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Mounting and switch-on instructions EN
Mains-operated geared motors
g500-B bevel geared motor / Smart Motor m300-E
Contents
Identification of the products
Connection via QUICKON V2 connector
Diagnostics and fault elimination
Contents
3
4
Contents
Standards and operating conditions
Protection of persons and device protection
Environmental notes and recycling
About this document
Document description
About this document
WARNING!
Read this documentation carefully before starting any work.
▶ Please observe the safety instructions!
Document description
This document is intended for skilled personnel who work with the products described.
The data and information compiled in this document serve to support you in the electrical and mechanical installation and commissioning.
• The document is only valid together with the complete documentation of the product!
• For safety-rated attachments observe the enclosed operating instructions of the manufacturer!
• The document includes safety instructions which must be observed.
• All persons working on and with the drives must have the documentation at hand during work and observe the information and notes relevant for it.
• The documentation must always be complete and in a perfectly readable state.
Further documents
Information and tools with regard to the Lenze products can be found on the
Internet: www.Lenze.com
à Downloads
5
6
About this document
Notations and conventions
Notations and conventions
Conventions are used in this document to distinguish between different types of information.
Numeric notation
Decimal separator Point Generally shown as a decimal point.
Example: 1 234.56
Warnings
UL Warnings
UR warnings
Text
Engineering Tools
UL
UR
" "
Are used in English and French.
Software
Example: "Engineer", "EASY Starter"
Icons
Page reference ¶
Documentation reference ,
Reference to another page with additional information.
Example: ¶ 16 = see page 16
Reference to other documentation with additional information.
Example: , EDKxxx = see documentation EDKxxx
Layout of the safety instructions
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Safety instructions
Basic safety instructions
Safety instructions
Basic safety instructions
Disregarding the following basic safety instructions and safety information may lead to severe personal injury and damage to property!
• Only use the product as directed.
• Never commission the product in the event of visible damage.
• Never modify the product technically.
• Never commission the product before assembly has been completed.
• Never operate the product without the required covers.
• Connect/disconnect all pluggable connections only in deenergized condition!
• Only remove the product from the installation in the deenergized state.
• The product can – depending on their degree of protection – have live, movable or rotating parts during or after operation. Surfaces can be hot.
• Observe all specifications of the corresponding documentation supplied. This is the condition for safe and trouble-free operation and the achievement of the specified product features.
• The procedural notes and circuit details given in the associated documentation are suggestions and their transferability to the respective application has to be checked. The manufacturer of the product does not take responsibility for the suitability of the process and circuit proposals.
• All work with and on the product may only be carried out by qualified personnel.
IEC 60364 and CENELEC HD 384 define the qualifications of these persons:
They are familiar with installing, mounting, commissioning, and operating the product.
They have the corresponding qualifications for their work.
They know and can apply all regulations for the prevention of accidents, directives, and laws applicable at the place of use.
Application as directed
• The product is a professional equipment intended for use by trades, specific professions or industry and not for sale to the general public. IEC 60050 [IEV 161 ‑ 05 ‑ 05]
• To prevent personal injury and damage to property, higher-level safety and protection systems must be used!
• All transport locks must be removed.
• Mounted eye bolts on the motor are not suitable for transporting geared motors.
• The product may only be operated under the specified operating conditions and in the specified mounting positions.
• The product is suitable for horizontal conveying only.
• The product may only be operated from the mains.
• Built-in brakes must not be used as safety brakes.
• The product must not be operated in private areas, in potentially explosive atmospheres and in areas with harmful gases, oils, acids and radiation.
7
8
Safety instructions
Residual hazards
Residual hazards
Even if notes given are taken into consideration and protective measures are implemented, the occurrence of residual risks cannot be fully prevented.
The user must take the residual hazards mentioned into consideration in the risk assessment for his/her machine/system.
If the above is disregarded, this can lead to severe injuries to persons and damage to property!
Product
Observe the warning labels on the product!
Dangerous electrical voltage:
Before working on the product, make sure there is no voltage applied to the power terminals!
After mains disconnection, the power terminals will still carry the hazardous electrical voltage for the time given next to the symbol!
High leakage current:
Carry out fixed installation and PE connection in compliance with:
EN IEC 61800−5−1 / EN IEC 60204 ‑ 1
Hot surface:
Use personal protective equipment or wait until the device has cooled down!
Protection of persons
• The power terminals may carry voltage in the switched-off state or when the motor is stopped.
Before working, check whether all power terminals are deenergized.
• Voltages may occur on the drive components (e.g. capacitive, caused by inverter supply).
Careful earthing in the marked positions of the components must be carried out.
• There is a risk of burns from hot surfaces.
Provide protection against accidental contact.
Use personal protective equipment or wait until the device has cooled down.
Prevent contact with flammable substances.
• There is a risk of injury due to rotating parts.
Before working on the drive system, ensure that the motor is at a standstill.
• There is a risk of accidental start-up or electric shock.
Motor protection
• Installed thermal detectors are no full protection for the machine.
If necessary, limit the maximum current. Parameterize the inverter so that it will be switched off after some seconds of operation with I > I rated
, especially if there is a risk of blocking.
Integrated overload protection does not prevent overloading under all conditions.
• The fuses are no motor protection.
Use a current-dependent motor protection switch.
Use the built-in temperature sensors.
• Too high torques cause a fraction of the motor shaft.
Do not exceed the maximum torques according to the technical data on the nameplate.
Safety instructions
Residual hazards
Gearbox protection
• Excessive vibration accelerations and resonances will damage the gearbox.
Do not operate the gearbox at vibration accelerations > 2 g (20 m/s 2 ) of the machine.
Do not operate the gearbox in the resonance range of the machine.
• Excessive torques will damage the gearboxes.
Do not exceed the output torques specified on the nameplate.
• Excessive input speeds lead to increased temperatures.
Do not exceed the input speeds specified on the nameplate.
• Avoid excessive lateral forces on the gearbox shaft.
Align the shafts of the gearbox and driven machine exactly with each other.
• Machine elements can be damaged by a lack of lubricant.
Mount the gearbox only in the mounting position indicated on the nameplate.
When changing the lubricant, use the lubricant type and quantity specified on the nameplate.
9
Product information
Identification of the products
Nameplates
Product information
Identification of the products
Nameplates
The nameplate is attached to the motor.
L
2
3
4
5.1
5.3
6
8.1
7.1
1
5.2
5.4
8.3
44
18
7.2
30
15
Hz kW
V
A r/min cos j
Nm
16.1
16.2
16.4
45
16.5
16.3
16.6
16.10
15
19
13
14.1
14.2
27
10.2
11
10.3
20.1
11
13
14
15
10
8
7
4
5
6
2
3
Position
1
5.1
5.2
5.3
7.2
8.1
8.3
5.4
7.1
Contents
Manufacturer / production location
Type of motor / standard
Gearbox type
Motor type
Technical data
Gearbox ratio
Output torque M2
Output speed n2
17
Position: Shaft, flange, terminal box, mounting position 18
Lubricant details
Lubricant quantity
19
20
Position
16
Contents
Rated data for various frequencies
16.1
Hz = frequency
16.2
kW = motor power
16.3
rpm = motor speed
16.4
V = motor voltage
16.5
A = motor current
16.6
cos ϕ = motor power factor
16.10
Nm = rated torque
-
Year of manufacture / week of manufacture
UL file number
Customer data
Lubricant
Brake data
Brake
Braking torque
27
30
44
Production data
10.2
Material number
10.3
Serial number
Bar code
Information on operating mode
Additional motor specifications
14.1
Temperature class
14.2
Protection class
Applicable conformities, approvals and certificates
45
20.1
Additional customer data
Permissible ambient temperature (e.g. Ta < 40°C)
Weight (optional)
"Br-resistor" brake resistor (if a brake resistor is available)
UL type rating/NEMA enclosure type
10
Product information
Identification of the products
Product codes
Product codes
Gearbox product code
Example
Product type
Product family
Generation
Gearbox type
Output torque
Type of construction
Shaft type
Housing type
Flange mounting
Number of stages
Motor mounting
Drive size
Gearboxes
Bevel gearbox
45 Nm
110 Nm
240 Nm
450 Nm
600 Nm
820 Nm
1500 Nm
2700 Nm
4300 Nm
8000 Nm
13000 Nm
20000 Nm
Geared motor
Gearboxes
Solid shaft with featherkey
Hollow shaft with keyway
Hollow shaft with shrink disc
Foot mounting + centering
Foot mounting
With centering
Threaded pitch circle
Without flange
Flange with through holes
2-stage
3-stage
4-stage
Integrated motor
IEC adapter with jaw coupling
IEC adapter with plug-in hollow shaft
NEMA adapter with jaw coupling
NEMA adapter with plug-in hollow shaft
Servomotor adapter with plug-in hollow shaft
Servomotor adapter with jaw coupling
G 50
G
50
A
B
A B 045 M
B
045
111
124
145
160
182
215
227
243
280
313
320
M
N
H
S
V
H
A
B
C
D
B
R
K
R 2 C
C
N
T
H
2
3
4
1A
A
B
S
E
D
G
1A
...
□H
08
...
82
11
Product information
Identification of the products
Product codes
Motor product code
Example
Meaning
Product family
Product type
Cooling
Internal key
Built-on accessories
Size
Variant
Motor
Smart Motor
Integral fan
Without built-on accessories
Brake
Overall length
Number of pole pairs
Design types
Approval
4-pole motors
Internal key
CE; UKCA
CE; UKCA; cULus
CE; UKCA; CCC
CE; UKCA; cULus; CCC
M S
Product code
M
S
E
E
MA XX 063
BR
XX
MA
063
080
-
4
3
4
C1
C1
2
2
C
C
L
3
5
12
Product information
Equipment
Equipment
The following figure provides an overview of the elements and connections on the product.
Their position, size and appearance may vary.
Ventilation
(depending on the mounting position)
Oil filler plug
(depending on the mounting position)
Remove oil control plug
(depending on the mounting position)
Output shaft
Oil drain plug
(depending on the mounting position)
Housing type
Torque plate mounting
X4 Brake resistor connection
External
Internal brake resistor
X1, X2 Control terminal
M12 connector
X3 Mains connection
In the terminal box
QUICKON V2 connector
M15 connector
PE
X5 Connection of spring-applied brake
(prewired upon delivery)
Cooling
Integral fan
Output flange
Torque plate mounting
Adjustment of speeds by means of Android smartphone by means of PC via NFC adapter
External brake resistor
Spring-applied brake
Standard
LongLife
Manual release lever
13
Transport
Transport
• Ensure appropriate handling.
• Make sure that all component parts are securely mounted. Secure or remove loose component parts.
• Only use safely fixed transport aids (e.g., eye bolts or support plates).
• Do not damage any components during transport.
• Avoid electrostatic discharges on electronic components and contacts.
• Avoid impacts.
• Check the carrying capacity of the hoists and load handling devices. The weights can be found in the shipping documents.
• Secure the load against tipping and falling down.
• Standing beneath suspended loads is prohibited.
The transport weights can be found in the shipping documents!
The motors mounted on the gearbox are sometimes equipped with ears. These are exclusively intended for mounting the motor on/removing the motor from the gearbox and must not be used for the complete geared motor!
CAUTION!
Danger from tipping or falling loads!
Standing beneath suspended loads is prohibited!
▶ Use additional appropriate lifting aids, if required, to achieve a direction of loading which is as vertical as possible (highest load carrying capacity). Secure lifting aids against shifting!
▶ Screw in the transport aids completely. They must have even and full-surface contact!
▶ Transport aids must be loaded vertically in the direction of the screw axis! Diagonal or lateral tension reduces the load carrying capacity! Observe data in standard DIN 580!
The thread in the output shaft can be used with smaller drives. Larger gearboxes have a transport thread for eye bolts in accordance with DIN 580 in the gearbox housing as standard.
The eye bolt is not included in the scope of supply!
The position of the transport thread can be seen in the following representations.
14
Position of the eye bolt
G50AB045...G50BB124
1.
2.
from G50BB145
1.
2.
Transport
Thread
Load carrying capacity kg
M6
80
M8
140
M10
230
M12
340
M16
700
M20
1200
M24
1800
15
Storage
Storage
Storage up to one year:
• Observe the climatic conditions according to the technical data
-
• Store in a dry, low-vibration environment (V eff
< 0.2 mm/s) without aggressive atmosphere in the interior
• Protect from dust, shocks and sunlight
• Avoid temperature changes with condensate formation.
• Store gearboxes with a ventilation unit with the ventilation element on top.
• Do not activate ventilation unit, in order to prevent air exchange with the ambient air.
• Treat damaged corrosion protection on shafts and bare surfaces subsequently
Storage for 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.
• Do not activate ventilation element
• Install gearbox in mounting position M1 (A)
• Fill gearbox with the lubricant type filled in (see nameplate) up to the filling/venting bore for mounting position M1 (A)
-
-
16
Mechanical installation
Important notes
Mechanical installation
Important notes
• Install the product according to the information in the chapter "Standards and operating conditions".
4 Standards and operating conditions
• The technical data and the data regarding the supply conditions can be found on the nameplate and in this documentation.
• Ambient media − especially chemically aggressive ones − may damage shaft sealing rings, lacquers and plastics.
• Lenze offers special surface and corrosion protection in this case.
• Only install the gearbox in the mounting position shown.
Preparation
• Protect shaft sealing rings from contact with solvents.
• Remove protection covers from shafts.
• Thoroughly remove anticorrosion agents from the shaft and from flange faces.
• Draw the transmission elements onto the output shaft only by using the centering thread.
• Align the output shaft and transmission elements exactly to avoid tensions.
• Mount belt pulleys, sprockets, or gear wheels as close as possible to the shaft shoulder in order to keep the bending load of the shaft and the bearing forces at a minimum level.
• Tighten all screw connections with the specified torques and secure them with standard screw locking adhesive.
• Check paint for damage and repair professionally.
17
Mechanical installation
Installation
Mounting positions
Installation
• The mounting surfaces must be plane, torsionally rigid and free from vibrations.
• The mounting areas must be suited to absorb the forces and torques generated during operation.
• Ensure an unhindered ventilation.
• For versions with a fan, keep a minimum distance of 10 % from the outside diameter of the fan cover in intake direction.
Mounting positions
M1
[ A ]
M6
[ F ]
M2
[ D ]
M4
[ C ]
M5
[ E ]
M3
[ B ]
18
Mechanical installation
Installation
Ventilation
Ventilation
No venting measures are required for the G50AB045 … BB124 gearboxes.
The G50BB124 gearbox can optionally be equipped with breather elements.
From G50BB145 onwards, the gearboxes are supplied with breather elements as standard.
Gearboxes that are delivered with a ventilation unit are provided with a label.
Remove the transport locking device on the vent valve before initial commissioning.
Loosely enclosed vent valves must be mounted in accordance with the mounting position.
G50BB124
Mounting position M1 (A) Mounting position M2 (D)
Filling and ventilation
Mounting position M3 (B)
+
+
+
Check
Drain
19
Mechanical installation
Installation
Ventilation
Mounting position M4 (C)
+
Mounting position M5 (E)
Filling and ventilation
Mounting position M6 (F)
Control
Drain
20
G50BB145
Mounting position M1 (A)
+
Mounting position M2 (D)
Filling and ventilation
+
Mechanical installation
Installation
Ventilation
Mounting position M3 (B)
+
Check
Drain
21
Mechanical installation
Installation
Ventilation
Mounting position M4 (C) Mounting position M5 (E)
Filling and ventilation
+
+
Control
Mounting position M6 (F)
+
Drain
22
G50BB160 ... BB243
Mounting position M1 (A)
+
+
Mounting position M2 (D)
Filling and ventilation
Mechanical installation
Installation
Ventilation
Mounting position M3 (B)
+
Check
Drain
①
②
④
⑤
③
①
②
③
④
⑤
G50BB160
G50BB182
G50BB215
G50BB227
G50BB243
23
Mechanical installation
Installation
Ventilation
Mounting position M4 (C)
①
②
+
+
③
+
④
⑤
Mounting position M5 (E)
Filling and ventilation
+
③ +
Check
Mounting position M6 (F)
+
④
⑤
+
①
②
③
③
Drain
①
②
③
④
⑤
G50BB160
G50BB182
G50BB215
G50BB227
G50BB243
24
Mechanical installation
Dimensions
Ventilation
Gearbox with oil compensation reservoir for mounting position M4 (C)
In order to guarantee a reliable lubrication of the toothed parts in mounting position M4 (C)
(motor is on the gearbox vertical from the top), a high filling level is required in the gearbox.
As a result of the reduced volume of air in the gearbox, this may lead to oil escaping from the ventilation at higher input speeds. The oil compensation reservoir increases the expansion space for the lubricant.
The oil compensation reservoir can be ordered as a mounting set for fastening to the gearbox.
If insufficient space is available, the oil compensation reservoir can also be mounted over the gearbox hose connection on nearby system parts.
Dimensions
Dimensions are contained in the configuration document.
25
Mechanical installation
Mounting
Mounting
Transmission elements
• Fit or remove transmission elements only using suitable equipment.
• For fitting the transmission elements use the center hole in the shaft.
• Avoid impacts and shocks.
• In case of a belt drive, tension the belt in a controlled manner according to manufacturer information.
• Be sure to carry out mounting in a manner free from distortion.
• Compensate minor inaccuracies by suitable flexible couplings.
Fastening
• Use screws with a minimum property class of 8.8.
• Observe prescribed tightening torques.
• Secure against unintended loosening.
• For alternating loads, we recommend applying anaerobic curing adhesive between flange and mounting surface.
Thread
Strength
8.8
10.9
Nm
Nm
M3
1.3
1.9
M4
3.0
4.6
M5
5.9
8.6
M6
10.1
14.9
M8 M10 M12 M16
Tightening torque Nm ±10 %
24.6
48 84 206
36.1
71 123 302
Gearbox with hollow shaft and shrink disk
• Use fitting grease in the area of the contact surfaces of machine shaft and hollow shaft bore.
• Be sure to carry out mounting in a manner free from distortion.
• Lead forces only across the hollow shaft and not across the housing.
• For axial fastening, use the snap ring grooves in the hollow shaft.
Proposed solution for axial fastening
M20
415
592
M24
714
1017
M27
1050
1496
M30
1428
2033
Dismounting
• Undo axial gearbox locking in the hollow shaft
• Extract the gearbox from the motor shaft using an appropriate auxiliary tool
Proposed solution for dismounting
26
Mechanical installation
Mounting
Gearbox with hollow shaft and shrink disc
NOTICE
▶ Never disassemble the new shrink disc.
▶ Thoroughly clean and degrease hollow shaft bore and machine shaft!
▶ Do not tighten clamping screws before the machine shaft has been inserted, the hollow shaft may undergo plastic deformation.
▶ Cover the shrink disc during operation so that it is secured against contact by implementing suitable measures (e.g. cover).
Mounting the machine shaft
1
2
1
1
2
Rotating cover
Clamping screws
1 .
Check machine shaft
Diameter in fit tolerance h6
Material yield point Re ≥= 360 MPa
E-module approx. 210000 MPa
Surface roughness R z
≤ 15 µm
Concentricity (to prevent unnecessary additional forces caused by tensioning)
2 .
Remove rotating cover (1) from the shrink disc
3 .
Thoroughly clean and degrease hollow shaft bore and machine shaft.
4 .
Slightly loosen clamping screws (2) one after the other, do not unscrew.
5 .
Push gearbox onto machine shaft.
6 .
Slightly tighten clamping screws manually.
7 .
Tighten clamping screws (2) one after the other (approx. 5) in several passes, with rising torque, evenly until the indicated screw-tightening torque is reached at all screws.
8 .
Pull the co-rotating cover (1) over the shrink disc.
27
Mechanical installation
Mounting
NOTICE
▶ The shrink disc is mounted correctly and fixed when the faces of the outer ring and the inner ring are aligned. Minimum misalignments are permissible.
3
4
A
3
4
[A]
Outer ring
Inner ring
Free of grease
NOTICE
▶ If a different tightening torque is indicated on the shrink disc, this tightening torque has priority over the value indicated in the table.
Tightening torques of clamping screws
Hollow shaft bore
Thread
Key size
Tightening torque mm mm mm
Nm
20
M6
10
12
Hollow shaft bore
Thread
Key size
Tightening torque mm mm mm
Nm
50
M8
13
34
M5
8
6
25
65
M10
17
70
M6
10
14
75
M10
17
70
M6
10
14
30
M8
13
30
80
M10
17
70
M6
10
14
85
M12
19
121
35
M8
13
30
105
M14
22
193
M6
10
14
40
125
M14
22
193
M8
13
34
28
Mechanical installation
Mounting
Product extensions
Product extensions
Mounting instructions for shrink disc cover
NOTICE
▶ The loosely enclosed cover is mounted as a protection against accidental contact with the shrink disc.
Gearboxes G50AB45 ... G50BB182
X
X
Press the cover with integrated mounting pins into the bore holes on the housing flange
Gearboxes G50BB215 ... G50BB243
X
1
X 2
3
1
2
3
Shrink disc cover
Cheese head screw
Reducing bush
1 .
Screw reducing bushes (3) into the threaded holes on the housing flange so that they are flush using a screwdriver.
2 .
Fasten the cover over the reducing bushes (3) using cheese head screws (2).
Mounting instructions for hose-proof hollow shaft cover
NOTICE
▶ The loosely enclosed hollow shaft cover is fitted to seal the hollow shaft bore.
29
Mechanical installation
Mounting
Product extensions
A
A-A
X
X
4
2
1
A
1
2
4
Hollow shaft cover
Cheese head screw
Flat gasket
1 .
Place flat gasket (4) between the housing flange and the hollow shaft cover (1).
2 .
Fasten the hollow shaft cover (1) with cheese head screws (2) to the housing flange.
Torque plate mounting
NOTICE
Impermissible load caused by incorrect mounting
▶ Support the socket of the torque plate at both ends.
▶ Check the socket’s axial clearance after mounting.
▶ In the case of a knee lever design, transfer the force at right angles to the torque plate, if possible (90 ° ±20°).
▶ Solvents, oils, greases and fuels damage the rubber elements. Avoid contact!
30
Mechanical installation
Mounting
Product extensions
At threaded pitch circle
1 .
Clean the contact surfaces between the housing and torque plate.
2 .
Align the torque plate to the gearbox flange according to the pitch of the bore belt.
3 .
Fasten torque plate with screws. Observe prescribed torques!
On the housing foot
1 .
Clean the contact surfaces between the housing and torque plate.
2 .
Align the torque plate with the gearbox foot.
3 .
Fasten torque plate with screws. Observe prescribed torques!
31
Electrical installation
Important notes
Electrical installation
Important notes
DANGER!
Risk of injury and risk of burns from dangerous voltage
Power terminals may also carry voltage in the switched-off state or when the motor is stopped and may cause life-threatening cardiac arrhythmia and serious burns.
▶ Disconnect the product from the mains.
▶ Check that the power terminals are deenergized before starting work.
• When working on energized products, comply with the applicable national accident prevention regulations.
• The electrical installation must be carried out according to the appropriate regulations
(e.g. cable cross-sections, fuses, PE connection).
• The manufacturer of the system or machine is responsible for adherence to the limits required in connection with EMC legislation.
32
Mains connection
Connection according to EN
The following data is valid for a three-phase mains connection with 400 V.
Electrical installation
Mains connection
Connection according to EN
Mains connection with QUICKON connector
Motor
Connection
Laying system
Connection type
Cable type
Cable cross-section
Typ.
Min.
Max.
mm 2 mm 2 mm 2
Mains connection M15 connector
Motor
Connection
Laying system
Connection type
Cable type
Cable cross-section
Typ.
Min.
Max.
mm 2 mm 2 mm 2
Mains connection cable L1, L2, L3, PE
Motor
Connection
Installation method
Connection type
Cable type
Cable cross-section
Typ.
mm 2
Min.
Max.
Stripping length mm 2 mm 2 mm
MSEMA ☐☐ 063-42
1.5
1.5
2.5
X3
B2
QUICKON connector
Flexible
MSEMA ☐☐ 080-32
2.5
1.5
2.5
MSEMA ☐☐ 063-42 MSEMA ☐☐ 080-32
X3
B2
M15 connector
Flexible
1.5
1.5
2.5
MSEMA ☐☐ 063-42
2.5
1.5
2.5
MSEMA ☐☐ 080-32
X3
B2
Cable rigid/flexible
1.0
0.75
1.5
10
1.5
0.75
1.5
10
33
Electrical installation
Mains connection
Connection according to EN
Single drive connection according to EN IEC 60204 ‑ 1
3/N/PE AC 400/480 V
L1
L2
N
PE
SELV/PELV
DC 24 V
(+19.2 … +28.8 V)
AC
DC
2
+
F1 … F3
Q
3
4
2
1
1 2 3
X1 n. c.
DI2
GND
-I
DI1
4
3
4
2
1
1 2 3 4
X2
24V DI3
GND
-O
DO1 max. 50 mA
+
X3
+
+
L1
1 2
L2 L3
3
X4
Rb1 Rb2
+
X3
+ L1 L2 L3
F1 … F3
Q
R b
Rb1 Rb2
X4
Rb1 Rb2
R b
①
X6
U V W BD1 BD2
X5
M
3~
① GND is bridged if the "DI/DO−GND bridged" version is specified on the nameplate.
Fuse data (F1 ... F3)
Motor
Cable installation in accordance with
Laying system
Fuse
Characteristic
Typ. Rated current
Max. rated current
Semiconductor fuse
Characteristic
Typ. Rated current
Max. rated current
Circuit breaker
Characteristic
Typ. Rated current
Max. rated current
A
A
A
A
A
MSEMA ☐☐ 063-42
6
16
6
16
6
16
• Use of copper cables insulated with PVC
• Conductor temperature < 70 °C, ambient temperature < 40 °C
• No bundling of cables or wires, thee wires under load
EN IEC 60204 ‑ 1
B2 gG/gL gRL
C
MSEMA ☐☐ 080-32
10
16
10
16
10
16
34
Electrical installation
Mains connection
Connection according to EN
Group drive connection according to EN IEC 60204 ‑ 1
L1
L2
N
PE
F1 … F3
K
A
1
+ PE L1 L2 L3
I
N1
A
2
+ PE L1 L2 L3
I
N2
A
3
+ PE L1 L2 L3
I
N3
A
4
+ PE L1 L2 L3
I
N4
M
3~
M
3~
M
3~
M
3~
M
3~
Max. total rated mains currents at 40 °C for different cable cross-sections
Cable installation in accordance with
Main cable
Laying system
Cable cross-section mm 2
Stub
Laying system
Cable cross-section mm 2
Max. current load of the cable
Fuse
Characteristic
Typ. Rated current
Max. rated current
Circuit breaker
Characteristic
Typ. Rated current
Max. rated current
I max
≥ I
N1
+ I
N2
+ I
N3
+ I
N...
A
A
A
A
A
A
1.5
1.5
13.1
-
10
-
10
7.6
EN IEC 60204 ‑ 1
B2
2.5
C
2.5
17.4
gG/gL
-
16 gRL
-
16
12.2
• Use of copper cables insulated with PVC
• Conductor temperature ≤ 70 °C, ambient temperature ≤ 40 °C
• No bundling of cables or wires, thee wires under load
• Typical utilization 80 % of the respective cable cross-section taken into account
4.0
2.5
21.0
-
20
-
20
17.6
Group drive sizing
Example:
Verification of the maximum permissible rated mains current taking into account the specified data and a simultaneity factor of 100 %.
MSEMAXX063-42
Mains voltage
Rated current per motor
Max. rated mains current
7 drives
400 V
1 A
I
N1
+ I
N2
+ I
N3
+ I
N...
≤ I max
7 x 1 A = 7 A ≤ 7.6 A
12 drives
12 x 1 A = 12 A ≤ 12.2 A
17 drives
17 x 1 A = 17 A ≤ 17.6 A
A n
+ PE L1 L2 L3
I
Nn
35
Electrical installation
Mains connection
Connection according to cULus
Connection according to cULus
The following data is valid for a three-phase mains connection with 480 V.
Mains connection with QUICKON connector
Motor
Connection
Connection type
Cable cross-section
Typ.
Min.
Max.
AWG
AWG
AWG
Mains connection M15 connector
Motor
Connection
Connection type
Cable cross-section
Typ.
Min.
Max.
AWG
AWG
AWG
Mains connection cable L1, L2, L3, PE
Motor
Connection
Connection type
Cable type
Cable cross-section
Typ.
Min.
Max.
Stripping length
AWG
AWG
AWG mm
MSEMA ☐☐ 063-42
16
16
14
X3
QUICKON connector
MSEMA ☐☐ 080-32
14
16
14
MSEMA ☐☐ 063-42 MSEMA ☐☐ 080-32
X3
M15 connector
16
16
14
MSEMA ☐☐ 063-42
14
16
14
MSEMA ☐☐ 080-32
X3
Cable rigid/flexible
18
18
16
10
16
18
16
10
36
Electrical installation
Mains connection
Connection according to cULus
WARNING!
▶ UL marking
▶ Use 75 °C copper wire only, except for control circuits.
▶ Maximum conductor size is AWG14.
▶ Cord connected drives are for use only in NFPA 79 applications.
▶ Overload protection: 125 % of rated FLA
▶ Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protectionmust be provided in accordance with the National Electrical Code and any additional local codes.
▶ CAUTION - Risk of electric shock. Do not disconnect under load.
▶ Marquage UL
▶ Utiliser exclusivement des conducteurs en cuivre 75 °C, sauf pour la partie commande.
▶ Taille de conducteur maximale : AWG14.
▶ Les entraînements avec câble d’alimentation sont destinés exclusivement à des applications conformes à la norme NFPA 79.
▶ Protection contre les surcharges : homologuée pour 125 % du courant assigné à pleine charge.
▶ La protection statique intégrée n’offre pas la même protection qu’un disjoncteur. Une protection par disjoncteur externe doit être fournie, conformément au National Electrical
Code et aux règlementations locales applicables.
▶ ATTENTION ! Risque de choc électrique. Ne pas débrancher l’équipement sous charge.
Single drive connection according to NFPA 70, NFPA 79
3/N/PE AC 400/480 V
L1
L2
N
PE
SELV/PELV
DC 24 V
(+19.2 … +28.8 V)
AC
DC
2
+
F1 … F3
Q
3
4
2
1
3
4
2
1 max. 50 mA
1 2 3
X1 n. c.
DI2
GND
-I
DI1
4 1 2 3 4
X2
24V DI3
GND
-O
DO1
+
X3
+
+
L1
1 2
L2 L3
3
X4
Rb1 Rb2
+
R b
X3
+ L1 L2 L3
F1 … F3
Q
R b
Rb1 Rb2
X4
Rb1 Rb2
①
X6
U V W BD1 BD2
X5
M
3~
① GND is bridged if the "DI/DO−GND bridged" version is specified on the nameplate.
37
Electrical installation
Mains connection
Connection according to cULus
Fuse data (F1 ... F3)
Motor
Cable installation in accordance with
Fuse
Standard
Typ. Rated current
Max. rated current
Semiconductor fuse
Standard
Typ. Rated current
Max. rated current
Circuit breaker
Standard
Typ. Rated current
Max. rated current
A
A
A
A
A
A
MSEMA ☐☐ 063-42
15
15
3
3
3
3
NFPA 70, NFPA 79
UL 248
UL 248
UL 489
WARNING!
▶ UL marking
▶ Suitable for use on a circuit capable of delivering not more than 5k rms symmetrical amperes, 480 V maximum.
▶ When protected by fuses rated, see table above.
▶ When protected by a circuit breaker having an interrupting rating not less than 5k rms symmetrical amperes, 480 Maximum, see table above.
▶ Marquage UL
▶ Convient à une utilisation sur un circuit non susceptible de délivrer plus de 5k ampères symétriques eff, maximum 480 V.
▶ Avec une protection par des fusibles du calibre indiqué dans le tableau ci-dessous,
▶ Avec une protection par un disjoncteur à courant de coupure assigné d’au moins
5k ampères symétriques eff, maximum 480 V, voir tableau ci-dessous.
Group drive connection according to NFPA 70, NFPA 79
L1
L2
N
PE
F1 … F3
K
MSEMA ☐☐ 080-32
6
10
6
10
15
15
M
3~
A
1
+ PE L1 L2 L3
I
N1
M
3~
A
2
+ PE L1 L2 L3
I
N2
M
3~
A
3
+ PE L1 L2 L3
I
N3
M
3~
A
4
+ PE L1 L2 L3
I
N4
M
3~
A n
+ PE L1 L2 L3
I
Nn
38
Electrical installation
Mains connection
Connection according to cULus
Max. total rated mains currents at 40 °C for different cable cross-sections
Cable installation in accordance with
Main cable
Cable cross-section
Stub
Cable cross-section
AWG
AWG
Fuse
Typ. Rated current
Max. rated current
Circuit breaker
Typ. Rated current
Max. rated current
I max
≥ I
N1
+ I
N2
+ I
N3
+ I
N...
A
A
A
A
A
16
16
---
10
---
10
8.0
NFPA 70, NFPA 79
• Use of copper cables insulated with PVC
• Conductor temperature ≤ 70 °C, ambient temperature ≤ 40 °C
• No bundling of cables or wires, thee wires under load
• Typical utilization 80 % of the respective cable cross-section taken into account
WARNING!
▶ UL marking
▶ Suitable for motor group installation on a circuit capable of delivering not more than 5k rms symmetrical amperes, 480 V maximum.
▶ When protected by fuses rated, see table above.
▶ When protected by a circuit breaker having an interrupting rating not less than 5k rms symmetrical amperes, 480/277 V Maximum, see table above.
▶ Marquage UL
▶ Convient aux circuits de groupes moteur non susceptibles de délivrer plus de 5k ampères symétriques eff, maximum 480 V.
▶ Avec une protection par des fusibles du calibre indiqué dans le tableau ci-dessous,
▶ Avec une protection par un disjoncteur à courant de coupure assigné d’au moins
5k ampères symétriques eff, maximum 480/277 V, voir tableau ci-dessous.
14
14
---
15
---
15
12.0
39
Electrical installation
Motor connection
Connection via terminal box
Motor connection
To connect the motor correctly, you must follow:
• The notes in the terminal box of the motor.
• The notes in the configuration document of the motor.
• The technical data on the motor nameplate.
Connection via terminal box
1
2
MSEMA terminal box
Contact
3
PE
Name
L1
L2
L3
PE
Meaning
Mains connection phase L1
Mains connection phase L2
Mains connection phase L3
PE conductor
Connection via QUICKON V2 connector
Mains connection X3
1
2
PE
3
2
3
4
QUICKON V2
Contact
1
Connection via M15 connector
Mains connection X3
Name
L1
L2
L3
PE
Meaning
Mains connection phase L1
Mains connection phase L2
Mains connection phase L3
PE conductor
2
3
2
3
B
1
PE
M15 power without temperature sensor
Contact Name
A
L1
L2
L3
PE
Meaning
Not assigned
Mains connection phase L1
Mains connection phase L2
Mains connection phase L3
PE conductor
40
Electrical installation
Motor connection
Connection via M12 connector
Connection via M12 connector
NOTICE
In the "DI/DO-GND bridged" version, the masses of the control terminal X1 and X2 (GND-I and
GND-O) are connected to each other. If only one speed is used, the connection to X2 is sufficient.
Control connection X1
3 2
2
3
4
M12 A coded X1
Contact
1
Control connection X2
Name n.c.
DI2
GND-I
DI1
4 1
3
Meaning
Digital input 2
Ground of digital input
Digital input 1
2
4 1
4
3
1
2
M12 A coded X2
Contact Name
24V
DI3
DO1
GND-O
Meaning
24 V supply (DO1 supply)
Digital input 3 (reference X1;3 = GND-I)
Digital output 1
Ground of digital output
Connection data - digital inputs for control connection X1/X2
Name Supply voltage
V in
DC V
DI1
DI2
DI3
24 (19.2 ... 28.8)
Internal resistance
R i
Ω
5600
41
Commissioning
Commissioning
You have two options to adapt the Lenze Smart Motor to the applications:
Preconditions
NFC-capable smartphone or tablet
• Android version from V3.0
• Lenze app "Lenze Smart Motor"
Download from www.Lenze.com or from the Google store
• Deenergize motor
• In order to ensure a trouble-free near field communication, find out first about the position of the NFC antenna on your mobile device
Possibly, this area is directly marked on your mobile device.
The standard smartphones are marked in the camera area.
• Comply with the distance of < 2 cm when reading/writing
PC
• Engineering tool EASY Starter
Download from www.Lenze.com
• Required licence:
EASY Advanced or Engineer HighLevel
• EZAETF001 NFC adapter for communication between PC and the Lenze Smart Motor
• Deenergize motor
• Comply with the distance of < 2 cm when reading/writing
Parameter set management
Parameter
Designation
PIN
Value
Delivery
---
New PIN ---
42
Setting range
[0000 ... 9999]
[0000 ... 9999]
Comment
PIN for the protection against unauthorised alteration of the parameter set (0 = no protection).
Alteration of "PIN" sets "new PIN" to the same value.
The parameters can also be read without a PIN.
Future PIN for protection against unauthorised alteration of the parameter set.
Commissioning
Standard settings
Parameter
Name
Parameter set name
Output speed 1
Output speed 2
Output speed 3
Output speed 4
Output speed 5
Acceleration time
Deceleration time
Energy-saving function
Diagnostics
Parameter
Designation
Peak load of the drive
Meters
Parameter
Designation
Elapsed-hour meter
Operating-hour meter
Logbook
Parameter
Designation
Error message 1 (last)
Error message 2
Error message 3
Error message 4 (earliest)
Value
Delivery
---
Peak load of the brake resistor ---
Value
Delivery
---
---
---
---
---
Value
Delivery
---
Value
Delivery
---
Setting range
[text] depending on the order [-2600/i ... -500/i] rpm
[0] rpm
[500/i ... 2600/i] rpm
[0.0 ... 20.0] s n max
[Off]
[On]
Setting range
[0 … 250] %
[0 … 250] %
Setting range
[0 ... 596523] h
[0 ... 596523] h
Setting range
[Text]
[Text]
[Text]
[Text]
Comment
File name of the parameter set without file extension *.lsm
CCW rotation: < 0 rpm
STOP: 0 rpm
CW rotation: > 0 rpm
Lenze Smart Motor with gearbox: The ratio i is taken into account when calculating the output speed.
Acceleration time t
1
of the ramp generator from
0 rpm to n max
[2600/i] rpm
Deceleration time t
2
of the ramp generator from n max
[2600/i] rpm to 0 rpm t
Optimized for:
• High dynamic performance
• Maximum starting torque and torque
• High speed accuracy
Reduced energy absorption in partial load operational range.
Approx. 50 % of the maximum starting torque is available.
Comment
Last peak value of the medium thermal load
(maximum value in the last mains switching cycle)
From firmware version 03.00.00.00
Last peak value of the thermal utilisation of the brake resistor (maximum value in the last mains switching cycle)
From firmware version 03.00.00.00
Comment
Total time of "Motor rotating"
Total time of "mains ON"
Comment
Meaning: See fault elimination table
43
Commissioning
Device data
Parameter
Designation
Material number
Device types
Firmware version
Hardware Version
Motor
Gearboxes
Ratio
Brake
Serial number
Activating speeds
1
2
3
4
5
Output speed
Parameter Value
Designation Delivery
---
---
---
---
---
Status message
Value
Delivery Setting range depending on the order [number]
[Text]
[Text]
[Text]
[Text]
[Text]
[number]
[Text]
[Text]
Comment
Drive identification
Setting range
[number]
[number]
[number]
[number]
[number]
X2.4 (DO1)
LOW
HIGH
Direction of rotation
CCW rotation Stop CW rotation
< 0 rpm 0 rpm > 0 rpm
X1.4 (DI1)
Activate output speed
X1.2 (DI2) X2.2 (DI3)
LOW
HIGH
LOW
HIGH
LOW/HIGH
LOW
LOW
HIGH
HIGH
LOW/HIGH
LOW
LOW
LOW
LOW
HIGH
Status
Not ready for operation
Ready for operation
44
Commissioning
Before initial switch-on
Advanced settings
I
Parameter
Name
U min
boost max in motor mode
Drives coupled mechanically
Motor overload setting (I 2 x t)
Value
Delivery
0.0 % device-dependent
No
100.00 %
Starting value of motor overload
(I 2 x t)
50.00 %
Motor brake switching threshold 100/i rpm
Setting range
[0.0 ... 100.0] %
[0.00 ... Imax] A
Comment
Effective only if Energy saving function = On:
• Boost of the motor voltage in the range of low speeds.
• In the case of conveyor applications with an inclined proportion, a turn-back during start-up can be prevented.
• Typical values approx. < 5 %.
Maximum motor current
MSEMAxx063-42: 5.6 A (recommended 1.4 ... 5.6 A)
MSEMAxx080-32: 13.2 A (recommended 3.3 ... 13.2 A)
With gearbox, the maximum setting range may be limited.
Reducing the I max causes a lower maximum torque.
No, yes Reducing compensation processes in case of heavy and long conveyed loads which occupy several conveying elements at the same time.
From firmware version 03.00.00.00
[0.00 ... 250.00] % Limit value for motor overload cut-off.
Recommended setting: 100 %
[0.00 ... 100.00] % Recommended setting for operation according to UL: 50.00 %
Brake resistor R
Rated power of brake resistor
Thermal capacity of brake resistor
Reduction of brake chopper threshold
Impact of oscillation damping
Oscillation damping filter time
- ohms
- W
- kWs
0 V
5.00 %
50 ms
[0 ... 499.9/i] rpm Motor brake is switched if the value is exceeded or is too low.
Higher value: In the case of conveyor applications with an inclined proportion, a turn-back during start-up can be prevented.
[150.0 ... 500.0]
Ohms
[10 ... 65535] W
[0 ... 6553.5] kWs
[0 ... 150] V
•
Enter data of a connected brake resistor correctly.
If fitted in the factory:
If an internal brake resistor is used, the values of the brake resistor are preset.
• If an external brake resistor is used, the values of the brake resistor are preset. Only the rated power can be increased from
20 W to max. 40 W if the mean speed is > 1000 rpm
(mathematical mean of the process speeds in relation to the motor speed, without standstill).
The threshold is reduced by the voltage value set here.
The switching threshold is adapted to the different mains voltage ranges.
Reduction by 20 ... 30 V can prevent overvoltage for operation in generator mode.
[0.00 ... 250.00] % For the suppression of no-load oscillations. Typically, the impact has
[2 ... 250] ms to be increased for this purpose.
Before initial switch-on
• That the drive does not show any visible signs of damage.
• Is the mechanical fixing o.k.?
• Is the electrical connection o.k.?
• Are all rotating parts and surfaces that may become hot protected against contact?
• Is the featherkey radially secured during the test run without output elements?
• Have all screwed connections of the mechanical and electrical parts been tightened?
• Is the free supply and removal of cooling air ensured?
• Has the PE conductor been connected correctly?
• Have the protective devices against overheating (e.g. temperature sensor evaluation) been activated?
• Is the contact of good electrical conductivity if a PE connection on the motor housing is used?
After a long period of downtime or after overhauling the motor, check the insulation resistance prior to initial switch-on, as condensation may have formed.
• If the values measured are ≤1 kΩ per volt of the rated voltage, the insulation resistance is inadequate and no voltage is to be applied.
• Dry the winding until the insulation resistance is >1 kΩ per volt of the rated voltage.
45
Commissioning
Functional test
Functional test
After commissioning, check all individual functions of the drive:
• Rotating direction in decoupled state
• Torque behavior and current consumption
• Brake function
During operation, carry out inspections on a regular basis. Pay special attention to:
• Unusual noises
• Irregular running
• Increased vibration
• Loose fixing elements
• Condition of electrical cables
• Speed variations
• Deposits on the drive and in the cooling channels
Direction of rotation of the output shaft
The direction of rotation of the output shaft is defined by the setpoint of the output speed.
The direction of rotation is changed when a positive (n > 0) or negative (n < 0) speed is specified.
n < 0 n > 0
46
Maintenance
WARNING!
Risk of injury due to non-compliance with the following safety measures
Disregarding the following safety measures may lead to severe personal injury and damage to property.
▶ Only work on the drive system when it is de-energised.
▶ Wait for the surfaces to cool down.
▶ Put the drive system in a load-free state or secure any loads acting on the drive.
▶ Protect the motors against the ingress of foreign bodies.
Maintenance
47
Maintenance
Maintenance intervals
Maintenance intervals
Geared motor/gearbox
Time interval Measures
After assembly and after 3 hours , check fastening.
On the first day, then every month
Every 6 months
Annually
General check
Check tightness
Clean geared motor/gearbox
Check rubber buffer
Relubricate roller bearings
Check vent valve
Description of the operations
Check all fixing screws on the gearbox (foot, flange and shrink disc fixing ...) for tightness.
Pay attention to unusual operating noises, vibrations and impermissibly high temperatures
In case of leakage, eliminate cause of leakage and check lubricant level.
Remove dirt and dust deposits. Clean more frequently in the case of heavy dirt accumulation
Check rubber buffer of the torque plate and replace it in the event of visible wear or damage
For gearboxes with adapter and grease nipple:
Relubricate the roller bearings in the adapter using a grease gun.
Grease: Klüber Microlube GLY 92, amount approx. 5 grams
Check whether air can pass through the breather element. If it shows blockages, replace it
Change lubricant
For type and amount of lubricant see nameplate
Rolling bearing greases should also be renewed when changing the lubricant
According to diagram; at the latest as specified in the lubricant table
Change lubricant
Replace roller bearing grease filling
The following gearboxes are lubricated for life:
• G50BB045
• G50BB111
• G50BB124
Lubricants
For gearboxes not lubricated for life, change the lubricant at regular intervals.
The type of lubricant is indicated on the nameplate. Only use the same type of lubricant.
The change interval depends on the lubricant temperature during operation.
The replacement intervals listed in the lubricant table are reference values for normal ambient conditions. Shorter periods are required for more difficult operating conditions (e.g.
aggressive ambient media).
At higher oil temperatures, determine the change interval from the following lubricant diagram.
48
Maintenance
Maintenance intervals
Determine change intervals for lubricants
1 .
Measure the lubricant temperature at the drain plug
2 .
Add 10 C
3 .
Determined the change interval from the diagram
Position Of the drain plug
110
100
90
80
A
70
60
1000 10000
B
A
B
Oil sump temperature [°C]
Change interval in operating hours [h]
Spring-applied brake
C
D
50000
C
D
Synthetic oil: CLP HC/CLP PG
Mineral oil: CLP
NOTICE
▶ A maintenance concept adapted to the operating conditions and the stresses to which the brakes are subjected must be drawn up for every application.
•
•
Application 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
• Standard brake: After 1 million cycles at the latest
• LongLife design: After 10 million cycles at the latest
• Provide shorter intervals in the case of frequent emergency stops
Description of the operations
• Remove contamination by oil and grease with brake cleaner, if necessary replace the brake after clarifying the cause.
• Remove dirt and particles in the air gap between stator and armature plate.
• Check ventilation function and activation/deactivation
• Check air gap (if required, re-adjust it)
• Measure rotor thickness (if required, replace rotor)
• Check for thermal damage of the armature plate or flange (tarnished in dark blue)
49
Maintenance
Maintenance work
Maintenance work
Check the oil level
NOTICE
▶ Check the oil level in cold condition!
Check the oil level by means of the displayed dipsticks. Depending on the gearbox type and the mounting position (M1 ... M6), make these according to the following templates. The gearbox type and mounting position are indicated on the nameplate.
The oil level must be within the marked range of the dipstick.
50
Gearbox G50BB124 ... B145
Template: Dipsticks for G50BB124
M1 3 + 4
M1 2
M4
M5
Maintenance
Maintenance work
M2
M3
M6
②
③
④
2-stage gearbox
3-stage gearbox
4-stage gearbox
51
Maintenance
Maintenance work
Template: Dipsticks for G50BB145
M1
M2
M3
M4
M5
M6
How to check the lubricant level:
1 .
Remove the control screw at the marked position.
2 .
Insert the dipstick through the threaded hole. Observe the position of the dipstick in the template!
3 .
Carefully pull out the dipstick and determine the lubricant level. The lubricant level must be within the marked range of the dipstick.
4 .
If the lubricant level is too low, top up lubricant until the lubricant level is in the marked area of the dipstick. If the loss is greater, determine the cause.
5 .
Insert the control screw and tighten it to the specified torque.
52
Maintenance
Maintenance work
Gearbox G50BB160 ... G50BB320
How to check the lubricant level:
1 .
Remove the control screw at the marked position.
2 .
Insert auxiliary tool through the threaded hole.
3 .
Carefully pull out the auxiliary tool and determine the lubricant level. The lubricant level may be between the threaded hole and dimension "x".
4 .
If the lubricant level is too low, top up lubricant until the lubricant level is in the marked area. If the loss is greater, determine the cause.
5 .
Insert the control screw and tighten it to the specified torque.
A C
90°
B
ÖL
A
B
C
Check bore hole
Auxiliary tool, e. g. angled wire (not included in the scope of supply)
Control screw
Threaded hole G
M10 x 1
M12 x 1.5
M16 x 1.5
M20 x 1.5
G 1/8"
G 1/4"
G 3/8"
G 3/4"
Screw head mm
14
17
21
25
14
18
22
32
Filling height x mm
2
3
4
5
2.5
3
4
7
53
Maintenance
Maintenance work
Change lubricant
NOTICE
Change from standard lubricant CLP or CLP HC to food grade lubricant CLP ... USDA H1.
The drain holes do not always allow complete draining of the gearbox. A residual amount of the lubricant may remain in the gearbox.
▶ Carefully flush the gearbox with the food grade lubricant before changing the lubricant.
NOTICE
▶ The gearbox should be lukewarm in order that the oil flows well but there is no risk of scalding.
How to change the lubricant:
1 .
Place a sufficiently large container (lubricant quantity indicated on the nameplate) under
2 .
Remove filler and drain plug at the marked position and drain lubricant completely.
3 .
Insert the drain plug with a new sealing ring and tighten to the prescribed torque.
4 .
Fill in defined amount of lubricant through the inlet.
5 .
Insert the filler plug and tighten it to the specified torque.
6 .
Dispose of waste oil according to the applicable regulations.
Tightening torques for venting elements and screw plugs
Threaded hole
M10 x 1
M12 x 1.5
M16 x 1.5
M20 x 1.5
G 1/8"
G 1/4"
G 3/8"
G 3/4"
Change roller bearing lubricant
Recommended lubricants:
Tightening torque
Nm
10
20
34
50
10
10
25
50
Gearbox roller bearing
Motor roller bearing
Biolubricant
(lubricant for forestry, agriculture and water supply and distribution)
Ambient temperature
−30 °C ... +50 °C
−30 °C ... +80 °C
-40 °C ... +60 °C
−30 °C ... +70 °C
−40 °C ... +80 °C
−40 °C ... +50 °C
Manufacturer
Fuchs
Klüber
Klüber
Lubcon
Klüber
Fuchs
How to change the lubricant:
• Clean rolling bearings before lubricating
• For fast-running bearings (gearbox drive end): Fill one third of the hollow spaces between the roller bearings with grease.
• For slow-running bearings (within gearbox and driven side of gearbox): fill two-thirds of the hollow spaces between roller bearings with grease.
Type
Renolit H 443
Petamo 133 N
Microlube GLY 92
Thermoplex 2TML
Asonic GHY 72
Plantogel 0120S
54
Maintenance work at the spring-applied brake
NOTICE
▶ Brakes with defective armature plates, springs or flanges must be completely replaced.
▶ Before carrying out maintenance work, identify the brake and motor protection type from the nameplate.
Before working on the brake, remove the integral fan cover or blower cover on the motor.
How to remove the fan cover:
1 .
Loosen and remove screws at the cover circumference.
2 .
If necessary, disconnect the connecting cable on the blower cover.
3 .
Remove fan cover.
Release brake and check voltage
DANGER!
Risk of injury due to rotary parts.
▶ Do not touch rotating components.
DANGER!
Risk of injury by electric shock.
▶ Do not touch live connections.
1 .
Check the function of the brake while the drive is running: The armature plate must be tightened and the rotor must move free of residual torque.
2 .
Measure the DC voltage on the brake.
Compare the measured DC voltage with the voltage specification on the nameplate. A deviation up to ±10 % is permissible.
When using bridge/half-wave rectifiers: After switching over to one-way voltage, the measured DC voltage may drop to 45% of the voltage indicated on the nameplate.
Check and adjust air gap
DANGER!
Risk of injury due to rotary parts.
▶ The motor must not be running when checking the air gap.
Maintenance
Maintenance work
55
Maintenance
Maintenance work
4 2 3
1 sL
1 Stator
2 Armature plate
3 Cylinder screw s
4 Sleeve bolt with hexagon
L
Air gap
How to check the air gap:
1 .
Do not energize the brake.
2 .
Measure the air gap s
L
between stator (1) and armature plate (2) in the vicinity of the cylinder screws (3) using a surface feeler gauge.
3 .
Compare the air gap with the value for the maximum permissible air gap s
L,max
.
4 .
Set air gap to s
L,N
.
How to set the air gap for the brake
1 .
Loosen cylinder screws (3) with an Allen key.
2 .
Screw the sleeve bolts (4) further into the stator (1) using an open-end wrench.
1/6 revolution reduces the air gap by approx. 0.15 mm.
3 .
Tighten the cylinder screws (3) to the prescribed torque.
4 .
Measure the air gap s
L
between stator (1) and armature plate (2) in the vicinity of the cylinder screws (3) using a surface feeler gauge.
Brake size Tightening torque Air gap s
L,max
06
08
Nm
3.0
5.9
0.30
s
L,N mm
0.2
+0.10
-0.05
56
Repair
NOTICE
We recommend having all repairs carried out by the Lenze service department.
If faults occur during the operation of the drive system:
• First check the possible causes of malfunction according to the
4 Diagnostics and fault elimination
• If the fault cannot be remedied using one of the measures listed, please contact the Lenze service department. The contact data can be found on the rear of this documentation.
Repair
57
Diagnostics and fault elimination
Diagnostics and fault elimination
Fault messages are stored in the logbook of the Lenze Smart Motor.
How to read out the fault messages:
1. Disconnect Lenze Smart motor from the mains.
2. Load parameter set onto the smartphone or the EASY Starter. Under "History", the last 4 messages are stored in the logbook.
a) Up to firmware version 02.00.00.00: Identical errors that occur successively are displayed as one entry.
b) From firmware version 02.01.00.00: Each error is displayed as an entry.
How to reset errors:
1. Eliminate the cause of malfunction.
2. The error is reset by mains switching.
The drive can be started again.
Error types
Fault
Type Meaning
F Fault
You can reset the fault without mains switching:
Select the input speed 0 rpm via the digital inputs.
Then select the desired speed again.
If the cause of malfunction is no longer active, the drive will restart.
Drive behaviour
W Warning
The digital output changes to LOW = not ready for operation.
The fault is entered in the history buffer.
• Lenze Smart Motor without brake: The motor is switched off and coasts down.
• Lenze Smart motor with brake: The motor is switched off; the brake is applied.
The fault is entered in the history buffer.
The Lenze Smart motor continues running.
58
Diagnostics and fault elimination
Malfunctions
F
F
F
F
F
F
F
Malfunctions
If faults occur during the operation of the drive, the table below helps you to identify the causes. If it is not possible to remedy the fault using the measures listed, please contact the
Lenze service department.
Fault
Type Message
F RFID read error (RFIR)
F RFID write error (RFIW)
Possible causes Remedy
F
F
F
F
F
F
W
F
RFID data CRC invalid (PS02)
RFID data version invalid (PS04)
Missing mains phase (SU02)
DC bus overvoltage (OU)
Electronics warning temperature (OH4)
Electronics overtemperature (OH1)
Electronics overload (Ixt ) (OC9)
Electronics overcurrent (OC11)
Motor overcurrent (OC7)
Motor short circuit (OC1)
Motor earth fault (OC2)
Motor overload I2xt (OC6)
Brake resistor overload I2xt (OC12)
Internal error (DH69)
Internal error (DF01)
...
Internal error (DF13)
NFC communication interrupted
NFC communication interrupted
1. Connect and disconnect mains.
2. Repeat action.
3. If the error occurs again, please contact the Lenze Service.
1. Load default setting.
2. Connect and disconnect mains.
3. Rewrite parameter set.
•
Incompatible software version
A mains phase of a three-phase supply has failed. Reliable detection from an utilization > 50 % rated motor power.
DC-bus voltage too high
Lacking or insufficient cooling.
Drive close to being disconnected due to overtemperature (OH1)
Ambient temperature too high.
The Ixt overload test has been triggered
• Motor load too high.
Load cycles not complied with.
Overcurrent limitation active
Update Lenze App or EASY Starter.
• Check mains connection.
• Check fuses.
• Increase deceleration ramp.
• Reduce speed for great regenerative loads.
• Use brake resistor.
• Check cooling.
• Clean cooling ribs.
Ambient temperature must be in the permissible range.
• Increase deceleration ramp.
• Reduce Imax.
• Check dimensioning.
• Reduce motor load.
• Increase deceleration ramp.
Reduce motor load.
The maximum current monitoring function has been triggered.
Short circuit in the motor phases
A motor phase has earth contact
Motor thermally overloaded
Reset error. If the error occurs again during restart, please contact the Lenze
Service.
• Reduce motor load.
• Check setting of the I2xt monitoring function.
• Increase acceleration and deceleration ramp.
Increase deceleration ramp.
Too frequent and too long braking processes
Lenze Smart motor without brake resistor:
DC-bus voltage too high
Various
• Reduce regenerative load.
• Use brake resistor.
• Increase deceleration ramp.
Reset error. If the error occurs again during restart, please contact the Lenze
Service.
59
Diagnostics and fault elimination
Malfunctions
Error
Drive is not running
Motor runs, gearbox does not
Unusual running noises
Oil discharge at the gearbox ventilation unit
Possible cause
Voltage supply interrupted
Faulty electrical connection
Load too high
Coupling components are missing or defective
Gearbox is defective
Clutch disengaged
Overload
Excessive temperature
Vibrations, noise
Overload
Inadequate heat dissipation
Lack of lubricant
Loose fixing elements
Shrink disc connection is spinning Correct screw tightening torque has not been reached
Insufficient number of passes, not all screws are tightened correctly.
Machine shaft and hollow shaft bore not sufficiently degreased
Wrong component part dimensions
Fits, roughnesses
Yield point of machine shaft material is too low
Re > 300 N/mm2 required
Friction factors are too low
Surface roughness Rz ≤ 15 µm required
Oil is leaking
The shrink disc itself has been degreased so that the screws and the bevels are dry. Due to incorrect friction factors, the shrink disc cannot be tightened correctly.
Wrong oil level for the applied mounting position
Initially slight leakage at the shaft seal
Overpressure due to lacking ventilation
Overpressure due to polluted ventilation
Worn-out shaft sealing rings
Cover / flange screws are loose
Incorrect oil level for the mounting position applied and/or incorrect position of ventilation unit
Remedy
Check connection
Check external voltage supply.
Reduce load
Check assignment drive - machine
Check mounting
Inform Lenze Service
Engage the clutch
Reduce load
Check assignment drive - machine
Reduce load
Improve cooling air supply, clean gearbox / motor
Top up lubricant according to regulations
Tighten fixing elements
Specifications for assembly, dimensions and material must be observed
Check mounting position (see nameplate) and oil level
Optimum sealing conditions only arise after the running-in phase
Install ventilation according to the mounting position
Clean ventilation
Check condition of sealing lip contact area, repair if necessary.
Check that the fixing screws are tightly fastened.
Continue to monitor the gearbox
Check mounting position (see nameplate) and oil level
Check position of ventilation unit
Use oil compensation reservoir
For resistance measurement, observe the data on the brake nameplate.
Trouble
Brake does not release,
Air gap is not zero
Rotor cannot rotate freely
Rotor thickness too small
Possible cause
Coil is interrupted
Remedy
Measure the resistance of the coil with a multimeter:
• Compare measured resistance with rated resistance.
• If resistance is too high, replace the spring-applied brake completely
Coil has interturn fault or short circuit to ground
Measure the resistance of the coil with a multimeter:
• Compare measured resistance with rated resistance.
• If the resistance is too low, replace the stator completely.
Check coil for short circuit to ground with a multimeter:
• Replace the spring-applied brake completely in case of short circuit to ground.
Readjust air gap Air gap s
L
too large
Air gap s
L
too small Check air gap s
Rotor was not replaced in time Replace rotor
L
and readjust if necessary.
60
Technical data
Standards and operating conditions
Conformity and approvals
Technical data
Standards and operating conditions
Conformity and approvals
Conformities
CE
EAC
2009/125/EC
2011/65/EU
2014/30/EU
2014/35/EU
TP TC 020/2011
TR TC 004/2011
UKCA
S.I. 2012/3032
S.I. 2016/1091
S.I. 2016/1101
S.I. 2021/745
Approvals
CCC
cULus
-
UL 61800-5-1
Ecodesign Directive
RoHS Directive
EMC Directive (reference: CE-typical drive system)
Low-Voltage Directive
Eurasian conformity: Electromagnetic compatibility of technical means
Eurasian conformity: Safety of low voltage equipment
The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment
Regulations 2012
The Electromagnetic Compatibility Regulations 2016
The Electrical Equipment (Safety) Regulations 2016
The Ecodesign for Energy-Related Products and Energy Information Regulations 2021
GB Standard 12350-2009
For USA and Canada (requirements of the CSA 22.2 No.14) Industrial Control Equipment, Lenze File
No. E132659
61
Technical data
Standards and operating conditions
Protection of persons and device protection
Protection of persons and device protection
Protection class
EN
EN IEC 60529,EN IEC
60034-5
IP55
NEMA NEMA 250
Type 12
Type 4 indoor only
Insulation resistance
Overvoltage category EN IEC 61800-5-1
Isolation of control circuits
EN IEC 61800-5-1
II
III
Safe mains isolation
Connect overvoltage device upstream
Information applies to the mounted and readyfor-use state
Depending on the configuration
>2000 m amsl
0 … 2000 m amsl
Double/reinforced insulation
Site altitude above 200 m amsl: Additional external separation measures are required to maintain safe separation.
Protective measures
Earth fault strength
Motor stalling protection
Short-circuit strength
Overvoltage resistance
Motor overtemperature
-
Leakage current
AC EN IEC 61800-5-1
Equipotential bonding
Total fault current
Earth-leakage circuit breaker
Cyclic mains switching
3 times per minute, max. 20 times per hour
Starting current
-
-
-
-
To a limited extent, error acknowledgement necessary
Yes
To a limited extent, error acknowledgement necessary
Yes
I²xt monitoring
> 3.5 mA
Please observe regulations and safety instructions!
Additional M5 thread with terminal on the terminal box for connection of a 6mm² PE cable
In TN systems
After switching the mains 3 times in one minute, there must be a switching pause of 9 minutes.
5.6 A mains power-on current
EMC data
Operation on public supply systems
-
< 1 kW
> 1 kW, mains current ≤ 16 A
Mains current > 16
A ... ≤ 75 A
Noise emission
Fulfills requirements according to
Category C2
Noise immunity
-
-
EN IEC 61000-3-2
EN IEC 61000-3-12
EN IEC 60034-1
EN IEC 61800-3
EN IEC 61800-3
The machine or system manufacturer is responsible for compliance with the requirements for the machine/system!
With mains choke
No additional measures
With mains choke or mains filter When designed for rated power.
A final overall assessment of the drive system is indispensable see rated data
Requirements for industrial environment are met
62
Technical data
Rated data
Environmental conditions
Environmental conditions
Climate
Storage
Transport
Operation
EN 60721-3-1:1997
1K3 (-30 ... +60°C)
1K3 (-30 ... +40 °C)
EN 60721-3-2:1997 2K3 (-30 ...+70 °C)
EN 60721-3-3:1995 +
A2:1997
3K3 (-30 ...+40 °C)
Site altitude
0 … 1000 m amsl
1000 … 4000 m amsl
-
Without current derating
Reduce rated output current by 5 %/1000 m
Pollution
-
Vibration resistance
Operation
Transport
Vibration severity
A
EN IEC 61800-5-1
EN 60721-3-3:1995 +
A2:1997
3M4
EN 60721-3-2:1997 2M2
EN IEC 60034-14 -
Degree of pollution 2
-
<3 months
>3 months
Operation
Electrical supply conditions
Possibility of connection to different types of mains power supply enables worldwide use.
The following is supported:
• 3-phase mains connection 400 V
• 3-phase mains connection 480 V
Type of mains power supply
TT
TN
Mains power supplies with earthed start point
Voltage against earth: max. 300 V
Rated data
Motor
Rated mains voltage
Rated power
Verstellbereich
Rated current
Rated torque
Starting torque
Power factor
Efficiency
at 75 % P rated
at 100 % P rated
Moment of inertia
Weight
J m
P rated
V kW rpm
I rated
M rated
A
Nm
M a cos ϕ
Nm
%
% kgcm² kg
400
1
063-42
0.476
1.75
7
65
66
3.70
5.9
480
MSEMA
-2600 ... -600 /0/ 600 ... 2600
0.8
2.8
0.99
400
080-32
1.361
5.00
20
73
74
26.0
12.5
480
2.3
63
Technical data
Ecodesign Directive
Ecodesign Directive
Product information according to REGULATION (EU) 2019/1781 (ANNEX I, Section 4)
η
Rated efficiency at full load rate d
Efficiency at 75 % rated load η
Efficiency at 50 % rated load η
Efficiency level
Manufacturer's name
Commercial register number
Model identifier of the product
Number of poles of the motor
Rated output power
Rated input frequency
P ra ted f rat
Rated voltage
Rated speed ed
V ra ted n ra ted
Number of motor phases
Altitudes above sea level
Ambient air temperature
Maximum operating temperature
Potentially explosive atmospheres
LMT_EDD_EXCEP_REASON
% kW
Hz
V min -1 m
°C
°C
%
% -
-
-
Lenze SE · Hans-Lenze-Str. 1 · 31855 Aerzen · GERMANY
Hannover HRB 204803
-
-
MSEMA□□063-42 MSEMA□□080-32
-
-
-
-
-
-
-
...
...
-
-
-
-
-
-
Die Motoren sind mit einer integrierten Drehzahlregelung ausgestattet (Kompaktantriebe) und die
Energieeffizienz der Motoren kann nicht unabhängig von der Drehzahlregelung geprüft werden.
64
Environmental notes and recycling
Environmental notes and recycling
Lenze has been certified to the worldwide environmental management standard for many years (DIN EN ISO 14001). As part of our environmental policy and the associated climate responsibility, please note the following information on hazardous ingredients and the recycling of Lenze products and their packaging:
Lenze products are partly subject to the EU Directive on the restriction of certain hazardous substances in electrical and electronic equipment 2011/65/EU: RoHS Directive [UKCA: S.I. 2012/3032 - The Restriction of the Use of Certain Hazardous Substances in
Electrical and Electronic Equipment Regulations 2012]. This is documented accordingly in the EU declaration of conformity and with the CE mark.
Lenze products are not subject to EU Directive 2012/19/EU: Waste Electrical and Electronic Equipment (WEEE) Directive
[UKCA: S.I. 2013/3113 - The Waste Electrical and Electronic Equipment Regulations 2013], but some contain batteries/rechargeable batteries in accordance with EU Directive 2006/66/EC: Battery Directive [UKCA: S.I. 2009/890 - The Waste Batteries and Accumulators
Regulations 2009]. The disposal route, which is separate from household waste, is indicated by corresponding labels with the
"crossed-out trash can".
Any batteries/rechargeable batteries included are designed to last the life of the product and do not need to be replaced or otherwise removed by the end user.
Lenze products are usually sold with cardboard or plastic packaging. This packaging complies with EU Directive 94/62/EC: Packaging and Packaging Waste Directive [UKCA: S.I. 1997/648 - The Producer Responsibility Obligations (Packaging Waste) Regulations 1997].
The required disposal route is indicated by material-specific labels with the "recycling triangle".
Example: "21 - other cardboard"
REACH Lenze products are subject to REGULATION (EC) No. 1907/2006: REACH Regulation [UKCA: S.I. 2008/2852 - The REACH Enforcement
Regulations 2008]. When used as intended, exposure of substances to humans, animals and the environment is excluded.
Lenze products are industrial electrical and electronic products and are disposed of professionally. Both the mechanical and electrical components such as electric motors, gearboxes or inverters contain valuable raw materials that can be recycled and reused. Proper recycling and thus maintaining the highest possible level of recyclability is therefore important and sensible from an economic and ecological point of view.
• Coordinate professional disposal with your waste disposal company.
• Separate mechanical and electrical components, packaging, hazardous waste (e.g. gear oils) and batteries/rechargeable batteries wherever possible.
• Dispose of the separated waste in an environmentally sound and proper manner (no household waste or municipal bulky waste).
What?
Pallets
Material
Wood
Disposal instructions
Return to manufacturers, freight forwarders or reusable materials collection system
Collect and dispose of separately Packaging material
Products
Electronic devices
Paper, cardboard, pasteboard, plastics
Metal, plastics, circuit boards, heatsinks
Gearbox
Motors
Dry-cell batteries/rechargeable batteries
Oil
Casting, steel, aluminium
Casting, copper, rotors, magnets, potting compound
As electronic waste give to professional disposer for recycling
Drain oil and dispose of separately
Dispose as metal scrap
As engine scrap give to professional disposer for recycling
As used batteries give to professional disposer for recycling
Further information on Lenze's environmental and climate responsibility and on the topic of energy efficiency can be found on the Internet: www.Lenze.com
à search word: "Sustainability"
65
Lenze SE
Postfach 101352 · 31763 Hameln
Hans-Lenze-Straße 1 · 31855 Aerzen
GERMANY
Hannover HRB 204803
Phone +49 5154 82-0
Fax +49 5154 82-2800 [email protected]
www.Lenze.com
© 11/2021 · 1.0 · www.Lenze.com
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Key Features
- Compact and robust design for demanding applications
- High efficiency and reliability for reduced operating costs
- Versatile mounting options for flexible installation
- Advanced control capabilities for precise motion control
- Durable construction for long service life
- Low noise operation for a quieter work environment
- Energy-efficient operation for reduced environmental impact
- Easy to install and maintain for minimal downtime
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Frequently Answers and Questions
What are the mounting options for the g500-B?
Is the g500-B suitable for outdoor use?
What is the maximum torque output of the g500-B?
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