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Siemens SIMOTICS XP 1MD4, Operating Instructions And Installation Instructions, Page: 41 / 128

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Siemens SIMOTICS XP 1MD4 Operating Instructions And Installation Instructions Download Page 41

Assembling

5

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

(Page 13) and the specifications contained in EN 50110‑1 regarding safe operation on 

electrical equipment.

5.1

Preparations for installation

5.1.1

Safety instructions for installation

WARNING

Danger caused by inappropriate fastening material
If screws of an incorrect property class have been selected or if they have been fastened to 

an incorrect tightening torque, they may break or become loose. This will cause the machine 

to move, which could damage the bearings. The rotor could smash into the machine enclosure 

and machine parts could be flung out of place. This can result in death, serious injury or 

material damage.
● Comply with the required property classes for screwed connections.
● Tighten the screwed connections to the specified tightening torques.

WARNING

Tensions on the fastening parts
If the machine has not been properly aligned, this will mean the fastening parts are subjected 

to stress/distortion. Screws may become loose or break, the machine will move, machine 

parts could be flung out of place. This can result in death, serious injury or material damage.
● Carefully align the machine to the driven machine.

NOTICE
Damage to the mounted parts
Mounting parts such as temperature sensors or speed sensors are attached to the machine 

and could be ripped off or destroyed as a result of improper handling. This could lead to 

machine malfunctions, extending even to total loss of the machine. 
● Where necessary, use suitable steps when performing installation work on the machine.
● Do not stand on cables or attachments during installation. Do not use attachments as 

steps.

SIMOTICS XP  1MD4/1MD5

Operating Instructions 05/2015

41

Summary of Contents for SIMOTICS XP 1MD4

Page 1: ...rating Instructions Installation Instructions N R 602d Edition 05 2015 For employment in zone 1 or zone 2 IEC EN 60079 10 1 0102 II 2G Ex d IIB IIC T Gb Optional For use in Zone 21 or 22 IEC EN 60079 10 2 0102 II 2D Ex tb IIIA B C T C Db or II 3D Ex tc IIIA B C T C Dc ...

Page 2: ...13 07 2015 11 26 V8 00 ...

Page 3: ...ional For use in Zone 21 or 22 IEC EN 60079 10 2 0102 II 2D Ex tb IIIA B C T C Db or II 3D Ex tc IIIA B C T C Dc Edition 05 2015 Introduction 1 Safety notes 2 Description 3 Preparations for use 4 Assembling 5 Electrical connection 6 Commissioning 7 Operation 8 Maintenance 9 Spare parts 10 Disposal 11 Service and Support A Technical data and drawings B Quality documents C ...

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

Page 5: ...Machines without final paint coating 27 4 3 Thermal motor protection 27 4 4 Interlock circuit for anti condensation heating 28 4 5 Noise emissions 28 4 6 Voltage and frequency fluctuations during line operation 28 4 7 Protection against impermissible temperature rise 29 4 8 System inherent frequencies 29 4 9 Transport and storage 29 4 9 1 Transport markings 29 4 9 2 Checking the delivery 30 4 9 3 ...

Page 6: ...ounting feet 46 5 3 3 Removing the rotor shipping brace 46 5 3 4 Alignment accuracy 47 5 3 5 Mounting the output elements 47 5 3 6 Axial and radial forces 49 6 Electrical connection 51 6 1 Preparation 51 6 1 1 Selecting cables 51 6 2 Connecting 52 6 2 1 Terminal boxes with type of protection Ex d 52 6 2 2 Terminal boxes with type of protection Ex e 52 6 2 3 Connecting the grounding conductor 53 6 ...

Page 7: ...ction for roller bearings 80 9 1 7 Maintenance 80 9 1 7 1 Explosion protection for machines with type of protection Ex d 80 9 1 7 2 Explosion hazard due to increased surface temperature 81 9 1 7 3 Insulation resistance and polarization index 81 9 1 7 4 Grease service life and fill quantities 82 9 1 7 5 Grease stability times and fill quantities 83 9 1 7 6 Regreasing intervals and types of grease f...

Page 8: ...paring for disassembly 107 11 3 Dismantling the machine 108 11 4 Disposal of components 108 A Service and Support 111 A 1 Siemens Industry Online Support 111 A 2 RoHS restricting the use of certain hazardous substances 112 B Technical data and drawings 113 B 1 Tightening torques for screw and bolt connections 113 C Quality documents 115 C 1 IECEx certificate 115 C 2 EC Declaration of Conformity 11...

Page 9: ...al inspection 78 Table 9 3 Bolt grade BG071 to BG315 79 Table B 1 Tightening torques for bolted connections with a tolerance of 10 113 Figures Figure 4 1 Schematic representation of a single drive 38 Figure 4 2 Schematic representation of a tandem drive 38 Figure 5 1 Balancing type on the drive end side 47 Figure 6 1 Example for conductor connection 56 Figure 6 2 Example for conductor connection 5...

Page 10: ...Table of contents SIMOTICS XP 1MD4 1MD5 10 Operating Instructions 05 2015 ...

Page 11: ...The warning notice system is explained on the rear of the inside front Always follow the safety instructions and notices in these instructions In addition to the safety related warning notices which you must read you will find the text in these instructions is formatted in the following way 1 Handling instructions are always formatted as a numbered list Always perform the steps in the order given ...

Page 12: ...Introduction SIMOTICS XP 1MD4 1MD5 12 Operating Instructions 05 2015 ...

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

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

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

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

Page 17: ...ng made of synthetic fibers Always place electrostatic sensitive devices on conductive bases Always pack store and transport electronic modules or components in conductive packaging e g metallized plastic or metal containers conductive foam material or domestic aluminum foil The necessary ESD protective measures for electrostatic sensitive devices are illustrated once again in the following drawin...

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

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

Page 20: ...Safety notes 2 11 Ventilation SIMOTICS XP 1MD4 1MD5 20 Operating Instructions 05 2015 ...

Page 21: ...f Zones 21 and 22 in the Ex tb type of protection and Zone 22 in the Ex tc type of protection according to IEC EN 60079 10 2 Use in hazardous areas Explosion proof electrical machines correspond to standards of the IEC EN 60034 and IEC EN 60079 series Only operate the machine in hazardous areas strictly complying with the specifications of the responsible supervisory authority The relevant supervi...

Page 22: ...tion are unfavorably affected in a particular hybrid mixture Motors with dual plates for G Gas andD Dust may only be used where these two simultaneously occur after the user has first analyzed the properties of the hybrid mixture NOTICE Use of machines without CE marking Machines without CE marking are intended for operation outside the European Economic Area EEA Do not use any machines without a ...

Page 23: ... T C Dc Ex tc IIIB T C Dc Ex tc IIIA T C Dc Machine design The regulations and standards used as the basis to design and test this machine are stamped on the rating plate The machine design basically complies with the subsequent standards Please refer to the EC Declaration of Conformity for the versions of the harmonized standards referenced Table 3 4 Machine design Feature Standard Rating and per...

Page 24: ... the stator frame and bearing shields are manufactured out of cast iron or steel The fan cover is made of sheet steel The stator frame surface has cooling ribs hollow ribs or tubes and mounted terminal box Cooling for machines with surface cooling hollow rib cooling or tube cooling For machines with rib hollow rib or tube cooling the cooling air is drawn in through openings in the fan cover The ai...

Page 25: ...The machine is painted according to the instructions in your order Monitoring equipment Monitoring equipment is provided corresponding to what has been ordered KTY83 and KTY84 semiconductor sensors are electrostatic sensitive devices ESD These elements can be damaged by electrostatic discharge Observe the ESD protective measures Page 17 DANGER Risk of explosion during operation due to too high sur...

Page 26: ...Description SIMOTICS XP 1MD4 1MD5 26 Operating Instructions 05 2015 ...

Page 27: ...your plant 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 2 Machines without final paint coating For machines which are only delivered with primer you must paint them to comply with the applicable guidelines for the specific application The primer alone does not provide adequate corrosi...

Page 28: ...h can cause hearing damage Take steps to reduce noise such as introducing covers and protective insulation or adopting hearing protection measures so that the machine can be operated safely within your system 4 6 Voltage and frequency fluctuations during line operation Unless stated otherwise on the rating plate the permissible voltage fluctuation is 10 and the permissible frequency fluctuation is...

Page 29: ... a delta connection in such a way that the tripping unit or relay is connected in series with the winding phases When selecting and setting the tripping unit define the rated value of the phase current The phase current is 0 58 times the rated motor current Any thermal motor protection via direct temperature monitoring to be used in addition to the motor starter protector is stated on the rating p...

Page 30: ...hese Operating Instructions are part of the scope of delivery keep them in a location where they can be easily accessed 4 9 3 Checking the load handling attachments Inspect the load handling attachments such as the load stands lifting eyes and ring bolts and also the lifting gear before lifting the machine Inspect the load handling attachments on the machine for possible damage Replace any load ha...

Page 31: ...devices The weight of the machine is stated on the rating plate WARNING Center of gravity when transporting or lifting the motor If the center of gravity of a load is not located centrally between the attachment points the motor can tip over or slip out of the lifting gear when it is being transported or lifted This can result in death serious injury or material damage 1 Always take account of the...

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

Page 33: ...ignited during commissioning Explosions can occur This can result in death serious injury or material damage The materials used are specially designed for the temperature range required by the customer Do not store the motor in conditions that lie outside the specified temperature limits The relevant temperature limits are specified on the rating plate 4 9 7 Storing motors together with the driven...

Page 34: ...or downtime Within the scope of maintenance work The following information is provided regarding the state of the winding insulation Is the winding head insulation conductively contaminated Has the winding insulation absorbed moisture As such you can determine whether the machine needs commissioning or any necessary measures such as cleaning and or drying the winding Can the machine be put into op...

Page 35: ...22 Speed torque characteristic for operation with a SINAMICS converter The load characteristics show the permanent permissible load torque as a function of the speed and the cooling method The load torque is specified as a percentage referred to the maximum torque according to the supplementary plate for converter operation 1 1V QF 0 0 PD Force ventilated external and internal Surface cooled self ...

Page 36: ...tential bonding conductors Use equipotential bonding conductors Between motor and driven machine Between motor and converter Between the terminal box and the RF grounding point at the motor enclosure Selecting and connecting the cable As far as possible use symmetrically arranged shielded connection cables The cable shielding made up of as many strands as possible must have good electrical conduct...

Page 37: ...ystem design To specifically reduce and prevent damage caused by bearing currents you must consider the system as a whole which comprises the motor converter and driven machine The following precautions help to reduce bearing currents In the overall system set up a properly meshed grounding system with low impedance Use the common mode filter damping cores at the converter output The Siemens sales...

Page 38: ...to the bearings if there is a flow of current Tandem operation If you connect two motors in series in tandem operation install an insulated coupling between the motors Driving machine Insulated bearings Motor Insulated tachometer fitting Coupling Insulated coupling Figure 4 2 Schematic representation of a tandem drive Preparations for use 4 10 Converter operation SIMOTICS XP 1MD4 1MD5 38 Operating...

Page 39: ...tage 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 up to 1000 V depending on the converter type Ensure that the five safety rules are followed before working on the motor Preparations for use 4 10 Converter operation SIMOTICS XP 1MD4 1...

Page 40: ...Preparations for use 4 10 Converter operation SIMOTICS XP 1MD4 1MD5 40 Operating Instructions 05 2015 ...

Page 41: ...r screwed connections Tighten the screwed connections to the specified tightening torques WARNING Tensions on the fastening parts If the machine has not been properly aligned this will mean the fastening parts are subjected to stress distortion Screws may become loose or break the machine will move machine parts could be flung out of place This can result in death serious injury or material damage...

Page 42: ...d value take appropriate remedial measures These remedial measures may necessitate the machine being removed again and transported NOTICE High temperatures The motor components get very hot during operation High temperatures can damage mounting parts such as the cable insulation Temperature sensitive parts such as normal cables or electronic components must not rest against or be attached to mount...

Page 43: ...e Replace any load handling attachments that are found to be damaged Check before use that the load handling attachments are correctly secured When lifting the machine use only approved and undamaged lifting gear of sufficient rated capacity Check these before using them WARNING The machine can be dropped If the load handling attachments and lifting gear are damaged or not correctly secured the ma...

Page 44: ...can result in death serious injury or material damage 1 Always take account of the center of gravity when transporting or lifting the machine The machine s center of gravity is indicated in the relevant dimension diagram 2 Observe the handling instructions on the motor when transporting it If the center of gravity is not located centrally between the attachment points then position the hoisting ho...

Page 45: ...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 3 Installing the machine 5 3 1 Preconditions for smooth vibration free operation Preconditions for smooth vibration free operation Stable foundation ...

Page 46: ... 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 Note Machine expansion When aligning make allowance for the thermal expansion of the machine when the temperature increases NOTICE Damage to the bearing Dismantling the rotor shipping brace when the machine is in a horizontal po...

Page 47: ...fset mm per 100 mm cou pling diameter 750 0 09 0 09 1500 0 06 0 05 3000 0 03 0 025 5 3 5 Mounting the output elements Balance quality The rotor is dynamically balanced For shaft extensions with feather keys the balancing type for machines with a frame size 100 is stamped on the rating plate For machines with a frame size 100 the balancing type is specified using the following marking on the face o...

Page 48: ...n the shaft or pushed on by hand Do not strike it with a hammer as this would damage the bearings Shaft extensions with feather key To maintain the balancing quality you have the following options If the transmission element is shorter than the feather key with balancing type H then you must machine off the section of feather key protruding from the shaft contour and transmission element in order ...

Page 49: ...en it by approximately half for balance type H 5 3 6 Axial and radial forces You can obtain the permissible values for axial and radial forces by contacting the Siemens Service Center or referring to the machine catalog NOTICE Damage to bearings or the shaft Large output masses and their centers of gravity outside the shaft extensions can lead to resonance in operation This can result in damage to...

Page 50: ...Assembling 5 3 Installing the machine SIMOTICS XP 1MD4 1MD5 50 Operating Instructions 05 2015 ...

Page 51: ...ng formation may occur in an explosive atmosphere it can lead to an explosion This could result in death serious injury or material damage to the machine or even in failure which could in turn lead indirectly to material failure of the system Tighten the screwed connections to the specified tightening torques Observe any specifications regarding the materials from which fixing elements must be mad...

Page 52: ...pe of protection Ex e WARNING If the seal of the pressure relief flap preset breaking point in the lower section of the terminal box is damaged then the explosion type of protection is no longer guaranteed An explosion may occur during operation This can result in death serious injury or material damage The damaged seal may only be repaired with original sealing material WARNING No cable or line e...

Page 53: ... for connecting stranded cables with cable lugs or connecting flat straps In addition all motors have a PE terminal within the terminal box When connecting up the grounding conductor ensure that the contact surface of the connection is bare and protected against corrosion using a suitable agent e g with acid free Vaseline 6 2 4 Circuit diagram in the terminal box cover Data on the connection and c...

Page 54: ...found in the machine dimension drawing Only use cable entries that are suitable for the cable Only use suitable cable entries and cables for the prevailing ambient temperature Check the cable glands and cables to ensure that they are correctly sealed and firmly seated Correctly close and seal threads or holes that are not being used ensuring that the IP degree of protection is maintained The IP de...

Page 55: ...s Table 6 3 Minimum air clearance dependent on rms value of the alternating 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 th...

Page 56: ... the terminal clamps in a U shape Alternatively with multi stranded and finely stranded conductors evenly divide the conductor into two parts and lay in a straight line under the U shaped terminal clamps See sketch Figure 6 1 Example for conductor connection Electrical connection 6 2 Connecting SIMOTICS XP 1MD4 1MD5 56 Operating Instructions 05 2015 ...

Page 57: ...riate torque as specified by the manufacturer after inserting the feeder cables The tightening torques depend on the cable gland used and the cable or wire used Tighten the standard cable glands supplied with the motor in accordance with the following table Table 6 4 Tightening torques for standard cable glands Nm Nominal size Cable gland for Ex e II TypeHSK M Cable gland for Ex e Ex d IIC Type AD...

Page 58: ...ssure Aluminum flows following installation due to the contact pressure The connection with the clamping nuts can loosen as a result The contact resistance would increase and the current carrying impeded as a consequence the terminal box and the surrounding components could burn This could result in material damage to the machine or even in total failure which could in turn lead to indirect materi...

Page 59: ...device Water and foreign bodies can penetrate the enclosure if the pressure relief device is damaged The degree of protection of the terminal box is no longer guaranteed a short circuit can occur which can result in death serious injury or material damage Do not operate the machine with a damaged pressure relief device Any damage may only be repaired after prior discussion with the person responsi...

Page 60: ...ed wire A copper braided strip a stranded wire or a metal contact is used to ensure potential equalization between the cable entry plate and the terminal box enclosure Electrical connection 6 2 Connecting SIMOTICS XP 1MD4 1MD5 60 Operating Instructions 05 2015 ...

Page 61: ... and aligned the transmission elements are correctly balanced and adjusted All fixing screws connection elements and electrical connections have been tightened to the specified tightening torques The operating conditions match the data provided in accordance with the technical documentation such as degree of protection ambient temperature etc Moving parts such as the coupling brake etc move freely...

Page 62: ...es have been maintained Any supplementary motor monitoring devices and equipment have been correctly connected and are functioning correctly All brakes and backstops are operating correctly At the monitoring devices the values for Warning and Shutdown are set Converter operation If the design of the motor requires connection to a particular converter type the rating plate will contain correspondin...

Page 63: ...the insulation resistance and polarization index 7 4 Testing the insulation resistance and polarization index WARNING Hazardous voltage at the terminals During and immediately after measuring the insulation resistance or the polarization index PI of the stator winding hazardous voltages may be present at some of the terminals Contact with these can result in death serious injury or material damage...

Page 64: ...ated voltage see the rating plate Umeas DC measuring voltage RC minimum insulation resistance at reference temperature of 40 C Conversion to the reference temperature When measuring with winding temperatures other than 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 re...

Page 65: ...x 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 not included in the assessment R 10...

Page 66: ...Commissioning 7 4 Testing the insulation resistance and polarization index SIMOTICS XP 1MD4 1MD5 66 Operating Instructions 05 2015 ...

Page 67: ...s injury or material damage can result if the required covers are removed Any covers that prevent live electrical or rotating parts from being touched or that ensure compliance with a particular degree of protection or are required for ensuring proper air flows and hence effective cooling must not be opened during operation WARNING Faults in operation Deviations from normal operation such as incre...

Page 68: ...ridging of the bearing insulation during operation NOTICE Excessive machine temperature If the anti condensation heating is operated while the machine is running this can increase the temperatures inside the machine This can result in material damage Make sure that the anti condensation heating is switched off before the machine is switched on Only operate anti condensation heating when the machin...

Page 69: ...se 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 4 1 Switching on the anti condensation heater If the machine has anti condensation heating then switch it on when the machine is not in operation WARNING Explosion hazard If the anti condensation heating is...

Page 70: ... NOTICE Damage as a result of an extended period out of service If the machine is going to be out of service for longer than six months then take the necessary measures for preservation and storing Otherwise damage to the machine will result Record the decommissioning steps This log will be useful upon recommissioning 8 6 Re commissioning the machine When you re commission the machine proceed as f...

Page 71: ...he power supply conditions X X X X X Stator winding incorrectly connected Check the winding connection in the terminal box X X X X Winding short circuit or phase short cir cuit in stator winding Determine the winding resistances and insulation resistances Carry out repair work after consulta tion with the manufacturer X Incorrect direction of rotation Check the connection 8 7 3 Mechanical faults T...

Page 72: ...bearing Use other bearing designs only after consulting the manufacturer Table 8 3 Roller bearing faults Bearing overheats Bearing whistles Bearing knocks Possible causes of faults Remedial measures X High coupling pressure Align the machine more accurately X Belt tension too high Reduce the drive belt tension X Bearing contaminated Clean the bearing or replace it Check the seals X High ambient te...

Page 73: ...X Friction marks on raceway Replace the bearing X Scoring brinelling Replace the bearing Avoid any vibration at standstill Operation 8 7 Faults SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 73 ...

Page 74: ...Operation 8 7 Faults SIMOTICS XP 1MD4 1MD5 74 Operating Instructions 05 2015 ...

Page 75: ...the machine Note Service Center Please contact the Service Center if you require support with servicing maintenance or repair 9 1 Inspection and maintenance WARNING Rotating and live parts Electric machines contain live and rotating parts Fatal or serious injuries and substantial material damage can occur if maintenance work is performed on the machine when it is not stopped or not de energized Pe...

Page 76: ...he machine When carrying out maintenance work make sure that no foreign bodies are left in or on the machine Securely attach all loose parts again once you have completed the maintenance procedures Carefully remove any dirt Note Operating conditions and characteristics can vary widely For this reason only general intervals for inspection and maintenance measures can be specified here WARNING Explo...

Page 77: ... current dependent overload protection device located in the three phases of the connecting cable we recommend that you also monitor the temperature rise in the motor with the aid of the temperature sensors built into the stator winding WARNING Risk of explosion when cleaning with compressed air If you clean the machine with compressed air plastic components may become statically charged and ignit...

Page 78: ...the motor 9 1 3 General inspection Check that the installation conditions are observed We recommend that the following checks are performed after approx 16 000 operating hours or at the latest after two years Table 9 2 Checks that have to be performed during the general inspection Checking When the motor is running At stand still The electrical parameters are maintained X The permissible bearing t...

Page 79: ...nerally not necessary to dismantle the machines The motor only has to be dismantled if the bearings are to be replaced 9 1 5 Bolt grade for roller bearings Check that all the bolts for attaching the bearing shields bearing cover gland plates and terminal boxes are present and properly tightened Replace damaged bolts with identical bolts of a perfect quality Depending on the ambient temperature onl...

Page 80: ...rease in the bearings The roller bearing service life under full specified load is at least 20 000 hours for machines subject to radial or axial forces The nominal roller bearing service life of machines which are not subject to any forces is at least 40 000 hours For roller bearings with external oil supply monitor that lubrication is maintained 9 1 7 Maintenance 9 1 7 1 Explosion protection for ...

Page 81: ...ation resistance and polarization index PI provides information on the condition of the machine It is therefore important to check the insulation resistance and the polarization index at the following times Before starting up a machine for the first time After an extended period in storage or downtime Within the scope of maintenance work The following information is provided regarding the state of...

Page 82: ...60 32 32 180 51 51 200 63 63 225 79 79 250 99 99 280 99 132 315 4000 8000 11000 2800 5600 8000 35 25 355 4000 5600 35 50 The specified grease stability times and or relubrication intervals are valid for maximum ambient temperatures of 40 C Reduce the lubrication interval for a 10 C increase in temperature by a factor of 0 7 of the value listed in the table max 20 C factor 0 5 With an ambient tempe...

Page 83: ...specified grease stability time applies to the ambient temperature range stated on the rating plate Reduce the lubrication interval for a 10 C increase in temperature by a factor of 0 7 of the value listed in the table max 20 C factor 0 5 Irrespective of the operating hours the roller bearing grease and the bearing 2Z bearing must be replaced after four years of service 9 1 7 6 Regreasing interval...

Page 84: ...on chambers at the intervals shown on the notice plate with the motor stopped and remove the used bearing grease If this is not done the grease will clog and the bearings will overheat WARNING Rotor can fall out If the machine is in a vertical position the rotor can fall out while work is being performed on the locating bearing This can result in death serious injury or material damage Support or ...

Page 85: ...an alternative type of grease that is permitted according to the table Bearings with permanent lubrication Completely remove the old grease from the bearing before regreasing it Fill roller bearings completely with grease and cavities in the bearing cover only up to one third Bearings with regreasing If complete replacement of grease and cleaning of the bearing is not possible keep the operating t...

Page 86: ...aintenance and repair for machines of protection type Ex d The machine marking based on IEC EN 60079 0 was added with the X symbol Maintain the special conditions for repairs The gap dimensions for the electric machine do not comply with the standardized values in IEC EN 60079 1 For repair work obtain the gap dimensions of the electrical machine from the manufacturer Perform maintenance repair and...

Page 87: ...nal boxes Requirement The machine is de energized Checking the terminal box Terminal boxes must be regularly checked for tightness undamaged insulation and tight terminal connections If dust or humidity have infiltrated the terminal box this should be cleaned and dried particularly the insulators Check all the seals and sealing surfaces and address the cause of the leakiness Check the insulators c...

Page 88: ...ing thickness 0 75 mm for motors of group II gas III Total paint coating thickness 0 45 mm for group III motors dust According to tests paint repair work up to the total paint coating thickness of the non conductive paint coating listed has also been examined and is harmless Limit the surface resistance of the paint used IIB IIC III Surface resistance 1 GΩ for motors of groups II and III gas and d...

Page 89: ...tly e g if unauthorized or untested spare parts are used this can result in explosions during operation in a potentially explosive gaseous atmosphere This can result in death serious injury or material damage Repairing and mounting the anti condensation heating and the subsequent routine testing must always be undertaken by experts from the Service Center because this work requires extensive speci...

Page 90: ...Maintenance 9 2 Repair SIMOTICS XP 1MD4 1MD5 90 Operating Instructions 05 2015 ...

Page 91: ...ta The serial number is also stamped on the end face of the shaft extension at the drive end 10 2 Replacing roller bearings Rolling contact bearings When ordering roller bearings in addition to the bearing identification code the supplementary specifying code is also necessary for the bearing version Both of these codes are stamped on the lubricant plate and specified in the motor documentation or...

Page 92: ... standard parts such as screws may be used 10 4 Anti condensation heating spare parts WARNING Risk of explosion If repairs to the anti condensation heating are not carried out correctly e g if unauthorized or untested spare parts are used this can result in explosions during operation in a potentially explosive gaseous atmosphere This can result in death serious injury or material damage Repairing...

Page 93: ... frame 4 24 Gamma ring 2 00 Shaft with rotor 4 34 Spacer washers 2 01 Feather key 4 44 Gamma ring 3 01 End shield drive end 5 10 Fan cover 3 08 Flange plate 5 11 Protective cover 3 21 End shield non drive end 5 56 Fan 4 01 Roller bearing DE 6 00 Terminal box 4 05 Roller bearings NDE Spare parts 10 5 Spare parts list frame sizes 071 to 132 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 93 ...

Page 94: ...10 6 Spare parts list frame sizes 160 to 280 Spare parts 10 6 Spare parts list frame sizes 160 to 280 SIMOTICS XP 1MD4 1MD5 94 Operating Instructions 05 2015 ...

Page 95: ... 0 0 Figure 10 2 E DN000 0008 Spare parts 10 6 Spare parts list frame sizes 160 to 280 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 95 ...

Page 96: ...se chamber cover NDE 2 01 Feather key 4 38 Grease slinger 3 01 End shield drive end 4 44 Gamma ring 3 08 Flange plate 4 54 Grease nipple 3 21 End shield non drive end 4 54 Regreasing assembly 4 01 Roller bearing DE 5 10 Fan cover 4 10 Outer grease chamber cover DE 5 11 Protective cover 4 12 Inner grease chamber cover DE 5 56 Fan 4 18 Grease slinger 6 00 Terminal box Spare parts 10 6 Spare parts li...

Page 97: ...slinger DE 2 00 Rotor complete balanced 4 24 Sealing ring DE outer 2 01 Keyway 4 32 Grease chamber cover NDE inner 3 01 Bearing shield DE 4 38 Outer grease chamber cover 3 08 Flange plate DE 4 44 Sealing ring NDE outer 3 21 Bearing shield NDE 4 54 Relubrication NDE Spare parts 10 7 Spare parts list frame size 315 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 97 ...

Page 98: ...4 01 Bearing DE 5 11 Protective cover 4 05 Bearing NDE 5 56 Fan complete 4 12 Grease chamber cover DE inner 6 00 Terminal box 10 8 Spare parts list frame size 355 0 9 0 Figure 10 4 E DN000 0010 Spare parts 10 8 Spare parts list frame size 355 SIMOTICS XP 1MD4 1MD5 98 Operating Instructions 05 2015 ...

Page 99: ...ange plate DE 4 38 Grease slinger NDE 3 21 Bearing shield NDE 4 44 Sealing ring NDE outer 4 00 Grease nipple 5 01 Fan cowl complete 4 01 Bearing DE 5 04 Fan hub NDE 4 05 Bearing NDE 5 11 Protective cover 4 10 Grease chamber cover DE outer 5 56 Fan complete 4 12 Grease chamber cover DE inner 6 00 Terminal box 4 13 Grease slinger DE 4 24 Sealing ring DE outer Spare parts 10 8 Spare parts list frame ...

Page 100: ...um ber Designation Part num ber Designation 6 03 Terminal box base 6 15 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 13 Terminal box seal Spare parts 10 9 Spare parts list for terminal boxes with type of protection Ex e frame sizes 071 160 SIMOTICS XP 1MD4 1MD5 100 Operating Instructions 05 2015 ...

Page 101: ...t num ber Designation Part num ber Designation 6 03 Terminal box base 6 15 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 07 Gland plate Spare parts 10 10 Spare parts list for terminal boxes with type of protection Ex d frame sizes 071 160 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 101 ...

Page 102: ...t num ber Designation Part num ber Designation 6 03 Terminal box base 6 15 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 10 Gland plate Spare parts 10 11 Spare parts list for terminal boxes with type of protection Ex e frame sizes 180 225 SIMOTICS XP 1MD4 1MD5 102 Operating Instructions 05 2015 ...

Page 103: ...t num ber Designation Part num ber Designation 6 03 Terminal box base 6 15 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 07 Gland plate Spare parts 10 12 Spare parts list for terminal boxes with type of protection Ex d frame sizes 180 225 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 103 ...

Page 104: ...Designation Part num ber Designation 6 03 Terminal box base 6 15 Gland terminal 6 05 Terminal box cover 6 16 Complete terminal board 6 07 Gland plate 6 17 Additional terminal Spare parts 10 13 Spare parts list for terminal boxes with type of protection Ex e frame sizes 250 to 355 SIMOTICS XP 1MD4 1MD5 104 Operating Instructions 05 2015 ...

Page 105: ...terminal boxes with type of protection Ex d frame sizes 250 to 355 Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 105 ...

Page 106: ...box base 6 16 Complete terminal board 6 05 Terminal box cover 6 17 Additional terminal 6 07 Gland plate Spare parts 10 14 Spare parts list for terminal boxes with type of protection Ex d frame sizes 250 to 355 SIMOTICS XP 1MD4 1MD5 106 Operating Instructions 05 2015 ...

Page 107: ...l disposal regulations 11 2 Preparing for disassembly Disassembly of the machine must be carried out and or supervised by qualified personnel with appropriate expert knowledge 1 Contact a certified waste disposal organization in your vicinity Clarify what is expected in terms of the quality of dismantling the machine and provision of the components 2 Follow the five safety rules Page 13 3 Disconne...

Page 108: ... recycling according to whether they are Iron and steel Aluminum Non ferrous metal e g windings The winding insulation is incinerated during copper recycling Insulating materials Cables and wires Electronic waste Process materials and chemicals Sort the process materials and chemicals for recycling according to whether they are for example Oil Grease Cleaning substances and solvents Paint residues...

Page 109: ...port consists of impregnated wood Observe the local regulations The foil used for water proof packaging is an aluminum composite foil It can be recycled thermally Dirty foil must be disposed of via waste incineration Disposal 11 4 Disposal of components SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 109 ...

Page 110: ...Disposal 11 4 Disposal of components SIMOTICS XP 1MD4 1MD5 110 Operating Instructions 05 2015 ...

Page 111: ...lowing machine data ready Machine type Machine number You can find this data on the rating plate of the machine Contact at Central Technical Support for our customers in Germany 49 911 895 7222 49 911 895 7223 support automation siemens com mailto support automation siemens com Outside Germany you can find your contact partners here http support automation siemens com WW view de 16604999 http supp...

Page 112: ...ting 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 not based on state of the art technology In doing so safety in operation and handling will take priority at all times Service and Support A 2 RoHS restricting the use of certain hazardous substances SIMOTICS XP...

Page 113: ...08 0 170 0 260 0 420 0 Nm C 3 5 8 20 40 70 170 340 600 120 0 200 0 310 0 470 0 750 0 Nm Applications The above mentioned tightening torques apply for the following applications Case A Applies to electrical connections in which the permissible torque is normally limited by the bolt materials and or the current carrying capacity of the insulators with the exception of the busbar connections in case ...

Page 114: ...Technical data and drawings B 1 Tightening torques for screw and bolt connections SIMOTICS XP 1MD4 1MD5 114 Operating Instructions 05 2015 ...

Page 115: ...x ID for the IECEx certificate can be found on the rating plate of the machine or on the extra plate for explosion protection 1 Enter the IECEx ID in the Quick access field You then have access to the certificate 2 If you scroll down completely to the bottom of the page shown you can open the certificate as a PDF file and download it SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 115 ...

Page 116: ...C 2 EC Declaration of Conformity Quality documents C 2 EC Declaration of Conformity SIMOTICS XP 1MD4 1MD5 116 Operating Instructions 05 2015 ...

Page 117: ...x T3 T6 BVS 13 ATEX E 012 X x x T3 T6 PTB 08 ATEX 1107 X x T3 T6 BVS 11 ATEX E 046 X x x T3 T6 BVS 12 ATEX E 103 X x x T3 T6 PTB 09 ATEX 1046 X x T3 T6 BVS 11 ATEX E 030 X x x T3 T6 BVS 11 ATEX E 045 X x x T3 T6 PTB 09 ATEX 1070 X x T3 T6 BVS 11 ATEX E 051 X x x T3 T6 BVS 12 ATEX E 029 X x x T3 T6 PTB 08 ATEX 1037 X x T3 T6 BVS 11 ATEX E 025 X x x T3 T6 BVS 12 ATEX E 051 X x x T3 T6 DJS 315 1PS 31...

Page 118: ... 06 ATEX 1022 X x T3 T6 D T 630 D V 630 1PS463 1MV463 sleeve PTB 07 ATEX 1075 X x T3 T6 anti friction PTB 09 ATEX 1009 X x T3 T6 sleeve BVS 13 ATEX E 045 X x T3 T6 PTB 09 ATEX 1078 X x T3 T6 BVS 11 ATEX E 170 X x T3 T6 D Q 800 1PS480 1MV480 sleeve PTB 06 ATEX 1049 X x T3 T6 D Q 910 1PS491 1MV491 sleeve BVS 10 ATEX E 103 X x T3 T6 1PS 63 1MV 63 anti friction D T 560 D V 560 1PS456 1MV456 sleeve Tem...

Page 119: ...C 3 EC Declaration of Conformity Zone 21 or 22 Quality documents C 3 EC Declaration of Conformity Zone 21 or 22 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 119 ...

Page 120: ...ATEX E 045 X A 160 E 160 1PS 16 A 180 E 180 1PS 18 A 200 E 200 1PS 20 D 180 1PS 18 1MD 18 D 160 1PS 16 1MD 16 1PS 13 1MD 13 D 132 D 112 1PS 11 1MD 11 D 100 1PS 10 1MD 10 EG Baumusterprüf bescheinigung EC Type Examination Certificate Gerät Equipment D 090 1PS 09 1MD 09 A 071 E 071 1PS 07 A 080 E 080 1PS 08 D 250 1PS 25 1MD 25 D 225 1PS 22 1MD 22 D 200 1PS 20 1MD 20 A 225 E 225 1PS 22 A 250 E 250 1P...

Page 121: ...Quality documents C 3 EC Declaration of Conformity Zone 21 or 22 SIMOTICS XP 1MD4 1MD5 Operating Instructions 05 2015 121 ...

Page 122: ... is to be adjusted to 1 5 x Icontin at a maximum 4 tshort is the period for which the inverter allows an exceeding of lcontin tshon is to be adjusted to 60 s at a maximum 5 The built in temperature sensors PTC thermistors which must be suitable for sole protection are to be connected to a tripping device provided with the EC type examination certificate like e g CK140 PTB 04 ATEX 3038 or CKI44 145...

Page 123: ...ounding conductor 53 D Damage during transportation 30 Damping cores 37 Delivery 30 Direction of rotation 54 Disassembly Disposal 107 Disposal Chemicals 108 Components 108 E Electrical faults 71 Electromagnetic compatibility 18 Electromagnetic fields 19 Emergency off 69 Emitted interference 19 Equipotential 59 Equipotential bonding conductor 36 ESD guidelines 17 Ex marking 22 Exceeding the toleran...

Page 124: ...s 42 N Noise emissions 16 28 O Operating mode 27 O ring seals 58 Output element 48 Overspeeds 27 P Paint finish 25 Paint system 88 Paintwork damage 88 Permanent lubrication 82 Polarization index 34 63 65 81 Positioning 46 Precision alignment 46 Preparations for assembly 42 Pressure relief device 59 Q Qualified personnel 14 R Radial force 49 Rating plate 24 Re commissioning 70 Regreasing 84 Regreas...

Page 125: ...9 System resonances 29 System inherent frequencies 29 T Tandem operation 38 Temperature class 68 69 Temperature limits 33 Terminal board 56 Terminal box close 59 Maintaining 87 Terminal designation 53 Thermal motor protection 28 Tightening torques 51 Bolted connection 113 Standard cable glands 57 Transporting 31 44 Turning the machine on to its side 46 Type of balancing 47 Type of protection 52 92...

Page 126: ...Index SIMOTICS XP 1MD4 1MD5 126 Operating Instructions 05 2015 ...

Page 127: ...AE EC Declaration of Conformity U161 AD EC Declaration of Conformity U163 AA R No 20000h U165 ...

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

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