Siemens SIMATIC S5 1P 243 Operating Instructions & Installation Instructions Download Page 82

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WARNING

Machine damage
If the machine is not maintained it can suffer damage. This can cause faults which can result

in eventual or immediate death, serious injury or material damage.
Perform regular maintenance on the machine.

CAUTION

Dust disturbances when working with compressed air
When cleaning with compressed air, dust, metal chips, or cleaning agents can be whirled up.

Injuries can result.
When cleaning using compressed air, make sure you use suitable extraction equipment and

wear protective equipment (safety goggles, protective suit, etc.).

NOTICE
Damage to insulation
If metal swarf enters the winding head when cleaning with compressed air, this can damage

the insulation. Clearance and creepage distances can be undershot. This may 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 increase noise in operation. They can also

damage the machine.
● When carrying out maintenance work, make sure that no foreign bodies are left in or on

the machine.

● Securely attach all loose parts again once you have completed the maintenance

procedures.

● Carefully remove any dirt.

Note
Operating conditions and characteristics can vary widely. For this reason, only general

intervals for inspection and maintenance measures can be specified here.

Maintenance
9.1 Inspection and maintenance

LOHER CHEMSTAR 1PS5

Operating Instructions 03/2014

Summary of Contents for SIMATIC S5 1P 243

Page 1: ...for industry LOHER CHEMSTAR Induction motor Type 1PS5 Operating Instructions Installation Instructions N R 601d Edition 03 2014 For employment in zone 1 or zone 2 IEC EN 60079 10 1 0102 II 2G Ex d IIC IIB T Gb ...

Page 2: ...11 03 2014 02 49 V4 00 ...

Page 3: ...zone 2 IEC EN 60079 10 1 0102 II 2G Ex d IIC IIB T Gb Edition 03 2014 Introduction 1 Safety notes 2 Description 3 Preparations for use 4 Assembling 5 Electrical connection 6 Commissioning 7 Operation 8 Maintenance 9 Spare parts 10 Disposal 11 Service and Support A Technical data and drawings B Quality documents C ...

Page 4: ...personnel are 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 manufacturer...

Page 5: ...guring the plant 27 4 2 Motors without final paint coating 27 4 3 Ensuring adequate cooling 27 4 4 Thermal motor protection 28 4 5 Interlock circuit for anti condensation heating 28 4 6 Interlock circuit for the external fan motor 28 4 7 Noise emissions 29 4 8 Voltage and frequency fluctuations during line operation 29 4 9 System inherent frequencies 30 4 10 Transport and storage 30 4 10 1 Transpo...

Page 6: ...49 5 2 7 Roughly aligning the machine 49 5 3 Installing the machine 49 5 3 1 Preconditions for smooth vibration free operation 49 5 3 2 Aligning the machine to the driven machine and mounting 50 5 3 2 1 Horizontal types of construction with mounting feet 50 5 3 2 2 Horizontal types of construction with flange 50 5 3 2 3 Vertical types of construction with flange 51 5 3 3 Alignment accuracy 51 5 3 ...

Page 7: ...ts 77 8 9 3 Mechanical faults 78 8 9 4 Roller bearing faults 79 8 9 5 Faults at the external fan 80 8 9 6 Cooling system faults water jacket cooling 80 9 Maintenance 81 9 1 Inspection and maintenance 81 9 1 1 Inspections in the event of faults 84 9 1 2 First inspection 84 9 1 3 General inspection 84 9 1 4 Servicing the roller bearings 85 9 1 5 Bolt grade 85 9 1 6 Mechanical explosion protection fo...

Page 8: ...10 11 Spare parts list for terminal boxes with type of protection Ex d frame sizes 180 225 112 10 12 Spare parts list for terminal boxes with type of protection Ex e frame sizes 180 225 114 10 13 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 115 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 117 11 Disposal 12...

Page 9: ...ator winding insulation resistance at 40 C 71 Table 8 1 Electrical faults 78 Table 8 2 Mechanical faults 78 Table 8 3 Roller bearing faults 79 Table 8 4 Cooling system faults 80 Table 8 5 Cooling system faults 80 Table 9 1 Checks after installation or repair 84 Table 9 2 Checks that have to be performed during the general inspection 84 Table 9 3 Bolt grade BG071 to BG315 85 Table 9 4 Bolt grade BG...

Page 10: ...igure 10 6 E 9 108_213 0001 110 Figure 10 7 E 9 108_213 0002 112 Figure 10 8 E 9 101_208 0002 114 Figure 10 9 E 9 101_285 0002 115 Table of contents LOHER CHEMSTAR 1PS5 10 Operating Instructions 03 2014 ...

Page 11: ... 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 the order given...

Page 12: ...Introduction LOHER CHEMSTAR 1PS5 12 Operating Instructions 03 2014 ...

Page 13: ... the plant is not guaranteed An explosion can result This can result in death serious injury or material damage Commission the machine only when the plant conformance with the explosion protection directive has been confirmed 2 2 The five safety rules For your personal safety and to prevent material damage when carrying out any work always observe the safety instructions and the following five saf...

Page 14: ...ine Always pay attention to your safety Also observe the following to prevent accidents General safety regulations applicable in the country where the machine is deployed Manufacturer specific and application specific regulations Special agreements made with the operator Separate safety instructions supplied with the machine Safety symbols and instructions on the machine and its packaging WARNING ...

Page 15: ... CAUTION Hazardous substances Chemical substances required for the setup operation and maintenance of machines can present a health risk Poisoning skin damage cauterization of the respiratory tract and other health damage may result Read the information in these operating instructions and the product information supplied by the manufacturer Observe the relevant safety regulations and wear the pers...

Page 16: ...erating risks and local operating conditions and the necessary monitoring methods must be clarified and made binding by the system operator in consultation with the responsible supervisory authority The required measures must be adhered to at all times The machine manufacturer cannot provide any generally applicable recommendations Please observe the information in these operating instructions Not...

Page 17: ...o contact with electrically insulating materials such as plastic film plastic parts insulating table supports or clothing made of synthetic fibers Always place electrostatic sensitive devices on conductive bases Always pack store and transport electronic modules or components in conductive packaging e g metallized plastic or metal containers conductive foam material or domestic aluminum foil The n...

Page 18: ...ING Interference voltages when operating the converter When a converter is in operation the emitted interference varies in strength depending on the converter manufacturer type interference suppression measures undertaken On machines with integrated sensors e g PTC thermistors interference voltages caused by the converter may occur on the sensor lead This can cause faults which can result in event...

Page 19: ...e plant by taking appropriate measures such as erecting identifying markings safety barriers and warning signs and giving safety talks Observe the nationally applicable health and safety regulations Do not carry any magnetic or electronic data media 2 11 Ventilation NOTICE Ventilation Do not obstruct ventilation Prevent the air expelled by neighboring equipment from being immediately drawn in agai...

Page 20: ...Safety notes 2 11 Ventilation LOHER CHEMSTAR 1PS5 20 Operating Instructions 03 2014 ...

Page 21: ...nd IEC EN 60079 31 This electrical machine corresponds to standards of the IEC EN 60034 IEC EN 60079 0 and IEC EN 60079 31 series Only operate the machine in hazardous areas strictly complying with the specifications of the responsible supervisory authorities The relevant supervisory authority is responsible for determining the hazard level of each area and classifying the zones The type of protec...

Page 22: ... used where these two simultaneously occur after the user has first analyzed the properties of the hybrid mixture NOTICE Use of machines without CE marking Machines without CE marking are intended for operation outside the European Economic Area EEA Do not use any machines without a CE marking in the EEA The roller bearing machines with Ex d type of protection can have the following Ex marking Tab...

Page 23: ...used as the basis to design and test this machine are stamped on the rating plate The machine design basically complies with the subsequent standards Please refer to the EC Declaration of Conformity for the versions of the harmonized standards referenced Table 3 4 Machine design Feature Standard Rating and performance IEC EN 60034 1 Degree of protection IEC EN 60034 5 Cooling IEC EN 60034 6 Type o...

Page 24: ...otor enclosure with water jacket cooling Stator frame and bearing shields are from cast iron or steel The stator jacket is formed as a double jacket through which the coolant is fed The frame is equipped with a cooling water inlet and outlet Motor enclosure with surface hollow fin or tube cooling Depending on their size the stator frame and bearing shields are from cast iron or steel The fan cover...

Page 25: ...or The rotor has a squirrel cage rotor manufactured out of die cast aluminum or a brazed copper rotor The rotor is dynamically balanced The balance condition is stated on the shaft end face or rating plate Bearings The motors are equipped with grease lubricated roller bearings The bearings of the standard version motors up to size 280 are permanently lubricated The bearings of motors from size 315...

Page 26: ...are only intended as additional protection for the winding They are not used to limit the maximum surface temperature of the frame see the data stamped on the rating plate Prevent the maximum surface temperature from being exceeded by maintaining the specified operating conditions External fan The machine can be fitted with an external fan For IC 666 there are two external fans The electrical conn...

Page 27: ...achine s operating mode Use a suitable control system to prevent overspeeds thus protecting the machine from damage 4 2 Motors without final paint coating Motors which are only delivered with primer must be painted to comply with the applicable guidelines for the specific application The primer does not provide adequate corrosion protection The paint used must fully comply with the requirements to...

Page 28: ...nction tested tripping devices with type of protection marking II 2 G No voltage 2 5 V may be applied for any continuity test required on the temperature sensor For each speed range of pole changing motors use only isolated interlocked protective devices that have been tested and certified by an approved test center 4 5 Interlock circuit for anti condensation heating If the anti condensation heati...

Page 29: ...nding Exceeding the permissible tolerances for voltage and frequency can lead to an impermissibly high temperature rise in the windings and thus cause long term damage to the machine Be aware that every machine must be protected against unpermitted heating The following notes apply here Every machine must be protected against an inadmissible temperature rise according to IEC EN 60079 14 using a cu...

Page 30: ... This way up Fragile goods Keep dry Keep cool Center of gravity Do not use hand hook Attach here When carrying out any work on the machine observe the general safety instructions and the specifications contained in EN 50110 1 regarding safe operation on electrical equipment 4 10 2 Checking the delivery The components are assembled on an individual basis When you take receipt of the delivery please...

Page 31: ...ices The weight of the machine is stated on the rating plate WARNING Center of gravity when transporting or lifting the motor 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 gear when it is being transported or lifted This can result in death serious injury or material damage 1 Always take account of the ce...

Page 32: ...f storage conditions are inappropriate there is a risk of bearing seizure damage This can result in material damage such as damage to bearings caused by vibration On machines that have been supplied with a rotor shipping brace secure the rotor as per the notes on transportation Protect the machine against strong radial vibrations since the rotor shipping brace might not absorb these completely NOT...

Page 33: ...hine and be ignited during commissioning Explosions can occur This can result in death serious injury or material damage The materials used are specially designed for the temperature range required by the customer Do not store the motor in conditions that lie outside the specified temperature limits The relevant temperature limits are specified on the rating plate 4 10 5 2 Storing motors with wate...

Page 34: ...ase the free parts of the shaft extension as well as all other bare metal parts such as mounting foot surfaces flange surfaces terminal box and cover contact surfaces Attach caps filled with roller bearing grease to the shaft output gland to provide protection against dust and humidity Fill the terminal boxes of the machines with a substance that will absorb moisture e g Branogel Store the machine...

Page 35: ...ation on testing and the limit values can be found here Testing the insulation resistance and polarization index Page 70 4 10 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 li...

Page 36: ...grease 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 11 Converter operation When controlling explosion protected machines from a conve...

Page 37: ...6 surface cooled force ventilated and IC71W water jacket cooled 3 IC411 surface cooled self ventilated 4 IC516 tube cooled force ventilated IC616 air air heat exchanger force ventilated externally IC81W air water heat exchanger self ventilated 5 IC511 tube cooled self ventilated IC611 air air heat exchanger self ventilated Converter operation If the motor design requires a special converter assign...

Page 38: ...ential bonding conductors Between motor and driven machine Between motor and converter Between terminal box and RF grounding point at the motor enclosure Use a separate RF equipotential bonding conductor Between motor enclosure and protective ground rail of the converter Between motor enclosure and driven machine Selecting and connecting the cable As far as possible use symmetrically arranged shie...

Page 39: ...Limit the rise in voltage by using output filters This dampens the harmonic content in the output voltage Note Converter documentation The operating instructions for the converter are not part of this documentation Refer also to the configuration information for the converter 4 11 2 Insulated bearings when operating the converter Depending on the machine s size and design an insulated bearing and ...

Page 40: ...ng machine Insulated bearings Motor Insulated tachometer fitting Coupling Insulated coupling Figure 4 2 Schematic representation of a tandem drive NOTICE Bearing damage If the coupling between the motors of the tandem drive is not insulated bearing currents can cause damage to the drive end bearings of both motors Use an insulated coupling to link the motors Preparations for use 4 11 Converter ope...

Page 41: ...not discharged there can be a voltage at the motor terminals even when the rotor is not moving The voltage is up to 1000 V depending on the converter type Ensure that the five safety rules are followed before working on the motor Preparations for use 4 11 Converter operation LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 41 ...

Page 42: ...Preparations for use 4 11 Converter operation LOHER CHEMSTAR 1PS5 42 Operating Instructions 03 2014 ...

Page 43: ...or screwed connections Tighten the screwed connections to the specified tightening torques WARNING Tensions on the fastening parts If the machine has not been properly aligned this will mean the fastening parts are subjected to stress distortion Screws may become loose or break the machine will move machine parts could be flung out of place This can result in death serious injury or material damag...

Page 44: ...stallation work Wherever possible measure the insulation resistance of the winding before starting installation work If the insulation resistance lies below the specified value take appropriate remedial measures These remedial measures may necessitate the machine being removed again and transported NOTICE High temperatures The motor components get very hot during operation High temperatures can da...

Page 45: ...y load handling attachments that are found to be damaged Check before use that the load handling attachments are correctly secured When lifting the machine use only approved and undamaged lifting gear of sufficient rated capacity Check these before using them WARNING The machine can be dropped If the load handling attachments and lifting gear are damaged or not correctly secured the machine may be...

Page 46: ...ion element correctly matches the type of balance of the rotor Use only ready drilled and balanced transmission elements Check the hole diameters and the balancing status before pulling them on Thoroughly clean the shaft extension Pulling on Warm up the transmission elements to expand them before pulling them on Select the temperature difference for the heating process to suit the coupling diamete...

Page 47: ...alancing The number of poles of the machine is specified on the rating plate in the designation of the motor type WARNING The feather key can fall out The feather keys are only locked against falling out during shipping 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 Do no...

Page 48: ... 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 hook ...

Page 49: ...ment The transmission element such as a coupling half has already been pulled on Roughly aligning the machine For horizontal positioning push the motor sideways across the foundation When doing so ensure that the axial position is maintained 5 3 Installing the machine 5 3 1 Preconditions for smooth vibration free operation Preconditions for smooth vibration free operation Stable foundation design ...

Page 50: ...tor s responsibility Note Machine expansion When aligning make allowance for the thermal expansion of the machine when the temperature increases 5 3 2 2 Horizontal types of construction with flange The standard flange is provided with a centering The choice of fit for the mating flange on the driven machine is the system manufacturer s or the plant operator s responsibility Note If the machine is ...

Page 51: ...ake the process easier 2 Screw in two studs into tapped holes on opposite sides of the driven machine flange The studs act as positioning aids 3 Lower the machine slowly toward the driven machine and into the centering so that the flanges do not quite touch Lowering too quickly risks damaging the centering 4 If necessary rotate the machine into the right position so that the clearance holes in the...

Page 52: ...perly The machine will overheat which could result in material damage or even a write off Remove the flange cover plate Insert the gaskets correctly 1 For the pipes select materials with the required chemical composition in accordance with the water conditions Also consider the pressure load and compatibility with the materials from which the cooler is made 2 Route and support the water pipes so t...

Page 53: ... you do not then put the machine into operation you must implement the measures necessary during stoppages NOTICE Bleed air from the cooling ducts If the cooling ducts are not completely filled with water sufficient machine cooling cannot be guaranteed and the machine may overheat Ensure that the air is bled from the cooling ducts during filling and that the cooling ducts are completely filled wit...

Page 54: ...Assembling 5 4 Cooling water supply for machines with water cooling LOHER CHEMSTAR 1PS5 54 Operating Instructions 03 2014 ...

Page 55: ...ger 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 material failure of the system Tighten the screwed connections to the specified tightening torques Observe any specifications regarding the materials from which fixing...

Page 56: ...ntrinsically safe power circuit Um 700 V alternating voltage Intrinsically safe power circuit in fail safe type of protection Ex ib IIB IIC only connected to certified intrinsically safe circuits that are galvanically isolated from ground Maximum values for total IIB IIC e g at T4 Ui 28 V Ui 24 V Ii 300 mA Ii 170 mA Pi 1 3 W Pi 1 3 W The effective internal inductance and capacitance are negligibly...

Page 57: ... threads are closed with non certified closures on delivery this means that the type of protection is no longer guaranteed An explosion may occur during operation This can result in death serious injury or material damage Replace the closures with cable entries that have been tested and certified in accordance with IEC EN 60079 1 6 2 3 Terminal boxes with type of protection Ex e WARNING If the sea...

Page 58: ...e installation regulations and also with IEC EN 60204 1 Table 6 2 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 casing or on the flanged endshield depending on the frame size The grounding point is marked The t...

Page 59: ...ou transpose two connections e g L1 L2 L3 at V U W the resulting rotation will be counter clockwise Machines which must run only in one specific direction of rotation are marked with a direction of rotation arrow 6 2 8 Terminal box The number and size of the cable entry tapped holes can be found in the machine dimension drawing Only use cable entries that are suitable for the cable Only use suitab...

Page 60: ...elief to the torque specified by the manufacturer 4 Seal the screwed sockets on the cable glands in accordance with the degree of protection Use only sealing plugs cable entries and conductor entries that are certified and marked for use in the respective hazardous area the zone 6 2 9 Minimum air clearances After proper installation verify that the minimum air clearances between non insulated part...

Page 61: ...eeded 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 11 Connection with terminal board Note that for terminal boards with U shaped terminal clamps the conductors to be connected must be placed under the terminal clamps in a U shape Alternatively with ...

Page 62: ... 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 5 Tightening torques for standard cable glands Nm Nominal size Cable gland for Ex e II TypeHSK M Cable gland for Ex e Ex d IIC Type ADE 1F ...

Page 63: ...essure 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 mater...

Page 64: ...ce 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 responsible ...

Page 65: ...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 1PS5 Operating Instructions 03 2014 65 ...

Page 66: ...Electrical connection 6 2 Connecting LOHER CHEMSTAR 1PS5 66 Operating Instructions 03 2014 ...

Page 67: ...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 documentation such as degree of protection ambient temperature etc Moving parts such as the coupling move freely If the second shaft extens...

Page 68: ...C thermistors that switch off the motor when the cooling water circuit fails The openings for the inlet and outlet are at the motor enclosure Vent plugs are optionally provided for the water chamber at the frame Vent the water chamber when filling for the first time and at regular intervals Use only clean non aggressive cooling water with a maximum sediment content of 10 mg l In order to avoid the...

Page 69: ...ons for the converter The specified limit speed nmax is not exceeded Limit speed nmin is not fallen below 7 2 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 ...

Page 70: ...stance of the winding in relation to the machine enclosure and the winding temperature The winding temperature should not exceed 40 C during the measurement Convert the measured insulation resistances to the reference temperature of 40 C according to the formula in the following table This thereby ensures that the minimum values specified can be compared 4 Read out the insulation resistance one mi...

Page 71: ... the formula from IEEE 43 2000 specified in the table In so doing doubling or halving the insulation resistance for a temperature change of 10 K is used as basis The insulation resistance halves every time the temperature rises by 10 K The resistance doubles every time the temperature falls by 10 K Dry new windings have insulation resistance of between 100 and 2000 MΩ or possibly even higher value...

Page 72: ... close to the critical value you must subsequently check the insulation resistance at shorter intervals See also Insulation resistance and polarization index Page 35 Limit values of the anti condensation heating insulation resistance The insulation resistance of the anti condensation heating with respect to the machine housing should not be lower than 1 MΩ when measured at 500 V DC Commissioning 7...

Page 73: ...us 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 operation such as incr...

Page 74: ...tween the rotor and the grounded motor This can cause the generation of sparks which especially in an explosive atmosphere can ignite surrounding dust or combustible gases Explosions can occur There is also a risk of an electric shock Death serious injury or material damage will result Do not open the bridging of the bearing insulation during operation NOTICE Excessive machine temperature If the a...

Page 75: ... does not switch off the air to water heat exchanger automatically switch it off when the machine is stopped 8 5 Switching on again after an emergency switching off Check the motor before restarting the driven machine after an emergency off Eliminate all the causes that have led to the emergency off 8 6 Stoppages The stoppage is a shutdown for a period of time during which the machine is stopped b...

Page 76: ... motor only with the contractually agreed water quality For avoidance of deposits the cooling water circuit must then be kept running So as to be certain of excluding the possibility of formation of condensation within the machine the anti condensation heating should also remain switched on if fitted 8 6 3 Avoidance of damage to roller bearings during stoppages Extended stoppages at the identical ...

Page 77: ...hat were taken for conservation and storage Perform the measures listed in the Commissioning section 8 9 Faults 8 9 1 Inspections in the event of faults Natural disasters or unusual operating conditions such as overloading or short circuit are faults that overload the machine electrically or mechanically Immediately perform an inspection after such faults Correct the cause of the fault as describe...

Page 78: ...ation with the manufacturer X Incorrect direction of rotation Check the connection 8 9 3 Mechanical faults Table 8 2 Mechanical faults Grinding noise Radial vibrations Axial vibrations Possible causes of faults Remedial measures X Rotating parts grind Establish the cause and realign the parts X Stator or coupling not balanced Disconnect the stator or coupling and rebalance If the machine has two s...

Page 79: ...nsion too high Reduce the drive belt tension X Bearing contaminated Clean the bearing or replace it Check the seals X High ambient temperature Use a suitable high temperature grease X X Insufficient lubrication Grease the bearings as instructed X X Bearing canted Properly install the bearing X X Insufficient bearing play Only after consultation with the manufacturer Fit a bearing with greater play...

Page 80: ...r faults on water cooled machines Table 8 5 Cooling system faults Overheating Water leaking Possible causes of faults Remedial measures X Reduced cooling Check the cooling water flow increase the amount of cooling water if necessary X Cooling water flow rate too low Consult the manufacturer If the specified cooling water quality is observed the cooling system is maintenance free X Inlet temperatur...

Page 81: ...ion on electrical equipment Comply with the IEC EN 60079 17 standard during all servicing and maintenance work on the machine Note Service Center Please contact the Service Center if you require support with servicing maintenance or repair 9 1 Inspection and maintenance WARNING Rotating and live parts Electric machines contain live and rotating parts Fatal or serious injuries and substantial mater...

Page 82: ...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 83: ...dust layers thicker than 5 mm to build up on the machine surface Do not switch the machine on until the dust has been removed WARNING Risk of explosion due to excessive bearing temperature The surface temperature cannot be maintained within maximum permissible limits if the bearing becomes too hot The dust can ignite resulting in an explosion This can result in death serious injury or material dam...

Page 84: ...ntations X X You can perform these checks while the motor is at standstill or if required while running Further checks Further checks may be required if so specified in supplementary instructions or in accordance with the plant specific conditions NOTICE If you detect any deviations during the inspection you must rectify them immediately They may otherwise damage the motor 9 1 3 General inspection...

Page 85: ...spection if you detect any impermissible deviations from the normal state you must rectify them immediately They may otherwise cause damage to the machine 9 1 4 Servicing the roller bearings When inspecting rolling contact bearings it is generally not necessary to dismantle the machines The motor only has to be dismantled if the bearings are to be replaced 9 1 5 Bolt grade Check that all the bolts...

Page 86: ...amage that could constitute a risk of ignition in accordance with IEC EN 60079 17 Comply with the following intervals Bearing replacement intervals Relubrication intervals Grease replacement intervals Oil change intervals Roller bearing service life Replace the roller bearings once the nominal service life is reached Alternatively you can verify they are free of mechanical damage as part of an ins...

Page 87: ...eased surface temperature WARNING Explosion hazard Components within the motor may be hotter than the maximum permissible surface temperature for the enclosure In an explosive atmosphere dust can ignite and an explosion occur This can result in death serious injury or material damage Do not open the motor in an explosive and dusty atmosphere when it is still at normal operating temperature Allow t...

Page 88: ...e whether the machine needs commissioning or any necessary measures such as cleaning and or drying the winding Can the machine be put into operation Must the windings be cleaned or dried Detailed information on testing and the limit values can be found here Testing the insulation resistance and polarization index Maintenance 9 1 Inspection and maintenance LOHER CHEMSTAR 1PS5 88 Operating Instructi...

Page 89: ...40 C For every 10 C increase in temperature reduce the lubrication interval specified in the table by a factor of 0 7 max 20 C factor 0 5 With an ambient temperature 25 C twice the grease stability time can be expected but a maximum of 40000 hours Times for operation on 60 Hz systems on request With pure coupling operation with flexible coupling the calculated bearing life is L10h greater than 500...

Page 90: ...of the value listed in the table max 20 C factor 0 5 Times for operation on 60 Hz systems on request 9 1 7 5 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 th...

Page 91: ...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 92: ... Firetemp XT2 Chevron 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 t...

Page 93: ...on Regularly check for pollution and clean the cooling air ducts through which the ambient air flows 9 1 7 8 Maintenance and repair for machines of protection type Ex d The machine marking based on IEC EN 60079 0 was added with the X symbol Maintain the special conditions for repairs The gap dimensions for the electric machine do not comply with the standardized values in IEC EN 60079 1 For repair...

Page 94: ...rding to the minimum specifications of IEC EN 60079 1 is not permissible This can result in death serious injury or material damage Obtain the gap dimensions of the electrical machine from the manufacturer for the repair or restoration of ignition gap geometries WARNING Rotating or live parts Live electrical parts are dangerous Contact with them can cause death serious injury or material damage Be...

Page 95: ...ace permanently lubricated roller bearings in the external fan motor as specified in the operating instructions for the external fan motor 9 1 7 9 Maintaining terminal boxes Requirement The machine is de energized Checking the terminal box Terminal boxes must be regularly checked for tightness undamaged insulation and tight terminal connections If dust or humidity have infiltrated the terminal box...

Page 96: ...rges can occur There is a risk of explosion if potentially explosive mixtures are also present at this moment This can result in death serious injury or material damage You must comply with one of the following requirements when you repaint painted surfaces Limit the total paint coating thickness according to the explosion protection group IIB Total paint coating thickness 2 mm IIC Total paint coa...

Page 97: ...p II motors gas III Limit value for the maximum capacity 10 pF for group III motors dust 9 2 Repair When carrying out any work on the machine observe the general safety instructions Page 13 and the specifications contained in EN 50110 1 regarding safe operation on electrical equipment Note If the motor has to be transported please observe the information and instructions in the Transport section N...

Page 98: ...pairing 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 9 2 2 Insulated roller bearings If roller contact bearings with an insulated design are installed use roller bearings of the same type as spare ...

Page 99: ...a The serial number is also stamped on the end face of the shaft extension at the drive end 10 2 Replacing roller bearings Rolling contact bearings When ordering roller bearings in addition to the bearing identification code the supplementary specifying code is also necessary for the bearing version Both of these codes are stamped on the lubricant plate and specified in the motor documentation or ...

Page 100: ...t standard parts such as screws may be used 10 4 Anti condensation heating spare parts 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 material damage Repairin...

Page 101: ...foot right 201 Bearings DE 032 Housing foot left 201 10 Spacer washer 070 Shaft with rotor 201 20 Gamma ring 105 End shield drive end 300 Roller bearings NDE 115 Flange plate 301 Bearings NDE 120 End shield non drive end 301 10 Spacer washers 130 Fan 301 20 Gamma ring 140 Fan cover 500 Terminal box 145 Protective cover Spare parts 10 5 Spare parts list frame sizes 071 to 132 LOHER CHEMSTAR 1PS5 Op...

Page 102: ...10 6 Spare parts list frame sizes 160 to 280 0 0 Figure 10 2 E AN000 0008 Spare parts 10 6 Spare parts list frame sizes 160 to 280 LOHER CHEMSTAR 1PS5 102 Operating Instructions 03 2014 ...

Page 103: ... 105 End shield drive end 301 Bearings NDE 115 Flange plate 301 03 Inner grease chamber cover 120 End shield non drive end 301 04 Outer grease chamber cover 130 Fan 301 06 Grease slinger 140 Fan cover 301 10 Spacer washers 141 Adapter screw 301 20 Gamma ring 145 Protective cover 330 Grease nipple 190 Feather key 331 Regreasing assembly 200 Roller bearing DE 500 Terminal box 201 Bearings DE Spare p...

Page 104: ...10 7 Spare parts list frame size 315 0 0 Figure 10 3 E AN000 0009 Spare parts 10 7 Spare parts list frame size 315 LOHER CHEMSTAR 1PS5 104 Operating Instructions 03 2014 ...

Page 105: ... Gamma ring 105 End shield drive end 300 Roller bearings NDE 115 Flange plate 301 Bearings NDE 120 End shield non drive end 301 03 Grease chamber cover 130 Fan 301 06 Grease slinger 140 Fan cover 301 20 Gamma ring 141 Adapter screw 330 Grease nipple 145 Protective cover 331 Regreasing assembly 190 Feather key 500 Terminal box 10 8 Spare parts list frame size 355 Spare parts 10 8 Spare parts list f...

Page 106: ...ring shield DE 4 35 Snap ring 3 08 Flange 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 complete Spare parts 10 8 Spare parts list frame size...

Page 107: ...arts Number Designation Parts Number Designation 4 13 Grease slinger DE 4 24 Sealing ring DE outer Spare parts 10 8 Spare parts list frame size 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 107 ...

Page 108: ...xes with type of protection Ex e frame sizes 071 160 Figure 10 5 E 9 101_162 0002 Spare parts 10 9 Spare parts list for terminal boxes with type of protection Ex e frame sizes 071 160 LOHER CHEMSTAR 1PS5 108 Operating Instructions 03 2014 ...

Page 109: ...on 050 Terminal box base 090 Additional terminals 070 Terminal board 120 Terminal box cover Spare parts 10 9 Spare parts list for terminal boxes with type of protection Ex e frame sizes 071 160 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 109 ...

Page 110: ...xes with type of protection Ex d frame sizes 071 160 Figure 10 6 E 9 108_213 0001 Spare parts 10 10 Spare parts list for terminal boxes with type of protection Ex d frame sizes 071 160 LOHER CHEMSTAR 1PS5 110 Operating Instructions 03 2014 ...

Page 111: ...land plate 090 Additional terminals 050 Terminal box base 120 Terminal box cover 070 Terminal board Spare parts 10 10 Spare parts list for terminal boxes with type of protection Ex d frame sizes 071 160 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 111 ...

Page 112: ...xes with type of protection Ex d frame sizes 180 225 Figure 10 7 E 9 108_213 0002 Spare parts 10 11 Spare parts list for terminal boxes with type of protection Ex d frame sizes 180 225 LOHER CHEMSTAR 1PS5 112 Operating Instructions 03 2014 ...

Page 113: ...and plate 090 Additional terminals 050 Terminal box base 120 Terminal box cover 070 Terminal board Spare parts 10 11 Spare parts list for terminal boxes with type of protection Ex d frame sizes 180 225 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 113 ...

Page 114: ...101_208 0002 Part number Designation Parts Number Designation 050 Terminal box base 090 Additional terminals 070 Terminal board 120 Terminal box cover Spare parts 10 12 Spare parts list for terminal boxes with type of protection Ex e frame sizes 180 225 LOHER CHEMSTAR 1PS5 114 Operating Instructions 03 2014 ...

Page 115: ... with type of protection Ex d frame sizes 250 to 355 Figure 10 9 E 9 101_285 0002 Spare parts 10 13 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 115 ...

Page 116: ... 090 Additional terminals 050 Terminal box base 100 Gland plate 070 Terminal board 120 Terminal box cover Spare parts 10 13 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 116 Operating Instructions 03 2014 ...

Page 117: ... terminal boxes with type of protection Ex d frame sizes 250 to 355 Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 117 ...

Page 118: ... Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 118 Operating Instructions 03 2014 ...

Page 119: ...inal box base 090 Additional terminals 051 Sealing washer 120 Terminal box cover 070 Terminal board Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 119 ...

Page 120: ...Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 120 Operating Instructions 03 2014 ...

Page 121: ...al disposal regulations 11 2 Preparing for disassembly Disassembly of the machine must be carried out and or supervised by qualified personnel with appropriate expert knowledge 1 Contact a certified waste disposal organization in your vicinity Clarify what is expected in terms of the quality of dismantling the machine and provision of the components 2 Follow the five safety rules Page 13 3 Disconn...

Page 122: ...r recycling according to whether they are Iron and steel Aluminum Non ferrous metal e g windings The winding insulation is incinerated during copper recycling Insulating materials Cables and wires Electronic waste Process materials and chemicals Sort the process materials and chemicals for recycling according to whether they are for example Oil Grease Cleaning substances and solvents Paint residue...

Page 123: ...sport consists of impregnated wood Observe the local regulations The foil used for water proof packaging is an aluminum composite foil It can be recycled thermally Dirty foil must be disposed of via waste incineration Disposal 11 4 Disposal of components LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 123 ...

Page 124: ...Disposal 11 4 Disposal of components LOHER CHEMSTAR 1PS5 124 Operating Instructions 03 2014 ...

Page 125: ... number below Please have the following machine data ready Machine type Machine number You can find this data on the rating plate of the machine Table A 1 Service numbers Local field service Phone 49 0 911 895 7444 Fax 49 0 911 895 7445 Technical queries or additional information Phone 49 0 911 895 7448 Fax 49 0 911 895 7449 Spare parts and repairs Phone 49 0 911 895 7222 Fax 49 0 911 895 7223 Con...

Page 126: ...Service and Support A 1 Siemens Service Center LOHER CHEMSTAR 1PS5 126 Operating Instructions 03 2014 ...

Page 127: ...h is taken as the distance between the head of the bolt and the point at which the bolt is screwed in Tightening torques The bolted connections with metal contact surfaces such as end shields bearing cartridge parts terminal box parts bolted onto the stator frame should be tightened to the following torques depending on the thread size Table B 1 Tightening torques for bolted connections with a tol...

Page 128: ...e C Applies to bolts with property class 8 8 or A4 70 according to ISO 898 1 however only to bolts screwed into components made from materials with higher property class e g cast iron steel or cast steel Note Non standard tightening torques Different tightening torques for electrical connections and bolted connections for parts with flat seals or insulating parts are specified in the relevant sect...

Page 129: ...Ex ID 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 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 129 ...

Page 130: ...C 2 EC Declaration of Conformity Quality documents C 2 EC Declaration of Conformity LOHER CHEMSTAR 1PS5 130 Operating Instructions 03 2014 ...

Page 131: ... x T3 T6 BVS 13 ATEX E 012 X x x T3 T6 PTB 08 ATEX 1107 X x T3 T6 BVS 11 ATEX E 046 X x x T3 T6 BVS 12 ATEX E 103 X x x T3 T6 PTB 09 ATEX 1046 X x T3 T6 BVS 11 ATEX E 030 X x x T3 T6 BVS 11 ATEX E 045 X x x T3 T6 PTB 09 ATEX 1070 X x T3 T6 BVS 11 ATEX E 051 X x x T3 T6 BVS 12 ATEX E 029 X x x T3 T6 PTB 08 ATEX 1037 X x T3 T6 BVS 11 ATEX E 025 X x x T3 T6 BVS 12 ATEX E 051 X x x T3 T6 DJS 315 1PS 3...

Page 132: ...12 ATEX E 092 X x T3 T6 PTB 06 ATEX 1028 X x T3 T6 PTB 06 ATEX 1022 X x T3 T6 D T 630 D V 630 1PS 63 sleeve PTB 07 ATEX 1075 X x T3 T6 anti friction PTB 09 ATEX 1009 X x T3 T6 sleeve BVS 13 ATEX E 045 X x T3 T6 PTB 09 ATEX 1078 X x T3 T6 BVS 11 ATEX E 170 X x T3 T6 D Q 800 1PS 80 sleeve PTB 06 ATEX 1049 X x T3 T6 D Q 910 1PS 91 sleeve BVS 10 ATEX E 103 X x T3 T6 D 800 1PS 80 anti friction D 450 1P...

Page 133: ...C 3 EC Declaration of Conformity Zone 21 or 22 Quality documents C 3 EC Declaration of Conformity Zone 21 or 22 LOHER CHEMSTAR 1PS5 Operating Instructions 03 2014 133 ...

Page 134: ...22 BVS 11 ATEX E 017 BVS 11 ATEX E 046 X BVS 12 ATEX E 103 X A 250 E 250 1PS 25 BVS 11 ATEX E 034 BVS 11 ATEX E 030 X BVS 11 ATEX E 045 X D 080 1PS 08 1MD 08 D 071 1PS 07 1MD 07 1PS 13 1MD 13 D 132 D 112 1PS 11 1MD 11 D 100 1PS 10 1MD 10 D 180 1PS 18 1MD 18 D 160 1PS 16 1MD 16 EG Baumusterprüf bescheinigung EC Type Examination Certificate Gerät Equipment D 090 1PS 09 1MD 09 D 250 1PS 25 1MD 25 D 2...

Page 135: ...n is to be adjusted to 1 5 x Icontin at a maximum 4 tshort is the period for which the inverter allows an exceeding of lcontin tshon is to be adjusted to 60 s at a maximum 5 The built in temperature sensors PTC thermistors which must be suitable for sole protection are to be connected to a tripping device provided with the EC type examination certificate like e g CK140 PTB 04 ATEX 3038 or CKI44 14...

Page 136: ...Quality documents C 4 Data LOHER CHEMSTAR 1PS5 136 Operating Instructions 03 2014 ...

Page 137: ...ater supply 52 Correct usage 24 Corrective maintenance Initial inspection 84 Corrosion protection 76 Cross section of the grounding conductor 58 Current transformer 74 D Damage during transportation 30 Damping cores 39 Delivery 30 Direction of rotation 59 Disassembly Disposal 121 Disposal Chemicals 122 Components 122 E Electrical faults 78 Electromagnetic compatibility 18 Electromagnetic fields 19...

Page 138: ... 28 Intrinsically safe circuits 56 L Lifting eye 31 47 48 Limit speed 69 Local field service Service numbers 125 Lubricant plate 90 M Machine Aligning to the driven machine 50 setting down 49 Machine design 24 IEC 23 Machine expansion 50 Machine marking 93 Maintenance Maintenance intervals 81 Mechanical faults 78 Minimum air clearances 60 Mounting parts 44 N Noise emissions 16 29 O Operating mode ...

Page 139: ... 125 Spare parts 125 Technical information 125 Setting down 49 Spare parts 100 Service numbers 125 Spare parts ordering 99 Standard cable glands 62 Standard flange 50 51 Stoppages 75 76 Roller bearings 76 Storage 33 Switching off 75 Switching on 75 System resonances 30 System inherent frequencies 30 T Tandem operation 40 Technical information Service numbers 125 Temperature class 76 Temperature li...

Page 140: ...Index LOHER CHEMSTAR 1PS5 140 Operating Instructions 03 2014 ...

Page 141: ...AC EC Declaration of Conformity U161 AB EC Declaration of Conformity U163 AA R No 20000h U165 ...

Page 142: ...Siemens AG Industry Sector Drive Technologies and Industry Automation P O Box 4848 90327 NUREMBERG GERMANY www siemens com drives ...

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