Lenze MH three-phase AC motor Operating Instruction

AC motors

Three−phase AC motors

M MA; Basic M ERA...V1

| 0.12 kW ... 45 kW

Operating Instructions EN

0Fig. 0Tab. 0

Please read these instructions before you start working!

Follow the enclosed safety instructions.

Note!

For safety−rated built−on accessories, the manufacturer’s operating instructions have to be observed!

Contents i

1

2

3

4

5

6

About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

1.2

1.3

1.4

Document history

Conventions used

Terminology used

Notes used

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Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

2.2

2.3

2.4

2.5

General safety instructions for drive components

Application as directed

Foreseeable misuse

Residual hazards

Disposal

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Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Identification

3.1.1

3.1.2

3.1.3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder code

Nameplate

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

General data and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

5.4

5.5

5.6

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

5.2

Important notes

Preparation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of built−on accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spring−applied brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking of the manual release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

6.2

6.3

6.4

6.5

6.6

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three−phase AC motor operation on a frequency inverter

EMC−compliant wiring

. . . . . . . . . . . . . . . . . . . .

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Screwed connections on the terminal box

6.4.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power connections on the terminal board . . . . . . . . . . . . . . . . . . . . . . . .

6.4.2

6.4.3

Brake connection to terminal

Feedback system to terminal

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug connectors

6.5.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor plug connection assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.2

6.5.3

Power connections

Feedback system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal box HAN connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lenze ¯ BA 33.0005 ¯ 5.0

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3

i Contents

7

8

Commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1

7.2

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

7.4

Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

8.2

8.3

8.4

8.5

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1

8.2.2

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.3

Spring−operated brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1

8.3.2

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spring−operated brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.3

8.3.4

8.3.5

8.3.6

8.3.7

8.3.8

Checking the component parts

Checking the rotor thickness

Rotor replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the air gap

Release / voltage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of a spring−applied brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1

8.4.2

Brake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.3

8.4.4

8.4.5

8.4.6

Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of the friction plate, sizes 06 to 16

Assembly of the flange

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of the cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting and fault elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1

Technical data as specified by ordinances (EU) No. 4/2014 and (EC) No. 640/2009

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4 Lenze ¯ BA 33.0005 ¯ 5.0

About this documentation

Document history

1

1 About this documentation

Contents

¯ The present documentation serves to safely work on and with the drives. It includes safety instructions which must be observed.

¯ All persons working on and with the drives must have the documentation available and must observe the information and notes relevant for their work.

¯ The documentation must always be in a complete and perfectly readable state.

If the information provided in this documentation is not sufficient in your case, please refer to the controller or gearbox documentation.

Tip!

Information and tools concerning the Lenze products can be found in the download area at www.lenze.com

Validity

This documentation is valid for three−phase AC motors:

Type

L−force M MA

Basic M ERA...V1

Name

Three−phase AC motors (squirrel cage induction motor)

Target group

This documentation is directed at qualified skilled personnel according to IEC 60364.

Qualified skilled personnel are persons who have the required qualifications to carry out all activities involved in installing, mounting, commissioning, and operating the product.

1.1

Material number

13366623

13403644

13493764

13496796

.S]N

Document history

Version

1.0

12/2010

2.0

03/2012

3.0

4.0

5.0

06/2015

08/2015

01/2016

Description

TD09 First edition of the operating instructions, separated from servo motors

TD09 Supplement with UL warning

Table "Screw−in depth B14 flange" added

Nameplates updated

TD09 Complete revision

TD09 Supplemented by chapter: Technical data according to EU and EG regulation

TD09 Supplement: M12 connector assignment, 8−pole for AM1024−8V−H feedback system; sin−cos absolute value encoder with Hiperface

Supplement: Conformity declarations and approvals

Lenze ¯ BA 33.0005 ¯ 5.0

5

1


Conventions used

1.2

Conventions used

This documentation uses the following conventions to distinguish different types of information:

Writing Example/notes Type of information

Spelling of numbers

Decimal

Decimal separator

Normal spelling Example: 1234

Point The decimal point is always used.

For example: 1234.56

Icons

Page reference

Documentation reference

Wildcard

Reference to another page with additional information

For instance: 16 = see page 16

Reference to another documentation with additional information

Example: EDKxxx = see EDKxxx documentation

Wildcard for options, selection data

1.3

Term

Motor

Controller

Drive system

Terminology used

Describes the following

Three−phase AC motor (squirrel cage induction motor) in versions according to product key,

14 .

Any servo inverter

Any frequency inverter

Drive systems including three−phase AC motors and other Lenze drive components

6 Lenze ¯ BA 33.0005 ¯ 5.0


Notes used

1

1.4

Notes used

The following pictographs and signal words are used in this documentation to indicate dangers and important information:

Safety instructions

Layout of the safety instructions:

Danger!

(characterises the type and severity of danger)

Note

(describes the danger and gives information about how to prevent dangerous situations)

Pictograph and signal word

Danger!

Danger!

Stop!

Meaning

Danger of personal injury through dangerous electrical voltage

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of personal injury through a general source of danger

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of property damage

Reference to a possible danger that may result in property damage if the corresponding measures are not taken.

Application notes

Pictograph and signal word

Note!

Meaning

Important note to ensure trouble−free operation

Useful tip for easy handling Tip!

Reference to another document

Warnings!

Important installation instructions for flange−mounted motors

The operating instructions indicates that the motor housing has threaded holes or through holes.

¯ These holes may not be used to install feet.

¯ Motor mounting is only allowed as fixed installation without feet.

Lenze ¯ BA 33.0005 ¯ 5.0

7

2 Safety instructions


2

2.1

Safety instructions


At the time of dispatch, the drive components are in line with the latest state of the art and can be regarded as operationally safe.

Scope

The following general safety instructions apply to all Lenze drive and automation components.

The product−specific safety and application notes given in this documentation must be observed!

General hazards

Danger!

Disregarding the following basic safety measures may lead to severe personal injury and damage to material assets!

¯ Lenze drive and automation components ...

... must only be used for the intended purpose.

... must never be operated if damaged.

... must never be subjected to technical modifications.

... must never be operated unless completely assembled.

... must never be operated without the covers/guards.

... can − depending on their degree of protection − have live, movable or rotating parts during or after operation. Surfaces can be hot.

¯ All specifications of the corresponding enclosed documentation must be observed.

This is vital for safe and trouble−free operation and for achieving the specified product features.

¯ Only qualified skilled personnel are permitted to work with or on Lenze drive and automation components.

According to IEC 60364 or CENELEC HD 384, these are persons ...

... who are familiar with the installation, assembly, commissioning and operation of the product,

... possess the appropriate qualifications for their work,

... and are acquainted with and can apply all the accident prevent regulations, directives and laws applicable at the place of use.

Storage

¯ In a dry, low−vibration environment without aggressive atmosphere;

¯ In the original packaging;

¯ Protect against dust and impacts;

¯ Observe climatic conditions according to the technical data.

8 Lenze ¯ BA 33.0005 ¯ 5.0

Safety instructions


2

Storage conditions

¯ Up to one year:

– Shafts and uncoated surfaces are delivered in a protected against rust status.

Aftertreatment is required where the corrosion protection has been damaged.

¯ More than one year, up to two years:

– Apply a long−term corrosion preventive (e.g. Anticorit BW 366 from the Fuchs company) to the shafts and uncoated surfaces before storing the motor away.

Transport

Before transport

¯ check that all component parts are safely mounted;

¯ check that all component parts with a loose fastening are secured or removed;

¯ tighten all transport aids (eye bolts or support plates).

Use an appropriate means of transport and lifting equipment! (

20)

Stop!

Danger by toppling or falling loads!

Observe payloads!

¯ The payload of the hoists and load handling devices must at least correspond to the weight of the load, for weights see the catalogue.

¯ Secure the load so that it will not topple or fall down.

¯ Walk under suspended loads prohibited!

Danger!

Completely screw in transport aids (such as eye bolts or bearing plates), they must be flat and applied over their entire surface!

If possible, the transport aids (such as eye bolts or bearing plates) must be stressed vertically in the direction of the screw axis! Angular tension or tension to the sides reduces the payload! Observe the information provided in DIN 580!

Use additional appropriate lifting aids, if required, to achieve a direction of loading which is as vertical as possible (highest payload). Secure lifting aids against shifting!

Corrosion protection

Lenze offers paints with different resistance characteristics for drive systems. Since the resistance may be reduced when the paint coat is damaged, defects in paint work (e.g.

through transport or assembly) must be removed professionally to reach the required corrosion resistance.

Mechanical installation

¯ Provide for careful handling and avoid mechanical overload. During handling neither bend components, nor change the insulation distances.

Lenze ¯ BA 33.0005 ¯ 5.0

9

2

Safety instructions


Electrical installation

¯ Carry out the electrical installation according to the relevant regulations (e. g.

cable cross−sections, fusing, connection to the PE conductor). Additional notes are included in the documentation.

¯ Only plug in or remove pluggable terminals in the deenergised state!

Commissioning

¯ If required, you have to equip the system with additional monitoring and protective devices in accordance with the respective valid safety regulations (e. g.

law on technical equipment, regulations for the prevention of accidents).

¯ Before commissioning remove transport locking devices and keep them for later transports.

2.2


Low−voltage machines are not household appliances but are intended as components that are only applied for re−use for industrial or professional purposes in terms of

IEC/EN 61000−3−2. They comply with the requirements of the Low−Voltage Directive and the harmonised standards of the IEC/EN 60034 series.

Low−voltage machines must only be operated under the operating conditions and power limits specified in this documentation.

The integrated brakes must not be used as safety brakes. It cannot be ruled out that interference factors which cannot be influenced cause a brake torque reduction.

Low−voltage machines with IP23 protection or less are only intended for outdoor use when applying special protective features.

Products included in the scope of application of the EU regulations (EG) 640/2009 and (EU) 4/2014 (and hence ErP Directive 2009/125/EG) and which did not comply with minimum efficiency requirements when first put into circulation, are not CE compliant and will not receive CE marking. The product is for exclusive use outside the European Economic Area (EEA) only.

Motors of efficiency class IE2 with a rated power of 7.5 kW ... 375 kW which are included in the scope of application of the EU regulations (EG) 640/2009 and (EU)

4/2014 and which were put into circulation in the European Economic Area (EEA) after 31 December 2014 may be exclusively used there on a frequency inverter for speed control only. These motors receive the following additional marking.

IE2

EU REGULATION 640/2009

USE WITH VARIABLE

SPEED DRIVE ONLY!

Any other use shall be deemed inappropriate!

10 Lenze ¯ BA 33.0005 ¯ 5.0

Safety instructions

Foreseeable misuse

2

2.3

Foreseeable misuse

¯ Do not operate the motors

– ... in explosion−protected areas

– ... in aggressive environments (acid, gas, vapour, dust, oil)

– ... in water

– ... in radiation environments

Note!

Increased surface and corrosion protection can be achieved by using adapted coating systems.

2.4

Residual hazards

Protection of persons

¯ The motor surfaces can become very hot. Danger of burns when touching!

– Provide protection against accidental contact, if necessary.

¯ Danger of unintentional starting or electrical shocks

– Connections must only be made when the equipment is deenergised and the motor is at standstill.

– Installed brakes are no fail−safe brakes.

Motor protection

¯ Installed thermal detectors are no full protection for the machine.

– Installed overload protection does not prevent an overload under any conditions.

¯ Installed brakes are no fail−safe brakes .

– The torque may be reduced by disruptive factors that cannot be influenced such as contamination by oil.

¯ Fuses are no motor protection.

– Use current−dependent motor protection switches at average operating frequency.

– Use installed thermal detectors at high operating frequency.

¯ Too high torques cause a fraction of the motor shaft.

– The maximum torques according to catalogue must not be exceeded.

¯ Lateral forces from the motor shaft may occur.

– Align shafts of motor and driving machine exactly to each other.

¯ If deviations from normal operation occur, e.g. increased temperature, noise, vibration, determine the cause and, if necessary, contact the manufacturer. If in doubt, switch off the motor.

Lenze ¯ BA 33.0005 ¯ 5.0

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2

Safety instructions

Disposal

Fire protection

¯ Fire hazard

– Prevent contact with flammable substances.

2.5

Disposal

Sort individual parts according to their properties. Dispose of them as specified by the current national regulations.

12 Lenze ¯ BA 33.0005 ¯ 5.0

Product description

Identification

3

3

3.1

Product description

Identification

Three−phase AC motors ...

M

LL

MA

Motor with standard output flange Motor with square flange for direct gearbox attachment

M L ERA...V1

Basic standard motor

MT−MDEMA−005.iso/dms

MT−MXERA−001.bmp/dms

Lenze ¯ BA 33.0005 ¯ 5.0

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3

Product description

Identification

Motor code

3.1.1

Motor code

Three−phase AC motors M LL MA

Example

Meaning

Product family

Efficiency class

Variant

Cooling

IE1

IE2

Natural ventilation

Integral fan

Blower

Internal key

Built−on accessories Without built−on accessories

Brake

Brake + resolver

Brake + incremental encoder

Brake + sin/cos absolute value encoder

Brake + 2nd shaft end

Brake + handwheel

Brake + grey iron fan

Resolver

Incremental encoder

Sin/cos absolute value encoder

2nd shaft end

Handwheel

Grey iron fan

Grey iron fan + 2nd shaft end

Grey iron fan + handwheel

Size

M D

Motor code

M

D

H

S

E

F

E MA XX 063

MA

ZE

HA

LL

LZ

LH

BL

RS

IG

AG

XX

BR

BS

BI

BA

BZ

BH

063

071

080

090

100

112

132

160

180

200

225

Overall length

−

−

2

3

0

1

4

Number of pole pairs 2−pole motors

4−pole motors

Design type

Approval

6−pole motors

Internal key

CE cURus

CCC

4

1

2

3

2 C1

C1

C

V

3

C

14 Lenze ¯ BA 33.0005 ¯ 5.0

Product description

Identification

Encoder code

3.1.2

Example

Meaning

Product line

Encoder code

Number

Type

Resolver

Resolver for safety function

Incremental encoder

Incremental encoder with commutation signal

Singleturn absolute value encoder

Multitum absolute value encoder

2−pole resolver for servo motors

2−pole resolver for three−phase AC motors

Number of pole pairs for resolvers

Number of steps / increments per revolution

Voltage

Interface or signal level

Medium supply voltage

Standard

TTL

HTL (for incremental encoders)

Hiperface (for absolute value encoders)

EnDat sin/cos 1 V ss

For safety function

TTL

HTL (for incremental encoders)

Hiperface (for absolute value encoders)

EnDat sin/cos 1 V ss

Safety integration level (SIL)

SFC 1024

Encoder code

RS

RV

IG

IK

SFC

AM

0

1

2, 3, 4,...

32, 128,

512,

1024,

2048, ...

−

−

8V

5V, 8V,

15V,

24V, ...

−

−

K

F

U

K

V

H

E

T

H

S

K

1

2

3

4

2

Note!

If feedback systems for safety functions are used, the manufacturer’s documentation must be observed!

3

Lenze ¯ BA 33.0005 ¯ 5.0

15

3

Product description

Nameplate

3.1.3

Nameplate

Three−phase AC motor for direct gearbox attachment

L

1 15

21

Hz kW 2

3

4

5.1

5.3

6

8.1

9

20.2

10.1

11

8.2

7.1

8.3

10.2

5.2

5.4

7.2

18

17

V

A

25 r/min h % cos j

C86

20.1

22

16.1

16.2

16.4

16.4

16.5

16.5

16.3

16.7

16.6

22

26

15

19

23

13

14.1

14.2

14.3

27

29

Three−phase AC motor with standard output flange

L

1

9

15

2

4

21

8.1

9

24

10.1

10.2

11

14.2

8.2

14.1

8.3

13

10.3

20.1

23 26

22

14.3

27

29

Hz kW r/min

V

18

A cos j h

%

16.1

16.2

16.3

16.4

16.4

16.5

16.5

16.6

16.7

Three−phase AC motor Basic type

M L ERA...V1/IE1

L

4

10.2

1

12

2

14.1

18

14.3

14.2

5.10

15

V / (10%)

16.4

Hz

16.1

kW

16.2

r/min

16.3

A D/Y

16.5

h %

16.7

Eff.CL.

23 cos j

16.6

M L ERA...V1/IE2

L

1

2

14.1

3

10.2

16.7

V / (10%) Hz

16.4

16.1

10.3

16.8

r/min kW

16.3

16.2

10.1

A /

16.5

18

23

13

16.9

15 cos j

14.3

14.2

5.10

16.6

16 Lenze ¯ BA 33.0005 ¯ 5.0

11

12

13

14

17

18

19

20

26

27

29

31

21

22

23

24

6

7

2

3

4

5

Pos.

1

8

9

10

15

16

16.1

16.2

16.3

16.4

16.5

16.6

16.7

16.8

16.9

Contents

Manufacturer / production location

Type of motor / standard

Gearbox type

Motor type

Technical data

Ratio 5.1

5.2

5.3

5.4

5.10

Rated torque

Rated speed

Rated frequency

Number of poles

Mounting position / position of the system blocks

Lubricant details

7.1

Lubricant amount

7.2

Lubricant type

Brake data

8.1

8.2

8.3

Type

AC/DC brake voltage

Braking torque, electrical power input

For feedback / pulse encoder or resolver data,

15

Production data

10.1

10.2

10.3

Bar code

Order number

Material number

Serial number

14.1

14.2

14.3

Motor number

Information with regard to the operating mode

Additional motor specifications

Temperature class

Enclosure

Motor protection

Applicable conformities, approvals and certificates

Rated data for various frequencies

Hz = frequency kW = rpm = motor power motor speed

V =

A = h h cos j

= h

=

=

= motor voltage motor current motor power factor motor efficiency: at a rated power of 100% motor efficiency: at a rated power of 75% motor efficiency: at a rated power of 50%

Application factor (specified if <1.0) / load capacity

Year of manufacture / week of manufacture

20.1

20.2

UL file number

Customer data

Additional customer data

Customer order number

UL category (e.g. inverter duty motor)

C86 = motor code for controller parameterisation (code 0086)

Efficiency class

Partial load efficiencies for 50Hz operation at a rated power of 50% and 75%

CC number Department of Energy (optional)

Permissible ambient temperature (e.g. Ta

£

40°C)

Standstill current (ampere locked rotor ALR)

Plug design (number of poles)

Product description

Nameplate

3

Lenze ¯ BA 33.0005 ¯ 5.0

17

4 Technical data

General data and operating conditions

4

4.1

Technical data


General data

Conformity declarations and approvals

Conformity declarations

CE

EAC

2006/42/EC

2014/35/EU

2009/125/EC

TP TC 004/2011

(TR CU 004/2011)

TP TC 020/2011

(TR CU 020/2011)

Machinery Directive

Low−Voltage Directive

ErP Directive

On safety of low voltage equipment

Electromagnetic compatibility of technical means

Eurasian Conformity

TR CU: Technical Regulation of

Customs Union

Eurasian Conformity

TR CU: Technical Regulation of

Customs Union

Approvals

UL

CSA

Energy Verified

UL 1004−8

CSA C22.2 No. 100

CFR Part 431.23

CSA C390−10

File No. E210321 Inverter Duty Motors

Motors and Generators

File No. E210321

CC1278B

Energy Efficiency Program for

Certain Commercial and

Industrial Equipment

Energy Efficiency Test

Methods for Three−Phase

Induction Motors

Safety requirements of small−power motors CCC GB Standard

12350−2009

The applicable approvals for the product you have ordered require labelling and are specified on the nameplate.

Protection of persons and devices

Enclosure IEC/EN 60034−5

Temperature class

Permissible voltage

F (155 °C)

IEC/EN 60034−1

See nameplate

Degrees of protection only apply to horizontal installation

All unused connectors must be closed with protection covers or blanking plugs.

Exceedance of the temperature limit weakens or destroys the insulation

As specified by limiting curve A of the pulse voltage from

IEC / TS 60034−25:2007 (corresponds to IVIC

C/B/B@500V)

EMC

Noise emission

Noise immunity

IEC/EN 61800−3 Depending on the controller, see documentation for the controller.

18 Lenze ¯ BA 33.0005 ¯ 5.0

Technical data


4

Operating conditions

Ambient conditions

Climatic

Transport

Storage

Operation

IEC/EN 60721−3−2 2K3 (−20 °C ... +70 °C)

IEC/EN 60721−3−1 1K3 (−20 °C ... +60 °C)

1K3 (−20 °C ... +40 °C)

IEC/EN 60721−3−3 3K3 (−20 °C ... +40 °C)

MCA, MCS, MD KS

< 3 months

> 3 months

3K3 (−15 °C ... +40 °C)

MCM, MQA

3K3 (−10 °C ... +40 °C)

3K3 (−15 °C ... +40 °C)

> +40 °C

Without brake

With brake

With blower

With power reduction, see catalogue

Site altitude < 1000 m amsl − without power reduction

> 1000 m amsl < 4000m amsl with power reduction, see catalogue

Relative humidity £ 85 %, without condensation Humidity

Electrical

The motor connection type depends on the controller

Length of the motor cable inverter instructions

Length of cable for speed feedback

Mechanical

IEC/EN60721−3−3 3M6

Lenze ¯ BA 33.0005 ¯ 5.0

19

5 Mechanical installation

Important notes

5

5.1


Important notes

Danger!

Some of the motors mounted to the gearboxes are equipped with transport aids. They are only intended for the mounting/dismounting of the motor to the gearbox and must not be used for the entire geared motor!

¯ Only move the drive with means of transport or hoists that have sufficient load−bearing capacity.

¯ Ensure safe fixing.

¯ Avoid shocks!

Screw−on dimensions B14 flange

Stop!

Observe the maximally permissible screw−in depth for B14 flange!

C

MDERA 056 V1

MDERA 063 V1

MDERA 071 V1

MDERA 080 V1

MDERA 090 V1

MDERA 100 V1

MDERA 112 V1

MDERA 132 V1

M MA N063

M MA N071

M MA N080

M MA N080

M MA N090

M MA N090

M MA N100

M MA N112

MHERA 080

MHERA 090

MHERA 100

MHERA 112

MHERA 132

20

FT75

FT85

FT100

FT130

FT115

FT130

FT130

FT130

FT100

FT115

FT130

FT130

FT165

[mm]

FT65

FT75

FT85

FT100

FT115

FT130

FT130

FT165 c max.

14

16

14

16

10

10

12

16

15

16

18

19

23

[mm]

14

19

21

22

11

14

14

16 s

M8

M8

M8

M8

M5

M6

M6

M8

M5

M5

M6

M6

M8

M8

M8

M10

M6

M8

M8

M8

M10

Lenze ¯ BA 33.0005 ¯ 5.0


Preparation

5

5.2

Preparation

Remove the corrosion protection from the shaft ends and flanges. If necessary, remove dirt using standard cleaning solvents.

Stop!

Bearings or seals must not come into contact with the solvent − material damages.

After a long storage period (> 1 year) you have to check whether moisture has entered the motor. For this purpose, measure the insulation resistance (measuring voltage 500 V

DC

). In case of values £ 1k W per volt of rated voltage, dry the winding.

Stop!

During transport and storage, condensation drain holes (see Fig. 1) are closed with plugs for pollution prevention reasons. Remove the plugs before commissioning!

Fig. 1 Motor with condensation drain holes

Condensation drain holes

Depending on the mounting position, the condensation drain holes are always at the bottom of the motor!

¯ For condensate drainage

– the motor must be deenergised;

– the plugs (screws) must be removed.

Stop!

To restore the enclosure, re−insert the plugs (screws) after condensate drainage. If the condensation drain holes are not sealed again, the IP enclosure of the motor will be reduced. For horinzontal motor shafts to

IP23 and for vertical motor shafts to IP20.

Lenze ¯ BA 33.0005 ¯ 5.0

21

5


Installation

5.3

Installation

¯ The mounting surface must be dimensioned for the design, the weight, and the torque of the motor.

¯ The foot and flange faces must rest flat on the mounting surface.

– An insufficient alignment of the motor shortens the service life of the roller bearings and the transmission elements.

Blows to shafts can cause damage to the bearings.

¯ Do not exceed the permissible range of ambient operating temperature (

19).

¯ Securely fasten the motor.

¯ Ensure unobstructed ventilation. The exhaust air, also that of adjacent aggregates, must not be inlet again immediately.

¯ During operation, surface temperatures of up to 140 °C are possible! Protect against contact!

Note!

From the air inlet to other component parts, a minimum distance of 10% of the outer diameter of the fan cover must be complied with!

Ensure an even surface, solid foot or flange mounting and exact alignment if a direct clutch is connected. Avoid resonances with the rotational frequency and double supply frequency which may be caused during assembly.

Only mount or remove transmission elements using appropriate means. In order to facilitate handling, heat them beforehand. Cover belt pulleys and clutches with a touch guard.

Stop!

Ensure a correct belt tension!

The machines are halfkey balanced. The clutch must be halfkey balanced, too. The visible jutting out part of the key must be removed.

Designs with shaft end at the bottom must be protected with a cover at the N−end, preventing the ingress of foreign particles into the fan.

22 Lenze ¯ BA 33.0005 ¯ 5.0


Assembly of built−on accessories

5

5.4

Assembly of built−on accessories

Follow these instructions carefully. Please note that the warranty and product liability will become void in the event of impermissible alterations or modifications to the motors.

¯ Mount the transmission elements:

– Shocks and impacts must be avoided! They could destroy the motor.

– For mounting always use the centre bore in the motor shaft as specified by DIN

332−DR−M...

– Tolerances of the shaft ends:

£ Æ 50 mm: ISO k6, > Æ 50 mm: ISO m6.

¯ Only use an extractor for the disassembly.

¯ When using belts for torque/power transmission:

– Tension the belts in a controlled manner.

– Provide protection against accidental contact! During operation, surface temperatures of up to 140°C are possible.

Lenze ¯ BA 33.0005 ¯ 5.0

23

5


Spring−applied brakes

5.5


Important notes

As an option, the motors can be fitted with a brake. The installation of brakes (in or on the motor) increases the length of the motor.

Note!

The brakes used are not fail−safe because interference factors which cannot be influenced (e.g. oil ingress) may lead to a reduction in torque.

The brakes are used as holding brakes and serve to hold the axes at standstill or in the deenergised state.

Emergency stops at higher speeds are possible but high switching energy increases wear on the friction surfaces and the hub, (

42).

The spring−applied brakes work on the basis of the closed−circuit principle, i.e. the brake is closed in the deenergised state. The brakes for DC supply can be fed with a bridge−rectified DC voltage (bridge rectifier) or with a smoothed DC voltage. The permissible voltage tolerance is ±10 %.

In case of long motor cables the voltage drop must be checked due to increasing conductor resistance and compensated for by higher input voltage if necessary.

The following applies to Lenze system cables:

U *

+

U

B

) ƪ

0.08

m

W

@

L

@

I

B ƫ

U* [V]

U

B

[V]

Resulting supply voltage

Rated voltage of the brake l [m]

I

B

[A]

Cable length

Rated current of the brake

Stop!

If no suitable voltage (incorrect value, incorrect polarity) is applied to the brake, the brake will be applied and can be overheated and destroyed by the motor continuing to rotate.

The shortest operating times of the brakes are achieved by DC switching of the voltage and an external suppressor circuit (varistor or spark suppressor). Without suppressor circuit, the operating times may increase. A varistor/spark suppressor limits the breaking voltage peaks. It must be ensured that the power limit of the suppressor circuit is not exceeded. This limit depends on the brake current, brake voltage, disengagement time and the switching operations per time unit.

Furthermore the suppressor circuit is necessary for interference suppression and for increasing the service life of the relay contacts (external, not integrated into the motor).

24 Lenze ¯ BA 33.0005 ¯ 5.0



Locking of the manual release

5

For permissible operating speeds and characteristics, please see the motor catalogue applicable in each case. Emergency stops at higher speeds are possible, but high switching energy increases wear on the friction surfaces and the hub.

Stop!

The friction surfaces must always be free from oil and grease because even small amounts of grease or oil will considerably reduce the braking torque.

The formula below provides a simplified way to calculate friction energy per switching cycle which must not exceed the limit value for emergency stops that depends on the operating frequency ( motor catalogue; Lenze drive solutions: formulas, dimensioning, and tables).

Q + ½ @ J tot

@ Dw 2 @

M

K

M

K

* M

L

Q [J] Friction energy

J tot

[kgm 2 ] Total mass inertia (motor + load)

Dw

[ 1 / s

] Angular velocity w

=2 p n /

60

, n= speed [rpm]

M

K

[Nm] Characteristic torque

M

L

[Nm] Load torque

Depending on the operating conditions and possible heat dissipation, surface temperatures can be up to 130 °C.

More detailed information on the used brakes is provided in the corresponding catalogues.

5.6


Scope of supply

Geared motor Shipping bag

GT−GNG−GST−010.iso/dms

¯ 1 Manual release lever with knob

¯ 1 Terminal block

¯ 1 Cheese head screw with nut

GT−GXX−012.iso/dms


Lenze ¯ BA 33.0005 ¯ 5.0

25

5

Mounting




2

1

4

3

Cheese head screw with nut

Manual release lever with knob


Terminal block

Manual release shackle (brake)

Handling

Stop!

¯ Lock the manual release only for service work!

¯ The manual release must not be locked during operation, otherwise the brake could be damaged!

¯ Always secure the terminal block against loosening in every position with cheese head screw and nut!

Brake not released / operating position Brake released / service position


Cheese head screw with nut

Manual release lever with knob

Terminal block

Fan cover


26 Lenze ¯ BA 33.0005 ¯ 5.0


Important notes

6

6

6.1


Important notes

Danger!

Hazardous voltage on the power connections even when disconnected from mains: residual voltage >60 V!

Before working on the power connections, always disconnect the drive component from the mains and wait until the motor is at standstill.

Verify safe isolation from supply!

Stop!

Electrical connections must be carried out in accordance with the national and regional regulations!

¯ Observe tolerances according to IEC/EN 60034−1:

– Voltage ±10 %

– Frequency ±2 %

– Wave form, symmetry (increases heating and affects electromagnetic compatibility)

¯ Observe notes on wiring, information on the nameplate, and the connection scheme in the terminal box.

¯ The terminal box has to be free of foreign bodies, dirt, and humidity.

¯ All unused cable entries and the box itself must be sealed against dust and water.

¯ The connection must ensure a continuous and safe electrical supply, i.e.

– no loose wire ends,

– use assigned cable end fittings,

– ensure good electrical conductivity of the contact (remove residual lacquer) if an

(additional) PE connection on the motor housing is used,

– establish a safe PE conductor connection,

– tighten the plugin connector to the limit stop,

– all connections at the terminal board are tightened.

¯ The smallest air gaps between uncoated, live parts and against earth must not fall below the following values.

Motor diameter

< 178 mm

> 178 mm

Minimum requirements for basic insulation according to IEC/EN

60664−1 (CE)

3.87 mm

Higher requirements for UL design

6.4 mm

9.5 mm

Lenze ¯ BA 33.0005 ¯ 5.0

27

6



6.2


The three−phase AC motors described in these instructions are optimised and qualified for the use on Lenze frequency inverters and can be combined without restrictions.

If another inverter is used for operation, the voltage peaks (U pk diagram must not be exceeded with the given rise time (t

R

).

) shown in the

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0

0.1

0.2

0.3

0.4

0.5

1.56 kV

0.6

0.7

0.8

0.9

1.0

1.1

1.2

MT−m500−001.des

Fig. 2 Permissible voltage peaks for operation on the frequency inverter

IEC/TS 60034−25:2007 (complies with IVIC C/B/B @500 V)

Lenze Standard A+

Possible countermeasures

Appropriate countermeasures must be taken if exceedance of the permissible voltage peaks cannot be ruled out:

¯ Reduce the DC−bus voltage (brake chopper threshold voltage);

¯ Use filters, chokes;

¯ Use of special motor cables.

6.3

EMC−compliant wiring

The EMC−compliant wiring of the motors is described in detail in the Operating

Instructions for the Lenze controllers.

¯ Use of metal EMC cable glands with shield connection.

¯ Connect the shielding to the motor and to the device.

28 Lenze ¯ BA 33.0005 ¯ 5.0



6

6.4


Tightening torques

[Nm] +/− 10%

M4 M5

2.2

3.5

M6

4.5

M8

−−−−−

CuZn

1.2

2.0

3.0

6.0

2.2

3.5

−−−−− −−−−−

Tab. 1

[Nm]

Material

Plastic

Metal

M12x1.5

0.7

3

M16x1.5

1

3

Locking screws and cable glands

M20x1.5

1

4

M25x1.5

2.5

6

M32x1.5

3

8

M40x1.5

3

10

M50x1.5

3

14

Lenze ¯ BA 33.0005 ¯ 5.0

29

6



Power connections on the terminal board

6.4.1

Power connections on the terminal board

Motor

Single−rotation motors

U D

Pole−changing motors

Dual−voltage motors

UU U

Legend

L1/L2/L3

TB1/TB2

UU

U

MT_MXXXX_001.iso/dms

Power connection

Thermal contact (TKO)

Low speed

High speed

Low voltage

High voltage

PE connection (optional)

Temperature monitoring

Terminal strip / terminal board

Contact

TB1

TB2

TP1

TP2

R1

R2

Meaning

Thermal contact − TCO

PTC thermistor

Thermal sensor +KTY

Thermal sensor −KTY

Note

Max. 250 V~

Max. 1.6 A ~

Observe polarity

Terminal board or terminal possible for all thermal sensors.

Blowers via blower terminal box / motor terminal box

Blower 3~

Terminal board

Contact Meaning

U1

V1

W1

Connection to L1 − mains

Connection to L2 mains


Note

Observe direction of rotation! In case of wrong direction of rotation, L1 − L2 must be interchanged

Separate fan 1~

Terminal board

Contact Meaning

U1

Note


V1 / U2 Connection to N − mains

30 Lenze ¯ BA 33.0005 ¯ 5.0




6.4.2

MS2

MS4

MS1

MS2

MS4

BD1

BD2

MS1

MS2

MS4

MS1


−

+

Contact

~

~

Meaning

AC−excited brake (rectifier)

1 2 3 4 5 6

- ~ ~ +

Brake, DC operated

Brake microswitch, release control

Brake microswitch, wear control

Brake microswitch, manual release

Additional specifications

Connection to L1 − mains

Connection to N − mains

Brake connection

Brake connection

Switching contact, DC switching

DC connection

Two−way switch

NC contact

NO contact

Two−way switch

NC contact

NO contact

Two−way switch

NC contact

NO contact

6.4.3

Feedback system to terminal

Resolver

Contact

B1

B2

B3

B4

B5

B6

B7

B8

Name

+ Ref

− Ref

Not assigned

+COS

−COS

+SIN

−SIN

Not assigned

Meaning

Transformer windings

(reference windings)

Stator winding cosine

Stator winding sine

Incremental encoder / sin/cos absolute value encoder with Hiperface

Contact

B1

B2

B3

B4

B5

B6

B7

B8

B10 1)

Designation

+ U

B

GND

A / + COS

A / Ref cos

B / − SIN

B / Ref sin

Z / data +

Z / data −

Shield − housing

Meaning

Supply +

Mass

Track A / process data channel

Track A inverse / process data channel

Track B / process data channel

Track B inverse / process data channel

Zero track / parameter channel + RS485

Zero track inverse / parameter channel − RS485

Shield − incremental encoder

1) The terminal is not assigned if insulation at N−end shield of the motor has been selected!

6

Lenze ¯ BA 33.0005 ¯ 5.0

31

6


Plug connectors

Motor plug connection assignment

6.5

Plug connectors

Stop!

¯ Tighten the coupling ring of the connector.

¯ If plugs without SpeedTec bayonet nut connectors are used, the connector boxes for the power / encoder / fan connections must be secured by O−rings if loadings by vibration occur:

– M17 connector box with O−ring 15 x 1.3 mm

– M23 connector box with O−ring 18 x 1.5 mm

Plug−in connectors (plug/connector box) with SpeedTec bayonet nut connectors are vibration−proof.

¯ If SpeedTec bayonet nut connectors are used, O−rings must be removed (if any)!

¯ Never disconnect plugs when voltage is being applied! Otherwise, the plugs could be destroyed! Inhibit the controller before disconnecting the plugs!

6.5.1

Motor plug connection assignment

Note!

When making your selection, the motor data and permissible currents of the cables according to the system cable system manual must be observed.

6.5.2

Power connections

Power / brake / thermal sensor

ICN, 6−pole and 8−pole

4

5

6

1

2

6−pole (external view of poles)

Contact Name

BD1 / BA1

BD2 / BA2

PE

V

V

W

Meaning

Brake + /

~

Brake − / ~

PE conductor

Power phase U

Power phase V

Power phase W

C

D

A

B

3

4

8−pole (external view of poles)

Contact Name

1 V

PE

W

V

TB1 / TP1 / R1

TB2 / TP2 / R2

BD1 / BA1

BD2 / BA2

Name

Power phase U

PE conductor

Power phase W

Power phase V

Thermal sensor:

TCO / PTC / + KTY

TCO / PTC / − KTY

Brake + / AC <250 V

Brake − / AC <250 V

M23

1

2

5

6

4

MT−Steckverbinder−001.iso/dms

M23

C

D

B

A

3

4

1


32 Lenze ¯ BA 33.0005 ¯ 5.0


Plug connectors

Power connections

C

D

A

B

3

4

8−pole (external view of poles) / connection variant ICN 8B

Contact Name Name

1 V Power phase U

PE PE conductor

W

V

TB1 / TP1 / R1

TB2 / TP2 / R2

BD1 / BA 1

BD2 / BA2

Power phase W

Power phase V

Thermal sensor

TCO / PTC / + KTY

TCO / PTC / − KTY

Switching contact of rectifier

M23

C

D

B

A

3

4

1


Connection variant ICN 8B − switching contact of the rectifier for DC switching. Rectifier supply via motor terminal board. Only possible during mains operation!

Fan

ICN, 7−pole

3

4

5

6

1

2

Single−phase (external view of poles)

Contact Name

PE

Meaning

PE conductor

U1

U2

AC fan

Not assigned

U+

U−

Not assigned

DC fan

5

6

3

4

1

2

Three−phase (external view of poles)

Contact Name Meaning

PE PE conductor

U

Not assigned

Fan

V Fan

Not assigned

W Fan

M17

4

5

6

3

1

2

M17

4

5

6

1

2

3 MT−Steckverbinder−001.iso/dms

6

Lenze ¯ BA 33.0005 ¯ 5.0

33

6


Plug connectors

Feedback system

6.5.3

Feedback system

Resolver / incremental encoder / absolute value encoder

ICN 8−pole

5

6

3

4

7

8

Sin−cos absolute value encoder with Hiperface (external view of poles)

Contact

1

Name

B

Meaning

−SIN

M12

2 B +SIN

A

A

Z

Z

GND

+ U

B

−COS

+COS

+ RS485

− RS485

Mass

Supply +

7

6

1

5

8

2

4

3

ICN, 12−pole

6

7

8

9

4

5

1

2

3

Resolver (external view of poles)

Contact Name

+ Ref

− Ref not assigned

+COS

−COS

+SIN

−SIN not assigned

10

11

12

Shield

+ KTY

− KTY

Meaning

Transformer windings

(reference windings)

Stator windings cosine

Stator windings

Sine

Encoder housing shield

Thermal detector KTY

M23 xxx


6

7

8

9

10

11

12

1

2

3

4

5

Incremental encoder / sin/cos absolute value encoder Hiperface (external view of poles)

Contact Name Meaning M23

B

A

A

+ U

B

GND

Track B / + SIN

Track A inverse / − COS

Track A / + COS

Supply +

Mass

Zero track inverse / − RS485

Zero track / + RS485

Z

Z

Not assigned

B

Shield

+ KTY

− KTY

Track B inverse / − SIN

Encoder housing shield

Thermal detector KTY

34 Lenze ¯ BA 33.0005 ¯ 5.0


Terminal box HAN connectors

6

3

4

Circular connector

4−pole

Incremental encoder (external view of poles)

Contact Name Meaning

1 + U

B

Supply +

2 B Track B

GND

A

Mass

Track A

M12

MT plug−in connector−001.iso/dms

Further information is provided in the system cables system manual at: www.Lenze.de ® Download ® Technical documentation ®

Finding technical documentation

Filter: Type of contents

System manual

Filter: Product

System cable

6.6

Terminal box HAN connectors

Contact pin HAN−Modular 16 A

HAN−GTM−004.iso

Contact pin HAN−Modular 40 A

HAN−GTM−007.iso

HAN−GTM−008.iso

Lenze ¯ BA 33.0005 ¯ 5.0

HAN−GTM−004.iso

35

6


Terminal box HAN connectors b c

Terminal box

Module a

2

3

Contact

1

4

5

6

2

3

Blind module

1

Name

U1

V1

W1

+KTY / PTC / TCO

+ / AC

− / AC

Switching contact

−KTY / PTC / TCO

Meaning

Terminal board

Terminal board

Terminal board

Thermal sensor

Brake

Brake

Rectifier

Thermal sensor

Contact pin HAN 10E

HAN−GTM−007.iso

7

8

5

6

9

10

2

3

4

Terminal box

Contact Name

1 U1

V1

W1

+ / AC

− / AC

W2

U2

V2

+KTY / PTC / TCO

−KTY / PTC / TCO

Meaning

Terminal board

Holding brake

Terminal board

Thermal sensor

Note!

Carry out the wiring in or in the counter plug:

¯ − wiring: 6−7−8

¯ − wiring: 1−6/2−7/3−8

HAN−GTM−004.iso

36 Lenze ¯ BA 33.0005 ¯ 5.0

Commissioning and operation

Important notes

7

7

7.1


Important notes

For trial run without output elements, lock the featherkey. Do not deactivate the protective devices, not even in a trial run.

Check the correct operation of the brake before commissioning motors with brakes.

7.2

Before switching on

Note!

Before switch−on, you must ensure that the motor starts with the intended direction of rotation.

Lenze motors rotate CW (looking at the driven shaft) if a clockwise three−phase field L1 U1, L2 V1, L3 W1 is applied.

Fig. 3 Direction of rotation of the driven shaft

Lenze ¯ BA 33.0005 ¯ 5.0

37

7


Functional test

Before initial commissioning, before commissioning after an extended standstill period, or before commissioning after an overhaul of the motor, the following must be checked:

¯ Measure the insulation resistance, in case of values £ 1 k W per volt of rated voltage, dry the winding.

¯ Have all screwed connections of the mechanical and electrical parts been firmly tightened?

¯ Is the unrestricted supply and removal of cooling air ensured?

¯ Has the PE conductor been connected correctly?

¯ Have the protective devices against overheating (temperature sensor evaluation) been activated?

¯ Is the controller correctly parameterised for the motor?

( Controller operating instructions)

¯ Are the electrical connections o.k.?

¯ Does the motor connection have the correct phase sequence?

¯ Are rotating parts and surfaces which can become very hot protected against accidental contact?

¯ Is the contact of good electrical conductivity if a PE connection on the motor housing is used?

7.3

Functional test

¯ Check all functions of the drive after commissioning:

¯ Direction of rotation of the motor

– Direction of rotation in the disengaged state (see chapter "Electrical connection").

¯ Torque behaviour and current consumption

¯ Function of the feedback system

38 Lenze ¯ BA 33.0005 ¯ 5.0


During operation

7

7.4

During operation

Stop!

¯ Fire hazard! Do not clean or spray motors with flammable detergents or solvents.

¯ Avoid overheating! Deposits on the drives impede the heat dissipation required and have to be removed regularly.

Danger!

During operation, motor surfaces must not be touched. According to the operating status, the surface temperature for motors can be up to 140°C.

For the protection against burn injuries, provide protection against contact, if necessary. Observe coolingoff times!

During operation, carry out inspections on a regular basis. Pay special attention to:

¯ Unusual noises

¯ Oil spots on drive end or leakages

¯ Irregular running

¯ Increased vibration

¯ Loose fixing elements

¯ Condition of electrical cables

¯ Speed variations

¯ Impeded heat dissipation

– Deposits on the drive system and in the cooling channels

– Pollution of the air filter

In case of irregularities or faults: (

50).

Lenze ¯ BA 33.0005 ¯ 5.0

39

8 Maintenance/repair

Important notes

8

8.1

Maintenance/repair

Important notes

Danger!

Hazardous voltage on the power connections even when disconnected from mains: residual voltage >60 V!

Before working on the power connections, always disconnect the drive component from the mains and wait until the motor is at standstill.

Verify safe isolation from supply!

Shaft sealing rings and roller bearings have a limited service life.

Regrease bearings with relubricating devices while the low−voltage machine is running.

Only use the grease recommended by the manufacturer.

If the grease drain holes are sealed with a plug, (IP54 drive end; IP23 drive and nondrive end), remove plug before commissioning. Seal bore holes with grease.

8.2

Maintenance intervals

Inspections

¯ If the machine is exposed to dirt, clean the air channels regularly.

8.2.1

Motor

¯ Only the bearings and shaft sealing rings become worn.

– Check bearings for noise (after approx. 15,000 h at the latest).

¯ In order to prevent overheating, remove dirt deposits on the drives regularly.

¯ We recommend carrying out an inspection after the first 50 operating hours. In this way, you can detect and correct any irregularities or faults at an early stage.

8.2.2

Encoder

The guarantor of the engine is a component for use with security features.

Danger!

If not properly performed work on the guarantor of the motor lead to the loss of safety functions.

Possible consequence: Property damage and / or personal injury.

Protection measure: Repair or replacement of the collateral provider is allowed only by

Lenze Service or its empower people.

After a service life of 10 years, an inspection of the metal elastomer torque plate is required for the AS1024−8V−K, AS1024−8V−K2; AM1024−8V−K, and AM1024−8V−K2 encoders. If no replacement is required, an inspection interval of max. 5 years has to be observed.

40 Lenze ¯ BA 33.0005 ¯ 5.0

Maintenance/repair

Maintenance operations

Spring−operated brakes

8.2.3


To ensure safe and trouble−free operation, spring−applied brakes must be checked and maintained at regular intervals. Servicing can be made easier if good accessibility of the brakes is provided in the plant. This must be considered when installing the drives in the plant.

Primarily, the necessary maintenance intervals for industrial brakes result from the load during operation. When calculating the maintenance interval, all causes for wear must be taken into account, ((

42). For brakes with low loads such as holding brakes with

emergency stop, we recommend a regular inspection at a fixed time interval. To reduce the cost, the inspection can be carried out along with other regular maintenance work in the plant if necessary.

If the brakes are not maintained, failures, production losses or damage to the system may occur. Therefore, a maintenance concept adapted to the particular operating conditions and brake loads must be defined for every application. For the spring−applied brakes, the maintenance intervals and maintenance operations listed in the below table must be provided. The maintenance operations must be carried out as described in the detailed descriptions.

Type

Spring−applied brake

Service brake

¯ according to service life calculation

¯ otherwise every six months

¯ after 4,000 operating hours at the latest

Holding brake with emergency stop

¯ at least every two years

¯ after 1 million cycles at the latest

¯ provide shorter intervals in the case of frequent emergency stops

8.3

8.3.1


Motor

Stop!

¯ Make sure that no foreign bodies can enter the inside of the motor!

¯ Do not remove plugs when voltage is being applied!

8.3.2


The brake is mounted to the N−end shield of the motor. Remove the fan cover or blower unit or the encoder, if available, to check, maintain, or set the brake.

Note!

Brakes with defective armature plates, cheese head screws, springs or counter friction faces must always be replaced completely.

Generally observe the following for inspections and maintenance works:

¯ Remove oil and grease linked impurities using brake cleaning agents, if necessary, replace brake after identifying the cause of the contamination. Dirt deposits in the air gap between stator and armature plate impair the function of the brake and must be removed.

¯ After replacing the rotor, the original braking torque will not be reached until the run−in operation of the friction surfaces has been completed. After replacing the rotor, run−in armature plates and counter friction faces have an increased initial rate of wear.

8

Lenze ¯ BA 33.0005 ¯ 5.0

41

8

Maintenance/repair



Wear on spring−applied brakes

The used spring−applied brakes have a low rate of wear and are designed for long maintenance intervals.

However, the friction lining, the teeth between the brake rotor and the hub, and also the braking mechanism are naturally subject to function−related wear which depends on the application case (see table). In order to ensure safe and problem−free operation, the brake must therefore be checked and maintained regularly and, if necessary, replaced

(see brake maintenance and inspection).

The following table describes the different causes of wear and their effect on the components of the spring−applied brake. In order to calculate the useful life of the rotor and brake and determine the maintenance intervals to be prescribed, the relevant influencing factors must be quantified. The most important factors are the applied friction energy, the starting speed of braking and the switching frequency. If several of the indicated causes of wear on the friction lining occur in an application, their effects are to be added together.

Component

Friction lining

Armature plate bracket

Effect Influencing factors

Wear on the friction lining Applied friction energy

Armature plate and flange

Running−in of armature plate and flange

Teeth of the brake rotor

Number of start−stop cycles

Applied friction energy

Teeth wear (primarily at the rotor end)

Armature plate, cap screws and bolts are deflected

Number of start−stop cycles,

Level of the braking torque,

Dynamics of the application,

Speed fins in operation

Number of start−stop cycles,

Level of braking torque

Cause

Braking during operation

(impermissible, holding brakes!)

Emergency stops

Overlapping wear when the drive starts and stops

Active braking by the drive motor with the help of the brake (quick stop)

Starting wear if motor is mounted in a position with the shaft vertical, even if the brake is open

Friction between the brake lining and the armature plate or flange e.g. during emergency braking or service brake operation

Relative movement and impacts between brake rotor and brake hub

Springs Fatigue failure of the springs

Number of switching operations of the brake

Load changes and impacts due to reversal error during interaction between armature plate, cap screws and guide bolts

Axial load cycle and shearing stress on the springs due to radial reversing error of the armature plate

Tab. 2 Causes for wear

42 Lenze ¯ BA 33.0005 ¯ 5.0

Maintenance/repair



8.3.3


With a mounted brake ¯ Check ventilation function and activation/deactivation

¯ Check air gap (if required, re−adjust it)

¯ Measure rotor thickness (if required, replace rotor)

¯ Thermal damage of the armature plate or flange

(tarnished in dark blue)

With a dismounted brake ¯ Check clearance of the rotor gear teeth (replace rotors that are damaged by vibration)

¯ Damage by vibration of the torque support at the sleeve bolts, cylindrical pins, and armature plate

¯ Check springs for damage

¯ Check armature plate and flange or end shield

– Evenness for size 06...12 < 0.06 mm

– Evenness from size 14 < 0.1 mm

– Max. run−in depth = rated air gap of the design size

44

44

43

45

Check the mounting dimension of the manual release

Stop!

Dimension "s" must be maintained! Check air gap "s

L

"!

( operating instructions) s

L

(mm) s +0.1 (mm)

12

14

16

18

Size

06

08

10

20

25

0.2

0.3

0.4

0.5

1

1.5

2

2.5

8.3.4

Checking the rotor thickness s + s

L

(mm)

1.2

1.8

2.4

3

Danger!

When the rotor thickness is checked, the motor must not run.

1. Remove fan cover and cover ring if attached.

2. Measure rotor thickness with calliper gauge. If a friction plate is attached, ensure a flanged edge at the outer diameter of the friction plate.

3. Compare measured rotor thickness with minimally permissible rotor thickness

(values

45).

4. If required, exchange the entire rotor. Description

45.

8

Lenze ¯ BA 33.0005 ¯ 5.0

43

8

Maintenance/repair



8.3.5


1. Check the air gap "s

L

" near the fixing screws between the armature plate and stator using a feeler gauge (

45).

2. Compare air gap measured to maximally permissible air gap "s

L max.

" (

45).

3. If required, set air gap to "s

LN

" ( 44).

8.3.6

Release / voltage

Danger!

The rotating rotor must not be touched.

Danger!

Live connections must not be touched.

1. Observe the brake’s function while the drive is being operated. The armature plate must be tightened and the rotor must move free of residual torque.

2. Measure the DC voltage on the brake.

– The DC voltage measured after the overexcitation time ( operating instructions, forced voltage rectifier) must equal the voltage for the holding. A deviation of up to ±10 % is permissible.

8.3.7

Adjusting the air gap

Danger!

The brake must be free of residual torque.

Stop!

For the flange design, please observe the following if the flange is mounted with additional screws:

Clearing holes in the end shield must be provided behind the threaded holes in the flange that are designed for the screws. Without clearing holes, the minimum rotor thickness cannot be utilised fully. In no case must the screws press against the end shield.

1. Loosen screws (10).

2. Screw the sleeve bolts further into the stator using an open−jawed spanner. 1 /

6 revolution reduces the air gap by approx. 0.15 mm.

3. Tighten screws, torques (

45).

4. Check air gap "s

L

" near the screws using a feeler gauge, "s

Lrated

" (

45).

5. If the deviation of "s

Lrated

" is too great, repeat the adjustment process.

44 Lenze ¯ BA 33.0005 ¯ 5.0

Maintenance/repair

Installation of a spring−applied brake

Rotor replacement

8.3.8

Rotor replacement

Danger!

The brake must be free of residual torque.

1. Loosen the connecting cable.

2. Evenly release the screws and remove them completely.

3. Completely remove the stator from the end shield. Observe the connecting cables.

4. Completely remove the rotor from the hub.

5. Check the toothed part of the hub.

6. In case of wear, replace the hub, too.

7. Check the friction surface of the end shield. If the flange / friction plate is severely gouged, it must be replaced. If the end shield is severely gouged, the friction surface must be reprocessed.

8. Measure the rotor thickness (new rotor) and the height of head of the sleeve bolts using a caliper gauge.

9. The distance between the stator and the armature plate is calculated as follows:

Distance = rotor thickness + s

Lrated

− height of head

"s

Lrated

" ( 45)

10.Evenly remove the sleeve bolts until the calculated distance is reached between the stator and the armature plate.

11.Mount and set new complete rotor and stator, (

46).

12.Connect the connecting cable again.

8.4


8.4.1

Brake characteristics

18

20

25

06

08

10

12

14

16

Tab. 3

Brake size s

LN

+0.1 mm

−0.05 mm

[mm]

0.2

0.3

0.4

0.5

s

Lmax.

service brake

[mm]

0.5

0.75

1.0

1.25

s

Lmax.

holding brake

[mm]

Max. adjustment, permissible wear path

[mm]

0.3

0.45

0.6

0.75

1.5

2.0

2.5

3.5

3.0

4.0

4.5

Rotor thickness min. 1) [mm]

4.5

5.5

7.5

8.0

7.5

8.0

10.0

12.0

15.5

Characteristics of the spring−applied brake

1) The dimension of the friction lining allows for adjustment of the brake for at least five times.

max. [mm]

6.0

7.0

9.0

10.0

10.0

11.5

13.0

16.0

20.0

Tightening torque of the fixing screws

[Nm]

3.0

5.9

10.1

10.1

24.6

24.6

24.6

48.0

48.0

8

Lenze ¯ BA 33.0005 ¯ 5.0

45

8

Maintenance/repair


Installation of the brake

8.4.2

Installation of the brake

4

Stop!

¯ Check the state of the end shield (15). It must be free from oil and grease.

15

3

K14.0502/8

Fig. 4 Rotor mounting

3 Rotor 4 Hub 15 End shield

1. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand

(Fig. 4).

Stop!

Please note the following for the version "brake with shaft sealing ring in torque adjustment ring":

2. Lightly lubricate the lip of the shaft seal with grease.

3. When assembling the stator (1), push the shaft sealing ring carefully over the shaft.

– The shaft should be located concentrically to the shaft seal.

4. Use the screws (10) to mount the stator (7) completely to the end shield (15)

(Fig. 5).

– Tighten the screws evenly, tightening torque (

45).

9

15

10

1

KL458−012−a

¬ s

Lrated

Fig. 5 Stator mounting

1 Stator

10 Cheese head screw

46

9 Sleeve bolt

15 End shield

Lenze ¯ BA 33.0005 ¯ 5.0

Maintenance/repair



1. Check air gap near the screws (10) using a feeler gauge and compare the values to the data for "s

Lrated

" in the table,

45.

Note!

Do not insert feeler gauge further than 10 mm between the armature plate (2) and stator (1)!

If "s

L

" (

45) is not within the tolerance, readjust the air gap.

8.4.3


10

1

9

Danger!

Disconnect voltage. The brake must be free of residual torque.

−

+

8

Fig. 6 Re−adjust air gap

1 Complete stator

9 Sleeve bolt


If the measured value "s

L

" is outside the tolerance of "s

LN

", set the dimension:

KL458−013−a

Lenze ¯ BA 33.0005 ¯ 5.0

47

8

Maintenance/repair



8.4.4


15

27

Fig. 7 Friction plate mounting

15 End shield 27 Friction plate

1. Put a friction plate (27) or flange (6) against the end shield (15).

Note!

The flanged edge of the friction plate must remain visible!

2. Align pitch circle and fastening bore hole thread.

8.4.5

Assembly of the flange

15

6.1

6

KL458−009−a

KL458−008−a

Fig. 8 Flange mounting

6 Flange

6.1

Set of screws

15 End shield

1. Hold the flange (6) against the end shield (15) and check the pitch circle and retaining screw drill hole threading.

2. Fasten the flange (6) on the end shield (15) with the screws (6.1).

3. Tighten the cheese head screws (6.1) evenly, (tightening torques (

45).

4. Check the height of the screw heads. The screw heads may not be higher than the minimum rotor thickness. We recommend using screws according to DIN 6912, dimensions (

45.

48 Lenze ¯ BA 33.0005 ¯ 5.0

Maintenance/repair

Repair

Assembly of the cover seal

Mounting the flange without additional screws

1. Apply the flange (6) to the end shield (15). Check pitch circle and thread of the screw−on bore holes.

2. Mount the brake.

8.4.6

10

Assembly of the cover seal

1

1.2

13

15

12

1 2 13 27 13 6 10 15

8

KL458−010−a

Fig. 9 Cover ring mounting

1

2

6

Complete stator

Armature plate

Flange


27 Friction plate

13 Cover ring

15 End shield

1. Insert the cable through the cover ring.

2. Push the cover ring over the stator.

3. Press the lips of the cover ring into the groove of rotor and flange.

– If a friction plate is used, the lip must be pulled over the flanged edge.

8.5

Repair

¯ We recommend having all repairs carried out by the Lenze customer service.

KL458−007−a

Lenze ¯ BA 33.0005 ¯ 5.0

49

9 Troubleshooting and fault elimination

9 Troubleshooting and fault elimination

If faults occur during operation of the drive system:

¯ First check the possible causes of malfunction according to the following table.

Note!

Also observe the corresponding chapters in the operating instructions for the other components of the drive system.

If the fault cannot be remedied using one of the listed measures, please contact the

Lenze Service.

Fault

Motor too hot

Can only be evaluated by measuring the surface temperature:

¯ Non−ventilated motors

> 140 °C

¯ Externally ventilated or self−ventilated motors

>

110 °C

Motor does not start

Motor suddenly stops and does not restart

Incorrect direction of rotation of the motor, correct display on the controller

Motor rotates normally but does not reach the expected torque

Motor turns in one direction at maximum speed in an uncontrolled manner

Motor rotates slowly in one direction and cannot be influenced by the controller

Irregular running

Cause

Insufficient cooling air, blocked air ducts.

Remedy

Ensure unimpeded circulation of cooling air

Preheated cooling air

Overload, with normal mains voltage the current is too high and the speed too low

Ensure a sufficient supply of fresh cooling air

Use larger drive (determined by power measurement)

Rated operating mode exceeded (S1 to

S8 IEC/EN 60034−1)

Loose contact in supply cable

(temporary single−phase operation!)

Fuse has blown (single−phasing!)

Overload of the drive

Adjust rated operating mode to the specified operating conditions.

Determination of correct drive by expert or Lenze customer service

Tighten loose contact

Replace fuse

Check load and, if necessary, reduce by means of longer ramp−up times

Check winding temperature

Heat dissipation impeded by deposits Clean surface and cooling fins of the drives

Voltage supply interrupted Check error message on the controller

Controller inhibited

Fuse has blown

Interrupted encoder cable

Check electrical connection,

27

Check display on the controller

Check controller enable

Replace fuse

Check error message on the controller

Brake does not release

Drive blocks

Motor cable with reverse polarity

Overload monitoring of the inverter is activated

Motor cable polarity is reversed

Check encoder cable


27

Check air gap, brake documentation

Check continuity of magnetic coil

Check components for easy movement, remove foreign particles if necessary


27

Check controller settings

Reduce load caused by longer acceleration times

Check the polarity and correct

Polarity of encoder cable reversed

Motor cable interchanged cyclically

Not all motor phases connected

Motor cable interchanged cyclically

Polarity of encoder cable reversed

Polarity of motor cable and encoder cable reversed

Insufficient shielding of motor or resolver cable

Drive controller gain too large

Connect the phases at the motor cable connection correctly

Check motor connector and, if necessary, correct

Check encoder connection and, if necessary, correct

Check the polarity and correct

Checking shielding and earth connection

Adjust the gains of the controllers (see Drive controller operating instructions)

50 Lenze ¯ BA 33.0005 ¯ 5.0

Troubleshooting and fault elimination

9

Fault

Vibrations

Cause

Insufficiently balanced coupling elements or machine

Inadequate alignment of drive train

Running noises

Loose fixing screws

Foreign particles inside the motor

Bearing damage

Surface temperature > 140°C Overload of the drive

Remedy

Rebalance

Realign machine unit, check foundation if necessary

Check and tighten screw connections

Repair by manufacturer if necessary

Check load and, if necessary, reduce by means of longer ramp−up times

Check winding temperature

Heat dissipation impeded by deposits Clean surface and cooling fins of the drives

Lenze ¯ BA 33.0005 ¯ 5.0

51

10 Appendix


10

10.1

Appendix

Technical data as specified by ordinances (EU) No. 4/2014 and

(EC) No. 640/2009

This chapter includes the technical data in compliance with the specifications laid down by ordinances (EU) No. 4/2014 and (EC) No. 640/2009.

Annex 1 Clause 2 of ordinance (EC) No. 640/2009 stipulates the publication of the following technical data in the fixed order 1 ... 12:

3

4

No. Meaning

1 Rated efficiency ( h

) at 100 %, 75 % and 50 % of the rated load and rated voltage (U rated

)

2 Efficiency level: "IE2" or"IE3"

Year of manufacture

Name or trademark, official registration number and manufacturer’s place of establishment

7

8

5

6

Model number of the product

Number of poles of the motor

Rated output power(s) or rated output power interval [kW]

Rated input frequency (frequencies) of the motor [Hz]

9 Rated voltage(s) or rated voltage interval [V]

10 Rated speed(s) or rated speed interval [rpm]

11 Relevant information for the disassembly, recycling or disposal after the final decommissioning

12 Information regarding the range of operating conditions for which the motor is specially designed: i) Altitudes above sea level ii) Ambient air temperatures, also for motors with air cooling iii) Cooling fluid temperature at the inlet of the product iv) Maximum operating temperature v) Hazardous areas

Technical data in compliance with ordinance (EC) No. 640/2009

No.

1 h

100% h

75% h

50%

2

3

4

5 Motor code

[%]

[%]

[%]

6

7

12 i) ii) iii) iv) v)

Number of poles

P

8 f r rated

9 V rated

10 n r

11

[kW]

[Hz]

[V]

[rpm]

79.6

79.6

74.9

IE2

82.0

81.6

77.4

82.8

83.4

82.2

MH L MA 080...132 motors

86.3

86.7

85.4

85.5

85.6

83.8

Permissible installation height:

19

Permissible ambient air temperatures:

88.3

88.2

86.3

19

Not relevant, since motors are not liquid−cooled.

Maximum operating temperature: 155  C (temperature class F)

Operation in hazardous areas prohibited.

89.2

89.3

88.2

MH MA

080−32

Lenze Drives GmbH, Breslauer Straße 3, D−32699 Extertal, GERMANY, HR Lemgo B 6478

MH MA

090−12

MH MA

090−32

MH MA

100−12

MH MA

100−32

MH MA

112−22

MH MA

132−12

4

0.75

50

400

1410

IE2 IE2 IE2 IE2 IE2 IE2

For year of manufacture and week of manufacture see nameplate:

16

4

1.1

50

400

1430

4

1.5

50

400

4

2.2

50

400

4

3.0

50

400

4

4.0

50

400

1435 1445 1445 1455

Information regarding the disposal:

12

4

5.5

50

400

1470

88.7

88.9

87.6

IE2

MH MA

132−22

4

7.5

50

400

1460

52 Lenze ¯ BA 33.0005 ¯ 5.0

Appendix


10

Technical data in compliance with ordinance (EC) No. 640/2009

3

4

No.

1 h

100% h

75% h

50%

2

5 Motor code

[%]

[%]

[%]

89.8

90.0

89.4

IE3

90.6

90.8

90.2

IE3

91.2

91.4

90.8

MH

L

MA 160...225 motors

91.6

92.0

91.4

92.3

92.5

91.9

92.3

92.5

91.9

IE3 IE3 IE3 IE3

Fertigungsjahr und Fertigungswoche siehe Typenschild:

16

94.3

94.6

94.0

IE3

MH MA

160−22

Lenze Drives GmbH, Breslauer Straße 3, D−32699 Extertal, GERMANY, HR Lemgo B 6478

MH MA

160−32

MH MA

180−12

MH MA

180−32

MH MA

180−42

MH MA

200−32

MH MA

225−12

6 Number of poles

7 P

10 n r

11 rated

8 f r

9 V rated

[kW]

[Hz]

[V]

[rpm]

12 i) ii) iii) iv) v)

4

11.0

50

400

1470

4

15.0

50

400

1470

4

18.5

50

400

4

22.0

50

400

4

30.0

50

400

4

30.0

50

400

1475 1470 1465 1465

Information regarding the disposal:

12

Permissible installation height:

19

Permissible ambient air temperatures:

19

Not relevant, since motors are not liquid−cooled.

Maximum operating temperature: 155  C (temperature class F)

Operation in hazardous areas prohibited.

4

37.0

50

400

1483

94.3

94.5

93.7

IE3

MH MA

225−22

4

45.0

50

400

1480

Lenze ¯ BA 33.0005 ¯ 5.0

53

!

Notes

54 Lenze ¯ BA 33.0005 ¯ 5.0

Notes

!

Lenze ¯ BA 33.0005 ¯ 5.0

55

© 01/2016 | BA 33.0005 |

.S]N

| 5.0 | TD09

Lenze Drives GmbH

Postfach 10 13 52, 31763 Hameln

Breslauer Straße 3, 32699 Extertal

GERMANY

HR Lemgo B 6478

+49515482−0

+49515482−2800 [email protected]

www.lenze.com

Lenze Service GmbH

Breslauer Straße 3, D−32699 Extertal

Germany

0080002446877 (24 h helpline)

+49515482−1112 [email protected]

10 9 8 7 6 5 4 3 2 1

Lenze MH three-phase AC motor Operating Instruction 56 Pages

Lenze MH three-phase AC motor Operating Instruction

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