Siemens LOHER CHEMSTAR 1PS2 Operating Instructions And Installation Download Page 65

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Start-up

When carrying out any work on the machine, observe the general safety instructions and the

specifications contained in EN 50110‑1 regarding safe operation of electrical equipment.

Summary of Contents for LOHER CHEMSTAR 1PS2

Page 1: ...iemens com LOHER CHEMSTAR Induction motor Type 1PS2 Operating Instructions Installation Instructions N R 601e Edition 08 2016 For employment in zone 1 or zone 2 IEC EN 60079 10 1 0102 II 2G Ex e IIC T Gb ...

Page 2: ...04 08 2016 11 45 V3 00 ...

Page 3: ...or zone 2 IEC EN 60079 10 1 0102 II 2G Ex e IIC T Gb Edition 08 2016 Introduction 1 Safety information 2 Description 3 Preparations for use 4 Assembly 5 Electrical connection 6 Start up 7 Operation 8 Maintenance 9 Spare Parts 10 Disposal 11 Service and Support A Technical data and drawings B Quality documents C ...

Page 4: ...re those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation If products and components from other manufacturers are used ...

Page 5: ...g the plant 25 4 2 Observing the operating mode 25 4 3 Terminal box with separate cable entry plate 26 4 4 Machines without final paint coating 27 4 5 Corrosion protection for bare metal surfaces 27 4 6 Ensuring adequate cooling 27 4 7 Interlock circuit for anti condensation heating 28 4 8 Interlock circuit for the external fan motor 28 4 9 Noise emissions 28 4 10 Voltage and frequency fluctuation...

Page 6: ...s for installation 40 5 3 2 Safety information do not lift below 55 C 40 5 3 3 Preparing the assembly area 41 5 3 4 Prepare the mating faces for wall mounting 41 5 4 Lift the machine to where it will be installed and position it 41 5 4 1 Preconditions for correct alignment and secure attachment 41 5 4 2 Checking the load handling attachments 42 5 4 3 Lifting and transportation 42 5 4 4 Putting the...

Page 7: ...polarization index 67 7 4 Heating in order to reach the required surface temperature 69 7 5 Testing the cooling of the machine 70 7 6 Commissioning an external fan 70 7 7 Greasing the roller bearings prior to commissioning 71 7 8 Test run 72 8 Operation 75 8 1 Safety instructions during operation 75 8 2 Current transformer 76 8 3 Explosion hazard during operation 77 8 4 Switching on with the anti ...

Page 8: ...intenance 97 9 2 1 Assembling the rolling contact bearings 98 9 2 2 Fixing stator cables at the terminal studs 99 9 2 3 Seal the motor 100 9 2 4 O ring seal 100 9 2 5 Anti condensation heating spare parts 101 10 Spare Parts 103 10 1 Ordering data 103 10 2 Anti condensation heating 104 10 3 Spare parts list frame sizes 071 to 132 105 10 4 Spare parts list frame sizes 160 to 280 106 10 5 Spare parts...

Page 9: ...ble 7 1 Stator winding insulation resistance at 40 C 68 Table 8 1 Assignment of the total risk factor to the required supplementary measures for Ex e 77 Table 8 2 Electrical faults 81 Table 8 3 Mechanical faults 82 Table 8 4 Roller bearing faults 82 Table 8 5 Cooling system faults 83 Table 9 1 Checks after installation or repair 87 Table 9 2 Checks that have to be performed during the general insp...

Page 10: ...0001 111 Image 10 6 E 9 101_208 0001 112 Image 10 7 E 9 101_285 0001 113 Image 10 8 Spare parts list for terminal boxes with type of protection Ex i 114 Table of contents LOHER CHEMSTAR 1PS2 10 Operating Instructions 08 2016 ...

Page 11: ...format features The warning notice system is explained on the rear of the inside front Always follow the safety instructions and notices in these instructions In addition to the safety related warning notices 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 ...

Page 12: ...Introduction 1 1 About these instructions LOHER CHEMSTAR 1PS2 12 Operating Instructions 08 2016 ...

Page 13: ...ion commissioning and servicing work You will find safety instructions in the individual sections of this document Follow the safety instructions for your own safety to protect other people and to avoid damage to property Observe the following safety instructions for all activities on and with the machine This machine has been designed and built in accordance with Directive 2014 34 EU Explosion Pr...

Page 14: ...ulfill the following requirements Through appropriate training and experience they are able to recognize and avoid risks and potential dangers in their particular field of activity They have been instructed to carry out work on the machine by the appropriate person responsible 2 4 Safe handling Workplace safety depends on the attentiveness care and common sense of the personnel who install operate...

Page 15: ...e machine properly Regularly and correctly maintain the machine Secure free standing shaft ends and other rotating parts such as couplings belt pulleys etc against touch WARNING Hot surfaces Electric machines have hot surfaces Do not touch these surfaces They could cause burns Allow the machine to cool before starting work on the machine Only remove the covers using the methods described by these ...

Page 16: ...permitted at the workplace which can cause hearing damage Take steps to reduce noise such as introducing covers and protective insulation or adopting hearing protection measures so that the machine can be operated safely within your system 2 5 Use in hazardous areas Electrical systems in hazardous zones must be assembled installed and operated by the applicable responsible persons in accordance wi...

Page 17: ...commissioning 2 6 Electrostatic sensitive devices ESD protective measures NOTICE Electrostatic discharge Electronic modules contain components that can be destroyed by electrostatic discharge These modules can be easily destroyed by improper handling To protect equipment against damage follow the instructions given below Only touch electronic modules if you absolutely have to work on them The body...

Page 18: ...on This can result in death serious injury or material damage Avoid carrying out work specified above on non metallic parts e g foam rubber for noise dampeners attenuators Please comply with ESD protective measures 2 7 Electromagnetic compatibility This machine is designed in accordance with IEC EN 60034 and when used as prescribed it satisfies the requirements of European Directive 2014 30 EU on ...

Page 19: ... during operation Potentially lethal malfunctions can occur in medical implants e g pacemakers in the vicinity of electrical power equipment Data may be lost on magnetic or electronic data carriers It is forbidden for people with pacemakers to enter the vicinity of the machine Protect the personnel working in the plant by taking appropriate measures such as erecting identifying markings safety bar...

Page 20: ...Safety information 2 10 Electromagnetic fields when operating electrical power engineering installations LOHER CHEMSTAR 1PS2 20 Operating Instructions 08 2016 ...

Page 21: ...termining the hazard level of each area and classifying the zones The type of protection as well as special regulations are stamped on the rating plate or in the test certificate If the certificate number is supplemented by an X to safely operate the machine observe the special notes in the operating instructions or if available in the EC or EU type examination certificate or in the IECEx Certific...

Page 22: ...EN 60034 14 Vibration limits DIN ISO 10816 3 For machines in line operation only See also Quality documents Page 121 The following standards additionally apply for explosion protected machines Table 3 3 Machine type with type of protection Ex e Characteristic Standard Type of protection Ex e IEC EN 60079 0 IEC EN 60079 7 Rating plate The rating plate shows the identification data and the most impo...

Page 23: ... are made of cast iron or steel The fan cover is made of sheet steel The stator frame surface has cooling ribs hollow ribs or tubes and mounted terminal box Cooling for machines with surface cooling hollow rib cooling or tube cooling For machines with rib hollow rib or tube cooling the cooling air is drawn in through openings in the fan cover The air is blown over the surface or through the coolin...

Page 24: ...for example Monitoring equipment Monitoring equipment is provided corresponding to what has been ordered KTY83 and KTY84 semiconductor sensors are electrostatic sensitive devices ESD These elements can be damaged by electrostatic discharge Observe the ESD protective measures External fan The machine can be fitted with an external fan For IC 666 there are two external fans The electrical connection...

Page 25: ...configuring the plant A number of residual risks are associated with the machine These are described in the chapter titled Safety information Page 13 and in related sections Take appropriate safety precautions covers barriers markings etc to ensure the machine is operated safely within your plant Observing the operating mode Observe the machine s operating mode Use a suitable control system to pre...

Page 26: ...ect the seals position the cable entry plate a short distance away from the terminal box Then if required connect the grounding strap to the cable entry plate 3 After making the electrical connections close the cover of the terminal box For versions without hinges place the terminal box cover onto the terminal box base The seal between the terminal box base and cover must be flush with the cable e...

Page 27: ...ting feet or the flange surface is bare metal Ensure that there is adequate corrosion protection e g using grease sealing paste or a similar product The terminal box cover also has bare metal surfaces Here only use a suitable grease to guarantee protection against corrosion 4 6 Ensuring adequate cooling Ensure that the machine is sufficiently cooled by the cooling air flow at the installation site...

Page 28: ...active Page 77 4 8 Interlock circuit for the external fan motor Interlock circuit for the external fan motor For machines with external fans install an interlock circuit that prevents the main machine being switched on if the external fan is not operational 4 9 Noise emissions WARNING Noise emissions During operation the machine s noise emission levels can exceed those permitted at the workplace w...

Page 29: ...ker with phase failure protection according to IEC EN 60947 or a similar device in all phases Set the protective device to the rated current value is stamped on the rating plate Select the protective device so that the machine is thermally protected even with a locked rotor For explosion protected electrical machines with type of protection Increased safety also monitor the starting starting monit...

Page 30: ...drive train WARNING Serious damage to the machine If the configuration does not correctly recognize the mechanical torsional loadings of the shaft assembly this can lead to serious damage to the machine This can result in death serious injury or material damage When planning the system make due allowance for the maximum air gap torques that can occur This data can be found in the Electrical Data i...

Page 31: ...epted if they are submitted at a later date Report any apparent transport damage to the delivery agent immediately Immediately report any apparent defects missing components to your contact partner These Operating Instructions are part of the scope of delivery keep them in a location where they can be easily accessed 4 13 3 Attaching the rotor locking device NOTICE Bearing damage caused by vibrati...

Page 32: ...and lifting gear are damaged or not correctly secured the machine may be dropped during lifting This can result in death serious injury or material damage Inspect the load handling attachments and lifting gear before use WARNING Falling down of the machine The lifting lugs on the machine are designed only for the weight of the machine If a machine set is lifted and transported on a single machine ...

Page 33: ...al damage to the bearings due to vibration at standstill For machines with closed condensation water drain holes check whether there is any condensation and if so drain it Then reseal the drain holes WARNING Risk of explosion due to damaged sealing materials Storing the machine at temperatures that do not fall within the specified limits can damage the material of the seals and cause them to fail ...

Page 34: ...3 7 Storage at low temperatures 4 13 7 1 Storing machines at temperatures down to 50 C If machines are stored at temperatures of down to 50 C then also take into account the following The normal roller bearing grease of machines is suitable for operating temperatures of between 30 C and 130 C Temperatures down to 50 C are harmless for the roller bearing grease if the machine is non operational or ...

Page 35: ...ditions Page 33 4 13 8 2 Commissioning Remove the moisture absorbing substance such as Branogel from the terminal boxes before commissioning See also Commissioning after storage Page 36 4 13 9 Storage outdoors If the machine is stored outdoors then the following should additionally be observed Provide protective cover against the effects of sun and rain Air must freely circulate to avoid condensat...

Page 36: ...rmation on testing and the limit values can be found here Testing the insulation resistance and polarization index 4 13 10 2 Lubricating the roller bearings If you correctly store the machine for a longer period of time it can be assumed that within a period of two years the grease in the bearings will not deteriorate For motors with thermal class 155 for normal ambient temperatures use a lithium ...

Page 37: ... specified on the lubricant plate Note Increased bearing noise Increased bearing noise can occur while the bearings are being run in The bearing noise is not dangerous if the operating temperature has not yet been reached and the noise is caused by the viscosity and the dynamic viscosity of the bearing grease 4 13 10 5 Releasing the rotor shipping brace before commissioning If one is being used re...

Page 38: ...Preparations for use 4 13 Transport and storage LOHER CHEMSTAR 1PS2 38 Operating Instructions 08 2016 ...

Page 39: ...an directives Unauthorized changes or modifications to the machine lead to the loss of conformity with European directives and the loss of warranty 5 2 Modifications to the machine WARNING Explosion hazard when making modifications to the machine Substantial modifications to the machine are not permitted or may only be performed by the manufacturer Otherwise an explosion can occur in an explosive ...

Page 40: ... High temperatures can damage mounting parts such as the cable insulation Temperature sensitive parts such as normal cables or electronic components must not rest against or be attached to mounted machine parts Only use heat resistant mounting parts The connecting cables and cable entries must be suitable for the ambient temperature 5 3 2 Safety information do not lift below 55 C WARNING Lifting a...

Page 41: ...the mating faces for wall mounting Ensure that the wall surface is flat and free of contaminations Check the dimensions of the mounting foot holes Support the machine from below e g using a wall bracket or by bolting it 5 4 Lift the machine to where it will be installed and position it 5 4 1 Preconditions for correct alignment and secure attachment Detailed specialist knowledge of the following me...

Page 42: ...s use WARNING The machine can be dropped If the load handling attachments and lifting gear are damaged or not correctly secured the machine may be dropped during lifting This can result in death serious injury or material damage Inspect the load handling attachments and lifting gear before use 5 4 3 Lifting and transportation Persons driving cranes and fork lift trucks must hold appropriate qualif...

Page 43: ...s can result in death serious injury or material damage 1 Always take account of the center of gravity when transporting or lifting the machine The machine s center of gravity is indicated in the relevant dimension diagram 2 Observe the handling instructions on the motor when transporting it If the center of gravity is not located centrally between the attachment points then position the hoisting ...

Page 44: ...izontal positioning push the motor sideways across the foundation When doing so ensure that the axial position is maintained 5 4 5 Turning a machine upright or laying it on its side Lifting beams must always be used when lifting and the machine or laying it on its side One of the beams must be free to rotate Persons driving cranes must hold appropriate qualifications When lifting the machine use o...

Page 45: ...nd lift the machine using this beam until it is perpendicular to the base ᆰ ᆱ ᆲ r Image 5 1 Erecting the motor Turning the machine on to its side To lay the machine on its side proceed in the reverse order 5 4 6 Removing anti corrosion protection Machined bare metal surfaces of machine parts and small components such as screws bolts wedges feather keys and dowel pins are treated with an anti corro...

Page 46: ... remove the anti corrosion protection as this could damage the surfaces of the machine parts Lightly oil the depreserved surfaces Thread and fastening parts Remove the anti corrosion protection from bolts and tapered pins Use the appropriate tap or cutting die to shave the tapped holes of machine parts and threads of screws etc See the drawings for the relevant male and female thread dimensions Us...

Page 47: ...te the regreasing devices They are sealed with screw plugs and retaining washers Regularly remove the screw plugs to allow the condensate to drain away Then re fit the screw plugs and lock washers so that the machine s degree of protection is ensured Drainage plugs which allow the water to drain away automatically can also be fitted Depending on the type of installation the water drainage holes ar...

Page 48: ...ufacturer 2 Align the machines with coupling output to the driven machine in such a manner that the center lines of the shafts are parallel with no offset This ensures that no additional forces affect their bearings during operation 3 For the vertical positioning x 0 place thin shims under the machine feet The number of shims should be kept as low as possible i e stack as few as possible This also...

Page 49: ... If necessary rotate the machine into the right position so that the clearance holes in the flange are central to the tapped holes 5 Lower the machine completely onto the mating flange so that it is fully in contact then remove the studs 6 Fix the machine using the flange fixing bolts NOTICE Removing the rotor shipping brace in the horizontal position Dismantling the rotor shipping brace when the ...

Page 50: ... feet the overall flatness of the installation surfaces must satisfy the values in the following table Table 5 2 Overall flatness of the installation surfaces Frame size Overall flatness of the installation surfaces 080 0 1 mm 090 355 0 2 mm 400 0 3 mm If shims are necessary for height adjustment and to avoid stresses make them out of adequately sized pieces of flat rolled strip Complete balancing...

Page 51: ...t extensions with feather key To maintain the balancing quality you have the following options If the 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 The feather key must be shortened if the coupling hub is shorter than the feather ...

Page 52: ... shaft Large output masses and their centers of gravity outside the shaft extensions can lead to resonance in operation This can result in damage to the bearings and shaft Ensure that the permissible loads for the forces on the shaft extension are adhered to in accordance with the catalog data or configuration data Assembly 5 5 Installing the machine LOHER CHEMSTAR 1PS2 52 Operating Instructions 0...

Page 53: ...que this could impair current transfer or cause connecting parts to become loose Fastening elements can work loosely so that the minimum air clearances are no longer maintained Sparking formation may occur in an explosive atmosphere it can lead to an explosion This could result in death serious injury or material damage to the machine or even in failure which could in turn lead indirectly to mater...

Page 54: ...guidelines 2 To protect the seals position the cable entry plate a short distance away from the terminal box Then if required connect the grounding strap to the cable entry plate 3 After making the electrical connections close the cover of the terminal box For versions without hinges place the terminal box cover onto the terminal box base The seal between the terminal box base and cover must be fl...

Page 55: ...ss section as defined by required length of cable etc Requirements according to IEC EN 60204 1 Requirements according to IEC EN 60079 14 when used in Zones 1 2 or 21 22 Configuration notes 6 2 Connecting 6 2 1 Terminal boxes with type of protection Ex e WARNING If the seal of the pressure relief flap preset breaking point in the lower section of the terminal box is damaged then the explosion type ...

Page 56: ...ction and installation specifications and to IEC EN 60204 1 Table 6 1 Determining the cross section of the grounding conductor External cable cross section S Cross section of the grounding conductor mm S 16 mm S 16 mm S 35 mm 16 mm S 35 mm S 2 A terminal strip for grounding is fitted either on the stator frame or on the flanged endshield depending on the type of construction The grounding point is...

Page 57: ...r with the incorrect direction of rotation This can result in machine damage Observe the direction of rotation data on the nameplate 6 2 5 Connecting the machine for a specific direction of rotation If the machine has one shaft extension or two shaft extensions with different diameters the direction of rotation when looking at the front of the single or the thicker shaft extension is defined as fo...

Page 58: ... cables with the cable glands onto the terminal box Inserting the cable into the terminal box 1 Only use cable entries that are suitable for the cable 2 Only use suitable cable entries and cables for the prevailing ambient temperature 3 Ensure that the power cables are strain relieved where they enter the terminal box 4 Carefully connect the cable and ensure a reliable protective conductor connect...

Page 59: ...sed by the end sleeve but is clamped together with it then this can lead to overheating The temperature class of the machine can be exceeded This can trigger ignition of an explosive mixture This can result in death serious injury or material damage Insert only one conductor end into each end sleeve Attach the end sleeve correctly 6 2 9 Connection with terminal board Note that for terminal boards ...

Page 60: ...riate torque as specified by the manufacturer after inserting the feeder cables The tightening torques depend on the cable gland used and the cable or wire used Tighten the standard cable glands supplied with the motor in accordance with the following table Table 6 4 Tightening torques for standard cable glands Nm Nominal size Cable gland for Ex e II Type HSK M Cable gland for Ex e Ex d IIC Type A...

Page 61: ...ressure Aluminum flows following installation due to the contact pressure The connection with the clamping nuts can loosen as a result The contact resistance would increase and the current carrying impeded as a consequence the terminal box and the surrounding components could burn This could result in material damage to the machine or even in total failure which could in turn lead to indirect mate...

Page 62: ... device Water and foreign bodies can penetrate the enclosure if the pressure relief device is damaged The degree of protection of the terminal box is no longer guaranteed a short circuit can occur which can result in death serious injury or material damage Do not operate the machine with a damaged pressure relief device Any damage may only be repaired after prior discussion with the person respons...

Page 63: ...ded wire A copper braided strip a stranded wire or a metal contact is used to ensure potential equalization between the cable entry plate and the terminal box enclosure Electrical connection 6 2 Connecting LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 63 ...

Page 64: ...Electrical connection 6 2 Connecting LOHER CHEMSTAR 1PS2 64 Operating Instructions 08 2016 ...

Page 65: ...ccordance with the specific situation on site The machine is undamaged The machine has been correctly installed and aligned the transmission elements are correctly balanced and adjusted All fixing screws connection elements and electrical connections have been tightened to the specified tightening torques The operating conditions match the data provided in accordance with the technical documentati...

Page 66: ...eeds specified in the technical data For this purpose compare the data on the rating plate or if necessary the system specific documentation The minimum insulation resistance values are within tolerance Minimum air clearances have been maintained Any supplementary motor monitoring devices and equipment have been correctly connected and are functioning correctly All brakes and backstops are operati...

Page 67: ... measurement until the risk is eliminated e g using the following measures Connect the terminals with the ground potential until the recharge voltage drops to a non hazardous level Attach the connection cable Measure the insulation resistance 1 Before you begin measuring the insulation resistance please read the operating manual for the insulation resistance meter you are going to use 2 Make sure ...

Page 68: ... the insulation resistance at a temperature change of 10 K is used as the basis The insulation resistance halves every time the temperature rises by 10 K The resistance doubles every time the temperature falls by 10 K For a winding temperature of approx 25 C the minimum insulation resistances are 20 MΩ U 1000 V or 300 MΩ U 1000 V The values apply for the complete winding to ground Twice the minimu...

Page 69: ...Ω when measured at 500 V DC 7 4 Heating in order to reach the required surface temperature Required surface temperature Always switch the heating on when the machine is at standstill When the heating is switched on for the first time commissioning make sure that the ambient air temperature does not fall below the minus temperature stated in the EC type examination certificate Otherwise the explosi...

Page 70: ... only a low dust content Checks before the first test run Before the first test run carry out the following checks The external fan is correctly fitted and aligned The rotor runs freely All of the retaining elements and electrical connections are securely tightened The grounding and equipotential bonding connections to the mains have been correctly made The air flow is not impeded or shut off by f...

Page 71: ...maximum room temperature of 40 C the maximum bearing temperature rise is 80 K Avoiding mechanical damage to bearings Regularly inspect all machines for any mechanical damage Especially observe that the bearing replacement intervals and relubrication intervals respectively grease change intervals or oil change intervals specified by the machine manufacturer are maintained Replace the bearings once ...

Page 72: ...serve the following Monitor the ramp up time and number of consecutive starts Comply with the limit values and or ramp up conditions specified in the catalog or the order documentation 4 During the test run check and document the following Check whether it is running smoothly Document the voltage current and power values As far as possible document the corresponding values of the driven machine If...

Page 73: ...peration are not maintained in accordance with DIN ISO 10816 3 then the machine can be mechanically destroyed During operation observe the vibration values in accordance with DIN ISO 10816 3 Start up 7 8 Test run LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 73 ...

Page 74: ...Start up 7 8 Test run LOHER CHEMSTAR 1PS2 74 Operating Instructions 08 2016 ...

Page 75: ...us Death serious injury or material damage can result if the required covers are removed Any covers that prevent live electrical or rotating parts from being touched or that ensure compliance with a particular degree of protection or are required for ensuring proper air flows and hence effective cooling must not be opened during operation WARNING Faults in operation Deviations from normal operatio...

Page 76: ...ch as rust can result 1 Depending on the environmental requirements and operating conditions remove the screw plugs with retaining washers to drain the water 2 Then refit the screw plugs and retaining washers If the machine is equipped with drainage plugs the water can drain away automatically 8 2 Current transformer CAUTION Terminal boxes with current transformers If you are using current transfo...

Page 77: ... in accordance with the motor s IP degree of protection See also the Stoppages section Table 8 1 Assignment of the total risk factor to the required supplementary measures for Ex e Rated voltage Explosion group Total risk fac tor Additional measures required in accord ance with IEC EN 60079 14 1 U 11 kV IIA IIB IIC 6 No 6 Yes operating the anti condensation heating and other special measures 8 4 S...

Page 78: ...when connected to the line supply the inrush starting current is a multiple of the rated current This can result in thermal overload This can damage the motor As a consequence when ramping up observe the following Monitor the ramp up time and number of consecutive starts Comply with the limit values and or ramp up conditions specified in the catalog or the order documentation 3 If this is possible...

Page 79: ...issioning the motor after a long period out of service carry out the measures recommended in the chapter entitled Commissioning 8 8 1 Switching on the anti condensation heater If the machine has anti condensation heating then switch it on when the machine is not in operation If the controller does not do this automatically switch on any anti condensation heating during stoppages This will avoid th...

Page 80: ...ves as reference markers During re commissioning refer to the information in the Commissioning section See also Start up Page 65 8 9 Decommissioning the machine NOTICE Damage as a result of an extended period out of service If the machine is going to be out of service for longer than six months then take the necessary measures for preservation and storing Otherwise damage to the machine will resul...

Page 81: ...o load operation High temperature rise with load High temperature rise of individual winding sections Possible causes of faults Remedial measures X X X X Overload Reduce the load X Interrupted phase in the supply cable Check the switches and cables X X X X Interrupted phase in the feeder cable af ter switching on Check the switches and cables X Mains voltage too low frequency too high Check the po...

Page 82: ... of gear unit Fix the gearing X X Resonance of the overall system com prising motor and foundation Stabilize the foundation following consultation X X Changes in foundation Establish the cause of the changes and eliminate them if necessary realign the machine 1 Take any changes into account when warming up the machine 8 11 4 Roller bearing faults Note Damage to roller bearings can be difficult to ...

Page 83: ...aring Avoid any vibration at standstill 8 11 5 Faults at the external fan The following table shows the possible causes of and remedial measures for faults on forced ventilated machines Table 8 5 Cooling system faults High temperature rise with load Possible causes of faults Remedial measures X Wrong direction of rotation of the external fan Check the electrical connections to the external fan X E...

Page 84: ...Operation 8 11 faults LOHER CHEMSTAR 1PS2 84 Operating Instructions 08 2016 ...

Page 85: ...ge 13 Comply with the IEC EN 60079 17 standard during all service and maintenance work on the machine Note Service Center Please contact the Service Center Page 117 if you require support with servicing maintenance or repair 9 1 Inspection and maintenance 9 1 1 Safety instructions for inspection and maintenance WARNING Rotating and live parts Electric machines contain live and rotating parts Fatal...

Page 86: ...cause damage to the machine extending to total failure When cleaning with compressed air ensure there is adequate extraction NOTICE Machine damage caused by foreign bodies Foreign bodies such as dirt tools or loose components such as screws etc can be left by accident inside the machine after maintenance is performed These can cause short circuits reduce the performance of the cooling system or in...

Page 87: ...ter such faults 9 1 4 First inspection Perform the following checks after approximately 500 operating hours or one year whichever comes first Table 9 1 Checks after installation or repair Check When the motor is running At stand still The electrical parameters are maintained X The permissible bearing temperatures are not exceeded X The smooth running characteristics and machine running noise have ...

Page 88: ...pports are correctly seated and properly bonded X The winding insulation resistances are sufficiently high X Any bearing insulation is fitted as shown on the plates and labels X The CABLES and insulating parts and components are in good condition and there is no evidence of discoloring X You can perform these checks while the motor is at standstill or if required while running NOTICE If you detect...

Page 89: ...ternal oil supply monitor that lubrication is maintained 9 1 7 Maintenance 9 1 7 1 Insulation resistance and polarization index Measuring the insulation resistance and polarization index PI provides information on the condition of the machine It is therefore important to check the insulation resistance and the polarization index at the following times Before starting up a machine for the first tim...

Page 90: ...8 160 32 32 180 51 51 200 63 63 225 79 79 250 99 99 280 99 132 315 4000 8000 11000 2800 5600 8000 35 25 355 4000 5600 35 50 The specified grease stability times and or relubrication intervals are valid for maximum ambient temperatures of 40 C Reduce the lubrication interval for a 10 C increase in temperature by a factor of 0 7 of the value listed in the table max 20 C factor 0 5 With an ambient te...

Page 91: ... value listed in the table max 20 C factor 0 5 Times for operation on 60 Hz systems on request 9 1 7 3 Regreasing intervals and types of grease for operating rolling contact bearings Regreasing intervals The regreasing intervals for roller bearings in operating hours and the grease types are stated on the machine s lubricant plate Regardless of the actual number of operating hours reached the mach...

Page 92: ...ion chambers at the intervals shown on the notice plate with the motor stopped and remove the used bearing grease If this is not done the grease will clog and the bearings will overheat WARNING Rotor can fall out If the machine is in a vertical position the rotor can fall out while work is being performed on the locating bearing This can result in death serious injury or material damage Support or...

Page 93: ...on Grease SRI2 Klüber Petamo GHY 133N SKF LGHP 2 Exxon Mobil Polyrex EM Observe the following when changing over to an alternative type of grease that is permitted according to the table Bearings with permanent lubrication Completely remove the old grease from the bearing before regreasing it Fill roller bearings completely with grease and cavities in the bearing cover only up to one third Bearing...

Page 94: ...s must be free of any dirt WARNING Explosion hazard Cleaning the machine in an explosive atmosphere is forbidden This can result in death serious injury or material damage Surfaces can become statically charged and discharge to ignite potentially explosive atmospheres 9 1 7 5 Cleaning the cooling air passages Regularly clean the cooling air passages through which the ambient air flows e g using dr...

Page 95: ...ce Note Flowrate The full flowrate is only achieved if the inward flow of air to the impeller is unrestricted Servicing the external fan motor Perform an occasional visual inspection of the external fan motor and check it electrically and mechanically every time the roller bearings are replaced Replace permanently lubricated roller bearings in the external fan motor as specified in the operating i...

Page 96: ...hey will provide you with more information about the correct paint system and methods of repairing paint damage Complete overpainting The paint applied must conform to the requirements to avoid electrostatic charging See DIN EN 60079 0 The repair of painted surfaces of the non conductive paint coating up to a nominal coating thickness of 350 μm was investigated and is acceptable 9 1 7 8 Repainting...

Page 97: ... charge transfer M IIB Limit value for the highest transferred charge 25 nC IIC Limit value for the highest transferred charge 10 nC for Group II machines gas III Limit value for the highest transferred charge 200 nC for Group III machines dust Incapability dangerous charge to be saved IIB Limit value for the maximum capacity 10 pF IIC Limit value for the maximum capacity 3 pF for Group II machine...

Page 98: ... shaft Avoid any blows that might damage the bearing 6 Make sure that the roller bearing is resting against the shaft shoulder or the second bearing Otherwise axial vibrations may occur 7 Fill the bearing to the top with the specified lubricating grease 8 Warm up the grease slinger and push it onto the shaft 9 Locate the locking ring in the shaft groove or attach the bearing using the shaft nut or...

Page 99: ... place it over the stator cable 4 Drill out the terminal studs according to DIN 46228 corresponding with the cross section of the stator cable 5 Place the terminal studs on the stator cable and secure these with a stud bolt according to DIN 916 6 Solder the terminal studs using soft solder L Sn 90 Stator cable with terminal studs WARNING Rotor can fall out If the motor is in a vertical position th...

Page 100: ...Hylomar M Follow the manufacturer s application and safety instructions when doing this Check all sealing elements such as those on the terminal boxes for elasticity aging or damage and renew them if they are no longer effective WARNING Damage to the machine possible Never dismantle the bearing shields and inner grease chamber cap or loosen the screws of these parts This can result in death seriou...

Page 101: ...ion in a potentially explosive gaseous atmosphere This can result in death serious injury or material damage Repairing and mounting the anti condensation heating and the subsequent routine testing must always be undertaken by experts from the Service Center because this work requires extensive specialist knowledge Only authorized and tested spare parts may be used Maintenance 9 2 Corrective Mainte...

Page 102: ...Maintenance 9 2 Corrective Maintenance LOHER CHEMSTAR 1PS2 102 Operating Instructions 08 2016 ...

Page 103: ...he drive end Terminal box If several terminal boxes are mounted on the machine please also indicate the type designation of the terminal box in addition to details of part designation and part number according to the legend as well as type and serial number of the motor when ordering spare parts Example Terminal box type Terminal box cover part 20 30 Serial number of the motor Machine type Rolling...

Page 104: ...nti condensation heating Please contact the Service Center for spare parts 10 2 Anti condensation heating WARNING Risk of explosion If repairs to the anti condensation heating are not carried out correctly e g if unauthorized or untested spare parts are used this can result in explosions during operation in a potentially explosive gaseous atmosphere This can result in death serious injury or mater...

Page 105: ... frame 4 24 Gamma ring 2 00 Shaft with rotor 4 34 Spacer washers 2 01 Feather key 4 44 Gamma ring 3 01 End shield drive end 5 10 Fan cover 3 08 Flange plate 5 11 Protective cover 3 21 End shield non drive end 5 56 Fan 4 01 Roller bearing DE 6 00 Terminal box 4 05 Roller bearings NDE Spare Parts 10 3 Spare parts list frame sizes 071 to 132 LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 105 ...

Page 106: ...10 4 Spare parts list frame sizes 160 to 280 0 0 Image 10 2 E AN000 0004 Spare Parts 10 4 Spare parts list frame sizes 160 to 280 LOHER CHEMSTAR 1PS2 106 Operating Instructions 08 2016 ...

Page 107: ...ver NDE inner 3 08 Flange plate DE 4 34 Spacer washer NDE 3 21 Bearing shield NDE 4 38 Outer grease chamber cover 4 00 Bearing shield NDE 4 44 Sealing ring NDE outer 4 01 Bearing DE 4 54 Relubrication NDE 4 05 Bearing NDE 5 10 Complete fan cowl 4 10 Grease chamber cover DE outer 6 00 Terminal box 4 12 Grease chamber cover DE inner Spare Parts 10 4 Spare parts list frame sizes 160 to 280 LOHER CHEM...

Page 108: ...4 24 Sealing ring DE outer 2 01 Keyway 4 30 Grease chamber cover NDE outer 3 01 Bearing shield DE 4 32 Grease chamber cover NDE inner 3 08 Flange plate DE 4 34 Spacer washer NDE 3 21 Bearing shield NDE 4 38 Outer grease chamber cover 4 00 Bearing shield NDE 4 44 Sealing ring NDE outer Spare Parts 10 5 Spare parts list frame size 315 LOHER CHEMSTAR 1PS2 108 Operating Instructions 08 2016 ...

Page 109: ... Bearing NDE 5 10 Complete fan cowl 4 10 Grease chamber cover DE outer 6 00 Terminal box 4 12 Grease chamber cover DE inner 10 6 Spare parts list frame size 355 0 9 0 Image 10 4 E DN000 0010 Spare Parts 10 6 Spare parts list frame size 355 LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 109 ...

Page 110: ...ange plate DE 4 38 Grease slinger NDE 3 21 Bearing shield NDE 4 44 Sealing ring NDE outer 4 00 Grease nipple 5 01 Fan cowl complete 4 01 Bearing DE 5 04 Fan hub NDE 4 05 Bearing NDE 5 11 Protective cover 4 10 Grease chamber cover DE outer 5 56 Fan complete 4 12 Grease chamber cover DE inner 6 00 Terminal box 4 13 Grease slinger DE 4 24 Sealing ring DE outer Spare Parts 10 6 Spare parts list frame ...

Page 111: ...signation Part num ber Designation 6 03 Terminal box base 6 14 Mounting plate 6 05 Terminal box cover 6 15 Complete terminal board 6 13 Terminal box seal 6 17 Additional terminal Spare Parts 10 7 Spare parts list for terminal boxes with type of protection Ex e frame sizes 071 160 LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 111 ...

Page 112: ...num ber Designation Part num ber Designation 6 03 Terminal box base 6 15 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 13 Terminal box seal Spare Parts 10 8 Spare parts list for terminal boxes with type of protection Ex e frame sizes 180 225 LOHER CHEMSTAR 1PS2 112 Operating Instructions 08 2016 ...

Page 113: ...ignation Part num ber Designation 6 03 Terminal box base 6 14 Mounting plate 6 05 Terminal box cover 6 15 Gland terminal 6 07 Gland plate 6 17 Additional terminal 6 10 Cable gland Spare Parts 10 9 Spare parts list for terminal boxes with type of protection Ex e frame sizes 250 to 355 LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 113 ...

Page 114: ...HQ HLFKQXQJVQU UDZLQJ1R 7HLOHNODVVH 3DUW FODVV 6SUDFKH DQJXDJH XVDW GG ODWW 6KHHW B PP Image 10 8 Spare parts list for terminal boxes with type of protection Ex i Part num ber Designation Part num ber Designation 6 03 Terminal box base 6 22 AK seal 6 05 Terminal box cover 6 23 AK seal 6 06 AK intermediate flange 6 24 AK seal 6 10 Cable gland 6 31 Mounting rail 6 17 Additional terminal 6 67 Support...

Page 115: ...certain Hazardous Substances we replace substances that are damaging to the environment by those that are not based on state of the art technology In doing so safety in operation and handling will take priority at all times Note Country specific legislation When disposing of the machine or of waste that is created during the individual phases of its life cycle please observe the statutory requirem...

Page 116: ...ease Cleaning substances and solvents Paint residues Anti corrosion agent Coolant additives such as inhibitors antifreeze or biocides Dispose of the separated components according to local regulations or via a specialist disposal company The same applies for cloths and cleaning substances which have been used while working on the machine Packaging material If necessary contact a suitable specialis...

Page 117: ...erson If you wish to request on site service or order spare parts please contact your local office This office will contact the responsible service center on your behalf You can find your contact person in the relevant contact database www siemens com yourcontact www siemens com yourcontact Siemens Support for on the move You can obtain optimum support anywhere you go using the Siemens Industry On...

Page 118: ...Service and Support LOHER CHEMSTAR 1PS2 118 Operating Instructions 08 2016 ...

Page 119: ...C 3 5 8 20 40 70 170 340 600 120 0 200 0 310 0 470 0 750 0 Nm Applications The above mentioned tightening torques apply for the following applications Case A Applies to electrical connections in which the permissible torque is normally limited by the bolt materials and or the current carrying capacity of the insulators with the exception of the busbar connections in case B Case B Applies to bolts ...

Page 120: ...Technical data and drawings LOHER CHEMSTAR 1PS2 120 Operating Instructions 08 2016 ...

Page 121: ...Quality documents C C 1 EC Declaration of Conformity LOHER CHEMSTAR 1PS2 Operating Instructions 08 2016 121 ...

Page 122: ...Quality documents C 1 EC Declaration of Conformity LOHER CHEMSTAR 1PS2 122 Operating Instructions 08 2016 ...

Page 123: ...e s but does not imply any guarantee of quality or durability The safety instructions of the accompanying product documentation shall be observed Tschechisch český jazyk Prohlášení o shodě s předpisy ES EU podle dodatku VII směrnice EU 94 9 ES 2014 34 EU Výrobce Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Výše uvedený výrobek se shoduje s předpisy následujících harmon...

Page 124: ...kaffenheds eller holdbarhedsgaranti Sikkerhedshenvisningerne i den medleverede produktinformation skal overholdes Estnisch eesti keel ELi vastavusdeklaratsioon vastavalt EÜ direktiivi 94 9 EÜ 2014 34 EL lisale VII Tootja Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Deklaratsiooni ülalkirjeldatud ese on kooskõlas Liidu asjaomase harmoniseeritud seadusandlusega 19 04 201...

Page 125: ... ή διάρκειας ζωής Πρέπει να τηρούνται οι οδηγίες ασφαλείας της συνοδευτικής τεκμηρίωσης προϊόντος Spanisch español Declaración CE UE de conformidad según el Anexo VII de la Directiva 94 9 CE 2014 34 UE Fabricante Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott El producto arriba mencionado es conforme a la legislación de armonización de la Unión pertinente 19 4 2016 94 9 ...

Page 126: ...produit fournie Italienisch italiano Dichiarazione di conformità CE UE secondo l allegato VII della Direttiva Europea 94 9 CE 2014 34 UE Costruttore Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott L oggetto della dichiarazione sopra descritto è conforme alle prescrizioni di armonizzazione pertinenti dell Unione 19 04 2016 94 9 CE Direttiva del Parlamento Europeo e del Con...

Page 127: ...t tā neietver nekādu kvalitātes vai ilgmūžīguma garantiju Jāievēro pievienotās izstrādājuma dokumentācijas drošības instrukcijas Litauisch lietuvių EB ES atitikties deklaracija pagal EB direktyvos 94 9 EB 2014 34 ES VII priedą Gamintojas Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Pirmiau aprašytas deklaruojamas dalykas atitinka atitinkamus Sąjungos derinamuosius teis...

Page 128: ...figyelembe kell venni Maltesisch Malti Dikjarazzjoni ta Konformità tal UE skont l Anness VII tad Direttiva 94 9 KE 2014 34 UE tal KE Manifattur Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Il prodott indikat fid dikjarazzjoni msemmija hawn fuq huwa f konformità mal leġiżlazzjoni rilevanti tal Unjoni dwar l armonizzazzjoni 19 04 2016 94 9 KE Direttiva tal parlament Ewro...

Page 129: ...ntie betreffende de gesteldheid of de houdbaarheid De veiligheidsaanwijzingen in de meegeleverde productdocumentatie dienen te worden nageleefd Norwegisch Norsk EU konformitetserklæring i henhold til vedlegg VII til EUs direktiv 94 9 EU 2014 34 EU Produsent Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Objektet for erklæringen overfor er i overensstemmelse med forskrift...

Page 130: ...a zawartych w dokumentacji dołączonej do produktu Portugiesisch português Declaração de conformidade CE UE segundo Anexo VII da Diretiva 94 9 CE 2014 34 UE Fabricante Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott O produto acima especificado está em conformidade com a legislação de harmonização da União Europeia relevante 19 4 2016 94 9 CE Directiva do Parlamento Europe...

Page 131: ...димо соблюдать указания по технике безопасности в документации из комплекта поставки изделия Slowakisch slovenský jazyk Prehlásenie o zhode s normami EÚ v súlade s prílohou VII Smernice 94 9 ES 2014 34 EÚ Výrobca Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Vyššie popísaný predmet prehlásenia je v súlade s príslušnými harmonizačnými právnymi predpismi Únie 19 4 2016 94...

Page 132: ...entacije izdelka Finnisch suomi EU vaatimustenmukaisuusvakuutus EY direktiivin 94 9 EY 2014 34 EU liitteen VII mukaan Valmistaja Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Edellä kuvattu vakuutuksen kohde on unionin sovellettavan yhdenmukaistamislainsäädännön mukainen 19 4 2016 94 9 EY Euroopan Parlamentin ja Neuvoston direktiivi räjähdysvaarallisissa tiloissa käytet...

Page 133: ...kumentationen Rumänisch România Declaraţie de conformitate CE UE în conformitate cu anexa VII a Directivei CE 94 9 CE 2014 34 UE Producător Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Obiectul declaraţiei descrise mai sus este conform cu legislaţia armonizată relevantă a Uniunii bis 19 4 2016 94 9 CE Directiva Parlamentului European şi a Consiliului cu privire la unif...

Page 134: ... с посочените директива и но не е гаранция за качество или трайност Да се спазват указанията за безопасност от придружаващата продукта документация Kroatisch hrvatski jezik Izjava o usklađenosti EU a u skladu s Prilogom VII Direktive EZ a 94 9 EZ 2014 34 EU Proizvođač Siemens Aktiengesellschaft Hans Loher Straße 32 D 94099 Ruhstorf a d Rott Predmet gore opisane izjave je usklađenost s relevantnim ...

Page 135: ...X 3005 NB 0102 1 E 160 1PS216 Niederspannung low voltage PTB 07 ATEX 3010 NB 0102 1 PTB 14 ATEX 3002 NB 0102 1 E 180 1PS218 Niederspannung low voltage PTB 08 ATEX 3002 NB 0102 1 PTB 13 ATEX 3023 NB 0102 1 E 200 1PS220 Niederspannung low voltage PTB 06 ATEX 3004 X X NB 0102 1 PTB 07 ATEX 3137 NB 0102 1 PTB 14 ATEX 3003 NB 0102 1 E 225 1PS222 Niederspannung low voltage PTB 07 ATEX 3009 NB 0102 1 PTB...

Page 136: ... E 800 1PS280 Niederspannung low voltage PTB 07 ATEX 3151 NB 0102 1 Hochspannung high voltage PTB 07 ATEX 3152 NB 0102 1 J 500 1PS250 Niederspannung low voltage PTB 06 ATEX 3031 NB 0102 1 Hochspannung high voltage J 560 1PS256 Niederspannung low voltage PTB 07 ATEX 3023 NB 0102 1 PTB 07 ATEX 3029 X X NB 0102 1 Hochspannung high voltage PTB 07 ATEX 3024 NB 0102 1 J 710 1PS271 Niederspannung low vol...

Page 137: ...D for the IECEx certificate can be found on the rating plate of the machine or on the extra plate for explosion protection 1 Enter the IECEx ID in the Quick access field You then have access to the certificate 2 If you scroll down completely to the bottom of the page shown you can open the certificate as a PDF file and download it Quality documents C 2 IECEx certificate LOHER CHEMSTAR 1PS2 Operati...

Page 138: ...Quality documents C 2 IECEx certificate LOHER CHEMSTAR 1PS2 138 Operating Instructions 08 2016 ...

Page 139: ...usage 22 Corrective maintenance Initial inspection 87 Cross section of the grounding conductor 56 Current transformer 76 D Damage during transportation 31 Delivery 31 Direction of rotation 57 Disposal Chemicals 116 Components 116 E Electrical faults 81 Electromagnetic compatibility 18 Electromagnetic fields 19 Emergency off 78 Emitted interference 19 End sleeve 99 Equipotential 62 ESD guidelines 1...

Page 140: ...nce intervals 85 Mechanical faults 82 Minimum air clearances 58 More information 117 Mounting parts 40 Mounting foot hole dimensions 41 N Noise emissions 16 28 O Operating mode 25 O ring seals 61 100 Output element 51 Overall flatness 50 Overspeed 25 Overspeeds 25 P Paint finish 24 Paint system 96 Paintwork damage 96 Permanent lubrication 90 Polarization index 36 66 69 89 Positioning 48 Precision ...

Page 141: ... Standard flange 49 Stoppages 79 Roller bearings 80 Supplementary devices 24 Switching off Anti condensation heating 79 Switching on 72 78 System resonances 30 System inherent frequencies 30 T Technical Support 117 Temperature class 78 79 Temperature limits 33 Terminal board 59 Terminal box close 62 Maintaining 95 Terminal designation 57 Terminal studs 99 Test run 72 Tightening torques 53 Bolted c...

Page 142: ...Index LOHER CHEMSTAR 1PS2 142 Operating Instructions 08 2016 ...

Page 143: ...AD EC Declaration of Conformity U161 ...

Page 144: ...Siemens AG Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY www siemens com drives ...

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