Three−phase AC motors - Lenze€¦ · Motor Three−phase AC motor (squirrel cage induction motor) in versions according to product key, 21 . Controller Any servo inverter Any frequency

BA 33.0005−EN.J),

Ä.J),ä

Operating Instructions

Three−phase AC motors

�

L−force M��MA; Basic M�ERA...V1

Three−phase AC motors

L−force

� 2 BA 33.0005−EN 2.0

� Please read these instructions before you start working!

Follow the enclosed safety instructions.

0Fig. 0Tab. 0

Contents i

� 3BA 33.0005−EN 2.0

1 About this documentation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Document history 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Conventions used 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Terminology used 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Notes used 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General safety instructions for drive components 8 . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Application as directed 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Improper use 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Residual hazards 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Product description 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Identification 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Nameplate 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Product key 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Technical data 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General data and operating conditions 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Mechanical installation 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Important notes 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Preparation 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Installation 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Assembly of built−on accessories 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Spring−applied brakes 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Locking of the manual release 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Electrical installation 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Important notes 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Three−phase AC motor operation on a frequency inverter 34 . . . . . . . . . . . . . . . . . . .

6.3 Wiring according to EMC 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Power connections on the terminal board 35 . . . . . . . . . . . . . . . . . . . . . . . .

6.3.2 Brake connection 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.3 Feedback system 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Plug connectors 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Motor plug connection assignment 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.2 Power connections 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.3 Feedback system 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Terminal box HAN connectors 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contentsi

� 4 BA 33.0005−EN 2.0

7 Commissioning and operation 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Important notes 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Before switching on 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Functional test 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 During operation 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Maintenance/repair 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Important notes 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Maintenance intervals 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 Motor 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 Spring−operated brakes 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Maintenance operations 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 Motor 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.2 Spring−operated brakes 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.3 Checking the component parts 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.4 Checking the rotor thickness 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5 Check air gap 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.6 Release / voltage 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.7 Readjustment of air gap 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.8 Rotor replacement 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Installation of a spring−applied brake 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1 Brake characteristics 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.2 Installation of the brake 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.3 Readjustment of air gap 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.4 Assembly of the friction plate, sizes 06 to 16 55 . . . . . . . . . . . . . . . . . . . . . .

8.4.5 Assembly of the flange 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.6 Assembly of the cover seal 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Repair 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Disposal 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Troubleshooting and fault elimination 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentation 1

� 5BA 33.0005−EN 2.0

1 About this documentation

Contents

ƒ The present documentation serves to safely work on and with the drives. It includessafety instructions which must be observed.

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

ƒ 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 referto the controller or gearbox documentation.

� Tip!

Information and auxiliary devices related to the Lenze products can be foundin the download area at

http://www.Lenze.com

Validity

This documentation is valid for three−phase AC motors:

Type Designation

L−force M��MABasic M�ERA...V1

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 outall activities involved in installing, mounting, commissioning, and operating the product.

About this documentationDocument history

1

� 6 BA 33.0005−EN 2.0

1.1 Document history

Material no. Version Description

13368637 1.0 12/2010 TD09 First edition of the operating instructions, separatefrom servo motors

.J), 2.0 03/2012 TD09 Extended with the UL warning"Screw−in depth B14 flange" table has beenextendedNameplate updated

1.2 Conventions used

This documentation uses the following conventions to distinguish different types ofinformation:

Type of information Identification Examples/notes

Spelling of numbers

Decimal separator Point In general, the decimal point is used.For instance: 1234.56

Icons

Page reference � Reference to another page with additionalinformationFor instance: � 16 = see page 16

Document reference � Reference to another documentationproviding additional informationE.g.: � Software manual ...

1.3 Terminology used

Term Describes the following

Motor Three−phase AC motor (squirrel cage induction motor) in versionsaccording to product key, � 21 .

Controller Any servo inverterAny frequency inverter

Drive system Drive systems including three−phase AC motors and other Lenze drivecomponents

About this documentationNotes used

1

� 7BA 33.0005−EN 2.0

1.4 Notes used

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

Safety instructions

Structure of safety instructions:

� Danger!

(characterises the type and severity of danger)

Note

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

Pictograph and signal word Meaning

� Danger!

Danger of personal injury through dangerous electrical voltage.Reference to an imminent danger that may result in death orserious personal injury if the corresponding measures are nottaken.

� Danger!

Danger of personal injury through a general source of danger.Reference to an imminent danger that may result in death orserious personal injury if the corresponding measures are nottaken.

Stop!Danger of property damage.Reference to a possible danger that may result in propertydamage if the corresponding measures are not taken.

Application notes

Pictograph and signal word Meaning

Note! Important note to ensure troublefree operation

� Tip! Useful tip for simple handling

� Reference to another documentation

� Warnings!

Important installation instructions for flange−mounted motors

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

ƒ These holes may not be used to install feet.

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

Safety instructionsGeneral safety instructions for drive components

2

� 8 BA 33.0005−EN 2.0

2 Safety instructions

2.1 General safety instructions for drive components

(in accordance with Low−Voltage Directive 2006/95/EC)

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

Scope

The following safety instructions generally apply to Lenze drive components.

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

General hazards

� Danger!

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

ƒ Lenze drive components ...

... must only be used as directed.

... must never be commissioned in the event of visible damage.

... must never be technically changed.

... must never be commissioned before assembly has been completed.

... must never be operated without required covers.

... can include live and rotating parts − depending on their type of protection − duringand after operation. Surfaces can be hot.

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

This is vital for a safe and trouble−free operation and for achieving the specified productfeatures.

ƒ Only qualified, skilled personnel is permitted to work on and with Lenze drivecomponents.

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

... are familiar with the installation, mounting, commissioning, and operation of theproduct.

... have the qualifications required for their occupation.

... know and are able to apply all national regulations for the preventions of accidents,directives and laws applicable on site.


2

� 9BA 33.0005−EN 2.0

Transport, storage

ƒ Transport and storage in a dry, low−vibration environment without aggressiveatmosphere; preferably in the packaging provided by the manufacturer.

– Protect against dust and shocks.– Comply with climatic conditions according to the technical data.

ƒ Before transport

– Check that all transport locking devices are mounted.

– Tighten all transport aids.

Note!

Do not apply extra loads to the product as the transport aids (such as eye boltsor bearing plates) are designed for the weight of the motor only (refer to thecatalogue for the weight).

� Danger!

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

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

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

If you do not install the motor immediately, ensure proper storage conditions.

ƒ 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.

– Remove the plug for motors with condensation drain holes (special version).

ƒ More than one year, up to two years:

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

Stop!

Observe load carrying capacity!

Staying under floating load is prohibited!


2

� 10 BA 33.0005−EN 2.0

Corrosion protection

Lenze offers paints with different resistance characteristics for drive systems. Since theresistance 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 requiredcorrosion resistance.

Mechanical installation

ƒ Provide for a careful handling and avoid mechanical overload. During handlingneither bend components, nor change the insulation distances.

Electrical installation

ƒ Carry out the electrical installation according to the relevant regulations (e. g. cablecross−sections, fusing, connection to the PE conductor). Additional notes areincluded in the documentation.

ƒ The documentation contains notes for the EMC−compliant installation (shielding,earthing, arrangement of filters and installation of the cables). The manufacturer ofthe system or machine is responsible for the compliance with the limit valuesrequired in connection with EMC legislation.

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

Commissioning

ƒ If required, you have to equip the system with additional monitoring and protectivedevices in accordance with the respective valid safety regulations (e. g. law ontechnical equipment, regulations for the prevention of accidents).

ƒ Before commissioning remove transport locking devices and keep them for latertransports.

Safety instructionsApplication as directed

2

� 11BA 33.0005−EN 2.0

2.2 Application as directed

Low−voltage machines are no household appliances, they are designed as components forindustrial or professional use in terms of IEC/EN 61000−3−2 only.

They comply with the harmonised standards of the series IEC/EN�60034.

Low−voltage machines are components for installation into machines as defined in theMachinery Directive 2006/42/EC. Commissioning is prohibited until the conformity of theend product with this directive has been established (follow i. a. IEC/EN 60204−1).

It is only permissible to use low−voltage machines with IP23 protection or less outdoors ifspecial protective measures are taken.

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

ƒ Drives

– ... must only be operated under the operating conditions and power limitsspecified in this documentation.

– ... comply with the protection requirements of the EC Low−Voltage Directive.

Note!

Generally, all products this documentation is valid for meet the requirementsof the Low−Voltage Directive 2006/95/EC. Products that do not meet theminimum efficiencies of the EU Directive 640/2009 (and hence the ErPDirective 2009/125/EC), will not be CE−compliant as of 16th June 2011 andthus do not receive a CE designation.

In that case, the product may only be used outside the EEA.

Any other use shall be deemed inappropriate!

2.3 Improper use

ƒ 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 adaptedcoating systems.

Safety instructionsResidual hazards

2

� 12 BA 33.0005−EN 2.0

2.4 Residual hazards

Protection of persons

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

– Provide protection against accidental contact, if necessary.

ƒ Highfrequency voltages can be capacitively transferred to the motor housingthrough the inverter supply.

– Earth motor housing carefully.

ƒ Danger of unintentional starting or electrical shocks

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

– Installed brakes are no fail−safe brakes.

Motor protection

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

– If required, limit the maximum current, parameterise the controller such that itwill be switched off after some seconds of operation with I > IN, especially if thereis the danger of blocking.

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

ƒ Installed brakes are no fail−safe brakes.

– The torque can be reduced due to disruptive factors that cannot be influenced, e.g.by ingressing oil due to a defect shaft sealing ring on the A side.

ƒ Fuses are no motor protection.

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

– Use installed thermal detectors at high operating frequency.

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

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

ƒ Lateral forces from the motor shaft may occur.

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

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

Fire protection

ƒ Fire hazard

– Prevent contact with flammable substances.

Product descriptionIdentification

3

� 13BA 33.0005−EN 2.0

3 Product description

3.1 Identification

Three−phase AC motors ...

M��MA

Motor with standard output flange Motor with square flange for direct gearboxattachment

MT−MDEMA−005.iso/dms

M�ERA...V1

Standard motor

MT−MXERA−001.bmp/dms

Product descriptionIdentificationNameplate

3

� 14 BA 33.0005−EN 2.0

3.1.1 Nameplate

Three−phase AC motor with square flange for direct gearbox attachment

Standard version

Typenschild−GNG−001.iso

CSA/UL version

Typenschild−GNG−002.iso


Nameplate

3

� 15BA 33.0005−EN 2.0

Pos. Contents

1 Manufacturer / production location

2 Motor type / standard

3 Gearbox type

4 Motor type

5 Technical data Ratio

Rated torque

Rated speed

Rated frequency

6 Mounting position / position of the system blocks

7 Lubricant

8 Brake data (if fitted) Type

AC/DC brake voltage

Braking torque, electrical power input

9 Feedback / pulse encoder or resolver data (if fitted), see product key � 23

10 Manufacture data Order number

Material number

Serial number

11 Bar code

12 Rectifier designation

13 Information on operating mode

14 Additional motorspecifications

Temperature class

Enclosure

Motor protection

15 Valid conformities, approvalsand certificates

CE identification; CCC identification

cURus logo / UL file number

UL energy efficiency logo

16 Rated data for variousfrequencies

Hz = frequency

kW = motor power

r/min. = motor speed

V = motor voltage

A = motor current

� = Motor efficiency: at a rated power of 100%

cos � = motor power factor

17 Application factor (given if < 1.0) / load capacity

18 Year / week of manufacture

19 UL file number

20 Additional customer data

21 Inverter duty motor

22 Motor code for controller parameterisation (code 0086)

23 Efficiency class

24 Maximum ambient temperature

25 Grade A = voltage tolerance range according to range A according to IEC/EN 60034−1

26 CC number of the Department of Energy (optional)

27 Ta � 40°C

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

29 ALR

30 Weight


3

� 16 BA 33.0005−EN 2.0

Three−phase AC motor with standard output flange

Standard version

Typenschild−MT−003.iso

UL version

Typenschild−MT−001.iso


Nameplate

3

� 17BA 33.0005−EN 2.0

Pos. Contents


2 Motor type

3 Motor type

4 Inverter duty − motor (UL version)

5 Brake data (if available)

6 Order no.

7 Bar code

9 ALR Ampere locked rotor (UL version)

10 Production data Material no.

Serial number

12 Motor protection

13 Efficiency class


Degree of protection

Thermal class

15 Applicable conformities,approvals and certificates

CE identification

CCC identification

cURus logo / UL file number

UL energy efficiency logo

16 Rated data forvarious frequencies

Hz = frequency

kW = motor power


V = motor voltage

A = motor current


� % = Efficiency at 100% rated power

17 Operating mode information

18 Feedback / pulse encoder or resolver information (if available), see product key � 23

19 CC number of the Department of Energy (optional)

20 Motor code for controller parameterisation (code 0086) for 50Hz/87Hz

22 Ta � 40°C

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

24 Additional customer data

25 Range A = voltages with tolerances according to range A according to IEC/EN 60034−1


3

� 18 BA 33.0005−EN 2.0

Three−phase AC motor, basic version

M�ERA...V1

Typenschild−MT−005.iso/dms

Typenschild−MT−005−1.iso/dms


Nameplate

3

� 19BA 33.0005−EN 2.0

Pos. Contents


2 Type of motor / standard

3 Motor type

4 Material no.

5 Serial number

6 Year of manufacture

7 Rated data for50 Hz and 60 Hz

V = motor voltage

Hz = frequency

kW = motor power


A = motor current



8.1 Degree of protection

8.2 Temperature class

8.3 Motor protection

9 Applicable conformity declarations and approvals

10 Number of poles

11 Efficiency class

12 Efficiency at 100% rated power



15 Operating mode

16 Order no.


3

� 20 BA 33.0005−EN 2.0

Examples


M�ERA...V1 IE1 M�ERA...V1 IE2

Typenschild−MT−005.iso/dms Typenschild−MT−005−1.iso/dms

Three−phase AC motor with standard output flange

Standard version UL version

Typenschild−MT−007.iso/dms Typenschild−MT−006.iso/dms


M�ERA...V1 IE1 M�ERA...V1 IE2

Typenschild−MT−005.iso/dms Typenschild−MT−005−1.iso/dms


Product key

3

� 21BA 33.0005−EN 2.0

3.1.2 Product key

Three−phase AC motors M��A

M −

�

�

�

�

�

�

�

�

Legend for product key

� type − type of current

D Three−phase AC current, standard efficiencyclass

H Three−phase AC current, efficiency class IE2 according to IEC 60034−30 (high)

E Single−phase AC current P Three−phase AC current, efficiency class IE3 according to IEC 60034−30 (premium)

F FI−optimised motor

� Cooling method / ventilation

E Self−ventilated (cooling with fan blades; speed−dependent)

F Forced ventilated (e.g. blower unit) S Natural ventilation (without fan)

� Design

M Modular application motor R Standard motor

� Machine type

A Asynchronous machine

� Built−on accessories

AG Sin−cos absolute value encoder BZ Brake, second shaft end RS Resolver

BA Brake with sin/cos absolute value encoder GX Prepared for encoder TA Tachometer generator

BF Brake, GG fan, handwheel HA Handwheel TI Tachometer and incrementalencoder

BG Brake, resolver and incremental encoder IG Incremental encoder XX Not assigned

BH Brake, handwheel KF Backstop, GG fan, handwheel ZE Second shaft end

BI Brake and incremental encoder KH Backstop, handwheel KZ Backstop, second shaft end

BL Brake, GG fan KI Backstop, incremental encoder LH GG fan, handwheel

BR Brake KL Backstop, GG fan LL GG fan

BS Brake and resolver KP Backstop LZ GG fan, second shaft end

BV Brake prepared KS Backstop, resolver

BX Brake prepared for encoder KV Backstop prepared for encoder

BY Brake, GG fan, second shaft end KY Backstop, GG fan, second shaft end

� Frame size

Overall length

0 VS, very short 2 M, medium 4 VL, very long

Product descriptionIdentificationProduct key

3

� 22 BA 33.0005−EN 2.0

1 S, short 3 L, long


Product key

3

� 23BA 33.0005−EN 2.0

Number of pole pairs

1 ... 6 Motors with a fixed number of pole pairs A ... L Pole−changing motors

� Internal information

� Approvals

Feedback system

Resolver / encoder ��

�

�

�

Legend

� Type

RSIGIKASAM

ResolverIncremental encoderIncremental encoder with commutation signalSingleturn absolute value encoderMultiturn absolute value encoder

Number

12, 3, 4...32, 512,1024,2048, ...

2−pole resolver for three−phase AC motorsNumber of pole pairs for resolversNumber of steps / increments per revolution

� Voltage

5 V, 9 V,15 V,24 V, ...

Medium supply voltage

� Interface or signal level

Standard with safety function

THHES

TTLHTL for incremental encodersHiperface for absolute value encodersEnDatsin/cos 1 Vss

UKKFV

TTLHTL (for incremental encoders)Hiperface (for absolute value encoders)EnDatsin/cos 1 Vss

Technical dataGeneral data and operating conditions

4

� 24 BA 33.0005−EN 2.0

4 Technical data

4.1 General data and operating conditions

General data

Conformity and approval

Conformity

CE 1) 2006/95/EC Low−Voltage Directive

2009/125/EC ErP Directive

Approvals

� File No. E210321 UL/CSA

CCC

1) Does not apply to all products, � 11

Protection of persons and equipment

Degree of protection IEC/EN 60034−5 See nameplate

Degrees of protection only apply to horizontal installation

All unused plug−in connections must be sealed with protectivecaps or dummy connectors.

Thermal class F (155 °C)IEC/EN 60034−1

Exceedance of the temperature limit weakens or destroys theinsulation

Permissible voltage According to limiting curve A of the pulse voltage fromIEC / TS 60034−25 (image 14)

EMC

Noise emission IEC/EN 61800−3 Depending on the controller, see documentation for thecontroller.Noise immunity

Operating conditions

Ambient conditions

Climatic

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

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

1K3 (−20 °C ... +40 °C) > 3 months

Operation IEC/EN 60721−3−3 3K3 (−20 °C ... +40 °C) Without brake

3K3 (−10 °C ... +40 °C) With brake

3K3 (−15 °C ... +40 °C) With power reduction

> +40 °C With power reduction see,catalogue

Site altitude < 1000 m amsl − without power reduction> 1000 m amsl < 4000m amsl with power reduction, seecatalogue

Humidity Average relative humidity 85 %, without condensation

Electrical

Motor connection dependent on the controller (� 33)

Length of motor cable � inverter instructions

Length of cable for speed feedback

Mechanical

IEC/EN60721−3−3 3M6

Mechanical installationImportant notes

5

� 25BA 33.0005−EN 2.0

5 Mechanical installation

5.1 Important notes

� Danger!

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

ƒ Only move the drive with means of transport or hoists that have sufficientload−bearing capacity.

ƒ Ensure safe fixing.

ƒ Avoid shocks!

Mechanical installationPreparation

5

� 26 BA 33.0005−EN 2.0

Screw−in depths − B14 flange

Stop!

Observe maximally permissible screw−on depth for B14 flange!

S

C

Motor type / motor size Flange size [mm] c max. [mm] s

MDERA��056 V1 FT65 11 M5

MDERA��063 V1 FT75 14 M5

MDERA��071 V1 FT85 14 M6

MDERA��080 V1 FT100 16 M6

MDERA��090 V1 FT115 14 M8

MDERA��100 V1 FT130 19 M8

MDERA��112 V1 FT130 21 M8

MDERA��132 V1 FT165 22 M10

M��MA�N063 FT75 10 M5

M��MA�N071 FT85 10 M6

M��MA�N080 FT100 12 M6

M��MA�N080 FT130 16 M8

M��MA�N090 FT115 14 M8

M��MA�N090 FT130 16 M8

M��MA�N100 FT130 14 M8

M��MA�N112 FT130 16 M8

MHERA��080� FT100 15 M6

MHERA��090� FT115 16 M8

MHERA��100� FT130 18 M8

MHERA��112� FT130 19 M8

MHERA��132� FT165 23 M10

5.2 Preparation

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

Stop!

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

After a long storage period (> 1 year) you have to check whether moisture has enteredthe motor. For this purpose, measure the insulation resistance (measuring voltage500 VDC). In case of values �1k�per volt of rated voltage, dry the winding.

Mechanical installationPreparation

5

� 27BA 33.0005−EN 2.0

Stop!

During transport and storage, condensation drain holes (see Fig. 1) are sealedwith plugs to protect them from pollution. Remove the plugs prior tocommissioning!

�

Fig. 1 Motor with condensation drain holes

� Condensation drain holes

Note!

ƒ Depending on the mounting position, the condensation drain holes arealways at the bottom of the motor!

ƒ 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 condensatedrainage. If the condensation drain holes are not sealed again, the IP enclosureof the motor will be reduced. For horinzontal motor shafts to IP23 and forvertical motor shafts to IP20.

The required maintenance intervals strongly depend on the corresponding ambient andoperating conditions. Initially, the condensation drain holes should be opened morefrequently (at least once a week) to obtain experimental values for the condensatequantity arising.

Mechanical installationInstallation

5

� 28 BA 33.0005−EN 2.0

5.3 Installation

ƒ The mounting surface must be dimensioned for the design, weight and torque ofthe motor.

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

– Incorrect motor alignment reduces the service life of the roller bearings andtransmission elements.

Impacts on shafts can cause bearing damages.

ƒ Do not exceed the permissible range of ambient operating temperature ((� 24).

ƒ Fasten the motor securely

ƒ Ensure that the ventilation is not impeded. The exhaust air, also the exhaust air ofother machines next to the drive system, must not be taken in immediately.

ƒ During operation, surfaces are hot, up to 140 °C! Ensure that guard preventingaccidental contact is in place!

Ensure an even surface, solid foot/flange mounting and exact alignment if a direct clutchis connected. Avoid resonances with the rotational frequency and double mains frequencywhich may be caused by the assembly.

Use appropriate means to mount or remove transmission elements (heating) and coverbelt pulleys and clutches with a touch guard. Avoid impermissible belt tensions.

The machines are half−key balanced. The clutch must be half−key balanced, too. The visiblejutting out part of the key must be removed.

Designs with shaft end at the bottom must be protected with a cover which prevents theingress of foreign particles into the fan.

5.4 Assembly of built−on accessories

Follow the instructions below carefully. Please note that, in the event of impermissiblealteration or modification of the motor, you will lose all entitlements to make claims underwarranty and to benefit from product liability obligations.

ƒ Mount the transmission elements:

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

– Always use the centre bore in the motor shaft (in accordance with DIN 332, designD) for mounting.

– Tolerances of the shaft ends:�� 50 mm: ISO k6, > � 50 mm: ISO m6.

ƒ Only use an extractor for the disassembly.

ƒ When using belts for torque/power transmission:

– Tension the belts in a controlled manner.

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

Mechanical installationSpring−applied brakes

5

� 29BA 33.0005−EN 2.0

5.5 Spring−applied brakes

Important notes

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

Note!

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

The brakes serve to hold the axes at standstill or in the deenergised state.

They operate according to the closed−circuit principle, i.e. the brake is closed in thedeenergised 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 %.

If long motor supply cables are used, pay attention to the ohmic voltage drop along thecable and compensate for it with a higher voltage at the input end of the cable.

The following applies to Lenze system cables:

U *�� UB� �� 0.08��m � �� L� �� IB� U* [V] Resulting supply voltage

UB [V] Rated voltage of the brake

l [m] Cable length

IB [A] Rated current of the brake

Stop!

If the brake is not supplied with the correct voltage (see nameplate), the brakeis applied and may be overheated and destroyed by the motor that possiblycontinues to rotate.

The shortest operating times of the brakes are achieved by DC switching of the voltage anda suppressor circuit (varistor or spark suppressor). Without suppressor circuit, theoperating times may increase. A varistor/spark suppressor limits the breaking voltagepeaks. 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 theswitching operations per time unit.

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

For permissible operating speeds and characteristics, please see the respective valid motorcatalogue. Emergency stops at higher speeds are possible, but high switching energyincreases wear on the friction surfaces and the hub.

Stop!

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

The formula below provides a simplified way to calculate friction energy per switchingcycle which must not exceed the limit value for emergency stops that depends on the

Mechanical installationSpring−applied brakesLocking of the manual release

5

� 30 BA 33.0005−EN 2.0

operating frequency (� motor catalogue; Lenze drive solutions: Formulas, dimensioning,and tables).

Q� �� ½� �� Jges� �� 2� ��MK

MK � ML

Q [J] Friction energy

Jtot [kgm2] Total mass inertia (motor + load)

[1/s] Angular velocity =2��n/60, n= speed [rpm]

MK [Nm] Characteristic torque

ML [Nm] Load torque

Depending on the operating conditions and possible heat dissipation, the surfacetemperatures can be up to 140 °C.

� More detailed information on the used brakes is provided in the correspondingcatalogues.

5.6 Locking of the manual release

Scope of supply

Geared motor Shipping bag

GT−GNG−GST−010.iso/dmsGT−GXX−012.iso/dmsGT−GXX−013.iso/dms

� 1 Manual release lever with knob� 1 Terminal block� 1 Cheese head screw with nut

Mounting

�

�

�2

1

3

4

GT−GXX−014.iso/dms

� Cheese head screw with nut � Terminal block

Manual release lever with knob � Manual release shackle (brake)

Mechanical installationSpring−applied brakes

Locking of the manual release

5

� 31BA 33.0005−EN 2.0

Handling

Stop!

ƒ Lock the manual release only for service work!

ƒ The manual release must not be locked during operation, otherwise thebrake could be damaged!

ƒ Always secure the terminal block against loosening in every position withcheese head screw and nut!

Brake not released / operating position Brake released / service position

� �

�

GT−GXX−015.iso/dms GT−GXX−016.iso/dms

� Cheese head screw with nut � Terminal block

Manual release lever with knob � Fan cover

Electrical installationImportant notes

6

� 32 BA 33.0005−EN 2.0

6 Electrical installation

6.1 Important notes

� Danger!

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

Before working on the power connections, always disconnect the drivecomponent 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 andregional regulations!

Observe tolerances according to IEC/EN 60034−1:

– Voltage ±5 %

– Frequency ±2 %

– Wave form, symmetry (increases heating and affects electromagneticcompatibility)

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

ƒ 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.

– After the connection is completed, make sure that all connections on the terminalboard are firmly tightened.

ƒ The smallest air gaps between uncoated, live parts and against earth must not fallbelow the following values.

Electrical installationThree−phase AC motor operation on a frequency inverter

6

� 33BA 33.0005−EN 2.0

Minimum requirements for basicinsulation according to IEC/EN60664−1 (CE)

Higher requirements for UL design Motor diameter

3.87 mm6.4 mm < 178 mm

9.5 mm > 178 mm

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

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

6.2 Three−phase AC motor operation on a frequency inverter

Stop!

Motors MF�MA are only suitable for frequency inverter operation.

L−force three−phase AC motors M��MA are suitable for the operation on Lenze frequencyinverters and can be combined without restriction.

If another inverter is used for operation, the voltage peaks (Upp) for given rise times (tR) asshown in the diagram must not be exceeded.

MT−MDXMA−005.iso/dms

Fig. 2 Permissible voltage peaks for frequency inverter operation (characteristic according to IEC60034−25, curve A)

Electrical installationWiring according to EMC

6

� 34 BA 33.0005−EN 2.0

Possible countermeasures

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

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

ƒ Use filters, chokes;

ƒ Use of special motor cables.

6.3 Wiring according to EMC

The EMC−compliant wiring of the motors is described in detail in the OperatingInstructions for the Lenze controllers.

ƒ Use of metal EMC cable glands with shield connection.

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

6.3.1 Power connections on the terminal board

Motor

Power connections on the terminal board

Single−rotation motors Pole−changing motors

� �

MT_MXXXX_001.iso/dms

Dual−voltage motors Legend

��

L1/L2/L3 Power connection

TB1/TB2 Thermal contact − TCO

� Low speed

High speed

�� Low voltage

� High voltage

� PE connection (optional)

Electrical installationWiring according to EMC

Brake connection

6

� 35BA 33.0005−EN 2.0

Temperature monitoring

Terminal strip / terminal board

Meaning Designation in accordance with EN 60034−8 Note

Thermal contact TCOTB1 Max. 250 V~

Max. 1.6 A~TB2

PTC thermistor TP1

TP2

Thermal sensor +KTY R1Observe polarity

Thermal sensor −KTY R2

Terminal board or terminal possible for all thermal sensors

Blowers via blower terminal box / motor terminal box

External blower 3~

Terminalboard/terminal

Meaning Note

U1 Connection to L1 − mainsObserve direction of rotation! In case ofincorrect rotation, interchange L1 − L2

V1 Connection to L2 − mains

W1 Connection to L3 − mains

External blower 1~

Terminal board /terminal

Meaning Note

U1 Connection to L1− mains

V1 / U2 Connection to N − mains

6.3.2 Brake connection

Terminal Meaning Add−on

~ AC−excited brake (rectifier) Connection to L1 − mains

~

M

3~

Connection to N − mains

+ Brake connection

− Brake connection

Switching contact, DC switching

BD1 Brake, DC operated DC connection

BD2

MS1 Brake microswitch, release control Two−way switch (black)

MS2 NC contact (brown)

MS4 NO contact (blue)

MS1 Brake microswitch, wear control Two−way switch (black)

MS2 NC contact (blue)

MS4 NO contact (brown)

MS1 Brake microswitch, manual release Two−way switch (black)

MS2 NC contact (blue)

MS4 NO contact (grey)

Electrical installationPlug connectorsFeedback system

6

� 36 BA 33.0005−EN 2.0

6.3.3 Feedback system

Resolver

Terminal Designation Meaning

B1B2

+ Ref− Ref

Transformer windings(reference windings)

B3 Not assigned

B4B5

+ Cos− Cos

Stator winding cosine

B6B7

+ Sin− Sin

Stator winding sine

B8 Not assigned

Incremental encoder / sin/cos absolute value encoder with Hiperface

Terminal Designation Meaning

B1B2

+ UBGND

Supply +Mass

B3B4

AA

Track A / + COSTrack A inverse / − COS

B5B6

BB

Track B / + SINTrack B inverse / − SIN

B7B8

ZZ

Zero track / + RS485Zero track inverse / − RS485

B10 1) Shield − housing Shield − incremental encoder

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

6.4 Plug connectors

Stop!

ƒ Tighten the coupling ring of the connector.

ƒ If plugs without SpeedTec bayonet nut connectors are used, the connectorboxes for the power / encoder / fan connections must be secured by O−ringsif 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 nutconnectors are vibration−proof.

ƒ If SpeedTec bayonet nut connectors are used, O−rings must be removed (ifany)!

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

Electrical installationPlug connectors

Motor plug connection assignment

6

� 37BA 33.0005−EN 2.0

6.4.1 Motor plug connection assignment

Note!

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

6.4.2 Power connections

Power / brake / thermal sensor

ICN, 6−pole and 8−pole

6−pole (external view of poles)

Pin Standard description Meaning M23

12

BD1 / BA1BD2 / BA2

Brake + / Brake − /

MT−Steckverbinder−001.iso/dms

� PE PE conductor

456

UVW

Power phase UPower phase VPower phase W

8−pole (external view of poles)

Pin Standard description Name M23

1 U Power phase U


� PE PE conductor

3 W Power phase W

4 V Power phase V

AB

TB1 / TP1 / R1TB2 / TP2 / R2

Thermal sensor TCO /PTC / + KTYTCO / PTC / − KTY

CD

BD1 / BA1BD2 / BA2

Brake + / Brake − /

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


1 U Power phase U


� PE PE conductor

3 W Power phase W

4 V Power phase V

AB

TB1 / TP1 / R1TB2 / TP2 / R2

Thermal sensor TCO /PTC / + KTYTCO / PTC / − KTY

CD

BD1 / BA 1BD2 / BA2

Rectifier: Switchingcontact

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

Electrical installationPlug connectorsPower connections

6

� 38 BA 33.0005−EN 2.0

Fan

ICN, 7−pole

Single−phase (external view of poles)


� PE PE conductor


12

U1U2

Fan

3456

Not assigned

Three−phase (external view of poles)


� PE PE conductor


1 U Fan

2 Not assigned

3 V Fan

4Not assigned

5

6 W Fan

Electrical installationPlug connectors

Feedback system

6

� 39BA 33.0005−EN 2.0

6.4.3 Feedback system

Resolver / incremental encoder / absolute value encoder

ICN, 12−pole

Resolver (external view of poles)

Pin Designation Meaning M23

12

+ Ref− Ref

Transformer windings(reference windings)


3 Not assigned

45

+ Cos− Cos

Stator windingscosine

67

+ Sin− Sin

Stator windingsSine

8910

Not assigned

1112

+ KTY− KTY

Thermal sensor KTY

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


1 B Track B / + SIN


23

AA

Track A inverse / − COSTrack A / + COS

45

+ UBGND

Supply +Earth

67

ZZ

Zero track inverse / − RS485Zero track / +RS485

8 Not assigned

9 B Track B inverse / − SIN

10 Not assigned

1112

+ KTY− KTY

KTY thermal detector

Circular connector

4−pole

Incremental encoder (external view of poles)


1 + UB Supply +


2 B Track B

3 GND Mass

4 A Track A

Electrical installationTerminal box HAN connectors

6

� 40 BA 33.0005−EN 2.0

� Further information is provided in the system cables system manual at:

www.Lenze.com � Download � Technical documentation � Library �X1_Accessories �X15_External_accessories � X153_System_cables

6.5 Terminal box HAN connectors

Contact pin HAN−Modular 16 A

HAN−GTM−007.iso HAN−GTM−004.iso

Contact pin HAN−Modular 40 A


Terminal box

Module Contact Core colour Connection

a 1 brown Terminal board: U1

2 black Terminal board: V1

3 red Terminal board: W1

b Blind module

c 1 white or blue Thermal sensor: +KTY / PTC / TCO

2 black Brake + /

3 black Brake − /

4 blue or brown Rectifier: Switching contact

5 blue or brown Rectifier: Switching contact

6 white or black Thermal sensor: −KTY / PTC / TCO

Electrical installationTerminal box HAN connectors

6

� 41BA 33.0005−EN 2.0

Contact pin HAN 10E


Terminal box

Contact Core colour Connection

1 brown Terminal board: U1



4 black Holding brake + /

5 black Holding brake − /


7 brown Terminal board: U2


9 white Thermal sensor: +KTY / PTC / TCO

10 white Thermal sensor: −KTY / PTC / TCO

Note!

Carry out the wiring in �or �in the counter plug:

ƒ � − wiring: 6−7−8

ƒ � − wiring: 1−6/2−7/3−8

Commissioning and operationImportant notes

7

� 42 BA 33.0005−EN 2.0

7 Commissioning and operation

7.1 Important notes

For trial run without output elements, lock the featherkey. Do not deactivate theprotective 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 intendeddirection of rotation.

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

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

ƒ Measure the insulation resistance, in case of values �1 k�per volt of rated voltage, drythe winding.

ƒ Have all screwed connections of the mechanical and electrical parts been firmlytightened?

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

ƒ Has the PE conductor been connected correctly?

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

ƒ Is the controller correctly parameterised for the motor?(� Controller operating instructions)

ƒ Are the electrical connections o.k.?

ƒ Does the motor connection have the correct phase sequence?

ƒ Are rotating parts and surfaces which can become very hot protected againstaccidental contact?

ƒ Is the contact of good electrical conductivity if a PE connection on the motor housingis used?

Commissioning and operationFunctional test

7

� 43BA 33.0005−EN 2.0

7.3 Functional test

ƒ Check all functions of the drive after commissioning:

ƒ Direction of rotation of the motor

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

ƒ Torque behaviour and current consumption

ƒ Function of the feedback system

7.4 During operation

Stop!

ƒ Fire hazard! Do not clean or spray motors with flammable detergents orsolvents.

ƒ Avoid overheating! Deposits on the drives impede the heat dissipationrequired and have to be removed regularly.

� Danger!

During operation, motor surfaces must not be touched. According to theoperating status, the surface temperature for motors can be up to 140°C. Forthe protection against burn injuries, provide protection against contact, ifnecessary. Observe coolingoff times!

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

ƒ Unusual noises

ƒ Oil spots on drive end or leakages

ƒ Irregular running

ƒ Increased vibration

ƒ Loose fixing elements

ƒ Condition of electrical cables

ƒ Speed variations

ƒ Impeded heat dissipation

– Deposits on the drive system and in the cooling channels

– Pollution of the air filter

In case of irregularities or faults: (� 57.

Maintenance/repairImportant notes

8

� 44 BA 33.0005−EN 2.0

8 Maintenance/repair

8.1 Important notes

� Danger!

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

Before working on the power connections, always disconnect the drivecomponent 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 lowvoltage 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 nondriveend), remove plug before commissioning. Seal bore holes with grease.

8.2 Maintenance intervals

Inspections

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

8.2.1 Motor

ƒ Only the bearings and shaft sealing rings become worn.

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

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

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

Maintenance/repairMaintenance intervals

Spring−operated brakes

8

� 45BA 33.0005−EN 2.0

8.2.2 Spring−operated brakes

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

Primarily, the necessary maintenance intervals for industrial brakes result from the loadduring operation. When calculating the maintenance interval, all causes for wear must betaken into account, ((� 47). For brakes with low loads such as holding brakes withemergency stop, we recommend a regular inspection at a fixed time interval. To reduce thecost, the inspection can be carried out along with other regular maintenance work in theplant if necessary.

Stop!

Stable properties of the organic friction lining are only achieved in the case ofcontinuous use. The readiness for operation of the brake has to be ensuredwith a braking energy that is equivalent to one emergency stop per week.Unplanned emergency stops occurring at a sufficient frequency have the sameeffect.

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

Versions Service brakes Holding brakes with emergencystop

INTORQ BFK458−�� E / N � according to service lifecalculation

� otherwise every six months� after 4,000 operating hours at

the latest

� at least every two years� after 1 million cycles at the

latest� provide shorter intervals in the

case of frequent emergencystops

INTORQ BFK458−�� L � at least every two years� after 10 million cycles at the

latest� provide shorter intervals in the

case of frequent emergencystops

Maintenance/repairMaintenance operationsMotor

8

� 46 BA 33.0005−EN 2.0

8.3 Maintenance operations

8.3.1 Motor

Stop!

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

ƒ Only work on the drive system when it is in a deenergised state!

ƒ Do not remove plugs when voltage is being applied!

ƒ Hot motor surfaces up to 140 °C. Observe cooling times!

ƒ Remove loads acting on motors or secure loads acting on the drive!

8.3.2 Spring−operated brakes

The brake is mounted to the N−end shield of the motor. Remove the fan cover or blowerunit to check, maintain, or set the brake.

Note!

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

Generally observe the following for inspections and maintenance works:

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

ƒ After replacing the rotor, the original braking torque will not be reacheduntil the run−in operation of the friction surfaces has been completed. Afterreplacing the rotor, run−in armature plates and counter friction faces havean increased initial rate of wear.

Maintenance/repairMaintenance operations

Spring−operated brakes

8

� 47BA 33.0005−EN 2.0

Wear on spring−applied brakes

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

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

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

Component Effect Influencing factors Cause

Friction lining Wear on the friction lining Applied friction energy Braking during operation(impermissible, holdingbrakes!)

Emergency stops

Overlapping wear when thedrive starts and stops

Active braking by the drivemotor with the help of thebrake (quick stop)

Number of start−stop cycles Starting wear if motor ismounted in a position withthe shaft vertical, even if thebrake is open

Armature plate andflange

Running−in of armatureplate and flange

Applied friction energy Friction between the brakelining and the armatureplate or flange e.g. duringemergency braking orservice brake operation

Teeth of the brakerotor

Teeth wear (primarily at therotor end)

Number of start−stop cycles,Level of the braking torque,Dynamics of the application,Speed fins in operation

Relative movement andimpacts between brakerotor and brake hub

Armature platebracket

Armature plate, cap screwsand bolts are deflected

Number of start−stop cycles,Level of braking torque

Load changes and impactsdue to reversal error duringinteraction betweenarmature plate, cap screwsand guide bolts

Springs Fatigue failure of the springs Number of switchingoperations of the brake

Axial load cycle and shearingstress on the springs due toradial reversing error of thearmature plate

Tab. 1 Causes for wear

Maintenance/repairMaintenance operationsChecking the component parts

8

� 48 BA 33.0005−EN 2.0

8.3.3 Checking the component parts

With assembled brake � Check function of ventilation and control� Measure the air gap (adjust if necessary)� Measure the rotor thickness (replace rotor if necessary)� Thermal damage to armature plate or flange (dark blue

tarnishing)

� 49 � 49� 48

After removing the brake � Check clearance of the rotor gearing (replace worn−outrotors)

� Wear of the torque bearing on threaded sleeves, dowelpins and armature plate

� Checking springs for damage� Checking armature plate and flange/endshield

– Evenness size 06...12 < 0,06 mm– Evenness from size 14 on < 0,1 mm– max. run−in depth = rated air gap of brake size

� 50

Check the mounting dimension of the manual release

Stop!

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

(� Operating Instructions INTORQ BFK458)

Size sLü (mm) s +0.1 (mm) s + sLü (mm)

06

0.2 1 1.208

10

12

0.3 1.5 1.814

16

180.4 2 2.4

20

25 0.5 2.5 3

8.3.4 Checking the rotor thickness

� 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 aflanged edge at the outer diameter of the friction plate.

3. Compare measured rotor thickness with minimally permissible rotor thickness(values � 51).

4. If required, exchange the entire rotor. Description � 50.

Maintenance/repairMaintenance operations

Check air gap

8

� 49BA 33.0005−EN 2.0

8.3.5 Check air gap

1. Check the air gap "sLü" near the fixing screws between armature plate and statorusing a feeler gauge (� 51).

2. Compare the measured air gap with the maximum permissible air gap "sLümax."(� 51).

3. If necessary, adjust the air gap to "sLürated" (� 49).

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 platemust 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 instructionsBFK 458, bridge half−wave rectifier) must equal the voltage for the holding. Adeviation of up to ±10 % is permissible.

8.3.7 Readjustment of air gap

� Danger!

The brake must be free of residual torque.

Stop!

Observe for the flange version when it is fixed with additional screws:

Behind the threaded holes for the screws in the flange there must be clearingholes in the endshield. Without clearing holes the minimum rotor thicknesscannot be used. Under no circumstances may the screws be pressed againstthe endshield.

1. Unbolt screws (Fig. 5).

2. Screw the threaded sleeves into the stator by using a spanner. 1/6 revolution reducesthe air gap by approx. 0.15 mm.

3. Tighten screws, for torques (� 51).

4. Check the air gap "sLü" near the screws using a feeler gauge, "sLürated" (� 51).

5. If the difference between the measured air gap and "sLürated" is too large, repeat thereadjustment.

Maintenance/repairMaintenance operationsRotor replacement

8

� 50 BA 33.0005−EN 2.0

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 severelygouged, it must be replaced. If the end shield is severely gouged, the friction surfacemust be reprocessed.

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

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

Distance = rotor thickness + sLürated − height of head

"sLürated", (� 51)

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

11. Completely mount the new rotor and set the stator, (� 51).

12. Connect the connecting cable again.

Maintenance/repairInstallation of a spring−applied brake

Brake characteristics

8

� 51BA 33.0005−EN 2.0

8.4 Installation of a spring−applied brake

8.4.1 Brake characteristics

Type sLürated +0.1 mm−0.05 mm

sLümax. Service brake

sLümax. Holding

brake

Max. adjustment,permissible wear

path

Rotor thickness Tighteningtorque of thefixing screws

[ mm ] [ mm ] [ mm ] [ mm ] min. 1) [mm] max. [mm] [Nm]

BFK458−06

0.2 0.5 0.3 1.5

4.5 6.0 3.0

BFK458−08 5.5 7.0 5.9

BFK458−10 7.5 9.0 10.1

BFK458−12

0.3 0.75 0.45

2.0 8.0 10.0 10.1

BFK458−14 2.5 7.5 10.0 24.6

BFK458−16 3.5 8.0 11.5 24.6

BFK458−180.4 1.0 0.6

3.0 10.0 13.0 24.6

BFK458−20 4.0 12.0 16.0 48.0

BFK458−25 0.5 1.25 0.75 4.5 15.5 20.0 48.0

Tab. 2 Characteristics of the INTORQ BFK458 spring−applied brake

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

8.4.2 Installation of the brake

Stop!

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

3

4

15

K14.0502/8

Fig. 3 Assembly of the rotor

3 Rotor 4 Hub 15 Endshield

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

Stop!

Please note the following for the version "brake with shaft seal in adjusternut":

Maintenance/repairInstallation of a spring−applied brakeInstallation of the brake

8

� 52 BA 33.0005−EN 2.0

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

3. When assembling the stator (7) push the shaft seal 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).

– Tighten the screws evenly, tightening torque (� 51).

9

7

10

�

KL458−012−a

Fig. 4 Torque adjustment

7 Stator 9 Threaded sleeve � sLürated

10 Allen screw

1. Check the air gap "sLü" near the screws (10) using a feeler gauge and compare thevalues to the values for "sLürated" in the table (� 51).

Note!

Do not insert feeler gauge more than 10 mm between armature plate (2) andstator (1.1)!

If "sLü" (� 51) is not within the tolerance, readjust the air gap.

Maintenance/repairInstallation of a spring−applied brake

Readjustment of air gap

8

� 53BA 33.0005−EN 2.0

8.4.3 Readjustment of air gap

� Danger!

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

+

−9

7

10

KL458−013−a

Fig. 5 Air gap adjustment

7 Stator 10 Allen screw9 Threaded sleeve

If "sLürated" is not within the tolerance, readjust the air gap (� 49).

8.4.4 Assembly of the friction plate, sizes 06 to 16

15

12

KL458−009−a

Fig. 6 Mounting the friction plate

12 Friction plate 15 End shield

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.

Maintenance/repairInstallation of a spring−applied brakeAssembly of the flange

8

� 54 BA 33.0005−EN 2.0

8.4.5 Assembly of the flange

15

6

6.1

KL458−008−a

Fig. 7 Mounting the flange

6 Flange 15 End shield6.1 Set of fastening screws

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

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

3. Tighten the screws (6.1) evenly, for the correct tightening torques, (� 51).

4. Check screw head height. The height must not exceed the minimal rotor thickness.We recommend using DIN 6912 screws, (� 51).

Mounting the flange without additional screws

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

2. Mount the brake.

Maintenance/repairRepair

Assembly of the cover seal

8

� 55BA 33.0005−EN 2.0

8.4.6 Assembly of the cover seal

15

13

12

10

7

1 7 1 15613 12 13 10

KL458−010−a KL458−007−a

Fig. 8 Assembly of the cover seal

1 Armature plate 10 Allen screw 15 Endshield6 Flange 12 Friction plate7 Stator 13 Cover seal

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

ƒ It is recommended to have all repairs performed by Lenze Service.

ƒ Delivery of spare parts is available upon request.

Maintenance/repairDisposal

8

� 56 BA 33.0005−EN 2.0

8.6 Disposal

Protect the environment! Packing material can be recycled. Dispose of your separatedresources according to the waste disposal regulations or via a waste managementcompany.

The following table provides recommendations for an environmentally friendly disposalof the machine and its components.

What? Where?

Transportmaterial

Pallets Return to the manufacturer orforwarder

Packaging material Cardboard box to waste paperPlastics to plastics recycling orresidual wasteReuse or dispose of wood wool

Lubricants Oil, greaseDetergents and solventsPaint residues

Dispose according to currentregulations

Components Housing:

Bearings, gear wheel shafts:Seals, electronic scrap

Cast iron, aluminium,copperSteelHazardous waste

Separate valuable substances anddispose

Troubleshooting and fault elimination 9

� 57BA 33.0005−EN 2.0

9 Troubleshooting and fault elimination

If faults occur during operation of the drive system:

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

Note!

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

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

� Danger!

ƒ Only work on the drive system when it is in a deenergised state!

ƒ Hot motor surfaces of up to 140 °C. Observe cooling times!

ƒ Remove loads acting on motors or secure loads acting on the drive!

Fault Cause Remedy

Motor too hot

Can only be evaluated bymeasuring the surfacetemperature:� Non−ventilated motors

� 140 °C� Externally ventilated or

self−ventilated motors� 110 °C

Insufficient cooling air, blocked airducts.

Ensure unimpeded circulation of cooling air

Preheated cooling air Ensure a sufficient supply of fresh cooling air

Overload, with normal mainsvoltage the current is too high andthe speed too low

Use larger drive (determined by power measurement)

Rated operating mode exceeded (S1to S8 IEC/EN 60034−1)

Adjust rated operating mode to the specified operatingconditions. Determination of correct drive by expert or Lenzecustomer service

Loose contact in supply cable(temporary single−phase operation!)

Tighten loose contact

Fuse has blown (single−phasing!) Replace fuse

Overloading of the drive � Check load and, if necessary, reduce by means of longerramp−up times

� Check winding temperature

Heat dissipation impeded bydeposits

Clean surface and cooling ribs of the drives

Motor does not start Voltage supply interrupted � Check error message on the drive controller� Check electrical connection � 32

Controller inhibited � Check display at drive controller� Check controller enable

Fuse has blown Replace fuse

Encoder cable broken � Check error message at drive controller� Check encoder cable

Brake does not release Check electrical connection, � 32

Check air gap, � 52

Check continuity of magnetic coil

Drive is blocked Check components for easy movement, remove foreignparticles if necessary

Motor cable polarity is reversed Check electrical connection, � 32

Motor suddenly stops anddoes not start again

Overload monitoring of the inverterresponds

� Check settings on controller� Reduce load by means of longer acceleration times

Troubleshooting and fault elimination9

� 58 BA 33.0005−EN 2.0

RemedyCauseFault

Incorrect direction ofrotation of the motor,correct display on thecontroller

Motor cable polarity is reversed Check and correct polarity

Encoder cable polarity is reversed

Motor rotates normallybut does not generates theexpected torque

Motor cable interchanged cyclically Connect the phases at the motor cable connection correctly

Motor rotates in onedirection at maximumspeed in an uncontrolledmanner

Motor cable interchanged cyclically Check motor connection and, if necessary, correct it

Polarity of encoder cable reversed Check encoder connection and, if necessary, correct it

Motor rotates slowly inone direction and cannotbe influenced by the drivecontroller

Polarity of motor cable and encodercable reversed

Check the polarity and correct it

Unsteady running Shielding of motor cable or resolvecable inadequate

Check shielding and earth connection

Gain of the drive controller too high Adapt gain of the controller (see operating instructions fordrive controller)

Vibrations Insufficiently balancing of couplingelements or machine

Rebalance

Inadequate alignment of drive train Realign machine, if necessary, check foundation

Loose fixing screws Check screwed connections and tighten them if necessary

Running noises Foreign particles inside the motor Repair by manufacturer if necessary

Bearing damage

Surfacetemperature > 140°C

Overload of the drive � Check overload and reduce through longer accelerationtimes, if necessary

� Check winding temperature

Heat dissipation impeded by dirtdeposits

Clean surface and cooling ribs of the drives

Notes �

� 59BA 33.0005−EN 2.0

�© 03/2012

� Lenze Drives GmbHPostfach 10 13 52D−31763 HamelnGermany

Service Lenze Service GmbHBreslauer Straße 3D−32699 ExtertalGermany

� +49�(0)51�54�/ 82−0 � 00�80�00�/ 24�4�68�77 (24 h helpline)

� +49�(0)51�54�/ 82−28 00 � +49�(0)51�54�/ 82−13 96

� [email protected] � [email protected]

� www.Lenze.com

BA 33.0005−EN � .J), � � 2.0 � TD09

10 9 8 7 6 5 4 3 2 1

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