................ 61
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Operating Instructions, 12/2018, A5E44455710A 5
5.3.1 Repainting/touching up the paint finish of explosion-protected machines.............................. 62
5.3.2 Measures for alignment and mounting ................................................................................... 62
5.3.3 Flatness of the supporting surfaces for conventional motors ................................................. 63
5.3.4 Machine frame mounting feet (special design) ....................................................................... 63
5.4 Installing the machine ............................................................................................................. 63
5.4.1 Preconditions for smooth, vibration-free operation ................................................................. 63
5.4.2 Aligning the machine to the driven machine and mounting .................................................... 64
5.4.2.1 Selecting bolts ......................................................................................................................... 64
5.4.2.2 Horizontal types of construction with mounting feet ............................................................... 64
5.4.2.3 Horizontal types of construction with flange ........................................................................... 64
5.4.2.4 Vertical types of construction with flange................................................................................ 65
5.4.3 Removing the rotor shipping brace ......................................................................................... 66
5.4.4 Recommended alignment accuracy ....................................................................................... 66
5.4.5 Mounting the output elements ................................................................................................ 67
5.4.6 Axial and radial forces............................................................................................................. 68
6 Electrical connection ............................................................................................................................. 69
6.1 Connecting the machine ......................................................................................................... 70
6.1.1 Selecting cables ...................................................................................................................... 70
6.1.2 Terminal box ........................................................................................................................... 72
6.1.2.1 Terminal marking .................................................................................................................... 72
6.1.2.2 Circuit diagram inside the terminal box cover ......................................................................... 73
6.1.2.3 Direction of rotation ................................................................................................................. 73
6.1.2.4 Knockout openings ................................................................................................................. 73
6.1.2.5 Cable entry .............................................................................................................................. 74
6.1.2.6 Protruding connection cables ................................................................................................. 75
6.1.2.7 Connecting protruding cables ................................................................................................. 75
6.1.2.8 Connection with/without cable lugs ......................................................................................... 76
6.1.2.9 Thread sizes in the terminal box ............................................................................................. 76
6.1.2.10 Minimum air clearances .......................................................................................................... 77
6.1.2.11 Internal equipotential bonding ................................................................................................. 77
6.1.3 Cable glands ........................................................................................................................... 77
6.1.3.1 Mounting position of sheet metal nuts in screw-type connections ......................................... 78
6.2 Tightening torques .................................................................................................................. 79
6.2.1 Cable entries, sealing plugs and thread adapters .................................................................. 79
6.3 Connecting the grounding conductor ...................................................................................... 79
6.3.1 Minimum surface area of grounding conductor ...................................................................... 79
6.3.2 Grounding connection type ..................................................................................................... 80
6.4 Connecting the temperature sensor/anti-condensation heater .............................................. 81
6.4.1 Connecting optional integrated devices and equipment ......................................................... 81
6.5 Conductor connection ............................................................................................................. 82
6.5.1 1MB.. ....................................................................................................................................... 83
6.5.2 Cable ends with wire end sleeves .......................................................................................... 85
6.5.3 Connecting aluminum conductors .......................................................................................... 85
6.6 Connecting the converter ........................................................................................................ 86
6.7 Final checks ............................................................................................................................ 88
7 Commissioning ..................................................................................................................................... 89
7.1 Measures before commissioning ............................................................................................ 89
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6 Operating Instructions, 12/2018, A5E44455710A
7.1.1 Insulation resistance and polarization index .......................................................................... 91
7.1.2 Testing the insulation resistance and polarization index ....................................................... 92
7.1.3 Testing the cooling of the machine ........................................................................................ 94
7.1.4 Commissioning an external fan .............................................................................................. 94
7.1.5 Further documents ................................................................................................................. 95
7.2 Setpoint values for monitoring the bearing temperature ........................................................ 96
7.3 Switching on ........................................................................................................................... 96
7.3.1 Test run .................................................................................................................................. 97
8 Operation .............................................................................................................................................. 99
8.1 Safety instructions for operation ............................................................................................ 99
8.1.1 Static charging when cleaning ............................................................................................. 104
8.1.2 Safety instructions relating to ventilation and cooling .......................................................... 104
8.1.3 Bridging insulated bearings .................................................................................................. 105
8.1.4 Switching on with the anti-condensation heating active ...................................................... 105
8.2 Switching on the machine .................................................................................................... 106
8.3 Switching off the external fan ............................................................................................... 106
8.4 Switching on again after an emergency switching-off.......................................................... 106
8.5 Stoppages ............................................................................................................................ 106
8.5.1 Avoidance of damage to rolling bearings during stoppages ................................................ 108
8.5.2 Decommissioning the machine ............................................................................................ 108
8.5.3 Re-commissioning the machine ........................................................................................... 108
8.6 faults ..................................................................................................................................... 109
8.6.1 Inspections in the event of faults.......................................................................................... 109
8.6.2 Electrical faults ..................................................................................................................... 109
8.6.3 Mechanical faults ................................................................................................................. 110
8.6.4 Rolling bearing faults ........................................................................................................... 111
8.6.5 Faults at the external fan ..................................................................................................... 111
8.7 Deactivating ......................................................................................................................... 111
9 Maintenance ........................................................................................................................................ 113
9.1 Preparation and notes .......................................................................................................... 113
9.1.1 North American market (optional) ........................................................................................ 113
9.1.2 Customs union Eurasia (optional) ........................................................................................ 114
9.2 Inspection and maintenance ................................................................................................ 114
9.2.1 Safety instructions for inspection and maintenance ............................................................ 114
9.2.2 Explosion hazard due to increased surface temperature .................................................... 115
9.2.3 Static charging when cleaning ............................................................................................. 116
9.2.4 Inspections in the event of faults.......................................................................................... 116
9.2.5 First inspection ..................................................................................................................... 117
9.2.6 General inspection ............................................................................................................... 117
9.2.7 Assessing the rolling bearings ............................................................................................. 118
9.2.8 Mechanical explosion protection for rolling bearings ........................................................... 118
9.2.9 Maintenance intervals .......................................................................................................... 119
9.2.10 Re-greasing .......................................................................................................................... 120
9.2.11 Cleaning ............................................................................................................................... 120
9.2.12 Risk of explosion due to damaged seals ............................................................................. 121
9.2.13 Drain condensate ................................................................................................................. 122
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Operating Instructions, 12/2018, A5E44455710A 7
9.2.14 Insulation resistance and polarization index ......................................................................... 122
9.2.15 Maintaining the external fan (forced ventilation) ................................................................... 123
9.2.16 Repainting ............................................................................................................................. 124
9.2.16.1 Touch up any damaged paintwork ........................................................................................ 124
9.3 Corrective maintenance ........................................................................................................ 125
9.3.1 Extended motor marking ....................................................................................................... 125
9.3.2 Anti-condensation heating .................................................................................................... 127
9.3.3 Sealing measures ................................................................................................................. 128
9.3.4 Rolling bearings .................................................................................................................... 128
9.3.4.1 Replacing bearings in explosion-proof machines ................................................................. 129
9.3.4.2 Bearing bushes ..................................................................................................................... 130
9.3.4.3 Fitting bearings ..................................................................................................................... 130
9.3.4.4 Explosion hazard due to overheating of the roller bearings ................................................. 132
9.3.5 Mounting dimension "x" ........................................................................................................ 132
9.3.6 Fan ........................................................................................................................................ 133
9.3.6.1 Metal fan disassembly .......................................................................................................... 133
9.3.6.2 Mounting fans ....................................................................................................................... 133
9.3.7 Cable entries, sealing plugs and thread adapters ................................................................ 134
9.3.8 Terminal boxes, end shields, grounding conductors, sheet metal fan covers ...................... 134
9.3.9 Terminal board and grounding .............................................................................................. 134
9.3.10 Screw lock washers .............................................................................................................. 134
9.3.11 Links ...................................................................................................................................... 135
9.3.12 Reassembly: Miscellaneous information .............................................................................. 135
9.3.13 Optional add-on units ............................................................................................................ 135
9.3.14 O-ring seal ............................................................................................................................ 135
10 Spare parts ......................................................................................................................................... 137
10.1 Parts order ............................................................................................................................ 137
10.2 Data matrix code on the machine ......................................................................................... 137
10.3 Ordering data ........................................................................................................................ 137
10.4 Purchasing commercially available spare parts ................................................................... 138
10.5 Ordering spare parts via the Internet .................................................................................... 138
10.6 Replacing rolling bearings .................................................................................................... 138
10.7 Roller bearings ...................................................................................................................... 139
10.8 Anti-condensation heating .................................................................................................... 139
10.9 Parts groups definition .......................................................................................................... 139
10.10 Ordering example ................................................................................................................. 140
10.11 Machine parts ....................................................................................................................... 141
10.11.1 Part lists ................................................................................................................................ 141
10.12 Standardized parts ................................................................................................................ 143
10.13 Exploded drawings ................................................................................................................ 144
10.13.1 1LA,1MA shaft heights 63 ... 90L, 1MB shaft heights 63 ... 71 ............................................ 144
10.13.2 1LA,1MA shaft heights 100 ... 160 ........................................................................................ 145
10.13.3 1LA5180 ... 225 ..................................................................................................................... 146
10.13.4 1MA6180 ... 200 .................................................................................................................... 147
10.13.5 Terminal boxes 1MA6180 ... 200 .......................................................................................... 148
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8 Operating Instructions, 12/2018, A5E44455710A
10.13.6 1MB1 SH80 ... 160 aluminum .............................................................................................. 149
10.13.7 1MB1 shaft heights 71 ... 90 cast iron.................................................................................. 150
10.13.8 1MB1 shaft heights 100 ... 200 cast iron ............................................................................. 151
10.13.9 1MB1 shaft heights 225 ... 315 cast iron ............................................................................. 152
10.13.10 1MB5 shaft height. 315 cast iron ......................................................................................... 153
10.13.11 1MB5 terminal box shaft height 315 cast iron ...................................................................... 154
10.13.12 1MB5 shaft height. 355 cast iron ......................................................................................... 155
10.13.13 1MB5 terminal box shaft height 355 cast iron ...................................................................... 156
10.13.14 1LG4/6 SH180 ... 315 .......................................................................................................... 157
10.13.15 Terminal box gk330, gt320, gk430, gt420 ........................................................................... 158
10.13.16 Terminal box gk431, gt421, gt520, gt540 ............................................................................ 159
10.13.17 Terminal box 1LG4/6, 1MB1, gt620, gt640, gt791 ............................................................... 160
11 Disposal ............................................................................................................................................... 161
11.1 Introduction .......................................................................................................................... 161
11.2 Country-specific legislation - LV machines .......................................................................... 161
11.3 RoHS - restricting the use of certain hazardous substances ............................................... 161
11.4 Information according to Article 33 of the REACH regulation .............................................. 162
11.5 Preparing for disassembly ................................................................................................... 162
11.6 Dismantling the machine ...................................................................................................... 162
11.7 Disposal of components ....................................................................................................... 163
A Service and support ............................................................................................................................. 165
A.1 Siemens Industry Online Support ........................................................................................ 165
A.2 Further documents ............................................................................................................... 166
B Technical data ..................................................................................................................................... 167
B.1 Tightening torques ............................................................................................................... 167
B.1.1 Tightening torques for screw and bolt connections ............................................................. 167
B.1.2 Stud-type bushings .............................................................................................................. 168
B.1.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers ..................... 168
B.1.3.1 Terminal board and grounding ............................................................................................. 168
B.1.4 Additional connecting terminals for monitoring equipment and anti-condensation
heating ................................................................................................................................. 168
C Quality documents ............................................................................................................................... 169
C.1 Quality documents SIMOTICS in SIOS ............................................................................... 169
Index ................................................................................................................................................... 171
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Operating Instructions, 12/2018, A5E44455710A 9
Introduction
1
1.1 About these instructions
These instructions describe the machine and explain how to handle it, from initial delivery to
final disposal of the equipment. Keep these instructions for later use.
Read these operating instructions before you handle the machine and follow the instructions
to become familiar with its design and operating principles and thus ensure safe, problem-
free machine operation and long service life.
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 165) 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.
1.2 Compiling personal documents
On the Internet pages in Industry Online Support you have the possibility of compiling
personal documents using the function Documentation
(https://support.industry.siemens.com/My/ww/en/documentation)
Using the "Documentation" function, from Product Support manuals, you can compile your
own "Documentation". However, you can also include other Product Support content such as
FAQs or characteristics in the documentation that you compile.
In the "Documentation" function, you have the option of creating your own compiled
documents in your own structure and managing them. You can delete or shift individual
chapters or topics. Further, using the note function you can import your own content. The
compiled "documentation" can be exported as PDF, for example.
Introduction
1.2 Compiling personal documents
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10 Operating Instructions, 12/2018, A5E44455710A
Using the "Documentation" function, you can efficiently compile your own plant or system
documentation. The "Documentation" compiled in a specific language can also be
automatically exported in one of the other available languages.
The full functionality is only available for registered users.
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Operating Instructions, 12/2018, A5E44455710A 11
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 165) for
planning, installation, commissioning and service work.
This machine has been designed, built and tested in accordance with Directive 2014/34/EU
("Explosion Protection Directive") and is intended for use in industrial plants with a potentially
explosive atmosphere. Commissioning the machine in hazardous zones is absolutely
prohibited until conformance with these guidelines has been proven based on the
appropriate certificate.
Only commission the machine if it has been absolutely confirmed that the plant or system is
in full conformance with the valid directive.
Please observe the country-specific regulations when using the machine outside the
European Community.
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.
Safety information
2.3 Qualified personnel
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12 Operating Instructions, 12/2018, A5E44455710A
5 safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.
2.3 Qualified personnel
All work at the machine must be carried out by qualified personnel only. For the purpose of
this documentation, qualified personnel is taken to mean people who fulfill the following
requirements:
● Through appropriate training and experience, they are able to recognize and avoid risks
and potential dangers in their particular field of activity.
● They have been instructed to carry out work on the machine by the appropriate person
responsible.
2.4 Safe handling
Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
● General safety regulations applicable in the country where the machine is deployed.
● Manufacturer-specific and application-specific regulations
● Special agreements made with the operator
● Separate safety instructions supplied with the machine
● Safety symbols and instructions on the machine and its packaging
Safety information
2.4 Safe handling
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Operating Instructions, 12/2018, A5E44455710A 13
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum clearance and creepage distances may be
violated when coming close to live parts. Touching or coming close to them can result in
death, serious injury or material damage.
● Ensure that all live parts are suitably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer
guaranteed if covers are removed. Touching rotating parts can result in death, serious injury
or material damage.
● Ensure that all rotating parts are reliably covered.
● Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
● Only remove covers when the rotating parts have come to a complete standstill.
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
Inspection and maintenance (Page 114)
Safety information
2.5 Use in hazardous areas
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14 Operating Instructions, 12/2018, A5E44455710A
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
Prevention of hearing damage
If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
Observe the permissible sound pressure level in accordance with ISO 1680. The maximum
permissible sound pressure level is 70 dB (A).
Electrical power equipment generate electromagnetic fields during operation. Potentially
lethal malfunctions can occur in medical implants, e.g. pacemakers, in the vicinity of
electrical power equipment. Data may be lost on magnetic or electronic data carriers.
● Protect the personnel working in the plant by taking appropriate measures, such as
erecting identifying markings, safety barriers and warning signs and giving safety talks.
● Observe the nationally applicable health and safety regulations.
● It is forbidden for people with pacemakers to be close to the machine.
● Do not carry any magnetic or electronic data media.
2.5 Use in hazardous areas
Electrical systems in hazardous zones must be assembled, installed, and operated by the
applicable responsible persons in accordance with the applicable rules and regulations.
Note
The basic requirements relating to
electrical systems and their operation in hazardous areas
are described, for instance, in EU Directive 1999/92/EC as well as in IEC
/ EN 60079-14.
Safety information
2.6 Electrostatic sensitive devices
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Ignition hazards
The assessment of operating risks and local operating conditions and the necessary
monitoring methods must be clarified and made binding by the system operator in
consultation with the responsible supervisory authority. The required measures must be
adhered to at all times. The machine manufacturer cannot provide any generally applicable
recommendations. Please observe the information in these operating instructions.
Note
The basic requirements relating to the assessment of ignition hazards arising from
electrical
equipment and their operation in hazardous zones are specified in the 2014/34/EU and
1999/92/EC directives as well as in the IEC/EN
60079 series of standards.
If a third-party certification is available for the machine, then carefully comply with the
technical data defined in it and any special conditions.
The certificate must be available before commissioning.
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
2.7 Electromagnetic compatibility
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16 Operating Instructions, 12/2018, A5E44455710A
The necessary ESD protective measures for electrostatic sensitive devices are illustrated
once again in the following drawings:
a = conductive floor sur-
face
b = ESD table
c = ESD shoes
d = ESD overall
e = ESD wristband
f = cabinet ground connection
Risk of explosion due to electrostatic discharge
Electrostatic discharge poses a potential ignition source. Dangerous electrostatic charges
can occur, for example as a result of mechanical friction, flowing air that contains particles -
or persons that are not appropriately grounded, e.g. when carrying out maintenance or
cleaning work.
In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious
injury or material damage.
● Avoid carrying out work specified above on non-metallic parts, e.g. foam rubber for noise
dampeners/attenuators.
● Please comply with ESD protective measures.
2.7 Electromagnetic compatibility
Electromagnetic compatibility
This machine is designed in accordance with IEC/EN 60034, and when used as prescribed it
satisfies the requirements of European Directive 2014/30/EU on Electromagnetic
Compatibility.
2.8 Interference immunity
By selecting suitable signal cables and evaluation units, ensure that the interference
immunity of the machine is not diminished.
Safety information
2.9 Influence on the line power supply through a strongly irregular torque
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2.9 Influence on the line power supply through a strongly irregular
torque
A strongly irregular torque, for example with the drive of a reciprocating motor, forces a non-
sinusoidal motor current. The emerging harmonics can have an impermissible influence on
the line power supply via the connection lines.
2.10 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.
2.11 Special designs and construction versions
Note
Before carry out any work on the machine, determine the machine version.
If there are any deviations or uncertainty, contact the manufacturer, specifying the type
designation and serial number (see the rating plate), or contact the
Service Center
(Page
165).
2.12 Special conditions for explosion-proof machines
Special conditions for the safe use of explosion-protected machines with X marking (excerpt
from EC or EU prototype test certificate, Point 17).
Zone 21 - DMT 01 ATEX E 014X
It is not permissible that the motors are operated with excessively thick deposits of dust.
When mounting motors with the free shaft extension facing upwards, foreign bodies must be
prevented from falling into ventilation openings by taking the appropriate measures.
For motors with permanently attached connecting cable. The free cable ends must be
connected corresponding to the valid installation regulations.
Safety information
2.12 Special conditions for explosion-proof machines
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If the three-phase motor is cooled using a external fan, then it must be carefully ensured that
the motor can only be operated with the cooling switched on.
When commissioning, it must be carefully ensured that when fed from a converter, no
inadmissibly high overvoltages occur at the motor terminals. The clearances and creepage
distances in the terminal box do not permit overvoltages as a result of converter operation
with a periodic peak value of more than:
- 1500 V for rated voltages ≤ 500 V.
The motor insulation system may mean that it is necessary to further limit periodically
occurring overvoltages.
Zone 1 - PTB 03 ATEX 3107X, PTB 02 ATEX 3060X, PTB 01 ATEX 3335X, PTB 01 ATEX
3336X, PTB 01 ATEX 3337X, PTB 04 ATEX 3041X
Special conditions relating to the installation:
If the non-terminated cable ends are connected to the external power circuit according to EN
60079-0, Paragraph 14.1 in the hazardous zone, then a terminal box with its own certification
and explosion protection marking must be selected according to the conditions that prevail at
the installation site.
Zone 1 - PTB 02 ATEX 3024X
It is only permissible that these types of motors are operated in conjunction with gas return
pumps at converters of the type specified above with the defined setting values. Further,
they must be monitored using the adapted equipment described in the data sheet. The
maximum cable length between the converter and motor is 4 m.
Zone 1 - PTB 03 ATEX 3053X, PTB 03 ATEX 3054X
It is only permissible that the motors are operated with a converter and filter of the types
specified in the data sheet with the setting values defined there. The motors must also be
monitored corresponding to what is specified in the data sheet.
Zone 2, 22 - BVS 14 ATEX E 081 X, BVS 14 ATEX E 082 X
It is only permissible that the motor is fed from a voltage-source DC link converter with pulse
width modulation, maintaining the parameters listed in Section 15.3.
Before commissioning it must be carefully ensured that when fed from a converter, no
inadmissibly high overvoltages occur at the motor terminals. The clearances and creepage
distances in the terminal box do not permit overvoltages as a result of converter operation
with a periodic peak value of more than 1500 V for rated voltages ≤ 1000 V.
The motor insulation system may mean that it is necessary to further limit periodically
occurring overvoltages.
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Description
3
3.1 Area of application
The rotating electrical motors of this series are used as industrial drives. They are designed
for a wide range of drive applications both for line operation as well as in conjunction with
frequency converters.
They are characterized by their high power density, extreme robustness, long service life
and outstanding reliability.
Intended use of the machines
These machines are intended for industrial installations. They comply with the harmonized
standards of the series EN / IEC 60034 (VDE 0530). It is prohibited to use these motors in
hazardous zones if the marking on the motor rating plate does not explicitly permit line or
converter operation. If other/more wide-ranging demands (e.g. protection so that they cannot
be touched by children) are made in special cases – i.e. use in non-industrial installations –
these conditions must be ensured by the customer.
Note
Machine directive
Low
-voltage motors are components designed for installation in machines in accordance
with the current Machinery Directive. Commissioning is prohibited until it has been absolutely
identified that the end product
is in conformance with this Directive. Please observe the
EN
/ IEC 60204-1 standard.
Use of machines without CE marking
Machines without CE marking are intended for operation outside the European Economic
Area (EEA). Do not use any machines without a CE marking in the EEA!
Use of machines without EAC marking
EAC machines are appropriately marked on the rating plate, and are intended for operation
within the Eurasian customs union.
Within the Eurasian customs union, do not use machines without the appropriate EAC
marking.
Description
3.1 Area of application
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Use in hazardous areas
Explosion-proof electrical machines correspond to standards of the IEC/EN 60034 and
IEC/EN 60079 series. Only operate the machine in hazardous areas, strictly complying with
the specifications of the responsible supervisory authority. The relevant supervisory authority
is responsible for determining the hazard level of each area and classifying the zones. The
type of protection as well as special regulations are stamped on the rating plate or in the test
certificate. If the certificate number is supplemented by an X, to safely operate the machine
observe the special notes in the operating instructions or if available in the EC or EU type-
examination certificate or in the IECEx Certificate of Conformity. Operation with a converter
must be certified. It is essential that you observe the separate manufacturer's information
and instructions.
Explosion hazard from hybrid mixtures
Hybrid mixtures are mixtures of flammable dusts with explosive gas/air atmospheres which
can together create a dangerous explosive atmosphere if they occur at the same time.
Changes can arise in the safety characteristics here, such as a change in the zonal
classification, increase in the explosion pressure, reduction in the minimum ignition energy
and a reduction in the maximum temperatures to be observed.
An explosion can result. This can result in death, serious injury or material damage.
● For this reason, the relative characteristics must be considered both for gas (zones 0, 1
and 2) and for dust (zones 20, 21 and 22) where hybrid mixtures arise. It is necessary for
a competent assessor to determine in the individual case whether the parameters
determining ignition are unfavorably affected in a particular hybrid mixture.
● Motors with dual plates for G (“Gas”) and D (“Dust”) may only be used where these two
occur after prior examination of the properties of the hybrid mixtures by the user.
Type of protection Ex nA or ex ec
This machine has type of protection "non-sparking" Ex nA according to IEC / EN 60079-0
and IEC / EN 60079-15 - or type of protection "Increased safety" Ex ec according to IEC / EN
60079-0 and IEC / EN 60079-7. Only operate the machine in hazardous Zone 2 according to
IEC / EN 60079-10-1.
Type of protection Ex e or Ex eb
This machine has type of protection "Increased safety" Ex e or ex eb according to IEC / EN
60079-0 and IEC / EN 60079-7. Only operate the machine in hazardous Zones 1 and 2
according to IEC / EN 60079-10-1.
Type of protection Ex tb, Ex tc
This machine has optionally (or exclusively) "Protection through enclosure" (Ex t) type of
protection according to IEC / EN 60079-0 and IEC / EN 60079-31. Only operate the machine
in hazardous Zones 21 and 22 in type of protection Ex tb - and only in Zone 22 in type of
protection Ex tc according to IEC / EN 60079-10-2.
Description
3.2 Rating plates
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3.2 Rating plates
Rating plate
The rating plate shows the identification data and the most important technical data. The
data on the rating plate and the contractual agreements define the limits of proper usage.
Data on the rating plate
Item
Description
Item
Description
General data
Electrical data
1 Type of machine 31 Electrical data
2
Machine type
33
Rated voltage V
3
Serial number (incl. date of manufacture YY.MM)
34
Winding connections
4
Standards
35
Frequency Hz
5
Additional details (optional)
36
Rated power kW
6
Customer data (optional)
37
Rated current A
7
Country of origin
38
Power factor cosφ
8
Production location
39
Rated speed rpm
9
Identification number of testing agency (optional)
40
Efficiency class
10
Regulations (optional)
41
Efficiency
49
Company logo
42
Torque Nm (optional)
52
Marine regulation
45
Starting current ratio
53
Motor family type
46
Operating mode (optional)
54
Data for explosion-protected machines
48
Anti-condensation heating (optional)
56
Converter type
51
Converter data
Mechanical data
57
Temperature class
11
Frame size
12
Type of construction
13
Degree of protection
14 Machine weight kg
15
Temperature class
16
Ambient temperature range (optional)
17
Installation altitude (only if higher than 1000 m)
18
Vibration severity grade
19
Bearing sizes
20
Relubrication data/specifications (optional)
24
Feather key arrangement
Description
3.3 Installation
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22 Operating Instructions, 12/2018, A5E44455710A
Line operation (DOL) rating plate
Converter operation (VSD) rating plate
3.3 Installation
Machine design
The regulations and standards used as the basis to design and test this machine are
stamped on the rating plate.
The machine design basically complies with the subsequent standards. Please refer to the
EU Declaration of Conformity for the versions of the harmonized standards referenced.
Description
3.3 Installation
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3.3.1 Regulations
Table 3- 1 Applicable general regulations
Feature
Standard
EAC
GB
Dimensioning and operating behavior
EN / IEC 60034-1
GOST R IEC 60034-1
GB 755
Procedure for determining the losses and the efficiency of
rotating electrical machines and inspections
EN / IEC 60034-2-
1
EN / IEC 60034-2-
2
EN / IEC 60034-2-
3
GOST R IEC 60034-2-1
GOST R IEC 60034-2-2
GOST IEC 60034-2-3
GB/T 1032
Degree of protection
EN / IEC 60034-5
GOST IEC 60034-5
GB/T 4942.1
Cooling
EN / IEC 60034-6
GOST R IEC 60034-6
GB/T 1993
Type of construction
EN / IEC 60034-7
GOST R IEC 60034-7
GB/T 997
Terminal designations and direction of rotation
EN / IEC 60034-8
GOST 26772
GB/T 1971
Noise emission
EN / IEC 60034-9
GOST IEC 60034-9
GB 10069.3
Starting characteristics of rotating electrical machines
EN / IEC 60034-12
GOST R IEC 60034-12
GB/T 21210
Vibration severity grades
EN / IEC 60034-14
GOST IEC 60034-14
GB 10068
Efficiency classification of three-phase squirrel-cage in-
duction motors
EN / IEC 60034-
30-1
GOST IEC 60034-30-1 GB 18613
IEC standard voltages
IEC 60038
GOST R IEC 61800-1
GB/T 156
Table 3- 2 Regulations applied for explosion-protected machines
Feature
Standard
EAC
GB
Electrical equipment for hazardous gas atmospheres, Part
0: General requirements
EN / IEC 60079-0 GOST 30852 0 - 2002 GB 3836.1
Electrical equipment for hazardous gas atmospheres – Part
1: Device protection provided by flameproof enclosure "d"
EN / IEC 60079-1 GOST 30852 1 - 2002 GB 3836.2
Electrical equipment for hazardous gas atmospheres, Part
7: Increased safety "e"
EN / IEC 60079-7 GOST 30852 8 - 2002 GB 3836.3
Electrical equipment for hazardous gas atmospheres, Part
14: Electric installations for endangered atmospheres (ex-
cept underground excavation)
EN / IEC 60079-14 GOST 30852 13 - 2002 GB 3836.15
Electrical equipment for hazardous gas atmospheres, Part
15: Type of protection "n"
EN / IEC 60079-15 GOST 30852 14 - 2002 GB 3836.8
Electrical equipment for use in the presence of combustible
dust - Part 17: Inspection and maintenance of electrical
systems in hazardous areas (except underground excava-
tion)
EN / IEC 60079-17 GOST 30852 16 - 2002 GB 3836.16
Electrical equipment for hazardous gas atmospheres, Part
19: Repairs and overhauls
EN / IEC 60079-19 GOST 30852 18 - 2002 GB 3836.13
Potentially explosive atmosphere - Part 31: Device dust
explosion protection by enclosure "t"
EN / IEC 60079-31 GOST IEC 60079-31 GB 12479.5
Directive on the approximation of the laws of the Member
States concerning equipment and protective systems in-
tended for use in hazardous areas.
Directive
2014/34/EU
TR CU Directive
2014/34/EU
Description
3.3 Installation
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3.3.2 Cooling and ventilation
The machines of this series are three-phase induction machines with a closed primary
(internal) cooling circuit and an open secondary cooling circuit (surface cooling). The surface
cooling varies depending on the version.
3.3.2.1 Machines with a fan
Self-ventilation (standard): Cooling method IC 411 according to EN / IEC 60034-6
Located at the ND end of the stator housing is an air intake cowl that guides the external air
on its way to the motor. The external air is drawn in through openings in the air intake cowl
and flows axially across the outer cooling ribs of the motor frame. The fan wheel for the
external flow of cooling air is attached to the machine shaft.
The fan wheels are bidirectional.
Check the cooling effect below rated speed in the case of frequent switching or braking – or
if the speed is controlled continually below the rated speed.
Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
Cooling that does not depend on the speed is achieved by means of a unit that is
independent of the motor operating state (forced ventilation). This unit is closed to the
outside by a fan cover. It has its own main drive with fan impeller which creates the cooling
air flow required for cooling the motor.
3.3.2.2 Machines without a fan (optional)
Cooling method IC 410
Surface cooling by free convection: Cooling method IC 410 according to EN / IEC 60034-6
Cooling method IC 418
Surface cooling by relative movement of cooling air: Cooling method IC 418 according to
EN / IEC 60034-6
3.3.3 Bearings
In order to support the machine shaft and maintain its position in the non-moving part of the
machine, only 2 rolling bearings are used. One rolling bearing performs the function of a
location bearing that transfers axial and radial forces from the rotating machine shaft to the
non-moving part of the machine. The second rolling bearing is implemented as floating and
support bearing in order to allow thermal expansion inside the machine and transfer radial
forces.
The nominal (calculated) useful life of the bearings according to ISO 281 is at least 20,000
hours with utilization of the permissible radial/axial forces. However, the achievable useful
life of the bearings can be significantly longer in the case of lower forces (e.g. operation with
self-aligning couplings).
Rolling bearings with permanent lubrication are maintenance-free.
Description
3.3 Installation
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The machine is equipped with grease-lubricated rolling bearings.
● In the standard version, the bearings of machines up to shaft height 250 are permanently
lubricated.
● The bearings of machines from shaft height 280 and above are equipped with a
relubrication system.
3.3.4 Balancing
As standard, the motor is balanced dynamically with a half feather key (code "H").
Vibration level "A" is standard and, if ordered as an option, vibration level B is specified on
the rating plate.
See also
Balancing (Page 58)
3.3.5 Types of construction/method of installation
The type of construction of the machine is stated on the rating plate.
Table 3- 3 Type of construction
Basic type of construc-
tion code
Diagram
Other methods of in-
stallation
Diagram
IM B3 (IM 1001)
IM V5 (IM 1011)
IM V6 (IM 1031)
IM B6 (IM 1051)
IM B7 (IM 1061)
IM B8 (IM 1071)
Description
3.3 Installation
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Basic type of construc-
tion code
Diagram
Other methods of in-
stallation
Diagram
IM B5 (IM 3001)
IM V1 (IM 3011)
IM V3 (IM 3031)
Basic type of construc-
tion code
Diagram
Other methods of in-
stallation
Diagram
IM B14 (IM 3601)
IM V18 (IM 3611)
IM V19 (IM 3631)
Basic type of construc-
tion code
Diagram
IM B35 (IM 2001)
IM B34 (IM 2101)
Types of construction/Installation conditions for explosion-proof machines
The type of construction of the machine is stated on the rating plate.
In the case of explosion-proof machines where the shaft extensions point downwards (types
of construction IM V5, IM V1 or IM V18 ) a protective top cover is mandatory. Explosion-
proof machines with IM V5, IM V1 and IM V18 types of construction are fitted with a canopy
at the factory.
Description
3.3 Installation
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Table 3- 4 Construction type with protective top cover
Conditions of installation
Graphics-Based Representation
IM V5 (IM 1011)
IM V1 (IM 3011)
IM V18 (IM 3611)
3.3.6 Degree of protection
The machine has a type of protection as stamped on the rating plate, and can be installed in
dusty or humid environments.
Machines intended for use in Zone 1 (type of protection flameproof enclosure "db" or
increased safety "eb") or in Zone 2 (type of protection "ec") are designed with IP 55 degree
of protection.
Machines intended for use in Zone 1 (increased safety "eb") or in Zone 2 (type of protection
"ec") are designed with an IP 55 degree of protection.
Machines intended for use in Zone 21 (dust explosion protection "tb") have IP 65 degree of
protection. Machines intended for use in Zone 22 (dust explosion protection "tc") have IP 55
degree of protection and can be used in dusty environments such as in grinders, silos,
animal feed plants, and malthouses, as well as in certain areas of the chemical industry.
3.3.7 Environmental conditions
Limit values for the standard version
Relative humidity for ambient temperature
T
amb
40 °C
Max. 55 %
Ambient temperature
-20 °C to +40 °C
Installation altitude
≤ 1000 m
Air with normal oxygen content, usually
21 % (
V
/
V
)
The standard machines are not suitable for use in corrosive atmospheres, atmospheres with
a high salt content, or outdoor applications.
Limit values for the special versions
If the environmental conditions are different from the details listed here, then the values on
the rating plate or in the catalog will apply.
Description
3.3 Installation
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3.3.8 Optional built-on and built-in accessories
Machines can be equipped with the following integrated components/devices:
● Temperature sensors integrated in the stator winding in order to monitor the temperature
and protect the stator winding from overheating.
● Anti-condensation heating for machines whose windings are subject to a risk of
condensation due to the climatic conditions.
Machines can be equipped with the following mounted components/devices:
● Brake
● Rotary pulse encoder
● External fan (forced ventilation)
● Measuring nipple for SPM shock pulse measurement for bearing monitoring
● Backstop
Note
Further documents
Observe all of the other documents provided with this machine.
Supplementary devices
Depending on the order, various supplementary devices can be installed or mounted. These
include sensors for bearing temperature monitoring or winding monitoring, for example.
DANGER
Risk of explosion during operation due to too high surface temperature
This can result in death, serious injury, or material damage.
• Prevent the maximum surface temperature from being exceeded by maintaining the
specified operating conditions.
• Monitor the coil temperature. Use the temperature sensor that is built into the stator
winding for this as specified on the rating plate or extra rating plate.
Description
3.3 Installation
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3.3.9 Class
3.3.9.1 Zone 1, type of protection increased safety Ex "e" or "eb"
0158
II
2
G
Ex
eb
IIC
T3
Gb
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
1
Ex
e
IIC
T3
Gb
X
①
②
③
⑫
⑦
⑧
⑨
⑩
⑪
⑬
①
CE
- or EAC marking
②
Identification number or name of nominated testing agency
③
Code for prevention of explosions
④
Device group: II not for mines susceptible to firedamp, but other hazardous zones
⑤
Device category: 2 for occasional danger
⑥
Atmosphere: G
for gas
⑦
Explosion protection: International
⑧
Explosion protection type "e" or "eb" increased safety
⑨
Explosion group: IIC for acetylene IIB für ethylene
⑩
Temperature class: T3 for maximum surface temperature of 200° C
⑪
Device protection level:
Gb for a high level of protection in hazardous zones with ex-
plosive gas mixtures
⑫
Zone 1
⑬
"X" special conditions
Description
3.3 Installation
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3.3.9.2 Zone 2, type of protection increased safety Ex "ec" or Non sparking "nA"
II
3
G
Ex
ec
IIC
T3
Gc
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
2
Ex
nA
IIC
T3
Gc
X
①
⑪
②
⑫
⑥
⑦
⑧
⑨
⑩
⑬
①
CE
- or EAC marking
②
Code for prevention of explosions
③
Device group: II not for mines susceptible to firedamp, but other hazardous zones
④
Device category: 3 for infrequent, short
-term danger
⑤
Atmosphere: G for gas
⑥
Explosion protection: International
⑦
Type of protection: "ec" increased safety or "nA" for Non Sparking
⑧
Explosion group: IIC for acetylene IIB für ethylene
⑨
Temperature Class: T3 for maximum surface temperature of 200° C
⑩
Device protection level: Gc for an extended level of protection
in hazardous zones with
explosive gas mixtures
⑪
Identification number or name of nominated testing agency
⑫
Zone 2
⑬
"X" special conditions
Description
3.3 Installation
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3.3.9.3 Zone 21 with type of protection Ex tb IIIC Db (equipment dust explosion protection
provided by the enclosure "t")
0158
II
2
D
Ex
tb
IIIC
T125°C
Db
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
Ex
tb
IIIC
T125°C
Db
X
①
②
③
⑦
⑧
⑨
⑩
⑪
⑫
①
CE
- or EAC marking
②
Identification number or name of nominated testing agency
③
Code for prevention of explosions
④
Device group: II not for mines susceptible to firedamp, but other hazardous zones
⑤
Device category: 2 for occasional danger
⑥
Atmosphere: D
for dust
⑦
Explosion protection: International
⑧
Type of protection: "tb" for protection by enclosure
⑨
Explosion group: IIIC for conductive dust
⑩
Maximum surface temperature: T 125°C
⑪
Device protection level: Db for a high level of protection in
flammable dusty atmos-
pheres
⑫
"X" special conditions
Description
3.3 Installation
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32 Operating Instructions, 12/2018, A5E44455710A
3.3.9.4 Zone 22 with type of protection Ex tc IIIB Dc (equipment dust explosion protection
provided by the enclosure "t")
II
3
D
Ex
tc
IIIB
T125°C
Dc
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
Ex
tc
IIIB
T125°C
Dc
X
①
⑪
②
⑥
⑦
⑧
⑨
⑩
⑫
①
CE
- or EAC marking
②
Code for prevention of explosions
③
Device group: II not for mines susceptible to firedamp, but other hazardous zones
④
Device category: 3 for infrequent, short
-term danger
⑤
Atmosphere: D for dust
⑥
Explosion protection: International
⑦
Type of protection: "tc" for protection by enclosure
⑧
Explosion group: IIIB for non
-conductive dust
⑨
Maximum surface temperature: T 125°C
⑩
Device protection level: Dc for an extended protection level in flammable dust atmos-
pheres
⑪
Identification
number or name of nominated testing agency
⑫
"X" special conditions
3.3.10 Terminal box
As an option, additional connecting terminals are available in the terminal box for monitoring
equipment. For larger machines, an additional terminal box can be optionally mounted. You
can see the number of available terminals in the circuit diagrams.
It is possible to turn the top side of a machine terminal box 4 x 90 degrees (if screwed on).
Description
3.3 Installation
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3.3.11 Paint finish
Paint finish
The machine is painted according to the instructions in your order.
Suitability test of the paint system for hazardous areas
Proof is available for the electrostatic suitability with explosion-proof machines for the paint
systems ordered by default. Such evidence is not available for paint systems that are non-
standard or specifically requested by customers. Take into consideration that the provided
evidence is not valid for repaintings.
Description
3.3 Installation
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34 Operating Instructions, 12/2018, A5E44455710A
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Operating Instructions, 12/2018, A5E44455710A 35
Preparing 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 11) and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.
4.2 Observing the operating mode
Observe the machine's operating mode. Use a suitable control system to prevent
overspeeds, thus protecting the machine from damage.
4.3 Machines without final paint coating
For machines, which are only delivered with primer, you must paint them to comply with the
applicable guidelines for the specific application. The primer alone does not provide
adequate corrosion protection.
The paint applied must conform to the requirements to avoid electrostatic charging, see
EN 60079-0.
Please contact the Service Center for recommendations relating to the paint finish.
Preparing for use
4.4 Delivery
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4.4 Delivery
Checking the delivery for completeness
The drive systems are put together on an individual basis. When you take receipt of the
delivery, please check immediately whether the items delivered are in accordance with the
accompanying documents. Siemens will not accept any claims relating to items missing from
the delivery and which are submitted at a later date.
● Report any apparent transport damage to the delivery agent immediately.
● Report any apparent defects/missing components to the appropriate Siemens office
immediately.
● Put the operating instructions included in the scope of supply in a secure place.
The rating plate optionally enclosed as a loose item with the delivery is provided to enable
the motor data to be attached on or near the machine or installation.
4.5 Transport and storage
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
WARNING
Risk of dropping and swinging when transported suspended
If you transport the motor suspended from cables or ropes, the cables or ropes can break,
e.g. as a result of damage. Further, if not adequately attached, the motor can swing. This
can result in death, serious injury, or material damage.
• Use additional, suitable lifting equipment for transport and during installation.
• Two cables alone must be able to carry the complete load.
• Prevent the lifting equipment from sliding by appropriately securing it.
• When using 2-cable lifting equipment, ensure that the maximum angle of inclination is
≤45° according to ISO 3266 (DIN 580).
• Align the eyebolts so that the cables used for lifting are aligned with the planes of the
eyebolts.
Preparing for use
4.5 Transport and storage
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WARNING
Toppling over or slipping of the motor
The motor can slide or topple over if it is not correctly lifted or transported. This can result in
death, serious injury, or material damage.
• Use all the lifting eyes on the machine.
• When using the lifting eyes on the machine, do not attach any additional loads or
weight. The lifting eyes are only designed for the weight of the machine itself.
• Any eyes that are screwed in must be tightly fastened.
• Eyebolts must be screwed in right up to their supporting surface.
• Comply with the permissible eyebolt loads.
• When necessary, use suitably dimensioned lifting equipment, for example hoisting
straps (EN1492-1) and load restraints (EN12195-2).
● Never remain under or in the immediate vicinity of the machine when it is lifted.
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.
Note
When lifting the machines for transport, only lift them in a position that
corresponds to their
basic construction type.
The type of construction of the machine is stated on the rating plate.
If any transport locks are in place, remove them before commissioning. Store the transport
locks or disable them. Use the transport locks when transporting the motors again or
reactivate the transport locks.
The machines are packed in different ways depending on how they are transported and their
size. If not otherwise contractually agreed, the packaging corresponds to the packing
guidelines according to ISPM (International Standards for Phytosanitary Measures).
Comply with the images shown on the packaging. Their meaning is as follows:
Up Fragile
goods
Protect
against
moisture
Protect
against
heat
Center of
gravity
Hand hooks
forbidden
Attach
here
Preparing for use
4.5 Transport and storage
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38 Operating Instructions, 12/2018, A5E44455710A
4.5.1 Storage
Storing outdoors
NOTICE
Damage to the motor
Damage can occur if incorrectly stored.
Take all precautions to protect the motor under extreme climatic conditions, e.g. salt-laden
and/or dusty, moist/humid atmospheres.
Choose a dry storage location which is safe from flooding and free from vibration. Repair any
damage to the packaging before putting the equipment into storage if this is necessary to
ensure proper storage conditions. In order to ensure protection against ground moisture,
locate machines, equipment and crates on pallets, wooden beams or foundations. Prevent
equipment from sinking into the ground. Do not impede air circulation under the stored items.
Covers or tarpaulins used to protect the equipment against the weather must not come into
contact with the surfaces of the equipment. Use wooden spacer elements to ensure that air
can circulate freely around the equipment.
Storing indoors
The storage rooms must provide protection against extreme weather conditions. They must
be dry, free from dust, frost and vibration and well ventilated.
Bare metal surfaces
For transport, the bare surfaces (shaft ends, flange surfaces, centering edges) should be
coated with an anti-corrosion agent which will last for a limited amount of time (<6 months).
Apply suitable anti-corrosion measures for longer storage times.
Condensation drain hole
Open any condensation drain holes to drain the condensation depending on the
environmental conditions, every six months at the latest.
The materials used are specially designed for the temperature range required by the
customer. The relevant temperature limits are specified on the rating plate.
WARNING
Risk of explosion due to damaged sealing materials
Storing the machine at temperatures that do not fall within the specified limits can damage
the material of the seals and cause them to fail. As a result, a potentially explosive gaseous
atmosphere can enter the machine and be ignited during commissioning. Explosions can
occur. This can result in death, serious injury or material damage.
• Do not store the machine in conditions that lie outside the specified temperature limits.
Preparing for use
4.5 Transport and storage
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Storage temperature
Permissible temperature range: -20 °C to +50 °C
Maximum permissible air humidity: 60%
For machines that have a special design regarding the ambient temperature in the operating
state or the installation altitude, other conditions could apply regarding the storage
temperature. In this case, refer to the machine rating plate for data on the ambient
temperature and installation altitude.
Storage time
Turn the shaft once every year to avoid bearing brinelling. Prolonged storage periods reduce
the useful life of the bearing grease (aging).
Open bearings
● For open bearings, e.g. 1Z, check the status of the grease when stored for longer than 12
months.
● Replace the grease if it is identified that the grease has lost its lubricating properties or is
polluted. The consistency of the grease will change if condensation is allowed to enter.
Closed bearings
● For closed bearings, replace the DE and NDE bearings after a storage time of 48 months.
NOTICE
Storage
The motor can be damaged if you use it or store it unprotected outdoors.
• Protect the motor against intensive solar radiation, rain, snow, ice and dust. Use a
superstructure or additional cover, for example.
• If required, contact the service center, or technically coordinate outdoors use.
Preparing for use
4.5 Transport and storage
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40 Operating Instructions, 12/2018, A5E44455710A
4.5.2 Securing the rotor
Depending on the version, the machine is fitted with a rotor shipping brace. This protects the
bearings against damage due to shock and vibration during transport or storage.
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.
Preparing for use
4.5 Transport and storage
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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.
①
Sleeve
②
Shaft screw and washer
Figure 4-1 Axial fastening of the rotor
Thread in the shaft extension
Tightening torque
M16
40 Nm
M20
80 Nm
M24
150 Nm
M30
230 Nm
Tightening torques for other rotor shipping brace types
● 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
M16
13 kN
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.
Preparing for use
4.5 Transport and storage
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42 Operating Instructions, 12/2018, A5E44455710A
4.5.3 Commissioning after storage
4.5.3.1 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 55)
4.5.3.2 Lubricating the rolling bearings
If you correctly store the machine for a longer period of time, it can be assumed that within a
period of two years, the grease in the bearings will not deteriorate.
● For motors with thermal class 155, for normal ambient temperatures, use a lithium-soap
rolling bearing grease with a melting point of at least 180° C.
● For machines with thermal class 180, and for certain special machines, use the special
grease specified on the machine lubricant plate.
4.5.3.3 Regreasing rolling bearings after storage periods of up to two years
● For machines with regreasing systems, briefly lubricate both bearings after
commissioning with the machine running as a precautionary measure.
● Grease type, grease quantity and relubrication intervals for the regreasing system are
stamped on the rating plate attached to the machine.
4.5.3.4 Releasing the rotor shipping brace before commissioning
If one is being used, release the rotor shipping brace before commissioning.
Preparing for use
4.6 Ensure adequate cooling
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4.6 Ensure adequate cooling
WARNING
Overheating and failure of the motor
Death, severe injury or material damage can occur if you do not carefully observe the
following points.
• Do not obstruct ventilation.
• Prevent the air expelled by neighboring equipment from being immediately sucked in
again.
• For machines with a vertical type construction with air entry from above, prevent the
ingress of foreign bodies and water in the air entry openings (standard IEC / EN 60079-
0).
• If the shaft extension is facing upwards, liquid must be prevented from entering by
moving along the shaft.
WARNING
Damage caused by small parts falling in
Material damage and injury can occur if the fan is destroyed and therefore the motor
overheats.
• For types of construction with the shaft extension facing downwards, prevent small parts
from falling into the fan cover by providing suitable covers (standard IEC / EN 60079-0).
• Ensure that the cooling air flow is not reduced as a result of covers and that the
minimum air clearances are maintained.
Table 4- 1 Air guidance
Incorrect
Correct
Preparing for use
4.7 Thermal protection
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44 Operating Instructions, 12/2018, A5E44455710A
Incorrect
Correct
Minimum dimension "x" for the distance between neighboring modules and the air intake of the ma-
chine
Table 4- 2 Minimum dimension "X" for the distance between adjacent modules and the air intake of
the machine
Shaft height
X
mm
63 ... 71
15
80 ... 100 20
112
25
132
30
160
40
180 ... 200
90
225 ... 250
100
280 ... 315
110
355
140
4.7 Thermal protection
Protect explosion-protected machines against overload according to IEC / EN 60079-14,
Section "Rotating electrical machines".
Use a motor circuit breaker, directly monitor the winding temperature or use equipment to
provide the same functionality corresponding to the explosion type of protection.
For pole-changing motors, in addition to the circuit breaker, use temperature sensors in the
windings.
Preparing for use
4.8 Interlock circuit for anti-condensation heating
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Ex d and Ex t
Line supply
● Set the protective device (e.g. circuit breaker) to the rated current (see the rating plate).
● Or protect the machine using the certified temperature monitoring specified on the
supplementary plate .
Converter
● Always operate explosion-protected machines fed from converters with temperature
sensors that directly monitor the temperature.
Ex e and Ex eb
Line supply
● Set the protective device (e.g. circuit breaker) to the rated current (see the rating plate),
ILR/IRated and the locked rotor time.
● Or protect the machine using the certified temperature monitoring specified on the
supplementary plate.
Converter
● Always operate explosion-protected machines fed from converters with temperature
sensors that directly monitor the temperature.
● Converter operation for these machines must be expressly certified. It is essential that
you observe the specific manufacturer's information and instructions. Converter, machine
and protective devices must be marked as belonging together and the permitted
operating data must be defined in the common EC or EU-type examination certificate.
Ex n and Ex ec
Line supply
● Set the protective device (e.g. circuit breaker) to the rated current (see the rating plate).
● Or protect the machine using the certified temperature monitoring specified on the
supplementary plate .
Converter
● Always operate explosion-protected machines fed from converters with temperature
sensors that directly monitor the temperature.
4.8 Interlock circuit for anti-condensation heating
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine.
● Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
● Only switch on the anti-condensation heating after the machine has been switched off.
Preparing for use
4.9 Noise emission
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See also
Switching on with the anti-condensation heating active (Page 105)
4.9 Noise emission
Prevention of hearing damage
If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
Observe the permissible sound pressure level in accordance with ISO 1680. The maximum
permissible sound pressure level is 70 dB (A).
4.10 Voltage and frequency fluctuations during line operation
Unless stated otherwise on the rating plate, the permissible voltage/frequency fluctuation is
corresponds to range B in IEC / EN 60034-1.
Material damage due to excessively high winding temperature rise
Do not exceed the winding temperature tolerances. Inadmissibly high winding temperatures
can damage the machine over the long term.
Keep within the permissible tolerance for voltage and frequency.
Every machine must be protected against an inadmissible temperature rise. Observe the
following notes:
● Protect every machine according to IEC/EN 60079–14 using a current-dependent,
delayed circuit breaker with phase failure protection according to IEC/EN 60947 or a
similar device in all phases.
● Set the protective device to the rated current (value is stamped on the rating plate).
● Protect the windings in a delta connection in such a way that the tripping unit or relay is
connected in series with the winding phases. When selecting and setting the tripping unit,
define the rated value of the phase current. The phase current is 0.58 times the rated
machine current. Any thermal machine protection via direct temperature monitoring to be
used in addition to the machine circuit breaker is specified on the rating plate if required.
See also
Thermal protection (Page 44)
Preparing for use
4.11 Rotational speed limit values
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4.11 Rotational speed limit values
Danger as a result of resonance within certain speed ranges
At over-critical speeds, machines encounter resonance within certain speed ranges. Such
vibrations can reach impermissibly high levels. This can result in death, serious injury or
material damage.
● The controller must ensure that those speed ranges are blocked when the converter is in
operation. Please note the data on the blocked speed ranges specified in the Electrical
Data.
● The blocked speed ranges must be run through rapidly.
Machine damage due to excessively high speeds
Excessive rotational speed can lead to serious damage to the machine. This can result in
death, serious injury or material damage.
● Avoid operation above the permissible speed by using the appropriate control function.
● Observe the speeds stamped on the rating plate and in the Electrical Data.
4.12 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.
4.13 Electromagnetic compatibility
Note
If the torque levels are very unequal (e.g. when a reciprocating compressor is being driven),
a non
-sinusoidal machine current will be induced whose harmonics can have an
impermissible effect on the supply system and cause impermissible interference e
missions
as a result.
Preparing for use
4.14 Converter operation
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Note
Converter
•
If operated with a frequency converter, the emitted interference varies in strength,
depending on the design of the converter (type, interference suppression measures,
manufacturer).
•
Avoid that the specified limit values stipulated for the drive system (consisting of the
motor and converter) are exceeded.
•
You must observe the EMC information from the manufacturer of the converter.
•
The most effective method of shielding is to conductively connect a shielded machine
supply cable to the metal terminal box of the machine (with a metal screw connection)
over a large surface area.
•
On machines with integrated sensors (e.g. PTC thermistors), disturbance voltages
caused by the converter may occur on the sensor cable.
When used in accordance with their intended purpose and operated on an electrical supply
system with characteristics according to EN 50160, the enclosed machines comply with the
requirements of the EC Directive concerning electromagnetic compatibility.
Immunity to interference
The machines fulfill the requirements of interference immunity in conformity with EN /
IEC 61000-6-2. If machines with integrated sensors (e.g. PTC thermistors) are used, the
operating company must ensure sufficient interference immunity by selecting a suitable
sensor signal lead (possibly with shielding, connected in the same way as the machine
feeder cable) and a suitable evaluation unit.
When operating the machines from a converter at speeds higher than the rated speed, then
the mechanical speed limits must be carefully observed (safe operating speed
EN / IEC 60034-1).
4.14 Converter operation
4.14.1 Parameterizing the converter
● If the design of the motor requires connection to a particular converter type, the rating
plate will contain corresponding additional information.
● Correctly parameterize the converter. Parameterizing data can be taken from the
machine rating plates.
You can find parameter data here:
– In the operating instructions for the converter.
– In the SIZER engineering tool
– In the SINAMICS Configuration Manuals.
– For explosion-protected machines, also in the declaration of compliance with the order
2.1.
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4.14 Converter operation
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● Do not exceed the specified maximum speed limit
n
max. You can either find this on the
rating plate
n
max or on the supplementary plate for converter operation as the highest
speed.
● Check that the machine is cooled sufficiently for commissioning purposes.
4.14.2 Converter input voltage
The insulation system of SIMOTICS machines always complies with the requirements of
stress category C (IVIC C = high stress). If voltage peaks higher than those specified
according to IVIC C can occur, then please contact your Siemens partner:
● For a line supply voltage (converter input voltage) up to max. 480 V, and when controlled
from a SINAMICS G/SINAMICS S converter with uncontrolled/controlled infeed: Comply
with the guidelines for configuring motor and converter.
● For line voltages (converter input voltages) higher than 480 V, motors, which are ordered
for converter operation, have an appropriate insulation system.
● Operation with a converter from another manufacturer: Comply with the permissible
voltage peaks according to IEC 60034-18-41 in accordance with stress category C,
dependent on the particular line voltage (converter input voltage) and the motor insulation
system.
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.
See also
Download Center
(http://w3app.siemens.com/mcms/infocenter/content/en/Pages/order_form.aspx)
4.14.3 Reducing bearing currents for converter operation
Taking the following actions will reduce the bearing currents:
● Ensure that the contacts are made over a large area. Solid copper cables are not suitable
for high-frequency grounding because of the skin effect.
Preparing for use
4.14 Converter operation
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Equipotential bonding conductors:
Use equipotential bonding conductors:
● between motor and driven machine
● between motor and converter
● between the terminal box and the RF grounding point at the motor enclosure.
Selecting and connecting the cable:
As far as possible, use symmetrically arranged, shielded connection cables. The cable
shielding, made up of as many strands as possible, must have good electrical conductivity.
Braided shields made of copper or aluminum are very suitable.
● The shield is connected at both ends, at the motor and converter.
● To ensure good discharging of high-frequency currents, provide contacting over a large
surface area:
– as contact established through 360° at the converter
– at the motor, for instance with EMC glands at the cable entries.
● If the cable shield is connected as described, then it ensures the specified equipotential
bonding between the motor enclosure and converter. A separate RF equipotential
bonding conductor is then not necessary.
Concentric copper or aluminum shield
Steel armor
● If the cable shield is not connected due to special secondary conditions, or not
adequately connected, then the specified equipotential bonding is not provided. In this
particular case, use a separate RF equipotential bonding conductor:
– Between the motor enclosure and protective ground rail of the converter.
– Between motor enclosure and driven machine
– Use braided flat copper straps or high-frequency cables with finely-stranded
conductors for the separate RF equipotential bonding cable.
– Ensure that the contacts are made over a large area.
Measures to reduce bearing currents
To specifically reduce bearing currents, you must consider the system as a whole, which
comprises the motor, converter, and driven machine. The following measures support you
when reducing bearing currents and help to avoid damage:
● In the overall system, set up a properly meshed grounding system with low impedance.
● Use the common-mode filter (damping cores) at the converter output. The Siemens sales
representative is responsible for selection and dimensioning.
Preparing for use
4.14 Converter operation
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● Limit the rise in voltage by using output filters. Output filters dampen the harmonic content
in the output voltage.
● The operating instructions for the converter are not part of this documentation. Refer to
the configuration information for the converter.
4.14.4 Insulated bearings when operated with a converter
If the machine is operated from a low-voltage converter, insulated bearings are fitted at the
NDE and an insulated encoder with insulated bearings (option).
Comply with the plates on the machine relating to bearing insulation and possible bridges.
①
Driving machine
④
Insulated bearings
②
Motor
⑤
Insulated tachometer fitting
③
Coupling
Figure 4-2 Schematic representation of a single drive
NOTICE
Bearing damage
The bearing insulation must not be bridged. Bearing currents can damage bearings.
• Do not bridge the bearing insulation for subsequent installation work, such as the
installation of an automatic lubrication system or a non-insulated vibration sensor.
• Please contact the service center if necessary.
Preparing for use
4.14 Converter operation
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Tandem operation
If you connect two motors in series in "tandem operation", install an insulated coupling
between the motors.
①
Driving machine
④
Insulated bearings
②
Motor
⑤
Insulated tachometer fitting
③
Coupling
⑥
Insulated coupling
Figure 4-3 Schematic representation of a tandem drive
NOTICE
Bearing damage
Bearing currents can flow if the coupling between the motors of the tandem drive is not
insulated. This can damage the DE bearings of both motors.
• Use an insulated coupling to link the motors.
4.14.5 Tandem operation
If you connect two motors in series in "tandem operation", locate a coupling between the
motors; this coupling should satisfy the Directive 2014/34/EU or the regulations that apply in
the country where the equipment is installed.
4.14.6 Speed limits for converter operation
Observe the information on the rating plate regarding the speed limits for converter
operation.
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Assembly
5
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
Loss of conformity with European directives
In the delivery state, the machine corresponds to the requirements of the European
directives. Unauthorized changes or modifications to the machine lead to the loss of
conformity with European Directives and the loss of the associated warranty.
Explosion hazard when making modifications to the machine
Substantial modifications to the machine are not permitted – or may only be performed by
the manufacturer. Otherwise an explosion can occur in an explosive atmosphere. This can
result in death, serious injury or material damage.
● If necessary, please contact the service center.
5.1 Preparing for installation
5.1.1 Requirements for installation
The following requirements must be satisfied prior to starting installation work:
● Staff have access to the operating and installation instructions.
● The machine is unpacked and ready for mounting at the installation location.
● Measure the insulation resistance of the winding before starting any installation work. If
the insulation resistance lies below the specified value, take appropriate remedial
measures. These remedial measures may necessitate the machine being removed again
and transported.
Note
Note also the technical data on the rating plates on the motor enclosure.
Assembly
5.1 Preparing for installation
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54 Operating Instructions, 12/2018, A5E44455710A
NOTICE
Damage to the motor
To avoid material damage, before commissioning, check whether the correct direction of
rotation of the machine has been set on the customer side, e.g. by decoupling from the
driven load.
Damage to mounted parts and components as a result of high temperatures
The motor components get very hot during operation. High temperatures can damage parts
mounted by customers, such as cables manufactured out of materials that are not heat
resistant.
● Temperature-sensitive parts must not come into contact with or be attached to
components mounted on the machine.
● Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the particular application.
5.1.2 Insulation resistance
5.1.2.1 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 55)
Assembly
5.1 Preparing for installation
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5.1.2.2 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
5.1 Preparing for installation
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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
C
Insulation resistance converted to 40° C reference temperature
K
T
Temperature coefficient according to equation (2)
R
T Measured 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.
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
Assembly
5.2 Mounting and installed the machine
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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 165).
• If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
Limit values of the anti-condensation heating insulation resistance
The insulation resistance of the anti-condensation heating with respect to the machine
housing should not be lower than 1 MΩ when measured at 500 V DC.
5.2 Mounting and installed the machine
5.2.1 Preparing the assembly area
1. Prepare a suitable assembly area (e.g. assembly stands). Make sure that the assembly
area has sufficient clearance from the floor for the DE shaft end. The necessary data is
provided in the machine dimension drawing.
2. Refer to the shipping documents to check that all motor components are available for
assembly.
Assembly
5.2 Mounting and installed the machine
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58 Operating Instructions, 12/2018, A5E44455710A
● For vertical installation, use all of the eyebolts provided and when necessary, hoisting
straps (DIN EN 1492-1) and/or lashing straps (DIN EN 12195-2) to stabilize the position
of the motor.
● Prevent foreign bodies from falling into the fan cover. For vertical machine installation
with the shaft end facing downwards, attach a protective canopy.
● If the shaft extension is facing upwards, the user must prevent liquid from moving along
the shaft and entering the motor.
● Clean bare metal surfaces with anti-corrosion agent using white spirit to ensure proper
installation and / or machine mounting.
● Do not obstruct the ventilation! Do not draw in the discharged air directly – also from
adjacent equipment.
● Avoid exposing them to direct, intense solar radiation, rain, snow, ice, or also dust for
extended periods. Attach a covering structure or an additional cover when using or
storing outdoors.
● Do not exceed the permissible axial and radial forces.
● Only use explosion-protected machines in appropriate areas in accordance with
directive 1999/92/EC.
If the certification is supplemented by an X, please note the special conditions in the EC
type examination certificate. Special conditions for explosion-proof machines (Page 17)
● When installing electrical systems in hazardous zones, observe EN/IEC 60079-14 and
the corresponding country regulations.
● The machine temperature class specified on the rating plate must be equal to or greater
than the temperature class of any combustible gases that may develop.
● Select optional mounted equipment according to the requirements of Directive
2014/34/EU.
5.2.2 Balancing
The rotor is dynamically balanced. For shaft extensions with feather keys, the balancing type
is specified using the following coding on the face of the drive end of the shaft:
● "H" means balancing with a half feather key (standard)
● "F" means balancing with a whole feather key
● "N" means balancing without a featherkey.
Assembly
5.2 Mounting and installed the machine
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Operating Instructions, 12/2018, A5E44455710A 59
CAUTION
Risk of injury due to Incorrect installation or removal
If the required touch protection measures for drive output elements are not observed this
can result in physical injury and material damage.
• The general touch protection measures for drive output elements must be observed.
• Drive output elements may only be pushed on or pulled off with the correct equipment.
• The feather keys are only locked against falling out during shipping. If you commission a
machine without a drive output element, the feather keys must be secured to prevent
them from being thrown out.
The featherkey data on the shaft and transmission element must indicate the correct type of
balancing in each case and must be correctly mounted.
The balancing quality corresponds to vibration severity grade "A" for the complete machine;
vibration severity grade "B" is possible as an option, i.e. in order to ensure the desired
balancing quality, it must be ensured that the featherkey data on the hub and machine shaft
complement each other in the case of a shorter or longer output transmission element.
Align the offset at the coupling between electrical machines and the driven machines so that
the maximum permissible vibration values according to ISO 10816-3 are not exceeded.
5.2.2.1 Mounting and withdrawing output transmission elements
Withdrawing output transmission elements
Assembly
5.2 Mounting and installed the machine
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60 Operating Instructions, 12/2018, A5E44455710A
Mounting output transmission elements
● When mounting output transmission elements (coupling, gear wheel, belt pulley etc. ) use
the thread at the shaft end.
If possible, heat up the output transmission elements as required.
● Use a suitable device when withdrawing output elements.
● When mounting or withdrawing, do not apply any blows, for example with a hammer or
similar tool, to the parts to be mounted or withdrawn.
● Only transfer radial or axial forces specified in the catalog to the motor bearings via the
shaft extension.
5.2.3 Machines with type of construction IM B15, IM B9, IM V8 and IM V9
Types of construction without bearings on the drive side
These machines do not have their own bearing system for the machine shaft at the drive end
(DE). The machine shaft is accepted by the (hollow) shaft or coupling of the system or driven
machine.
● Using the centering edge, the machine is aligned with respect to enclosures, flanges or
driven machines.
● Note that the temperature of the motor and motor shaft increases during operation. The
thermal expansion of the machine shaft must be compensated by the customer by
applying suitable measures.
Use the spring washers provided to locate the NDE bearing without any play.
Assembly
5.3 Alignment and fastening
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NOTICE
Damage to the motor
Material damage can occur if the following notes are not carefully observed:
• The IM B3 bearing shield with integrated distance ring mounted at the drive end (DE) is
only used transport lock. A warning label is attached to this bearing shield.
• The spacer ring is not a roller bearing.
• Remove the bearing shield and the spacer ring.
• Remove the transport lock before commissioning.
5.2.4 Foot mounting
Note
Only authorized retrofit partners must be employed to relocate the bolted on mounting feet at
the machine enclosure.
After attaching the mounting feet, you must note the following in order to avoid stressing and
deforming the machine.
● Ensure that the foot mounting surfaces are aligned in one plane and are parallel to the
machine shaft.
● Post-machine the foot mounting surfaces or use thin shims, for example.
● Professionally touch up damaged painted surfaces.
● Observe the information provided in Chapter Aligning and mounting (Page 61)
5.3 Alignment and fastening
Observe the following when aligning and mounting:
● Ensure a flat and uniform contact surface for foot and flange mounting.
● When mounting on the wall, support the machine from below, e.g. using a bracket, or bolt
it.
● Precisely align the machine when couplings are used.
● Ensure that the mounting surfaces are clean and free of any dirt.
● Remove any anti-corrosion protection using white spirit.
● Avoid installation-related resonances with the rotating frequency and twice the line
frequency.
● Note any unusual noise when the rotor is manually turned.
Assembly
5.3 Alignment and fastening
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● Check the direction of rotation with the motor uncoupled.
● Avoid rigid couplings.
● Repair any damage to the paint, this must be done immediately and correctly.
5.3.1 Repainting/touching up the paint finish of explosion-protected machines
Note
Repainting/touching up the paint finish of explosion-protected machines
For explosion
-protected machines, observe the information in Chapter Repainting/touching
up
(Page 124).
5.3.2 Measures for alignment and mounting
The following measures are required in order to compensate any radial offset at the coupling
and to horizontally adjust the electrical machine with respect to the driven load:
● Vertical positioning
For vertical mounting positions, avoid deforming the machines by placing shims under the
mounting feet. Keep the number of shims low; only use a few stacked shims.
● Horizontal positioning
To position the machine horizontally, shift it sideways on the foundation and ensure that
the axial position is maintained (angularity error).
● When positioning the motor, ensure that a uniform axial gap is maintained around the
coupling.
● Smooth running
Preconditions for smooth, vibration-free operation:
– Stable foundation design free of any shock or vibration.
– A precisely aligned coupling.
– A well-balanced drive output element (coupling, belt pulleys, fans, ...)
Maintain the maximum permissible vibration values in operation according to ISO 10816-
3.
Avoid inadmissible vibration caused by imbalance, for example (drive output element),
external vibration or any resonance over the complete speed range.
It may be necessary to completely balance the machine with the drive output element or
the system resonance frequency must be shifted.
Assembly
5.4 Installing the machine
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● Foot mounting/flange mounting
– Use the specified thread size laid down in EN 50347 when flanging the machine to a
foundation or a machine flange.
– Mount the machine at all the foot or flanged holes provided. The choice of fixing
elements depends on the foundation and is the plant operator's responsibility. Comply
with the required property classes for screwed connections and materials for fixing
elements.
– Select the correct screw length for IM B14 flanges.
– Ensure that the screw heads are in full contact with the flange surface. Use additional
flat washers (ISO 7093), especially for elongated foot mounting holes.
5.3.3 Flatness of the supporting surfaces for conventional motors
Shaft height
Flatness
[mm]
≤ 132
0.10
160 0.15
≥ 180
0.20
5.3.4 Machine frame mounting feet (special design)
Please note that when the terminal box is mounted at the NDE (option H08), dimension C
can deviate from EN 50347.
To comply with dimension C according to EN 50347, for machines with double or triple holes
at the NDE, use the appropriate screw bore.
5.4 Installing the machine
5.4.1 Preconditions for smooth, vibration-free operation
Preconditions for smooth, vibration-free operation:
● Stable foundation design
● Precise alignment of the machine
● Correct balancing of parts to be fitted to the shaft end.
● Vibration values in compliance with ISO 10816-3
Assembly
5.4 Installing the machine
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5.4.2 Aligning the machine to the driven machine and mounting
5.4.2.1 Selecting bolts
● Unless specified otherwise, use fixing screws with at least strength class 8.8 to ISO 898-1
to ensure that the machine is securely mounted and to transmit the torque-generated
forces.
● When selecting the bolts and the design of the foundation, take into account the
maximum forces occurring in the case of a fault such as short circuit or system transfers
in phase opposition, etc.
Request the foundation force values from the Service Center if required.
5.4.2.2 Horizontal types of construction with mounting feet
1. Refer to any instructions for aligning the driven machine and those of the coupling
manufacturer.
2. Align the machines with coupling output to the driven machine in such a manner that the
center lines of the shafts are parallel with no offset. This ensures that no additional forces
affect their bearings during operation.
3. For the vertical positioning (x→0) place thin shims under the machine feet. The number of
shims should be kept as low as possible, i.e. stack as few as possible. This also prevents
the machine being subjected to any stress/distortion. If available, use the existing tapped
holes for the forcing-off bolts to somewhat raise the machine.
4. When positioning the machine, ensure that a uniform axial gap (y→0) is maintained
around the coupling.
5. Fix the machine to the foundation. The choice of fixing elements depends on the
foundation and is the plant operator's responsibility.
Note
Machine expansion
When aligning, make allowance for the thermal expansion of the machine when the
temperature increases.
5.4.2.3 Horizontal types of construction with flange
The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Assembly
5.4 Installing the machine
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Procedure
The machine axis must be horizontal when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw three studs into tapped holes spaced about 120° apart around the driven machine
flange. The studs act as positioning aids.
3. Position the machine so that its axis is aligned with that of the driven machine, but not yet
quite touching. Advance the machine slowly towards the driven machine; advancing too
quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Move the machine fully up against the mating flange so that it is fully in contact.
6. Fix the machine using the flange fixing bolts, finishing by replacing the studs.
5.4.2.4 Vertical types of construction with flange
The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Procedure
The machine axis must be vertical when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw in two studs into tapped holes on opposite sides of the driven machine flange. The
studs act as positioning aids.
3. Lower the machine slowly toward the driven machine and into the centering, so that the
flanges do not quite touch. Lowering too quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Lower the machine completely onto the mating flange so that it is fully in contact; then
remove the studs.
6. Fix the machine using the flange fixing bolts.
Assembly
5.4 Installing the machine
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5.4.3 Removing the rotor shipping brace
If a rotor shipping brace is attached to the machine, remove it at the last possible moment,
for example, when you are ready to push on the output or drive element.
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
Details about the alignment accuracy can be found in the Section "Information about the
machine dimension drawing".
5.4.4 Recommended alignment accuracy
The alignment accuracy required depends essentially on the configuration of the overall
machine train. Observe the required alignment accuracy of the coupling manufacturer in all
cases when aligning the machine.
Table 5- 2 Recommended alignment accuracy
Speed
rpm
Parallel offset
mm
Angular offset
mm per 100 mm coupling diameter
750
0.09
0.09
1500 0.06 0.05
3000
0.03
0.025
To avoid stressing the motor feet, the overall flatness of the installation surfaces must satisfy
the values in the following table:
Table 5- 3 Overall flatness of the installation surfaces
Shaft height
Overall flatness of the installation surfaces
≤ 080 0.1 mm
090 - 355
0.2 mm
≥ 400
0.3 mm
If shims are necessary for height adjustment and to avoid stresses, make them out of
adequately sized pieces of flat rolled strip. Complete balancing of the rotor together with the
transmission element may be found necessary.
Assembly
5.4 Installing the machine
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5.4.5 Mounting the output elements
Balance quality
The rotor is dynamically balanced. For shaft ends with feather keys, the balancing type is
specified using the following coding on the rating plate:
● "H" means balancing with a half feather key
● "F" means balancing with a whole feather key
● "N" means balancing without a featherkey.
Figure 5-1 Balancing type on the drive-end side
Pushing on the power output elements
● Requirements:
– The coupling and/or the output element must be appropriately dimensioned for the
operating case at hand.
– Comply with the coupling manufacturer's instructions.
– Make sure that the balancing type of the transmission element correctly matches the
type of balance of the rotor.
– Use only ready drilled and balanced transmission elements. Check the hole diameters
and the balancing status before pulling them on. Thoroughly clean the shaft extension.
● Pulling on:
– Warm up the drive output elements to expand them before pulling them on. Select the
temperature difference for the heating process to suit the coupling diameter, fit and
material. See the coupling manufacturer's instructions.
– Power output elements may only be pushed on or pulled off with the correct
equipment. The transmission element must be pulled on in one continuous operation
via the front thread holes in the shaft or pushed on by hand.
– Do not use a hammer, as this will damage the bearings.
Assembly
5.4 Installing the machine
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Shaft extensions with feather key
To maintain the balancing quality, you have the following options:
● If the transmission element is shorter than the feather key with balancing type "H", then
you must machine off the section of feather key protruding from the shaft contour and
transmission element in order to maintain the balance quality.
● If the transmission element is drawn up on to the shoulder of the shaft, you must ensure
that the part of the coupling groove where the feather key is not inserted is taken into
consideration when balancing the coupling.
The following applies to all four-pole machines with a frequency ≥ 60 Hz:
● The feather key must be shortened if the coupling hub is shorter than the feather key.
● The center of gravity of the coupling half should be within the length of the shaft end.
● The coupling used must be prepared for system balancing.
Danger as a result of a feather key being flung out
Rotating parts are dangerous. The feather keys are only locked against falling out during
shipping. If a machine with 2 shaft extensions does not have an output element on one shaft
extension, the feather key can be flung out during operation. Rotating parts can result in
death, serious injury or material damage.
● Do not operate the machine unless the transmission elements have been pulled on.
● On shaft extensions without drive output element, take suitable measures to ensure that
the feather key cannot be flung out. For balancing type "H", shorten the feather key by
about half.
5.4.6 Axial and radial forces
You can obtain the permissible values for axial and radial forces by contacting the Service
Center or referring to the machine catalog.
WARNING
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. In an
explosive atmosphere, there is a risk of explosion. Death, serious injury, or material
damage can result.
• Ensure that the permissible loads for the forces on the shaft extension are adhered to in
accordance with the catalog data or configuration data.
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Electrical connection
6
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
DANGER
Hazardous voltages
Death, injury or material damage can occur. Note the following safety information before
connecting-up the machine:
• Only qualified and trained personnel should carry out work on the machine while it is
stationary.
• Disconnect the machine from the power supply and take measures to prevent it being
reconnected. This also applies to auxiliary circuits.
• Check that the machine really is in a no-voltage condition.
• Establish a safe protective conductor connection before starting any work.
• If the incoming power supply system displays any deviations from the rated values in
terms of voltage, frequency, curve form or symmetry, such deviations will increase the
temperature and influence electromagnetic compatibility.
• Operating the machine on a line supply system with a non-
grounded neutral point is only
permitted over short time intervals that occur rarely, e.g. the time leading to a fault being
eliminated (ground fault of a cable, EN 60034-1).
Note
Service Center
If you require support when electrically connecting up the machine, please contact the
Service Center.
Electrical connection
6.1 Connecting the machine
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Risk of explosion by fixing elements becoming loose
If you use fixing elements made from the wrong material or apply the wrong tightening
torque, this could impair current transfer or cause connecting parts to become loose.
Fastening elements can work loosely, so that the minimum air clearances are no longer
maintained. Sparking formation may occur, in an explosive atmosphere it can lead to an
explosion. This could result in death, serious injury or material damage to the machine or
even in failure, which could in turn lead indirectly to material failure of the system.
● Tighten the screwed connections to the specified tightening torques.
● Observe any specifications regarding the materials from which fixing elements must be
made.
● When performing servicing, check the fastenings.
6.1 Connecting the machine
6.1.1 Selecting cables
Take the following criteria into account when selecting the connecting cables:
● Rated current
● Rated voltage
● If required, service factor
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Configuration notes
● Requirements according to IEC/EN 60204-1
● Dimensioning for bundled cable routing, e.g. according to DIN VDE 0298 Part 4 or
IEC 60364-5-52
● Observe the information in EN / IEC 60034-1 (VDE 0530-1) regarding operation at the
limits of A and B zones, especially in respect of temperature increase and deviation of the
operating data from the rated data stamped on the rating plate. Do not exceed these
limits.
● Connect up so that a permanently safe electrical connection is guaranteed (no protruding
wire ends); use the assigned cable-end fittings (e.g. cable lugs, end sleeves).
Connect up the line supply voltage and arranged the disconnecting link in accordance
with the circuit diagram provided in the terminal box.
● Select the connecting cables in accordance with DIN VDE 0100 taking into account the
rated current and the installation-specific conditions – e.g. ambient temperature, routing
method etc. - according to DIN VDE 0298 and/or EN / IEC 60204-1.
Electrical connection
6.1 Connecting the machine
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The technical specifications stipulate the following that have to be taken into account with
respect to the motor connection:
● Direction of rotation
● The number and arrangement of the terminal boxes.
● The circuit and connection of the motor winding
● Protect every explosion-protected machine according to EN / IEC 60079-14 Chapter
"Rotating electrical machines".
● For machines with type of protection increased safety "eb", select the overcurrent device
with current-dependent delayed trip so that the tripping time, which should be taken from
the characteristic of the switch for the ratio IA / IN of the machine to be protected, is not
longer than the safe locked rotor time tE. Take the ratio IA / IN as well as the safe-locked
rotor time tE from the rating plate. Set the protective device to the rated current. Use a
tripping unit certified according to directive 2014/34/EU.
● For machines with increased safety "eb" type of protection, in the event of a locked rotor
the protective device must disconnect within the safe locked rotor time (tE time) specified
for the relevant temperature class. Protect electric machines used for heavy duty starting
(acceleration time > 1.7 x tE time - locked rotor time) by monitoring the starting process
using suitable equipment corresponding to the data provided in the EC or EU type
examination certificate.
Direct monitoring of the winding temperature is permissible as a means of thermal
machine protection, provided that this is certified and specified on the rating plate.
● With pole-changing machines, separate, interlocked protective devices are required for
each speed step. Equipment with EC or EU type examination certificate are
recommended.
See also
Thermal protection (Page 44)
All cable entries and sealing plugs must be approved for use in the respective hazardous
zone.
● Any openings that are not being used must be sealed using the appropriate certified
sealing plugs.
● Please observe the manufacturer's specifications when fitting cable entries.
Electrical connection
6.1 Connecting the machine
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6.1.2 Terminal box
DANGER
Hazardous voltage
Electric motors have high voltages. When incorrectly handled, this can result in death or
severe injury.
Switch off the machine so that it is in a no-voltage condition before you open the terminal
box.
NOTICE
Damage to the terminal box
If you incorrectly carry out work on or in the terminal box, this can result in material
damage. You must observe the following to avoid damaging the terminal box:
• Ensure that the components inside the terminal box are not damaged.
• It must be ensured that there are no foreign bodies, dirt or moisture in the terminal box.
• Close the terminal box using the original seal so that it is dust tight and water tight.
• Use O-rings or suitable flat gaskets to seal entries in the terminal box (DIN 42925) and
other open entries.
• Please observe the tightening torques for cable entries and other screws.
See also
Tightening torques for screw and bolt connections (Page 167)
6.1.2.1 Terminal marking
According to IEC / EN 60034-8, the following basic definitions apply to the terminal markings
for 3-phase machines:
Table 6- 1 Terminal markings using the 1U1-1 as an example
1
U
1
-
1
Marking
x Index for pole assignment for pole-changing machines where applicable. A lower
index signifies a lower speed. Special case for split winding.
x
Phase designation U, V, W
x Index for winding start (1) or end (2) or if there is more than one connection per
winding
x Additional indices for cases in which it is obligatory to connect parallel power
feed cables to several terminals with otherwise identical markings
Electrical connection
6.1 Connecting the machine
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6.1.2.2 Circuit diagram inside the terminal box cover
Data on the connection and connecting the machine winding can be found in the circuit
diagram in the cover of the terminal box.
6.1.2.3 Direction of rotation
The standard motors are suitable for clockwise and counter-clockwise rotation.
For defined directions of rotation (direction of rotation arrow), appropriately connect the line
power cables.
● If you connect the line cables with phase sequence L1, L2, L3 at U, V, W or according to
NEMA at T1 T2 T3 , then the machine rotates in the clockwise direction.
● If you interchange two connections, e.g. L1, L2, L3 at V, U, W or according to NEMA at
T2 T1 T3 , then the machine rotates counter-clockwise.
According to IEC According to NEMA
Clockwise rotation
U V W
T
1
T
2
T
3
Counter-clockwise
rotation
V U W T2 T1 T3
Direction of rotation of the motor when looking at DE
6.1.2.4 Knockout openings
NOTICE
Damage to the terminal box
To avoid damaging the terminal box:
• Knockout openings in the terminal box must be knocked out using appropriate methods.
• Do not damage the terminal box, the terminal board, the cable connections etc. inside
the terminal box.
Electrical connection
6.1 Connecting the machine
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74 Operating Instructions, 12/2018, A5E44455710A
Note
Have additional holes i
n the terminal box with type of protection Ex d made only by the
manufacturer or by a specialist workshop for electrical machinery authorized by the
manufacturer.
Making holes in the terminal box
If you drill holes in the terminal box for explosion-protected motors, then document the data
about these holes in the motor documentation:
● Number and size of the holes
● Type of thread, e.g. metric or NPT
Data regarding the installation of pipes and accessories is provided in IEC / EN 60079-14.
Requirements placed on drilled holes in Zone 21/22
For applications in Zone 21 (Ex tb) or Zone 22 (Ex tc), according to EN 60079-31, the
following requirements are placed on drilled holes:
Through holes:
● The nominal diameter of the through holes for the entry may not be 0.7 mm larger than
the nominal diameter of the thread of the cable entry or connection element.
● The inside of the terminal box must have sufficient space to attach a locking nut at the
cable entry or at the connection element.
Openings with thread must have the following attributes:
● Conical thread: Without additional sealant or seals, not less than three and one half
thread turns.
● Cylindrical threads: At least five thread turns, tolerance of 6H, even better according to
ISO 965-1. For less than five thread turns, an additional seal or sealant is required.
6.1.2.5 Cable entry
Certified cable entries, thread adapters and sealing plugs
Only use sealing plugs, cable entries and conductor entries or thread adapters that are
suitable, certified and marked for use in the respective explosion protection type and degree
of protection (DIN EN 60079-14).
Terminal box
The number and size of the cable entry tapped holes is provided in the machine dimension
drawing.
Electrical connection
6.1 Connecting the machine
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Inserting cables into the terminal box
1. Only use cable entries that are suitable for the cables.
2. Only use cable entries and cables suitable for the prevailing ambient temperature.
3. Ensure that the power cables are strain relieved when inserting them in the terminal box.
4. Carefully connect the cables and ensure a reliable protective conductor connection.
5. Tighten the glands and the elements for the strain relief with the torque specified by the
manufacturer.
6. Check the cable entries and cables to ensure that they are correctly sealed and firmly
seated.
7. Correctly close and seal threads or holes that are not being used ensuring that the IP
degree of protection is maintained. The IP degree of protection is specified on the rating
plate.
6.1.2.6 Protruding connection cables
WARNING
Risk of short-circuit and voltage hazard
A short circuit can occur if connecting cables are clamped and crushed between parts of
the enclosure and the cover plate.
This can result in death, severe injury and material damage.
• During disassembly and particularly when installing the cover plate, make sure that the
connecting cables are not clamped between enclosure parts and the cover plate.
CAUTION
Damage to connecting cables that are freely led out
You must observe the following note to avoid damaging connecting cables that are freely
led out:
• It must be ensured that there are no foreign bodies, dirt, or moisture in the terminal base
of the machine enclosure.
• Use O-rings or suitable flat gaskets to seal entries in cover plates (DIN 42925) and other
open entries.
• Seal the terminal base of the machine enclosure using the original seal of the cover
plate to prevent dust and water from entering.
• Please observe the tightening torques for cable entries and other screws.
6.1.2.7 Connecting protruding cables
In the case of connection cables brought out of the machine, no terminal board is installed
on the terminal base of the machine housing. The connection cables are directly connected
to stator winding terminals at the factory.
The connection cables are color-coded or labeled. The customer directly connects individual
cables in the control cabinet for their system in accordance with the labeling.
Electrical connection
6.1 Connecting the machine
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76 Operating Instructions, 12/2018, A5E44455710A
6.1.2.8 Connection with/without cable lugs
In the case of terminals with terminal clamps, distribute the conductors in such a way that the
clamping heights on both sides of the fillet are about the same. This method of connection
requires that you must bend a single conductor in a U shape or use a cable lug. The same
applies to the inner and outer terminals of the ground conductor.
When connecting up using cable lugs, select their size corresponding to the required cable
cross-section and the stud size. An inclined arrangement is only permitted provided the
required air clearances and creepage distances are carefully maintained.
Remove insulation from the ends of the conductors so that the remaining insulation almost
reaches the cable lug.
Note
The direct contact between the cable lug surfaces and the contact nuts or contact screws
ensure that the connection can conduct current.
WARNING
Short-circuit hazard
Live conductors released from the terminal board can cause short circuits. Death or serious
injury can result.
• You must bend single-core line conductors into a U shape in order to prevent the
contact force being transferred at just one side.
• In order to prevent the cable lug from rotating, for a line connection using a cable lug,
angle single- or multi-core cables downwards through an angle of approx. 40°.
6.1.2.9 Thread sizes in the terminal box
Shaft height
Threaded entry
Size
Quantity
71 ... 90 M 16 x 1.5
M 25 x 1.5
1
100 ... 132
M 32x1.5
2
160 ... 180
M 40x1.5
2
200 ... 225
M 50x1.5
2
250 ... 315
M63x1.5
2
355
M 80x2
2
Thread size for additional entries, e.g. PTC thermistor or heater M16x1.5 or M20x1.5.
Other thread sizes are possible as an option.
Electrical connection
6.1 Connecting the machine
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6.1.2.10 Minimum air clearances
After proper installation, verify that the minimum air clearances between non-insulated parts
are maintained. Be aware of any protruding wire ends.
Table 6- 2 Minimum air clearance dependent on rms value of the alternating voltage
U
rms
Rms value of the alternating
voltage
U
rms
Minimum air clearance
mm
Ex tc
Ex tb
Ex nA
Ex ec
Ex e
Ex eb
≤ 250 V 3.0 2.5 5.0
≤ 500 V
3.0
5.0
8.0
≤ 630 V
5.5
5.5
10.0
≤ 1000 V
8.0
8.0
14.0
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 in-
creased by a factor of 1.1, so that the rated input voltage range is taken into account during gen-
eral use.
6.1.2.11 Internal equipotential bonding
The internal equipotential bonding between the grounding terminal in the terminal box, the
terminal box components and the machine enclosure is ensured via metallic contact, a
copper braided strip or a stranded wire.
6.1.3 Cable glands
Cable glands with (sheet metal) nuts (EN 50262)
①
②
Nut
O ring
Electrical connection
6.1 Connecting the machine
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78 Operating Instructions, 12/2018, A5E44455710A
Cable glands with reductions and (sheet metal) nuts (EN 50262)
①
②
Nut
O ring
6.1.3.1 Mounting position of sheet metal nuts in screw-type connections
②
③
O ring
Mounting position of metal
-sheet
nuts
Cable glands with connecting thread in the terminal box (EN 50262)
②
O ring
Electrical connection
6.2 Tightening torques
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6.2 Tightening torques
Note the information in Chapter Tightening torques (Page 167).
6.2.1 Cable entries, sealing plugs and thread adapters
All cable entries and sealing plugs must be approved for use in the respective hazardous
zone.
● Any openings that are not being used must be sealed using the appropriate certified
sealing plugs.
● Please observe the manufacturer's specifications when fitting cable entries.
Note the following when mounting:
● Avoid damaging the cable jacket.
● Adapt the tightening torques to the cable jacket materials.
Observe the documentation for tightening torques of the cable entries and sealing plugs for
direct mounting at the machine as well as additional glands (e.g. adapters).
6.3 Connecting the grounding conductor
The machine's grounding conductor cross-section must comply with EN / IEC 60034-1.
Please also observe installation regulations such as those specified in EN / IEC 60204-1.
Basically, there are two ways of connecting a grounding conductor to the machine.
● Internal grounding with a connection in terminal box at the location intended for this
purpose and marked accordingly.
● External grounding with connection at the stator housing at the locations intended for this
purpose and marked accordingly.
6.3.1 Minimum surface area of grounding conductor
Table 6- 3 Minimum cross-sectional area of grounding conductor
Minimum cross-section of the phase conductor
for installation
S
[mm²]
Minimum cross-section of the associated ground-
ing connection
[mm²]
S ≤ 25
S
25 < S ≤ 50 25
S > 50
0.5 S
Electrical connection
6.3 Connecting the grounding conductor
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6.3.2 Grounding connection type
Enclosure grounding method
Conductor cross-
section
mm²
Connection of an individual conductor under the
external grounding bracket.
… 10
Connection is made using a DIN cable lug under
the external grounding bracket. DIN 46 234
… 25
Internal ground terminal
When making connections, ensure the following:
● Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
● Arrange the flat washer and spring washer under the bolt head.
● Locate the cable lug under the clamping bracket.
● Use the terminals designated for the grounding conductor in the terminal box.
● Observe the tightening torque (Page 168) for the locking screw.
External ground terminal
When making connections, ensure the following:
● Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
● Position the cable lug between the contact bracket and the grounding bracket; do not
remove the contact bracket pressed into the enclosure!
● Arrange the flat washer and spring washer under the bolt head.
● Use the marked connection location for the grounding conductor on the stator housing.
Electrical connection
6.4 Connecting the temperature sensor/anti-condensation heater
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● Observe the tightening torque (Page 168) for the locking screw.
Shaft height
Thread size for the grounding conductor
63 ... 160
1 x M 5
180 1 x M 6
200
2 x M 6
225 ... 315
2x M8
315 ... 355
(1MB)
2 x M 12
The additional grounding point (generally on the opposite side) is optionally available.
6.4 Connecting the temperature sensor/anti-condensation heater
6.4.1 Connecting optional integrated devices and equipment
In addition to the current-dependent overload protective device located in the connecting
cables, use the optionally available integrated devices and equipment, for example,
temperature sensor, anti-condensation heating.
Depending on the terminal box version, connect the auxiliary circuits to the terminal block or
to the terminal board.
Terminal block connection
Terminal board connection
Electrical connection
6.5 Conductor connection
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6.5 Conductor connection
Cross-sections that can be connected depending on the size of the terminal (possibly
reduced due to size of cable entries)
Table 6- 4 Max. conductor connection for standard machines and Ex tc
Shaft height
Max. connectable conductor cross-section
mm²
63 ... 90 1.5
2.5 with cable lug
100 ... 112
4.0
132
6.0
160 ... 180
16.0
200
25.0
225
35.0 with cable lug
250 ... 280
120.0
315
240.0
Table 6- 5 Max. conductor connection for explosion-protected machines (with the exception of Ex
tc) and VIK in the standard version
Shaft height
Max. connectable conductor cross-section
mm²
63 ... 112
4.0
132
6.0
160
16.0
180
10.0
180 (1LG4, 1LG6)
16.0
200 ... 225
50.0
250 ... 280
120.0
315
240.0
Electrical connection
6.5 Conductor connection
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6.5.1 1MB..
Type of connection
Terminal studs
Cable cross-section
mm²
Connection with cable lug DIN 46234
M 4 1 ... 4
1 ... 6 (shaft height 132)
M5 1 ... 16
M6 4 ... 35
Connection of a single conductor
M 4
1 ... 4
1 ... 6 (shaft height 132)
M5
1 ... 16
M6 4 ... 35
Connection of two conductors of the same
thickness with terminal clamp
M 4
Not permitted
M5
Not permitted
M6 4 ... 35
Electrical connection
6.5 Conductor connection
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Type of connection
Terminal studs
Cable position with terminal
Cable cross-section
mm²
M 8
2.5 … 25
16 ... 50
10 … 16
M 10
10 ... 95
M 12
25 … 185
M 16 50 … 300
M 10
50 … 120
M 12
95 … 240
M 16 120 … 300
M 10
16 … 35
M 12
16 … 70
M 16 16 … 120
M 20
25 ... 300
Assembly of clamping device
M8
Mount the clamping devices on the terminal board at a distance of
0.1 ... 1 mm to the lock nuts.
Electrical connection
6.5 Conductor connection
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6.5.2 Cable ends with wire end sleeves
1. Preferably use end sleeves instead of soldering cable ends.
2. Before connecting, attach the end sleeves so as to form a technically correct, current-
carrying crimped joint at the end of the conductor.
WARNING
Risk of explosion due to excessive temperature rise
If the end of the conductor is not correctly enclosed by the end sleeve, but is trapped by
it, this can lead to overheating. The temperature class of the machine can be exceeded.
This can trigger ignition of an explosive mixture. This can result in death, serious injury
or material damage.
• Insert only one conductor end into each end sleeve. Attach the end sleeve correctly.
6.5.3 Connecting aluminum conductors
If you are using aluminum conductors, then comply with the following:
● Use only cable lugs that are suitable for connecting aluminum conductors.
● Immediately before inserting the aluminum conductor, remove the oxide layer from the
contact areas on the conductor and/or the mating piece. Do this using a brush or file.
● Then grease the contact areas immediately using neutral Vaseline. This prevents a new
oxide layer from forming.
NOTICE
Aluminum flow due to contact pressure
Aluminum flows following installation due to the contact pressure. The connection using
clamping nuts can loosen as a result. The contact resistance increases, obstructing the
current from being conducted. This can result in fire and material damage to the
machine – or even in total failure, as well as material damage to the plant or system due
to machine failure.
• Retighten the clamping nuts after approximately 24 hours and then again after
approximately four weeks. Make sure that the terminals are de-energized before you
tighten the nuts.
Electrical connection
6.6 Connecting the converter
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6.6 Connecting the converter
NOTICE
Excessively high supply voltage
Material damage can occur if the supply voltage is too high for the insulation system.
SIMOTICS machines can be operated with SINAMICS G converters and SINAMICS S
converters (uncontrolled and controlled infeed) when maintaining the permissible peak
voltages.
Carefully observe the values in the following tables.
Rise times tr > 0.1 µs.
The insulation system of SIMOTICS machines corresponds to the specifications laid down
in IEC 60034-18-41 according to voltage stress category C (IVIC C = high stress).
Table 6- 6 Maximum voltage peaks at the motor terminals for line (DOL) motors, converter operation possible
Rated motor voltage
V
Maximum peak voltage at the motor terminals
Û
max
dependent on the rise time t
r
Ûphase-to-phase
Vpk
Ûphase-to-ground
Vpk
Rise time tr
μs
DC link UDC
V
≤ 500 V
1500
1100
0.5
750
900
900
0.1
Table 6- 7 Maximum voltage peaks at the motor terminals for motors specifically designed for converter operation (e.g.
VSD 10)
Rated motor voltage
V
Maximum peak voltage at the motor terminals
Ûmax dependent on the rise time tr
Ûphase-to-phase
V
pk
Ûphase-to-ground
V
pk
Rise time tr
μs
DC link UDC
V
≤ 500 V
1600
1400
0.5
750
1000 1000 0.1
> 500 V to 690 V
2200
1800
0.5
1080
1000
1000
0.1
See also
Further documents (Page 166)
Electrical connection
6.6 Connecting the converter
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WARNING
Machine overheating
Operating explosion-protected machines at the converter without using the appropriate
protective equipment can result in death or severe injury.
Always use PTC thermistor monitoring when operating explosion-protected machines at the
converter. Tripping units according to Directive 2014/34/EU ("Explosion Protection
Directive") are always necessary when using PTC thermistor monitoring.
Machines with non-sparking "ec" "nA" type of protection
The operation of the explosion-proof machines on the converters is permitted, when the
specifications for the speed control range and torque characteristic are observed, and if
winding temperature monitoring is ensured via the integrated temperature sensors in
conjunction with a certified tripping unit.
Machines with increased safety "eb" type of protection
Converter operation for these machines must be expressly certified. It is essential that you
observe the separate manufacturer's information and instructions. Converter and protective
devices must be marked as belonging together and the permitted operating data must be
defined in the common EC-type examination certificate.
Machines with type of protection, dust explosion protection "tb" or dust explosion protection
"tc"
These machines are generally equipped with 3 PTC thermistors in accordance with DIN
44082 with a rated response temperature that depends on the maximum possible surface
temperature. Select the PTC thermistors in accordance with this standard. The maximum
temperature at the cable entries is 120 °C. Use suitable cables for this temperature. Do not
exceed the maximum frequency dependent on the number of poles, which is stamped on the
rating plate.
System, converter - cable - electrical machine
Please observe the information and data provided in EN / IEC 60034-17 and
EN / IEC 60034-25 regarding winding stress. For line supplies with operating voltages up to
690 V, the maximum value of the voltage peaks at the end of the cable must not exceed
twice the value of the converter's DC-link voltage.
See also
Thermal protection (Page 44)
Electrical connection
6.7 Final checks
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6.7 Final checks
Before closing the terminal box/terminal base of the machine enclosure, check the following:
● Establish the electrical connections in the terminal box in accordance with the information
in this documentation.
● Maintain the air clearances between non-insulated parts as described in Chapter
Minimum air clearances. (Page 77)
● Avoid protruding wire ends.
● In order not to damage the cable insulation, freely arrange the connecting cables.
● Connect the machine corresponding to the specified direction of rotation.
● Keep the inside of the terminal box clean and free from trimmed-off ends of wire.
● Ensure that all seals and sealing surfaces are undamaged and clean.
● Correctly and professionally close unused openings in the terminal boxes. Observe the
information in this documentation.
● Observe the information on torques in this documentation.
See also
Tightening torques for screw and bolt connections (Page 167)
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Commissioning
7
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
● Before commissioning, carefully observe the requirements laid down in Standard IEC /
EN 60079-14 or IEC / EN 60079-17.
Note
Service Center
Please contact the Service Center if you require commissi
oning support.
7.1 Measures before 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.
Commissioning
7.1 Measures before commissioning
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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.
Risk of losing the IP degree of protection as a result of damaged shaft sealing rings
This can result in death, serious injury, or material damage.
● Replace damaged components immediately.
● Rotate the rotor to ensure that it does not touch the stator.
● Ensure that the bearing insulation is not bridged/jumpered.
● Using the appropriately designed and adjusted control and speed monitoring functions
ensure that the permissible speeds specified on the rating plate cannot be exceeded.
● Ensure that any supplementary equipment used to monitor the motor is correctly
connected and is functioning.
Electrical connection
● Carefully check the grounding and potential bonding connections.
● Connect the machine corresponding to the specified direction of rotation.
● Using the appropriate open-loop control and speed monitoring functions, carefully ensure
that no higher speeds can be achieved than are permitted and specified in the technical
data. For this purpose, compare the data on the rating plate or, if necessary, the 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.
● 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.
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.
Commissioning
7.1 Measures before commissioning
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● 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.
7.1.1 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"
Commissioning
7.1 Measures before commissioning
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7.1.2 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.
Commissioning
7.1 Measures before commissioning
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Limit values for the stator winding insulation resistance
The following table specifies the measuring voltage and limit values for the insulation
resistance. These values correspond to IEEE 43-2000 recommendations.
Table 7- 1 Stator winding insulation resistance at 40° C
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
C
Insulation resistance converted to 40° C reference temperature
K
T
Temperature coefficient according to equation (2)
R
T Measured 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.
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.
Commissioning
7.1 Measures before commissioning
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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 165).
• If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
Limit values of the anti-condensation heating insulation resistance
The insulation resistance of the anti-condensation heating with respect to the machine
housing should not be lower than 1 MΩ when measured at 500 V DC.
7.1.3 Testing the cooling of the machine
Cooling
● Check that the machine cooling is available for commissioning.
See also
Preparing for use (Page 35)
7.1.4 Commissioning an external fan
The external fan ensures that the machine is cooled irrespective of the machine speed or
direction of rotation. The external fan is only suitable for one direction of rotation.
Commissioning
7.1 Measures before commissioning
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Checks before the first test run
Before the first test run, carry out the following checks:
● The external fan is correctly fitted and aligned.
● The rotor runs freely.
● All of the retaining elements and electrical connections are securely tightened.
● The grounding and equipotential bonding connections to the mains have been correctly
made.
● The air flow is not impeded or shut off by flaps, covers or similar.
● If the cooling air is in open circulation, it has only weak, chemically abrasive properties
and a low dust content.
● All protection measures have been taken to prevent accidental contact with moving or live
parts.
Performing the test run
1. Switch the external fan motor on and off briefly.
2. Compare the direction of rotation of the external fan with the specified direction of
rotation. The direction of rotation of the external fan is indicated with an arrow on the fan
cover specifying the direction of rotation or with a terminal designation on the rating plate
of the external fan unit.
Depending on the version, the fan impeller is visible through the air inlet opening in the
fan cover on the external fan motor.
3. If the direction of rotation is wrong, then interchange two line cables in the external fan
motor terminal box.
Note
Use these operating instructions for motors with external fans.
7.1.5 Further documents
Note
Further documents
Observe all of
the other documents provided with this machine.
Commissioning
7.2 Setpoint values for monitoring the bearing temperature
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7.2 Setpoint values for monitoring the bearing temperature
Prior to commissioning
If the machine is equipped with bearing thermometers, set the temperature value for
disconnection on the monitoring equipment before the first machine run.
Table 7- 2 Set values for monitoring the bearing temperatures before commissioning
Set value
Temperature
Alarm
115 °C
Shutting down
120 °C
Normal operation
Determine the maximum operating temperature of the bearings Toperation taking into account
the temperature, bearing load and influences of the plant on the motor in °C. Set the values
for shutdown and warning corresponding to the operating temperature Top.
Table 7- 3 Set values for monitoring the bearing temperatures
Set value
Temperature
Alarm
T
operation
+ 5 K ≤ 115 °C
Shutting down
T
operation
+ 10 K ≤ 120 °C
7.3 Switching on
Measures for start-up
After installation or inspections, the following measures are recommended for normal start-
up of the machines:
● Start the machine without a load. To do this, close the circuit breaker and do not switch
the machine off prematurely. 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 to a standstill
before switching it back on again.
● Check mechanical operation for noise or vibration at the bearings or end shields.
● If the machine is not running smoothly or is emitting abnormal noises, switch it off, and
determine the cause of the fault as it runs down.
● If mechanical operation improves immediately after the machine is switched off, then the
cause is magnetic or electrical, e.g. voltage imbalance, magnetic imbalance. If
mechanical operation does not improve immediately after switching the machine off, then
the cause is mechanical, e.g. an imbalance in the electrical machines or in the driven
Commissioning
7.3 Switching on
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machine, inadequate alignment of the machine set, operation of the machine with the
system resonating (system = machine + base frame + foundations etc.).
● If the machine runs perfectly in terms of its mechanical operation, switch on any cooling
devices present and continue to monitor the machine for a while as it idles.
● If it runs perfectly, connect a load. Check that it runs smoothly.
Read off and document the values for voltage, current, and power.
Where possible, read off corresponding values for the driven machine and document
them as well.
● Monitor the bearing temperature, winding temperature, etc. until the system reaches a
steady state.
Document these, provided this is possible with existing measuring instruments.
NOTICE
Destruction of the machine
The machine can be destroyed if the vibration values are not strictly complied with.
• In operation, maintain vibration values in accordance with DIN ISO 10816-3.
● Start the machine without a load; to do this, close the motor starter protector and do not
switch the machine off prematurely.
● You should limit how often you switch the machine off while it is starting up and still
running at a slow speed, for checking the direction of rotation or the required dimensions,
for example.
● Allow machines to reach a standstill before switching them back on.
7.3.1 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.
Commissioning
7.3 Switching on
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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.
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Operation
8
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
8.1 Safety instructions for operation
Risk of injury due to rotating parts
Rotating parts are dangerous. Touch protection against rotating parts is no longer
guaranteed if covers are removed. Touching rotating parts can result in death, serious injury
or material damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● Only remove the covers when the rotating parts have come to a complete standstill.
Danger as a result of stationary parts under voltage (live parts)
Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum air and creepage distances may be fallen
below (violated) when coming close to active parts. Touching or coming close can result in
death, serious injury or material damage.
● Carefully ensure that all of the covers are closed while operational.
● First switch off and disconnect the machine if you must remove covers. Comply with the
"Five safety rules":
● When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and in a no-voltage
condition.
Operation
8.1 Safety instructions for operation
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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.
These changes can cause faults which can result in eventual or immediate death, serious
injury or material damage.
● Immediately inform the service personnel.
● If you are in doubt, immediately switch off the machine, carefully observing the system-
specific safety conditions.
Damage caused by condensation
Humidity in the air can condense for intermittent duty or load fluctuations. Condensate can
collect. Moisture can have a negative impact on the winding insulation or result in damage,
such as corrosion.
● Ensure that any condensation can freely flow away.
Risk of burn injuries as a result of hot surfaces
Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
● Never touch machine parts during operation.
● Allow the machine to cool down before starting work.
● Check the temperature of parts before touching them. If required, wear suitable protective
equipment.
Hazardous substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk. Poisoning, skin damage, cauterization of the respiratory tract, and
other health damage may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.
Substances that can be easily ignited and are flammable
Chemical substances required for the setup, operation and maintenance of machines may
be flammable. Burns and other damage to health and material may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.
Operation
8.1 Safety instructions for operation
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Switching on the machine
DANGER
Hazardous voltages
Electrical machines are at hazardous voltage levels. Contact with these can result in death,
serious injury or material damage.
Operating the machine on a line supply system with a non-grounded neutral point is only
permitted for short periods of time that occur rarely, e.g. the time leading to a fault being
eliminated. Cable ground fault EN / IEC 60034-1.
NOTICE
Damage to the machine or premature bearing failure
The bearings can be damaged if the following is not observed.
• It is absolutely crucial that you maintain the permissible vibration values to avoid
damage to the machine or its destruction.
• In operation, observe the vibration values in accordance with ISO 10816-3.
• Under all circumstances maintain the minimum radial load of cylindrical roller bearings
of 50% corresponding to what is specified in the catalog.
• Take the appropriate measures to reduce bearing currents. Observe the Chapter
Converter operation.
WARNING
Faults in operation
Changes with respect to normal operation indicate that there is an impaired function. This
can cause faults which can result in eventual or immediate death, severe injury or material
damage.
For instance, observe the following signs that could indicate a malfunction:
• Higher power drawn than usual
• Higher temperatures than usual
• Unusual noises
• Unusual smells
• Response of monitoring equipment
Immediately contact the maintenance personnel if you identify any irregularities. If you are
in doubt, immediately switch off the machine, being sure to observe the system-specific
safety conditions.
Operation
8.1 Safety instructions for operation
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NOTICE
Risk of corrosion due to condensation
If the machine and/or ambient temperatures fluctuate, this can result in condensation inside
the machine.
• If available, remove the drain plugs or drain screws to drain the water depending on the
ambient and operating conditions.
• If available, re-attach the drain plugs or drain screws.
If the motor is equipped with drain plugs, then the water can drain away by itself.
Switching on the machine with anti-condensation heating (optional)
CAUTION
Machine overheating
Minor injury or material damage can occur if you do not observe the following:
• If available, switch off the anti-condensation heating each time before switching on.
See also
Converter operation (Page 48)
Explosion hazard from hybrid mixtures
Hybrid mixtures are mixtures of flammable dusts with explosive gas/air atmospheres which
can together create a dangerous explosive atmosphere if they occur at the same time.
Changes can arise in the safety characteristics here, such as a change in the zonal
classification, increase in the explosion pressure, reduction in the minimum ignition energy
and a reduction in the maximum temperatures to be observed.
An explosion can result. This can result in death, serious injury or material damage.
● For this reason, the relative characteristics must be considered both for gas (zones 0, 1
and 2) and for dust (zones 20, 21 and 22) where hybrid mixtures arise. It is necessary for
a competent assessor to determine in the individual case whether the parameters
determining ignition are unfavorably affected in a particular hybrid mixture.
● Motors with dual plates for G (“Gas”) and D (“Dust”) may only be used where these two
occur after prior examination of the properties of the hybrid mixtures by the user.
Operation
8.1 Safety instructions for operation
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WARNING
Explosion hazard
These explosion-protected machines are not suitable for hybrid explosive environments.
This can result in death, serious injury or material damage.
Use in atmospheres where there is a risk of explosion caused by both gas and dust
simultaneously is absolutely prohibited.
Only install machines with type of protection increased safety "eb" and machines "ec" in
hazardous zones, carefully complying with the regulations laid down by the responsible
regulatory body. They are responsible for determining the hazard level of each area (division
into zones). For machines with Ex "t", under no circumstances must a layer of dust be
greater than 5 mm!
● If there are no other specifications in the EC or EU-type examination certificate or on the
rating plate regarding operating mode and tolerance, electrical machines are designed for
continuous duty and normal starting procedures that are performed infrequently and do
not result in excessive temperature rise. Only use these machines for the operating mode
specified on the rating plate.
● If an anti-condensation heating system is available, it may only be switched on when the
machines are not in operation.
See also
Thermal protection (Page 44)
Explosion hazard due to overheating of the machine caused by a layer of dust
Deposits of dust have a thermal insulation effect, which can lead to the machine overheating.
The maximum surface temperature of the machine cannot be adhered to. The dust can
ignite, resulting in an explosion. This can result in death, serious injury, or material damage.
● Dust the machine regularly.
● Do not allow dust layers thicker than 5 mm to build up on the machine surface.
● Do not switch the machine on until the dust has been removed.
Operation
8.1 Safety instructions for operation
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Explosion hazard due to excessive bearing temperature
The surface temperature cannot be maintained within maximum permissible limits if the
bearing becomes too hot. The dust can ignite, resulting in an explosion. This can result in
death, serious injury, or material damage.
● Monitor the storage temperature temperature.
● In addition to the current-dependent overload protection device located in the three
phases of the connecting cable, we recommend that you also monitor the temperature
rise in the machine with the aid of the temperature sensors built into the stator winding.
● You will find the alarm and shutdown temperatures in the Technical Data.
8.1.1 Static charging when cleaning
Risk of explosion due to static charging
If you clean the motor, plastic components may become statically charged and ignite a
potentially explosive atmosphere. An explosion can occur. This can result in death, serious
injury or material damage.
● When cleaning ensure that there is absolutely no explosive atmosphere present.
● Clean the plastic parts and components so that absolutely no static charging occurs
● Do not use compressed air for cleaning.
8.1.2 Safety instructions relating to ventilation and cooling
Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
WARNING
Risk of burning
Operating the machine without external fan results in overheating. This may result in death,
personal injury and material damage.
• Never commission the machine without an external fan.
CAUTION
Risk of injury when touching the fan
There is a risk of injury at machines equipped with a fan cover (e.g. on machines in the
textile industry), as the fan is not completely touch protected.
• Do not touch the rotating fan.
• Do not put your fingers into the larger air discharge openings.
• Prevent manual intervention by using suitable measures, e.g. appropriate housings or a
protective grating.
Operation
8.1 Safety instructions for operation
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8.1.3 Bridging insulated bearings
Explosion hazard if the bridging is removed from the insulated bearing
Removing the factory-fitted bridging of the insulated bearing leads to potential differences
between the rotor and the grounded motor. This can cause the generation of sparks, which
especially in an explosive atmosphere can ignite surrounding dust or combustible gases.
Explosions can occur. There is also a risk of an electric shock. Death, serious injury, or
material damage will result.
● Do not open the bridging of the bearing insulation during operation.
8.1.4 Switching on with the anti-condensation heating active
Excessively high machine temperature when heating is switched on
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine. Material damage can result.
● Make sure that the anti-condensation heating is switched off before the machine is
switched on.
● Only operate anti-condensation heating when the machine is switched off.
WARNING
Explosion hazard
If the anti-condensation heating is switched on during operation, the temperature class or
the maximum surface temperature of the machine can be exceeded.
In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious
injury or material damage.
Only switch the anti-condensation heating on after the motor has been switched off.
Operation
8.2 Switching on the machine
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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.
8.3 Switching off the external fan
Do not immediately switch off the separately-driven (external) fan after switching off the
machine. First wait for the machine to cool down. This will prevent the accumulation of
residual heat.
8.4 Switching on again after an emergency switching-off
● Check the machine before recommissioning the driven machine after an Emergency Off.
● Eliminate all the causes that have led to the emergency off
8.5 Stoppages
The stoppage is a shutdown for a period of time, during which the machine is stopped but
remains at the location of use.
Under normal ambient conditions, e. g. the stopped machine is not exposed to any vibration,
no increased level of corrosion, etc. in general, the following measures are necessary during
stoppages.
Operation
8.5 Stoppages
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Longer non-operational periods
Note
•
For longer non-operational periods (> 1 month), either operate the machine or at least
turn the rotor regularly, approximately once per month.
•
Please refer to the section "Switching on" before switching on to recommission the motor.
•
Remove any machine rotor locking devices before you turn the rotor.
NOTICE
Restricted motor function
If not used for longer periods of time, material damage or complete motor failure can occur.
If the motor is out of service for a period of more than 12 months, then environmental
effects can damage the motor.
• Apply suitable corrosion protection, preservation, packing and drying measures.
Switching on the anti-condensation heater
Switch on any anti-condensation heating while the machine is not being operated.
Taking the machine out of service
Details regarding the necessary measures, Chapter Preparing for use (Page 35).
Lubricating before recommissioning
NOTICE
Dry running bearings
Bearings can be damaged if they do not have sufficient grease.
• Re-grease the bearings if they have been out of service for more than one year. The
shaft must rotate so that the grease can be distributed in the bearings. Observe the data
on the lubricant plate.
Chapter
Installing rolling bearings
.
WARNING
Explosion hazard
If the anti-condensation heating is switched on directly after the machine is switched off, the
temperature class or the maximum surface temperature of the machine can be exceeded.
In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious
injury or material damage.
• Only switch on the anti-condensation heating after the motor has been switched off.
Carefully comply with the data on the anti-condensation heating plate.
Operation
8.5 Stoppages
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8.5.1 Avoidance of damage to rolling bearings during stoppages
Extended stoppages at the identical or almost identical resting position of the rotor in the
rolling bearings can result in damage, such as brinelling or corrosion.
● During stoppages, regularly start up the machine for a brief period once a month. As a
minimum, turn the rotor several times.
If you have uncoupled the machine from the driven machine and secured the rotor with a
rotor shipping brace, then remove this before turning the rotor over or starting up the
machine.
Make sure that the resting position of the rotor after the rotor has been turned over is
different from its previous position. Use the fitted key or the coupling halves as reference
markers.
● During recommissioning, refer to the information in Chapter "Commissioning".
8.5.2 Decommissioning the machine
● Record the decommissioning steps. This log will be useful upon recommissioning.
● If the machine is going to be out of service for longer than six months, then take the
necessary measures for preservation and storage. Otherwise, the machine could be
damaged as a result of not being operated.
8.5.3 Re-commissioning the machine
When you re-commission the machine, proceed as follows:
● Study the record made when the machine was decommissioned, and reverse the
measures that were taken for conservation and storage.
● Perform the measures listed in the "Commissioning" section.
See also
Commissioning (Page 89)
Operation
8.6 faults
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8.6 faults
8.6.1 Inspections in the event of faults
Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.
Correct the cause of the fault as described in the respective remedial measures section.
Repair any damage to the machine.
8.6.2 Electrical faults
Note
If you are operating the motor with a converter, the operating instructions of the converter
must also be observed if electrical faults occur.
Table 8- 1 Electrical faults
↓ Motor fails to start
↓ Motor accelerates sluggishly
↓ Rumbling noise during startup
↓ Rumbling noise during operation
↓ High temperature rise during no-load operation
↓ High temperature rise with load
↓ High temperature rise of individual winding sections
Possible causes of faults
Remedial measures
X
X
X
X
Overload
Reduce the load.
X
Interrupted phase in the supply cable
Check the switches and cables.
X X X X Interrupted phase in the feeder cable
after switching on
Check the switches and cables.
X Mains voltage too low, frequency too
high
Check the power supply conditions.
X Mains voltage too high, frequency too
low
Check the power supply conditions.
X X X X X Stator winding incorrectly connected Check the winding connection in the terminal
box.
X X X X Winding short circuit or phase short
circuit in stator winding
Determine the winding resistances and insula-
tion resistances. Carry out repair work
after
consultation with the manufacturer.
X
Incorrect direction of rotation
Check the connection.
Operation
8.6 faults
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8.6.3 Mechanical faults
Table 8- 2 Mechanical faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults
Remedial measures
X Rotating parts grind Establish the cause and realign the parts.
X Rotor or coupling not balanced.
Disconnect the rotor or coupling and rebalance.
If the machine has two shaft ends, and a transmission element is
only fitted to one end, secure the fitted key at the other end to
prevent it from being thrown out. If the rotor has balance type "H"
(standard type), the fitted key must be cut back to roughly half of
its length.
X
Rotor out of round, shaft bent
Consult the manufacturing plant.
X
X
Poor alignment
Align the machine set; check the coupling.
(1)
X
Coupled machine not balanced
Rebalance the coupled machine.
X
Shocks from coupled machine
Investigate the coupled machine.
X
X
Uneven running of gear unit
Fix the gearing.
X X Resonance of the overall system com-
prising motor and foundation
Stabilize the foundation following consultation.
X X Changes in foundation Establish the cause of the changes and eliminate them if neces-
sary; realign the machine.
(1)
Take any changes into account when warming up the machine.
Operation
8.7 Deactivating
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8.6.4 Rolling bearing faults
Damage to rolling bearings can be difficult to detect in some cases. If in doubt, replace the
rolling bearing. Use other bearing designs only after consulting the manufacturer.
Table 8- 3 Rolling bearing faults
↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
Possible causes of faults
Remedial measures
X High coupling pressure Align the machine more accurately.
X
Belt tension too high
Reduce the drive belt tension.
X
Bearing contaminated
Clean or replace the bearing. Check the seals.
X
High ambient temperature
Use a suitable high-temperature grease.
X
X
Insufficient lubrication
Grease the bearings as instructed.
X
X
Bearing canted
Contact the service center.
X
X
Insufficient bearing play
Contact the service center.
X
Excessive bearing play
Contact the service center.
X
X
Bearing corroded
Replace the bearing. Check the seals.
X
Too much grease in bearing
Remove surplus grease.
X
Wrong grease in the bearing
Use the correct grease.
X
Friction marks on raceway
Replace the bearing.
X
Brinelling or scoring
Replace the bearing. Avoid any vibration at standstill
8.6.5 Faults at the external fan
The following table shows the possible causes of and remedial measures for faults on
forced-ventilated machines.
Table 8- 4 Cooling system faults
↓ High temperature rise with load
Possible causes of faults
Remedial measures
X
Wrong direction of rotation of the external fan
Check the electrical connections to the external fan.
X
External fan is not running
Check the external fan and its connections.
X
Reduced air flow
Check the air ducts; clean the machine.
8.7 Deactivating
Commission any devices provided for protection against condensation after switching off the
machine.
Operation
8.7 Deactivating
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Maintenance
9
Through careful and regular maintenance, inspections, and overhauls you can detect faults
at an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
Comply with the IEC / EN 60079-17 standard during all service and maintenance work on
the machine.
Note
Please contact the
service center (Page 165), if you require support with service,
maintenance or repair.
9.1 Preparation and notes
9.1.1 North American market (optional)
When making changes or repairs, maintain the corresponding design standards! These
machines are labeled on the rating plate with the following markings.
Underwriters Laboratories
Canadian Standard Association
Canadian Standard Association E
nergy Efficiency Verification
Maintenance
9.2 Inspection and maintenance
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9.1.2 Customs union Eurasia (optional)
When making changes or repairs, maintain the corresponding design standards! These
machines are labeled on the rating plate with the following markings.
Customs union Eurasia
Eurasian customs union
Explosion
-protected
9.2 Inspection and maintenance
9.2.1 Safety instructions for inspection and maintenance
WARNING
Rotating and live parts
Electric machines contain live and rotating parts. Fatal or serious injuries and substantial
material damage can occur if maintenance work is performed on the machine when it is not
stopped or not de-energized.
• Perform maintenance work on the machine only when it is stopped. The only operation
permissible while the machine is rotating is regreasing the rolling bearings.
• When performing maintenance work, comply with the five safety rules (Page 11).
WARNING
Machine damage
If the machine is not maintained it can suffer damage. This can cause faults which can
result in eventual or immediate death, serious injury or material damage.
Perform regular maintenance on the machine.
CAUTION
Dust disturbances when working with compressed air
When cleaning with compressed air, dust, metal chips, or cleaning agents can be whirled
up. Injuries can result.
When cleaning using compressed air, make sure you use suitable extraction equipment
and wear protective equipment (safety goggles, protective suit, etc.).
Maintenance
9.2 Inspection and maintenance
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NOTICE
Damage to insulation
If metal swarf enters the winding head when cleaning with compressed air, this can
damage the insulation. Clearance and creepage distances can be undershot. This may
cause damage to the machine extending to total failure.
When cleaning with compressed air, ensure there is adequate extraction.
NOTICE
Machine damage caused by foreign bodies
Foreign bodies such as dirt, tools or loose components, such as screws etc., can be left by
accident inside the machine after maintenance is performed. These can cause short
circuits, reduce the performance of the cooling system or increase noise in operation. They
can also damage the machine.
• When carrying out maintenance work, make sure that no foreign bodies are left in or on
the machine.
• Securely attach all loose parts again once you have completed the maintenance
procedures.
• Carefully remove any dirt.
Note
Operating conditions and characteristics can vary widely. For this reason, only general
intervals for inspection and maintenance measures can be specified here.
9.2.2 Explosion hazard due to increased surface temperature
WARNING
Explosion hazard due to increased surface temperature
Components within the motor may be hotter than the maximum permissible surface
temperature for the enclosure. In an explosive atmosphere, dust can ignite and an
explosion occur. This can result in death, serious injury or material damage.
• Do not open the motor in an explosive and dusty atmosphere when it is still at normal
operating temperature.
• Allow the machine to cool down before opening it.
Maintenance
9.2 Inspection and maintenance
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Explosion hazard due to overheating of the machine caused by a layer of dust
Deposits of dust have a thermal insulation effect, which can lead to the machine overheating.
The maximum surface temperature of the machine cannot be adhered to. The dust can
ignite, resulting in an explosion. This can result in death, serious injury or material damage.
● Dust the machine regularly.
● Do not allow dust layers thicker than 5 mm to build up on the machine surface.
● Do not switch the machine on until the dust has been removed.
Risk of explosion due to excessive bearing temperature
The surface temperature cannot be maintained within maximum permissible limits if the
bearing becomes too hot. The dust can ignite, resulting in an explosion. This can result in
death, serious injury or material damage.
● Monitor the bearing temperature.
● In addition to the current-dependent overload protection device located in the three
phases of the connecting cable, we recommend that you also monitor the temperature
rise in the machine using temperature sensors integrated in the stator winding.
9.2.3 Static charging when cleaning
Risk of explosion due to static charging
If you clean the motor, plastic components may become statically charged and ignite a
potentially explosive atmosphere. An explosion can occur. This can result in death, serious
injury or material damage.
● When cleaning ensure that there is absolutely no explosive atmosphere present.
● Clean the plastic parts and components so that absolutely no static charging occurs
● Do not use compressed air for cleaning.
9.2.4 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
9.2 Inspection and maintenance
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9.2.5 First inspection
● 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.
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.
9.2.6 General inspection
Check that the installation conditions are observed. We recommend that the following
checks are performed after approx. 16 000 operating hours or at the latest after two years:
Table 9- 1 Checks that have to be performed during the general inspection
Checking
When the
motor is
running
At stand-
still
The electrical parameters are maintained
X
The permissible bearing temperatures are not exceeded
X
The smooth running characteristics and machine running noise have not
deteriorated
X
The motor foundation has no cracks and 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
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
(*) You can perform these checks while the motor is at standstill or, if required, while running.
Maintenance
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NOTICE
Machine damage
When carrying out the inspection, if you detect any impermissible deviations from the
normal state, you must rectify them immediately. They may otherwise cause damage to the
machine.
9.2.7 Assessing the rolling bearings
To assess the rolling bearings, it is generally not necessary to dismantle the machines. The
motor only has to be dismantled if the bearings are to be replaced.
The state of a rolling bearing can be assessed by analyzing the bearing vibration. The
measured values provide an indication and can be assessed by specialists. In this case,
please contact the Service Center.
9.2.8 Mechanical explosion protection for rolling bearings
All machines marked in accordance with Directive 2014/34/EU ("Explosion Protection
Directive") must be regularly inspected for mechanical damage which could constitute a risk
of ignition in accordance with IEC/EN 60079-17 .
● Comply with the following intervals:
– Bearing replacement intervals
– Relubrication intervals
– Grease replacement intervals
– Oil change intervals
● Rolling bearing service life
– Replace the rolling bearings once the nominal service life is reached. Alternatively,
you can verify they are free of mechanical damage as part of an inspection.
– In the case of rolling bearings without a regreasing system, it is ensured that the
nominal service life will only be achieved clearly after achievement of the service life of
the grease in the bearings.
– The rolling bearing service life under full specified load is at least 20 000 hours for
machines subject to radial or axial forces.
– The nominal rolling bearing service life of machines which are not subject to any
forces is at least 40 000 hours.
● For rolling bearings with external oil supply, monitor that lubrication is maintained.
Maintenance
9.2 Inspection and maintenance
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9.2.9 Maintenance intervals
Please note the following in order to identify faults at an early stage, rectify them and avoid
follow-on damage:
● Maintain the machine regularly and carefully.
● Inspect the machine.
● Motors must be allocated a revision/inspection number after inspection.
NOTICE
Motor failure
Material damage can occur if the machine develops faults or is overloaded.
• Immediately inspect the machine if faults occur.
• An immediate inspection is especially necessary, if the three-phase motor is
excessively stressed, either electrically or mechanically (e.g. overload or short-
circuit).
The machines are equipped with permanently lubricated rolling bearings. The machine may
be equipped with a regreasing device.
CAUTION
Skin irritations and eye inflammations
Many greases can cause skin irritations and eye inflammations.
• Follow all safety instructions of the manufacturer.
Measures, intervals and deadlines
Measures after operating period intervals or deadlines have elapsed:
Operating situations and characteristics can vary widely. For this reason, only general
maintenance intervals are specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Table 9- 2 Operating period intervals
Measures
Operating period intervals
Intervals
Initial inspection
After 500 operating hours
After 1/2 year at the latest
Relubrication (optional)
See the lubricant plate
Clean
Depending on the degree of pollution
Main inspection Approximately every 16000 operating
hours
After two years at the latest
Drain condensate
Depending on the climatic conditions
Maintenance
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9.2.10 Re-greasing
For machines with regreasing system, relubrication intervals, grease quantity and grease
grade are provided on the lubricant plate. Additional data can be taken from the main
machine rating plate.
Grade of grease for standard motors (IP55) UNIREX N3 - ESSO.
Note
It is not permissible to mix different types of grease.
Prolonged storage periods reduce the useful lifetime of the bearing grease. Check the
condition of the grease if the equipment has been in storage for more than 12 months. If the
grease is found to have lost oil content or to be contaminated, the machine must be
immediately relubricated before commissioning. For information on permanently-greased
bearings, please refer to the section titled Rolling bearings (Page 128).
Procedure
To relubricate the rolling bearings, proceed as follows:
1. Clean the grease nipples at the drive end and non-drive end.
2. Press-in the specified grease and amount of grease according to the data stamped on the
lubrication plate.
– Please observe the information on the rating and lubricant plates.
– Regreasing should be carried out when the motor is running (max. 3600 rpm).
The bearing temperature can rise significantly at first, and then drops to the normal value
again when the excess grease is displaced out of the bearing.
WARNING
Rotor can fall out
If the machine is in a vertical position, the rotor can fall out while work is being performed
on the locating bearing. This can result in death, serious injury or material damage.
Support or relieve the rotor when carrying out work with the machine in a vertical position.
9.2.11 Cleaning
Cleaning the grease ducts and spent grease chambers
The spent grease collects outside each bearing in the spent grease chamber of the outer
bearing cap. When replacing bearings, remove the spent grease.
Dismantle the bearing cartridges to replace the grease in the lubrication duct.
Maintenance
9.2 Inspection and maintenance
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Cleaning the cooling air ducts
Regularly clean the cooling air ducts through which the ambient air flows.
The frequency of the cleaning intervals depends on the local degree of fouling.
Damage to the machine when cleaning with compressed air or water jets
● Do not direct compressed air or water jets in the direction of the shaft outlet or machine
openings.
● Avoid direct impact of compressed air and water jets on sealing elements of the machine.
Note
Please note the safety instructions for cleaning.
9.2.12 Risk of explosion due to damaged seals
WARNING
Risk of explosion due to damaged seals
The seals can be damaged if you clean motors with type of protection Ex t using
compressed air. The type of protection is no longer complied with. An explosion can occur.
This may result in death, personal injury and material damage.
• Avoid pointing compressed air directly onto shaft sealing rings or labyrinth seals of the
machine.
Maintenance
9.2 Inspection and maintenance
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9.2.13 Drain condensate
If there are condensation drain holes present, open these at regular intervals, depending on
climatic conditions.
WARNING
Hazardous voltage
The winding can be damaged if objects are introduced into the condensation holes
(optional). This can lead to death, serious injury or material damage.
Note the following to maintain the degree of protection:
• Switch off the machine so that it is in a no-voltage condition before you open the
condensation drain holes.
• Close the condensation drain holes, e.g. using T-plugs, before commissioning the
machine.
NOTICE
Reduction of the degree of protection
If condensation drain holes are not closed, then this can result in material damage to the
motor.
In order to maintain the degree of protection, after the condensation has been drained, you
must close all of the drain holes.
9.2.14 Insulation resistance and polarization index
Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 92)
Maintenance
9.2 Inspection and maintenance
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9.2.15 Maintaining the external fan (forced ventilation)
WARNING
Rotating or live parts
Live electrical parts are dangerous. Contact with them can cause death, serious injury or
material damage.
Before performing any maintenance work on the external fan, disconnect it from the mains,
particularly before opening the terminal box. Make sure that the device cannot be switched
back on.
Servicing the external fan
The external fan is essentially maintenance-free. However, dirt and dust deposits on the
impeller and the motor, particularly in the gap between the impeller and the inlet nozzle can
impair its function.
● Remove the dirt and dust deposits regularly; the intervals depend on how dirty the
surrounding area is.
● Make sure that the impeller is evenly cleaned, as irregular deposits can lead to an
imbalance.
The full flowrate is only achieved if the inward flow of air to the impeller is unrestricted.
Servicing the external fan motor
Please observe all specifications and intervals in the operating instructions for the external
fan motor. If a SIMOTICS XP 1MB1.5/1MB5.5 low-voltage motor is used as an external fan
motor, these operating instructions also apply for the external fan motor.
To avoid unnecessary downtimes, always carry out all inspection and maintenance work on
the main and external fan motor simultaneously.
● Perform an occasional visual inspection of the external fan motor and check it electrically
and mechanically every time the rolling bearings are replaced.
● Replace permanently lubricated rolling bearings in the external fan motor as specified in
the operating instructions for the external fan motor.
Maintenance
9.2 Inspection and maintenance
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9.2.16 Repainting
9.2.16.1 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 165) 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.
You must comply with one of the following requirements when you repaint painted surfaces:
● Limit the total paint film thickness according to the explosion protection group:
– IIA, IIB: Total paint coating thickness ≤ 2 mm
– IIC: Overall coating thickness ≤ 0.2 mm for motors of group II (gas)
● Limit the surface resistance of the paint used:
– Surface resistance ≤ 1 GΩ for motors of groups II and III (gas and dust)
● Charge transfer limit
– 60 nC for Group I or Group IIA devices
– 25 nC for Group IIB devices
– 10 nC for Group IIC devices
– 200 nC for Group III devices (values not valid for strongly charge generating
processes)
● Breakdown voltage ≤ 4 kV for explosion group III (gas and dust)
WARNING
Explosion hazard caused by incorrect painting
The paint coat can become electrostatically charged if an excessively thick paint coat is
applied. Electrostatic discharge can then occur. There is a risk of explosion if potentially
explosive mixtures are also present at this moment. This can result in death, serious injury
or material damage.
Maintenance
9.3 Corrective maintenance
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WARNING
Risk of explosion as a result of processes with high levels of electrostatic charging
For paint finishes in explosion group III, the paint can be electrostatically charged as a
result of intensive dust turbulence or processes with high levels of electrostatic charging.
Electrostatic discharges can occur. Minimize the risk of electrostatic charging by applying
effective measures according to IEC 60079-32-1. This can result in death, serious injury or
material damage.
Note
Paint finishes for IIC are optionally available with more than 200 µm coat thickness.
Paint finishes exceeding 200 µm are tested with respect to electrostatic charging.
Motors with a coating thickness exceeding 200 µm may only be painted over if the conditions
mentioned above are complied with.
Suitability test of the paint system for hazardous areas
Suitability certificates for the electrostatic suitability on explosion-protected machines are
available for paint systems ordered as standard. These certificates are not available for non-
standard or customized paint systems. Take into consideration that the provided evidence is
not valid for repaintings.
9.3 Corrective maintenance
Observe the following when carrying out any work on the machine:
● Comply with the general safety instructions (Page 11)
● Comply with the applicable national and sector-specific regulations.
● When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
If the motor has to be transported, please observe the information and instructions in the
"Transport (Page 36)" chapter.
9.3.1 Extended motor marking
The machine marking based on IEC / EN 60079–0 was supplemented by the "X" symbol.
● Maintain the special conditions for repairs. The gap dimensions for the electric machine
do not comply with the standardized values in IEC / EN 60079–1. For repair work, obtain
the gap dimensions of the electrical machine from the manufacturer.
● Perform maintenance, repair and modification work on explosion-protected machines in
strict compliance with the corresponding national health and safety legislation, the safety
instructions and descriptions in the general maintenance instructions.
Maintenance
9.3 Corrective maintenance
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Have work influencing explosion protection performed by the manufacturer or by a specialist
workshop for electrical machinery authorized by the manufacturer. This includes the
following operations, for example:
● Repairs to the stator or rotor windings and to the terminals
● Repairs to the ventilation system
● Repairs to the bearings
● Dismantling machines with flameproof enclosures
● Connection work performed in the terminal box
Identify the work performed by an additional repair plate bearing the following information:
● Date
● Company carrying out repair
● Type of repair
● Reference number of the repair technician regarding repair work
Test in accordance with the relevant EU directives after repair.
WARNING
Risk of explosion due to alteration of the ignition gap geometry
Changing ignition gap geometries (gap dimensions) as part of repair work according to the
minimum specifications of IEC / EN 60079–1 is not permissible.
This can result in death, serious injury or material damage.
• Obtain the gap dimensions of the electrical machine from the manufacturer for the repair
or restoration of ignition gap geometries.
Comply with the IEC / EN 60079-17 standard during all service and maintenance work on
the machine.
Risk of explosion as a result of inadmissible repair work
Repairs are only permissible within the scope of the work described in these operating
instructions. Otherwise an explosion can occur in an explosive atmosphere. This can result
in death, serious injury or material damage.
● For repairs to go beyond this scope, please contact the Service Center.
Maintenance
9.3 Corrective maintenance
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WARNING
Explosion hazard due to increased surface temperature
Components within the motor may be hotter than the maximum permissible surface
temperature for the enclosure. In an explosive atmosphere, dust can ignite and an
explosion occur. This can result in death, serious injury or material damage.
• Do not open the motor in an explosive and dusty atmosphere when it is still at normal
operating temperature.
• Allow the machine to cool down before opening it.
9.3.2 Anti-condensation heating
Explosion hazard due to improper maintenance of the anti-condensation heating
If the anti-condensation heating is not correctly repaired, e.g. if unauthorized or untested
spare parts are used, this can result in explosions during operation in a potentially explosive
atmosphere. This can result in death, serious injury or material damage.
● Only appropriately trained specialists in the service center (Page 165) are authorized to
repair anti-condensation heating systems. The anti-condensation heating must then be
subject to a routine test, which requires extensive specialist knowledge.
● Only use authorized and tested spare parts.
WARNING
Explosion hazard due to improper maintenance
If repairs to the anti-condensation heating are not carried out correctly, e.g. if unauthorized
or untested spare parts are used, this can result in explosions during operation in a
potentially explosive gaseous atmosphere. This can result in death, serious injury, or
material damage.
• Repairing and mounting the anti-condensation heating and the subsequent routine
testing must always be undertaken by experts from the service center (Page 165),
because this work requires extensive specialist knowledge.
• Only authorized and tested spare parts may be used.
Note
Before commencing removal, you should mark how each of the fastening elements has been
assigned, as well as how internal connections are arranged. This simplifies subsequent
reassembly.
If possible, assemble the machine on and alignment plate. This ensures that the mounting
feet surfaces are all on the same plane.
Maintenance
9.3 Corrective maintenance
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Avoid damaging the windings protruding out of the stator enclosure when assembling the
end shield.
9.3.3 Sealing measures
Sealing measures
1. For 1MB10, shaft heights 100...160, apply the appropriate liquid sealant, e.g. Fluid-D or
Hylomar to the centering edge.
2. Check the terminal box seals, and if required, replace these.
3. Repair any damage to the paint, also to screws/bolts.
4. Take the necessary measures to ensure compliance with the applicable degree of
protection.
5. Do not forget the foam rubber cover in the cable entry. Completely seal the holes, and
ensure that cables do not come into contact with sharp edges.
9.3.4 Rolling bearings
Refer to the rating plate or the catalog for the designations of the bearings being used.
Bearing lifetime
Prolonged storage periods reduce the useful lifetime of the bearing grease. For permanently
lubricated bearings, this reduces the bearing service life.
We recommend that the grease is replaced after a storage time of 12 months. Replace
greased bearings also in the case of closed bearings (suffix 2Z or 2 RS). After 4 years in
storage, generally replace all rolling bearings and grease.
Replacing bearings
Recommended interval after which bearings are to be replaced under normal operating
conditions:
Table 9- 3 Bearing replacement intervals
Ambient temperature
Principle of operation
Bearing replacement intervals
40 °C
Horizontal coupling operation
40 000 h
40 °C With axial and radial forces 20 000 h
● Do not reuse bearings that have been removed.
● Remove the dirty spent grease from the bearing shield.
● Replace the existing grease with new grease.
● Replace the shaft seals when the bearings are replaced.
● Slightly grease the contact surfaces of the sealing lips.
Maintenance
9.3 Corrective maintenance
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Note
Special operating conditions
The operating hours are reduced, e.g.
•
When machines are vertically mounted.
•
High vibration and surge loads
•
Frequent reversing operation
•
Higher ambient temperatures.
•
High speeds etc.
① Heat up 80 ... 100 °C
9.3.4.1 Replacing bearings in explosion-proof machines
● When changing the bearings, renew the sealing rings and only use original Siemens
spare parts.
● For radial sealing rings with dust protection lip (DIN 3760-AS), completely fill the spaces
(100%) in the sealing ring as well as in the bearing shield hub with a suitable grease.
Maintenance
9.3 Corrective maintenance
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9.3.4.2 Bearing bushes
Protect the bearings against the ingress of dirt and moisture.
9.3.4.3 Fitting bearings
Sealing the bearings
Note the following details:
● Shaft sealing rings are used to seal machines at the rotor shaft.
– For V rings, comply with the assembly dimension.
● Use the specified bearings.
● Ensure that the bearing sealing disks are in the correct position.
● Insert the elements for bearing preloading at the correct end.
● Fixed bearings can have a locking ring or bearing cover.
● Seal the bearing cap screws with the appropriate gaskets or with grease.
● Do not interchange the position of the bearing covers (DE and NDE or inner and outer).
Danger as a result of rotor falling out
If the motor is in a vertical position, the rotor can fall out while work is being performed on the
locating bearing. This can result in death, serious injury or damage.
● Support or unload the rotor when carrying out work with the machine in a vertical position.
Bearing seals for explosion-protected machines
Note
Bearing seals for explosion-protected machines
For explosion
-protected machines, only use the original replacement and repair parts.
Fitting the bearing cartridges
When fitting the bearing cartridges, observe the specified screw tightening torques
(Page 134).
Maintenance
9.3 Corrective maintenance
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Installing rolling bearings
● Extreme caution and attention to cleanliness are vital when installing rolling bearings.
Observe the correct assembly sequence of the components.
● Attach all components with the specified tightening torques (Page 167).
Note
For further information about mounting the rolling bearing, please refer to the catalog or
the information provided by the rolling bearing manufacturer.
Procedure
1. Replace the damaged components.
2. Remove any dirt from the components. Remove any grease and the remains of sealant or
liquid threadlocker.
3. Prepare the bearing seats:
– Lightly oil the inner ring seat.
– Grease the outer ring seat with a solid lubricant such as Altemp Q NB 50.
– Press the inner bearing cover onto the shaft.
4. Warm up the rolling bearing.
5. Push the inner ring of the warmed up rolling bearing onto the shaft. Avoid any blows that
might damage the bearing.
6. Make sure that the rolling bearing is resting against the shaft shoulder or the second
bearing.
7. Fill the bearing to the top with the specified lubricating grease as stamped on the lubricant
plate.
8. Warm up the grease slinger and push it onto the shaft.
9. Depending on the particular version, fix the bearing with a locking ring or shaft nut.
10.Support the rotor when installing the bearing housing or bearing end shield.
11.Use a suitable sealant when assembling.
12.Assemble the bearing shield or bearing housing together with the bearing shield.
13.Install the outer bearing cover if one is being used.
14.Install the sealing elements:
See also
Replacing rolling bearings (Page 138)
Maintenance
9.3 Corrective maintenance
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9.3.4.4 Explosion hazard due to overheating of the roller bearings
WARNING
Explosion hazard due to overheating of the rolling bearings
If the rolling bearings are not regularly regreased, local overheating may be possible, and,
as a consequence, an explosion in an explosive atmosphere. This can result in death,
serious injury, or material damage.
• Regrease the rolling bearings regularly according to the lubrication plate.
• Implement bearing temperature monitoring if not yet in existence.
9.3.5 Mounting dimension "x"
Mounting dimension "x" of V rings
Shaft height
x
mm
71
4.5 ±0.6
Standard design
Special design
80 ... 112
6 ±0.8
132 ... 160
7 ±1
180 ... 200 (1LA, 1MA)
180 ... 225
11 ±1
250 ... 355 13.5 ±1.2
● Extreme caution and attention to the correct positioning are vital during installation and
assembly.
● Make sure the sealing surface is free of dirt and damage.
● Lightly grease the sealing lips.
Maintenance
9.3 Corrective maintenance
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9.3.6 Fan
NOTICE
Destruction of the fan
Material damage can occur by forcefully removing the fan from the shaft.
Take care not to damage the snapping mechanisms on fans that are equipped with these.
Plastic fan
● Correctly expose the breakout openings provided in the fan plate.
● Heat up the fans to a temperature of approximately 50° C around the area of the hub.
● Use a suitable tool to pull off the fan (puller).
● Locate the arms of the pulling tool in the breakout openings and slightly tension the
pressure screw of the tool.
● For fans with snapping mechanisms, simultaneously release the two snap-in lugs of the
fan from the annular shaft groove.
Keep the snap-in lugs in this position.
● Uniformly withdraw the fan from the shaft by turning the pressure screw of the pulling tool.
● Do not apply any hammer blows to avoid damaging the rotor shaft, the fan and the
bearings.
● Order the appropriate new parts if damaged.
9.3.6.1 Metal fan disassembly
Metal fan
● Remove the locking ring.
● Use a suitable tool to pull off the fan (puller).
● Locate the arms of the pulling tool in the openings in the fan in the vicinity of the hub.
● Alternatively, place the pulling tool at the outer edge of the fan plate.
● Uniformly withdraw the fan from the shaft by turning the pressure screw of the pulling tool.
● Do not apply any hammer blows to avoid damaging the rotor shaft, the fan and the
bearings.
● Order the appropriate new parts if damaged.
9.3.6.2 Mounting fans
● Take care not to damage the snapping mechanisms on fans that are equipped with these.
● To ensure this, the fans should be heated to a temperature of approximately 50 °C
around the area of the hub.
● If any damage is caused, request new parts.
Maintenance
9.3 Corrective maintenance
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9.3.7 Cable entries, sealing plugs and thread adapters
All cable entries and sealing plugs must be approved for use in the respective hazardous
zone.
● Any openings that are not being used must be sealed using the appropriate certified
sealing plugs.
● Please observe the manufacturer's specifications when fitting cable entries.
Note the following when mounting:
● Avoid damaging the cable jacket.
● Adapt the tightening torques to the cable jacket materials.
Observe the documentation for tightening torques of the cable entries and sealing plugs for
direct mounting at the machine as well as additional glands (e.g. adapters).
9.3.8 Terminal boxes, end shields, grounding conductors, sheet metal fan covers
If no other tightening torques are specified, then the values in the following table apply.
Table 9- 4 Tightening torques for screws on the terminal box, end shields, screw-type grounding conductor connections
Thread ∅
M 3.5
M 4
M 5
M 6
M 8
M 10
M 12
M 16
M20
Nm
min
0.8
2
3.5
6
16
28
46
110
225
max 1.2 3 5 9 24 42 70 165 340
9.3.9 Terminal board and grounding
Table 9- 5 Tightening torques for electrical connections on the terminal board and grounding
Thread ∅
M 3.5
M 4
M 5
M 6
M 8
M 10
M 12
M 16
Nm
min
0.8
0.8
1.8
2.7
5.5
9
14
27
Max.
1.2
1.2
2.5
4
8
13
20
40
9.3.10 Screw lock washers
Nuts or bolts that are mounted together with locking, resilient and/or force-distributing
elements (e.g., safety plates, spring-lock washers, etc.) must be refitted together with
identical, fully functional elements.
Locking and sealing elements must always be replaced!
Maintenance
9.3 Corrective maintenance
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9.3.11 Links
● Replace any corroded screws.
● Take care not to damage the insulation of live parts.
● Document the position of any rating and supplementary plates that have been removed.
● Avoid damaging the centering edges.
9.3.12 Reassembly: Miscellaneous information
● Position all rating and supplementary plates as in the original state.
● Where relevant, fix electric cables.
● Check the tightening torques of all screws, as well as those of screws that have not been
released.
9.3.13 Optional add-on units
You can find additional operating instructions here:Service and support (Page 165)
9.3.14 O-ring seal
If O-ring seals are present, you should check that they are in perfect condition and that the
O-ring seals are properly seated in the grooves between the components. Replace damaged
O-ring seals.
O-ring seals can be present on the following components, for instance:
● Adapters, tapers
● Entries, glands
● Bearing seals
● End shield seals
● Terminal box sealing
● etc.
Maintenance
9.3 Corrective maintenance
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Spare parts
10
10.1 Parts order
In addition to the exact part designation, please specify the machine type and the serial
number of the machine in all orders for spare parts and repair parts. Ensure that the part
designation is the same as that in the parts list, and make sure you also use the associated
part number.
When spare and repair parts are ordered, the following details must be provided:
● Designation and part number
● Order number and serial number of the machine
The machine type and serial number can be found on the rating plate.
See also
Spares On Web (https://www.sow.siemens.com/)
10.2 Data matrix code on the machine
Data matrix code
A data matrix code is provided on machines manufactured in Europe. You can retrieve the
following information from the data matrix code:
● Machine type
● Serial number
● Customer material number, if ordered as option Y84
● Using the Data Matrix code and the App "SIMOTICS Digital Data", you can access the
technical data, spare parts and operating instructions for your motor.
10.3 Ordering data
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.
Spare parts
10.4 Purchasing commercially available spare parts
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10.4 Purchasing commercially available spare parts
WARNING
Explosion hazard due to unsuitable spare parts
If you use parts other than the original spare parts, the type of protection can no longer be
guaranteed. This can result in an explosion during operation in a potentially explosive
atmosphere. This can result in death, serious injury, or material damage.
• Use only original spare parts for explosion-proof machines, including components, such
as seals, terminals, cables, and cable entries. If you have any questions, please contact
the service center (Page 165).
• Commercially available equivalent standard parts such as screws and bolts may be
used.
10.5 Ordering spare parts via the Internet
You can use "Spares on Web" to determine the order numbers for motor
spare parts quickly and easily.
Spares on Web (
https://www.sow.siemens.com/?lang=en).
See also
Guide for Spares on Web (https://www.weblogx.siemens.de/SoWHilfe_HS/motors/en/)
10.6 Replacing rolling bearings
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.
Spare parts
10.7 Roller bearings
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10.7 Roller 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.
10.8 Anti-condensation heating
WARNING
Explosion hazard due to improper maintenance
If repairs to the anti-condensation heating are not carried out correctly, e.g. if unauthorized
or untested spare parts are used, this can result in explosions during operation in a
potentially explosive gaseous atmosphere. This can result in death, serious injury, or
material damage.
• Repairing and mounting the anti-condensation heating and the subsequent routine
testing must always be undertaken by experts from the service center (Page 165),
because this work requires extensive specialist knowledge.
• Only authorized and tested spare parts may be used.
10.9 Parts groups definition
A distinction is made between the following groups of parts:
Spare parts
Spare parts are machine parts that can be ordered during the production time - and for a
further 5 years after discontinuation of production. These parts should only be replaced by
authorized service or modification partners.
Repair parts
Repair parts are machine parts that can be supplied during the active production of the
machine (until the product discontinuation).
Repair parts are parts used for the repair or modification of the current products. These parts
should be replaced only by authorized service or modification partners.
Standardized parts
Standardized parts are machine parts obtained from free trade outlets in accordance with
their necessary dimensions, materials and surface finish. A detailed list can be found in the
"Standardized parts" section.
Spare parts
10.10 Ordering example
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Other parts
Other parts are small parts required to complete the exploded drawing. However, these parts
cannot be supplied as individual spare or repair parts. The delivery in assembly units (e.g.
complete terminal box) is possible on request.
The following supply commitments apply to replacement machines and repair parts following
delivery of the motor:
● For up to 3 years after the delivery of the original machine, in the event of total machine
failure, Siemens will supply a comparable replacement machine with regard to the
mounting dimensions and functions; it is possible that this will involve a new series.
● If a replacement machine is supplied within the 3 year period, this does not mean that the
warranty restarts.
● Replacement machines delivered after the active production of the machine series are
also identified as spare motors on the rating plate.
● Spare parts are offered only for these spare motors on request; repair and replacement
are not possible.
● After a period of 3 years (after the delivery of the original machine), it is only possible to
repair these machines (depending on the availability of the spare parts required).
● For up to 5 years after the delivery of the original motor, spare parts will be available and
for a further 5 years, Siemens will provide information about spare parts and will supply
documents when required.
10.10 Ordering example
Table 10- 1 Ordering example
End shield, drive end
1.40 End shield
Machine type *
1MB1543-2BB03-4AA4
Ident: No. *
UC 1706/218923701
* corresponding to the rating plate
Take the type and serial number from the rating plate and the machine documentation.
When replacing rolling-contact bearings, in addition to the bearing identification code, the
replacement code for the bearing version is required. Both of these codes are specified on
the rating plate and in the machine documentation. They are also shown on the installed
bearings.
The graphical representations in this chapter show schematic diagrams of the basic
versions. They are used for spare part definitions. The supplied version may differ in details
from these representations.
Spare parts
10.11 Machine parts
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 141
10.11 Machine parts
10.11.1 Part lists
Part
Description
Part
Description
1.00
DE bearings
Terminal box, complete
1.30 Bolt 5.37 Spring lock washer
1.31
Spring lock washer
5.42
Terminal box housing, including seal
1.32 Bolt 5.43 Entry plate
1.33
Nut
5.44
Terminal box upper section
1.40
End shield
5.45
Enclosure
1.43
Shaft sealing ring
5.46
Screw
1.44
Bearing cover DE, inner
5.47
Screw
1.45
Screw (bearing cover)
5.48
Spring lock washer
1.46
Cover ring
5.49
Screw
1.47
O ring
5.51
Flanged nut
1.48
Bolt
5.52
Cable entry
1.49
Bolt
5.53
Screw plugs
1.50
Flanged nut
5.54
O ring
1.56
Spacer washer
5.55
Nut
1.58
Spring washer
5.60
Screw
1.60
Roller bearing
5.61
Screw
1.61
Spring band for end shield hub
5.62
Spring lock washer
1.63
Condensation drain plug
5.63
Mounting rail
1.65
Grease nipple
5.64
Spring lock washer
1.67 Bearing cover NDE, outer 5.65 Bolt
1.68
Grease slinger (optional)
5.68
Screw plugs
1.69
Compression spring
5.69
O ring
3.00
Rotor, complete
5.70
Terminal clamp
3.02
Locking ring
5.72
Contact bracket
3.03
Locking ring
5.76
Terminal plate / contact bracket
3.38 Featherkey 5.78 Spring lock washer
3.88
Featherkey for fan
5.79
Screw
4.00
Stator, complete
5.81
Screw
4.04
Eyebolt
5.82
O ring
4.05
Disk
5.83
Seal
4.07
Housing foot
5.84
Terminal box cover
4.08
Housing foot, left
5.85
Terminal box cover including seal (optional screw)
4.09
Housing foot, right
5.88
Spring lock washer
4.10
Spring lock washer
5.89
Screw
4.11 Bolt 5.90 Upper terminal box section can be rotated 4 x 90 de-
grees, complete
(for subsequent mounting)
Spare parts
10.11 Machine parts
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
142 Operating Instructions, 12/2018, A5E44455710A
Part
Description
Part
Description
4.12
Nut
5.91
Screw
4.18 Rating plate 5.92 Terminal box cover
4.19
Self tapping screw or slotted pin
5.93
Seal
4.20 Cover 5.94 Screw
4.30
Contact bracket
5.95
Terminal box upper section
4.31
Grounding bracket
5.96
Screw plugs
4.35
Disk
5.97
Locknut
4.37
Terminal board
5.98
Sheet metal nut
4.38
Spring lock washer
5.99
Adapter plate
4.39
Grounding stud
6.00
Bearings, NDE
4.40
Disk
6.02
Locking ring
5.00
Terminal box, complete
6.03
Bearing cover NDE, inner
5.02
spacer
6.10
Rolling bearings
5.03
Seal (upper terminal box section)
6.11
Spring band for end shield hub
5.04
Seal (adapter plate)
6.12
Locking ring
5.06
Mounting rail
6.20
End shield
5.08
Spacer sleeve
6.23
Shaft sealing ring
5.09
Bolt
6.25
Lubrication sleeve
5.10
Complete terminal board
6.26
Cover
5.11
Terminal block
6.27
Bearing cover NDE, outer
5.13 Link rail 6.29 Screw
5.15
Plug
6.31
Nut
5.16
Spring locking ring for busbar
6.65
Grease nipple
5.17
Screw
6.67
Rubber bushing
5.18
Spring lock washer
6.66
Screw (bearing cover)
5.19
Bolt
6.72
Grease slinger
5.21 Screw (drilled) 6.74 Sleeve
5.24
Bolt
6.75
Bolt
5.27
Clamp
7.00
Ventilation system, complete
5.28
Upper saddle terminal
7.04
Fan
5.29
Lower saddle terminal
7.12
Locking ring
5.30
Rubber plug
7.40
Fan cover
5.31
Terminal clamp
7.41
bracket
5.32
Bracket
7.47
Sleeve
5.33
Disk
7.48
Disk
5.35
Cable entry
7.49
Bolt
5.36
Spring lock washer
Tools for mounting and withdrawing roller bearings; fans and output transmission elements cannot be supplied.
Spare parts
10.12 Standardized parts
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 143
10.12 Standardized parts
Table 10- 2 Purchase standard parts according to dimensions, material and surface properties through normal commercial
channels.
No
Standard
Picture
No
Standard
Picture
3.02
6.02
7.12
DIN 471
1.32 DIN 939
6.12 DIN 472
5.17 EN ISO 4014
4.04 DIN 580
1.49
4.11
4.39
5.60
5.61
5.65
5.89
7.49
EN ISO 4017
DIN 582
6.75 EN ISO 4026
1.60
6.10
DIN 625
1.30
1.45
4.11
5.19
5.46
5.47
5.49
5.60
6.29
6.66
EN ISO 4762
3.38 DIN 6885
4.19
5.09
5.91
5.94
EN ISO 7045
1.33
4.12
4.14
5.55
EN ISO 4032
5.24 EN ISO 7049
5.51 EN ISO 4035
4.05
7.48
EN ISO 7089
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
144 Operating Instructions, 12/2018, A5E44455710A
10.13 Exploded drawings
10.13.1 1LA,1MA shaft heights 63 ... 90L, 1MB shaft heights 63 ... 71
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 145
10.13.2 1LA,1MA shaft heights 100 ... 160
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
146 Operating Instructions, 12/2018, A5E44455710A
10.13.3 1LA5180 ... 225
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 147
10.13.4 1MA6180 ... 200
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
148 Operating Instructions, 12/2018, A5E44455710A
10.13.5 Terminal boxes 1MA6180 ... 200
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 149
10.13.6 1MB1 SH80 ... 160 aluminum
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
150 Operating Instructions, 12/2018, A5E44455710A
10.13.7 1MB1 shaft heights 71 ... 90 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 151
10.13.8 1MB1 shaft heights 100 ... 200 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
152 Operating Instructions, 12/2018, A5E44455710A
10.13.9 1MB1 shaft heights 225 ... 315 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 153
10.13.10 1MB5 shaft height. 315 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
154 Operating Instructions, 12/2018, A5E44455710A
10.13.11 1MB5 terminal box shaft height 315 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 155
10.13.12 1MB5 shaft height. 355 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
156 Operating Instructions, 12/2018, A5E44455710A
10.13.13 1MB5 terminal box shaft height 355 cast iron
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 157
10.13.14 1LG4/6 SH180 ... 315
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
158 Operating Instructions, 12/2018, A5E44455710A
10.13.15 Terminal box gk330, gt320, gk430, gt420
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 159
10.13.16 Terminal box gk431, gt421, gt520, gt540
Spare parts
10.13 Exploded drawings
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
160 Operating Instructions, 12/2018, A5E44455710A
10.13.17 Terminal box 1LG4/6, 1MB1, gt620, gt640, gt791
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 161
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.
11.2 Country-specific legislation - LV machines
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.
11.3 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.
Disposal
11.4 Information according to Article 33 of the REACH regulation
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
162 Operating Instructions, 12/2018, A5E44455710A
11.4 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.
11.5 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 11).
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.
See also
Corrective maintenance (Page 125)
11.6 Dismantling the machine
Dismantle the machine using the general procedures commonly used in mechanical
engineering.
WARNING
Machine parts can fall
The machine is made up of heavy parts. These parts are liable to fall during dismantling.
This can result in death, serious injury or material damage.
• Before you release any machine parts, secure them so that they cannot fall.
Disposal
11.7 Disposal of components
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 163
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
● 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
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
164 Operating Instructions, 12/2018, A5E44455710A
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 165
Service and support
A
A.1 Siemens Industry Online Support
Technical questions or additional information
If you have any technical questions or require additional information,
please contact Technical Support
(
https://support.industry.siemens.com/cs/ww/en/sc/4868).
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 da-
tabase:
www.siemens.com/yourcontact (
www.siemens.com/yourcontact)
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
anywhere.
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 Foru
m 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.
Service and support
A.2 Further documents
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
166 Operating Instructions, 12/2018, A5E44455710A
A.2 Further documents
These operating instructions can also be obtained at the following Internet site:
http://support.industry.siemens.com (Page 165)
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 167
Technical data
B
B.1 Tightening torques
B.1.1 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 %.
Thread
∅
M5
M6
M8
M10
M12
M16
M20
M24
Nm
5
8
20
40
70
170
340
600
The tightening torques stated above apply to screws 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 the same or higher property class, e.g. cast iron, steel or cast steel.
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
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
168 Operating Instructions, 12/2018, A5E44455710A
B.1.2 Stud-type bushings
Table B- 2 Tightening torques for stud-type bushings
Thread ∅
M 4
M 5
M 6
M 8
M 10
M 12
M 16
M 20
Nm
Min.
1
1.6
2.5
5
8
13
25
42
Max.
1.2
2
3
6
10
15.5
30
52
B.1.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers
If no other tightening torques are specified, then the values in the following table apply.
Table B- 3 Tightening torques for screws on the terminal box, end shields, screw-type grounding conductor connections
Thread ∅
M 3.5
M 4
M 5
M 6
M 8
M 10
M 12
M 16
M20
Nm
min
0.8
2
3.5
6
16
28
46
110
225
max
1.2
3
5
9
24
42
70
165
340
Tightening torque for the condensation drain plug
Tighten the condensation drain plug M6x0.75 with a torque between 1.5 and 2.0 Nm.
B.1.3.1 Terminal board and grounding
Table B- 4 Tightening torques for electrical connections on the terminal board and grounding
Thread ∅
M 3.5
M 4
M 5
M 6
M 8
M 10
M 12
M 16
Nm
min
0.8
0.8
1.8
2.7
5.5
9
14
27
Max.
1.2
1.2
2.5
4
8
13
20
40
B.1.4 Additional connecting terminals for monitoring equipment and anti-condensation
heating
Table B- 5 Tightening torques for monitoring equipment and anti-condensation heating
Main terminal box
EN 60999-1: 2000 table 4 III
0.4 Nm
Auxiliary terminal box
min 0.6 Nm
max 0.8 Nm
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 169
Quality documents
C
C.1 Quality documents SIMOTICS in SIOS
You can find the quality documents here:
https://support.industry.siemens.com/cs/ww/de/ps/13310/cert
(
https://support.industry.siemens.com/cs/ww/en/ps/13310/cert)
Quality documents
C.1 Quality documents SIMOTICS in SIOS
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
170 Operating Instructions, 12/2018, A5E44455710A
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 171
Index
"
"Siemens Industry Online Support" App, 165
5
5 safety rules, 12
A
Aligning, 64, 65
Alignment accuracy, 66
Aluminum conductors, 85
Anti-condensation heating, 45, 105, 127
Insulation resistance, 57, 94
Repairs, 127, 139
Assembly
Rolling bearings, 131
Axial force, 68
Axial gap, 64
B
Balance quality, 67
Balancing type, 58
Bearing currents
Reduction, 49
Bearing insulation, 51
Bearing shipping brace, 42
Bearing temperature
Monitoring, 96
Set values, 96
Blocked speed ranges, 47
Bolt locking device, 167
C
Cable entries
certified, 74
Centering flange, 64, 65
Circuit diagram, 73
Common-mode filters, 50
Connecting cables
Selection of, 70
Cooling system
faults, 111
Correct usage, 21
Coupling, 52
D
Damping cores, 50
Data matrix code, 137
Disassembly
Disposal, 162
Disposal
Chemicals, 163
Components, 163
E
Electrical faults, 109
Electromagnetic compatibility, 16
Electromagnetic fields, 14
Emergency off, 106
Emitted interference, 14
Equipotential bonding conductor, 50
ESD guidelines, 15
Explosion hazard, 38, 115, 127, 127, 139
Bearing temperature, 104
Bridging the insulated bearing, 105
Electrostatic discharge, 16
Layer of dust, 103, 103
Spare parts, 138
External fan
Commissioning, 95
Maintenance, 123
Test run, 95
F
faults
Mechanical, 110
Faults
Cooling system, 111
Electric, 109
Inspection, 109, 116
Rolling bearings, 111
Faults in operation, 100
Feather key, 68
Flammable substances, 13
Index
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
172 Operating Instructions, 12/2018, A5E44455710A
Foundation forces, 64
G
General inspection, 117
Grounding system
Meshed, 50
H
Hazardous substances, 13
Hearing damage, 14
Hot surfaces, 13
Hybrid mixtures, 20, 102
I
Ignition hazard, 15
Inspection
Faults, 109, 116
Installation
Initial inspection, 117
Insulated bearings, 51, 105
Insulated coupling, 52
Insulation resistance, 42, 54, 91, 122
Anti-condensation heating, 57, 94
measure, 55, 92
Interference immunity, 16
Interference voltages, 17
Interlocking circuit
Anti-condensation heating, 45
L
Limit speed, 49
Live parts, 13
Low-Voltage Directive, 11
M
Machine
Aligning to the driven machine, 64
Securing, 64
Machine expansion, 64
Machine marking, 125
Maintenance
Maintenance intervals, 113
Mechanical faults, 110
Minimum air clearances, 77
More information, 165
N
Noise emissions, 14
O
On-site service, 165
Operating mode, 35
O-ring seals, 135
Output element, 67
Overall flatness, 66
Over-critical machine, 47
Overspeed, 35
P
Paint finish, 33
Paint system, 124
Paintwork damage, 124
Polarization index, 42, 54, 57, 91, 94, 122
Positioning, 64
Precision alignment, 64
Preload
Rotor bracing, 41
Preparations for assembly, 53
Property class, 64
Q
Qualified personnel, 12
R
Radial force, 68
Rating plate, 21
REACH regulation, 162
Re-commissioning, 108
Regreasing system, 42
Repainting, 124
Repair
Initial inspection, 117
Residual risks, 35
Restriction of certain Hazardous Substances, 161
RF grounding point, 50
Risk of explosion, 127
Bearing temperature, 116
Cleaning, 104, 116
Layer of dust, 116
RoHS, 161
Rolling bearings
Assembly, 131
Index
1LA5/6/7/9, 1LG4/6, 1MA6/7, 1MB..1/2/3/4 - AH 63 ... 355
Operating Instructions, 12/2018, A5E44455710A 173
faults, 111
Inspection, 118
Replacement, 138
Rotating parts, 13
Rotor shipping brace, 40
Remove, 66
S
Safety instructions
Flammable substances, 13
Hazardous substances, 13
Hot surfaces, 13
Live parts, 13
Maintenance work, 114
Rotating parts, 13
Sealing plugs
certified, 74
Selection of bolts, 64
Siemens Industry Online Support
App, 165
SIMOTICS Digital Data, 137
Spare parts, 138, 165
Spares on Web, 138
Standard flange, 64, 65
Stoppages, 106
Rolling bearings, 108
Supplementary devices, 28
Switching on, 97, 97, 106
System resonances, 47
T
Tandem operation, 52
Technical Support, 165
Temperature class, 105, 107
Temperature limits, 38
Terminal marking, 72
Test run, 97
Tightening torques, 70
Bolted connection, 167
Type of balancing, 67
Type of protection, 138
V
Vibration values, 47, 47, 98