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Service and maintenance

9.3 General inspection guidelines

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

Operating Instructions, 03/2014, 610.45002.40

9.3

General inspection guidelines

When inspecting a motor, you do not generally need to dismantle it. The motor only be

dismantled if the bearings need to be replaced.
While the motor is running, check that:

●

The smooth running characteristics and machine running noise have not deteriorated.

●

The cooling water system is not leaking.

Once the machine has been shut down, check that:

●

All the fixing bolts/screws for the mechanical and electrical connections have been

securely tightened.

NOTICE

If you identify any problems during the inspection, rectify them immediately. Otherwise

the machine may be damaged.

9.4

Bearing replacement intervals

The bearings are subject to wear and must be replaced after a defined number of operating

hours. For average load levels, the bearings must be replaced after approx. 20,000 h,

however, at the latest after 5 calendar years. The address for service & support is provided

in the Appendix under Siemens Service Center.

Содержание SIMOTICS A-1FV5

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Страница 3: ...________________ ___________________ ___________________ ___________________ ___________________ SIMOTICS A 1FV5 1PV5 synchronous induction motors Operating Instructions 03 2014 610 45002 40 Introduction 1 Safety notes 2 Description 3 Preparing for use 4 Mounting 5 Connection 6 Commissioning 7 Operation 8 Service and maintenance 9 Decommissioning and disposal 10 Appendix A ...

Страница 4: ...nly by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens pro...

Страница 5: ... 12 2 6 Electrostatic sensitive devices ESD 13 3 Description 15 3 1 Application 15 3 2 Rating plate type plate 16 3 3 Technical features 17 3 4 Design 18 3 4 1 Regulations 18 3 4 2 Types of construction 18 3 4 3 Degree of protection 18 3 4 4 Ambient conditions 19 3 4 5 Cooling 19 3 4 6 Noise emission 22 4 Preparing for use 23 4 1 Shipment and packaging 23 4 2 Transport and storage 23 4 2 1 Transpo...

Страница 6: ... 6 2 9 Connecting up a converter 42 7 Commissioning 43 7 1 Measures prior to commissioning 43 7 2 Performing a trial run 45 7 3 Checking the insulation resistance 45 7 4 Switching on the motor 47 7 5 Liquid cooling 47 8 Operation 49 8 1 Safety instructions during operation 49 8 2 Stoppages 50 8 3 Shutdown 50 8 4 Faults 50 9 Service and maintenance 53 9 1 Safety information 53 9 2 Maintenance inter...

Страница 7: ...rvice Center Always follow the safety instructions and notices in these operating instructions The warning notice system is explained on the rear of the inside front Note All data that are generally applicable for the motor also always apply to the generator Text format features In addition to the safety related notices and instructions which you must read you will find the text in these operating...

Страница 8: ...Introduction SIMOTICS A 1FV5 1PV5 synchronous induction motors 8 Operating Instructions 03 2014 610 45002 40 ...

Страница 9: ...ocal and plant system specific regulations and requirements must be carefully observed Special versions and construction variants may differ with respect to certain technical aspects If in doubt you are strongly advised to contact the manufacturer specifying the type designation and serial number see rating plate or arrange for any maintenance work to be carried out by the SIEMENS Service Center V...

Страница 10: ... trained personnel in accordance with its intended purpose Those responsible for plant safety must ensure the following The basic planning work for the system and all work relating to transportation assembly installation commissioning maintenance and repairs is carried out by qualified personnel and checked by responsible suitably skilled personnel The operating instructions and the motor document...

Страница 11: ...sure that the auxiliary circuits are also disconnected 2 Protect against reconnection 3 Make sure that the equipment is de energized 4 Ground and short circuit 5 Cover or enclose adjacent components that are still live When work has been completed remove these measures in reverse order 2 4 Thermal hazard CAUTION The surface temperature of the motors can exceed 65 C Do not touch any hot surfaces Te...

Страница 12: ...ed Electromagnetic fields can interfere with electronic devices which could cause them to malfunction Heart pacemakers can be affected for example which could potentially damage a person s health or even result in death Steps must be taken therefore to ensure that persons with heart pacemakers cannot enter these areas The plant operator is responsible for taking appropriate measures labels and haz...

Страница 13: ...ve to be touched the body of the person concerned must be electrostatically discharged immediately beforehand and be grounded Electronic modules should not come into contact with electrically insulating materials e g plastic foil plastic parts insulating table supports or clothing made of synthetic fibers Always place the modules on conductive bases Always store and transport electronic modules or...

Страница 14: ... 45002 40 The necessary ESD protective measures for electrostatically sensitive devices are illustrated once again in the following drawings 1 Sitting 2 Standing 3 Standing sitting ESD protective measures a conductive floor b ESD table c ESD footwear d ESD coat s ESD wrist strap f cubicle ground connection Figure 2 1 ESD protective measures ...

Страница 15: ...direct connection to the three phase line supply is not permissible It is forbidden to install them in hazardous areas unless they are explicitly designed for this Mode of operation and design The 1PV5 motors are liquid cooled squirrel cage induction motors The 1FV5 generators are liquid cooled synchronous motors with permanent magnet rotors Both active parts are equipped with two temperature sens...

Страница 16: ...ription No Description L010 MLFB L170 Rated power PN 3 L020 Factory serial number L180 Unit rated power 3 L025 Consecutive number L190 Rated current IN 3 L030 Z For options L200 Unit rated current IN 3 L040 Options L210 Rated speed nN 3 L050 Rated voltage L220 Rated speed nN 3 L060 Maximum speed nmax L230 Temperature class L070 Operating mode 1 L240 Degree of protection L071 Rated time 1 L250 Type...

Страница 17: ...ic material Speed encoder optional Rotor position encoder RPE Toothed wheel encoder 64 pin Insulation of stator winding according to EN 60034 1 Thermal class 180 H Cooling Liquid cooling Installation altitude according to EN 60034 1 2500 m above sea level otherwise power derating Type of construction acc to EN 60034 7 IM B5 Degree of protection to EN60034 5 IP65 IP69K without DE shaft output Tempe...

Страница 18: ...034 14 1 The degree of protection and type of construction of the motor are stamped on its rating plate The three phase motors comply with the relevant sections of EN 60034 and EN 60204 1 Three phase motors comply with Low Voltage Directive 2006 95 EC Standard motors comply with the UL regulations UR is stamped on the rating plate of these motors Note Make sure that your end product is in complian...

Страница 19: ...ion with an outer diameter of 18 Female thread in the bearing shield Pg 13 5 8 deep Cooling water flow 16 l min Lower values will result in a derating Max pressure at inlet max 2 5 bar Pressure loss between inlet and outlet 0 2 bar for minimum cooling water flow with 1PV513 1FV513 0 4 bar for minimum cooling water flow with 1FV516 Min cooling water inlet temperature Tcool Tambient 5 K at Tambient ...

Страница 20: ...pted The values specified for the cooling water refer to the following table correspond to the requirements of closed cooling circuits Not all of the specified concentrations will occur in the cooling water at the same time Table 3 5 Water specifications for the coolant Contents and chemical composition Value pH value 6 8 Chloride ions 40 ppm Sulfate ions 50 ppm Nitrate ions 50 ppm Dissolved solid...

Страница 21: ... cast iron Pipes motors Closed circuit and use of strainers and flushback filters Fe separator for stainless heat sink High alloy steel Group 1 V2A Pipes valves and fittings Can be used for drinking or municipal water with a chloride content up to 250 ppm suitable according to definition in Chapter Coolant definition High alloy steel Group 2 V4A Pipes valves and fittings Can be used for drinking o...

Страница 22: ...oling unit manufactured out of stainless steel that dissipates the heat through a water water heat exchanger All other components such as cooling circuit cables and fittings manufactured out of ABS stainless steel or general construction steel 3 4 6 Noise emission In operation in the speed range extending from 0 up to rated speed 1PV5 and 1FV5 motors can reach the following measuring surface sound...

Страница 23: ...indication of the motor data in the vicinity of the motor The rating plate is located in the terminal box 4 2 Transport and storage 4 2 1 Transport Use suitable load bearing equipment when transporting and installing the motor Make sure that all of the available eyebolts are used during transportation Country specific regulations must be observed If the motor is not to be commissioned immediately ...

Страница 24: ... The motor can fall down This can result in death or serious injury as well as damage or total loss of the motor NOTICE Transporting and lifting the motor using a cross beam When lifting and transporting the motors using the eyebolts supplied acc to DIN 580 you must use a cross beam The following should be noted The ring bolt must be screwed in completely and secured by hand approx 8 Nm Do not ove...

Страница 25: ...the 1FV516x Transporting a motor that has already been in operation If you want to transport a motor that has already been in operation proceed as follows 1 Allow the motor to cool down 2 Remove the connections provided by the customer 3 Empty the motor of any cooling water and purge it carefully with air 4 Close and seal all openings on the terminal box and housing 5 Always transport and lift the...

Страница 26: ...ost free and vibration free The relative air humidity should be less than 60 and the temperature should not drop below 15 C in accordance with EN 60034 1 Well ventilated Offers protection against extreme weather conditions The air in the storage area must not contain any harmful gases Protect the motor against shocks and humidity Make sure that motor is covered properly Avoid contact corrosion You...

Страница 27: ...ix months Check the motor for any damage Carry out any necessary maintenance work Document all preservation measures taken so that they can be reversed before the machines are recommissioned Make sure that storage area is air conditioned Protecting the cooling water system When delivered the cooling system is not filled with coolant When you place the motor in storage after use drain the cooling w...

Страница 28: ...Preparing for use 4 2 Transport and storage SIMOTICS A 1FV5 1PV5 synchronous induction motors 28 Operating Instructions 03 2014 610 45002 40 ...

Страница 29: ...tes The following must be taken into account when the motors are installed Observe the data on the rating plate as well as the warning and information plates on the motor The permissible cantilever and axial forces at the shaft end of the motors may not be exceeded Table 5 1 Permissible forces at the motor 1PV513x 1FV513x 1FV516x Radial force 1100 N 1800 N Axial force both directions 700 N 1100 N ...

Страница 30: ...tely before installing the respective parts 5 2 Fixing To ensure smooth vibration free operation the motor must be precisely aligned and the components to be mounted on the shaft end correctly balanced Mounting using the motor flange flange mounting Note When the motor is flange mounted this creates a system that is capable of oscillation with specific natural mounting frequencies In operation thi...

Страница 31: ... Nm Property class of the screws 1PV513x 1FV513x DE M 12 85 8 8 NDE M12 screw in depth 25 30 mm 85 8 8 1FV516x DE M 16 190 10 9 NDE M12 screw in depth 18 20 mm 85 8 8 Alignment accuracy for coupling output The maximum permissible concentricity deviation of the shafts of the motor and the driven machine is 0 05 mm in the diameter 5 3 Attaching the output elements Note Do not subject the motor s sha...

Страница 32: ...ments must be balanced to balance quality grade G2 5 to ISO 1940 Rotary forces that exceed this are not permissible Please note that rotary forces can also occur with coupling output If the output element is shorter than the feather key with balancing method H the section of the feather key that protrudes from the shaft contour and output element must be removed to maintain the balance quality Fit...

Страница 33: ...5 4 Vibration load The on site system vibration characteristics depend on factors such as the output elements assembly conditions alignment installation and external vibrations and can increase the level of vibration on the motor Under certain circumstances the rotor may have to be balanced completely with the output element To ensure problem free operation and a long service life the vibration va...

Страница 34: ...mum peak value in the time range is to be considered To measure the vibration velocity the measuring equipment must fulfill the requirements of ISO 2954 Note Continuous operation within the natural frequency Continuous operation within the natural frequencies of the mounted system should be avoided Generally this results in permissible vibration values being exceeded resulting in damage to the sys...

Страница 35: ...vailable see the rating plate type plate 3 Attach the cooling water pipes to the cooling water connections You can connect the inlet and outlet as required 4 Ensure that the maximum permissible operating pressure does not exceed 2 5 bar 5 Ensure that the cooling water connections and the cooling water pipes are not subject to continuous forces Adjusting the outlet direction of the cooling water co...

Страница 36: ...rsonnel Regulations regarding work carried out in electrical installations must be observed DANGER Motor damage warning The motor will be destroyed if it is directly connected to the three phase line supply Only operate the motors with the appropriately engineered converters Ensure the correct phase sequence is used NOTICE Electrostatically sensitive devices The motor contains electrostatic sensit...

Страница 37: ...nnector is clean and free of cable cuttings and moisture Tighten all of the screws for the electrical connections terminal board connections with the exception of the terminal strips to the specified torque Table 6 1 Tightening torques at the terminal board Thread M6 M8 M10 Tightening torque Nm 4 10 8 10 13 10 When connecting or changing internal connection cables always observe the minimum air cl...

Страница 38: ...connecting the motor winding and signal lines Figure 6 1 Circuit diagram_1FV5 without position encoder contacts 1 5 not assigned Figure 6 2 Circuit diagram_1PV5 without encoder contacts 1 5 not assigned Note Cable outlet direction If the direction of the cable outlet is not changed correctly this can damage the connecting cables The direction of the cable outlet must not be changed as this invalid...

Страница 39: ... U1 connected to L1 V1 to L2 and W1 to L3 Signal Ua1 is received before Ua2 Counter clockwise direction of rotation when viewing the shaft extension Phase U1 connected to L3 V1 to L2 and W1 to L1 Signal Ua2 is received before Ua1 Terminal assignment in the terminal box should be implemented as shown in the following diagrams Terminal box 1PV51xx 1FV51xx Use cable lugs to DIN 46234 Screw the cover ...

Страница 40: ...erminal box Figure 6 5 Attaching cable lugs 6 2 5 Data for electrical connection Table 6 2 1PV513x 1FV513x motors Terminal box Cable entry power Cable entry external signals Max external cable diameter 1 Number of main terminals Cross section per terminal max Integrated in the motor 3 x PG16 1 x M23 15 mm Phases 3 x M6 Grounding 1 x M8 1 x 35 mm2 1 Dependent on the cable gland design ...

Страница 41: ...ors do not have an encoder then only the temperature sensor signals are assigned in the connector as shown in the following table Table 6 4 Signal connection view of connector pins Pin 1PV5 1FV5 1PV5 without encoder 1FV5 without position encoder Connector 1 Signal Ua2 Signal T Not assigned 2 Signal Ua1 Signal S Not assigned 3 Not assigned Signal R Not assigned 4 Power supply Not assigned 5 Groundi...

Страница 42: ... g according to IEC EN 60204 1 See also Terminal box Page 39 6 2 9 Connecting up a converter Selecting and connecting the cables Use shielded connection cables to connect the motor to a converter The cable shielding made up of many strands must have a high electrical conductivity Braided shields made of copper or aluminum are well suited The shield must be connected at both ends to the motor and t...

Страница 43: ...c cables electronic components must not be placed on hot surfaces Mechanical connection The following conditions must be fulfilled and suitable for the operating conditions All touch protection measures for moving and live parts must have been applied The motor has been assembled and aligned properly The rotor must be able to be manually rotated or using suitable equipment without coming into cont...

Страница 44: ... speed limit nmax is not exceeded during operation on a converter CAUTION If the speed nmax is exceeded this can damage the bearings short circuiting rings press fits etc To ensure that the motor does not run at excessive speeds the controller must configured accordingly or speed monitoring must be activated in the drive system Monitoring equipment Appropriately configured control and speed monito...

Страница 45: ...s Take suitable measures to ensure that feather keys if used cannot fall out 7 3 Checking the insulation resistance After long storage or shutdown periods the insulation resistance of the windings must be measured to ground with direct voltage WARNING Work on power installations must only be carried out by specialists Before measuring the insulation resistance read the manual for the insulation re...

Страница 46: ...o the minimum value could be due to moisture and or dirt accumulation The insulation resistance of the motor winding can drop during the course of its service life can drop due to ambient and operational influences The critical insulation resistance for a temperature of 25 C on the winding can be calculated by multiplying the rated voltage kV by the specific critical resistance value 0 5 MΩ kV Exa...

Страница 47: ...ied on the rating plate If the speed nmax is exceeded this can damage the bearings short circuiting rings press fits etc To ensure that the motor does not run at excessive speeds the controller must configured accordingly or speed monitoring must be activated in the drive system 7 5 Liquid cooling The motor must always be connected to the cooling water supply when in operation NOTICE If the coolin...

Страница 48: ...Commissioning 7 5 Liquid cooling SIMOTICS A 1FV5 1PV5 synchronous induction motors 48 Operating Instructions 03 2014 610 45002 40 ...

Страница 49: ...d during operation WARNING Faults during operation Deviations from normal operation e g increased power consumption temperatures or vibrations unusual noises or odors tripping of monitoring devices etc indicate that the machine is not functioning properly This can cause faults that can result in eventual or immediate death serious injury or material damage Inform maintenance personnel immediately ...

Страница 50: ...mmended in Commissioning 8 3 Shutdown Measures during shutdown When switching off the motor refer to the operating instructions for the converter Switch off the cooling water supply if the standstill period is expected to be lengthy 8 4 Faults Note Damage to the machine caused by faults Correct the cause of the fault as specified in the remedial measures section Repair any damage to the machine mo...

Страница 51: ...ow Check the settings on the frequency converter perform automatic motor identification E Stator winding incorrectly connected Check winding connections F Winding short circuit or phase short circuit in stator winding Measure the winding resistances and insulation resistances repair after consultation with manufacturer G Cooling water not connected switched off Check cooling water connection switc...

Страница 52: ...ecouple rotor and rebalance N Rotor out of true shaft bent Consult the manufacturer O Poor alignment Align motor unit check coupling P Coupled machine not balanced Re balance coupled motor Q Shocks from coupled machine Check coupled motor R Imbalance originating from gearing Adjust repair gearing S Cooling water pipe water connection defective Locate leaks and seal as necessary or consult the manu...

Страница 53: ...e machines make sure that the plant or system has been disconnected in a manner that is compliant with the appropriate specifications and regulations In addition to the main currents make sure that supplementary and auxiliary circuits particularly in heating devices are also disconnected Note all the information provided in Safety information and application information in these operating instruct...

Страница 54: ...ation During cleaning make sure that appropriate methods of extracting fumes are in place and that you wear the appropriate protective gear e g gloves goggles face masks If using chemical cleaning agents observe the instructions and any warnings provided in the relevant safety data sheet Chemical cleaning agents must be suitable for use with the machine s components particularly where plastic comp...

Страница 55: ...in the section Transport and storage 9 2 Maintenance intervals General Within the scope of the bearing change intervals the motors are maintenance free within the specified usage time Careful and regular maintenance inspections and overhauls are essential for detecting and eliminating faults in good time before they can cause any damage Note Inspection if there are faults or unusual conditions Unu...

Страница 56: ... cooling water system is not leaking Once the machine has been shut down check that All the fixing bolts screws for the mechanical and electrical connections have been securely tightened NOTICE If you identify any problems during the inspection rectify them immediately Otherwise the machine may be damaged 9 4 Bearing replacement intervals The bearings are subject to wear and must be replaced after...

Страница 57: ...ne is made up of heavy parts These parts can fall during dismantling This can result in death serious injury or material damage Secure the machine parts being dismantled to prevent them falling The motors must be disposed of in accordance with domestic and local regulations as part of the standard recycling process or they can be returned to the manufacturer The encoder electronics must be properl...

Страница 58: ... Grease Solvents Cleaner solvent Paint residues Do not mix solvents cleaner solvents and paint residues Insulating materials Electrical insulation materials are mainly used in the stator Some supplementary components are made of similar materials and must therefore be handled in the same manner The insulating materials in question are used on the following items of equipment Various insulators whi...

Страница 59: ...machine to be subject to thermal treatment by a specialist disposal company Return the machine to the manufacturer who can then remove and demagnetize the rotor and or permanent magnets Rotors that are still installed and have not been demagnetized must not be transported NOTICE Removing the rotor It is only permissible that the manufacturer removes a permanent magnet rotor Contact the Siemens Ser...

Страница 60: ...Decommissioning and disposal 10 2 Disposal SIMOTICS A 1FV5 1PV5 synchronous induction motors 60 Operating Instructions 03 2014 610 45002 40 ...

Страница 61: ...man Industry Standard EC European Community ESD Electrostatically sensitive devices EMC Electromagnetic compatibility EN Euro Norm EPDM Ethylene propylene diene rubber H Halfkey balancing IEC International Electrotechnical Commission IM Type of construction IP International Protection ISO International Organization for Standardization KTY Temperature sensor LG Position encoder MLFB Machine readabl...

Страница 62: ...he Internet address http www siemens com automation service support There you can find Siemens contacts worldwide for information about specific technologies Wherever possible you will find a local contact partner for Technical support Spare parts repairs Service Training Sales Technical support engineering You start by selecting a country a product or a sector Once the remaining criteria have bee...

Страница 63: ...Appendix A 3 Declaration of conformity SIMOTICS A 1FV5 1PV5 synchronous induction motors Operating Instructions 03 2014 610 45002 40 63 A 3 Declaration of conformity ...

Страница 64: ...Appendix A 3 Declaration of conformity SIMOTICS A 1FV5 1PV5 synchronous induction motors 64 Operating Instructions 03 2014 610 45002 40 ...

Страница 65: ...ormity 63 Degree of protection 18 E Electrical connection 36 ESD guidelines 13 F Faults 50 Flange mounting 30 I Inspection and maintenance 53 M Maintenance intervals 55 Mounting the motor 30 O Output elements 32 R Rating plate 16 Regulations 18 S Safety information 9 Shutdown 50 Siemens Service Center 62 Storage 26 T Terminal box 39 Tightening torques Electrical connections 37 Transportation 23 Ty...

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