Siemens SIMOTICS HT Series Operating Instructions & Installation Instructions Download Page 21

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Description

Area of application

The series 1FW4 motors are multi-pin, permanent-magnet synchronous motors with full-shaft

rotors. The motors are liquid or air cooled. The operating behavior is comparable to that of

electrically excited synchronous motors.
Motors of the 1FW4 series are used together with converters as slow running direct drives,

e.g. in the following sectors:
● Pulp and paper industry
● Steel industry
● Plastics industry
● Marine
● Crushers

WARNING

Risk of explosion
This machine is not designed for use in hazardous areas. An explosion can occur if the

machine is operated in these areas. This can result in death, serious injury or material damage.
● Never operate this machine in hazardous areas.

Figure 3-1

1FW4 water-cooled motor

SIMOTICS HT Series HT-direct 1FW4...1......A

Operating Instructions 11/2018

Summary of Contents for SIMOTICS HT Series

Page 1: ...www siemens com drives Low voltage motor SIMOTICS HT Series HT direct Type 1FW4 1 A Operating Instructions Installation Instructions Edition 11 2018 ...

Page 2: ...13 11 2018 16 25 V5 00 ...

Page 3: ...ctions Installation Instructions Edition 11 2018 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 B Quality documents C ...

Page 4: ...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 the...

Page 5: ...e plant 27 4 2 Observing the operating mode 27 4 3 Cooling water quality 27 4 4 Cooling water inlet temperature water cooled motor 28 4 5 Interlock circuit for anti condensation heating option 31 4 6 Thermal motor protection 31 4 7 Noise emissions 31 4 8 Rotational speed limit values 31 4 9 System inherent frequencies 32 4 10 Torsional loading of the drive train due to faults in the electrical sup...

Page 6: ...3 5 3 8 Lifting and transporting the machine 54 5 3 9 Putting the machine down 56 5 3 10 Roughly aligning the machine 56 5 4 Installing the machine 56 5 4 1 Selecting fixing screws 57 5 4 2 Preconditions for smooth vibration free operation 57 5 4 3 Connection cables 57 5 4 4 Aligning the machine to the driven machine and mounting IM B3 57 5 4 5 Aligning the machine to the driven machine and mounti...

Page 7: ...ex for the commissioning 84 7 7 Switching on the machine 84 7 8 Set values for temperature monitoring of the bearing thermometer 85 7 9 Setting values for temperature monitoring slot thermometer 85 7 10 Switching off the machine 85 7 11 Avoidance of condensation or formation of condensation within the machine 85 8 Operation 87 8 1 Safety instructions for operation 87 8 2 Switching on the machine 8...

Page 8: ...ctive Maintenance 103 9 2 1 Prepare servicing work 104 9 2 2 Anti condensation heating 104 9 2 3 Changing the bearings 104 9 2 4 Replacing the speed encoder 105 10 Spare parts 109 10 1 Ordering data 109 10 2 Ordering spare parts via the Internet 109 10 3 Anti condensation heating 110 11 Disposal 111 11 1 Introduction 111 11 2 RoHS restricting the use of certain hazardous substances 111 11 3 Inform...

Page 9: ... winding thermometers 85 Table 8 1 Electrical faults 94 Table 8 2 Mechanical faults 94 Table 8 3 Roller bearing faults 95 Table 8 4 Cooling system faults 96 Table B 1 Tightening torques for bolted connections with a tolerance of 10 119 Figures Figure 3 1 1FW4 water cooled motor 21 Figure 3 2 Rating plate diagram 23 Figure 4 1 Example of a cooling circuit 30 Figure 4 2 Axial fastening of the rotor ...

Page 10: ...Table of contents SIMOTICS HT Series HT direct 1FW4 1 A 10 Operating Instructions 11 2018 ...

Page 11: ... any suggestions on how to improve this document Text format features You can find the following text format features in these instructions 1 Handling instructions are always formatted as a numbered list Always perform the steps in the order given Lists are formatted as bulleted lists Lists on the second level are hyphenated Note The note provides you with additional information about the product ...

Page 12: ...an efficiently compile your own plant or system documentation The Documentation compiled in a specific language can also be automatically exported in one of the other available languages The full functionality is only available for registered users Introduction 1 1 Compiling personal documents SIMOTICS HT Series HT direct 1FW4 1 A 12 Operating Instructions 11 2018 ...

Page 13: ...ting conditions are taken into account at all times The specific setup and safety regulations as well as regulations on the use of personal protective equipment are observed Note Use the services and support provided by the local service center Page 117 for planning installation commissioning and service work 2 2 The 5 safety rules For your own personal safety and to prevent material damage when c...

Page 14: ... Separate safety instructions supplied with the machine Safety symbols and instructions on the machine and its packaging Danger as a result of stationary parts under voltage live parts Live parts represent a hazard Touch protection against active live parts is no longer guaranteed if covers are removed The minimum clearance and creepage distances may be violated when coming close to live parts Tou...

Page 15: ...y damage Observe the product information provided by the manufacturer See also The 5 safety rules Page 13 Inspection and maintenance Page 97 Noise emissions During operation the machine s noise emission levels can exceed those permitted at the workplace which can cause hearing damage Ensure that nobody is in the area of increased noise emissions during machine operation Take steps to reduce noise ...

Page 16: ...u never wear or carry any of the following objects and that they are kept a safe distance from the machine All kinds of magnetic metal parts such as keys glasses tools knives scissors tape measures etc Magnetic jewelry such as rings chains needles watches etc Electronic devices and data carriers such as service cards check cards credit cards calculators cell phones etc Wallets or other iron contai...

Page 17: ...ectly To protect equipment against damage follow the instructions given below Only touch electronic modules if you absolutely have to work on them The body of the person concerned must have been electrostatically discharged and grounded immediately before any electronic modules are touched Electronic modules should not be brought into contact with electrically insulating materials such as Plastic ...

Page 18: ...sor lead This can cause faults which can result in eventual or immediate death serious injury or material damage Comply with the EMC information provided by the manufacturer of the converter This is how you prevent the limit values stipulated by IEC EN 61000 6 3 for the drive system consisting of the machine and converter from being exceeded You must put appropriate EMC measures in place 2 9 Elect...

Page 19: ...e close to the machine Do not carry any magnetic or electronic data media Safety information 2 9 Electromagnetic fields when operating electrical power engineering installations SIMOTICS HT Series HT direct 1FW4 1 A Operating Instructions 11 2018 19 ...

Page 20: ...Safety information 2 9 Electromagnetic fields when operating electrical power engineering installations SIMOTICS HT Series HT direct 1FW4 1 A 20 Operating Instructions 11 2018 ...

Page 21: ...h converters as slow running direct drives e g in the following sectors Pulp and paper industry Steel industry Plastics industry Marine Crushers WARNING Risk of explosion This machine is not designed for use in hazardous areas An explosion can occur if the machine is operated in these areas This can result in death serious injury or material damage Never operate this machine in hazardous areas Fig...

Page 22: ...e of protection IEC EN 60034 5 Cooling IEC EN 60034 6 Type of construction IEC EN 60034 7 Terminal markings and direction of rotation IEC EN 60034 8 Noise emission IEC EN 60034 9 Mechanical vibrations IEC EN 60034 14 IEC standard voltages IEC DIN IEC 60038 Vibration limit values DIN ISO 10816 3 See also Quality documents Page 121 Rating plate The rating plate shows the identification data and the ...

Page 23: ...egulations Degree of protection Rated power kW Rated torque Nm Rated current A Rated speed rpm Rated frequency Hz Induced voltage Rated voltage V Motor weight t Figure 3 2 Rating plate diagram Degree of protection The machine is available with degree of protection IP55 Ambient conditions The standard machines are not suitable for use in corrosive atmospheres atmospheres with a high salt content or...

Page 24: ...r these motors The converter module is selected depending on many influencing parameters e g Torque Speed Overload Duty cycles Control precision Capable of energy recovery More detailed information is provided in Catalog D86 2 SIMOTICS HT direct For more complex questions contact your Siemens sales representative Anti condensation heating option The machine is fitted with anti condensation heating...

Page 25: ...p The latter also forms the sealing grease chamber with the labyrinth sealing ring optional The second lubricating nipple containing the grease duct for pressing in the sealing grease is also located in the outer bearing cap The chamber is sealed off from the space where the lubricating grease collects by a V ring or a V ring and felt ring combination which prevents the sealing grease in the chamb...

Page 26: ...Description SIMOTICS HT Series HT direct 1FW4 1 A 26 Operating Instructions 11 2018 ...

Page 27: ... ensure the machine is operated safely within your plant 4 2 Observing the operating mode Observe the machine s operating mode Use a suitable control system to prevent overspeeds thus protecting the machine from damage 4 3 Cooling water quality The cooling water must circulate in a closed cooling circuit Avoid fluctuations in the oxygen content of the cooling water The cooling system is maintenanc...

Page 28: ...or winding overhang the magnetic rotor and the bearings The motor housing is designed with a water cooling system This allows a high power density The coolant flows through a duct that runs in a spiral from the DE to the NDE in the cooling jacket The coolant inlet is on the DE the coolant outlet is on the NDE Seen from the shaft end connection is possible from the right and from the left Close the...

Page 29: ...G1 1FW4507 1FW4508 80 0 5 G1 1 A maximum pressure drop of approximately 0 1 MPa occurs in the water jacket Cooling water quality The cooling water must meet the following prerequisites Chemically neutral reaction Water cleaned by solids Max particle size of particles carried 0 1 mm No salt water NOTICE Damage due to sea water The cooling system is made of St37 steel This material is not resistant ...

Page 30: ...inlet temperature of 25 C You can operate several motors and or the converter on one cooling unit Use a closed cooling cooling circuit This will prevent deposits in the cooling circuit cooling is then permanently guaranteed The cooling unit is not part of the motor s scope of delivery ཱ ི ཱི ུ ཱུ ྲྀ ཷ ླྀ Filter1 Coolant temperature sensing Flow quantity display Compressor cooling unit Flow regulating ...

Page 31: ...r monitoring 4 7 Noise emissions Noise emissions During operation the machine s noise emission levels can exceed those permitted at the workplace which can cause hearing damage Ensure that nobody is in the area of increased noise emissions during machine operation Take steps to reduce noise so that the machine can be operated safely within your system The following measures may help to reduce nois...

Page 32: ...es 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 consider the configuration data The system planner is responsible for the entire drive train Note More information about this may be found in the catalog 4 11 Transport 4 11 1 Safety ins...

Page 33: ...in death serious injury or material damage Do not lift machine sets by attaching lifting tackle to the individual machines Use only the equipment provided e g the openings or lugs on the base plates for transporting machine sets Note the maximum capacity of the lifting lug 4 11 2 Checking the delivery The components are assembled on an individual basis When you take receipt of the delivery please ...

Page 34: ...ing as the rotor shipping brace cannot completely absorb these forces Do not remove the rotor shipping brace until you are ready to push on the output element If the customer already has mounted parts such as a coupling or belt pulley the bearings can be damaged during transport In this case make sure that the customer uses a rotor shipping brace For machines with a vertical type of construction D...

Page 35: ...or shipping brace types The thread in the shaft extension indicates the rotor weight This indirectly specifies the required preload force when axially fastening the rotor Thread in the shaft extension Preload M20 20 kN M24 30 kN M30 40 kN Axial preload force for other rotor shipping brace types Store the rotor locking device Be sure to store the rotor locking device It must be remounted for possib...

Page 36: ...stem Do not remove the protective cover until you are ready to make the final water connections NOTICE Temperatures below 0 C Damage may be caused to the cooling circuit if the cooling water freezes at temperatures below 0 C Drain the water from the cooling system before you transport and store the motor Drain the cooling water ducts Blow out the cooling water ducts with compressed air 4 11 5 Tran...

Page 37: ...machine in a position appropriate for its construction the machine can tip slip into the lifting equipment or fall down This can result in death serious injury or material damage Use only the load carrying device on the stator frame for lifting Use the load carrying device appropriate for the machine position Only use suitable rope guiding or spreading devices WARNING Center of gravity not centere...

Page 38: ... it after it has been delivered NOTICE Bearing seizure damage if incorrectly stored If storage conditions are inappropriate there is a risk of bearing seizure damage Resulting damage can include scoring brinelling and corrosion Follow the storage guidelines Preconditions and preparations Only store goods in undamaged packaging Unpack the goods if the packaging is damaged Correctly store the goods ...

Page 39: ...sition machines devices and crates on pallets wooden beams or foundations that protect them against rising damp and water Ensure that the air circulation under the equipment is not impeded Place wooden spacer blocks between the covers and the machine Covers or tarpaulins must not trail on the floor around the machine Storing outdoors When storing the machines outside the storage location must comp...

Page 40: ...d over is different from its previous position Use the feather key as a reference point if present 4 Replace the corrosion protection 5 Reattach the rotor shipping brace if present 6 Pack the machine again Long term storage If you are storing a machine for more than six months you must check its condition every six months Store the machine in accordance with the specifications in Section Storage P...

Page 41: ...stem will be damaged if the supply voltage is too high for the insulation system This can completely destroy the machine Comply with the peak voltages as laid down in the guidelines above 4 13 2 Reducing bearing currents If you want to prevent damage due to bearing currents you must take the entire system into account i e the motor converter and driven machine The following measures help to preven...

Page 42: ...e grounding bar of the converter Use a separate high frequency equipotential bonding cable between the motor enclosure and the driven machine Use the common mode filter damping cores at the converter output The Siemens sales representative is responsible for selection and dimensioning Limit the rise in voltage by using output filters Output filters dampen the harmonic content in the output voltage...

Page 43: ... to the bearings if there is a flow of current Also when performing subsequent installation work e g installing an automatic lubrication system or a non insulated vibration sensor ensure the bearing insulation is not bridged Contact your Service Center if necessary See also Service and Support Page 117 Preparations for use 4 13 Converter operation SIMOTICS HT Series HT direct 1FW4 1 A Operating In...

Page 44: ...Preparations for use 4 13 Converter operation SIMOTICS HT Series HT direct 1FW4 1 A 44 Operating Instructions 11 2018 ...

Page 45: ...erial damage Comply with the required property classes for screwed connections Tighten the screwed connections to the specified tightening torques Injury and material damage caused by incorrect machine alignment 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 coul...

Page 46: ...ust be satisfied prior to starting installation work Staff have access to the operating and installation instructions The machine is unpacked and ready for mounting at the installation location Note Measure the insulation resistance of the winding before starting installation work Measure the insulation resistance of the winding before starting any installation work If the insulation resistance li...

Page 47: ... 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 Short circ...

Page 48: ... 40 C convert the measuring value to the reference temperature of 40 C according to the following equations from IEEE 43 2000 1 RC KT RT RC Insulation resistance converted to 40 C reference temperature KT Temperature coefficient according to equation 2 RT Measured insulation resistance for measuring winding temperature T in C 2 KT 0 5 40 T 10 40 Reference temperature in C 10 Halving doubling of th...

Page 49: ...ble Measuring the polarization index 1 To determine the polarization index measure the insulation resistances after one minute and ten minutes 2 Express the measured values as a ratio PI Rinsul 10 min Rinsul 1 min Many measuring devices display these values automatically following the measurement For insulation resistances 5000 MΩ the measurement of the PI is no longer meaningful and consequently ...

Page 50: ...g using a wall bracket or by bolting it 5 3 Lift the machine to where it will be installed and position it 5 3 1 Preconditions for correct alignment and secure attachment Detailed specialist knowledge of the following measures is required in order to correctly align and securely fit the equipment Preparing the foundation Selecting and mounting the coupling Measuring the concentricity and axial ecc...

Page 51: ... serious injury or material damage Inspect the load handling attachments and lifting gear before use 5 3 3 Removing the rotor shipping brace If a rotor shipping brace is attached to the machine remove it at the last possible moment for example when you are ready to push on the output or drive element Note Store the rotor locking device Be sure to store the rotor locking device It must be remounted...

Page 52: ...e petroleum petroleum ether or a similar solvent or cleaning agent NOTICE Paintwork damage Painted surfaces can be damaged if they come into contact with detergents or solvents Use a suitable solvent to soften thick layers of anti corrosion agent Then push off the softened layers using a piece of hardwood approximately 10 x 10 x 1 cm Do not sand the protective coating down or scrape it off NOTICE ...

Page 53: ...F means balancing with a whole feather key Figure 5 1 Balancing type on the drive end side Pushing on the power output elements Prerequisites The coupling and or the output element must be appropriately dimensioned for the operating case at hand Comply with the coupling manufacturer s instructions Make sure that the balancing type of the transmission element correctly matches the type of balance o...

Page 54: ...ey is not inserted is taken into consideration when balancing the coupling Danger when feather keys are flung out The feather key is only secured to prevent it falling out during transport The feather key may be flung out if the motor is operated without fitted transmission elements such as coupling etc This can result in death serious injury or material damage Only operate the motor with the tran...

Page 55: ...is not located centrally between the attachment points the machine can tip over or slip out of the lifting equipment and fall when it is being transported or lifted This can result in death serious injury or material damage Comply with the handling instructions on the machine when transporting it Be aware of the possibility of different loads on the sling ropes or lifting straps and the carrying c...

Page 56: ...ation location to avoid any impact 5 3 10 Roughly aligning the machine Requirement 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 4 Installing the machine Note Service Center For any installation work that is...

Page 57: ...ion cables must not be damaged Connection cables must not be under tension Connection cables must not be touched by rotating parts Observe the technical data in these operating instructions and on the rating plate 5 4 4 Aligning the machine to the driven machine and mounting IM B3 1 Refer to any instructions for aligning the driven machine and those of the coupling manufacturer 2 Align the machine...

Page 58: ...lings 4 When positioning the machine ensure that a uniform axial gap y 0 is maintained around the coupling 5 Fix the machine to the foundation The choice of fixing elements depends on the foundation and is the plant operator s responsibility Plates placed under the motor for alignment Laser alignment Figure 5 2 Schematic diagram Aligning the machine to the driven machine Table 5 2 Permissible devi...

Page 59: ...e the centering flange with assembly paste to make 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 ri...

Page 60: ...nd support the water pipes so that the connecting flanges are not exposed to excessive stress strain or vibration loads 3 Remove the flange cover plate 4 Insert the gaskets correctly 5 Rinse out the water circuit before you connect the cooling water supply to the motor This removes deposits and foreign bodies 6 Should there be a possibility of the cooling water containing dirt and foreign bodies i...

Page 61: ...ed bearings on the non drive end NOTICE Bearing damages The bearing insulation must not be bridged Damage may be caused to the bearings if there is a flow of current Assembly 5 6 Insulated bearings SIMOTICS HT Series HT direct 1FW4 1 A Operating Instructions 11 2018 61 ...

Page 62: ...Assembly 5 6 Insulated bearings SIMOTICS HT Series HT direct 1FW4 1 A 62 Operating Instructions 11 2018 ...

Page 63: ...ven in total failure which could in turn lead indirectly to material damage to the system Tighten the screwed connections to the specified tightening torques Observe any specifications regarding the materials from which fixing elements must be made When performing servicing check the fastenings Note Service Center If you require support when electrically connecting up the machine please contact th...

Page 64: ...aration 6 3 1 Terminal designation According to IEC EN 60034 8 the following basic definitions apply to the terminal designations for 3 phase machines Table 6 1 Terminal designations using the 1U1 1 as an example 1 U 1 1 Designation x Index for pole assignment for pole changing machines where applicable A lower index signifies a lower speed Special case for split winding x Phase designation U V W ...

Page 65: ... thicker shaft extension is defined as follows If you connect the power cables in the phase sequence L1 L2 L3 to U V W the resulting rotation will be clockwise If you interchange two connections e g L1 L2 L3 to W V U the resulting rotation will be counter clockwise On machines which are only allowed to run in one direction the rating plate shows an arrow which indicates the permitted direction of ...

Page 66: ...ubstance e g acid free Vaseline The flat and spring washers are located under the bolt head The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not exceeded The minimum required screw in depth and the tightening torque for the clamping bolt as given in the table below are observed Screw in depth and tightening torque are different depending on whether cable lugs or gr...

Page 67: ...gh frequency grounding Connecting using flat ribbon cables is recommended Connection with cable lugs is possible High frequency grounding for water cooled motors For water cooled motors a radio frequency ground is required between the terminal box and the housing due to the steel housing Electrical connection 6 3 Preparation SIMOTICS HT Series HT direct 1FW4 1 A Operating Instructions 11 2018 67 ...

Page 68: ...e wired in the main terminal box by the servicing or commissioning personnel Figure 6 3 Neutral point connection Data on the connection and connecting the motor winding can be found in the circuit diagram in the cover of the terminal box Electrical connection 6 4 Inserting and routing the cables SIMOTICS HT Series HT direct 1FW4 1 A 68 Operating Instructions 11 2018 ...

Page 69: ... scope of supply The cable entry can be turned by 180 Insert the cable into the terminal box 1 Unscrew the cable entry plate 2 Drill the required number of holes or tapped holes in the required size into the cable entry plate if necessary Ensure that the cable entry plate can be assembled after drilling and that it features sufficient stiffness 3 Fit the required cable glands 4 Route the cables th...

Page 70: ...en the cable lug to the end of the conductor correctly e g by squeezing Figure 6 5 Connection with cable lug and fixing screw schematic diagram 4 Insulate the cable lug sleeves where necessary to ensure minimum air clearances and the creepage distance are maintained 5 Place the cable lug on the terminal support If you are using a disconnecting link check its positioning 6 Tighten the fixing elemen...

Page 71: ...ant or system due to machine failure Retighten the clamping nuts after approximately 24 hours and then again after approximately four weeks Make sure that the terminals are de energized before you tighten the nuts 6 4 6 Using single stranded cables NOTICE High temperatures from induced eddy currents With high currents and where several single stranded cables are used instead of multiple stranded c...

Page 72: ...he rated input voltage range is taken into account during general use 6 4 8 Internal equipotential bonding The internal equipotential bonding between the grounding terminal in the box enclosure and the motor frame is established through the terminal box retaining bolts The contact locations underneath the bolt heads are bare metal and protected against corrosion The standard cover fixing screws ar...

Page 73: ...ng screws see Chapter Tightening torques for screw connections Page 119 6 5 Connecting the auxiliary circuits The type designations of the mounted auxiliary terminal boxes their arrangement and the relevant connection terminals are documented in the Technical data section The information required to connect anti condensation heating and the auxiliary circuits is provided in the connection diagram ...

Page 74: ...enter The plate is generally delivered with threaded holes and cable glands 1 Open the auxiliary terminal box and undo the cable entry plate screws Depending on the terminal box version the cable entry plate is below a steel screening plate 2 For the undrilled version drill the required number of holes or threads in the required size of the cable gland into the cable entry plate 3 Mark the cables ...

Page 75: ...required apply additional measures to fully comply with the requirements set out in IEC 60664 1 or IEC 61800 5 1 Hazard due to electric shock 6 5 4 Internal equipotential bonding in the auxiliary terminal box The equipotential bonding between the PE terminals in the relevant auxiliary terminal box enclosure and the machine enclosure is established via a fixing bolt in each auxiliary terminal box e...

Page 76: ...cable entries are sealed The sealing elements are firmly screwed in and can only be released using a tool All of the seals gaskets and sealing surfaces of the terminal box are in good condition The screws of all of the screw clamps are fully tightened even if they are not being used 2 Close the auxiliary terminal box using the cover supplied for this purpose See section Tightening torques for scre...

Page 77: ...rotective conductor currents When the machine is operated on a converter with current limiter but without ground fault monitoring protective conductor currents of up to 1 7 times the external conductor current can arise if there is a ground fault on the output side Neither the PE conductors of normally rated multi core connecting cables nor the PE connecting points of normal terminal boxes are sui...

Page 78: ...Electrical connection 6 6 Converter operation SIMOTICS HT Series HT direct 1FW4 1 A 78 Operating Instructions 11 2018 ...

Page 79: ...ll times when operating the machine Danger to life as a result of voltage at the motor terminals when the rotor is rotating There is always a magnetic flux in the motor due to the permanent magnets in the rotor With each rotation of the rotor a voltage occurs at the motor terminals As a result of this there is also a voltage at the converter output terminals via the connecting cable Contact with t...

Page 80: ... to prevent them from becoming loose For test operation or when commissioning without output element carefully secure the feather key using a suitable security element When doing this take into account the balancing type of the motor Second shaft extension If the second shaft extension is not used Carefully secure the feather key to prevent it from being thrown out and for balancing type H standar...

Page 81: ...n carefully ensure that the motor cannot exceed the specified upper speed limit nmax or fall below the lower speed limit nmin The permissible acceleration time to the limit speed nmin depends on the parameter assignment The bearing insulation should be implemented as shown on the plates If the machine can be driven by the mechanical system then protect the converter DC link voltage against overvol...

Page 82: ...See also Transport Page 32 Service and Support Page 117 7 4 Setting the converter pulse frequency At the converter set a minimum pulse frequency of 2 5 kHz in operation This means that the guaranteed machine parameters can be maintained 7 5 Test run After installation or inspection carry out a test run 1 Start up the machine without a load To do this close the circuit breaker and do not switch off...

Page 83: ...ng equipment check the bearing and stator winding temperatures until they have reached steady state values Check the machine for noise or vibrations on the bearings or bearing shields as it runs 5 In case of uneven running or abnormal noise switch off the machine As the machine runs down identify the cause If the mechanical operation improves immediately after the machine is switched off then the ...

Page 84: ...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 Page 47 7 7 Switching on the machine After starting the motor observe it for a while to see if it is running smoothly and check the monitoring devices Monitor operation and the monitoring devices regularly and record th...

Page 85: ...ripping temperature of winding thermometers Set value Temperature class F B Temperature class F F Prior to commis sioning for shutdown T0 120 C T0 140 C During operation for warning T1 T 10 K max 135 C T1 T 10 K max 150 for shutdown T2 T 15 K max 140 C T2 T 15 K max 155 T temperature in steady state C 7 10 Switching off the machine Do not switch off the water cooling system immediately after switc...

Page 86: ...Start up 7 11 Avoidance of condensation or formation of condensation within the machine SIMOTICS HT Series HT direct 1FW4 1 A 86 Operating Instructions 11 2018 ...

Page 87: ...ne if you must remove covers Comply with the Five safety rules Only remove the covers when the rotating parts have come to a complete standstill Danger as a result of stationary parts under voltage live parts Live parts represent a hazard Touch protection against active live parts is no longer guaranteed if covers are removed The minimum air and creepage distances may be fallen below violated when...

Page 88: ...of burn injuries as a result of hot surfaces Individual machine parts can become hot in operation Burns can result when coming into contact with these parts Never touch machine parts during operation Allow the machine to cool down before starting work Check the temperature of parts before touching them If required wear suitable protective equipment Danger to life as a result of voltage at the moto...

Page 89: ...e generated which escapes under high pressure The cooling water system can burst This can result in death serious injury or material damage Do not connect the cooling water supply until the machine has cooled down 8 2 Switching on the machine 1 If at all possible run the machine without load and check that it is running smoothly 2 If it runs perfectly connect a load NOTICE Thermal overload of moto...

Page 90: ...he location of use Under normal ambient conditions e g the stopped machine is not exposed to any vibration no increased level of corrosion etc in general the following measures are necessary during stoppages 8 3 1 Prolonged outage periods If the machine is out of operation for longer than one month start up the machine regularly that is approximately once a month Alternatively as a minimum turn th...

Page 91: ...ly switch on any anti condensation heating during stoppages This will avoid the formation of condensation Do not switch on the anti condensation heating for at least two hours after the motor has been switched off This prevents damage to the winding insulation 8 3 4 Avoidance of damage to roller bearings during stoppages Extended stoppages at the identical or almost identical resting position of t...

Page 92: ...leaned or dried Detailed information on testing and the limit values can be found here Testing the insulation resistance and polarization index Page 47 8 4 Switching off the machine Do not switch off the water cooling system immediately after switching off the machine Wait for the machine to cool This will prevent the accumulation of residual heat See also Avoidance of condensation or formation of...

Page 93: ...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 described in the respective remedial measures section Repair any damage to the machine 8 8 2 Electrical faults water cooled machines Note When operating the mach...

Page 94: ...r supply switched off Water connection pipes defective Check the cooling water connection Switch on the cooling water supply Find the leak and seal it Contact the Service Center X X Cooling water flow rate too low Inlet temperature too high Increase the cooling water flow Set the correct upstream temperature 8 8 3 Mechanical faults Table 8 2 Mechanical faults Grinding noise Radial vibrations Axial...

Page 95: ...nt lubrication Grease the bearings as instructed X Too much grease in bearing Remove surplus grease Contact the Service Center if necessary X Wrong grease in the bearing Use the correct grease X Belt tension too high Reduce the drive belt tension X Bearing contaminated Contact the Service Center X X Bearing canted X X Insufficient bearing play X X Bearing corroded X Friction marks on raceway X Bri...

Page 96: ...ing agents X Cooling water flow rate too low Consult the manufacturer If the specified cooling water quality is ob served the cooling system is maintenance free X Inlet temperature too high Set the correct upstream temperature X Cooling water supply switched off Switch on the cooling water supply X Cooling water contains too many or unsuit able antifreeze and corrosion protection agents Use coolin...

Page 97: ...mum air and creepage distances may be fallen below violated when coming close to active parts Touching or coming close can result in death serious injury or material damage Take the machine out of operation Switch off the machine and ensure that it is in a no voltage condition Carefully comply with the 5 safety rules Page 13 Only open the terminal box when the motor is stationary and in a no volta...

Page 98: ...d maintenance intervals Damage from foreign bodies in the machine Foreign bodies such as dirt tools or loose components 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 motor Ensure that no foreign bodies are left in or on the motor Securely a...

Page 99: ...while the motor is at standstill or if required while running Further checks may be required if so specified in operating instructions of components or in accordance with the plant specific conditions If you find any deviations during the inspection you must rectify them immediately They may otherwise damage the motor Checking the cooling system With the machine stopped check the condition of the ...

Page 100: ...y flow away X This check can be made at standstill or when running If you detect any deviations during the inspection you must rectify them immediately They may otherwise cause damage to the machine 9 1 5 Measuring the insulation resistance during the course of maintenance work Measuring the insulation resistance and polarization index PI provides information on the condition of the machine It is ...

Page 101: ...uired relubrication intervals for roller bearings are not the same as the servicing intervals It is essential to adhere to them The bearings may be damaged if the relubrication intervals are not adhered to Note Lubrication data Information on regreasing e g grease type grease quantity and relubrication intervals is given on the lubrication plate on the machine 9 1 8 Regreasing intervals and types ...

Page 102: ... you use other KP2N greases some of which only meet the minimum requirements per DIN 51825 halve the regreasing intervals 1 Clean the lubricating nipple and press in suitable grease The shaft should rotate so that the new grease can be distributed throughout the bearing The bearing temperature rises sharply at first then drops to the normal value again after the excess grease has been displaced ou...

Page 103: ...en carrying out any work on the machine Comply with the general safety instructions Page 13 Comply with the applicable national and sector specific regulations When using the machine within the European Union comply with the specifications laid down in EN 50110 1 regarding safe operation of electrical equipment WARNING Strong magnetic field when the machine is open A strong magnetic field is alway...

Page 104: ...the part is supported after it is pulled off The centerings in the shaft extensions have reset threads Use lifting gear which is suitable for the rotor weight and direction of loading See also Service and Support Page 117 9 2 2 Anti condensation heating The anti condensation heater is mounted directly on the winding The anti condensation heater cannot be removed without causing damage to the windi...

Page 105: ...w of the speed encoder To remove the speed encoder proceed as follows 1 Unscrew the speed encoder cover 2 Detach the electrical connection Carefully withdraw the cable out of its holder Withdraw the connector Maintenance 9 2 Corrective Maintenance SIMOTICS HT Series HT direct 1FW4 1 A Operating Instructions 11 2018 105 ...

Page 106: ...crew M6x70 one after the other This releases the speed encoder from the shaft journal taper Remove the speed encoder Speed encoder Hübner Berlin HOG10 HOG11 andHMG111 Remove screw M6x25 Screw in the screw M8x60 This releases the speed encoder hollow shaft from the shaft journal Remove the speed encoder Figure 9 2 Replacing a speed encoder Maintenance 9 2 Corrective Maintenance SIMOTICS HT Series H...

Page 107: ...ournal using the three grub screws in such a way that the height of the shaft journal is less than 0 1 mm when rotating the rotor Install the outer bearing cover with contact guard 5 Mount the new speed encoder 6 Mount the torque arm of the speed encoder 7 Insert the connector into the socket 8 Press the cable into the holder provided for it 9 Screw on the speed encoder cover Take care that you do...

Page 108: ...Maintenance 9 2 Corrective Maintenance SIMOTICS HT Series HT direct 1FW4 1 A 108 Operating Instructions 11 2018 ...

Page 109: ... the drive end Note The graphical representations in this chapter show schematic diagrams of the basic versions They are used for spare parts definitions The supplied version may differ in details from these representations 10 2 Ordering spare parts via the Internet You can use Spares on Web to determine the order numbers for motor spare parts quickly and easily See also Spares on Web https www so...

Page 110: ...umentation or can also be taken from the installed bearings Always replace the rolling bearings with the identical bearings If insulated rolling bearings are fitted use insulated rolling bearings of the same type as spare parts This will prevent any bearing damage being caused by bearing currents 10 3 Anti condensation heating The anti condensation heater is mounted directly on the winding The ant...

Page 111: ... during the individual phases of its life cycle please observe the statutory requirements applicable in the country of use Please contact your local authorities for more information about disposal 11 2 RoHS restricting the use of certain hazardous substances In compliance with RoHS Restriction of certain Hazardous Substances we replace substances that are damaging to the environment by those that ...

Page 112: ...t no magnetic fields which may be to your health are detectable outside the machine WARNING Strong magnetic field when the machine is open A strong magnetic field is always present inside the machine If the housing is open e g when maintenance openings are open or when working inside the machine magnetic objects can be suddenly attracted by this magnetic field This can result in death serious inju...

Page 113: ...nsure that no parts fall into the inside of the machine Do not perform any cutting at the machine e g manufacturing threaded holes Any exceptions require written approval from the manufacturer 11 6 Disposing of permanent magnets If the entire motor is melted down no special action is required for the permanent magnets Remove all cables before the melting process Demagnetizing the motor If the moto...

Page 114: ...osal companies Information regarding authorized waste disposal companies and workshops can be obtained from the Siemens Service Center Page 117 11 7 Disposal of components Components The machines consist mainly of steel and various proportions of copper and aluminum Metals are generally considered to be unlimitedly recyclable Sort the components for recycling according to whether they are Iron and...

Page 115: ... used while working on the machine Packaging material If necessary contact a suitable specialist disposal company Wooden packaging for sea transport 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 7 Disposal of components SI...

Page 116: ...Disposal 11 7 Disposal of components SIMOTICS HT Series HT direct 1FW4 1 A 116 Operating Instructions 11 2018 ...

Page 117: ...ntact data base Technical Support https support industry siemens com cs ww en sc 2090 Siemens Support for on the move With the Siemens Industry Online Support App you can access more than 300 000 documents for Siemens Industry products any time and any where The App supports you in the following areas Resolving problems when executing a project Troubleshooting when faults develop Expanding a syste...

Page 118: ...Service and Support SIMOTICS HT Series HT direct 1FW4 1 A 118 Operating Instructions 11 2018 ...

Page 119: ...than 25 mm The clamping length 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 ...

Page 120: ... to bolts with property class 8 8 according to ISO 898 1 Case C Applies to bolts with property class 8 8 A4 70 or A4 80 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...

Page 121: ...uality documents can be found here https support industry siemens com cs ww en ps 13323 cert https support industry siemens com cs ww en ps 13323 cert SIMOTICS HT Series HT direct 1FW4 1 A Operating Instructions 11 2018 121 ...

Page 122: ...Quality documents SIMOTICS HT Series HT direct 1FW4 1 A 122 Operating Instructions 11 2018 ...

Page 123: ...3 Connecting terminals 73 Connection cables 57 Converter 24 81 Converter documentation 42 Coolant inlet temperature 28 Coolant supply 28 Coolant temperature sensing 30 Cooling circuit 28 Cooling power 24 Cooling system Faults 96 Cooling unit 30 Cooling volumetric flow 29 Cooling water Connection 60 Cooling water ducts 36 Protect 36 Cooling water inlet temperature 23 Cooling water quality 29 Coolin...

Page 124: ...stances 15 Hearing damage 15 31 High frequency grounding 41 67 Hot surfaces 15 I Increased degree of protection 25 Induced eddy currents 71 Induced voltage 23 Insert cable 69 Inspection Faults 93 98 Installation Initial inspection 99 Installing 57 Insulated bearings 42 Insulation resistance 46 84 92 100 Anti condensation heating 49 measure 47 Interference immunity 18 Interference voltages 18 Inter...

Page 125: ...ncoder 105 Repair Initial inspection 99 Residual risks 27 Restriction of certain Hazardous Substances 111 RF equipotential bonding cable 42 RF grounding point 42 Risk of explosion 21 RoHS 111 Roller bearings Faults 95 Regreasing 82 Rolling bearings Replacement 110 Rotating parts 14 Rotor 113 Demagnetizing 114 Rotor shipping brace 24 34 51 Remove 51 S Safety instructions Flammable substances 15 Haz...

Page 126: ...am 74 Test pressure 60 Test run 82 Thermal motor protection 31 Tightening torques 63 66 Bolted connection 119 Torsional loadings 32 Transporting 37 55 Turning the machine on to its side 52 Type 23 Type of balancing 53 V Vibration values 32 83 Voltage via the converter 76 W Wall face 50 Wall mounting 50 Water cooling Switching off 85 92 Water drip loop 64 Water pressure 23 29 Water cooling 28 Index...

Page 127: ......

Page 128: ...Further Information www siemens com drives Siemens AG Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY ...

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