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Siemens SIMOTICS T-1FW4407-1KM81-1BC0-Z, Operating Instructions Manual

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9.2.3

Replacing the speed encoder

Preparation

NOTICE
Electrostatic discharge
Electronic modules contain components that can be seriously damaged by electrostatic 

discharge. These modules can easily be destroyed unless they are handled properly.
To protect your equipment against damage, follow the instructions given in the chapter 

headed "Electrostatic Sensitive Devices" (Page 17).

ແ

ໂ

ໃ

ໄ

①

Shaft

③

Speed encoder

②

Torque arm

④

Encoder cover

Figure 9-1

Schematic diagram: Detailed view of the speed encoder

1. Unscrew the cover of the speed encoder.
2. Detach the electrical connection.

– Pull the cable carefully out of its holder.
– Pull out the connector.

3. Remove the screwed union connections for the speed encoder from the end shield.

Maintenance

9.2 Corrective Maintenance

SIMOTICS T-1FW4 Heavy Duty  1FW4407-1KM81-1BC0-Z

Operating Instructions 11/2018

91

Summary of Contents for SIMOTICS T-1FW4407-1KM81-1BC0-Z

Page 1: ...www siemens com drives Low voltage motor SIMOTICS T 1FW4 Heavy Duty Type 1FW4407 1KM81 1BC0 Z Operating Instructions Installation Instructions Edition 11 2018 ...

Page 2: ...13 11 2018 16 04 V5 00 ...

Page 3: ...nstructions 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: ...erving the operating mode 25 4 3 Cooling water quality 25 4 4 Cooling water inlet temperature plug on shaft 26 4 5 Noise emissions 26 4 6 Rotational speed limit values 27 4 7 System inherent frequencies 27 4 8 Torsional loading of the drive train due to faults in the electrical supply 27 4 9 Transport 28 4 9 1 Safety instructions for transport 28 4 9 1 1 Transporting the machine set 28 4 9 2 Check...

Page 6: ...ables 47 5 4 4 Aligning the machine to the driven machine and attaching it to it IM B5 48 5 4 5 Axial and radial forces 48 5 5 Connecting the cooling water supply 49 5 6 Insulated bearings 50 6 Electrical connection 51 6 1 Safety instructions relating to the electrical connection 51 6 2 Basic rules 51 6 3 Preparation 52 6 3 1 Terminal designation 52 6 3 2 Selecting cables 53 6 3 3 Connecting the g...

Page 7: ...72 7 11 Switching off the machine 72 8 Operation 73 8 1 Safety instructions for operation 73 8 2 Switching on the machine 75 8 3 Stoppages 76 8 3 1 Prolonged outage periods 76 8 3 2 Avoidance of frost and corrosion damage in the cooling system 76 8 3 3 Avoidance of damage to roller bearings during stoppages 77 8 3 4 Measuring the insulation resistance after an extended non operational period 77 8 ...

Page 8: ...cle 33 of the REACH regulation 97 11 4 Preparing for disassembly 98 11 5 Working on machines with permanent magnets 98 11 6 Disposing of permanent magnets 99 11 7 Disposal of components 100 A Service and Support 103 B Technical data 105 B 1 Tightening torques for screw and bolt connections 105 C Quality documents 107 Index 109 Tables Table 3 1 Machine design 21 Table 4 1 Cooling water specificatio...

Page 9: ...m faults 81 Table B 1 Tightening torques for bolted connections with a tolerance of 10 105 Figures Figure 3 1 Rating plate diagram 22 Figure 4 1 Schematic representation of a single drive 35 Figure 6 1 Water drip loop 52 Figure 6 2 Neutral point connection 55 Figure 9 1 Schematic diagram Detailed view of the speed encoder 91 Figure 9 2 Electrical connection of the speed sensor 93 Table of contents...

Page 10: ...Table of contents SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 10 Operating Instructions 11 2018 ...

Page 11: ...y to protect other people and to avoid material damage Please contact the Service Center Page 103 if you have 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...

Page 12: ...documentation can be exported as PDF for example Using the Documentation function you can 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 T 1FW4 He...

Page 13: ...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 103 for planning installation commissioning and service work 2 2 The 5 safety rules For your own personal safety and to prevent material damage when carryi...

Page 14: ...rate 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 Touching...

Page 15: ...age Observe the product information provided by the manufacturer See also The 5 safety rules Page 13 Inspection and maintenance Page 83 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 th...

Page 16: ...er 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 containing ...

Page 17: ... 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 film ...

Page 18: ...ead 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 Electromag...

Page 19: ...se 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 T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z Operating Instructions 11 2018 19 ...

Page 20: ...Safety information 2 9 Electromagnetic fields when operating electrical power engineering installations SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 20 Operating Instructions 11 2018 ...

Page 21: ...ne design The regulations and standards used as basis for designing and testing this machine are stamped on the rating plate The machine design basically complies with the subsequent standards Please refer to the EU Declaration of Conformity for the versions of the harmonized standards referenced Table 3 1 Machine design Feature Standard Dimensions and operation characteristics IEC EN 60034 1 Degr...

Page 22: ...umber Required amount of cooling water l min at the maximum cooling water inlet tempera ture C Type Maximum water pressure bar Temperature class Rotors standards and regulations 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 1 Rating plate diagram Degree of protection The machine is avai...

Page 23: ... use with these converters No liability is assumed in respect of damage to the motor or converter and no warranty is issued in respect of the drive function if you operate the motor with a different converter As far as the SINAMICS Motor Modules are concerned special control software has been developed for these motors The converter module is selected depending on many influencing parameters e g T...

Page 24: ...Description SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 24 Operating Instructions 11 2018 ...

Page 25: ...erving 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 values specified for the cooling water correspond to the requirements for a closed cooling circuit Not all of the specified concentrations will occur in the cooling water at the same time You can use a filter to ens...

Page 26: ...ndensation forming in the machine This results in material damage Make sure that the condensation can drain away freely Adopt appropriate measures to achieve the required intake temperature of the cooling water Alternatively dry the ambient air 4 5 Noise emissions Noise emissions During operation the machine s noise emission levels can exceed those permitted at the workplace which can cause hearin...

Page 27: ...ing to DIN ISO 10816 3 must not be exceeded 4 8 Torsional loading of the drive train due to faults in the electrical supply In the event of faults in the electrical connection during operation excessive air gap torques can lead to additional mechanical torsional load on the line shaft Risk of torsional stress on the drive train If the configuration does not correctly recognize the mechanical torsi...

Page 28: ...d for the weight of the machine only If a machine set is lifted and transported at a single machine this can fracture the attachment point The machine or machine set may fall This can result 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 transp...

Page 29: ...ne use only approved and undamaged sling guides and spreaders of sufficient rated capacity Check the lifting equipment prior to its use The weight of the machine is shown on the rating plate When lifting the machine refer to the information on the lifting plate Comply with the specified spreading angles Do not exceed the maximum lifting acceleration and lifting speed specified on the lifting plate...

Page 30: ...esult of a machine falling If the lifting gear or load handling attachments were to fail the machine could fall This can result in death serious injury or material damage In order to gain easy and safe access to the underside of the machine place it in a secure and raised position 4 10 Storage You must correctly store the machine if you do not install and use it after it has been delivered NOTICE ...

Page 31: ...n 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 comply wi...

Page 32: ...r 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 Page 3...

Page 33: ... than those specified according to IVIC C can occur then please contact your Siemens partner For a line supply voltage converter input voltage up to max 480 V and when controlled from a SINAMICS G SINAMICS S converter with uncontrolled controlled infeed Comply with the guidelines for configuring motor and converter For line voltages converter input voltages higher than 480 V motors which are order...

Page 34: ...the largest possible surface area at both ends Establish a 360 contact of the cable shielding on the motor housing and on the protective grounding bar of the converter On the motor end for example this can be done using EMC screw joints at the cable entry ports On the converter end you can use EMC shielded clips for example In the overall system set up a properly meshed grounding system with low i...

Page 35: ... machine relating to bearing insulation and possible bridges Driven machine Insulated bearings Motor Insulated tachometer mounting Coupling Figure 4 1 Schematic representation of a single drive NOTICE Bearing damage The bearing insulation must not be bridged Damage may be caused to the bearings if there is a flow of current Also when performing subsequent installation work e g installing an automa...

Page 36: ...Preparations for use 4 11 Converter operation SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 36 Operating Instructions 11 2018 ...

Page 37: ... 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 could be ...

Page 38: ...e 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 lies be...

Page 39: ...urement 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 circuit t...

Page 40: ... 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 the ins...

Page 41: ... see above table 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 ...

Page 42: ...mage Replace any load suspension equipment that is found to be damaged Before use check that the load suspension equipment is correctly attached When lifting the machine use only approved and undamaged lifting gear of sufficient rated capacity Check the lifting gear prior to its use WARNING The machine can be dropped If the load handling attachments and lifting gear are damaged or not correctly se...

Page 43: ...ly oil the depreserved surfaces 5 3 4 Shock load and shaft adaptation The acceleration rates 0 peak measured in the frequency range from 0 Hz to 2 kHz at the bearings must not exceed the following values The position of the measuring points is based on ISO 10816 1 Radial 10 g Axial 5 g Shaft adaptation Align the motor precisely This will prevent distortion and over determination in the bearing For...

Page 44: ...o insert the transmission element into the inner centering of the plug on shaft without skewing Pay attention to the location of the holes irregular drilling pattern 3 Do not strike it with a hammer as this would damage the bearings 4 Secure the transmission element using suitable screws strength class 8 8 for the axial threads 5 Remove the guide bolts and insert the screws Secure the screws to pr...

Page 45: ...t 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 capaci...

Page 46: ... Use compressed air to regularly clean the plugs or when dirt accumulates so that the condensation always freely drains NOTICE Damage due to condensation Under the following conditions it is possible that condensate may accumulate within the machine Wide fluctuations in the ambient temperature such as direct sunshine combined with high atmospheric humidity Intermittent operation or load fluctuatio...

Page 47: ... opposition When selecting the bolts When designing the foundation 5 4 2 Preconditions for smooth vibration free operation Preconditions for smooth vibration free operation Stable foundation design Precise alignment of the machine Correct balancing of parts to be fitted to the shaft end Maintaining the vibration velocity according to ISO 10816 3 5 4 3 Connection cables Observe the following when i...

Page 48: ...that its axis is aligned with that of the driven machine but not yet quite touching Advance the machine slowly towards the driven machine advancing too quickly risks damaging the centering 4 If necessary rotate the machine into the right position so that the clearance holes in the flange are central to the tapped holes 5 Move the machine fully up against the mating flange so that it is fully in co...

Page 49: ...oling water meets the required cooling water specification see section headed Cooling Water Quality Page 25 3 Make sure that the appropriate volume of cooling water is available see Rating Plate Page 21 Flow rate Pressure drop 45 l min 1 6 bar 4 Hold the hexagon head steady with an open ended spanner while you screw in the water pipes 5 Screw the cooling water pipes into the female thread You can ...

Page 50: ...damage when opening the bridging If the bridging of the insulated DE bearing is opened this leads to potential differences between the rotor and the grounded machine Touching them can cause death serious injury or material damage due to electric shock Do not disconnect the bridging of the bearing insulation at the drive end during operation Assembly 5 6 Insulated bearings SIMOTICS T 1FW4 Heavy Dut...

Page 51: ...n 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 the Ser...

Page 52: ...on 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 x Ind...

Page 53: ...g conductor The grounding conductor cross section of the machine must be in full conformance with the installation specifications and to 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 There is a hexagon bolt with a flat washer and a spring washer o...

Page 54: ... Tightening torques of bolts cable lug Bolt Screw in depth Tightening torque M12 x 25 16 mm 38 Nm M16 x 35 20 mm 92 Nm Table 6 4 Bolt tightening torques ground terminals Bolt Screw in depth Tightening torque M6 9 mm 8 Nm M8 12 mm 20 Nm M10 15 mm 40 Nm M12 18 mm 70 Nm M16 20 mm 170 Nm Connecting the grounding conductor in the terminal box In the terminal box use the connection terminals designated ...

Page 55: ...ircuit diagram in the cover of the terminal box 6 4 2 Terminal box Terminal box 1XB7 700 is mounted as standard Table 6 5 Data for electrical connection Terminal box 1XB7 700 Cable entry 3 x M75 x 1 5 Max poss cable outer diameter 68 mm Number of main terminals 3 x 3 x M12 Max cross section per terminal 3 x 150 mm2 Current per terminal max 700 A Current carrying capacity based on IEC EN 60204 1 or...

Page 56: ...Connecting cables section for more information 6 4 4 Connecting cables with cable lugs 1 To connect the cables to the main terminals select cable lugs that match the necessary cable cross section and appropriate screw size The cable lug size defines the cable cross section which can be connected e g cable lug to DIN 46234 or DIN 46235 from 35 mm2 up to 185 mm2 Observe the possible outer diameter o...

Page 57: ... flows following installation due to the contact pressure The connection using clamping nuts can loosen as a result The contact resistance increases obstructing the current from being conducted This can result in fire and material damage to the machine or even in total failure as well as material damage to the plant or system due to machine failure Retighten the clamping nuts after approximately 2...

Page 58: ...lternating voltage Urms Rms value of the alternating voltage Vrms Minimum air clearance 500 V 8 mm 630 V 10 mm 800 V 12 mm 1000 V 14 mm 1250 V 18 mm Values apply at an installation altitude of up to 2000 m When determining the required minimum air clearance the voltage value in the table may be increased by a factor of 1 1 so that the rated input voltage range is taken into account during general ...

Page 59: ...rews see Chapter Tightening torques for screw connections Page 105 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 locat...

Page 60: ...try 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 if necessary for subsequent assignment 4 Pull the cables through the cable glands and the cable entry plate and connect the cables ...

Page 61: ... 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 enclosure The contact point underneath the bolt head is bare metal and protected against corrosion WARNING Ineffe...

Page 62: ...he 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 screw and bolt connections Page 105 for the tightening torque of the fixing bolts for the cover 6 6 Converter operation 6 6 1 Connection to a converter Selectin...

Page 63: ...entative is responsible for selection and dimensioning Limit the voltage rate of rise by using an output filter to dampen harmonic components in the output voltage WARNING Dangerous voltage via the converter As long as the feeding converter is switched on or the DC link of the converter is not discharged there can be a voltage at the motor terminals even when the rotor is not moving The voltage is...

Page 64: ...ent can arise if there is a ground fault on the output side Neither the PE conductors of normally rated multi core connecting cables nor the PE connecting points of normal terminal boxes are suitable for this purpose Material damage can result Use an appropriately sized PE conductor Connect the PE conductor to the grounding terminal on the motor enclosure Electrical connection 6 6 Converter operat...

Page 65: ...mes 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 them c...

Page 66: ...revent 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 standard typ...

Page 67: ...he 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 overvoltage conditions Limit the...

Page 68: ...le Regreasing roller bearings before commissioning You must regrease the roller bearings under the following conditions If the machine has been in storage for more than four years If the machine has not been stored in accordance with the specifications in the Storage section Contact the Service Center See also Transport Page 28 Service and Support Page 103 7 4 Setting the converter pulse frequency...

Page 69: ...um for example for checking the direction of rotation or for checking in general Allow the machine to run down before switching it on again 2 If the machine is running smoothly and evenly switch on the cooling equipment Continue to observe the machine for a while in no load operation 3 If it runs perfectly connect a load NOTICE Thermal overload of motors connected directly to the line supply In ad...

Page 70: ...ng operated at the system resonance point System motor base frame foundation NOTICE Serious damage to the machine If the vibration values in operation are not maintained in accordance with DIN ISO 10816 3 then the machine can be mechanically destroyed During operation observe the vibration values in accordance with DIN ISO 10816 3 7 7 Measure the insulation resistance and polarization index for th...

Page 71: ... certain speed range If a motor is operated at impermissible speeds damage to the winding bearings or complete destruction of the motor can be the result Ensure that the speeds specified on the rating plate are not exceeded by appropriately configuring controller and speed monitoring components See also Description Page 21 7 9 Set values for temperature monitoring of the bearing thermometer Before...

Page 72: ...op Table 7 2 Alarm and shutdown temperatures of the temperature monitoring Set value Temperature Prior to commissioning Shutdown 145 C In operation Alarm Top 10 K 165 C Shutdown Top 15 K 180 C 7 11 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 Start up...

Page 73: ... 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 comi...

Page 74: ...rn 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 motor ter...

Page 75: ...erated 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 motors co...

Page 76: ...n the cooling system For avoidance of frost and corrosion damage completely drain the water from the cooling system Then blow air through the cooling system to dry it If the cooling system cannot be drained because standby capability is required at short notice protect the cooling circuit against frost and corrosion damage To do this add suitable additives to the cooling water NOTICE Impairment of...

Page 77: ...ization index PI provides information on the condition of the machine It is therefore important to check the insulation resistance and the polarization index at the following times Before starting up a machine for the first time After an extended period in storage or downtime Within the scope of maintenance work The following information is provided regarding the state of the winding insulation Is...

Page 78: ...n you re commission the machine proceed as follows Study the record made when the machine was decommissioned and reverse the measures that were taken for conservation and storage Perform the measures listed in the Commissioning section See also Start up Page 65 8 8 Faults 8 8 1 Inspections in the event of faults Natural disasters or unusual operating conditions such as overloading or short circuit...

Page 79: ... short circuit or inter phase short circuit in stator winding Determine the winding resistances and insulation re sistances Contact the Service Center X Converter output voltage too high frequency too low Check the settings at the frequency converter and perform the automatic motor identification X X Cooling water not connected Cooling water supply switched off Water connection pipes defective Che...

Page 80: ...ng Contact the Service Center Table 8 3 Roller bearing faults Bearing overheats Bearing whistles Bearing knocks Possible causes of fault Remedial measures X High coupling pressure Align the machine more accurately X Ambient temperature higher than 40 C Use high temperature grease X X Insufficient lubrication Grease the bearings as instructed X Too much grease in bearing Remove surplus grease Conta...

Page 81: ...gents 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 cooling wat...

Page 82: ...Operation 8 8 Faults SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 82 Operating Instructions 11 2018 ...

Page 83: ...ir 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 voltage co...

Page 84: ...ntenance 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 attach...

Page 85: ... 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 cooli...

Page 86: ...ow 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 ther...

Page 87: ...ls 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 7 Regreasing intervals and types of grease for operating rolling bearings Grease types Lubcon Thermogrease DSV 2 EP grease i...

Page 88: ...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 out of ...

Page 89: ...rrying 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 always pre...

Page 90: ...g down before you dismantle them e g by replacing fastening elements with extra long screws threaded bolts or similar This ensures that 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 103 9 2 2 Changing the bearings We recommend t...

Page 91: ...the chapter headed Electrostatic Sensitive Devices Page 17 ແ ໂ ໃ ໄ Shaft Speed encoder Torque arm Encoder cover Figure 9 1 Schematic diagram Detailed view of the speed encoder 1 Unscrew the cover of the speed encoder 2 Detach the electrical connection Pull the cable carefully out of its holder Pull out the connector 3 Remove the screwed union connections for the speed encoder from the end shield M...

Page 92: ... of 3 Nm 4 Loosen the screws of the torque arm so as to relieve the stress and tighten them crosswise with a tightening torque of 0 6 Nm 5 Establish the electrical connection 6 Screw on the cover of the speed encoder 9 2 4 Connecting the speed encoder NOTICE Electrostatic discharge Electronic modules contain components that can be seriously damaged by electrostatic discharge These modules can easi...

Page 93: ...on of the speed sensor Note Replacing or adjusting the speed encoder Replacing or adjusting the speed encoder in an incorrect manner can result in machine malfunctions Arrange to have the speed encoder replaced or adjusted by Siemens service personnel This will ensure problem free functioning Maintenance 9 2 Corrective Maintenance SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z Operating Instructi...

Page 94: ...Maintenance 9 2 Corrective Maintenance SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 94 Operating Instructions 11 2018 ...

Page 95: ... 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 sow si...

Page 96: ...e is also necessary for the bearing version Both of these codes are stamped on the lubricant plate and specified in the motor documentation 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 ...

Page 97: ...ng 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 are n...

Page 98: ...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 injury or...

Page 99: ... 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 motor is ...

Page 100: ...companies Information regarding authorized waste disposal companies and workshops can be obtained from the Siemens Service Center Page 103 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 stee...

Page 101: ... 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 SIMOTIC...

Page 102: ...Disposal 11 7 Disposal of components SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 102 Operating Instructions 11 2018 ...

Page 103: ... 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 system or ...

Page 104: ...Service and Support SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 104 Operating Instructions 11 2018 ...

Page 105: ...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 bolte...

Page 106: ...olts 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 flat...

Page 107: ...y 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 T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z Operating Instructions 11 2018 107 ...

Page 108: ...Quality documents SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 108 Operating Instructions 11 2018 ...

Page 109: ... 60 Connection cables 47 Connection data 55 Converter 67 Converter documentation 35 Cooling capacity 23 Cooling system Faults 81 Cooling water Connection 49 Specification 25 Cooling water inlet temperature 22 Cooling water intake temperature 26 Cooling water quantity 22 Cooling water supply 67 Correct usage 22 Corrosion protection 76 Removing 42 Creepage distance 56 D Damage during transportation ...

Page 110: ...8 Interference voltages 18 L Lifting 29 45 Live parts 14 Long term storage 32 Low Voltage Directive 13 M Machine Mounting 47 setting down 46 Machine design 21 IEC 21 Machine type 95 Magnetic fields 16 90 96 98 Minimum air clearances 58 Minimum clearances 56 More information 103 Motor type 22 Motor weight 22 N Neutral point 55 Noise emissions 15 26 O On site service 103 Operating mode 22 25 Operati...

Page 111: ...aptation 43 Shaft assembly 27 Siemens Industry Online Support App 103 Spare parts 103 Spare parts ordering 95 Spares on Web 95 Speed 27 Speed encoder Adjusting 93 Electrical connection 93 Mounting 92 Replacing 93 Separating 92 Standard flange 48 Stoppages 76 Roller bearings 77 Storage 31 Storage location 31 Strap 54 Supplementary devices 23 Switching on 69 75 Synchronous motor 21 System resonances...

Page 112: ...Index SIMOTICS T 1FW4 Heavy Duty 1FW4407 1KM81 1BC0 Z 112 Operating Instructions 11 2018 ...

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Page 114: ...Further Information www siemens com drives Siemens AG Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY ...

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