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1. Table 2 5 Elements on the rating plate No Description No Description L010 Article No L210 Rated power Pn 3 L012 Consecutive number L220 cos 3 L020 Factory serial number L230 Rated frequency fn 3 L025 UL mark L240 Rated speed nn 3 L030 Type of construction L250 Operating mode 3 L040 Degree of protection L257 Rated voltage Un 4 L042 Temperature class L258 Connection method 4 L045 Balancing code L260 Rated current In 4 L048 Operating mode L261 Rated power Pn 4 L049 For synchronous motors induced voltage at rated L263 cos 4 speed Vin For induction motors cos L265 Rated frequency fn 4 LO50 Rated voltage Un 1 L266 Rated speed nn 4 L051 Connection method 1 L267 Operating mode 4 L060 Rated current In 1 L270 Maximum current Imax L070 Rated power Pn 1 L275 Maximum torque Mmax LO80 cos 1 L280 Maximum speed nmax LO90 Rated frequency fn 1 L285 Temperature sensor L100 Rated speed nn 1 L290 Tachometer resolver L110 Operating mode 1 L295 Cooling method L120 Rated voltage Un 2 L296 Throughput l min m s L121 Connection method 2 L297 System pressure L130 Rated current In 2 L298 Maximum coolant temperature L140 Rated power Px 2 L315 Options I L150 cos 2 L320 Options Il L160 Rated frequency fn 2 L325 Optional customer informat
2. 6 4 Brake shaft 13 removal rie Motor design 8 Driven components balancing 9 Condition at delivery 10 Troubleshooting 11 Definitions 006 12 Technical specifications 13 Revision history sceseeeeeeeeeeeeeeeees Document information Issued by Kendrion Villingen GmbH Replacement for document Type of document Translation of German operating instructions BA 77 500 B Designation of document BA 77 500 B Englisch Kendrion Villingen GmbH 126 Operating Instructions 77 500 B Division Industrial Drive Systems Replaces the issue dated 2 July 2012 Document status Released Last updated 12 Dec 2013 Page 2 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions RKENDRION INDUSTRIAL DRIVE SYSTEMS WE MAGWETISE THE WORLO 14 General information 4 1 Introduction These Operating Instructions describe the operating principle and features of Kendrion Binder spring applied single disc brake modules type 77 500 B The safety information provided in this manual must be strictly observed during the set up of the machine e g motor and during the start up operation and maintenance of the spring applied brake module Should any queries arise with respect to torques torque variations installation position wear wear reserve switching work break in conditions release ran
3. Check OK Has it been ensured that speeds no higher than the maximum speed Nmax can be reached is the drive speed limited Have all supplementary motor monitoring devices and equipment been correctly connected and are they functioning correctly 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 83 Commissioning 6 2 Checklists for commissioning Table 6 5 Checklist 5 checks regarding the cooling system Check OK Water cooling Has the cooling water supply been connected and is it ready for operation Is the cooling water circulation flow rate temperature in compliance with the specifications Forced ventilation Have you checked all safety related and function relevant details Examples e Have you compared the data of the external cooling unit with the supply data It is not permissible that the external cooling unit is connected if the supply data deviates from the data of the external cooling unit to such an extent that an overload condition would occur e Is the electrical installation of the external cooling unit including accessories OK e g has the protective conductor been connected e Are the mechanical installation and electrical installation of the safety relevant components OK These include the installation of a circuit breaker and attaching protective guards e Are the cable entry glands correctly sealed e Are the fan air intake and the area around
4. Recommended additional documents System components Manufacturer s manuals Motor e Configuration Manual Encoder system e User Manual e Operating Instructions Brake e Operating Instructions Sensor module e Manual Drive system e Commissioning Manual e List Manual e Function Manual 1PH813 1PH816 main motors 6 Operating Instructions 01 2015 610 48006 40c Introduction More information Information on the following topics is available under the link e Ordering documentation overview of documentation e Additional links to download documents e Using documentation online find and search in manuals information http www siemens com motioncontrol docu Please send any questions about the technical documentation e g suggestions for improvement corrections to the following e mail address docu motioncontrol siemens com Current manuals and operating instructions for motors direct drives are available on the Internet under the following link http www siemens com motioncontrol docu Any manuals or operating instructions that you may have in printed or electronic file form could be of an older product version My Support The following link provides information on how to create your own individual documentation based on Siemens content and adapt it for your own machine documentation http support industry siemens com Note If you want to use this function you must first register
5. The brake module is a DC operated system Permanent voltage variations on the power source of the electromagnetic brake must be limited to 10 of the rated voltage The following checks must be carried out when connecting the brake amp Check that the connecting cables are suitable for the intended use and for the voltage and amperage of the brake E Check that the connecting cables are secured with screws clamps or other suitable fixtures to avoid interruptions in the power supply E Check that the connecting cables are long enough for the intended use and that suitable torsion strain and shear relief features as well as bending protections are provided amp Check that the PE conductor only for protection class is connected to the earthing point amp Check that no foreign matter dirt or humidity is trapped inside the terminal box amp Check that unused cable entries and the terminal box are suitably sealed to ensure compliance with the protection class requirements to EN 60529 The spring applied single disc brake module must be supplied with DC voltage Connection to an AC power source is via a half wave rectifier 19 2 Brakes equipped with a built in rectifier 19 2 can be connected directly to the AC power source The contact assignment is shown in Fig 16 1 Brakes equipped with connecting terminal 19 2 must be connected directly to DC voltage The customer specific connecting cable must be connected to the
6. e Carefully observe the information in Chapter Handling electrostatic sensitive devices ESD The Siemens Service Center Bad Neustadt Germany should be contacted when carrying out motor repair work You can replace a defective encoder on site where the motor is installed e Read and follow the notes and descriptions in this documentation 1PH813 1PH816 main motors 104 Operating Instructions 01 2015 610 48006 40c Maintenance 8 2 Corrective maintenance 8 2 1 Removing installing the motor Removal e When removing the motor mark the original position of the components with respect to each other e g using a colored pen scribing iron to make subsequent installation easier e Removing the encoder see Chapter Removing mounting the encoder e Unscrew the NDE bearing shield screws and carefully remove the NDE bearing shield e Unscrew the bearing cap screws see Spare parts item 1 02 e Remove the grease slingers from the shaft shoulder DE e Remove the rotors from the motor Use a suitable device to remove the rolling contact bearings Mounting e Do not reuse rolling contact bearings that have been removed e Heat up the new rolling contact bearings evenly to 80 100 C and attach them When doing so make sure that the bearing inner ring lies on the shaft shoulder e The device must not be subject to hard knocks e g do not use a hammer etc e Insert the motor rotor into the stator e Secure th
7. e Ensure that nobody is at risk at switch on e Before switching on check that there are no loose objects in or on the motor that can fall or can be flung off The motor is switched on at the converter e Read about this topic in the converter operating instructions Operation While the motor is operational ensure that the specified parameters are maintained Make sure that e The current drawn is in the specified range e Cooling is ensured For water cooling Check the liquid level and coolant circulation For forced ventilation Check that the heat can be dissipated unobstructed e There are no abnormal motor noises e The motor does not overheat e If available the sealing air intake functions 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 89 Operation 7 1 Faults 7 1 90 NOTICE Motor damage caused by worn bearings Worn bearings cause motor damage e Always comply with the bearing change intervals depending on the operating state Switching off The motor is switched off at the converter e Read about this topic in the converter operating instructions Faults Awarnine Injuries caused by the drive system as a result of ineffective protective devices Injuries can be caused if protective devices are deactivated while troubleshooting e Only operate the drive system with functioning protective devices Note Damage to the machine caused
8. L Rotating parts are grinding Determine cause and adjust parts concerned Foreign bodies in the motor Send to manufacturer for repair Bearing damage Send to manufacturer for repair M Rotor not balanced Decouple rotor and rebalance N Rotor out of true shaft bent Consult the manufacturer O Poor alignment Align machine set check coupling P Coupled machine not balanced Rebalance coupled machine Q Mechanical shocks from coupled machine Inspect coupled machine R Uneven gearbox operation Repair the gearbox S Cooling water pipe water connection Locate leaks and seal as necessary or consult the manufacturer defective If the fault still cannot be resolved after applying the measures specified above please contact the manufacturer or the Siemens Service Center 1PH813 1PH816 main motors 92 Operating Instructions 01 2015 610 48006 40c Operation 7 2 Non operational periods 7 2 Non operational periods Measures for longer non operational periods NOTICE Damage due to improper storage The motor can be damaged if it is not stored properly e lf the motor is not operational for longer periods of time preserve it by using anti corrosion protection and ensure that it remains dry e g appropriate drying agents e When recommissioning after longer non operational periods of the motor perform the checks and measures listed in Chapter Commissioning e Disconnect the motor from the cooling water system e Remove any cooling
9. Later you can log on with your login data Websites of third parties This publication contains hyperlinks to websites of third parties Siemens does not take any responsibility for the contents of these websites or adopt any of these websites or their contents as their own because Siemens does not control the information on these websites and is also not responsible for the contents and information provided there Use of these websites is at the risk of the person doing so Internet address for products http www siemens com motioncontrol EC Declaration of Conformity The EC Declaration of Conformity for the Low Voltage Directive can be found in the Appendix 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 7 Introduction 1PH813 1PH816 main motors 8 Operating Instructions 01 2015 610 48006 40c Table of contents MPVETOOUCUON eeaeee esee ee AE EE EEE EEEE EEEE EER 5 1 Fundamental safety instructions cccsscescserssccessneessenenessnensnnensennenanceessnnenssenenancnenssnenanenetanenersnneanes 13 1 1 General Safety INSttUuCtONs usesti nsr ea EEE ESEE EEGA SE EEE AE AEAEE EATE AEE 13 1 2 Handling electrostatic sensitive devices ESD eccceeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeseeeeeeeeennaees AT 1 3 IMGUStHlal SOCUIILY cecseteic ea E E seceded epiteue tcp a a tyes apne 1 4 Residual risks during the operation of electric MOtOMS ceccece cee cteeeeeeteeteeeeeeteenaeeseenees
10. approx 2 m to the components may cause the devices to malfunction influence the functional safety of machines therefore putting people at risk or causing material damage e Switch the wireless devices or mobile phones off in the immediate vicinity of the components WARNING Danger of an accident occurring due to missing or illegible warning labels Missing or illegible warning labels can result in accidents involving death or serious injury e Check that the warning labels are complete based on the documentation e Attach any missing warning labels to the components in the national language if necessary e Replace illegible warning labels Awarnine Danger to life when safety functions are inactive Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that could lead to serious injury or death e Observe the information in the appropriate product documentation before commissioning e Carry out a safety inspection for functions relevant to safety on the entire system including all safety related components e Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through appropriate parameterizing e Perform a function test e Only put your plant into live operation once you have guaranteed that the functions relevant to safety are running correctly Note Important safety noti
11. 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Description 2 4 Design Table 2 8 Chemical requirements of the cooling water Content and chemical composition Value pH value 6 9 Chloride ions lt 40 ppm Sulfate ions lt 50 ppm Nitrate ions lt 50 ppm Dissolved solids lt 340 ppm Total hardness lt 170 ppm Electrical conductivity lt 500 uS cm Size of any particles in the coolant lt 100 um Tyfocor anti freeze 20 25 NALCO 00GE056 inhibitor 0 2 0 25 Note Storing or transporting the motor The cooling circuit must be emptied when storing the motor when the motor is out of service for a long period and when the motor is being transported 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 31 Description 2 4 Design 2 4 3 Holding brake option 2 4 3 1 Properties Operation with holding brake on the SINAMICS S The SINAMICS S drive system has various types of brake control A detailed description of the individual functions and corresponding parameter assignment information can be found in the following manuals e SINAMICS 120 Function Manual 6SL3097 DABO00 0OPL Section 6 14 e SINAMICS 120 S150 List Manual 6SL3097 DAP00 0OPL Section 2 12 Information on the current carrying capacity for the brake outputs adapters of the individual SINAMICS power units can be found in the corresponding manuals Control of
12. 3 dB tolerance Water cooled 68 dB A 3 dB tolerance 1 External fan operation 50 Hz Table 2 4 Measuring surface sound pressure level for 1PH816 Cooling method Measuring surface sound pressure level Lpa 1 m at rated load and 4 kHz rated pulse frequency Forced ventilation 73 dB A 3 dB tolerance Water cooled 69 dB A 3 dB tolerance 1 External fan operation 50 Hz The motors are certified for a wide range of installation and operating conditions These conditions such as rigid or vibration isolated foundation design influence noise emission sometimes significantly 1PH813 1PH816 main motors 24 Operating Instructions 01 2015 610 48006 40c Description 2 3 Rating plate data type plate 2 3 Rating plate data type plate The rating plate type plate shows the technical specifications for the supplied motor 3 Mot 1P L010 L315 IM LO30 iP L040 TH CL L042 a Croo frost froo toro roo wooo ooo Puno _ Ci ue fio eo furo ceo oro foo _ Coo fu fo o o o j o e isr e fo fo Soss S s j e r M Nm L275 n 1 min L280 UL L025 Siemens AG Industriestr 1 DE 97616 Bad Neustadt Made in Germany Some fields may also be empty options customer data Figure 2 1 Schematic layout of rating plate 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 25 Description 2 3 Rating plate data type plate
13. 5 C to 40 C At tempera tures below 5 C and longer periods without power being applied to the brake then it cannot be excluded that the friction disk freezes In this case special measures must be applied after first contacting the manufacturer Note Restricted maximum motor speed for a motor equipped with brake Description 2 4 Design The maximum speed of a motor with brake is limited to the maximum speed of the brake see Nmax Br Speed specified in the characteristic curves Note Selection and ordering data The selection and ordering data can be found in the Configuration Manual SIMOTICS M 1PH8 main motors Chapter Selection and ordering data The holding brakes are not UL approved Motors with mounted brake therefore do not have the CUR marking Technical data of the holding brakes T ise o 3 5 5 HRES z 5 3 o5 5g 8 S e 2 2 S E 6 5 S eel amp sS S J 2 D D D z 9 He Q D oD E E o gt BEL E S 8 s 8 S e amp Ef se 8 e8 sie o g a sS 8 5 a a z eu amp 28 6 lo 230 V AC 10 24 V DC 10 W z A A ky ms 132 1PH8139 Size 24 140 310 4500 0 0141 46 ade 6 9 15 5 0 218 3600 2000 650 100 160 1PH8160 Size 29 280 500 4000 0 0266 66 1 4 6 7 24 0 456 3100 2000 750 150 1 Max 3 switching operations per hour Figure 2 4 Technical data of the mounted holding brake DE with emergency
14. oil injector connection tightening torque Ma Nm 4 4 10 10 Table 25 1 Technical specifications for brake shaft 13 removal 7 Motor design The brake module must be mounted to a motor that complies with the following requirements Motor mounting type IMB5 or IMB35 amp Motor shaft end and flange tolerances axial and radial runout to EN 50347 R amp Brake module shaft end and flange tolerances to EN 50347 N after mounting to motor amp Motor shaft without feather key due to brake shaft removal from motor shaft by means of an oil pressure system amp The fits and surface roughness depths of the brake shaft bore and motor shaft Rz lt 6 3 required to ensure reliable press fit must be agreed with the brake manufacturer amp Balancing of the brake shaft with a half key half key balancing to DIN ISO 8821 The permitted transverse forces acting on the shaft end of the motor brake unit and the permitted axial forces are specified in the motor specification sheet Hi Note Mounting of the brake module to the motor may cause heat build up on the A face motor end shield as heat dissipation towards the machine wall is inhibited Consequently only fan cooled motors must be used Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 25 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 149 Appendix A 3 Holding brake operating instructions DKENDRION INDUSTRI
15. the U2 coil voltage is lower by factor 0 445 than the rectifier input voltage Half wave rectifiers produce voltage with high residual ripple which depending on the brake size may slightly reduce the switching times when compared to bridge rectifiers Due to the shorter switching times and the lower coil voltage half wave rectifiers are generally preferred to bridge rectifiers However brake humming may occur when small size brakes are used Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 17 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 141 Appendix A 3 Holding brake operating instructions RKENDRION INDUSTRIA DC side switching In case of DC side brake switching an auxiliary contact is provided on the motor contactor for example This auxiliary contact is designed to interrupt the power supply on the DC side 5 3 3 Electrical connection of brake modules with microswitch 27 E Note Machinery specific regulations and requirements e g for hoists cranes and elevators must be observed when using brakes with microswitches 27 When the brake is used for applications during which a load torque is generated the system user is responsible to ensure correct and safe wiring of the microswitch 27 and brake module A Warning The motor circuit must be protected in such a way that no accidental motor start up can occur when the microswitch 27 conta
16. then first contact your local Siemens office The motors are designed for use in covered areas under normal climatic conditions such as those found in production areas The 1PH813 and 1PH816 three phase induction and synchronous motors are used as industrial drives for machine tools and production machines They are designed for use in a wide range of drive engineering applications The variable speed three phase motors are supplied by a frequency converter and are characterized by their high power density ruggedness long lifetime and overall reliability 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 21 Description 2 2 Technical characteristics and ambient conditions 2 2 Technical characteristics and ambient conditions 2 2 1 Regulations The motors comply with the following regulations acc to IEC EN 60034 Table 2 1 Regulations that have been applied Feature Standard Rated and operation characteristics IEC EN 60034 1 Degree of protection 1 IEC EN 60034 5 Cooling IEC EN 60034 6 Type of construction 1 IEC EN 60034 7 Terminal markings IEC EN 60034 8 Noise emission IEC EN 60034 9 Temperature monitoring IEC EN 60034 11 Vibration severity grades IEC EN 60034 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 6020
17. 113 Removal 113 Holding brakes 32 Hotline 6 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Inspection and maintenance 96 M Maintenance intervals 96 Mounting the motor 44 N Noise emission 24 Non operational periods of the motor 93 O Output elements 46 R Rating plate 25 25 Regulations 22 Removal installation Motor 105 Speed encoder 106 Toothed wheel encoder 111 Replacing an encoder 103 Replacing the DRIVE CLiQ interface 112 S Safety instructions Commissioning 79 Electrical connection 60_ Maintenance 95 Mounting 43 Operation 92 Transportation 37_ Siemens Service Center 6 Spare parts 115 Storage 40 155 Index T Technical Support 6 Terminal box 63 Tightening torques Electrical connections 61_ Foot flange mounting 45 Screwed union connections 113 Training 6 Transportation 38 Types of construction 27 U Use for the intended purpose 21 V Vibration strength 47 Vibration values 47 W Water cooling 29 1PH813 1PH816 main motors 156 Operating Instructions 01 2015 610 48006 40c Siemens AG Subject to change without prior notice Digital Factory Siemens AG 2010 2015 Motion Control P O Box 3180 91050 ERLANGEN For further GERMANY information about SIMOTICS M 1PH8 scan the QR code www siemens com automation
18. Check whether the existing auxiliary supply circuits are de energized Ensure that the motors cannot move 3 Identify all other dangerous energy sources e g compressed air hydraulic systems or water 4 Isolate or neutralize all hazardous energy sources by closing switches grounding or short circuiting or closing valves for example 5 Secure the energy sources against switching on again 6 Ensure that the correct machine is completely interlocked After you have completed the work restore the operational readiness in the inverse sequence WARNING Danger to life through a hazardous voltage when connecting an unsuitable power supply Touching live components can result in death or severe injury e Only use power supplies that provide SELV Safety Extra Low Voltage or PELV Protective Extra Low Voltage output voltages for all connections and terminals of the electronics modules 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 13 Fundamental safety instructions 1 1 General safety instructions WARNING Danger to life when live parts are touched on damaged motors devices Improper handling of motors devices can damage them For damaged motors devices hazardous voltages can be present at the enclosure or at exposed components e Ensure compliance with the limit values specified in the technical data during transport storage and operation e Do not
19. Examples of such implants include Heart pacemakers metal implants insulin pumps Further people that have magnetic or electrically conductive implants are at risk e If you are such a person with heart pacemaker or implant then keep a minimum distance of 2 m from an opened motor e Only the Siemens Service Center should remove the rotor 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 103 Maintenance 8 2 Corrective maintenance NOTICE Data loss due to strong magnetic fields The permanent magnets of synchronous motor rotors generate strong magnetic fields and forces of attraction If you are located close to the rotor any magnetic or electronic data storage media as well as electronic devices that you might be carrying could be damaged e Do not wear or carry any magnetic or electronic data storage media e g credit cards USB sticks floppy disks and no electronic devices e g watches if you are close to a rotor NOTICE Damage to components that are sensitive to electrostatic discharge The DRIVE CLiQ interface has direct contact to components that can be damaged destroyed by electrostatic discharge ESDS Encoder systems and temperature sensors are components that can be destroyed by electrostatic discharge ESD Components that are sensitive to electrostatic discharge can be damaged if you touch the connections with your hands or with electrostatically charged tools
20. Field coil 16 Circlip 2 Armature 17 Screw plug 3 Flange 18 Rubber bolt 4 Friction disc 19 Connector box 5 Straight pin 20 Feather key 6 Sealing ring 7 Compression spring 22 Sealing washer 8 Stud not used in size 13 brakes 23 Cover 2 x arranged at 180 9 Adjusting ring not used in size 13 brakes 24 Hand release accessories 10 Cheese head screw 25 Set screw 11 Sealing ring 26 O ring 12 Disc E Adjusting ring clearance 13 Brake shaft A Contact surface motor side 14 Spring washer B Contact surface brake shaft 13 bonded with Loctite 243 installed in brake shaft 13 accessories for size 19 and 24 brakes included as standard parts of friction disc 4 in size 13 brakes 3 only used in brakes without hand release 24 only in size 29 brakes Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 10 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions PKENDRION Release direction Output side J Ps N g PANIS ia AL P NEDA Si LLA maw Fig 11 1 Spring applied single disc brake module 77 500 B15 Microswitch TEE i Direction paman eae Brake with microswitch Fig 11 2 Microswitch installation on spring applied single disc brake module 77 500 B15 Kendrion Villingen GmbH Operating Instructions 77 500 B Last upda
21. If the brake module is equipped with a microswitch make sure the microswitch is not exposed to shocks and vibrations during brake transport and storage This is crucial to avoid any changes in the microswitch adjustment The same applies to the connector box of the brake module If the brake is not installed immediately upon delivery it must be stored in a dry dust free and vibration proof place Fault Cause Corrective actions B Voltage applied to field coil toolow Check the field coil supply voltage and correct faults if found Table 27 1 Possible faults causes and corrective actions list not exhaustive Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 27 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 151 Appendix A 3 Holding brake operating instructions OKENDRION gt 11 Definitions based on DIN VDE 0580 November 2011 not exhaustive Transmissible torque M4 Rated voltage Un Rated air gap s Maximum air gap Smax highest torque that can be applied to the engaged brake or clutch without causing the brake clutch to slip supply voltage specified by the manufacturer for voltage windings to identify the device or component air gap of a new brake maximum possible air gap at the wear limit during brake operation 152 The switching times are defined in DIN VDE 0580 When using static systems holding operation the switching tim
22. It is not possible to perform adjustments air gap adjustments to compensate for wear 4 If the ball bearing 15 accessories needs to be replaced make sure to use bearings of the same type or of identical design 5 The sealing rings 6 and 11 do not require any maintenance However they should be replaced every time the brake unit is opened 6 The new sealing rings 6 and 11 must be glued in place after having cleaned the contact surfaces To this end Loctite 480 or an equivalent adhesive must be applied to individual spots on the front face of the solenoid housing 1 1 and on the circumference of the flange 3 before the sealing rings 6 and 11 are inserted and pressed on Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 21 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 145 Appendix A 3 Holding brake operating instructions 146 RKeENDRION 6 2 Brake module removal from motor and replacement of component parts The following instructions must be strictly followed when replacing individual brake components Centre the friction disc 4 relative to the centre of the brake module Adjust the microswitch 27 when using brakes equipped with microswitch Ensure that the friction disc is free from grease and oil Adjust the required clearance E of the adjusting ring 9 see marking on bottom of solenoid housing Tighten the cheese head scr
23. Max cur box type power external signals cable diameter 2 terminals section per rent per terminal terminal 3 gk863 1 x M50 x 1 5 1 x M16 x 1 51 38 mm Phases 3 x M6 1 x 50 mm 133 A Grounding 2 x M6 gk873 1 x M63 x 1 5 1 x M16 x 1 51 42 6 mm Phases 3 x M6 1 x 50 mm 133 A Grounding 2 x M6 gk876 1 x M63 x 1 5 1 x M16 x 1 51 42 6 mm Phases 6 x M6 1 x 25 mm 88 A Grounding 2 x M6 gk874 1 x M63 x 1 5 1 x M16 x 1 51 42 6 mm Phases 3x M10 2x 70 mm 240A Grounding 2 x M6 1 Thread M16 x 1 5 arranged with 90 to signal connection thread only for options A12 A25 and encoder version A without encoder 2 Depending on design of metric cable gland 3 Current carrying capacity based on EN 60204 1 and IEC 60364 5 52 routing type E 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 67 Connection 5 2 Electrical connection 5 2 6 68 Motors with DRIVE CLiQ interface NOTICE Damage to components that are sensitive to electrostatic discharge The DRIVE CLiQ interface has direct contact to components that can be damaged destroyed by electrostatic discharge ESDS Encoder systems and temperature sensors are components that can be destroyed by electrostatic discharge ESD Components that are sensitive to electrostatic discharge can be damaged if you touch the connections with your hands or with electrostatically charged tools e Carefully observe the information
24. Screw Washer ISO 7092 Tightening torque 10 Nm Foot mounting M12 12 d2 20 70 Flange mounting M16 16 d2 28 165 Depending on the installation space corresponding screws must be used Use screws of property class 8 8 or higher 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 4 3 Attaching the output elements Balancing The rotors are balanced dynamically The motors are equipped with a smooth shaft as standard For shaft extensions with feather keys the balancing method at the DE of the shaft is indicated as follows e H means half feather key balancing with a half feather key e F means fullkey balancing with a whole feather key 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 45 Mechanical mounting 4 3 Attaching the output elements Attaching the output elements e Make sure that the balancing method of the output element is correct The output elements must be balanced to balance quality grade G2 5 to ISO 1940 Rotary forces that exceed this are not permissible Note that rotary forces can also occur with coupling output e Ifthe 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 e Fit
25. Standards and directives 1 3 Manufacturer s liability INDUSTRIA 1 4 Declaration of Incorporation in accordance with Annex II part 1 Section B of Machinery Directive 2 2 1 2 2 2 3 General safety information 2 3 1 Installation 066 2 3 2 2 3 3 2 3 4 Maintenance and repair 0 000 3 Emissions 3 1 MOE EN RE 3 2 HOAT soseer nainn pease anaana 3 3 Electromagnetic compatibility 4 Product description 4 1 Operating principle S Mechanical installation 5 1 1 Brake shaft 13 installation 12 5 1 2 Mounting the brake module to the Motor seeee 13 5 2 Installation of accessories not applicable to the brake shaft 13 oo c cscesssceesesereetseeesesseeeeeeeneeee 14 5 3 EXSCHICALSONNECTON and ONGFALION s sesccesvncasenssarsncenrecasessrcennssvecsosnnseeshsennesdenesbassasasexsensistencecssnsepceasenene 15 5 3 1 DC power supply 00000 AT 5 3 2 AC power supply 5 3 3 Electrical connection of brake modules with microswitch 27 5 4 Set up and start up ecccsseeeeeseeeeee 5 4 1 Manual brake release 0 00 5 M transmissible torque adjustments 6 Maintenance iinan 6 1 Cheka amd SOP WI CS in TaN R en bata ca boca eka dees anak NA tae 6 2 Brake module removal from motor and replacement of component parts 6 3 Microswitch 27 adjustment only applicable to brake modules with microswitch 27
26. accelerate the drive The brake user is required to take adequate precautions to ensure that no hazardous situations are caused by the load torque when the brake module is released and engaged in jog mode Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 19 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 143 Appendix A 3 Holding brake operating instructions GKENDRION ad The spring applied single disc brake module can be released manually by means of a mechanical hand release 24 accessories In case of failure of the regular power supply it is also possible to use a commercial UPS e g UPS battery system for the electrical release of the brake module For this purpose the brake user is required to install a UPS system that complies with the voltage specifications given on the brake module rating plate 5 5 M transmissible torque adjustments A Attention When adjusting the adjusting ring 9 on the basis of the values given in the offer drawing make absolutely sure that the M transmissible torque is not below the minimum torque required The changed adjusting ring clearance E must be marked on the bottom of the solenoid housing The adjusted theoretical M transmissible torque must be entered in the blank field provided on the rating plate of the brake module see rating plate example After adjustment of the M transmissible torque the brake user i
27. approx 14 M transmissible torque standard value Nm 150 310 500 Maximum transmissible torque M4 max 150 310 500 Table 20 1 Change in the M transmissible torque from 1 mm axial adjustment of the adjusting ring 9 M transmissible torque standard value and maximum transmissible torque Mg max Note Torque adjustments are not possible for size 13 brakes Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 20 1PH813 1PH816 main motors 144 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions DKENDRION INDUSTRIAL DRIVE SYSTEMS WE MAGWETISE THE WORLO A Warning Whenever carrying out inspection and maintenance work ensure that amp the machine e g motor is secured against accidental or unintentional start up amp no load torque acts on the shaft the lock provided to prevent accidental start up of the machine e g motor is removed after completion of inspection and maintenance work all friction surfaces are free from grease and oil An oily or greasy friction disc 4 cannot be cleaned no swelling of the friction lining has occurred to be checked by air gap measurement no hardening glazing of the friction lining has occurred only visible when the brake is released the brake module has been switched off and disconnected from the power supply 6 1 Checks and service A Attention Depending on its operating condit
28. as a result of the high voltage test The motor insulation can be damaged when a motor high voltage test is carried out You can get an electric shock when touching live components Further electronic components can be destroyed The components involved include temperature sensors and encoders for example e Do not carry out a high voltage test on the motor 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 79 Commissioning 6 7 Safety instructions for commissioning WARNING Danger to life as a result of rotating output elements and loose parts that are flung out Rotating output elements and feather keys that are flung out while the motor is operational can result in severe injuries e Remove any loose feather keys or secure them so that they cannot be flung out e Do not touch any rotating parts e Secure output elements using the appropriate safety guards WARNING Danger to life when the cooling system bursts The motor will overheat if it is operated without cooling When cooling water enters the hot motor this immediately and suddenly generates hot steam that escapes under high pressure This can cause the cooling water system to burst resulting in death severe injury and material damage e Never operate the motor without cooling e Only commission the cooling water circuit when the motor is in a cool condition Awarnine Danger to life when the forced ventilation dra
29. authorized to compile the documentation Kendrion Villingen GmbH Industrial Drive Systems Villingen Authorized signatory 12 Dec 2013 DrUwe Gnauert Kendrion Villingen GmbH Enclosure protection ratings Electromagnetic devices and components Electromagnetically released spring applied single disc brake module 77 50013B16 77 50019B15 77 50024B15 77 50029B15 Kendrion Villingen GmbH Industrial Drive Systems Wilhelm Binder StraRe 4 6 78048 Villingen Schwenningen Germany Dr Uwe Gnauert Kendrion Villingen GmbH Industrial Drive Systems Wilhelm Binder Strake 4 6 78048 Villingen Schwenningen Germany Head of Development at IDS Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 4 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions RKENDRION 2 Safety 2 1 Safety and warning symbols Safety information Personal injury or equipment damage Symbol Signal word Warns against Potential risks and hazards Danger imminent personal injury fatal accidents or serious injury potential risk of serious r sone no Warning personal injury fatal accidents or serious injury Caution potential risk of personal injury minor injury A potential risk of equipment damage to components or other Attention damage equipment Information Symbol Signal word Provides information on il Note the safe use and o
30. can be expected the measurement range must be adapted accordingly This does not alter the maximum permissible values Rotor supported rotating unions for 1PH8 hollow shaft motors Introduction 1PH8 main motors with a hollow shaft 13th position in the Article No 3 are designed as main spindle motors for machine tools and machining centers with internal tool cooling A rotating union is required for the provision of the coolant in the rotating motor shaft A rotor supported rotating union can be mounted on the NDE shaft extension In addition to coolant suitable rotating unions can also transfer oil mist minimum quantity lubrication cutting oils or even compressed air at standstill Rotor supported rotating unions consist of the following components e Rotor with bearing e Stator e Enclosure with cable connections e Floating ring shaft seal 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Rotor supported rotating unions are easy to fit and change They are screwed into the motor shaft via the thread on the rotor The advantage of these rotating unions is the leading off of the leakage via the housing and the integrated leakage connection The rotor supported rotating unions also do not exert any axial forces on the motor shaft The axial forces caused by the coolant pressure are absorbed by the bearings of the rotatin
31. container 1 3 Industrial security Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants solutions machines equipment and or networks They are important components in a holistic industrial security concept With this in mind Siemens products and solutions undergo continuous development Siemens recommends strongly that you regularly check for product updates For the secure operation of Siemens products and solutions it is necessary to take suitable preventive action e g cell protection concept and integrate each component into a holistic state of the art industrial security concept Third party products that may be in use should also be considered For more information about industrial security visit this address http www siemens com industrialsecurity To stay informed about product updates as they occur sign up for a product specific newsletter For more information visit this address http support automation siemens com 1PH813 1PH816 main motors 18 Operating Instructions 01 2015 610 48006 40c Fundamental safety instructions 7 4 Residual risks during the operation of electric motors WARNING Danger as a result of unsafe operating states resulting from software manipulation Software manipulation e g by viruses Trojan horses malware worms can cause unsafe operating states to develop
32. equipped with an optional microswitch The friction disc is centred relative to the brake centre to facilitate brake mounting A Attention In order to avoid any shift of the friction disc the brake unit should only be released electromagnetically or by means of the hand release lever when the friction disc is guided by the brake shaft Brakes equipped with microswitches are delivered with factory adjusted microswitch Upon receipt of the shipment the brake must be checked for transit damage before storage Ordered accessories are delivered together with the brake The spring applied single disc brake module is delivered ready for mounting with factory adjusted M transmissible torque and factory adjusted rated air gap s A Attention The brake module should be transported and stored in vertical position with the output side solenoid housing 1 1 flange pointing upwards This flange must be provided with eye bolts e g to DIN 580 fixed to two diagonally opposite fixing bores These eye bolts are required to attach handling equipment secured with nuts for internal transport purposes or for mounting the brake module to the motor Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 26 1PH813 1PH816 main motors 150 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions Ekenorion INDUSTRIAL DRIVE SYSTEMS WE MAGWETISE THE WORLO Eg Note
33. in Chapter Handling electrostatic sensitive devices ESD Motors designed for SINAMICS drive systems are equipped with an internal Sensor Module which contains an encoder and temperature evaluation system as well as an electronic rating plate The Sensor Module is mounted instead of the signal connector and is equipped with a 10 pin RJ45plus socket This is known as a DRIVE CLiQ interface The pin assignment is independent of the motor internal encoder The Sensor Module can be rotated through approx 180 The typical torsional torque is between 4 and 8 Nm The Sensor Module must only be rotated by hand The use of pipe wrenches hammers etc is not permitted Figure 5 9 Motor with DRIVE CLiQ interface example The signal connection between the motor and Motor Module is established by means of a MOTION CONNECT DRIVE CLiQ cable The MOTION CONNECT DRIVE CLiQ cable connector must be inserted far enough so that the catch springs engage 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection DRIVE CLiQ Power cable Control cabinet Figure 5 10 Encoder interface with DRIVE CLiQ 5 2 7 Motors without DRIVE CLiQ interface If a motor is not equipped with a DRIVE CLiQ interface the speed encoder and temperature sensor are connected via a signal connector Motors that are not equipped with DRIVE CLiQ require a Sensor Module Cabinet Mounted SMC or a Sensor Mo
34. in your installation which can result in death severe injuries and or material damage e Keep the software up to date You will find relevant information and newsletters at this address http support automation siemens com e Incorporate the automation and drive components into a holistic state of the art industrial security concept for the installation or machine You will find further information at this address http Awww siemens com industrialsecurity e Make sure that you include all installed products into the holistic industrial security concept 1 4 Residual risks during the operation of electric motors The motors may be operated only when all protective equipment is used Motors may be handled only by qualified and instructed qualified personnel that knows and observes all safety instructions for the motors that are explained in the associated technical user documentation 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 19 Fundamental safety instructions 7 4 Residual risks during the operation of electric motors When assessing the machine s risk in accordance with the respective local regulations e g EC Machinery Directive the machine manufacturer must take into account the following residual risks emanating from the control and drive components of a drive system 1 Unintentional movements of driven machine components during commissioning operation maintenance and repairs
35. rating plate with respect to the mounting position and protection class amp Ensure that power is supplied separately to the spring applied single disc brake module and not to the motor and turn the motor shaft while the brake is released to check that the friction disc 4 and brake shaft 13 move smoothly Proceed to perform a functional test of the axial armature movement amp Check that the axial and radial runout is within the tolerance range specified in EN 50347 N amp Information on ball bearing break in conditions bearing lubrication intervals etc is provided in the specification sheets of the bearing manufacturers and in the motor manual After completion of mounting all necessary covers and guards must be installed Specifications on rating plates example Variant number Offer drawing index Transmissible torque Brake number factory set Rated current 77 50024815 Var 0002 Index neu EINS Spule 102 VDC 0 74A M 310 Nm rA Gleichrichter 230 VAC 40 60 Hz k 5191813002 A Nr P12345678901 AO Coil voltage Production ID code Type number Supply voltage 5 4 1 Manual brake release A Warning Extreme caution is advised during manual release jog mode of the spring applied single disc brake module e g for maintenance work on the machine e g motor or in case of failure of the regular power supply and use of a UPS system If the drive system is unbalanced the load torque may
36. remove the output elements only by means of suitable equipment Use the threaded hole in the shaft extension front If necessary heat up the output element When removing output elements use a washer to maintain the centering in the shaft extension Awarnine Danger to life if rotating output elements have no guard Exposed rotating output elements can result in severe injury e Cover all exposed output elements using an appropriate guard Figure 4 2 Fitting removing output elements A intermediate washer for maintaining the centering in the shaft extension 1PH813 1PH816 main motors 46 Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 4 Vibration stressing Motor without output element WARNING Danger to life if feather keys are flung out The feather key in a shaft is only secured during transport to prevent it from falling out An open feather key sitting in the shaft will be flung out in operation Death or serious injury can result e Remove an open feather key sitting in the shaft or secure it so that it cannot be flung out e For balancing type H shorten the feather key by about half 4 4 Vibration stressing The on site mechanical system vibration characteristics depend on factors such as the output elements mounting situation alignment installation and external vibration and can increase the level of motor vibration Under certain c
37. shaft extension Tighten the rotating union with the correct tightening torque For this use the wrench grip surface on the NDE motor shaft extension to hold the other side 5 Position the rotating union horizontally in such a way that the leakage connection is at the lowest point 6 Always connect the hose for leakage sloping downward at least 15 7 Also connect the hose for the inlet sloping downward 8 If necessary provide a ventilation hose for the leakage chamber Lead the ventilation hose upward 9 Manually check that the rotor turns easily 10 Test the mounting under pressure for leaks 11 Make a burr free cutout in the intermediate housing for the inlet and leakage hoses 12 Push the intermediate housing with the cutout over the hoses Screw the intermediate housing onto the motor 13 Screw the fan onto the intermediate housing 14 Seal the remaining openings between the cutout and the hoses 1PH813 1PH816 main motors 54 Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Sealing cover Balancing disk Intermediate housing Rotor supported rotating union e g DEUBLIN 1109 020 188 Cutout Cover Leakage hose Inlet hose OOQOOOOHO Fan Figure 4 5 Rotating union for air cooled motors 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 55 Mechanical mounting 4 5 Rotor supported rotating unions f
38. stop function 1PH813 1PH816 main motors 33 Operating Instructions 01 2015 610 48006 40c Description 2 4 Design Current Brake opened to ss t opening time t closing time Figure 2 5 Terminology time for holding operation Explanation of terminology in the table 34 Holding torque Nm On motors with shaft heights 100 160 the holding torque can be continuously set in the specified value range using an adjusting ring The dynamic braking torque is approximately 70 of the set holding torque Maximum speed nmax rpm Maximum permissible speed Perm single switching energy We kJ Permissible operating energy during an emergency stop We Jtotai X N2 182 4 x 10 3 J in kgm2 n in rpm Lifetime switching energy Wmax MJ Max possible switching energy of the brake for emergency stop until the friction disk has to be replaced Wmax We x Z Number of emergency stops z The specified number of emergency stops refers to the specified conditions A conversion can be made for operation under different conditions Number of emergency stops z Wmax We Coil current A Current to release the brake Release time ms Separating time until the brake releases the specified values refer to the maximum braking torque and rated voltage Engaging time ms Connecting time until the brake engages according to the diagram Terminology time for holding operation The values refer to the maximum bra
39. the brake via additional switching elements may be required Make sure the parameter assignments for the brake data in the SINAMICS are correct This is particularly important for the setting values e Maximum motor speed reduced value for the holding brake option e Release and engaging times of the holding brake e Moment of inertia of the holding brake The corresponding setting values are listed for the specific brakes in the Technical data of the holding brake table Functional principle of the holding brake A brake can be mounted at the DE side of 1PH8 motors shaft heights 132 and 160 These brakes are electromagnetic units for dry running operation An electromagnetic field is used to release the brake which is applied using spring force They function according to the closed circuit principle i e the spring applied brake is triggered when the current is interrupted and holds the drive When power is applied to the brake it is released and the drive is free to rotate When the power fails or an emergency stop is issued the drive is braked from its actual speed down to standstill Connection of the brakes must be provided by the customer e Alternating voltage 230 V AC 50 60 Hz e DC voltage of 24 V DC 1PH813 1PH816 main motors 32 Operating Instructions 01 2015 610 48006 40c Ambient temperature The brake module is designed for an ambient temperature of
40. the fan blades free of foreign bodies e Does the fan have the correct direction of rotation An arrow is stamped on the fan rating plate This arrow indicates the correct direction of rotation of the fan An arrow is also marked on the fan blades When the fan starts you can visually check the direction of rotation using the arrows The fan functions correctly if the direction of rotation matches the direction of the arrow on the fan rating plate Table 6 6 Checklist 6 checks regarding the optional brake Check OK Does the brake open when the operating voltage is connected Does the brake open and close correctly Table 6 7 Checklist 7 checks regarding roller bearings Check OK Are the roller bearings OK For motors that were stored were the storage conditions according to Chapter Storage and the bearing change intervals according to Chapter Bearing change interval complied with 1PH813 1PH816 main motors 84 Operating Instructions 01 2015 610 48006 40c Commissioning 6 3 Checking the insulation resistance 6 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 Danger to life through electric shock During and immediately after the measurement the terminals are in some cases at hazardous voltages which can lead to death when touch
41. the following diagram 1PH813 1PH816 main motors 70 Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection M16 x 1 5 Figure 5 13 Encoder connection via additional terminal box The following circuit diagram is available to connect an HTL incremental encoder 15V BN 7 OV RD BU 7 UA WH 8 UAS Bu UA1 SR UA1 GYIPK L amp i _5_ UAO BN GN UAO VT 3 VA GN Figure 5 14 Circuit diagram to connect an HTL incremental encoder Note Additionally supplied sensors Connect the following additional sensors in the terminal box according to Chapter Terminal boxes e Temperature sensor as a standby or e PTC thermistor circuit for warning and shutdown Note Temperature sensor The type of temperature sensor is to be found on the rating plate 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 71 Connection 5 2 Electrical connection 5 2 9 Connecting the temperature sensor The temperature sensor in the motor winding is connected to the signal connector together with the speed encoder signal NOTICE Thermal motor damage Windings and bearings can be destroyed if the motor overheats e Make sure that the temperature sensor is evaluated 5 2 10 Connecting a grounding conductor in the terminal box The motor grounding conductor cross section must be in full compliance with the in
42. 13 1PH816 main motors Operating Instructions 01 2015 610 48006 40c A1 Preparations for use 3 2 Transportation and storage 42 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 4 1 Installation NOTICE Thermal damage to temperature sensitive parts Some parts of the motor enclosure can reach temperatures that exceed 100 C If tempera ture sensitive parts e g electric cables or electronic components are in contact with hot surfaces they can be damaged e Ensure that no temperature sensitive parts are in contact with hot surfaces NOTICE Damage to the motor caused by incorrect installation Blows and pressure to the shaft extension can damage the motor e When installing and mounting the motor ensure that the shaft extension is neither subject to any blows nor to any pressure Note Technical data on the motor enclosure e Observe the technical data on the rating plate type plate on the motor enclosure The following must be taken into account when the motors are installed e Observe the type of construction and degree of protection stamped on the rating plate and check that they comply with the conditions at the installation location e Refer to the configuration manual for the permissible radial and axial forces e Check that they match the conditions temperature installation altitude at the installation location e Ensure that the en
43. 19 2 DOSCHIPUOM asin tisceiesecddecteastetanue tiisbpivstndesabinaabanndeetuceeelsineptvaybeaetenenaede Anaa aa kki ra aaan aaa aaa AKUA i 21 2 1 Use forthe intended PpurpOSe 2 c c 2 cseecie etecceentesceusesstececectedieasceonts sebgetedsetepulaetustesceastndneseurs 21 2 2 Technical characteristics and ambient conditions ccc cscs cesecteeeecneeeeeeeeeseesaeeeeeneenes 22 2 2 1 Regulations ieie a aE A thse eE E Aaa T AE aE Second venient ated alas eee 2 2 2 Technical Characteristics ccccccccssccsecsecnecseeeecesecseeeeeesecsaecesesecsaeesecsecaecsaceeassecsasesaenaenas 22 2 2 3 AMDIC ME COMMONS AE TE EE E S E A E ERN 2 2 4 Degree Of protectloMs sseni ae ee a e a E O 2 2 5 NOISE STMISSIOM 22 eiga setae eE a A EEE e E EAE ie EE E E E A 2 3 Rating plate data type plate nsnnsnnsnssnnennsnnsensinssnnnissnnnnnsinsnnsnnnnnnnnnsnnensnnnnnnnnnnnnnennennen ne ZOD 2 4 BESIM one e a a a e 2 4 1 TYPOS Of CONSWUCTON ioscxenrste aiena e a E a E eia eae anA 2 4 2 COON Gaee nee a E a E a a G 2 4 3 Holding brake OPON ssie sonsir cancccs nuniy arasina an aE EEE EEEE Karia ai O 2 4 3 1 PROP CICS 3 tec tee Se OA 2 4 3 2 Mounted holding brake for SH 132 and SH 160 cece cceeeecesecseeeeentecneeeseeecraeeseeteeneereees OO 3 Preparations fof USE cccsnccecnnnssenevesevesesnsincsnewecnensseatssnne fanspensinentennnencnnenssntbavebevssenetbecnecesnrnsvansasueeeennenase 37 3 1 Shipment and packaging cccccccccee
44. 2 0 01 0 1 0 05 x 105 0 1 x 105 lt 8 lt 3 An improved level of protection is achieved by applying a low static pressure without having a permanent flow of sealing air The sealing air must comply with the specified air quality 78 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Commissioning 6 1 Safety instructions for commissioning WARNING Danger to life as a result of hazardous voltages when connected to inadequately grounded line supplies In the case of a fault connecting a motor to an inadequately grounded line supply can result in death severe injury and or motor damage e Connect motors as part of the drive system to TN and TT line supplies with grounded neutral point or to IT line supplies e Verify that the SINAMICS devices and motors are compatible with the residual current device according to EN 61800 5 1 before you connect the devices and motors to the line supply using residual current devices RCDs e For line supplies with grounded line conductor e g TT line supplies use an isolating transformer with grounded neutral point on the secondary side between the line supply and the drive system so that the motor insulation is not overstressed e When connected to IT line supplies a monitoring device must signal the first fault between an active part and ground Remove this fault immediately WARNING Danger to life when the insulation is damaged
45. 2 Transportation and storage 3 2 2 Storage Storing indoors 40 Note Replacing roller bearings e Even if the motor was stored for more than three years under favorable conditions i e in a dry dust free room that is not susceptible to vibration you must replace the bearings e If the motor was stored under unfavorable conditions you must replace the bearings after approx 18 months NOTICE Seizure damage to bearings If the motors are stored incorrectly bearing seizure damage can occur e g brinelling as a result of vibrations e Observe the instructions for putting into storage The motors can be stored for up to two years in a dry dust free room that is not susceptible to vibration Ve lt 0 2 mm s without the specified storage time being reduced e Apply a preservation agent e g Tectyl to bare external components e g shaft extensions if this has not already been carried out in the factory e Store the motor in an area that fulfills the following requirements Dry dust free frost 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 e Protect the motor against shocks and humidity e Make sure that motor is covered properly e Avoid cont
46. 4 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 Low voltage motors are components designed for installation in machines in accordance with the Machinery Directive They must not be commissioned until it has been verified that the end product complies with this directive also take into account EN 60204 1 Note Complying with regulations Make sure that your end product is in compliance with all of the applicable legislation The applicable national local and system specific regulations and requirements must be taken into account 2 2 2 Technical characteristics The most important technical characteristics of the motors can be found on the rating plate type plate You will find detailed overviews of the technical characteristics of the motors in the Configuration Manual SIMOTICS M 1PH8 Main Motors for SINAMICS 120 or in catalogs PM 21N and NC 61 1PH813 1PH816 main motors 22 Operating Instructions 01 2015 610 48006 40c 2 2 3 Ambient conditions The following temperature ranges apply to motors with forced ventilation Permissible temperature range during operation T 15 C to 40 C Description 2 2 Technical characteristics and ambient conditions Under conditions other than those specified above ambient temperature gt 40 C or installation altitude gt 1000 m above sea level the permissibl
47. 615 Bad Neustadt a d Saale Germany Produktbezeichnung Drehstrommotoren Synchron und Asynchron Typ 1PH8 Description of the product Three phase motors synchronous and asynchronous type 1PH8 Achshohen shaft heights 80 100 112 132 160 Die bezeichneten Produkte stimmen in der von uns in Verkehr gebrachten Ausf hrung mit den Vorschriften folgender Europ ischer Richtlinie berein The products described above in the form as placed on the market are in conformity with the provisions of the following European Directive 2006 95 EG Richtlinie des Europ ischen Parlaments und de Rates vom 12 Dezember 2006 zur Angleichung der Rechtsvorschriften der Mitgliedstaaten betreffend elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Spannungsgrenzen Directive of the European Parliament and the Council of 12 December 2006 on the approximation of the laws of the Member States related to electrical equipment designed for use within certain voltage limits Die Konformit t mit der Richtlinie wird nachgewiesen durch die Einhaltung folgender Normen Conformity to the Directive is assured through the application of the following standards EN 60034 1 2010 EN 60204 1 2006 A1 2009 EN 60204 1 AC 2010 mit allen relevanten Teilen with all relevant parts Die Sicherheitshinweise und Betriebsanleitungen sind zu beachten The safety and manual documentation shall be considered in detail Erste CE Kennzeichnung 2008 first CE m
48. AL DRIVE SYSTEMS WE MACHETISE THE WORKO The installation and removal of driven components such as clutch gear pulley etc on the brake shaft must be carried out using suitable devices and tools Use the thread in the brake shaft for installation purposes and heat the components prior to assembly if possible In order to protect the centring piece and thread in the brake shaft a shim must be inserted before removing driven components see Fig 26 1 The brake shaft is balanced with a half key half key balancing to DIN ISO 8821 Check that the correct balancing method is used when installing the driven components E Note General precautions must be taken to prevent accidental contact with driven components The brake is an electromagnetic device which may generate electromagnetic stray flux In general driven components remain unaffected by the presence of such stray flux Fig 26 1 Shim The brake module is delivered in a preassembled condition with factory adjusted standard transmissible torque My The brake shaft with screw plug spring washer ball bearing circlip feather key hand release rubber bolts size 19 and 24 brakes and O ring size 29 brakes are not included in the scope of supply The ball bearing set ball bearing spring washer circlip hand release brake shaft with screw plug rubber bolts size 19 and 24 brakes or O ring size 29 brakes can be ordered as accessories The brake module can be
49. DSB All si is eiei ae ai ea eai A A APPENd X sv sscccci ve iicccccececdencienet cectcecaa eink eraa aE a EEEE EEEE segue EEEE EEEE EEEE LEKET NEEE ENERE 123 A 1 Declaration Of CONFOFMItY e aan aa a aane aana KeA a KAREENA AR e ERNA Bi eaha 123 A 2 Note regarding a holding Drake eecceeeeeeeeeeeceeeeeeeeeeeaeeeeeeeaeeeseeaaeeeeeeaaeeeseeaeeeseenaeeeeeeaas 124 A 3 Holding brake operating instructions cece cece ee eeeeeeeeseeeeeeeeeeeaeeeseeaaeeeseeaaeeeseenaeeeeeeaas 125 MN ON aires sare ee sacs ace EE EEE ta su cote ex deed EEEE E EE E EEEE NE 155 1PH813 1PH816 main motors 11 Table of contents 12 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Fundamental safety instructions 1 1 1 General safety instructions Danger to life due to live parts and other energy sources Death or serious injury can result when live parts are touched e Only work on electrical devices when you are qualified for this job e Always observe the country specific safety rules Generally six steps apply when establishing safety 1 Prepare for shutdown and notify all those who will be affected by the procedure 2 Disconnect the machine from the supply Switch off the machine Wait until the discharge time specified on the warning labels has elapsed Check that it really is in a no voltage condition from phase conductor to phase conductor and phase conductor to protective conductor
50. SIEMENS SIMOTICS SIMOTICS M 1PH8 Main Motors 1PH813 1PH816 Operating Instructions Answers for industry SI E M E N S Introduction Fundamental safety 1 instructions SIMOTICS Description lt Preparations for use Drive technology 1PH813 1PH816 main motors Mechanical mounting Connection Operating Instructions Commissioning Operation Maintenance Oo AD N OQO O A O IN Spare parts Decommissioning and 4 0 disposal Appendix A 01 2015 610 48006 40c Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety as well as to prevent damage to property The notices referring to your personal safety are highlighted in the manual by a safety alert symbol notices referring only to property damage have no safety alert symbol These notices shown below are graded according to the degree of danger indicates that death or severe personal injury will result if proper precautions are not taken WARNING indicates that death or severe personal injury may result if proper precautions are not taken CAUTION indicates that minor personal injury can result if proper precautions are not taken NOTICE indicates that property damage can result if proper precautions are not taken If more than one degree of danger is present the warning notice representing the hig
51. The motor can be damaged if operated at inadmissible speeds e Ensure that the maximum permissible speed is not exceeded Realize this using a suitable control system or activate the speed monitoring function in the drive NOTICE Damage or destruction of the holding brake If the holding brake is used as an operating brake then it will be damaged or destroyed e Control the holding brake so that it can never be used as an operating brake e The holding brake microswitch must be connected to the control and evaluated also refer to the supplementary sheet on the holding brake 4BZFM 100 e It must be completely ruled out that the motor is operated with the holding brake closed e tis only permissible to control the holding brake when the motor is at a standstill Note Grease distribution operation for High Performance bearing version The manufacturer operates 1PH8 High Performance drives for approximately 15 min to distribute the grease After this run in time users can operate the motors up to the maximum speed without causing bearing damage The grease distribution with the optimum formation of a lubricating film in the roller bearing is completed after an operating time of approx 30 hours When excess grease is being pressed out of the bearing cage certain noises can occur which do not necessarily mean potential bearing damage 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 81 Com
52. ace rotating unions with radial connections are advisable for air cooled motors e g DEUBLIN 1109 020 188 Rotating unions with axial connections are not suitable e Remove the fan with the intermediate housing before mounting the rotating union e Make a burr free cutout in the intermediate housing for the hoses for the coolant inlet and leakage Protect the hoses against abrasion e Close the remaining openings between the cutout and the hoses again so that cooling air cannot escape e f necessary use a ventilation line in addition to the leakage line A ventilation line equalizes the negative pressure caused by the fan Connect a hose to the rotating union via an additional ventilation leakage connection Route the hose upward out of the intermediate housing 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 53 Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Installation steps gt 1 Remove the fan and intermediate housing from the motor 2 If necessary perform complete balancing of the motor using the exterior balancing disks To do this remove the sealing cover Note Sealing cover e Remount the sealing cover after balancing 3 Attach hoses for the inlet and leakage to the rotating union Use angle elements if necessary Note Rotating union to be used e Use a rotating union with radial connections 4 Screw the rotating union into the NDE motor
53. act corrosion You are advised to rotate the shaft extension manually every three months 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Preparations for use 3 2 Transportation and storage Protection against humidity If a dry storage area is not available the following measures must be taken e Wrap the motor in humidity absorbent material and then wrap it in film so that it is air tight e Include several bags of desiccant in the seal tight packaging Check the desiccant and replace as required e Place a humidity meter in the seal tight packaging to indicate the level of air humidity inside it e Inspect the motor on a regular basis Long term storage If you intend to place the motor in storage for longer than six months you must check its condition every six months e Check the motor for any damage e Carry out any necessary maintenance work e Document all preservation measures taken so that they can be reversed before the machines are recommissioned e Control the climate in the storage room if the conditions for storage cannot be complied with e Rotate the shaft extension by hand Protecting the cooling water system When the units are delivered the stainless steel cast iron cooling water pipe system is not filled with cooling water e When you place the motor in storage after use drain the cooling water ducts and purge them with air so that they are completely empty 1PH8
54. and also provide anti kink protection It is not permissible to subject the connector to continuous force e The coding slot for the plug in connections must be aligned when inserted into the socket connector The union nut must be tightened by hand up to the endstop e Plug in or remove the connector only when the system is de energized e The insulating film must be present in the terminal box Current carrying capacity for power and signal cables The current carrying capacity of PVC PUR insulated copper cables is specified in EN 60204 1 5 2 2 Circuit diagram The circuit diagram contains information about wiring and connecting the motor winding The circuit diagram can be found on the lid of the terminal box Encoder Figure 5 1 Circuit diagram NOTICE Cable damage caused by inappropriately changing the cable outlet direction You will damage connecting cables if you inappropriately change the cable outlet direction e The direction of the cable outlet must not be changed as this invalidates warranty claims 1PH813 1PH816 main motors 62 Operating Instructions 01 2015 610 48006 40c 5 2 3 Terminal box Connection 5 2 Electrical connection Assign the terminals in the terminal box as shown in the diagrams Terminal box 3 pole and Terminal box 6 pole Connect the PE conductor Use cable lugs to DIN 46234 Do not remove the insulation strips Screw the terminal box cover on again tightening tor
55. ansformers e Power lines e Instrument wiring e Surge arrester e Capacitors 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Decommissioning and disposal 10 2 Disposal Disposing of permanent magnets Permanent magnets must be demagnetized prior to disposal This helps avoid potential hazards caused by permanent magnets during and after disposal Permanent magnets are heated to demagnetize them Permanent magnets can be demagnetized in one of the following ways e Arrange for the entire machine to be subject to thermal treatment by a specialist disposal company e 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 Note Removing the rotor The rotor in a machine containing permanent magnets must only be removed by the manufacturer Contact the Siemens Service Center 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 121 Decommissioning and disposal 10 2 Disposal 1PH813 1PH816 main motors 122 Operating Instructions 01 2015 610 48006 40c Appendix A 1 Declaration of conformity 1PH813 1PH816 main motors SIEMENS EG Konformitatserklarung EC Declaration of Conformity No 664 20036 04 Hersteller Siemens Aktiengesellschaft Manufacturer Industrie Sector DT MC MF M Anschrift Industriestra e 1 Address 97
56. ards to persons or damage to equipment caused by amp direct or indirect effects of electromagnetic fields amp heated components moving parts 2 3 2 Start up The brakes must not be started up when amp power supply cables wires or connections are damaged amp the solenoid housing or coil sheath is damaged amp other defects are suspected 2 3 3 Operation Make sure that live components such as plug contacts or the field coil are not exposed to water The brake cable connections must not be crushed squeezed or exposed to mechanical loads Check that the friction surfaces of the friction elements are not contaminated with grease oil or other fluids to avoid substantial torque reduction Bear in mind that the original torque cannot be restored even if the friction surfaces are cleaned after contact with fluids The gradual brake wear towards the end of the brake service life may cause an approximately 10 torque reduction This must be taken into consideration in the set up of the machine or overall system Due to the diverse ambient conditions in which the brakes may be used always check that the brake module is in perfect working order before start up Torque reductions cannot be excluded if the brake module is used for applications where only minimum friction work is required In such cases the user should ensure that the brake occasionally performs sufficient friction work Kendrion Villingen GmbH Operating Instructi
57. arking 2008 Die bezeichneten Produkte sind zum Einbau in andere Maschinen bestimmt Die Inbetriebnahme ist solange untersagt bis die Konformit t des Endproduktes mit der Richtlinie 2006 42 EG festgestellt ist Alle Sicherheitshinweise der zugeh renden Produktdokumentation sind zu beachten sowie dem Endanwender zur Kenntnis zu geben The products supplied are intended exclusively for installation in a machine Commissioning is prohibited until it has been established that the end product conforms with the Directive 2006 42 EU All safety instructions in the associated product documentation must be observed and given to the end user for his her information Bad Neustadt den Siemens Aktie lischaft a1 a e E Peter Deml Center Motors Head of Supply Chain Management Erkl rung bescheinigt die bereinstimmung mit der genannten Richtlinie ist jedoch keine Beschaffenheits oder Haltbarkeitsgarantie nach 443 BGB This declaration certifies the conformity to the specified directive but does not imply any warranty for properties Ersatz f r Substitute for 664 20036 03 Stand Status 10 2013 Ausgabestand Status 08 2014 Erstausgabe first document 04 2008 Siemens Aktiengeselischaft Chairman of the Supervisory Board Gerhard Cromme Managing Board Joe Kaeser Chairman President and Chief Executive Officer Roland Busch Lisa Davis Kiaus Heimrich Hermann Requarct Siegfried Russwurm Ralf P Thomas Registered offices Berlin and Mun
58. arried out if the encoder is already mounted 2 If necessary remove the threaded pin used earlier to remove the encoder 3 Unscrew the screw 1 for the replacement encoder 4 Remove the connector cover 2 for the replacement encoder Place the encoder with torque bracket 9 06 onto the cone of the motor rotor and screw in the encoder screw 9 05 tightening torque 5 1 Nm Prevent the motor rotor from starting to rotate as well 5 Secure the torque bracket 9 06 by means of screws 9 07 on the bearing shield 6 01 note the radial deflection of the encoder 6 Press on the metal sleeve for the connector cable 7 Insert the connector with signal cable and place the cable into the guide 8 Fix the plug cover 2 with the screw 1 and secure in place e g with Loctite 243 Note Re adjusting the encoder system With synchronous motors the encoder system has to be realigned 1PH813 1PH816 main motors 108 Operating Instructions 01 2015 610 48006 40c Maintenance 8 2 Corrective maintenance 8 2 3 Removing installing the toothed wheel encoder Note Toothed wheel encoder The toothed wheel encoder has the following description without the DRIVE CLIiQ interface Incremental encoder sin cos 1 Vpp 256 S R without C and D tracks encoder IN256 S R The marking is 1PH8 0C The toothed wheel encoder has the following description with the DRIVE CLiQ interface Incremental encoder 19 bit without commutation po
59. art 8 In order to install the ball bearing 15 pressure must be evenly applied both to the inner and outer rings of the bearing 15 to force it onto the motor shaft until it touches the shaft shoulder of the brake shaft 13 The necessary pressure is generated through a mounting sleeve and the thread provided at the front end of the brake shaft 13 9 The solenoid housing 1 1 is thus centred through the ball bearing Proceed to install the disc 12 and circlip 16 A Attention The Ma tightening torque Table 13 1 specified for the fixing screws must be strictly observed The screws must be tightened evenly in diametrically opposite sequence 10 Tighten the fixing screws to the Ma tightening torques specified in Table 13 1 Size 13 19 24 29 Ma tightening torque fixing 42 70 165 165 screws Nm Table 13 1 Ma tightening torques for fixing screws Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 13 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 137 Appendix A 3 Holding brake operating instructions 138 RKENDRION 5 2 Installation of accessories not applicable to the brake shaft 13 Hand release 24 only applicable to retrofitted hand release 1 Remove the two covers 23 located opposite each other on the circumference of the solenoid housing 1 1 see Fig 14 1 2 Screw the cams 24 1 with the threaded bush into the bo
60. arts that are flung out e g feather keys in operation can result in severe injury or death e Remove any loose parts or secure them so that they cannot be flung out e Do not touch any moving parts e Safeguard all moving parts using the appropriate safety guards WARNING Danger to life due to fire if overheating occurs because of insufficient cooling Inadequate cooling can cause overheating resulting in death or severe injury as a result of smoke and fire This can also result in increased failures and reduced service lives of motors e Comply with the specified coolant requirements for the motor 1PH813 1PH816 main motors 16 Operating Instructions 01 2015 610 48006 40c Fundamental safety instructions 1 2 Handling electrostatic sensitive devices ESD WARNING Danger to life due to fire as a result of overheating caused by incorrect operation When incorrectly operated and in the case of a fault the motor can overheat resulting in fire and smoke This can result in severe injury or death Further excessively high tempera tures destroy motor components and result in increased failures as well as shorter service lives of motors e Operate the motor according to the relevant specifications e Only operate the motors in conjunction with effective temperature monitoring e Immediately switch off the motor if excessively high temperatures occur caution Risk of injury due to touching ho
61. be commissioned known e g 1PH8 Are the environmental conditions in the permissible range 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Commissioning 6 2 Checklists for commissioning Table 6 2 Checklist 2 checks regarding the mechanical system Check OK Have all touch protection measures for moving and live parts been taken Has the motor been correctly mounted and aligned Can you rotate the rotor without it touching the stator Do the operating conditions correspond to the data specified on the rating plate Are all mounting screws connecting elements and electrical connections tight and attached properly Do the output elements have the correct setting conditions according to type Examples e Have the couplings been aligned and balanced e Has the tension of a belt drive been correctly adjusted e Have the gear tooth flank and gear tooth tip play as well as radial play been correctly adjusted for geared outputs Table 6 3 Checklist 3 checks regarding the electrical system Check OK Has the motor been connected so that it rotates in the specified direction Have the minimum insulation resistance values been maintained Have the grounding and equipotential bonding connections been correctly established Do the brakes function perfectly Table 6 4 Checklist 4 checks regarding monitoring devices
62. by faults e Correct the cause of the fault as specified in the remedial measures section e Repair any damage to the machine motor Note When faults occur observe the converter operating instructions e f changes occur with respect to normal operation or faults determine the cause using the Possible faults table e If you have identified the cause attempt to resolve the fault using the Key fault causes and remedial measures table e In this regard observe the relevant chapter in the documentation associated with the components of the complete drive system 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Operation 7 1 Faults Table 7 1 Possible faults Fault Cause of fault see key table Motor does not start AJB E Motor starts slowly A C E Rumbling noise when starting C E Rumbling noise in operation A C EIF High temperature rise under no load D G H operation High temperature rise under load A C G H High temperature rise of individual E winding sections F Uneven running JIK Grinding sound running noise L Radial vibration M N O P R Axial vibration O QIR Water is leaking S 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 91 Operation 7 1 Faults Table 7 2 Key to
63. caused by for example Hardware and or software errors in the sensors control system actuators and cables and connections Response times of the control system and of the drive Operation and or environmental conditions outside the specification Condensation conductive contamination Errors during the assembly installation programming and parameterization Use of wireless devices mobile phones in the immediate vicinity of the control system External influences damage 2 In case of failure unusually high temperatures inside and outside the motor including open fire as well as the emission of light noise particles gases etc can result for example in Component failure Software errors in converter operation Operation and or environmental conditions outside the specification External influences damage 3 Hazardous shock voltages caused by for example Component failure Influence during electrostatic charging Induction of voltages in moving motors Operation and or environmental conditions outside the specification Condensation conductive contamination External influences damage 4 Electrical magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker implants or metal replacement joints etc if they are too close 5 Release of noxious substances and emissions in the case of improper operation and or improper dis
64. causes of faults and remedial measures No Cause of fault Remedial measures A Overload Reduce load B Interrupted phase in the supply Check the converter and supply cables measure the winding cable motor winding resistances and insulation resistances repair after consultation with manufacturer C Interrupted phase in the feeder cable Check the converter and supply cables check the winding resistances after switching on D Converter output voltage too high Check the converter settings perform automatic motor identification frequency too low F Winding short circuit or phase short circuit Measure the winding resistances and insulation resistances repair after in stator winding consultation with manufacturer G Cooling water not connected or switched Check cooling water connection switch on cooling water off H Cooling water flow rate too low Increase cooling water flow rate Inlet temperature too high Set correct inlet temperature E Stator winding incorrectly connected Check winding connection l Heat dissipation obstructed by deposits Clean the drive surfaces Ensure that the cooling air can flow in and out unimpeded Cooling air inlet outlet is blocked by Remove the blockage Ensure that the cooling air can flow in and out foreign bodies unimpeded Fan motor does not start Check the function of the fan motor J Insufficient shielding for motor and or Check the shielding and grounding encoder cable Drive controller gain too high Adjust the controller
65. ces for Safety Integrated functions If you want to use Safety Integrated functions you must observe the safety notices in the Safety Integrated manuals 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 15 Fundamental safety instructions 1 1 General safety instructions WARNING Danger to life from electromagnetic fields Electromagnetic fields EMF are generated by the operation of electrical power equipment such as transformers converters or motors People with pacemakers or implants are at a special risk in the immediate vicinity of these devices systems e Ensure that the persons involved are the necessary distance away minimum 2 m WARNING Danger to life from permanent magnet fields Even when switched off electric motors with permanent magnets represent a potential risk for persons with heart pacemakers or implants if they are close to converters motors e f you are such a person with heart pacemaker or implant then keep a minimum distance of 2 m e When transporting or storing permanent magnet motors always use the original packing materials with the warning labels attached e Clearly mark the storage locations with the appropriate warning labels e IATA regulations must be observed when transported by air WARNING Injury caused by moving parts or those that are flung out Touching moving motor parts or drive output elements and loose motor p
66. cesecssecseesecsseeseesecesecseceeeesecsaeeeeesscaseseeesensecaseeseseenas of 3 2 Transportation ANG Storage isseire dh ates Pe ee ates ee eed cane ed eee ot 3 2 1 Transport sac eae nasien pace ube acecet hens t vhtcadeesshtac covistecerube usc tnacdasvesaie ovicde rulebictcstaein vhives eet OO 3 2 2 Stole e etait eee eu ee ee ee ee ai eee ee oe AD 4 Mechanical Mounting isisiisissisectsesccteteectestsiessieisipiecsteiaasceiensti ces ennabsbebassonisus peetbessadhnnveiecdabebasbbaedaoieane 43 4 1 NMS TAN ATION occ ceeds A A coy eds T E E E E 4 2 FIXING arein ad a i d aa aa a a a a a aa aa 44 4 3 Attaching the output elements 0 0 0 2 ccccceceecccceeeecceeeeeeeceeeeeeceeneeeeceeneeeeaceneseecaeneeeeeceneeeeaeeneeees 45 4 4 VIDATION SIESSIING mesnice e a ea aiae e neeaae eas A 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors s ssesssnssssnsnnsnnsnsnse nenne 48 4 5 1 INthODUGUOM sot tesedetet Pent cei Sal odd ee en ee cae tee a 4 5 2 MOUNTING seses sicdeasesecestvecvenscaradcavsvestecseegsccatsvacedecss saceduth sigs O 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 9 Table of contents 10 CONMOCHON vispre iinu Raan EEEa EEEE EEEE EEEE EEEE EEEE dannii EEEE EEEE EE EALES EEEE EEEE EEEE ANETES 59 5 1 Mechanical connection of water cooling System s ss ssrssissrnsissinsrnsrnsrnnrisnnrinsrnnrnsrnnen 59 5 2 Electrical CONNect ON eeeene ene eer een eet eet en tere torre eee eer er ee
67. cooling circuit by means of two female threads on the rear of the motor The operator can decide on the best method of connecting the inlet and outlet Table 2 7 Technical data relating to water cooling Cooling water connection G3 8 for 1PH813 G1 2 for 1PH816 Cooling water flow 12 I min for 1PH813 15 I min for 1PH816 Max pressure at inlet Max 6 bar Pressure loss between inlet and outlet lt 0 9 bar for minimum cooling water flow with 1PH813 lt 0 2 bar for minimum cooling water flow with 1PH816 Maximum cooling water inlet temperature lt 30 C without derating higher values will result in derating 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 29 Description 2 4 Design 30 Note Cooling water inlet temperature Select the cooling water inlet temperature so that condensation does not form on the surface of the motor Cooling water temperatures that are lower than the ambient temperature tend to result in increased water condensation The difference between the cooling water inlet temperature and the ambient temperature depends on the relative air humidity For instance 50 air humidity at an ambient temperature of 40 C corresponds to a temperature difference of 10K Tcool gt Tambient temperature difference Further you must also shutoff the flow of cooling water when the motor is not operational for prolonged periods of time Only water enriched with ap
68. ct closes If brakes are equipped with a microswitch 27 to control the release status released engaged of the spring applied single disc brake module the microswitch 27 must be tied into the control circuit of the machine e g motor This is crucial to ensure that the microswitch 27 prevents start up of the machine e g motor before the spring applied single disc brake module has been released The optional microswitch 27 must be ordered together with the brake as it cannot be retrofitted to the brake at a later date The microswitch 27 is factory adjusted prior to shipment of the brake module 5 4 Set up and start up A Warning The functional check of the brake must not be performed unless the machine e g motor has been switched off disconnected and secured against accidental or unintentional start up A Attention When using machines e g motors with vertically upward directed shaft end any ingress of fluids water or cooling lubricant into the ball bearing 15 of the brake module must be avoided The brake module must be mounted in such a way that sufficient heat dissipation is ensured A Attention Check that the brake has been connected in accordance with the specifications provided on the rating plate before it is started Even short term operation outside the specified supply voltage limits may cause irreversible damage to the brake or electronic accessories Such damage may not be apparent immediately DC
69. d of the shaft is completely free of any anti corrosion protection use a commercially available solvent e Ensure that the flange or mounting foot has even contact with the mounting surface No stress or strain is permissible e Ifthe motor is installed vertically with the end of the shaft facing up ensure that no liquid can enter into the upper bearing 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 43 Mechanical mounting 4 2 Fixing e Rotate the output elements by hand If you hear any grinding noise rectify the cause or contact the manufacturer e Eyebolts that have been screwed in must either be tightened or removed after installation e Air cooled motors must be installed in such a way that the cooling air can flow in and out without any obstruction and that the minimum distance s is maintained between the air inlet and discharge openings and adjacent components see Minimum distance diagram in Cooling section It is not permissible that the hot air is drawn in again Note Covers attached to the motor e You must remount the covers for air cooled motors which were removed to allow the motors to be secured before commissioning Figure 4 1 Cover for foot mounting at NDE example 4 2 Fixing To ensure smooth vibration free operation the foundation must be designed in accordance with DIN 4024 the motor must be precisely aligned and the components to be mounted on the shaft extension must b
70. dapt the maintenance intervals to match the local conditions such as pollution dirt switching frequency load etc e Carry out the following measures according to what is specified in the table 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Maintenance 8 1 Inspection and maintenance Table 8 1 Operating intervals or periods and measures Operating intervals or periods Measures After 500 operating hours after 6 months at the latest Initial inspection General inspection Approx every 8000 operating hours after 2 years at the latest Without radial shaft sealing ring Approx every 5000 operating hours after 2 years at the latest With radial shaft sealing ring Note the recommended bearing replacement intervals Replace the bearings see Bearing replacement intervals Approx every 5000 operating hours Replace the radial shaft sealing rings Depending on local degree of pollution Clean the fan for forced ventilation cooling systems Maintenance free provided that the required cooling water quality is ensured Cooling water system water cooling 8 1 3 Initial inspection Carry out a first inspection after e installation e 500 operating hours at the latest after 6 months e corrective maintenance of the motor Note Adapt the inspection to the plant specific conditions Further tests are also necessary in line with the component documentation or corresponding to the
71. de protection against accidental contact 3 3 Electromagnetic compatibility As required by the German Electromagnetic Compatibility Act EMVG electromagnetic compatibility must be guaranteed to ensure immunity to external electromagnetic fields and conducted interference Furthermore the emission of electromagnetic fields and line conducted interference during brake operation must be minimized Since the brake features depend on the circuitry and operation a declaration of conformity with the applicable EMC standard can only be furnished for the wiring type but not for a specific brake The spring applied single disc brake modules type 77 500 B are designed for industrial applications to which the following EMC standards apply Generic Immunity Standard EN 61000 6 2 and Generic Emission Standard EN 61000 6 3 EN 61000 6 4 Other applications may be subject to different generic standards which must be considered by the manufacturer of the overall system The requirements in terms of electromagnetic compatibility of devices and components are determined by basic standards derived from the generic standards Brake wiring recommendations will be provided in the following sections to ensure compliance with the individual basic standards that are relevant for industrial use of the brake and some other applications For additional information on electromagnetic compatibility especially with respect to the recommended electronic rectifiers specified
72. diately and must not be restarted until correct operation of the hand release 24 and automatic return of the hand release lever in its central position see Fig 11 1 has been ensured A Caution The brake torque can be neutralized manually by means of an attached hand release 24 Consequently the brake must be mounted in such a way that any unintentional actuation of the hand release 24 e g by removing the hand release lever is excluded E Note Machinery specific regulations and requirements e g for hoists cranes and elevators must be observed when using brakes with hand release 24 Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 14 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions Ekenorion EAN T WE UAGWETISE THE WORLO Ball bearing set ball bearing 15 spring washer 14 circlip 16 The ball bearing set is required as a second bearing for the motor shaft The complete ball bearing set must be installed as described in Section 5 1 1 Rubber bolts 18 size 19 and 24 brakes O ring 26 size 29 brakes To reduce the noise produced by the brake module during operation rubber bolts 18 size 19 and 24 brakes or an O ring 26 size 29 brakes can be installed in the brake shaft 13 as described in Section 1 1 5 3 Electrical connection and operation A Warning
73. dule External SME when operated with SINAMICS 120 The motor is connected to the SMC or the SME via the signal cable The SMC or SME is connected to the Motor Module via a MOTION CONNECT DRIVE CLiQ cable DRIVE CLiQ Signal cable 1 IJ l Sensor Module Cabinet SMC Power cable Control cabinet Figure 5 11 Encoder interface without DRIVE CLIQ 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 69 Connection 5 2 Electrical connection Incremental encoder Absolute encoder IC 2048 S R AM 2048 S R 7 M Encoder SW M Sense P Encoder P Sense 1R2 not connected connected Incremental encoder Incremental encoder IN 256 S R HTL 2048 S R IN 512 S R HTL 1024 S R not connected not connected ay not connected N not connected k 7 M Encoder Z M Sense P Encoder P Sense 1R2 not connected Figure 5 12 Signal connection view of connector pins A suitable socket connector can be used to rotate the angle plug Make sure that the socket connector is completely secure to avoid damaging the pin contacts 5 2 8 Connecting an HTL incremental encoder Encoder connection with terminal block using an additional terminal box Induction motors can be equipped with an additional terminal box This means that you can connect the following HTL incremental encoders for operation with a SINAMICS G via a terminal block e HTL1024 S R and e HTL2048 S R The additional terminal box is shown in
74. e bearing cap e Insert the NDE bearing with shaft spring into the NDE flange keep the bearing straight and tighten the screws e Press on the grease slinger gamma ring housing 9RB without sealing lip with a suitable sleeve dimension x 0 mm flush with cover see figure Installing the gamma ring When disassembling do not reuse damaged grease slingers With the bearing type increased radial forces 14th position of the Article No F the grease slinger must protrude 1 mm over the cover i e dimension x 1 mm E O Qj y N whiz i Figure 8 1 Installing the gamma ring 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 105 Maintenance 8 2 Corrective maintenance Running in the bearings Once you have replaced the bearings allow the rolling contact bearings to run in to distribute the grease evenly When doing so the motors should be initially run continuously from 0 to approx 75 of the maximum speed Nmax over a period of 15 minutes 8 2 2 Removing installing the speed encoder WARNING Uncontrolled motor motion as a result of incorrect adjustment Incorrect adjustment of the encoder regarding motor EMF can lead to uncontrolled motion which can cause personal injury and or material damage e Only change an encoder and adjust it if you are appropriately qualified to do so Note Removing installing the encoder e Unscrew the terminal box cover and disc
75. e carried out and or supervised by qualified personnel with appropriate expert knowledge gt 1 2 You must carefully follow the five safety rules as listed in Chapter Fundamental safety NO oO fF OQ Contact a certified waste disposal organization in your vicinity Clarify what is expected in terms of the quality of dismantling the motor and provision of the components instructions Disconnect all electrical connections Remove all liquids such as oil water Remove all cables Remove the fixing elements from the motor Transport the motor to a suitable location for disassembly Also observe the notes provided in Chapter Maintenance Dismantle the motor using the general motor typical procedures WARNING Danger to life caused by falling machine parts The machine partially comprises heavy individual components When removing the machine these components can fall This can result in death serious injury or material damage Secure the machine components that are being released so that they cannot fall The motors must be disposed of in accordance with national and local regulations as part of the standard recycling process or they can be returned to the manufacturer The encoder electronics must be properly disposed of electronic waste 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 119 Decommissioning and disposal 10 2 Disposal 10 2 Compone
76. e correctly balanced Mounting the motor using its motor feet foot mounting The contact surfaces of the motor feet must lie on one plane 1PH motors in type of construction IMB3 or IMB35 with mounting feet must be mounted on flat surfaces with a planeness specification of lt 0 15 mm If the motor needs to be aligned locate metal shims below the motor feet in order to prevent the motor from being subject to any strain The number of shims should be kept as low as possible i e stack as few as possible 1PH813 1PH816 main motors 44 Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 3 Attaching the output elements Mounting using the motor flange flange mounting Note Flange mounting When the motor is flange mounted this creates a system that is capable of oscillation with specific natural mounting frequencies In operation this can result in excessive vibration To counter this additional support can be provided at the NDE Ensure that the motor is not subject to excessive tension Tightening torques for foot flange mounting Table 4 1 Tightening torques 1PH813 Retaining type Screw Washer ISO 7092 Tightening torque 10 Nm Foot mounting M10 10 d2 18 42 Flange mounting M16 16 d2 28 165 Depending on the installation space corresponding screws must be used Use screws of property class 8 8 or higher Table 4 2 Tightening torques 1PH816 Retaining type
77. e eee eee 60 5 2 1 Cable UU eth thee tad el Scat cca deh ets E E 61 5 2 2 Circ it diagram 232 eres Sak ecs on taiea cscs ehdescosnttatastavicent ssetuntisiedncandvecadec enhas saiesteusieteaseden nscessbease 62 5 2 3 Terminal OX 3253 set ool oss chee ee ase a ea e eee eee 63 5 2 4 Power connector for 1PH813 only eessssseessesresssrrsssirrsstirrssttrrnsttrrsstinnnntennnntnnnnntensnten nnt 66 5 2 5 Electricaliconnection data israr ntact he tia eee eet ret eee a 66 5 2 6 Motors with DRIVE CLIQ interface cece cee ceeene cee ceeeeceseeseeeseesecsaseaeeesnecnsecsasesaenaenas 68 5 2 7 Motors without DRIVE CLIiQ interface 0 0 0 cece cece cetecneeceeeeeeeceeesecaseaeeecneceseesaeeeeesaenas 69 5 2 8 Connecting an HTL incremental encoder cccecccscceeceeeeenecneecseenecnaeesseeesneeeseesaeeseeneenas 70 5 2 9 Connecting the temperature SENSO ccccccccesecseeeecetecneeceeeecaesaeeaeenecaeesaeeseesecsaeeeaeneenas 72 5 2 10 Connecting a grounding conductor in the terminal DOX ssseseesssserssesirssesrrssrerssrrrsserenssrens 72 5 2 11 Connecting the external famers ieena ieee E TEE Lg ee ee 173 5 2 12 Connecting p a Convene soecinnrnatininasnei inaani inaanak aiana in ai kaanak ie 76 5 2 13 Connecting a holding brake Option aessseeeesseessssseernenssnnsseennnsrnnnnntinnannnnnnntannnetnnnnntannaananae 16 5 2 14 Sealing air connection Option Q12 eecceeeeeteeeeeeeneeeeeeeeeeeeeaeeeeeeaeeeeeeaaeeeeeea
78. e leaks in the rotating union and the hoses the motor may be flooded and fail e Avoid leaks in the rotating union Note the following points when mounting the rotating union e Screw the rotating union for the coolant on to the NDE shaft centering of the motor shaft e Screw the thread tightly into the NDE shaft extension so that no coolant can leak e When you mount the rotating union pay attention to special aspects that differ between air cooled and water cooled motors e When installing the rotating union observe the manufacturer s data 1PH813 1PH816 main motors 50 Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Mounting the rotating union for water cooled motors Water cooled motors have a 2 in the 11th position in the Article No With water cooled motors you can mount the rotating union directly on the motor Use rotating unions with radial or axial connections Installation steps gt 1 2 N OD WO If necessary perform complete balancing of the motor using the exterior balancing disks To do this remove the sealing cover Note Sealing cover e Remount the sealing cover after balancing Attach hoses for the inlet and leakage to the rotating union Use angle elements if necessary Screw the rotating union into the NDE motor shaft extension Tighten the rotating union with the correct tighteni
79. e thread absolutely tightly into the NDE shaft extension Ensure that no coolant can leak e Check the rotating union and hoses regularly for tightness 1PH813 1PH816 main motors 56 Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Intermediate housing for air cooled motors 0260 1 200 wo N x is E Cutout for hoses to be made by the customer Motor side Fanside Figure 4 6 Intermediate housing SH132 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 57 58 Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors 0314 200 max 180 Cutout for hoses to be made by the customer Motor side Fanside Figure 4 7 Intermediate housing SH160 225 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Connection 5 5 1 Mechanical connection of water cooling system The inlet and outlet holes for the cooling water supply are located on the NDE in the bearing shield 1 1 Make sure that the cooling water fulfills the required cooling water specification see the 2 chapter titled Cooling 2 Make sure that the appropriate volume of cooling water is available see the rating plate type plate 3 Screw the cooling water pipes into the female thread You can connect the inlet and
80. e torque power must be determined from the following table Ambient temperatures and installation altitudes are rounded off to 5 C and 500 m respectively Table 2 2 Power derating as a function of the installation altitude and ambient temperature Installation altitude above Ambient temperature in C sea level m 30 40 45 50 55 1000 1 00 0 96 0 92 0 87 1500 0 97 0 93 0 89 0 84 2000 0 94 0 90 0 86 0 82 2500 0 90 0 86 0 83 0 78 3000 0 86 0 82 0 79 0 75 3500 0 82 0 79 0 75 0 71 4000 0 77 0 74 0 71 0 67 Note Unsuitable installation locations The motors are not suitable for operation e in salt laden or corrosive atmospheres e outdoors 2 2 4 Degree of protection The motors with forced ventilation 1PH813 or 1PH816 have degree of protection IP55 The water cooled motors 1PH813 or 1PH816 have degree of protection IP65 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 23 Description 2 2 Technical characteristics and ambient conditions 2 2 5 Noise emission When operated in the speed range from 0 to 5000 rpm 1PH813 and 1PH816 motors can reach the following measuring surface sound pressure level Lpa in accordance with DIN EN ISO 1680 Table 2 3 Measuring surface sound pressure level for 1PH813 Cooling method Measuring surface sound pressure level Lpa 1 m at rated load and 4 kHz rated pulse frequency Forced ventilation 70 dB A
81. e with respect to torques torque variations installation positions wear wear reserve switching work break in conditions release range ambient conditions and the like please contact Kendrion Binder and ask for clarification before using the brake Retrofitting or modification work to be carried out on the brake is subject to the approval from Kendrion Binder Accident prevention regulations applying to the specific field of application of the brake must be strictly observed The brakes described in this manual are not designed for use as safety brakes This means that torque reductions caused by factors beyond the user s control cannot be excluded 2 3 1 Installation When connecting the brakes described in these Operating Instructions check that the voltage and voltage type comply with the specifications on the rating plate Sufficient heat dissipation must be ensured when the brake is fitted to or incorporated into other equipment Adequate precautions must be taken to avoid overvoltage during disconnection or voltage peaks The magnetic field of the products may cause interference outside the brake or even feedback to the brake in case of adverse installation conditions Should you have queries concerning mounting and fitting conditions please contact the brake manufacturer and ask for clarification Adequate safety measures DIN VDE 0848 part 4 DIN 31000 VDE 1000 DIN VDE 0100 part 0420 must be taken by the brake user to avoid haz
82. ecsaeeseesecsaseseceeesecsasesseaseneenas 99 8 1 6 Cleaning the motor and fan external fan sseeesssesessseessrnesernneessnnestenneerinnastenneenannaarenneens 101 8 1 7 Replacing an encode esri ateedeesencccdihatcensespuccenesatecued puedenthat gees pcedbespenecelaieeend ate 103 8 2 Corrective MaNteNaANGE sssrinin k eaa a A aa 103 8 2 1 Removing installing the MOtOM cccceeeeeceeeeeeeeeeeeeneeeeeeaaeeeeeeaaeeeeeeaaeeeseeaaeeeeeenaeeeesenaeeeeeaas 105 8 2 2 Removing installing the speed encoder sssseseessssssseseernnsrennsstnnenrnnunntinnnntnnnnnttnnantannnneann 106 8 2 3 Removing installing the toothed wheel encoder ssssssessssrrssesrrssssrrsstirresrtrrssrennnnrennssnnn 109 8 2 4 Replacing the DRIVE CLiQ interface encoder module 0 00 0 ee ceceeeeeeeeeeeeeeeeeeetteeeeeeneeeeeeas 112 8 2 5 Tightening torque for screwed CONNECTIONS ee eeeeeceeeteeeeeeeeeeeceeeaeeeeeeeaeeeseeaaeeeeeenaeeeeeenaes 113 8 2 6 Removing mounting a holding brake Option cccceeeeeeeeeeeeeeeeeeeeneeeeeeseaeeeeesaeeeerenaeeeeeeaa 113 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Table of contents Operating Instructions 01 2015 610 48006 40c 9 Spare Palit sci ona nin ons isis on ier onan wanna 115 10 Decommissioning and disposal cccccsssececeeeeeeeeeseeeeeeeeeeeeeasseeeeeeessseeaassseeeeeesseeaaaseseeeesssssaaaneeeeees 119 10 1 DSCOMMISSIONIIAG cc EEEE A AE 119 10 2
83. ed e Only check the insulation resistance if you are appropriately qualified to do this e Before measuring the insulation resistance read the manual for the insulation resistance meter you are going to use e Never touch the terminals when making measurements or immediately after the measurement e Check the connected supply feeder cables to ensure that the line supply voltage cannot be connected Always measure the insulation resistance of the winding to the motor enclosure when the winding temperature is between 20 and 30 C When performing the measurement wait until the final resistance value is reached this takes approx one minute 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 85 Commissioning 6 3 Checking the insulation resistance Limits The table below specifies the measuring circuit voltage as well as the limit values for the minimum insulation resistance and the critical insulation resistance with a rated motor voltage of Un lt 2 kV Table 6 8 Stator winding insulation resistance at 25 C Rated voltage Un lt 2 kV Measurement voltage 500 V at least 100 V time Minimum insulation resistance with new cleaned or repaired 10 MQ windings Critical specific insulation resistance after a long operating 0 5 MO kKV Note the following e Dry new windings have an insulation resistance of between 100 and 2000 MQ sometimes higher I
84. ed on all poles wait for five minutes before touching the device Allow the motor and external cooling unit to cool down To clean the fan blades remove the guard from the cooling unit The motor remains attached to the guard If at all possible lock the fan blades so that they cannot rotate 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 101 Maintenance 8 1 Inspection and maintenance Cleaning Awarnine Danger to life due to risk of explosion caused by solvents When using solvents vapors are released which can explode if they come into contact with a source of ignition The explosion can cause death or severe injury e Remove or extinguish all sources of ignition e Only use tools where sparking can be completely ruled out e Ensure good ventilation caution Risk of injury through contact with cleaning agents and solvents Contact with cleaning agents and solvents can cause chemical burns and irritate the skin and mucous membranes e Carefully observe all of the safety and application notes provided on the packaging of the cleaning agents and solvents e Ensure that any vapors that are released are drawn out and that the work area is well ventilated e Use the appropriate personnel protection equipment e g protective eyewear gloves respiration filter NOTICE Damaged fan blades as a result of excessive force Fan blades can be damaged if subject t
85. ed wheel encoder 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 111 Maintenance 8 2 Corrective maintenance 8 2 4 112 Replacing the DRIVE CLiQ interface encoder module WARNING Danger to life when using an incorrect encoder module The DRIVE CLiQ encoder contains motor and encoder specific data and an electronic type plate If you use an incorrect DRIVE CLiQ encoder this can result in death severe injury and severe material damage e Only use the DRIVE CLiQ encoder and the electronic type plate for the original motor e Do not mount the DRIVE CLiQ encoder onto other motors e Do not replace a DRIVE CLiQ encoder by a DRIVE CLiQ encoder belonging to another motor e Only appropriately trained Siemens service personnel should replace DRIVE CLiQ encoders NOTICE Electrostatic discharge Electronic modules contain components that can be destroyed by electrostatic discharge These modules can be easily destroyed if they are not handled properly e To protect your equipment against damage follow the instructions given in the chapter ESD Guidelines 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 8 2 5 Tightening torque for screwed connections For screwed connections with metal contact surfaces e g bearing end shields active Maintenance 8 2 Corrective maintenance bearing components or terminal box parts screwed onto the stator
86. eeeeeecaeeeeeeaas 76 C mmissIoniINI raaa E 79 6 1 Safety instructions for COMMISSIONING s ssssessshssrstttttirtnttnttttntnrt nt nntnt ntan tnnn rtnn anneanne enen 79 6 2 Checklists for COMM ISS ONINg s nssnsenesnsenssintissirenssinnnstnesnnninsinninsinntnsrnnnnnnnnnnnnnnsnnennnennen en 82 6 3 Checking the insulation resistance sssesssseeesnerstststrtrtntirtttsnsnntnnrnnnnt rnnr nn nnnnnnnn nnne nenea 85 6 4 Switching on and switching off snsssssnssnneissinenssinsnnsrnntnnninsnnninsinnnnsrnntnnnnnnnnnnnnnnnnnnrnnen nee 87 6 5 7 os als eee een E E E E 88 Operati essri senna ine een eI a 89 7 1 FE UINS E A Fen ina Shae wc sat E E N EAA 90 7 2 Non op rational PONMOUS seici6c5sicatcsisieasscaeiciaiigeienoiat aacitielaindeerchsd abana daaslace eee 93 Mainta nN Ce siere a suns EEEE EEEE ie sessile dui cvcnbeddunedsilvi sedate dunitedusudedsuiedauniedcusn E KEER EEE 95 8 1 INSPECTION ANG MaiMtenant Eisessig si nainii Kuara EAEE Aei REEE Eia 96 8 1 1 General inspection guidelines s ssesrsnstssistrtistnttttt inent ntan nnnart nt innnn ntan tnnn rnanan nn aneneen 96 8 1 2 Maintenance and inspection intervals ccccccccccesecsseeeeesecsseeseeecnaecseenecnsecseseeeeseeasessenes 96 8 1 3 MitalinspEctom scree a E E E aE 97 8 1 4 General INSPCCUOM a iiiar eiserne aen EAEE paee OSE EEUE EEOSE ERTE pR ENEE ENERE 98 8 1 5 Bearing replacement intervals ccceccccccseesecsecseeeecnseceeeeees
87. eplacement intervals tlw are reduced by up to 50 Difficult operating conditions include for example e continuous operation with nmax e high vibration and surge loads e frequent reversing operation Table 8 2 Bearing version maximum speeds and bearing replacement intervals Shaft height Bearing version Maximum Average operating Statistical Recommended bearing speed speed bearing replacement interval Nmax Nm lifetime tuw h rom rom a Permanent Relubrication lubrication 132 Standard with 8000 lt 6500 20000 20000 locating bearing Standard 8000 lt 4500 20000 20000 Performance 10000 lt 8500 12000 12000 High Performance 15000 lt 10000 12000 12000 Advanced Lifetime 4500 lt 2500 40000 40000 Increased radial 6500 lt 1800 20000 20000 forces 160 Standard with 6500 lt 5400 20000 20000 locating bearing Standard 6500 lt 3500 20000 20000 Performance 9000 lt 7000 12000 12000 High Performance 10000 lt 8000 12000 12000 Advanced Lifetime 4000 lt 2300 40000 40000 Increased radial 5300 lt 1500 16000 16000 forces Calculating the average speed _ mt Naty Nn tj 100 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 99 Maintenance 8 1 Inspection and maintenance Table 8 3 Recommended bearing replacement intervals at maximum speed Shaft height Beari
88. ervoltage during disconnection is 1500 V If Kendrion Binder rectifiers are used see Table 16 1 the protective circuit required for the built in electronic components and field coil 1 2 is included in the rectifier and limits the disconnection voltage to approx 300 V This also applies to contacts S1 and S2 DC side disconnection AN Us operating voltage coil voltage Attention Uvmax disconnection voltage In case of DC side switching and connection to a DC power source the brake must be operated with a protective circuit to avoid overvoltage Additional protective elements e g varistors spark arresters etc must be installed to avoid damage such as burns or fusing of contacts A Attention Sensitive electronic components e g logical components may also be damaged by the lower voltage 5 3 2 AC power supply A Warning Work on the brake must only be carried out by qualified specialist personnel Make sure that no voltage is applied during brake connection The specifications on the rating plate and the information provided in the circuit diagram in the terminal box or in the Operating Instructions must be strictly observed Direct connection of the spring applied single disc brake to an AC power source is only possible if a rectifier is used The coupling times vary depending on the switching type DC side switching or AC side switching see Section 5 3 Half wave rectification In case of half wave rectification
89. es can also be determined on the basis of the current flow see Fig 28 1 Current i Brake Voltage U released Un lio i to i tes i t gt i 5 tio f gt Fig 28 1 Definition of switching times for static holding operation Definitions k opening time open ta closing time close too activation time brake mechanically open brake mechanically closed brake mechanically closed and full holding torque reached almost completely 12 Technical specifications 13 19 24 29 Rated air gap s mm 0 3 0 35 0 47078 0 45 5 Max air gap Smax at 70 of rated current mm 0 65 0 8 1 05 12 Table 28 1 Air gap Snom and Smax Size 13 19 24 29 Speed n rpm 250 125 125 125 Coil ON time ts s 6 6 6 Coil OFF time ts s 1 1 1 1 Break in period tto min 3 3 3 3 Table 28 2 Break in process parameters for the spring applied single disc brake module Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 28 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions RKENDRION Technical specifications 250 VAC 5A Switching capacity 400 VAC 1 5A 24 VAC 2A Min switching power 12 VDC 10 mA Mech service life switching operations 5x10 Contact type normally open contact Temperature range C 40 to 130 Protection IP 67 Table 29 1 M
90. ews 10 in the flange 3 to the tightening torques specified in Table 22 1 o i wz Before removing the brake module from the motor cautiously remove all components still fitted to the brake shaft 13 such as gear feather key etc Loosen the fixing screws to allow the brake to be removed 1 After having removed the fixing screws the brake module can be pulled off the motor shaft by means of a withdrawal device This device must be applied to the fixing corners on the output side flange of the solenoid housing 1 1 and supported on the front face of the brake shaft 13 2 To avoid damage to the centring bore in the brake shaft 13 a shim ring can be inserted under the withdrawal device i Substantial forces may have to be applied as the ball bearing 15 needs to be pulled off together with the brake module Extreme caution is advised during these operations If the brake module is in a horizontal position when removing it from the motor shaft the brake must be supported in radial direction Ball bearings 15 must not be reused after removal regardless of their service life 1 If individual components of the brake module need to be replaced loosen the set screw 25 and unscrew the adjusting ring 9 to unload the compression springs 7 2 Unscrew the cheese head screws 10 so that the flange 3 and all other components can be removed 3 Use only grease free cleaning agents to clean the brake components when necessar
91. f the insulation resistance is close to the minimum value this could be due to humidity and or an accumulation of dirt e 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 MO kV Example Critical resistance for a rated voltage Vn of 0 6 kV 0 6 kV x 0 5 MO KV 0 3 MO Note Cleaning and or drying the windings when reaching critical insulation resistance If the critical insulation resistance is less than or equal to this value the windings must be dried or if the fan is removed cleaned thoroughly and dried Note that the insulation resistance of dried clean windings is lower than that of warm windings The insulation resistance can only be evaluated accurately when measured on a winding that has been cooled down to room temperature approx 20 to 30 C Note Measured value close to critical value If the measured value is close to the critical value the insulation resistance should be subsequently checked at suitably regular intervals Values apply for measurement at a winding temperature of 25 C 1PH813 1PH816 main motors 86 Operating Instructions 01 2015 610 48006 40c Commissioning 6 4 Switching on and switching off 6 4 Sw
92. ft the tangential torque arm should be applied to the square socket size 13 19 24 brakes or to the external teeth of the brake shaft 13 size 29 brakes The technical specifications applicable to the brake shaft 13 removal are given in Table 25 1 Ey Note Pressure oil type LHDF900 with a viscosity of 900 mm s at 20 C supplied by SKF can be used for instance SAZI ps mw LALLZZZLZZZZZ tl LA eA f PAOA Key to Fig 24 1 13 Brake shaft Li Forcing pin 35 length 17 1 Oilinlet bore L2 Forcing screw 37 thread length 35 Forcing pin D Shaft end diameter motor 36 Oil pump S Forcing pin 35 diameter 37 Forcing screw M Forcing screw 37 thread diameter L Shaft end length motor Ma Forcing screw 37 loosening torque Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 24 1PH813 1PH816 main motors 148 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions Ekenorion Size 13 19 24 29 Motor shaft height AH 80 AH 100 AH 132 AH 160 Oil inlet bore screw in depth t mm M6 7 5 M6 8 Rp1 8 9 5 Rp1 8 10 Oil pressure Pmax bar 1400 1400 1400 1400 Forcing pin 35 length L mm 124 124 160 170 Forcing screw 37 thread length L2 mm 130 130 170 170 Forcing pin 35 diameter S mm 9 8 9 8 13 17 Forcing screw 37 thread diameter M mm 12 12 16 20 Forcing screw tightening torque Ma Nm 15 35 60 90 Oil pump
93. g union Depending on the type of rotating unions the sealing rings may be permanently or temporarily in contact Example of a closed seal DEUBLIN series 1116 and 1108 Example of an opening seal DEUBLIN series 902 and 1109 With opening seals the sealing surfaces are separated when there is no coolant pressure e g during a tool change In this case coolant runs out of the supply line and out of the motor shaft through the opened seal This leakage and also the leakage from the wear of the sealing rings must be led away via the leakage lines NOTICE Motor failure due to incorrectly mounted leakage line If the leakage line does not lead downward the leakage can flood the rotating union and the motor This can result in failure of the rotating union and motor To ensure the leakage is led away the leakage line must always lead downward so that nothing can flow back e When mounting ensure that the leakage line always leads downward Hollow shaft version Table 4 5 Hollow shaft version 1PH8130 1PH8160 Thread on DE M16 x 1 5 RH Centering on DE 20H7 Thread on NDE M16 x 1 5 LH Centering on NDE 18 0 007 0 003 Through hole 11 5 Key surface NDE SW27 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 49 Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors 4 5 2 Mounting NOTICE Leaks in the rotating union If there ar
94. ge ambient conditions and the like please contact Kendrion Binder and ask for clarification before starting to use the brake Kendrion Binder spring applied single disc brake modules type 77 500 B are not ready to use devices but are intended to be incorporated into or assembled with other equipment Consequently these brakes will be referred to as components in the following sections The output side of the spring applied single disc brake modules has the same fitting dimensions as the motor end shield As a result the brakes are designed as fail safe holding brakes with emergency stop function for attachment to electric motors 1 2 Standards and directives The state of the art spring applied brakes have been designed built and tested in accordance with the requirements of DIN VDE 0580 concerning electromagnetic devices and components Being classified as electromagnetic components spring applied single disc brake modules are not subject to the Low Voltage Directive and must not bear a CE mark of conformity The user is required to employ suitable switching devices and controls to ensure use of the brakes in accordance with EMC Directive 2004 108 EC 1 3 Manufacturer s liability The manufacturer will not assume any responsibility for damage caused by failure to use the products in accordance with their intended use or by failure to observe safety information and other instructions provided in this manual The information in this manual
95. ger many times over than interference fields the brake function will remain unaffected The spring applied single disc brake modules comply at least with severity level 4 The recommended rectifiers conform at least to severity level 3 EN 61000 4 11 Voltage dips short interruptions and short supply voltage variations a Voltage interruptions Spring applied single disc brake modules that comply with the requirements of DIN VDE 0580 are de energized after the specified switching times at the latest The switching time depends on the control and mains conditions e g generator effect of running down motors Voltage interruptions of shorter duration than the response delay specified by DIN VDE 0580 will not cause any malfunctions The user must ensure that any consequential damage is avoided e g motor start up before the brake has been released caused by phase failure in the case of two phase energized motors or by the slipping of an electromagnetically engaged system due to torque drop The functional reliability of the electromagnetic brake and its electronic accessories remains unaffected provided that the aforementioned consequential damage is avoided b Voltage dips and short supply voltage variations Electromagnetically released systems Voltage dips and supply voltage variations to below 60 of the rated voltage and lasting longer than the response delay specified by DIN VDE 0580 may cause the brake to be de energized temporarily Conse
96. hest degree of danger will be used A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage Qualified Personnel The product system described in this documentation may be operated only 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 Trademarks 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 these must be recommended or approved by Siemens Proper transport storage installation assembly commissioning operation and maintenance are required to ensure that the products operate safely and without any problems The permissible ambient conditions must be complied with The information in the relevant documentation must be observed All names identified by are registered trademarks of Siemens AG The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner Disclaimer of Liability We have reviewed
97. housing the following tightening torques apply depending on the thread size with a tolerance of 10 property class 8 8 and 8 or higher to DIN ISO 898 Table 8 4 Tightening torque for screwed connections Thread diameter M4 M5 M6 M8 M10 M12 M16 Tightening torque Nm 3 5 9 24 42 70 165 Bolt locking devices Nuts or bolts that are mounted together with locking resilient and or force distributing elements e g safety plates spring lock washers etc must be refitted together with identical fully functional elements Always renew keyed elements 8 2 6 Removing mounting a holding brake option Removing mounting a holding brake option is described in the Appendix Holding brake operating instructions 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 113 Maintenance 8 2 Corrective maintenance 1PH813 1PH816 main motors 114 Operating Instructions 01 2015 610 48006 40c Spare parts 9 Note The diagram provided is merely intended as an example of the different motor versions and does not detail every aspect of the different versions The spare parts are available from our Service Centers in parts kits and can be ordered by specifying the motor designation Spares on Web provides a quick and uncomplicated way for you to determine the article numbers of standard spare parts and parts kits for motors Si
98. ich Germany Commercial registries Berlin Charlottenburg HRB 12300 Munich HRB 6664 WEEE Reg No DE 23691322 Operating Instructions 01 2015 610 48006 40c 123 Appendix A 2 Note regarding a holding brake A 2 Note regarding a holding brake Depending on what has been ordered a holding brake can be mounted on the motor Note UL certification The holding brakes are not UL approved Motors with mounted brake therefore do not have the CUR marking Notes on operation are provided in the operating instructions provided Note Maintenance and corrective maintenance Maintenance and corrective maintenance must only be carried out by personnel that have been appropriately authorized by Siemens See also Properties Page 32 Holding brake operating instructions Page 125 1PH813 1PH816 main motors 124 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions A 3 Holding brake operating instructions KENDRION INDUSTRIAL DRIVE SYSTEMS WE MAGNETISE THE WORLD MODULE LINE Operating Instructions 77 500 B Spring applied single disc brake module Types 77 50013B16 77 50019B15 77 50024B15 77 50029B15 BINDER 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 125 Appendix A 3 Holding brake operating instructions RKENDRION WE MACHETISE THE WORLD Contents 4 General information sccsesseseessseeees 1 1 Introduction s 1 2
99. icroswitch specifications The required operating conditions specified in DIN VDE 0580 must be observed during operation of the spring applied single disc brake module Specifications subject to change without notice 13 Revision history Date of issue Modifications Issue dated 12 December 2013 Text revisions on page 16 and 17 Issue dated 2 July 2012 initial issue Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 29 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 153 Appendix A 3 Holding brake operating instructions 154 PRENDRION h u WE MAGNETISE THE WORLD Kendrion Villingen GmbH Industrial Drive Systems Wilhelm Binder Stra e 4 6 78048 Villingen Schwenningen Tel 49 7721 877 1417 Fax 49 7721 877 1462 www kendrion com sales ids kendrion com INDUSTRIAL DRIVE SYSTEMS 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Index A Ambient conditions 23 Area of application 21 B Bearing replacement intervals 99 C Circuit diagram 62_ Cleaning 96 Commissioning 82 Connecting the temperature sensor 72 Connection 59 Corrective maintenance 104 D Declaration of conformity 123 Degree of protection 23 F Faults 91 Flange mounting 45_ Foot mounting 44 Forced ventilation 28 G Gamma ring 105 H Holding brake option Connecting 76 Mounting 36
100. ielded cable ends as short as possible e Establish the connection through a larger surface area so that high frequency currents are suitably discharged Establish a 360 connection at the converter and at the motor for instance using EMC cable glands at the cable entries 5 2 13 Connecting a holding brake option Electrically connecting a holding brake option is described in the Appendix Holding brake operating instructions See also Holding brake operating instructions Page 125 Note regarding a holding brake Page 124 5 2 14 Sealing air connection option Q12 Cooling lubricants containing oil with creepage which can also be aggressive are mainly used for machine tools and transfer machines For critical applications involving media with extremely high creepage rates generally degree of protection against water according to EN 60034 5 IEC 60034 5 is not sufficient To address these particular applications 1PH8 main motors can be ordered with sealing air connection by specifying option Q12 Note Improved protection against oils and media that can creep You do not increase the IP degree of protection against water with sealing air However you improve the protection against oils and media that can creep 1PH813 1PH816 main motors 76 Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection Hose Connection nipple inner diameter 2 5 mm e g Festo QSM B M5 4 20 outer diameter 4 mm Tigh
101. in Section 5 3 please refer to the applicable data sheets Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 7 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 131 Appendix A 3 Holding brake operating instructions PKENDRION INDUSTRIA WE MACHETISE THE WORLD Immunity according to EN 61000 4 EN 61000 4 2 Electrostatic discharge The spring applied single disc brake modules comply at least with severity level 3 without requiring additional measures The recommended rectifiers specified in Section 5 3 conform to severity level 3 without additional measures EN 61000 4 3 Electromagnetic fields The spring applied single disc brake modules comply at least with severity level 3 without requiring additional measures The recommended rectifiers conform to severity level 3 without additional measures EN 61000 4 4 Fast transients burst The spring applied single disc brake modules comply at least with severity level 3 without requiring additional measures The recommended rectifiers conform to severity level 3 EN 61000 4 5 Surge The spring applied single disc brake modules comply at least with severity level 3 without requiring additional measures The recommended rectifiers conform to severity level 3 EN 61000 4 9 Pulse magnetic fields EN 61000 4 10 Damped oscillatory magnetic fields Since the operating magnetic fields of the electromagnetic brakes are stron
102. in the friction disc with the brake shaft 13 with the brake shaft being rigidly connected with the motor shaft This applies to size 13 19 and 24 brakes When a size 29 brake is used the friction disc is connected with the brake shaft by means of the teeth provided on the disc and shaft The ball bearing 15 located between the solenoid housing 1 1 and brake shaft 13 ensures that the brake can be centred relative to the brake shaft 13 and motor shaft when it is mounted to the motor flange The bearing also absorbs transverse forces that act radially on the brake shaft 13 The ball bearing is factory sealed An additional sealing ring 6 is provided which protects the friction disc 4 against dirt grease or oil ingress in case the factory installed ball bearing sealing rings are damaged and ensures that abrasive grit and dust produced by the friction disc cannot escape On the drive side the flange 3 and brake shaft 13 are sealed by the sealing ring 11 The optional hand release 24 allows the spring applied single disc brake module to be released manually e g in case of power failure The brake must be connected directly to the terminals in the connector box 19 The transmissible torque of the brake module can be changed with the adjusting ring 9 Rubber bolts 18 and an O ring 26 are provided to reduce the noise and vibration produced by the friction disc 4 Key to Fig 11 1 1 Solenoid housing 15 Ball bearing 1 2
103. inal box 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 65 Connection 5 2 Electrical connection 5 2 4 Power connector for 1PH813 only e Use connector size 3 e Assign the connector as shown in the Power connector diagram Connect the protective conductor Connector size 3 V Figure 5 8 Power connector view of connector pins 5 2 5 Electrical connection data Table 5 2 1PH8 motors shaft height 132 Terminal Cable entry Cable entry Max external Number of main Max cross Max cur box type power external signals cable diameter 2 terminals section per rent per terminal terminal 3 gk833 1x M40 x 1 5 1 x M16 x 1 51 32 mm Phases 3 x M6 1 x 35 mm 110A Grounding 2 x M6 gk843 1 x M50 x 1 5 1 x M16 x 1 51 38 mm Phases 3 x M6 1 x 50 mm 133 A Grounding 2 x M6 gk846 1x M50 x 1 5 1x M16 x 1 51 38 mm Phases 6 x M6 1 x 25 mm 88 A Grounding 2 x M6 1 Thread M16 x 1 5 arranged with 90 to signal connection thread only for options A12 A25 and encoder version A without encoder 2 Depending on design of metric cable gland 3 Current carrying capacity based on EN 60204 1 and IEC 60364 5 52 routing type E 1PH813 1PH816 main motors 66 Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection Table 5 3 1PH8 motors shaft height 160 Terminal Cable entry Cable entry Max external Number of main Max cross
104. ion L170 Rated speed nn 2 L330 Anti condensation heating L180 Operating mode 2 L335 Weight L190 Rated voltage Un 3 L191 Connection method 3 L200 Rated current In 3 1PH813 1PH816 main motors 26 Operating Instructions 01 2015 610 48006 40c Description 2 4 Design 2 4 Design 2 4 1 Types of construction The motor can have the following types of construction Table 2 6 Types of construction Motor Types of construction 1PH813 IM B3 IM V5 IM V6 IM B6 IM B7 IM B8 IM B5 IM V1 IM V3 IM B35 IM V15 IM V35 1PH816 IM B3 IM V5 IM V6 IM B6 IM B7 IM B8 IM B5 IM V1 IM V3 IM B35 IM V15 IM V35 IM B3 IM V5 IM V6 IM B5 IM V1 IM V3 IM V15 M V35 Figure 2 2 Types of construction Two lifting eyebolts which can be screwed onto the motor in accordance with its type of construction are supplied with the motor for transportation purposes 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 27 Description 2 4 Design 2 4 2 Cooling Forced ventilation 28 This cooling method is realized using a separate ventilation module equipped with a fan external fan that operates independently of the motor NOTICE Risk of overheating if external cooling is inadequate If the external fan fails or the motor is operated for a short time without forced ventilation this can cause it to overheat Overheating can cause failu
105. ion it may no longer be possible to release the spring applied single disc brake when the maximum air gap Smax See Table 28 1 air gap Snom ANd Smax has been exceeded In this case the braking effect cannot be neutralized This may cause thermal overloading of and irreversible damage to the brake module if the machine e g motor is started before the brake has been released Thermal overloading of the machine e g motor may occur if the machine e g motor is not started while the brake is still engaged 1 The spring applied single disc brake module does not require any particular maintenance except that the air gap s see Table 28 1 air gap Snom ANd Smax and the degree of wear of the friction disc 4 must be measured at regular intervals 2 For this purpose the brake must be released electromagnetically during motor standstill to allow the air gap s between the armature 2 and friction disc 4 to be measured through the threaded bore 1 3 by means of a feeler gauge The air gap can only be measured after having removed the cover 23 or when using brakes with hand release after having removed the hand release lever 24 2 and complete cam assembly 24 1 see Fig 14 1 3 If the maximum air gap Smax See Table 28 1 is reached the friction disc 4 must be replaced to ensure functional reliability and safety of the brake When replacing the friction disc 4 check the friction surfaces of the armature 2 and flange 3
106. ion resistance of windings lies in the permissible tolerance range e any bearing insulation is fitted in accordance with the labeling e cables and insulating parts and components are in a good condition and are not discolored e the permissible radial forces cantilever forces of the roller bearings are complied with Note The permissible radial forces are listed in Catalog NC 62 PM21 and in the Configuration Manual SIMOTICS M 1PH8 main motors NOTICE Machine damage when ignoring abnormalities identified during the inspection Abnormalities identified during inspection that are subsequently ignored can result in machine damage e Analyze and remove any abnormalities identified taking into consideration Chapters Faults and Maintenance e Contact the Siemens Service Center if you require any support 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Maintenance 8 1 Inspection and maintenance 8 1 5 Bearing replacement intervals The bearings are subject to wear and must be replaced after a defined number of operating hours The recommended bearing replacement intervals tw are listed in the following table Bearing replacement intervals can be extended if the motor is operated under favorable conditions e g low or medium speeds low radial forces cantilever forces vibration load Note Difficult operating conditions Under difficult operating conditions the bearing r
107. ircumstances the rotor may have to be balanced completely with the output element To ensure problem free operation and a long service life the vibration values specified to ISO 10816 must not be exceeded at the defined measuring points on the motor Table 4 3 Max permissible radial vibration values Vibration frequency Vibration values lt 6 3 Hz Vibration displacement s lt 0 16 mm 6 3 250 Hz Vibration velocity Vrms lt 4 5 mm s gt 250 Hz Vibration acceleration a lt 10 m s2 1 Both values must be maintained simultaneously Table 4 4 Max permissible axial vibration values Vibration velocity Vibration acceleration Vrms 4 5 mm s Apeak 2 25 m s2 1 Both values must be maintained simultaneously 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 47 Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors 4 5 4 5 1 48 Figure 4 3 Max permissible vibration velocity taking into account the vibration displacement and vibration acceleration To measure the vibration velocity the measuring equipment must fulfill the requirements of ISO 2954 The vibration acceleration must be measured as a peak value in the time range in a frequency band of 10 to 2000 Hz If appreciable vibration excitation in excess of 2000 Hz e g gear teeth meshing frequencies
108. itching on and switching off Note EMERGENCY OFF To avoid accidents inform yourself about the EMERGENCY OFF function before you switch on the system The motor is switched on and off using the converter e Read about this topic in the converter operating instructions Before switching on e Ensure that the converter is correctly parameterized e Use the appropriate commissioning tools e g Drive ES or STARTER e Switch on the cooling system gt 1 Switching on 2 1 Switch on the motor at the converter Observe any uneven running and abnormal noise of the motor 2 3 Check the function of the motor cooling system 4 Check the function of the safety equipment 5 Check as to whether the motor reaches the required parameters Switching off e Switch off the motor at the converter fl The motor has been commissioned 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 87 Commissioning 6 5 Cooling 6 5 Cooling Water cooling The motor must always be connected to the cooling water supply when in operation Awarnine Danger to life when the cooling system bursts The motor will overheat if it is operated without cooling When cooling water enters the hot motor this immediately and suddenly generates hot steam that escapes under high pressure This can cause the cooling water system to burst resulting in death severe injury and material damage e Never operate the motor w
109. ithout cooling e Only commission the cooling water circuit when the motor is in a cool condition NOTICE Overheating because there is no cooling water If the cooling water supply fails or the motor is operated for a short time without cooling water this can cause it to overheat This can result in material damage or destroy the motor completely e Never operate the motor without the cooling water supply Monitor the permissible water inlet temperatures Forced ventilation Steps must be taken to ensure that the motor is only operated in conjunction with the external fan NOTICE Risk of overheating if external cooling is inadequate If the external fan fails or the motor is operated for a short time without forced ventilation this can cause it to overheat Overheating can cause failures and shorten the service life of devices systems e Always operate the motor together with an external fan 1PH813 1PH816 main motors 88 Operating Instructions 01 2015 610 48006 40c Operation F Note EMERGENCY OFF To avoid accidents inform yourself about the EMERGENCY OFF function before you switch on the system Switching on WARNING Danger to life caused by the machine moving and loose objects Machine movement and loose objects which can fall or are flung out can cause severe injury e Ensure that the machine has been completely installed and all of the setting work completed
110. king torque and rated voltage 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Description 2 4 Design Use for the intended purpose Spring applied single disk brake modules are for mounting on induction or synchronous motors and intended for use in commercial or industrial systems It is prohibited to use the brake in hazardous areas and zones or areas with firedamp The externally mounted spring applied single disk brake electromagnetically released system is designed as a holding brake Occasional emergency stop operations are possible Awarnine Danger to life when incorrectly using the holding brake If you incorrectly use the holding brake e g you use it as safety brake this can lead to severe accidents with personal injury and or material damage e Depending on the particular application observe the corresponding accident prevention regulations NOTICE Irreversible reduction of the braking effect The braking effect can be irreversibly reduced if you do not observe the permissible number of braking operations per hour and or the maximum permissible operating energy per hour Further this can have a negative impact on the function of the holding brake e When setting up machines and systems when using the jog mode observe the information provided in the Table Technical data of holding brakes e The holding brake can be equipped with a manual release to remove the holding t
111. l with the field coil 1 2 limits the peak voltage to the values specified in Table 9 2 B Note If the brake is used in connection with other electronic accessories the user is responsible to ensure compliance with EMC requirements Compliance with applicable standards concerning the design and operation of components sub assemblies or equipment employed shall not relieve the user and manufacturer of the overall system from their obligation to furnish proof of conformity of the overall system with such standards i Rated input voltage range DC at L load Capacitor Rectifier type U VAC 40 60 Hz ADC nFIVAC no additional a rya fier up to 500 810 up to 2 0 interference suppression measures required Table 9 1 Max rectifier operating voltage Recommended disconnection voltage for DC side switching Table 9 2 Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 9 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 133 Appendix A 3 Holding brake operating instructions 134 RKeENDRION INDUSTRIAL DRIVE SYSTEMS 4 1 Operating principle The brake module is an electromagnetic component with built in electromagnetically released spring applied single disc brake designed to operate dry The braking effect is produced by the spring force and neutralized electromagnetically The brake module with ball bearing supported brake shaft should preferably be moun
112. limit values applicable to Class A equipment Interference suppression capacitors should be used which must be dimensioned to suit the connection data of the electromagnetic components and the specific mains conditions The recommended rectifiers specified in Section 5 3 are CE mark certified in accordance with the EMC Directive They have built in interference suppression components and comply at least with the requirements of EN 55011 for Class A equipment unless otherwise specified in the specification sheets When brakes are used with the specified rectifiers or with other types of rectifiers the recommended values listed in Table 9 1 should be observed Interference suppression components should be installed as close as possible to the consumer Interference caused during switching operations of the electromagnetic component is generally attributable to the inductive load Where necessary assemblies designed to limit the disconnection voltage e g anti parallel diode or voltage limiting components e g varistors suppressor diodes resistance diodes and the like can be installed However such components will inevitably change the switching times of the brake and increase the generated noise level The rectifiers specified in Section 5 3 are equipped with free wheel diodes and or varistors to limit the disconnection voltage In case of DC side switching a varistor rated for the type specific maximum operating voltage and connected in paralle
113. ll find the following text features Operating instructions Operating instructions with the specified sequence are designated using the following symbols The arrow indicates the start of the operating instructions The individual handling steps are numbered 1 Execute the operating instructions in the specified sequence The square indicates the end of the operating instruction Operating instructions without a specified sequence are identified using a bullet point e Execute the operating instructions Enumerations e Enumerations are identified by a bullet point without any additional symbols Enumerations at the second level are hyphenated 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Introduction Notes Notes are shown as follows Note A Note is an important item of information about the product handling of the product or the relevant section of the document Notes provide you with help or further suggestions ideas Target group These operating instructions are intended for electricians fitters service technicians and warehouse personnel Training The following link provides information on SITRAIN training from Siemens for products systems and automation engineering solutions http siemens com sitrain Technical Support Country specific telephone numbers for technical support are provided on the Internet under Contact https support industry siemens com
114. missioning 6 2 Checklists for commissioning 6 2 82 Checklists for commissioning Note Checks that are required This list below does not claim to be complete It may be necessary to perform additional checks and tests in accordance with the situation specific to the particular installation site e Before commissioning the system check that it is properly installed and connected e Commission the drive system corresponding to the operating instructions of the converter or inverter e Thoroughly familiarize yourself with the safety instructions and observe the checklists below before starting any work Table 6 1 Checklist 1 general checks Check OK Are all of the necessary components of the configured drive line up available correctly dimensioned installed and connected Are the manufacturer s documentation for the system components e g drive system encoder cooling system brake and the SIMOTICS M 1PH8 main motors Configuration Manual available If the 1PH8 motor is to be fed from a SINAMICS S120 drive system Is the following current SINAMICS documentation available e SINAMICS 120 Commissioning Manual e Getting Started 120 e 120 Function Manual e 120 150 List Manual If the 1PH8 motor is to be fed from a SINAMICS S120 drive system Was the Chapter Checklists for commissioning SINAMICS S in the SINAMICS 120 Commissioning Manual carefully observed Is the motor type to
115. mply enter the the article number machine type and serial number at www siemens com sow 1 00 6 00 7 00 1PH813 1PH816 main motors DE bearing assembly complete 1 01 Bearing cap 1 02 Screw 1 03 USIT washer 1 04 O ring 1 05 Cover 1 06 Grease slinger 1 07 Roller bearings 1 08 Screw NDE bearing assembly complete 6 02 Roller bearings 6 03 Screw 6 04 O ring 6 05 O ring bearing 6 06 Distance piece 6 07 Corrugated spring Fan module complete 7 01 Fan motor 7 02 Screw Shaft sealing ring shaft sealing ring rotor sleeve not in diagram Replacement parts example Operating Instructions 01 2015 610 48006 40c 115 Spare parts 116 9 00 Encoder kit for the individual encoder version solid shaft 9 01 9 04 9 05 9 06 9 07 Encoders O ring Screw Torque bracket Screw Encoder kit for hollow shaft encoders not in diagram Replacement parts example Measuring wheel O ring Sensor head DRIVE CLiQ interface not in diagram Replacement parts example 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Spare parts sere 181515 A Bc Yeme 7 1 i Dg au Figure 9 1 Spare parts example 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 117 Spare parts 1PH813 1PH816 main motors 118 Operating Instructions 01 2015 610 48006 40c Decommissioning and disposal 1 10 1 Decommissioning Disassembly of the motor must b
116. n the terminal box so that the PE conductor has an excess length and the insulation of the cable conductors cannot be damaged Only remove insulation from the cable ends so that the insulation reaches up to the cable lug terminal or wire end ferrule Adapt the size of the cable lugs or end sleeves in line with the dimensions of the terminal board connections and the cross section of the power cable use parallel connecting cables if necessary Make sure that the inside of the terminal box or connector 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 5 1 Tightening torques Thread M4 M5 M6 M8 M10 Tightening torque Nm 0 8 1 2 1 8 2 5 2 7 4 5 5 8 9 13 When connecting or changing internal connection cables always observe the minimum air clearance of 5 5 mm Avoid protruding cable ends Seal unused cable entries and screw in sealing elements so that they are secure and airtight 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 61 Connection 5 2 Electrical connection e Check seals and sealing surfaces of the terminal box or connector to ensure that the degree of protection is maintained e Take measures to ensure that connecting cables cannot rotate are not subject to strain and pushing force
117. n unit is not operational Note External ground connection Motors with a power rating of more than 100 kW must be grounded via the additional grounding screw M12 at the mounting flange A cable lug in accordance with DIN 46234 must be used 1PH813 1PH816 main motors 74 Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection Connection of the external fan by means of connector for 1PH813 Note If you order the motor with a power connector the external fan is connected with a size 1 power connector Connector size 1 with full thread Connector SPEED CONNECT size 1 Terminal for the cable shield Pin assignment Circuit diagram Cable shield Conductor designation U V W power cable 1 5 mm each cable separately shielded PE protective conductor 1 2 3 4 5 6 7 Figure 5 17 3 phase connection of external fan via connector 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 75 Connection 5 2 Electrical connection 5 2 12 Connecting up a converter Selecting and connecting the cables e To connect the motor to a converter use MOTION CONNECT cables or shielded connecting cables Note The cable shielding made up of as many strands as possible must have a high electrical conductivity Braided shields made of copper or aluminum are well suited e Connect the shield at both ends at the motor and at the converter e Keep unsh
118. ng torque For this use the wrench grip surface on the NDE motor shaft extension to hold the other side Position the rotating union horizontally in such a way that the leakage connection is at the lowest point Always connect the hose for leakage sloping downward at least 15 Also connect the hose for the inlet sloping downward Manually check that the rotor turns easily Test the mounting under pressure for leaks 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 51 Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors 52 Sealing cover Balancing disk Rotor supported rotating union e g DEUBLIN 1109 020 188 Leakage hose OOOO Inlet hose Figure 4 4 Rotating union for water cooled motors 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Mechanical mounting 4 5 Rotor supported rotating unions for 1PH8 hollow shaft motors Mounting the rotating union in air cooled motors Air cooled motors have a 0 or a 1 in the 11th position of the Article No Air cooled motors are equipped with an intermediate housing between the motor and the axially mounted fan The intermediate housing is used to accommodate the rotating union The intermediate housing is suitable for rotating unions with the following dimensions e Length up to 120 mm without rotor connection thread and centering e Diameter up to 55 mm Due to limitations of sp
119. ng version Maximum Statistical Recommended bearing speed bearing lifetime replacement interval Nmax Lion tiw h rom ih Permanent Relubrication P lubrication 132 Performance 10000 8000 8000 High Performance 15000 8000 8000 160 Performance 9000 8000 8000 High Performance 10000 8000 8000 Note 1PH8 motors require special bearings which can be obtained via the Siemens Service Center 1PH813 1PH816 main motors 100 Operating Instructions 01 2015 610 48006 40c Maintenance 8 1 Inspection and maintenance 8 1 6 Cleaning the motor and fan external fan Check the degree of pollution of the motor and the external cooling unit at regular intervals Clean the motor and the external cooling unit if cooling is no longer adequate Preparing for cleaning WARNING Danger to life as a result of rotating fan blades When carrying out repair and maintenance work on the external cooling unit rotating fan blades can cause severe injury Switch off the external cooling unit Disconnect the external cooling unit circuit and lock out the external cooling unit so that it cannot be switched on again If at all possible lock the fan blades so that they cannot rotate AA OO N gt o Switch off the motor and external cooling unit Disconnect both of them from the power supply by disconnecting all phases Ensure that they both cannot be accidentally switched on again Once the voltage has been disconnect
120. nts Disposal Protecting the environment and preserving its resources are corporate goals of the highest priority for us Our worldwide environmental management system to ISO 14001 ensures compliance with legislation and sets high standards in this regard Environmentally friendly design technical safety and health protection are always firm goals even at the product development stage Recommendations for the environmentally friendly disposal of the machine and its components are given below Be sure to comply with local disposal regulations Sort the components for recycling according to whether they are e Electronics waste e g sensor electronics e iron to be recycled e Aluminum e Non ferrous metal e g motor windings e Insulating materials Process materials and chemicals Sort the process materials and chemicals for recycling according to whether they are e Oil Dispose of the spent oil as special waste in accordance with the spent oil ordinance e Grease e Solvents e Cleaner solvent e Paint residues Do not mix solvents cleaner solvents and paint residues Insulating materials 120 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 e Various insulators which are used in terminals boxes e Voltage and current tr
121. o excessive force e Avoid applying excessive force to the fan Note Use a lint free cloth or a soft brush to clean the fan blades ensure that no moisture enters the inside of the motor e Clean the motor and the external cooling unit with commercially available cleaning agents 1PH813 1PH816 main motors 102 Operating Instructions 01 2015 610 48006 40c Maintenance 8 2 Corrective maintenance After cleaning gt Allow the motor and external cooling unit to dry After wet cleaning check the insulation resistance If available remove the rotation locking element of the fan blades AA OO N gt Screw the guard with fan back onto the fan unit To do so tighten the 6 screws with a torque of 6 5 Nm 1 Nm 5 Check that you have removed all of the cleaning equipment and cleaning agents 6 Check that you have reattached all of the parts that were removed for cleaning 7 Reconnect the power supply 8 Switch on the motor and external fan unit again 0O 8 1 7 Replacing an encoder When replacing the motor bearings we also recommend that you replace the encoder equipped with their own bearings 8 2 Corrective maintenance WARNING Danger to life from permanent magnet fields The permanent magnets of synchronous motor rotors generate strong magnetic fields and forces of attraction The permanent magnets represents a danger for people with active medical implants who come close to the motors
122. o not overtighten the eyebolts Do not remove the pressboard washers and do not use deformed or damaged eyebolts Loads that run transverse to the ring plane are not permitted Ifthe motor is installed with the shaft extension pointing downwards or upwards the lifting eyebolts must be changed over as indicated in the following diagrams showing the arrangement of the eyebolts 3 2 1 Transport Information will be provided in this chapter on how to correctly lift and transport the motors Figure 3 1 Lifting and transporting the motor with a cross beam example 1PH813 1PH816 main motors 38 Operating Instructions 01 2015 610 48006 40c Preparations for use 3 2 Transportation and storage Ansicht X View X Ansicht X View X Horizontal shaft extension standard Shaft extension pointing upwards Shaft extension pointing downwards Figure 3 2 Location of the lifting eyebolts on 1PH813 and 1PH816 Transporting a motor that has already been in operation gt If you want to transport a motor that has already been in operation proceed as follows a 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 Always transport and lift the motor by the lifting eyebolts on the bearing end shields 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 39 Preparations for use 3
123. onnect the power cables e Unscrew the external fan unit if installed and the encoder cover 1PH813 1PH816 main motors 106 Operating Instructions 01 2015 610 48006 40c Maintenance 8 2 Corrective maintenance iii rit I9 5 5 0 1 S lt a c EA 0 05 i Tolerance applies for mounted encoder be SY lt F Ya o Ee SS 9 05 1 Screw 5 Encoder shaft 2 Connector cover 6 Screws 3 Motor shaft 9 xx See section Spare parts 4 Jacking thread Figure 8 2 Motor shaft encoder shaft connection 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 107 Maintenance 8 2 Corrective maintenance Removal gt Unscrew the screw 1 e Remove the connector cover 2 Remove the connector with signal cable Unscrew the screws 9 07 for the torque bracket a A OO N gt a Unscrew the encoder screw 9 05 make sure that the motor rotor does not also start to rotate 6 Removing the encoder from the motor shaft Screw the threaded pin e g DIN 913 M5 x 15 for protection of the centering bore thread into the motor shaft extension as a disassembly aid and then separate the encoder by inserting an M6 x min 40 screw E Mounting gt 1 Screw the torque bracket 9 06 onto the encoder by means of screws 6 and secure in 2 place e g with Loctite 243 Observe the distance between the torque bracket and encoder this step does not need to be c
124. ons 77 500 B Last updated 12 Dec 2013 Page 6 1PH813 1PH816 main motors 130 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions m n Ekenorion INDUSTRIAL DRIV WE MACNETISE TH Li er The maximum air gap Smax see Table 28 1 air gap Snom and Smax Must not be exceeded throughout the entire brake module service life Please refer to Section 6 Maintenance for details 2 3 4 Maintenance and repair Repair work must only be carried out by qualified specialist personnel definition to IEC 364 Failure to perform repairs according to requirements may cause serious personal injury or equipment damage Make sure that no voltage is applied to the brakes when carrying out maintenance work 3 Emissions 3 1 Noise The spring applied single disc brake module produces switching noise during engagement and release The noise level is determined by the installation conditions circuitry and air gap Depending on the mounting position operating conditions and state of the friction surfaces audible vibrations squealing may be produced during braking 3 2 Heat Braking operations and gradual heating of the field coil cause the solenoid housing temperature to increase substantially Under adverse conditions the surface temperature may rise to well over 100 C A Caution Risk of burns in case of contact with hot surfaces Suitable covers and hand guards must be installed to provi
125. or 1PH8 hollow shaft motors Mounting information and instructions e Do not mount any additional anti rotation pins e Never screw pipes directly to the rotating union e Always use a hose between the rotating unnion and the fixed piping To do this route the hoses in curves and torsion free e Avoid twisting the hoses e First screw the flexible hoses onto the rotating union Then screw the rotating union onto the shaft with the specified torque e Avoid stressing due to incorrect hose lengths and unsuitable mounting material e Always keep the rotating union and hoses free of tension e The rotating union must be easy to turn when mounted e Keep rotating unions free of chips and burrs e Position the rotating union horizontally in such a way that the leakage connection is at the lowest point e Always route the leakage hose downward at at least 15 with a large cross section e If the leakage hose is higher than the leakage connection and the mechanical seal is open the rotating union and possibly also the motor will be flooded The motor can fail e Also route the inlet hose downward This causes the coolant to flow back in the supply line when the mechanical seal is open e g tool change or standstill and not through the motor shaft and the leakage connection e Filter the coolant so that no particles or chips can reach the mechanical seal and damage it Note Mounting the rotating union e During assembly screw th
126. orque NOTICE Inadvertent actuation of the holding brake Material damage can occur if you inadvertently actuate release the holding brake e Secure the holding brake against inadvertent actuation and misuse The mechanical manual brake release must always be in the center position when not actuated see the diagram Spring applied single disk brake module Only then is the brake completely engaged and it is ensured that the spring applied single disk brake module can provide its full braking effect e You can remove the manual release lever Observe the specific system related regulations e g in the crane construction area relating to whether manual release is permissible e The rated operating conditions refer to DIN VDE 0580 1994 10 The degree of protection refers to DIN VDE 0470 part 1 Coordinate possible special measures with the manufacturer if deviations exist 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 35 Description 2 4 Design Note Special measures Ask the manufacturer for support when already designing the plant or system if you find references to special measures and or it is necessary to contact the manufacturer See also Note regarding a holding brake Page 124 2 4 3 2 Mounted holding brake for SH 132 and SH 160 Mounting the holding brake option is described in the Appendix Holding brake operating instructions Note Radial and axial forces The
127. otors Operating Instructions 01 2015 610 48006 40c 147 Appendix A 3 Holding brake operating instructions RKENDRION NOUSTRIAL eee WE MACHETISE THE WORLD 6 4 Brake shaft 13 removal A Caution As high pressures are generated during the removal of the brake shaft personal protection equipment such as face guards gloves etc and protective covers must be used Proceed with extreme caution and follow all relevant safety instructions when removing the brake shaft 13 The brake shaft 13 must be removed by means of an oil pressure system see Fig 24 1 1 To this end a withdrawal device consisting of a forcing screw 37 a forcing pin 35 and an oil injector or oil pump 36 must be used Remove the screw plug 17 and screw the oil injector or oil pump 36 connection into the oil inlet bore 17 1 2 Insert the forcing pin 35 on the front face of the brake shaft 13 up to the limit stop and slightly tighten it by means of the forcing screw 37 3 The pressure oil must be supplied through the oil inlet bore The oil pressure should be gradually increased to about 60 of the maximum pressure Pmax Then the pressure should be kept constant for about 60 minutes 4 Proceed to increase the pressure to the maximum oil pressure Pmax After the maximum pressure has been reached screw in the forcing screw 37 smoothly and evenly so that the brake shaft 13 can be pulled off the motor shaft While removing the brake sha
128. outlet as required 4 Ensure that the maximum permissible operating pressure does not exceed 6 bar 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 59 Connection 5 2 Electrical connection 5 2 60 Electrical connection Awarnine Danger to life through electric shock As a result of the permanent magnets in the rotors of 1PH8 synchronous motors when the motors rotate this induces a voltage If you use defective cable ports you could suffer an electric shock e Do not touch the cable ports e Connect the motor cable ports correctly or insulate them properly Awarnine Risk of electric shock if the insulating foil is removed The insulating foil in the terminal box is used to protect against voltage flashover to the cover e Never remove the insulating foil in the terminal box NOTICE Destruction of the motor if it is directly connected to the three phase line supply The motor will be destroyed if it is directly connected to the three phase line supply e Only operate the motors with the appropriately configured converters NOTICE Damage to components that are sensitive to electrostatic discharge The DRIVE CLiQ interface has direct contact to components that can be damaged destroyed by electrostatic discharge ESDS Encoder systems and temperature sensors are components that can be destroyed by electrostatic discharge ESD Componen
129. particular system specific conditions Test scope While the motor is running check that e the equipment conforms to the stated electrical characteristics e the smooth running characteristics and motor noise during operation have not changed NOTICE Machine damage when ignoring abnormalities identified during the inspection Abnormalities identified during inspection that are subsequently ignored can result in machine damage e Analyze and remove any abnormalities identified taking into consideration Chapters Faults and Maintenance e Contact the Siemens Service Center if you require any support 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 97 Maintenance 8 1 Inspection and maintenance 8 1 4 98 General inspection Note Adapt the inspection to the plant specific conditions Further tests are also necessary in line with the component documentation or corresponding to the particular system specific conditions Test scope While the motor is running check that e the electrical parameters are maintained e the smooth running characteristics and motor noise during operation have not changed When the motor is at a standstill check that e the motor foundation has no indentations or cracks e the machine is aligned within the permissible tolerance ranges e all of the mounting bolts screws for the mechanical and electrical connections are tight e the insulat
130. perating Instructions are intended to be assembled with electric machines in particular electric motors for use on industrial equipment Operation in potentially explosive or firedamp atmospheres is not allowed The brake modules must be used in accordance with the operating requirements detailed in this manual The rated power limits specified herein must not be exceeded Use of the brake modules as service brakes or safety brakes is not permitted Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 5 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 129 Appendix A 3 Holding brake operating instructions RKENDRION INDUSTRIA WE MACWETISE THE WORLD 2 3 General safety information Brakes fitted to motors feature hazardous live components and rotating parts and may exhibit hot surfaces Any work associated with the transport connection start up and periodical maintenance of the brakes must be carried out by authorized and qualified specialist personnel in accordance with VDE 0105 IEC 364 Failure to observe safety operating and maintenance instructions may cause serious personal injury and severe damage to the equipment Whenever special measures are required in accordance with the instructions contained herein such measures should be agreed with the brake manufacturer before the machinery into which the brake is to be incorporated is set up Should any queries aris
131. peration of the product The brakes described in these Operating Instructions have been designed and built on the basis of an analysis of hazards and in accordance with the requirements of the applicable harmonized standards and technical specifications They correspond to the state of the art and provide maximum safety However safety hazards can only be avoided if the user of the equipment takes adequate precautions and makes sure that safety instructions are strictly adhered to It is the duty of the user of the machine to plan these measures and to check their implementation The user is required to ensure that a the brakes are only used in accordance with their intended use see Product description section the brakes are in perfect working order and checked at regular intervals amp a complete copy of these Operating Instructions is kept available at the place of use of the brakes at all times amp all applicable local and machinery specific regulations and requirements are followed amp start up maintenance and repair work is only done by authorized and suitably qualified personnel a such personnel are kept informed on all relevant occupational safety and environmental protection issues and familiar with these Operating Instructions and with the safety information contained herein amp brake functionality is not interfered with by an external magnetic field 2 2 Intended use The brake modules described in these O
132. posal of components 1PH813 1PH816 main motors 20 Operating Instructions 01 2015 610 48006 40c Description 2 2 1 Use for the intended purpose WARNING Danger to life and material damage when incorrectly used If you do not use the motors or their components correctly there is a risk of death severe injury and or material damage e Only use the motors for industrial or commercial plants and systems e f in an exceptional case you do not use the motors in industrial or commercial plants and systems ensure that increased requirements are complied with e g regarding touch protection e Do not use the motors in hazardous areas where there is a risk of explosion if the motors have not been expressly released and authorized for these types of applications Carefully observe any special supplementary notes that may be attached e Only use the motors and their components for the applications specified by Siemens e Protect the motors against dirt and contact with aggressive substances e Ensure that the site conditions comply with the rating plate data and the conditions specified in this documentation When necessary take into account deviations regarding approvals or country specific regulations e If you have any questions regarding the intended use please contact your local Siemens office e f you wish to use special versions and design variants whose specifications vary from the motors described in this document
133. propriate quantities of additives to protect against corrosion and minimize the growth of algae can be used as a Coolant Other coolants e g cooling lubricating medium water oil mixtures with 10 oil and higher can lead to derating If there is a risk of frost preventive measures must be taken during operation storage and transportation anti freeze emptying and blowing out with air etc Use and concentration of the anti freeze according to the manufacturer s data max 25 Different anti freeze agents should not be mixed A filter 100 um must be installed in the inlet pipe to protect the motor against pollution Additional protection for the motor must be provided by means of a pressure relief valve installed downstream from the filter Pipes valves and fittings can be made out of brass stainless steel or plastic If different materials are used in close proximity to each other however the electrochemical series must be taken into account which is why zinc must not be used in cooling water circuits If a throttle is needed to restrict the flow it is best to install it downstream of the motor It must not be installed directly in front of the inlet because the effects of cavitation may damage the motor 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
134. que 5 Nm Terminal screw M6 Grounding screw M6 Insulation strips Figure 5 2 Terminal box gk833 and gk863 3 pole Terminal screw M6 Grounding screw M6 Insulation strips Figure 5 3 Terminal box gk843 and gk873 3 pole 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 63 Connection 5 2 Electrical connection Terminal stud M6 Jumper Grounding screw M6 OOOO Insulation strips Figure 5 4 Terminal box gk846 1PH813 and gk876 1PH816 6 pole can be switched between star and delta Terminal screw M10 Grounding screw M6 Insulation strips Figure 5 5 Terminal box gk874 3 pole for synchronous motors only 1PH813 1PH816 main motors 64 Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection Terminal screw M6 Grounding screw M6 Insulation strips Figure 5 6 Terminal box gk843 1PH813 gk873 1PH816 3 pole cable entry DE Note Cable exit direction DE The motor with the cable exit direction DE has a D in the 15th position of the Article No Star delta connection A star delta connection is implemented by means of an external contactor circuit or as a fixed configuration in terminal box gk846 1PH813 and gk876 1PH816 Standard configuration star connection via jumpers Star connection ie Delta connection Standard Figure 5 7 Fixed star delta connection in the term
135. quential damage as described under a above must be avoided by the user by taking adequate precautions Electromagnetically engaged systems Voltage dips and supply voltage variations to below the minimum tolerance threshold will cause torque reductions The user is required to take adequate precautions to avoid consequential damage Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 8 1PH813 1PH816 main motors 132 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions PKENDRION Radio interference suppression in accordance with EN 55011 The brake modules and the recommended electronic rectifiers are classified as Group 1 equipment in accordance with EN 55011 As far as the emissions from this equipment are concerned one distinguishes between field guided radiated interference and line conducted interference a b Radiated interference When operated with DC voltage or rectified 50 60 Hz AC voltage all brakes comply with the limit values applicable to Class B equipment Conducted interference When connected to a DC power source the electromagnetic brakes meet the limit values applicable to Class A equipment If the brakes are connected to a 50 60 Hz AC power source and equipped with electronic rectifiers or other electronic controls interference suppression measures as shown in Fig 9 1 must be taken to ensure compliance with the
136. r the microswitch status is open or closed by using a continuity tester connected to NO and C see Fig 11 2 When closed push the microswitch 27 back beyond the change over point in the direction indicated by B see Fig 11 2 When open screw in the screw 34 hexagon head cap screw M2 5x8 not supplied to push the microswitch in the direction indicated by A up to the change over point At this point continue to tighten the screw 34 by the adjustment length L or by the screw in angle amp specified in Table 23 1 and position it correctly by tightening one of the cheese head screws 29 Secure the second cheese head screw 29 with Loctite type 241 and tighten it Ma tightening torque specified in Table 23 1 Loosen the first cheese head screw 29 apply Loctite 241 and re tighten it Remove the screw 34 after completion of the microswitch adjustment Switch the brake module on and off to check that the microswitch 27 works correctly C common contact NO normally open contact Size 13 19 24 y4 Adjustment length L of screw 34 mm 0 11 0 15 0 2 0 2 Screw in angle amp of screw 34 90 120 160 160 Ma tightening torque of machine screw 29 Nm 0 7 0 7 0 7 0 7 Table 23 1 Ma tightening torque of cheese head screws 29 adjustment length L and screw in angle amp of screw 34 Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 23 1PH813 1PH816 main m
137. res and shorten the service life of devices systems e Always operate the motor together with an external fan WARNING Danger to life caused by fire if ventilation clearances are inadequate Inadequate ventilation cooling clearances can result in overheating and fire Overheating can cause failures and shorten the service life of devices systems e Ensure compliance with the specified minimum clearance as ventilation cooling clearance for the particular motor The motors must be arranged in such a way that the cooling air can flow in and out without obstruction and that the minimum distance s between the inlet outlet air openings and adjacent components is maintained see Minimum distance diagram below Steps must be taken to ensure that hot discharged air cannot be drawn back into the system The covers Pos 1 in Minimum distance diagram below which were removed to allow the motors to be secured must be reattached before the system is commissioned The arrow must point upwards 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Description 2 4 Design BE mO 7a l gg Ss A minimum clearance of 60 mm applies to 1PH813 A minimum clearance of 80 mm applies to 1PH816 1 Cover for NDE mounting foot Figure 2 3 Minimum distance s Water cooling The motor can only be operated in a closed cooling water circuit with a heat exchanger unit The motor is connected to the
138. res of the covers 23 making sure they are correctly positioned see figure to the right Apply Loctite 243 to secure the cams 3 Insert the hand release lever 24 2 into the square socket provided in the cams 24 1 The hand release can be operated by pushing the lever 24 2 in one direction see Fig 14 1 4 The mechanical release forces F required to release the brake and the maximum permitted release forces actuation forces Fmax are specified in Table 14 1 The Fig 14 1 Hand release and air gap control release forces F are based on the highest transmissible standard torque see Technical specifications Key to Fig 14 1 1 1 Solenoid housing 4 Friction disc 13 Bore for air gap measurement 24 1 Cam complete 2 Armature 24 2 Hand release lever 3 Flange s Air gap Size 13 19 24 29 Threaded bush tightening torque Ma Nm 20 26 35 35 Release force F Nm 80 130 200 240 Max permitted release force actuation force Fmax N 120 180 280 330 Table 14 1 Release force F max permitted release force actuation force Fmax of hand release 24 Mag tightening torque of threaded bush of cams 24 1 A Warning Check that the mechanical hand release 24 is in a central position see Fig 11 1 when not in use This is crucial to ensure reliable brake engagement Otherwise the full braking effect of the spring applied single disc brake module may not be reached In this case the machine e g motor must be stopped imme
139. s When you clean using compressed air this can stir up dust metal chips and cleaning agents which can cause injury e When cleaning with compressed air ensure there is adequate extraction equipment e Use the appropriate personnel protection equipment e g gloves protective overall 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Maintenance 8 1 Inspection and maintenance 8 1 8 1 2 General Cleaning Inspection and maintenance General inspection guidelines The motor is not disassembled for inspection If you have any questions please contact the manufacturer informing them of the machine type and serial number We recommend that a Siemens Service Center carries out inspection and maintenance work The contact data is provided in the introduction under Technical support Maintenance and inspection intervals e Inspect and maintain the motor at regular intervals to be able to identify faults at an early stage and remove them NOTICE Resulting damage to the machine Unusual conditions or faults of the motor e g overload or short circuit can result in consequential damage to the machine e Immediately inspect the motor if faults or exceptional conditions occur e Regularly clean the drive system to ensure that it is adequately cooled Inspection maintenance intervals periods measures 96 The maintenance intervals depend on the operating conditions e A
140. s required to ensure that the adjusting ring 9 is secured with the set screw 25 applying a tightening torque of Ma 3 Nm The adjusting ring 9 must be turned in such a way that the set screw 25 can be located between the studs 8 The M torque tolerance is 15 5 1 The brake modules are factory adjusted to the standard M transmissible torque specified in the specification sheet The M transmissible torque applicable at the time of shipment is specified on the rating plate 2 The torque can be adjusted by means of the adjusting ring 9 After completion of adjustment the ring must be locked by means of the set screw 25 The adjusting ring clearance E see Fig 11 1 is marked on the bottom of the solenoid housing near the set screw 25 After having loosened the set screw 25 the M standard torque can be changed by changing the adjusting ring clearance E by means of a pin spanner 3 After having changed the torque the new adjusting ring clearance E must be marked on the solenoid housing The adjusting ring must be locked by means of the set screw 25 making sure however that the set screw is not within the reach of the studs 8 4 Secure the set screw 25 with Loctite 243 for example 5 While torque variations only have a minor impact on coupling times t the disconnection time tz is reduced proportionally to the torque reduction Size 19 24 4 Transmissible torque change HM4 mm approx 15 approx 12
141. sible see Fig 16 1 Depending on the brake size and torque voltage ripple due to intermittent power supply may cause brake humming or incorrect brake operation Perfect brake operation must be ensured by the user or system manufacturer by providing suitable electrical controls Attention When connecting the rectifier 19 2 the terminals must be tightened to a tightening torque of Ma 0 4 Nm Normal coupling time ty brake coil Shorter coupling time ty In case of DC side switching AC side switching is also required Fig 16 1 Rectifier contact assignment Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 16 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions PKENDRION NOUSTRIAL DRIVE SYS WE UAGWETISE THE WOR 5 3 1 DC power supply The figure to the right shows the voltage curve after the field coil 1 2 has been de energized A Attention The peak voltage Uymax during disconnection without protective circuit may reach several thousand V in the millisecond region This may cause irreversible damage to the field coil 1 2 switching contacts and electronic components Sparking will occur on the switch during disconnection Consequently a protective circuit must be provided to reduce the current during disconnection and to limit the voltage The maximum permitted ov
142. side brake switching without protective circuit as described in Section 3 3 will cause damage to electronic rectifiers electronic accessories switching contacts and to the field coil 1 2 A Warning Before starting the machine e g motor test run without driven components the feather key if used must be secured in such a way that it cannot be hurled out The shaft must not be exposed to load torques Before the machine e g motor is re started the brake must be de energized Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 18 1PH813 1PH816 main motors 142 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions QKENDRION A Caution The brake surface temperature may rise to over 100 C Heat sensitive parts such as conventional cables or electronic components must not be fixed to or be in contact with these surfaces If necessary suitable protections and hand guards must be installed to avoid accidental contact with hot surfaces A Attention High voltage tests performed during brake mounting within an overall system or during start up must be carried out in such a way that damage to the built in electronic accessories is avoided The limits for high voltage tests and follow up tests specified by DIN VDE 0580 must be observed The following checks must be carried out amp Check compliance with the specifications provided on the
143. sition encoder IN19DQ The marking is 1PH8 0S 7 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 109 Maintenance 8 2 Corrective maintenance 1 Screws 2 Cover 8 3 Balancing weight 9 4 Screws 10 5 Cover 11 6 Screw 12 Figure 8 3 Installing the toothed wheel encoder 110 Connector Screws Scanning unit Toothed wheel Motor shaft 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Removal O Mounting AA OO N gt Maintenance 8 2 Corrective maintenance Unscrew the screws 1 and remove the cover 2 Pull out the balancing weight 3 Unscrew the screws 4 and remove the cover 5 Scanning unit Unscrew the screw 6 Remove the connector 8 for the signal cable Remove the screws 9 with washers and remove the scanning unit 10 Toothed wheel Pull off the toothed wheel 11 Mount the toothed wheel encoder in the reverse order to the order in which you removed it with the following differences 1 Heat up the toothed wheel 11 approx 150 C push it onto the motor shaft 12 and allow it to cool down Lock the screws 9 for attaching the scanning unit 10 e g with Loctite 243 Observe the mounting dimensions see Fig Installing the tooth
144. specifications for the standard bearing version apply for the permissible radial and axial forces Refer to the Configuration Manual SIMOTICS M 1PH8 main motors See also Note regarding a holding brake Page 124 Holding brake operating instructions Page 125 1PH813 1PH816 main motors 36 Operating Instructions 01 2015 610 48006 40c Preparations for use 3 1 Shipment and packaging Checking the delivery for completeness The drive systems are assembled on an individual basis Upon receipt of the delivery check immediately whether the items delivered are in accordance with the accompanying documents Siemens will not accept any claims relating to items missing from the delivery and which are submitted at a later date e Report any apparent transport damage to the delivery agent immediately e Report any apparent defects missing components to the appropriate Siemens office immediately These safety instructions are part of the scope of supply keep them in a location where they can be easily accessed The additional rating plate supplied separately with the consignment should be used for indication of the motor data in the vicinity of the motor In the case of e motors with terminal boxes it is inside the terminal box e motors with connectors it is included with the safety data sheet 3 2 Transportation and storage WARNING Danger to life when lifting and transporting Improper lifting and transport proced
145. stallation regulation e g according to IEC EN 60204 1 The grounding conductor is connected in the terminal box sA Figure 5 15 Connecting the grounding conductor Equipotential bonding The internal equipotential bonding between the grounding terminal in the terminal box enclosure and the motor enclosure is established through the terminal box retaining bolts The contact locations underneath the bolt heads are bare metal and protected against corrosion The standard cover fixing screws are sufficient for equipotential bonding between the terminal box cover and terminal box enclosure 1PH813 1PH816 main motors 72 Operating Instructions 01 2015 610 48006 40c Connecting the external fan The fan connection is located in the fan terminal box Connection 5 2 Electrical connection Table 5 4 Connection specifications for external fans on 1PH813 Air flow Max current consumption at direction 400 V 50 Hz 10 400 V 60 Hz 10 480 V 60 Hz 10 A A A NDE gt DE 0 13 0 16 0 17 DE gt NDE 0 21 0 19 0 23 Table 5 5 Connection specifications for external fans on 1PH816 Air flow Max current consumption at direction 400 V 50 Hz 10 400 V 60 Hz 10 480 V 60 Hz 10 A A A NDE gt DE 0 17 0 22 0 22 DE gt NDE 0 26 0 32 0 33 Note the following information regarding connections e Only use cables that comply with the relevant in
146. stallation regulations regarding voltage current insulation material and load carrying capacity e Before connecting the device make sure that the line voltage matches the device voltage e Check whether the data on the fan rating plate matches the connection data e Open the terminal box and route the cables not supplied into the terminal box e Connection cables must not be subject to excessive tensile stress e Connect the protective conductor PE e Connect the other cables to the relevant terminals refer to the connection diagrams 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 73 Connection 5 2 Electrical connection NOTICE Fan damage caused by moisture The fan can be damaged for example if water enters the terminal box along the cables e Use suitable cables and terminal box cable glands e Ensure that the terminal box cover is correctly fitted and completely closed Lil Figure 5 16 Connection of external fan in the terminal box NOTICE Damage to the fan when inappropriately operated The fan can be destroyed if inappropriately operated e Use blocking protection stall protection to protect the fan against inappropriate operation To do this use a suitable motor circuit breaker where all poles can be disconnected Operate the fan using this circuit breaker e Provide an interlocking circuit that prevents the main motor from being switched on when the fa
147. t surfaces In operation the motor can reach high temperatures which can cause burns if touched e Mount the motor so that it is not accessible in operation When maintenance is required e allow the motor to cool down before starting any work e Use the appropriate personnel protection equipment e g gloves 1 2 Handling electrostatic sensitive devices ESD Electrostatic sensitive devices ESD are individual components integrated circuits modules or devices that may be damaged by either electric fields or electrostatic discharge 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 17 Fundamental safety instructions 7 3 Industrial security NOTICE Damage through electric fields or electrostatic discharge Electric fields or electrostatic discharge can cause malfunctions through damaged individual components integrated circuits modules or devices e Only pack store transport and send electronic components modules or devices in their original packaging or in other suitable materials e g conductive foam rubber of aluminum foil e Only touch components modules and devices when you are grounded by one of the following methods Wearing an ESD wrist strap Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring e Only place electronic components modules or devices on conductive surfaces table with ESD surface conductive ESD foam ESD packaging ESD transport
148. ted 12 Dec 2013 Page 11 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 135 Appendix A 3 Holding brake operating instructions Ekendorion INDUSTRIAL DRIVE SYSTEMS Key to Fig 11 2 27 Microswitch 31 Stud 28 Strap 32 Straight pin 29 Cheese head screw 2x 33 Bellows 30 Oval head screw 2x 34 Hexagon head cap screw M2 5x8 not supplied A Attention Every time the spring applied single disc brake module is reassembled the fixing screws and cheese head screws 10 must be tightened to the Ma tightening torques specified in Table 13 1 and Table 22 1 The adjusting ring 9 must be secured with the set screw 25 tightening torque Ma 3 Nm Loctite 243 must be applied to the set screw 25 When maintenance work is carried out on the connector box 19 see Section 5 3 the cheese head screws 19 3 must be tightened to Ma 1 6 Nm when installing the cover 19 1 with the connector box 19 Damage to the seal between the connector box 19 and cover 19 1 must be avoided 5 1 Mechanical installation 5 1 1 Brake shaft 13 installation The press fit connection of the brake shaft 13 with the motor shaft provides reliable transmission of the brake torque An additional form fit connection in the form of a feather key for example is not allowed The motor shaft must not have a feather key groove A Attention The fits and surface roughness required for the motor shaft must be chosen by the brake
149. ted to the A face end shield of electric motors The brake can also be equipped with an optional hand release so that it can be released manually 4 2 Design The solenoid housing 1 1 with the encapsulated field coil 1 2 accommodates the armature 2 friction disc 4 and flange 3 The flange is fixed by means of the cheese head screws 10 The compression springs 7 located in the solenoid housing 1 1 are supported on the adjusting ring 9 and solenoid housing 1 1 by the studs 8 size 13 brakes compression springs 7 only These compression springs generate an axial force that is transmitted to the friction disc 4 through the armature 2 As a result the friction disc 4 is clamped between the firmly fixed flange 3 and the armature 2 and the braking effect torque is produced Straight pins 5 are provided which act as tangential torque supports for the armature 2 relative to the solenoid housing 1 1 When DC voltage is applied to the field coil 1 2 the electromagnetic force thus generated causes the armature 2 to be attracted overcoming the force of the compression springs 7 The friction disc 4 is thus released and the braking effect is neutralized As the brake module is a closed system no forces are transmitted outwards away from the brake Transmission of the braking force from the axially moveable friction disc 4 to the brake shaft 13 is achieved through the form fit connection of the square socket
150. tening torque max 5 0 Nm lies min 3 5 Nm 2 Connection hole Mounting example Figure 5 18 Sealing air connection option Q12 Conditioning A 1PH8 motors without shaft sealing ring option K18 Min air intake temperature C Ambient temperature Max air intake temperature C 40 Max residual water content g m 0 12 Max residual oil content g m 0 01 Max residual dust mg m 0 1 Min supply pressure Pa 2 5 x 105 Max supply pressure Pa 3 x 105 Particle size for hollow shaft encoders um lt 8 Particle size for optical encoders um lt 3 Volumes Volumes Nm h Nm standard cubic meter 1 1 5 The volume data refers to the specified minimum supply pressure For higher supply pressures the flow rate increases corresponding to the motor flow resistance A permanent flow of sealing air results in an improved level of protection The sealing air must comply with the specified air quality 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 77 Connection 5 2 Electrical connection Conditioning B 1PH8 motors with shaft sealing ring option K18 Min air intake temperature C Max air intake temperature C Max residual water content g m Max residual oil content g m Max residual dust mg m3 Min supply pressure Pa Max supply pressure Pa Particle size for hollow shaft encoders um Particle size for optical encoders um Ambient temperature 40 0 1
151. terminal 19 2 or built in rectifier 19 2 by means of a cable gland M16x1 5 for cross sections of between 5 and 10 mm Remove the cover 19 1 of the connector box 19 so that the individual strands of the connecting cable can be connected to the terminal 19 2 or to the contacts of the built in rectifier 19 2 Fig 15 1 Connector box 19 with terminal 19 2 or rectifier 19 2 Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 15 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 139 Appendix A 3 Holding brake operating instructions 140 OKENDRION gt Rectifier series Rectifier type U VAC 40 60 Hz Max output current GEIE ELE LE G Output voltage R load L load U2IVDC ADC ADC 32 07332B40 half wave 0 500 810 U1 80 445 1 6 2 0 Specific rectifier specification sheets must be observed Table 16 1 Rectifier for single phase AC voltage supply via connecting terminal 19 2 A Attention When installing the cover 19 1 and connector box 19 the cheese head screws 19 3 must be tightened to Ma 1 6 Nm Damage to the seal between the connector box 19 and cover 19 1 must be avoided Brakes equipped with built in rectifiers 19 2 use half wave rectification The built in rectifier 19 2 can be wired in such a way that AC side switching normal coupling time t or DC side switching short coupling time t is pos
152. th the motor shaft pointing upwards 2 Close the oil supply bore in the brake shaft 13 with the screw plug 17 Apply Loctite 222 3 Mount the brake module to the motor by slipping it onto the brake shaft 13 until it makes contact with the motor flange Ensure that the brake is parallel to the motor shaft and that a form fit connection is established between the brake shaft 13 and the square socket size 13 19 24 brakes or with the internal teeth size 29 brakes of the friction disc 4 4 The friction disc 4 is factory centred in the spring applied single disc brake module to ensure easy installation 5 Slightly tighten the fixing screws after having taken the preliminary assembly steps described above Ensure that the brake is released electromagnetically after the spring applied single disc brake module has been connected see Section 5 3 6 Manual brake release by means of an attached hand release 24 for example is not allowed To complete brake mounting use the ball bearing set accessories 7 The spring washers 14 must be placed into the solenoid housing 1 1 as shown in Fig 11 1 Size 13 and 19 brakes require only one spring washer each whereas size 24 and 29 brakes must be equipped with two spring washers A Attention The brake shaft and ball bearing must not be exposed to any axial shocks The disc 12 is essential to the correct operation of the brake module and must only be replaced by an original spare p
153. the contents of this publication to ensure consistency with the hardware and software described Since variance cannot be precluded entirely we cannot guarantee full consistency However the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions Siemens AG Order number 610 48006 40c Copyright Siemens AG 2010 2015 Division Digital Factory 06 2015 Subject to change All rights reserved Postfach 48 48 90026 NURNBERG GERMANY Introduction Text features These operating instructions describe the motor and explain how to handle the motor from the delivery to the disposal stage e Before you start using the motor you must read these operating instructions to ensure safe problem free operation and to maximize the service life These operating instructions complement the relevant SIEMENS Configuration Manual Siemens strives continually to improve the quality of information provided in these operating instructions e f you find any mistakes or would like to offer suggestions about how this document could be improved contact the Siemens Service Center e Always follow the safety instructions and notices in these operating instructions The warning notice system is explained on the rear of the inside front In addition to the notes that you must observe for your own personal safety as well as to avoid material damage in these operating instructions you wi
154. ts that are sensitive to electrostatic discharge can be damaged if you touch the connections with your hands or with electrostatically charged tools e Carefully observe the information in Chapter Handling electrostatic sensitive devices ESD 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Connection 5 2 Electrical connection Note Comply with the protective requirements regarding EMC Systems and machines with converter fed low voltage three phase motors must fulfill the protective requirements of the EMC Directive The machine manufacturer is responsible for ensuring that installation is carried out properly The signal and power cables to the motor must be shielded Apply the EMC installation guideline of the converter manufacturer For Siemens converters this is available under document order number 6FC5297 DAD30 00PD 5 2 1 Cable routing When selecting the required connecting cables make sure that you take into account the rated current and plant specific conditions such as ambient temperature routing type etc according to IEC EN 60364 5 52 and IEC EN 60204 1 Use EMC cable glands for permanently installed cable entries Use shielded cables whose shields are conductively connected to a large area of the terminal box of the motor using EMC cable glands Make sure that the cable shields are properly connected Arrange the exposed connecting cables i
155. ures unsuitable or damaged lifting gear and load handling equipment can cause death severe injury and or material damage e Only use suitable and intact lifting gear and load handling equipment which comply with the specific national regulations e Only use lifting gear and load handling equipment which are suitable for the weight of the motor The weight of the motor appears on the rating plate e Do not attach any additional loads to lifting gear and load handling equipment e Only use suitable strap guiding systems rope guides and spreading devices for lifting and transporting the motor 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 37 Preparations for use 3 2 Transportation and storage WARNING Danger to life as a result of incorrect transport and or lifting of the motor Incorrectly transporting and or lifting the motor can lead to severe injuries and or material damage For instance the motor can fall e Only lift the motor using the lifting eyebolts on the bearing end shields e Use all of the lifting eyebolts when transporting e Do not attach a lifting eyebolt to the shaft extension e Never lift the motor using the Sensor Module or the cooling water pipe system e Use a crossbeam if you lift and or transport the motor using the eyebolts provided according to DIN 580 Note the following Completely screw in the eyebolts lifting eyebolts and tighten by hand approx 8 Nm D
156. use any damaged motors devices A WARNING Danger to life through electric shock due to unconnected cable shields Hazardous touch voltages can occur through capacitive cross coupling due to unconnected cable shields e As a minimum connect cable shields and the conductors of power cables that are not used e g brake cores at one end at the grounded housing potential WARNING Danger to life due to electric shock when not grounded For missing or incorrectly implemented protective conductor connection for devices with protection class high voltages can be present at open exposed parts which when touched can result in death or severe injury e Ground the device in compliance with the applicable regulations WARNING Danger to life due to electric shock when opening plug connections in operation When opening plug connections in operation arcs can result in severe injury or death e Only open plug connections when the equipment is in a no voltage state unless it has been explicitly stated that they can be opened in operation 1PH813 1PH816 main motors 14 Operating Instructions 01 2015 610 48006 40c Fundamental safety instructions 1 1 General safety instructions A WARNING Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile wireless devices or mobile phones with a transmit power gt 1 W closer than
157. user according to the adjusted transmissible brake torque and must be suitable to ensure reliable transmission of the generated brake torques 1 Before heating the brake shaft 13 make sure that both the brake shaft 13 and the motor shaft end are dry and free from grease and that the following parts have been removed screw plug 17 any brake size rubber bolts 18 accessories sizes 19 24 O ring 26 accessories size 29 2 Check the position of the motor shaft contact shoulder relative to the contact surface of the brake on the motor flange and correct it by installing shim rings if necessary The permitted tolerance is 0 5 mm 3 Before mounting the brake shaft 13 check the radial runout on the motor shaft end and mark the maximum runout angle on the front face of the motor shaft 4 After completion of the above operations the brake shaft 13 must be evenly heated in an electric oven or by means of an inductive heating system until it has reached a temperature of 280 C to 300 C Once heated the brake shaft 13 must be slipped onto the motor shaft end until it touches the contact shoulder and secured in axial direction until is has cooled down Make sure that the brake shaft 13 is mounted in such a way that the radial runout mark is offset by 180 relative to the runout mark on the motor shaft After the brake shaft has cooled down screw the screw plug 17 into the brake shaft 13 and secure it with Loctite t
158. was correct and up to date before going to print The information contained herein shall not entitle users to raise claims with respect to components purchased at an earlier date Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 3 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 127 Appendix A 3 Holding brake operating instructions 128 RKENDRION c we MACHETISE wosto 1 4 Declaration of Incorporation in accordance with Annex Il part 1 Section B of Machinery Directive 2006 42 EC We hereby declare that the products below comply with the essential health and safety requirements specified in Annex of Machinery Directive 2006 42 EC Annex General Principles Annex Sections 1 1 2 1 1 3 1 1 5 1 3 2 1 5 1 The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of Machinery Directive 2006 42 EC The relevant technical documentation required for the partly completed machinery has been compiled in accordance with Annex VII part B of Machinery Directive 2006 42 EC The manufacturer undertakes to submit an electronic copy of the relevant technical documentation compiled for the partly completed machinery if reasonably requested by national authorities Standards and directives EN 60529 DIN VDE 0580 Products Manufacturer Person
159. water from the motor e Blow out the cooling ducts with compressed air to dry them e Ifthe motor is not operational for extended periods of time run it at regular intervals roughly once a month or spin the rotor by hand e Before switching on to commission the drive carefully read the Section Switching on in the Chapter Switching on and switching off 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c 93 Operation 7 2 Non operational periods 94 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Maintenance caution Risk of burns when hot cooling water escapes There is a risk of burns caused by escaping hot cooling water and steam if you open the cooling circuit of a motor that was previously in operation e Do not open the motor cooling circuit until the motor has cooled down caution Risk of injury through contact with cleaning agents and solvents Contact with cleaning agents and solvents can cause chemical burns and irritate the skin and mucous membranes e Carefully observe all of the safety and application notes provided on the packaging of the cleaning agents and solvents e Ensure that any vapors that are released are drawn out and that the work area is well ventilated e Use the appropriate personnel protection equipment e g protective eyewear gloves respiration filter caution Injuries caused by blown particle
160. ws in hair and articles of clothing There is a danger of being drawn into the machine by means of hair ties loose articles of clothing etc at the air intake e Remove any ties or similar e Wear a hat or hair net to prevent hair from being drawn in e Keep the air intake area free of any loose objects e Take the appropriate protective measures to prevent hair and articles of clothing from being drawn in NOTICE Thermal damage to temperature sensitive parts The motors can have surface temperatures of over 100 C Temperature sensitive parts in contact with the motor or attached to the motor can be damaged Temperature sensitive parts include cables and electronic components for example e Never attach temperature sensitive parts to the motor e Ensure that no temperature sensitive parts are in contact with the motor 1PH813 1PH816 main motors 80 Operating Instructions 01 2015 610 48006 40c Commissioning 6 7 Safety instructions for commissioning NOTICE Thermal motor damage Windings and bearings can be destroyed if the motor overheats Further if a synchronous motor overheats this can demagnetize the permanent magnets e Only operate the motors in conjunction with effective temperature control NOTICE Motor damage when the maximum speed is exceeded The maximum speed Nmax is the highest permissible operating speed The maximum speed Nmax is stamped on the rating plate nameplate
161. y Bear in mind that the friction disc 4 cannot be cleaned When using brakes equipped with microswitch 27 the armature 2 can only be removed after having taken off the stud 31 and the straight pin 32 Used studs 31 and straight pins 32 must be replaced by new parts after the brake module has been reassembled Installation of the brake module must be carried out in reverse order of removal Size 13 19 24 r4 Ma tightening torques of cheese head screws 10 of flange 3 5 9 14 22 Table 22 1 Mag tightening torques of cheese head screws 10 for flange 3 Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 22 1PH813 1PH816 main motors Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions RKENDRION 6 3 Microswitch 27 adjustment only applicable to brake modules with microswitch 27 A Warning The motor circuit must be protected in such a way that no accidental motor start up can occur when the microswitch 27 contact closes The cheese head screws 29 must be tightened to the specified Ma tightening torques When using brake modules equipped with a microswitch 27 the microswitch may need to be adjusted during maintenance and service work 1 4 5 6 The microswitch can only be adjusted after the brake has been released electrically and the cheese head screws 29 have been slightly loosened Check whethe
162. ype 222 This applies to all brake sizes When rubber bolts 18 are used size 19 and 24 brakes insert the bolts 18 into the bores provided in the brake shaft 13 see Fig 11 1 after the shaft has cooled down When using a size 29 brake insert the O ring 26 into the groove in the brake shaft 13 see Fig 11 1 If rubber bolts 18 size 19 24 brakes or an O ring 26 size 29 brakes are used check that they are correctly positioned rubber bolts 18 rounded end pointing outwards in the bores of the brake shaft 13 square socket O ring 26 located in the groove near the brake shaft teeth 9 During brake mounting apply talc to the projecting surface of the rubber bolts 18 or O ring 26 to reduce slip on forces eo m ON Kendrion Villingen GmbH Operating Instructions 77 500 B Last updated 12 Dec 2013 Page 12 1PH813 1PH816 main motors 136 Operating Instructions 01 2015 610 48006 40c Appendix A 3 Holding brake operating instructions OKENDRION 5 1 2 Mounting the brake module to the motor A Attention The friction surfaces of the friction disc 4 the guide surfaces of the square socket size 13 19 24 brakes or the teeth of the friction disc 4 size 29 brakes must be free from grease or oil Do not use any lubricant to improve the axial guide properties of the friction disc 4 and make sure to avoid damage to the sealing rings 6 and 11 1 Mount the brake module in vertical position wi

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