1gh5-en.pdf

Operating Instructions Edition 02/2008

DC motor

Type 1GH5

22.02.2008 13:26

Introduction 1

Safety notes 2

Description 3

Preparations for use 4

Assembling 5

Connection 6

Commissioning 7

Operation 8

Maintenance 9

Spare Parts 10

Decommissioning 11

Appendix A

DC motor

Operating Instructions

Edition 02/2008

This documentation pertains to Type 1GH5

Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage Note the following:

WARNING This device may only be used for the applications described in the catalog or the technical description and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Automation and Drives Postfach 48 48 90327 NRNBERG GERMANY

A5E02099247A AA 02/2008

Copyright Siemens AG . Technical data subject to change

A5E02099247A AA Siemens AG Operating Instructions V1.04 1GH5 3

Table of contents 1 Introduction................................................................................................................................................ 9

1.1 About these operating instructions ................................................................................................9 2 Safety notes............................................................................................................................................. 11

2.1 Observing the five safety rules.....................................................................................................11 2.2 Safety and application instructions ..............................................................................................11

3 Description............................................................................................................................................... 13 3.1 Applications..................................................................................................................................13 3.2 Relevant standards ......................................................................................................................13 3.3 Rating plate ..................................................................................................................................13 3.4 Motor variant 1GH........................................................................................................................15 3.5 Terminal box ................................................................................................................................15 3.6 Rolling-contact bearing bushes....................................................................................................16

4 Preparations for use ................................................................................................................................ 17 4.1 Shipment and packaging .............................................................................................................17 4.1.1 Scope of delivery .........................................................................................................................17 4.2 Transport and storage..................................................................................................................18 4.2.1 Transporting.................................................................................................................................18 4.2.2 Storage.........................................................................................................................................19 4.2.3 Protection against corrosion ........................................................................................................21

5 Assembling .............................................................................................................................................. 23 5.1 Installing the motor.......................................................................................................................23 5.2 Noise emission.............................................................................................................................24 5.3 Connecting ventilation / cooling systems.....................................................................................24 5.4 Aligning the motor ........................................................................................................................25 5.5 Mounting the motor securely........................................................................................................25 5.6 Pushing on the power output elements .......................................................................................26

6 Connection .............................................................................................................................................. 27 6.1 General ........................................................................................................................................27 6.2 Cable entry...................................................................................................................................28 6.3 Connecting the main circuit..........................................................................................................28 6.4 Connecting the earthing conductor..............................................................................................30 6.5 Internal equipotential bonding......................................................................................................32

Table of contents

A5E02099247A AA 4 Siemens AG Operating Instructions V1.04 1GH5

6.6 Connecting auxiliary circuits........................................................................................................ 32 6.7 Connecting an external fan ......................................................................................................... 33 6.8 Final measures............................................................................................................................ 33

7 Commissioning ........................................................................................................................................ 35 7.1 Safety information ....................................................................................................................... 35 7.2 Measures to be performed prior to startup.................................................................................. 36 7.3 Checking the insulation resistance ............................................................................................. 37 7.4 Power on ..................................................................................................................................... 38 7.5 Deactivating ................................................................................................................................ 39 7.6 Final measures............................................................................................................................ 40

8 Operation................................................................................................................................................. 41 8.1 Safety information ....................................................................................................................... 41 8.2 Switch on..................................................................................................................................... 42 8.3 Deactivating ................................................................................................................................ 43 8.4 Special operating conditions ....................................................................................................... 43 8.5 Stoppages ................................................................................................................................... 43 8.6 Faults........................................................................................................................................... 44 8.6.1 Safety notes during operation ..................................................................................................... 44 8.6.2 Faults in operation....................................................................................................................... 46 8.6.3 Rolling-contact bearing faults...................................................................................................... 47 8.6.4 Brush faults ................................................................................................................................. 48 8.6.5 Commutator faults....................................................................................................................... 49

9 Maintenance ............................................................................................................................................ 51 9.1 Servicing...................................................................................................................................... 51 9.1.1 Safety information ....................................................................................................................... 51 9.1.2 Initial inspection........................................................................................................................... 52 9.1.3 MTTR .......................................................................................................................................... 53 9.1.4 Main inspection ........................................................................................................................... 54 9.1.5 Lubrication intervals and lubrication types for the operation of rolling-contact bearings ............ 55 9.1.6 Cleaning ...................................................................................................................................... 56 9.1.7 Checking the carbon brushes ..................................................................................................... 57 9.1.8 Replacement of carbon brushes ................................................................................................. 58 9.1.9 Adjusting the brush rocker .......................................................................................................... 58 9.1.10 Maintenance of commutator........................................................................................................ 59 9.1.11 Maintenance of terminal boxes ................................................................................................... 61 9.2 Repair.......................................................................................................................................... 62 9.2.1 Sicherheitshinweise .................................................................................................................... 62 9.2.2 Dismantling the machine............................................................................................................. 63 9.2.3 Dismantling the bearings............................................................................................................. 64 9.2.4 Assembling the motor ................................................................................................................. 64 9.2.5 Mounting the bearings................................................................................................................. 65 9.2.6 Tightening torques for bolted connections .................................................................................. 65 9.2.7 Speed sensor .............................................................................................................................. 66 9.2.7.1 Disassembling and assembling a speed sensor with a conical hub........................................... 66 9.2.7.2 Disassembling and assembling the speed sensor for overhung mounting ................................ 68 9.2.7.3 Disassembling and assembling the speed sensor for construction type IM B5.......................... 69

Table of contents


10 Spare Parts.............................................................................................................................................. 73 10.1 Ordering data ...............................................................................................................................73 10.2 Ordering spare parts ....................................................................................................................73 10.3 Stator and rotor for 1G.5, 1H.5, shaft heights 500 to 630............................................................74 10.4 Replacing rolling-contact bearings...............................................................................................75 10.5 Rolling-contact bearing, drive end ...............................................................................................75 10.5.1 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................75 10.6 Rolling-contact bearing, non-drive end ........................................................................................76 10.6.1 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................76 10.7 Terminal boxes.............................................................................................................................77 10.7.1 1XB7710 main terminal box.........................................................................................................77 10.7.2 1XB7942 main terminal box.........................................................................................................78 10.7.3 Auxiliary terminal box...................................................................................................................79 10.8 Speed sensor ...............................................................................................................................80 10.8.1 Shaft heights 180 to 630 ..............................................................................................................80 10.8.1.1 Speed sensor with conical hub ....................................................................................................80 10.8.1.2 Speed sensor for overhung mounting..........................................................................................81 10.8.1.3 Speed sensor for construction type IM B5...................................................................................82

11 Decommissioning .................................................................................................................................... 83 11.1 Disposal of components with electrical insulation........................................................................83

A Appendix.................................................................................................................................................. 85 A.1 SIEMENS Service Center ............................................................................................................85 A.2 Starting check list .........................................................................................................................86 A.3 Commissioning check list.............................................................................................................87 A.4 Inspection check list.....................................................................................................................88 A.5 Notes............................................................................................................................................90

Index........................................................................................................................................................ 93

Tables Table 3-1 Relevant standards ......................................................................................................................13 Table 3-2 Rating plate data..........................................................................................................................14 Table 3-3 Insulation classes of series 1G... and 1H... .................................................................................14 Table 4-1 Tightening torques for the shaft screw on the rotor shipping brace.............................................18 Table 6-1 Terminal designations in example B1..........................................................................................28 Table 6-2 Air insulation clearances ..............................................................................................................29 Table 6-3 Terminal box connection data......................................................................................................29 Table 6-4 Tightening torque of screws with cable lugs ................................................................................31 Table 6-5 Tightening torque of screws with ground terminals .....................................................................31 Table 7-1 Winding insulation resistance at 25 C ........................................................................................38 Table 8-1 Vibration magnitude as a function of vibration frequency............................................................42

Table of contents


Table 8-2 Faults in operation....................................................................................................................... 46 Table 8-3 Rolling-contact bearing faults...................................................................................................... 47 Table 8-4 Brush faults ................................................................................................................................. 48 Table 8-5 Commutator faults....................................................................................................................... 49 Table 9-1 MTTR in fault-free operation ....................................................................................................... 53 Table 9-2 Suitable greases for rolling-contact bearings (down to -20 C) .................................................. 55 Table 9-3 Commutator overhaul - minimum permissible diameter ............................................................. 60 Table 9-4 Tightening torques dependent on thread size [Nm 10%] ........................................................ 66 Table 9-5 Recommended torques for tightening the shaft journal .............................................................. 67 Table 9-6 Recommended torques for tightening the shaft journal .............................................................. 68 Table 9-7 Recommended torques for tightening the half-coupling ............................................................. 70 Table 9-8 Tightening torques for joining coupling ....................................................................................... 71 Table 10-1 Spare parts stator and rotor 1G.5, 1H.5, shaft heights 500 to 630............................................. 74 Table 10-2 Spare parts rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630............................. 75 Table 10-3 Spare parts rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630............................. 76 Table 10-4 Spare parts main terminal box 1XB7710 .................................................................................... 77 Table 10-5 Spare parts main terminal box 1XB7942 .................................................................................... 78 Table 10-6 Spare parts auxiliary terminal box............................................................................................... 79 Table 10-7 Spare parts speed sensor with conical hub for shaft heights 180 to 630 ................................... 80 Table 10-8 Spare parts speed sensor for overhung mounting for shaft heights 180 to 630......................... 81 Table 10-9 Spare parts speed sensor for construction type IM B5 for shaft heights 180 to 630.................. 82 Table 11-1 Heat treating................................................................................................................................ 84 Table 11-2 Afterburning of the binding material vapors ................................................................................ 84 Table A-1 Technical support........................................................................................................................ 85 Table A-2 Starting check list ........................................................................................................................ 86 Table A-3 Commissioning check list............................................................................................................ 87 Table A-4 Check list for inspection at standstill ........................................................................................... 88 Table A-5 Check list for inspection in operation .......................................................................................... 89

Figures Figure 3-1 Example of rating plate ............................................................................................................... 14 Figure 3-2 Machine type 1GH... ................................................................................................................... 15 Figure 4-1 Rotor shipping brace device without coupling (1) and with coupling (2)..................................... 18 Figure 6-1 Connection of main terminals with cable lug............................................................................... 29 Figure 6-2 Connection of auxiliary terminals with cable lug ......................................................................... 30 Figure 6-3 Connection without cable lugs .................................................................................................... 30

Table of contents


Figure 9-1 Adjusting the brush rocker: Fixed part (1), brush rocker (2) ........................................................59 Figure 9-2 View and section A - B.................................................................................................................60 Figure 9-3 Details X and Y ............................................................................................................................61 Figure 9-4 Speed sensor assembly...............................................................................................................67 Figure 9-5 Speed sensor assembly...............................................................................................................69 Figure 9-6 Speed sensor assembly...............................................................................................................70 Figure 10-1 Stator and rotor 1G.5, 1H.5, shaft heights 500 to 630.................................................................74 Figure 10-2 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................75 Figure 10-3 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................76 Figure 10-4 Main terminal box 1XB7710.........................................................................................................77 Figure 10-5 Main terminal box 1XB7942.........................................................................................................78 Figure 10-6 Auxiliary terminal box...................................................................................................................79 Figure 10-7 Speed sensor with conical hub for shaft heights 180 to 630 .......................................................80 Figure 10-8 Speed sensor for overhung mounting for shaft heights 180 to 630.............................................81 Figure 10-9 Speed sensor for construction type IM B5 for shaft heights 180 to 630......................................82


Introduction 11.1 About these operating instructions

These operating instructions describe the machine and explain best practices in machine handling, from initial delivery to final disposal of the equipment. Read these instructions before you handle the machine to become familiar with its design and operating principles and thus ensure safe, problem-free machine operation and long service life. This document and/or excerpts thereof may not be reproduced or copied without express, written permission from SIEMENS. Its content may not be passed to third parties or used for any proscribed purpose. We strive continually to improve the quality of information provided in these instructions. Please therefore contact us if you discover any errors or wish to make suggestions for improvements. For contact information, please refer to Chapter "Siemens Service Center (Page 85)" If the description in these operating instructions is inconsistent in any regard with the actual supplied machine, you must either make an informed decision as to the best course of action or, if you are uncertain, contact the Siemens Service Center (Page 85). Always follow the safety instructions and notices in these instructions.

Text format features In addition to the safety-related notices and instructions which you must read, you will find the text in these instructions is formatted in the following way: 1. Handling instructions are always formatted as a numbered list. Always perform the steps

in the order given. Lists are formatted as bulleted lists.

Lists on the second level are hyphenated.

Note A Note is an important item of information about the product, handling of the product or the relevant section of the document. Notes provide you with help or further suggestions/ideas.


Safety notes 22.1 Observing the five safety rules

For your personal safety and to prevent material damage when working on the device, always observe the safety instructions on the product and the following five safety rules: You must read the information provided in "Safety information".

The five safety rules: 1. isolate, 2. Protect against reconnection, 3. verify that the equipment is not live, 4. Ground and short circuit, 5. Cover or enclose adjacent components that are still live

Qualified personnel Commissioning and operation of this machine are to be carried out by qualified personnel only. For the purpose of the safety information in this Instruction Manual, a qualified person is someone who is authorized to energize, ground, and tag equipment, systems, and circuits in accordance with established safety procedures.

2.2 Safety and application instructions The safe use of electrical machines

WARNING

Rotating or live parts Rotating or live parts are dangerous. Fatal or severe injuries and substantial material damage can occur if the required covers are removed or if the machines are not handled, operated, or maintained properly. Only remove covers in accordance with regulations and operate machines correctly. Perform regular maintenance on the machine.

Safety notes 2.2 Safety and application instructions


Qualified personnel These operating instructions only contain the information that is necessary for the machines to be used by qualified personnel in accordance with their intended purpose. Those responsible for plant safety must ensure the following: The basic planning work for the system and all work relating to transportation, assembly,

installation, commissioning, maintenance and repairs is carried out by qualified personnel and checked by responsible, suitably skilled personnel.

The operating instructions and machine documentation are always available. The technical data and specifications relating to installation, connection, ambient and

operating conditions are taken into account at all times. The system-specific installation and safety regulations are observed. Personal protective equipment is used. Work on or in the vicinity of these machines by unqualified persons is prohibited. If the machines are used outside industrial areas, the installation site must be

safeguarded against unauthorized access by means of suitable protection facilities (e.g., safety gates) and appropriate warning signs.

Note

Siemens Service Center We recommend engaging the support and services of your local Siemens Service Center (Page 85) for all planning, installation, commissioning, and maintenance work.

[ID 2.02]


Description 33.1 Applications

Series 5, 6 and 7 DC motors are designed with open-circuit cooling or as closed-circuit-cooled machines with laminated stator yoke. They are designed for the widest possible range of drive and energy conversion applications and comply with the harmonized standards of series IEC / EN 60034 (VDE 0530). They are not approved for operation in hazardous zones and areas. Unless otherwise specified, the rated powers apply for continuous operation at a coolant temperature of 40 C and an installation altitude of up to 1000 m above sea level. Please note any data to the contrary on the rating plate. Operating conditions must comply with all specifications on the rating plate. DC motors are components for installation in machines as defined by the Machinery Directive 89/392/EEC. The system may not be commissioned until it has been proven that the final product is in conformance with this directive. Please refer to IEC / EN 60204-1 in this respect.

3.2 Relevant standards Information about degree of protection, cooling and construction type can be found on the rating plate. The DC machines comply with the following standards:

Table 3-1 Relevant standards Title Standard General specifications for rotating electrical machines IEC / EN 60034-1

IEC / EN 60085 Terminal designations and direction of rotation for rotating electrical machines

IEC / EN 60034-8

3.3 Rating plate The rating plate shows the technical specifications for the supplied motor.

Description 3.3 Rating plate


Figure 3-1 Example of rating plate

Table 3-2 Rating plate data Item Description Item Description 1 Type 9 Supply connection data 2 Serial number 10 Degree of protection 3 Temperature class 11 Construction type 4 Armature voltage [V] 12 Standards and regulations 5 Armature current [A] 13 Motor weight [t] 6 Exciter data 14 Power [kW] 7 Cooling method 15 Speed [RPM] 8 Brush equipment 16 Air flow direction

General The machine has no housing, but is designed with a fully laminated stator yoke which allows a rate of current change of up to 250 IN/sec.

Insulation system The high-quality DURIGNIT 2000 insulation system means that the motors are suitable for use in both tropical humidity and industrial environments. You will find the insulation classes in the following table.

Table 3-3 Insulation classes of series 1G... and 1H... Series Insulation class 1GG5

Description 3.4 Motor variant 1GH


Series Insulation class 1GH5 1HS5 1HQ5

155 (F)

1GG6, 1GG7 1GH6, 1GH7 1HS6, 1HS7 1HQ6, 1HQ7

180 (H)

3.4 Motor variant 1GH Schematic representation of a variant 1GH motor

Figure 3-2 Machine type 1GH...

Ventilation and cooling The motors are open-circuit ventilated machines. They are force ventilated by a separately mounted fan and a pipe connection. With a pipe connection at one end (cooling method IC 17), they have IP23 degree of protection; with a pipe connection at both ends (cooling method IC 37), they have IP54 degree of protection. The fan and cooling pipe are not included in the scope of supply. It must be ensured that the air-flow rate meets the requirement specified on the motor rating plate.

3.5 Terminal box The terminal box contains terminals for the main circuit and auxiliary circuit (excitation) and possibly for other auxiliary circuits. The terminal boxes fulfill degree of protection IP55.

Description 3.6 Rolling-contact bearing bushes


The screw-mounted cable entry plate is supplied as standard without drilled holes so that the construction, quantity and size of cable screw connections can be tailored to meet specific cabling requirements. If a separate wiring space is prescribed for specific auxiliary circuits, an additional auxiliary terminal box is mounted on the side of the terminal box.

3.6 Rolling-contact bearing bushes The rolling-contact bearing is normally a floating bearing at the drive end and a locating bearing at the non-drive end. For variants and application of bearing bushes, please refer to Chapter "Spare parts (Page 73)". On machines with a regreasing device, the lubricant plate specifies the types of rolling-contact bearing fitted.


Preparations for use 44.1 Shipment and packaging

4.1.1 Scope of delivery

Checking the scope of delivery for completeness The drive systems are put together on an individual basis. When you take receipt of the delivery, please check immediately whether the scope of

the delivery matches up with the accompanying documents. Report any apparent transport damage to the delivery agent immediately. Report any apparent defects/missing components to the appropriate Siemens office

immediately. Siemens will not accept any retrospective warranty claims relating to items missing from the delivery.

Never commission a damaged machine. The Operating Instructions are included in the scope of supply. Store them in an accessible location.

Preparations for use 4.2 Transport and storage


4.2 Transport and storage

4.2.1 Transporting

CAUTION Transport damage if the rotor shipping brace device is not used. The motor can be damaged if it is jolted during transport. Material damage can result. Always transport the motor with the rotor shipping brace supplied. It must be securely attached during transportation. Do not remove it until you are ready to push on the output element. When the motor has to be transported after the output element is pushed on, you must take other appropriate measures to fix the axial position of the rotor. Please refer to the illustration below.

Figure 4-1 Rotor shipping brace device without coupling (1) and with coupling (2).

Sleeve Fixture Coupling Shaft screw

Table 4-1 Tightening torques for the shaft screw on the rotor shipping brace Thread in the shaft extension Tightening torque Preload M20 50 Nm 12 kN M24 100 Nm 20 kN M30 180 Nm 32 kN



WARNING Transporting or lifting the machine The motor or the motor set may only be transported and lifted with the hoisting lugs, as it might otherwise tip over or slip out of the lifting equipment. Death, serious injury, or material damage can result. Always use the lugs on the stator frame to lift the motor. Use suitable rope guidance or spreading devices. You will find the weight of the motor on the rating plate. Only lift and transport the motors in a position appropriate to their design. Only the intended openings, eyebolts, and lifting pins on the base plates must be used for transporting motor sets. Note the maximum capacity of the lifting lug. Motor sets must not be lifted by attachment to the individual motors. The auxiliary eyebolts provided, e.g. on fan cowls and cooler attachments, are suitable only for hoisting the part to which they are fitted.Vertical-design motors must always be transported in the vertical position if the rotor is not fixed. If transport in a horizontal position should prove to be necessary in special cases, the rotor must be fixed again before the motor is turned back up. Vertical motors with suitable bearings can be supplied in the horizontal position from the manufacturing plant.

WARNING

Center of gravity when transporting or lifting the machine If the center of gravity of a load is not located centrally between the attachment points, the motor can tip over or slip out of the lifting equipment when it is being transported or lifted. Death, serious injury, or material damage can result. Always take account of the center of gravity when transporting or lifting the motor. The machine's center of gravity is indicated in the relevant dimension diagram. Observe the handling instructions on the machine when transporting it. If the center of gravity is not located centrally between the attachment points, then position the hoisting hook above it. Be aware of the possibility of different loads on the sling ropes or lifting straps and the carrying capacity of the lifting equipment.

4.2.2 Storage If you do not intend to commission the machine immediately, take the following precautions: Always keep the terminal box's cover tightly sealed. Do not remove the rotor shipping brace device supplied. Open the pressure fingers of the brush holders and take the brushes out of the holders. If necessary, reapply the anti-corrosion protection at the shaft extension.

Storing outdoors Store the machine in an area which meets the following criteria:



Choose a dry storage location with plenty of space, which is safe from flooding and free from vibrations.

Repair any damage to the packaging before putting the equipment into storage insofar as this is necessary to ensure proper storage conditions.

Place the machine and accessories on pallets, wooden beams or foundations that guarantee protection against ground dampness.

Prevent the machine sinking into the ground. Ensure that the air circulation under the equipment is not impeded.

Covers or tarpaulins used to protect the equipment against the weather must not make contact with the surfaces of the equipment.

Covers or tarpaulins must not trail on the floor around the machine. Place wooden spacer blocks between the covers and the machine.

Storing indoors Store the machine in an area which meets the following criteria:

Dry, dust-free, frost-free and vibration-free Well ventilated Offers protection against extreme weather conditions The air in the room must not contain any harmful gases.

Protect the machine from shocks and humidity.

CAUTION Damage to the rolling-contact bearing Improper storage and vibrations can damage the rolling-contact bearing. If the motor is supplied with a rotor shipping brace, use it to secure the rotor. Protect the machine against severe radial vibrations, since the rotor shipping brace is not capable of absorbing these completely.

Protection against humidity If a dry storage area is not available, then take the following precautions:

Wrap the machine in moisture-absorbent material and then wrap it in film to create an air-tight unit.

Place a humidity meter inside the film wrapping. Inspect the machine regularly.

Long-term storage If you are storing a machine for more than six months, you must check its condition every six months. Check the machine for damage.



Carry out any necessary maintenance work. Document all preservation measures taken so that they can be reversed before the

machines are put back into service. Provide a constant source of low heat to the machine windings, along with forced air

ventilation.

Condensation water Severe fluctuations in the ambient temperature, direct solar radiation and high humidity levels in the storage area can cause condensate to collect in the machine. Make sure that the storage conditions are such that condensate cannot form in the machine.

4.2.3 Protection against corrosion

General anti-corrosion measures If the machine is stored in dry conditions, then take the following precautions: Storage up to six months:

Apply a coat of corrosion protective compound to all accessible bare metal parts such as the exposed shaft extension, flange or machine feet.

Storage for longer than six months: Apply a coat of anti-corrosion compound which provides long-term protection, e.g. Tectyl 506.

Inspect the machine regularly and apply an additional coating of corrosion protection if necessary.


Assembling 55.1 Installing the motor

CAUTION High surface temperatures The surface of the machine heats up during operation. Built-on parts can be damaged by high temperatures. Only use heat-resistant built-on parts. Temperature-sensitive parts such as normal cables or electronic components must not be allowed to touch nor be attached to these parts.

Rotor shipping brace If at all possible, do not remove the rotor shipping brace (if fitted) until after installation is complete.

Motor foundation Please take appropriate measures to ensure a resonance-free installation of the motor. When designing the foundation, please observe DIN 4024, Part 2.

Water drain holes In the bearing shields at the DE and NDE, water drain holes are situated in the foot area and opposite the regreasing devices. These have the following degrees of protection: Degree of protection IP23 water drain holes open Degree of protection IP54 / IP55 water drain holes sealed with plastic plugs. Where drain holes in the foot area are sealed, it can be useful to remove the appropriate screws or plugs depending on the ambient and operational conditions.

NOTICE Degree of protection The degree of protection of motors with IP54 or higher is nominally reduced to IP44 by removal of the plastic plug or screw.

Assembling 5.2 Noise emission


5.2 Noise emission When the machine is in operation, the A-weighted sound pressure level (measured in accordance with ISO 1680) might exceed 70 dB(A). Take this into account when evaluating the noise levels at any operating personnel workstations. If necessary take suitable noise protection measures.

5.3 Connecting ventilation / cooling systems External fans ensure that the motor is cooled independently of its speed. Observing the following conditions ensures proper cooling of the motor: The cooling air must be able to enter unimpeded through the air inlets and be discharged

unimpeded through the air outlets. Discharged air must not be immediately sucked back into the machine. The cooling air must be clean. The normal ventilation air-flow direction is from NDE to DE. The ventilation air-flow

direction is specified on the rating plate and must not be changed without prior consultation, as derating may be required. In the case of motors with winding temperature monitoring, the temperature monitor may cease to function if the air-flow direction is subsequently changed.

If ventilation openings are covered by grilles, the openings must be directed downward to maintain the degree of protection. Note the motor's type of construction.

If the type of construction dictates that ventilation openings are on top of the motor, you must make and mount the covers to suit the local installation conditions in order to maintain the degree of protection.

In the case of motors with open-circuit cooling that are designed for a pipe connection and/or operation with an external fan in accordance with the intended cooling method to IEC / EN 60034-6, you must install and connect pipes, external fan and air ducts of an appropriate type and design. With the IC 37 cooling method, replace the grilles on unused openings by closed covers.

On pipe-ventilated machines, the cooling-air flow and direction must comply with the rating plate specification.

In the case of motors with a built-on external fan or with an air-to-air or air-to-water heat exchanger, the relevant operating instructions must be observed.

Inlet air ducts and machine components must not be sealed by agents containing silicone.

If you need to change the position of the external fan, then reposition the grilles, filters and sound absorbers in such a way that the cooling efficiency and degree of protection are maintained.

Please observe the following for side-mounted external fans: External fans are supplied separately. Do not mount the external fan until the foot bolts have been finally tightened. Ensure the external fan is supported, if necessary.

Assembling 5.4 Aligning the motor


5.4 Aligning the motor Requirements

Detailed specialist knowledge of the following measures is required in order to correctly align and securely mount the machine: preparing the foundation, selecting and mounting the coupling, measuring the concentricity and axial eccentricity tolerances, axial and horizontal positioning. If you are not familiar with the prescribed measures and procedures, make use of the services offered by the local Siemens Service Centers (Page 85).

Vertical and horizontal alignment The following measures are required in order to compensate any radial offset at the coupling and to horizontally adjust the electric motor with respect to the driven load: Place shims under the feet of the motor to position it vertically and to prevent

stress/distortion. The number of shims should be kept as low as possible, so stack the lowest possible number of strong ones as opposed to several thinner ones.

For horizontal positioning, push the motor sideways onto the foundation. Pay attention to maintaining the axial position.

When positioning the motor, ensure that a uniform axial gap is maintained around the coupling.

5.5 Mounting the motor securely Requirements

Preconditions for smooth, vibration-free operation: Stable foundation or stable machine suspension in the case of flange-mounted motors. Precise motor alignment. Correct balancing of parts to be fitted to the shaft extension.

Secure mounting of different motor variants Use fixing bolts with the necessary ISO 898-1 classification (e.g. 10.9) to secure the

machine and safely transmit forces resulting from torque. On motors with an upward oriented shaft extension, make sure that no water can

penetrate the top bearing. Machines that are attached to the wall by their mounting feet because of their type must

be supported from below by a wall strip, for example, or pinned.

Assembling 5.6 Pushing on the power output elements


Install motors with a belt output on clamping bars. This will ensure the correct belt tension.

5.6 Pushing on the power output elements Balance quality

The rotors are balanced dynamically. For shaft extensions with featherkeys, the balancing type is specified using the following coding on the face of the drive end of the shaft: "H" means balancing with a half feather key "F" means balancing with a whole feather key.

Pushing on the power output elements Make sure that the balancing method of the output element is correct! If the power output element is shorter than the feather key with balancing type "H", then

you must machine off the section of feather key protruding from the shaft contour and output element in order to maintain the balance quality.

Power output elements may only be pushed on or pulled off with the correct equipment.

WARNING The feather key can fall out The featherkeys are only secured during transport to prevent them from falling out. If a machine with two shaft extensions does not have an output element on one shaft extension, the feather key can fall out during operation. Death or serious injury can result. On shaft extensions without output element, make sure that the feather key cannot fall out and shorten it by approximately half for balance type "H".


Connection 66.1 General Safety notes

Please observe the five safety regulations when working with the motor. All of the work must be carried out by qualified, skilled personnel.

Connection The machine is connected to the supply in the terminal box. Supplementary connections for auxiliary circuits with terminal strips for cable cross-sections of up to 2.5 mm2 are provided. Terminal post insulators or Terminal Boards (depending on construction type) are provided for connecting the excitation circuit. Terminal boxes can also be rotated by 90 in each case depending on the connecting

direction. Please ensure that winding feeder cables are relaid correctly. In this case, the insulator plate does not need to be repositioned. Under difficult conditions, e.g. with large cross sections or a large number of cables, it might not always be possible to reposition a terminal box or special adaptation measures may need to be taken.

The connection must be made in such a way that a permanent, safe electrical connection is maintained. Depending on their design, the connecting parts may be suitable for connection with or without cable lugs. Use the matching cable end pieces.

Make sure the protective conductor connection is secure. Make sure that you follow the rating plate data and the terminal diagram in the terminal

box when making the electrical connections.

Choosing the connecting leads When choosing connecting leads, you must take into account the rated current and the

plant-specific conditions (e.g. ambient temperature, cable installation, etc. to IEC / EN 60204-1).

Terminal designation According to IEC / EN 60034-8, the following basic definitions apply to the terminal designations on DC motors:

Connection 6.2 Cable entry


Table 6-1 Terminal designations in example B1 B 1 Designation x Code letter for winding parts (A, B, C, D, E, F) x Identification number showing winding start (1), end (2), or tapping if there is more than

one connection per winding The terminal diagram pasted into the terminal box shows only the conditions required to make the mains connection, i.e. with detailed representation of inner connections or winding components.

6.2 Cable entry Cable entry and routing

1. The screw-mounted entry plate is not normally supplied with holes. Make sure the type, number, and size of the screw connections are appropriate to the specific cabling requirements.

2. Only use guide elements which meet the following requirements: Guide elements must be adapted to suit the type and diameter of the cables. Guide elements must guarantee IP55 degree of protection. The same applies to

insertion points, where sealing rings and adhesive should be used. Guide elements must be appropriate to cable installation conditions. For example, use

cable grips where cables are not securely installed. 3. Connecting leads and, in particular, protective conductors in the terminal box should be

laid out in an open arrangement, preferably with spare length to prevent chafing of the cable insulation.

4. Close unused cable entries with suitable seal inserts. Please ensure the following: The seals are made of resistant, approved material. The degree of protection is guaranteed. Use sealing rings or adhesive, if necessary Cable entries can only be opened with a tool.

6.3 Connecting the main circuit Requirements

Remove the insulation from the conductor ends so that the remaining insulation is almost long enough to reach the cable lug.

Insulate the cable lug sleeves to ensure air clearances are maintained.

Connection 6.3 Connecting the main circuit


WARNING Short circuits caused by projecting wire ends The specified air insulation clearance can be reduced by projecting wire ends, resulting in short circuits. This could result in death, serious injury or material damage. Remove protruding cables. Ensure that air insulation clearances as specified in the table below are maintained.

Table 6-2 Air insulation clearances Voltage Air clearance Up to 600 V > 8 mm Up to 800 V > 10 mm Up to 1200 V > 14 mm

Connecting using cable lugs Select the cable lugs corresponding to the required cable cross-section and the specified

dimensions of the terminal connection. Tighten the contact and fastening nuts to the torque specified in the table below:

Table 6-3 Terminal box connection data Terminals 1XB7 gk 602 / gk 604 gk 702 / gk 704

Terminal size M16 M10 M12 Tightening torque 83 Nm 13 Nm 20 Nm

Main terminals

Connectable cable cross-section 6 x 240 mm2 2 x 35 mm2 2 x 70 mm2 Terminal size M6 M4 M4 Tightening torque 4 Nm 1.2 Nm 1.2 Nm

Auxiliary terminals

Connectable cable cross-section 35 mm2 6 mm2 6 mm2

Figure 6-1 Connection of main terminals with cable lug

Connection 6.4 Connecting the earthing conductor


Figure 6-2 Connection of auxiliary terminals with cable lug If the fittings for connection to busbars are not supplied, use only approved fittings, e.g. to

DIN 43673 - corrosion-proof hexagon bolts (minimum strength class 5.6) with hexagonal nuts and spring elements, e.g. spring lock washers to DIN 128.

Connection without cable lugs If terminal box size gk 602 or gk 702 is mounted on the machine, you can also connect the cables without cable lugs.

Figure 6-3 Connection without cable lugs The design of the terminals makes it possible to connect finely stranded conductors

without the use of wire end ferrules. Only use end sleeves after first applying sufficient force to the conductor to ensure it is

able to bear almost all the transferred binding power. Stiff wire end ferrules, which have not yet been placed under pressure, reduce the binding power exerted on the conductor, thereby affecting the quality of the contact.

6.4 Connecting the earthing conductor The grounding conductor cross-section of the motor must be in full conformance with the installation specifications, e.g. in accordance with IEC / EN 60204-1.

Connection 6.4 Connecting the earthing conductor


CAUTION Damage resulting from protective conductor currents When the machine is operated on a converter with current limiter, but without ground-fault monitoring, protective conductor currents of up to 1.7 times the external conductor current can arise if there is a ground fault on the output side. Neither the PE conductors of normally rated multi-core connecting cables nor the PE connecting points of normal terminal boxes are suitable for this purpose. This results in material damage. Install an adequately sized parallel protective conductor and connect this to the ground terminal on the motor housing. Use only the screws supplied.

Connecting the grounding conductor A hexagon bolt with spring lock washer and flat washer or a ground terminal is provided at the designated grounding conductor connection points. The hexagon bolt can be used for connecting stranded conductors with cable lugs or ribbon cables with an appropriately shaped conductor end. When making connections, ensure the following: the connecting surface is bare and protected against corrosion using a suitable

substance, e.g. acid-free Vaseline the flat and spring washers are located under the bolt head. The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not

exceeded The minimum required screw-in depth and the tightening torque comply with the values

specified in the tables below. These differ depending on whether cable lugs or ground terminals are used.

Table 6-4 Tightening torque of screws with cable lugs Bolt Screw-in depth Tightening torque M12 x 25 > 16 mm 38 Nm M16 x 35 > 20 mm 92 Nm

Table 6-5 Tightening torque of screws with ground terminals Bolt Screw-in depth Tightening torque M6 > 9 mm 8 Nm M8 > 12 mm 20 Nm M10 > 15 mm 40 Nm

Equipotential bonding Terminals are provided on the bearing shield for the connection of an equipotential bonding conductor.

Connection 6.5 Internal equipotential bonding


6.5 Internal equipotential bonding The equipotential bonding between the protective conductor terminal in the terminal box and the motor housing is established through the terminal box fixing screws. These screws are rated and designed as an "equivalent conductive connection" in relation to the protective conductor cross-section specified for the phase conductor in standard (IEC / EN 60034-1).

Equipotential bonding In order to guarantee the current carrying capacity of the connection via the retaining bolts in the event of a short circuit, make sure that the following conditions are fulfilled: Use only original gaskets. The contact points underneath the bolt heads or spring lock washers must be bare metal

and protected against corrosion. The standard cover fixing screws are an adequate equipotential bonding connection

between the terminal box cover and terminal box housing.

WARNING

Electric shock If the equipotential bonding connection fails, parts of the machine may become live. If you touch them, you will receive an electric shock. This could result in death, serious injury or material damage. When performing any installation work you must always take care to ensure that all equipotential bonding connections remain effective.

6.6 Connecting auxiliary circuits Auxiliary circuit

Terminal strips for cable cross-sections of up to 2.5 mm2 are provided for connecting auxiliary circuits (e.g. temperature sensor or anti-condensation heater). The information required to connect the auxiliary circuits is provided in the connection diagram, located on the inside of the terminal box cover, and in the machine documentation. The required length of stripped insulation on conductors for auxiliary terminals varies: From 6 mm to 9 mm depending on the terminal type. When the length is correct, the bare conductor must reach the center stop in the terminal and at the same time the conductor insulation must reach the contact part of the terminal.

Brush monitoring Signal transmitters for brush monitoring may be installed depending on the machine design. The brush monitoring device senses the brush height limit value. When a brush height reaches approximately 2 mm above the specified minimum height limit, a signal is generated via a microswitch. For normal operation at average speeds, this corresponds to a residual operating period of about 500 to 1,000 operating hours. The carbon brushes must be replaced punctually.

Connection 6.7 Connecting an external fan


The electrical connection requirements are shown on the terminal diagram pasted into the terminal box.

Speed sensor With add-on speed sensors, the electrical connection is made on the line side. Please follow the supplementary operating instructions in this respect.

Temperature monitoring On machines with temperature sensors, design the temperature evaluation and control circuits such that any risk of unexpected, automatic restart of the installation after it has cooled down following a temperature monitor response can be completely precluded.

WARNING Temperature monitoring If the temperature monitoring system fails to prevent the machine from restarting automatically after it has cooled, there is a risk of death or serious physical injury to personnel caused by hazardous voltage and rotating parts if they are working on the machine when it restarts unexpectedly. On machines with temperature sensors, design the temperature evaluation and control circuits in such a way that it is impossible for the machine to restart automatically.

6.7 Connecting an external fan Procedure

1. Connect the external fan motor in accordance with the terminal connection diagram pasted in the associated terminal box and in accordance with any information provided on plates and operating instructions.

2. The direction of rotation of the external fan must match the arrow indicating the direction of rotation. The fan impeller is visible through the air inlet point in the fan cowl on the motor. If the direction of rotation is incorrect, change it by swapping over two of the phase conductors in the terminal box of the fan motor.

3. A protective circuit must be provided for electric machines with an external fan to ensure that the main machine cannot be switched on when the fan unit is not in operation.

6.8 Final measures Checks prior to closing the terminal box

1. Before closing the terminal box, please check that: The cables and links match the terminal diagram inside the terminal box cover.

Connection 6.8 Final measures


The electrical connections in the terminal box are tight and fully comply with the specifications in the chapters above.

The inside of the terminal box is clean and free of any cable debris. All of the clamping bolts and entry parts are securely tightened (this also applies to

unused terminals). Minimum air clearances have been respected. The connecting leads are laid in an open arrangement, and the cable insulation

cannot be damaged. Any unused entry points are sealed. The sealing elements can only be removed with a

tool. All of the seals/gaskets and sealing surfaces of the terminal box are in a good

condition. If the joins are sealed purely by metal sealing surfaces, these must be cleaned and lightly greased again.

The right cable guides are fitted with respect to degree of protection, method of laying, permissible cable diameter, etc., as stated in the specifications.

With a U-shaped terminal box casing, the entry plate is aligned and secured in such a way that the seat for the box cover seal is continuous all the way round.

2. Then close the terminal box. Tightening torque for the cover fixing screws is 22 Nm.


Commissioning 77.1 Safety information Qualified personnel

Only qualified personnel should be allowed to commission and operate this device. In the safety instructions provided in this manual, qualified persons are those who have the necessary authorization to commission, ground, and identify equipment, systems, and circuits in accordance with the relevant safety standards. Please note the general safety information in the chapter titled "Safety notes (Page 11)".

WARNING

Rotating and live parts Covers prevent contact with live or rotating parts, or are used for proper air routing and thus effective cooling of the motor. Removing the covers during operation can result in death, serious injury, and material damage. Never open covers during operation.

WARNING

Faults in operation All deviations from normal operation, such as higher power consumption, higher temperatures and vibration levels, unusual noises and odors and tripped monitoring devices, are indications that the motor is no longer functioning correctly. In this case, maintenance personnel must be notified immediately to prevent disturbances that could either directly or indirectly lead to severe personal injury or substantial material damage. If in doubt, switch off the drive in question immediately.

Commissioning 7.2 Measures to be performed prior to startup


DANGER Overspeed When the exciter circuit is deactivated, the machine can reach dangerously high speeds. Death, serious injury, or material damage will result. The control must be interlocked in such a way that the armature circuit can be connected only when the exciter circuit is energized. If the exciter circuit fails, switch off the armature circuit immediately.

7.2 Measures to be performed prior to startup This list below does not claim to be complete. It may be necessary to perform additional checks and tests in accordance with the situation specific to the particular place of installation.

Checks Once the system has been correctly installed, you should check the following prior to commissioning: All electrical and mechanical connections are securely seated and functioning properly. The motor has been assembled and aligned properly. The cover sheets have been remounted correctly to ensure effective cooling of the motor. The operating conditions correspond to the data specified on the rating plate. Any supplementary motor monitoring devices and equipment have been correctly

connected and are fully functional. Appropriately configured control and speed monitoring functions ensure that the motor

cannot exceed the permissible speeds specified on the rating plate. The power output elements have the proper setting conditions according to type, for

example: Couplings are aligned and balanced. The belt tension is properly adjusted if there is a belt drive. Gear tooth flank play and gear tooth tip play, as well as radial play, are properly

adjusted if there is a gearwheel output. The minimum insulation resistance values are maintained. The grounding and equipotential bonding connections have been established correctly. All fixing screws, connecting elements and electrical connections are firmly tightened. The rotor can spin without coming into contact with the stator. All touch protection measures for moving and live parts have been taken. If the second shaft extension has not been used, its featherkey has been secured to

prevent it from being thrown out. All external fans are ready for operation and have been connected so that they rotate in

the direction specified.

Commissioning 7.3 Checking the insulation resistance


The flow of cooling air is not impeded. All brakes are operating correctly. Carbon brushes and brush levers can move freely in the brush guides. The spring action

is identical on all carbon brushes. The machine is connected up appropriately for the specified direction of rotation.

Commissioning converters Before the motor is commissioned, the converter must be commissioned as described in

its operating instructions. Be aware of the motor parameters. Make sure any work done is documented on the correct checklist.

7.3 Checking the insulation resistance Checking the insulation resistance of the winding

The insulation resistance check on the winding relative to frame with DC voltage must be performed prior to commissioning and again after any extended periods of storage or idle time.

WARNING

Hazardous voltage Dangerous voltages are sometimes present on the terminals during and immediately after measurement of the winding insulation resistance. Contact with the terminals can result in death, serious personal injury and damage to property. If any power cables are connected, check them to ensure that no supply voltage can be generated. Once you have measured the insulation resistance, discharge the winding by connecting the ground potential.

Measuring the insulation resistance Before you begin measuring the insulation resistance, please read the manual for the

insulation resistance meter you are going to use. The measuring voltage for insulation resistance measurements on electrical components

must never exceed 500 V. As an exception, a measuring voltage of 1000 V may be used to test new windings on condition that they are insulation-tested beforehand with a measuring voltage of max. 500 V and the measurement result is not below the minimum permissible insulation value.

When measuring, wait until the full-scale resistance value is reached. This is the case after approximately one minute.

After measuring, ground the electrical components to discharge them.

Commissioning 7.4 Power on


Limit values of winding insulation resistance Table 7-1 Winding insulation resistance at 25 C Rated voltage

UN < 2 kV Measuring circuit voltage 500 V (at least 100 V) Minimum insulation resistance with new, cleaned or repaired windings

10 M

Critical specific insulation resistance after a long operating time

0.5 M/kV

Dry, new windings have insulation resistance of between 100 and 2000 M, or possibly values that are even higher. If the insulation resistance is close to the minimum value, then the cause could be humidity and/or pollution.

Over its operating lifetime, the motor winding insulation resistance can drop due to ambient and operational influences. The critical insulation resistance value for a winding temperature of 25 C can be calculated, depending on the rated voltage, by multiplying the rated voltage (kV) by the specific critical resistance value. Example: Critical resistance for UN of 400 V: 0.4 kV x 0.5 M/kV = 0.2 M

NOTICE Critical insulation resistance is reached or insufficient If the critical insulation resistance is reached or is insufficient, damage to the insulation and flashover voltages can result. Dry the windings or clean and dry them thoroughly, having first removed the rotor. If the clean windings have not cooled to 25 C after drying, a lower insulation

resistance will be measured. The insulation resistance can only be properly assessed after conversion to the reference temperature of 25 C. Allow the windings to cool to 25 C or convert the insulation resistance using 25 C as the reference temperature.

If the measured value is close to the critical value, you must check the insulation resistance at appropriately frequent intervals subsequently.

7.4 Power on Trial run

If the period between installation and commissioning is expected to be fairly long, make sure that water-cooled machines undergo a test run without water cooling.

Procedure Start up the motor without a load, temporarily. Check the direction of rotation at this point.

Commissioning 7.5 Deactivating


As the motor is coasting down, check the mechanical operation for noise and vibration at the bearings and bearing shields.

Where the motor is running without any mechanical problems, switch it back on again. Continue to the maximum speed allowed (according to the rating plate).

If the motor is not running smoothly or is emitting abnormal noises, switch it off and determine the cause of the fault as the motor coasts down.

If the mechanical operation improves immediately after the motor is switched off, then the cause is magnetic or electrical.

If mechanical operation does not improve immediately after switching the motor off, then the cause is mechanical (e.g. imbalance of electrical machines, etc.).

If the motor is running perfectly, switch on the cooling equipment. Observe the motor for a while during no-load operation.

NOTICE Overheating during test runs without water cooling The motor can overheat without water cooling. Reduce the ON duration accordingly if the water cooler is not to be operated during a test run.

If it runs perfectly, connect a load. Check whether it is running smoothly. Record the voltage, current, and power values. As far as possible, record the corresponding values of the driven machine. Monitor and record the temperatures of the bearings, windings, and so on until the

system reaches a steady state.

See also Starting check list (Page 86)

7.5 Deactivating In most cases, the motor will be shut down by an automatic control system. If switch-off is not performed by the correct control system, please proceed as follows: 1. Switch the machine off. 2. Switch off any external fans. 3. Switch off the coolant supply. Follow the operating instructions provided by the

manufacturer. 4. Switch on the anti-condensation heating.

Commissioning 7.6 Final measures


7.6 Final measures This list below does not claim to be complete. It may be necessary to perform additional checks and tests in accordance with the situation specific to the particular place of installation.

Measures to be performed prior to commissioning the plant After proper installation, and prior to commissioning the plant, the following measures and checks must be performed: The installation and operating conditions comply with the specifications on the rating

plate. The manufacturer has been consulted if the motor is to be operated continuously under

light-load conditions (I < 50% IN), due to the risk of high brush wear or commutator problems.

The bearings have been regreased as appropriate for the model. If the bearings are insulated, the insulation has not been bridged. If an air-to-water heat exchanger is installed, the water cooler is connected, filled, air

bled, and ready to run. This also applies after long outage periods. Make a record of all work undertaken.

See also Commissioning check list (Page 87)


Operation 88.1 Safety information

DANGER Overspeed When the exciter circuit is deactivated, the machine can reach dangerously high speeds. Death, serious injury, or material damage will result. The control must be interlocked in such a way that the armature circuit can be connected only when the exciter circuit is energized. If the exciter circuit fails, switch off the armature circuit immediately.

WARNING

Rotating or live parts Covers prevent contact with live or rotating parts, or are used for proper air routing and thus effective cooling of the motor. Removing the covers during operation can result in death, serious injury, and material damage. Never open covers during operation.

WARNING

Faults in operation All deviations from normal operation, such as higher power consumption, higher temperatures and vibration levels, unusual noises and odors and tripped monitoring devices, are indications that the motor is no longer functioning correctly. Keep maintenance personnel fully informed to prevent faults that could directly or indirectly cause serious injury to personnel or damage to equipment. If in doubt, switch off the drive in question immediately.

Operation 8.2 Switch on


NOTICE Operating the motor at the natural installation frequency Operating the motor at the natural installation frequency can lead to damage to both the motor and the foundation. Never operate the motor at the natural installation frequency.

WARNING

Risk of burns Some parts of the frame of electrical machines can reach temperatures in excess of 100 C. Serious burn injuries can be caused by touching components when the machine is in operation. Do not touch frame parts while the machine is in operation or immediately after machine operation. Let frame parts cool off before starting any work.

8.2 Switch on Procedure

1. If at all possible, run the machine without load and check that it is running smoothly. 2. If it runs perfectly, connect a load. 3. If it is possible using the available measuring equipment, check the bearing and stator

winding temperatures.

Vibration magnitudes The vibration characteristics of the system at the installation site are affected by factors such as power output elements, alignment, installation and external vibration and may in turn increase the level of vibration on the motor. In the interests of achieving perfect commutation, very low brush wear and long service life of bearings, the level of motor vibration must not exceed the limits specified in DIN ISO 10816-3 as given in the table below.

Table 8-1 Vibration magnitude as a function of vibration frequency Vibration magnitude values Vibration frequency

[Hz] Vibration magnitudes

Frame size 280 and lower

Frame size 355 and higher

< 6.3 Hz Vibration displacement s [mm] 0,1 0,16 6.3 to 63 Hz Vibration speed Vrms[mm/s] 2,8 4,5 > 63 Hz Vibration acceleration a [m/s2] 1,6 2,55

Operation 8.3 Deactivating


If higher levels of vibration than the above specified occur in operation, then special measures must be taken. For more information, please contact your local Siemens sales office.

8.3 Deactivating Measures when switching off

If the corresponding control action does not take place automatically, switch on the anti-condensation heating if present. This prevents damage to the winding insulation.

If this does not happen automatically, switch off any external fans or coolers.

8.4 Special operating conditions Operating under light-load conditions

If a motor is operated continuously or over a prolonged period under light-load conditions, at approximately half rated current or less, then problems with high brush wear or commutator malfunctions may occur. For more information, please refer to chapter "Faults (Page 44)". Consult the manufacturer if the motor is to be operated continuously under light-load conditions.

Loading at standstill Stationary DC motors may be loaded with armature current only for short periods so as to protect the commutator against damage. The permissible current and time values for loading at standstill can be obtained from the manufacturer.

8.5 Stoppages Necessary measures when motors are at standstill and ready for operation

Keep the motor dry using anti-condensation heating. After prolonged idle time and when commissioning at very low ambient temperatures ( 0

C), the inside of the motor should receive additional heat to de-ice and dry it out. This should be done by heating the exciter winding with 30% rated exciter current, without ventilation, for a period of at least 30 minutes. This cannot be achieved by the anti-condensation heater alone.

Take care with motors using water cooling to avoid possible problems with corrosion and freezing. Follow the operating instructions provided by the water cooler manufacturer.

Operation 8.6 Faults


Operate the motor regularly, at least once monthly, in the event of lengthy downtimes. Alternatively, turn the rotor as a minimum.

NOTICE Bearing damage due to external factors Where cylindrical-roller bearings are used, bearing damage can be caused by external vibration in standby mode. Consult the manufacturer for details of suitable corrective action.

Prolonged outage periods If the motor is out of operation for a prolonged period, suitable measures must be taken

with respect to anti-corrosion protection, mothballing, packaging and drying, as described in chapter "Transport and storage" (Page 18).

When restarting the motor after a long downtime, carry out the measures recommended in chapter "Commissioning" (Page 35).

8.6 Faults

8.6.1 Safety notes during operation

Safety notes

WARNING

Faults in operation All deviations from normal operation (e.g. higher power consumption, higher temperatures or vibration levels, unusual noises or odors, tripped monitoring devices, etc.) are indications that the motor is no longer functioning correctly. This can cause faults which can result in eventual or immediate death, serious injury, or material damage. Immediately inform the maintenance personnel. If you are in doubt, immediately shut down the motor, being sure to observe the system-specific safety conditions. Correct the cause of the fault as specified in the remedial measures section. Repair any damage to the machine. Ensure that the skilled personnel responsible investigate the cause and remedy the error.



WARNING Do not remove covers when the machine is running Rotating or live parts are dangerous. Death, serious injury, or material damage can result if the required covers are removed during operation. De-energize the machine first, if you need to remove any covers. Ensure that any covers which are designed to prevent active or rotating parts from being touched, or which are necessary to ensure correct air guidance and thus effective cooling, remain closed during operation.

The tables of faults below can be used as troubleshooting and repair guides in the event of electrical or mechanical faults. Consult the manufacturer if necessary.



8.6.2 Faults in operation Table 8-2 Faults in operation Symptoms of fault General uneven running of machine

Vibrating brushes High temperature rise (general)

Severe brush sparking Possible causes of faults Remedial measures

Plant fault X Coupled motor out of balance Check coupling, rebalance system X X Poor alignment Align motor set X X X Resonance in system Improve installation conditions or reduce

excitation of vibration Operating mode or operating error X Continuous light-load duty (partial load) Change number of brushes and/or material X Temporary overload Correct current limit on converter X Continuous overload Correct current limit on converter/reduce

down periods of rest Cooling fault X Cooling air-flow rate too low (commutator

temperature too high) Improve ventilation circuit

Component defect X Interturn fault Repair winding X X Out-of-round commutator Rework commutator X Rotor imbalance Balance rotor X Bearing damage Repair or replace bearing



8.6.3 Rolling-contact bearing faults

Note Damage to rolling-contact bearings can be difficult to detect in some cases. If in doubt, replace the bearing. The manufacturer must be consulted before the bearing is modified in any way.

Table 8-3 Rolling-contact bearing faults Symptoms of fault Bearing too hot

Bearing "whistles" Bearing "knocks"

Possible causes of fault Remedial measures

X Too much grease in bearing Remove excess grease X Felt rings pressing on shaft Refit felt rings or replace with new ones X High coupling pressure Align machine more accurately X Belt tension too high Reduce belt tension X Bearing contaminated Clean or replace bearing; check seals X Ambient temperature higher than 40 C Use high-temperature grease X X Insufficient lubrication Lubricate as specified X X Bearing canted Check mounting, adjust outer ring X X Insufficient bearing play Only after consultation with the manufacturer:

Fit a bearing with higher play X X Bearing corroded Replace bearing, check seals X Friction marks on raceway Replace bearing X Scoring (brinelling) Replace bearing, prevent vibration when

motor is stationary X Excessive bearing play Only after consultation with the manufacturer:

Fit a bearing with lower play



8.6.4 Brush faults

Note The arrangement of brush components or the brush material may only be changed with the manufacturer's agreement.

Table 8-4 Brush faults Symptoms of fault Knocked out or sh

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