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Operating Instructions Edition 02/2008

DC motorType 1GG5

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22.02.2008 13:10

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Introduction 1Safety notes 2Description 3Preparations for use 4Assembling 5Connection 6Commissioning 7

Operation 8Maintenance 9Spare Parts 10Decommissioning 11Appendix A

DC motor

Operating Instructions

Edition 02/2008

This documentation pertains toType 1GG5

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Safety Guidelines

This manual contains notices you have to observe in order to ensure your personal safety, as well as to preventdamage to property. The notices referring to your personal safety are highlighted in the manual by a safety alertsymbol, notices referring only to property damage have no safety alert symbol. These notices shown below aregraded according to the degree of danger.

DANGERindicates that death or severe personal injury will result if proper precautions are not taken.

WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.

CAUTIONwith a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTIONwithout a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICEindicates that an unintended result or situation can occur if the corresponding information is not taken intoaccount.

If more than one degree of danger is present, the warning notice representing the highest degree of danger willbe used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating toproperty damage.

Qualified PersonnelThe device/system may only be set up and used in conjunction with this documentation. Commissioning andoperation of a device/system may only be performed by qualified personnel. Within the context of the safety notesin this documentation qualified persons are defined as persons who are authorized to commission, ground andlabel devices, systems and circuits in accordance with established safety practices and standards.

Prescribed UsageNote the following:

WARNINGThis device may only be used for the applications described in the catalog or the technical description and onlyin connection with devices or components from other manufacturers which have been approved orrecommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,positioning and assembly as well as careful operation and maintenance.

TrademarksAll names identified by are registered trademarks of the Siemens AG. The remaining trademarks in thispublication may be trademarks whose use by third parties for their own purposes could violate the rights of theowner.

Disclaimer of LiabilityWe have reviewed 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, theinformation in this publication is reviewed regularly and any necessary corrections are included in subsequenteditions.

Siemens AGAutomation and Drives

Postfach 48 4890327 NRNBERGGERMANY

A5E02059153A AA 02/2008

Copyright Siemens AG .Technical data subject to change

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A5E02059153A AASiemens AG Operating Instructions V1.04 1GG5 3

Table of contents1 Introduction................................................................................................................................................ 9

1.1 About these operating instructions ................................................................................................9

2 Safety notes............................................................................................................................................. 112.1 Observing the five safety rules.....................................................................................................11

2.2 Safety and application instructions ..............................................................................................11

3 Description.................................................. ............................................................................................. 133.1 Applications..................................................................................................................................13

3.2 Relevant standards ......................................................................................................................13

3.3 Rating plate ..................................................................................................................................13

3.4 Motor variant 1GG .......................................................................................................................15

3.5 Terminal box ................................................................................................................................15

3.6 Rolling-contact bearing bushes....................................................................................................16

4 Preparations for use ........................................................................................................ ........................ 174.1 Shipment and packaging .............................................................................................................174.1.1 Scope of delivery .........................................................................................................................17

4.2 Transport and storage..................................................................................................................184.2.1 Transporting.................................................................................................................................184.2.2 Storage.........................................................................................................................................194.2.3 Protection against corrosion ........................................................................................................21

5 Assembling.............................................................................................................................................. 235.1 Installing the motor.......................................................................................................................23

5.2 Noise emission.............................................................................................................................24

5.3 Connecting ventilation / cooling systems.....................................................................................24

5.4 Aligning the motor ........................................................................................................................25

5.5 Mounting the motor securely........................................................................................................255.6 Pushing on the power output elements .......................................................................................26

6 Connection .............................................................................................................................................. 276.1 General ........................................................................................................................................27

6.2 Cable entry...................................................................................................................................28

6.3 Connecting the main circuit..........................................................................................................28

6.4 Connecting the earthing conductor..............................................................................................30

6.5 Internal equipotential bonding......................................................................................................32

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Table of contents

A5E02059153A AA4 Siemens AG Operating Instructions V1.04 1GG5

6.6 Connecting auxiliary circuits........................................................................................................ 32

6.7 Connecting an external fan ......................................................................................................... 33

6.8 Final measures............................................................................................................................ 33

7 Commissioning............................................................................................................... ......................... 357.1 Safety information ....................................................................................................................... 35

7.2 Measures to be performed prior to startup.................................................................................. 36

7.3 Checking the insulation resistance ............................................................................................. 37

7.4 Power on ..................................................................................................................................... 38

7.5 Deactivating ................................................................................................................................ 39

7.6 Final measures............................................................................................................................ 40

8 Operation.................................................... ............................................................................................. 418.1 Safety information ....................................................................................................................... 41

8.2 Switch on..................................................................................................................................... 428.3 Deactivating ................................................................................................................................ 43

8.4 Special operating conditions ....................................................................................................... 43

8.5 Stoppages ................................................................................................................................... 43

8.6 Faults........................................................................................................................................... 448.6.1 Safety notes during operation ..................................................................................................... 448.6.2 Faults in operation....................................................................................................................... 468.6.3 Rolling-contact bearing faults...................................................................................................... 478.6.4 Brush faults ................................................................................................................................. 488.6.5 Commutator faults....................................................................................................................... 49

9 Maintenance............................................................................................................................................ 519.1 Servicing...................................................................................................................................... 519.1.1 Safety information ....................................................................................................................... 519.1.2 Initial inspection........................................................................................................................... 529.1.3 MTTR .......................................................................................................................................... 539.1.4 Main inspection ........................................................................................................................... 549.1.5 Lubrication intervals and lubrication types for the operation of rolling-contact bearings ............ 559.1.6 Cleaning ...................................................................................................................................... 569.1.7 Checking the carbon brushes ..................................................................................................... 579.1.8 Replacement of carbon brushes ................................................................................................. 589.1.9 Adjusting the brush rocker .......................................................................................................... 599.1.10 Maintenance of commutator........................................................................................................ 599.1.11 Maintenance of terminal boxes ................................................................................................... 61

9.2 Repair.......................................................................................................................................... 629.2.1 Sicherheitshinweise .................................................................................................................... 629.2.2 Dismantling the machine............................................................................................................. 639.2.3 Dismantling the bearings............................................................................................................. 649.2.4 Assembling the motor ................................................................................................................. 649.2.5 Mounting the bearings................................................................................................................. 659.2.6 Tightening torques for bolted connections .................................................................................. 659.2.7 Speed sensor .............................................................................................................................. 669.2.7.1 Disassembling and assembling a speed sensor with a conical hub........................................... 669.2.7.2 Disassembling and assembling the speed sensor for overhung mounting ................................ 689.2.7.3 Disassembling and assembling the speed sensor for construction type IM B5.......................... 69

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Table of contents


10 Spare Parts................................................................................................................ .............................. 7310.1 Ordering data ...............................................................................................................................73

10.2 Ordering spare parts ....................................................................................................................73

10.3 Stator and rotor for 1G.5, 1H.5, shaft heights 500 to 630............................................................74

10.4 1GG5 external fan........................................................................................................................75

10.5 Replacing rolling-contact bearings...............................................................................................77

10.6 Rolling-contact bearing, drive end ...............................................................................................7710.6.1 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................77

10.7 Rolling-contact bearing, non-drive end ........................................................................................7810.7.1 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................78

10.8 Terminal boxes.............................................................................................................................7910.8.1 1XB7710 main terminal box.........................................................................................................7910.8.2 1XB7942 main terminal box.........................................................................................................8010.8.3 Auxiliary terminal box...................................................................................................................81

10.9 Speed sensor...............................................................................................................................8210.9.1 Shaft heights 180 to 630 ..............................................................................................................8210.9.1.1 Speed sensor with conical hub ....................................................................................................8210.9.1.2 Speed sensor for overhung mounting..........................................................................................8310.9.1.3 Speed sensor for construction type IM B5...................................................................................84

11 Decommissioning ............................................................................................................ ........................ 8511.1 Disposal of components with electrical insulation........................................................................85

A Appendix.................................................................................................................... .............................. 87A.1 SIEMENS Service Center ............................................................................................................87

A.2 Starting check list .........................................................................................................................88

A.3 Commissioning check list.............................................................................................................89

A.4 Inspection check list.....................................................................................................................90

A.5 Notes............................................................................................................................................92

Index......................................................... ............................................................................................... 95

TablesTable 3-1 Relevant standards......................................................................................................................13Table 3-2 Rating plate data..........................................................................................................................14Table 3-3

Insulation classes of series 1G... and 1H... .................................................................................14

Table 4-1 Tightening torques for the shaft screw on the rotor shipping brace.............................................18Table 6-1 Terminal designations in example B1..........................................................................................28Table 6-2 Air insulation clearances..............................................................................................................29Table 6-3 Terminal box connection data......................................................................................................29Table 6-4 Tightening torque of screws with cable lugs................................................................................31Table 6-5 Tightening torque of screws with ground terminals .....................................................................31Table 7-1 Winding insulation resistance at 25 C ........................................................................................38

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Table of contents


Table 8-1 Vibration magnitude as a function of vibration frequency........................................................... 42Table 8-2 Faults in operation....................................................................................................................... 46Table 8-3 Rolling-contact bearing faults...................................................................................................... 47Table 8-4 Brush faults ................................................................................................................................. 48Table 8-5 Commutator faults....................................................................................................................... 49Table 9-1 MTTR in fault-free operation ....................................................................................................... 53Table 9-2 Suitable greases for rolling-contact bearings (down to -20 C) .................................................. 55Table 9-3 Commutator overhaul - minimum permissible diameter ............................................................. 60Table 9-4 Tightening torques dependent on thread size [Nm 10%] ........................................................ 66Table 9-5 Recommended torques for tightening the shaft journal .............................................................. 67Table 9-6 Recommended torques for tightening the shaft journal .............................................................. 68Table 9-7 Recommended torques for tightening the half-coupling ............................................................. 70Table 9-8 Tightening torques for joining coupling ....................................................................................... 71Table 10-1 Spare parts stator and rotor 1G.5, 1H.5, shaft heights 500 to 630............................................. 74Table 10-2 Spare parts external fan 1GG5 ................................................................................................... 76Table 10-3 Spare parts rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630............................. 77Table 10-4 Spare parts rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630............................. 78Table 10-5 Spare parts main terminal box 1XB7710 .................................................................................... 79Table 10-6 Spare parts main terminal box 1XB7942 .................................................................................... 80Table 10-7 Spare parts auxiliary terminal box............................................................................................... 81Table 10-8 Spare parts speed sensor with conical hub for shaft heights 180 to 630 ................................... 82Table 10-9 Spare parts speed sensor for overhung mounting for shaft heights 180 to 630......................... 83Table 10-10 Spare parts speed sensor for construction type IM B5 for shaft heights 180 to 630.................. 84Table 11-1 Heat treating................................................................................................................................ 86Table 11-2 Afterburning of the binding material vapors ................................................................................ 86Table A-1 Technical support........................................................................................................................ 87Table A-2 Starting check list ........................................................................................................................ 88Table A-3 Commissioning check list............................................................................................................ 89Table A-4 Check list for inspection at standstill ........................................................................................... 90Table A-5

Check list for inspection in operation .......................................................................................... 91

FiguresFigure 3-1 Example of rating plate ............................................................................................................... 14Figure 3-2 Machine type 1GG... ................................................................................................................... 15Figure 4-1 Rotor shipping brace device without coupling (1) and with coupling (2)..................................... 18Figure 6-1 Connection of main terminals with cable lug............................................................................... 29

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Figure 6-2 Connection of auxiliary terminals with cable lug..........................................................................30Figure 6-3 Connection without cable lugs .....................................................................................................30Figure 9-1 Adjusting the brush rocker: Fixed part (1), brush rocker (2)........................................................59Figure 9-2 View and section A - B.................................................................................................................61Figure 9-3 Details X and Y ............................................................................................................................61Figure 9-4 Speed sensor assembly...............................................................................................................67Figure 9-5 Speed sensor assembly...............................................................................................................69Figure 9-6 Speed sensor assembly...............................................................................................................70Figure 10-1 Stator and rotor 1G.5, 1H.5, shaft heights 500 to 630.................................................................74 Figure 10-2 External fan 1GG5 .......................................................................................................................75Figure 10-3 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................77Figure 10-4 Rolling-contact bearing for 1G.5, 1H.5, shaft heights 500 to 630................................................78Figure 10-5 Main terminal box 1XB7710.........................................................................................................79Figure 10-6 Main terminal box 1XB7942.........................................................................................................80Figure 10-7 Auxiliary terminal box...................................................................................................................81Figure 10-8 Speed sensor with conical hub for shaft heights 180 to 630 .......................................................82Figure 10-9 Speed sensor for overhung mounting for shaft heights 180 to 630.............................................83 Figure 10-10 Speed sensor for construction type IM B5 for shaft heights 180 to 630......................................84

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Introduction 11.1 About these operating instructions

These operating instructions describe the machine and explain best practices in machinehandling, from initial delivery to final disposal of the equipment.

Read these instructions before you handle the machine to become familiar with its designand operating principles and thus ensure safe, problem-free machine operation and long

service life.This document and/or excerpts thereof may not be reproduced or copied without express,written permission from SIEMENS. Its content may not be passed to third parties or used forany proscribed purpose.

We strive continually to improve the quality of information provided in these instructions.Please therefore contact us if you discover any errors or wish to make suggestions forimprovements. For contact information, please refer to Chapter "Siemens Service Center(Page 87)"

If the description in these operating instructions is inconsistent in any regard with the actualsupplied machine, you must either make an informed decision as to the best course of actionor, if you are uncertain, contact the Siemens Service Center (Page 87).

Always follow the safety instructions and notices in these instructions.

Text format featuresIn addition to the safety-related notices and instructions which you must read, you will findthe text in these instructions is formatted in the following way:

1. Handling instructions are always formatted as a numbered list. Always perform the stepsin the order given.

Lists are formatted as bulleted lists. Lists on the second level are hyphenated.

NoteA Note is an important item of information about the product, handling of the product or therelevant section of the document. Notes provide you with help or further suggestions/ideas.

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Safety notes 22.1 Observing the five safety rules

For your personal safety and to prevent material damage when working on the device,always observe the safety instructions on the product and the following five safety rules: Youmust read the information provided in "Safety information".

The five safety rules:1. isolate,2. Protect against reconnection,3. verify that the equipment is not live,4. Ground and short circuit,5. Cover or enclose adjacent components that are still live

Qualified personnelCommissioning and operation of this machine are to be carried out by qualified personnelonly. For the purpose of the safety information in this Instruction Manual, a qualified personis someone who is authorized to energize, ground, and tag equipment, systems, and circuitsin accordance with established safety procedures.

2.2 Safety and application instructionsThe safe use of electrical machines

WARNINGRotating or live partsRotating or live parts are dangerous.

Fatal or severe injuries and substantial material damage can occur if the required coversare removed or if the machines are not handled, operated, or maintained properly.

Only remove covers in accordance with regulations and operate machines correctly.Perform regular maintenance on the machine.

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Safety notes

2.2 Safety and application instructions


Qualified personnelThese operating instructions only contain the information that is necessary for the machinesto be used by qualified personnel in accordance with their intended purpose.

Those responsible for plant safety must ensure the following:

The basic planning work for the system and all work relating to transportation, assembly,installation, commissioning, maintenance and repairs is carried out by qualified personneland checked by responsible, suitably skilled personnel.

The operating instructions and machine documentation are always available. The technical data and specifications relating to installation, connection, ambient and

operating conditions are taken into account at all times.

The system-specific installation and safety regulations are observed. Personal protective equipment is used. Work on or in the vicinity of these machines by unqualified persons is prohibited. If the machines are used outside industrial areas, the installation site must be

safeguarded against unauthorized access by means of suitable protection facilities (e.g.,safety gates) and appropriate warning signs.

NoteSiemens Service CenterWe recommend engaging the support and services of your local Siemens Service Center(Page 87) for all planning, installation, commissioning, and maintenance work.

[ID 2.02]

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Description 33.1 Applications

Series 5, 6 and 7 DC motors are designed with open-circuit cooling or as closed-circuit-cooled machines with laminated stator yoke.

They are designed for the widest possible range of drive and energy conversion applicationsand comply with the harmonized standards of series IEC / EN 60034 (VDE 0530). They are

not approved for operation in hazardous zones and areas.Unless otherwise specified, the rated powers apply for continuous operation at a coolanttemperature of 40 C and an installation altitude of up to 1000 m above sea level. Pleasenote any data to the contrary on the rating plate. Operating conditions must comply with allspecifications on the rating plate.

DC motors are components for installation in machines as defined by the MachineryDirective 89/392/EEC. The system may not be commissioned until it has been proven thatthe final product is in conformance with this directive. Please refer to IEC / EN 60204-1 inthis respect.

3.2 Relevant standardsInformation about degree of protection, cooling and construction type can be found on therating plate. The DC machines comply with the following standards:

Table 3-1 Relevant standards

Title StandardGeneral specifications for rotating electrical machines IEC / EN 60034-1

IEC / EN 60085

Terminal designations and direction of rotation forrotating electrical machines

IEC / EN 60034-8

3.3 Rating plateThe rating plate shows the technical specifications for the supplied motor.

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Description

3.3 Rating plate


Figure 3-1 Example of rating plate

Table 3-2 Rating plate data

Item Description Item Description1 Type 9 Supply connection data

2 Serial number 10 Degree of protection

3 Temperature class 11 Construction type

4 Armature voltage [V] 12 Standards and regulations5 Armature current [A] 13 Motor weight [t]

6 Exciter data 14 Power [kW]

7 Cooling method 15 Speed [RPM]

8 Brush equipment 16 Air flow direction

GeneralThe machine has no housing, but is designed with a fully laminated stator yoke which allowsa rate of current change of up to 250 IN/sec.

Insulation systemThe high-quality DURIGNIT 2000 insulation system means that the motors are suitable foruse in both tropical humidity and industrial environments. You will find the insulation classesin the following table.

Table 3-3 Insulation classes of series 1G... and 1H...

Series Insulation class1GG5

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Description

3.4 Motor variant 1GG


Series Insulation class1GH5

1HS5

1HQ5

155 (F)

1GG6, 1GG7

1GH6, 1GH7

1HS6, 1HS7

1HQ6, 1HQ7

180 (H)

3.4 Motor variant 1GGSchematic representation of a variant 1GG motor

Figure 3-2 Machine type 1GG...

Ventilation and coolingVariant 1GG DC motors feature a built-on external fan which provides speed-independentventilation.

The motors are designed as open-circuit ventilated machines with IP23 degree of protection.The external fan, which is normally mounted at the NDE (cooling method IC 06), impels thecooling air through the machine.

3.5 Terminal boxThe terminal box contains terminals for the main circuit and auxiliary circuit (excitation) andpossibly for other auxiliary circuits. The terminal boxes fulfill degree of protection IP55.

The screw-mounted cable entry plate is supplied as standard without drilled holes so that theconstruction, quantity and size of cable screw connections can be tailored to meet specificcabling requirements.

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Description

3.6 Rolling-contact bearing bushes


If a separate wiring space is prescribed for specific auxiliary circuits, an additional auxiliaryterminal box is mounted on the side of the terminal box.

3.6 Rolling-contact bearing bushesThe rolling-contact bearing is normally a floating bearing at the drive end and a locatingbearing at the non-drive end. For variants and application of bearing bushes, please refer toChapter "Spare parts (Page 73)".

On machines with a regreasing device, the lubricant plate specifies the types of rolling-contact bearing fitted.

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Preparations for use 44.1 Shipment and packaging

4.1.1 Scope of deliveryChecking the scope of delivery for completeness

The drive systems are put together on an individual basis.

When you take receipt of the delivery, please check immediately whether the scope ofthe delivery matches up with the accompanying documents.

Report any apparent transport damage to the delivery agent immediately. Report any apparent defects/missing components to the appropriate Siemens office

immediately. Siemens will not accept any retrospective warranty claims relating to itemsmissing from the delivery.

Never commission a damaged machine.The Operating Instructions are included in the scope of supply. Store them in an accessiblelocation.

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Preparations for use

4.2 Transport and storage



4.2.1 TransportingCAUTIONTransport damage if the rotor shipping brace device is not used.The motor can be damaged if it is jolted during transport.

Material damage can result.

Always transport the motor with the rotor shipping brace supplied. It must be securelyattached during transportation. Do not remove it until you are ready to push on the outputelement. When the motor has to be transported after the output element is pushed on, youmust take other appropriate measures to fix the axial position of the rotor. Please refer to

the illustration below.

Figure 4-1 Rotor shipping brace device without coupling (1) and with coupling (2).

Sleeve Fixture

Coupling Shaft screw

Table 4-1 Tightening torques for the shaft screw on the rotor shipping brace

Thread in the shaft extension Tightening torque PreloadM20 50 Nm 12 kN

M24 100 Nm 20 kN

M30 180 Nm 32 kN

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WARNINGTransporting or lifting the machineThe motor or the motor set may only be transported and lifted with the hoisting lugs, as itmight otherwise tip over or slip out of the lifting equipment.

Death, serious injury, or material damage can result.

Always use the lugs on the stator frame to lift the motor. Use suitable rope guidance orspreading devices. You will find the weight of the motor on the rating plate. Only lift andtransport the motors in a position appropriate to their design.

Only the intended openings, eyebolts, and lifting pins on the base plates must be used fortransporting motor sets. Note the maximum capacity of the lifting lug. Motor sets must notbe lifted by attachment to the individual motors. The auxiliary eyebolts provided, e.g. on fancowls and cooler attachments, are suitable only for hoisting the part to which they are fitted.

Vertical-design motors must always be transported in the vertical position if the rotor is not

fixed. If transport in a horizontal position should prove to be necessary in special cases, therotor must be fixed again before the motor is turned back up. Vertical motors with suitablebearings can be supplied in the horizontal position from the manufacturing plant.

WARNINGCenter of gravity when transporting or lifting the machineIf the center of gravity of a load is not located centrally between the attachment points, themotor can tip over or slip out of the lifting equipment when it is being transported or lifted.

Death, serious injury, or material damage can result.

Always take account of the center of gravity when transporting or lifting the motor. The

machine's center of gravity is indicated in the relevant dimension diagram. Observe thehandling instructions on the machine when transporting it. If the center of gravity is notlocated centrally between the attachment points, then position the hoisting hook above it.Be aware of the possibility of different loads on the sling ropes or lifting straps and thecarrying capacity of the lifting equipment.

4.2.2 StorageIf you do not intend to commission the machine immediately, take the following precautions:

Always keep the terminal box's cover tightly sealed. Do not remove the rotor shipping brace device supplied. Open the pressure fingers of the brush holders and take the brushes out of the holders. If necessary, reapply the anti-corrosion protection at the shaft extension.

Storing outdoorsStore the machine in an area which meets the following criteria:

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Choose a dry storage location with plenty of space, which is safe from flooding and freefrom vibrations.

Repair any damage to the packaging before putting the equipment into storage insofar asthis is necessary to ensure proper storage conditions.

Place the machine and accessories on pallets, wooden beams or foundations thatguarantee protection against ground dampness. Prevent the machine sinking into the ground. Ensure that the air circulation under the equipment is not impeded.

Covers or tarpaulins used to protect the equipment against the weather must notmake contact with the surfaces of the equipment.

Covers or tarpaulins must not trail on the floor around the machine. Place wooden spacer blocks between the covers and the machine.

Storing indoors Store the machine in an area which meets the following criteria:

Dry, dust-free, frost-free and vibration-free Well ventilated Offers protection against extreme weather conditions The air in the room must not contain any harmful gases.

Protect the machine from shocks and humidity.CAUTIONDamage to the rolling-contact bearingImproper storage and vibrations can damage the rolling-contact bearing.

If the motor is supplied with a rotor shipping brace, use it to secure the rotor. Protect themachine against severe radial vibrations, since the rotor shipping brace is not capable ofabsorbing these completely.

Protection against humidity If a dry storage area is not available, then take the following precautions:

Wrap the machine in moisture-absorbent material and then wrap it in film to create anair-tight unit.

Place a humidity meter inside the film wrapping. Inspect the machine regularly.

Long-term storageIf you are storing a machine for more than six months, you must check its condition every sixmonths.

Check the machine for damage.

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Carry out any necessary maintenance work. Document all preservation measures taken so that they can be reversed before the

machines are put back into service.

Provide a constant source of low heat to the machine windings, along with forced airventilation.

Condensation waterSevere fluctuations in the ambient temperature, direct solar radiation and high humiditylevels in the storage area can cause condensate to collect in the machine. Make sure thatthe storage conditions are such that condensate cannot form in the machine.

4.2.3 Protection against corrosionGeneral anti-corrosion measures

If the machine is stored in dry conditions, then take the following precautions:

Storage up to six months:Apply a coat of corrosion protective compound to all accessible bare metal parts such asthe exposed shaft extension, flange or machine feet.

Storage for longer than six months:Apply a coat of anti-corrosion compound which provides long-term protection, e.g.Tectyl 506.

Inspect the machine regularly and apply an additional coating of corrosion protection ifnecessary.

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Assembling 55.1 Installing the motor

CAUTIONHigh surface temperaturesThe surface of the machine heats up during operation. Built-on parts can be damaged byhigh temperatures.

Only use heat-resistant built-on parts. Temperature-sensitive parts such as normal cablesor electronic components must not be allowed to touch nor be attached to these parts.

Rotor shipping braceIf at all possible, do not remove the rotor shipping brace (if fitted) until after installation iscomplete.

Motor foundationPlease take appropriate measures to ensure a resonance-free installation of the motor.When designing the foundation, please observe DIN 4024, Part 2.

Water drain holesIn the bearing shields at the DE and NDE, water drain holes are situated in the foot area andopposite the regreasing devices. These have the following degrees of protection:

Degree of protection IP23 water drain holes open Degree of protection IP54 / IP55 water drain holes sealed with plastic plugs.Where drain holes in the foot area are sealed, it can be useful to remove the appropriatescrews or plugs depending on the ambient and operational conditions.

NOTICEDegree of protectionThe degree of protection of motors with IP54 or higher is nominally reduced to IP44 byremoval of the plastic plug or screw.

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Assembling

5.2 Noise emission


5.2 Noise emissionWhen the machine is in operation, the A-weighted sound pressure level (measured inaccordance with ISO 1680) might exceed 70 dB(A).

Take this into account when evaluating the noise levels at any operating personnel

workstations. If necessary take suitable noise protection measures.

5.3 Connecting ventilation / cooling systemsExternal fans ensure that the motor is cooled independently of its speed. Observing thefollowing conditions ensures proper cooling of the motor:

The cooling air must be able to enter unimpeded through the air inlets and be dischargedunimpeded through the air outlets.

Discharged air must not be immediately sucked back into the machine.

The cooling air must be clean.

The normal ventilation air-flow direction is from NDE to DE. The ventilation air-flowdirection is specified on the rating plate and must not be changed without priorconsultation, as derating may be required. In the case of motors with winding temperaturemonitoring, the temperature monitor may cease to function if the air-flow direction issubsequently changed.

If ventilation openings are covered by grilles, the openings must be directed downward tomaintain the degree of protection. Note the motor's type of construction.

If the type of construction dictates that ventilation openings are on top of the motor, youmust make and mount the covers to suit the local installation conditions in order tomaintain the degree of protection.

In the case of motors with open-circuit cooling that are designed for a pipe connectionand/or operation with an external fan in accordance with the intended cooling method toIEC / EN 60034-6, you must install and connect pipes, external fan and air ducts of anappropriate type and design. With the IC 37 cooling method, replace the grilles onunused openings by closed covers.

On pipe-ventilated machines, the cooling-air flow and direction must comply with therating plate specification.

In the case of motors with a built-on external fan or with an air-to-air or air-to-water heatexchanger, the relevant operating instructions must be observed.

Inlet air ducts and machine components must not be sealed by agents containingsilicone.

If you need to change the position of the external fan, then reposition the grilles, filtersand sound absorbers in such a way that the cooling efficiency and degree of protectionare maintained.

Please observe the following for side-mounted external fans: External fans are supplied separately. Do not mount the external fan until the foot bolts have been finally tightened. Ensure the external fan is supported, if necessary.

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Assembling

5.4 Aligning the motor


5.4 Aligning the motorRequirements

Detailed specialist knowledge of the following measures is required in order to correctly alignand securely mount the machine:

preparing the foundation, selecting and mounting the coupling, measuring the concentricity and axial eccentricity tolerances, axial and horizontal positioning.If you are not familiar with the prescribed measures and procedures, make use of theservices offered by the local Siemens Service Centers (Page 87).

Vertical and horizontal alignmentThe following measures are required in order to compensate any radial offset at the couplingand to horizontally adjust the electric motor with respect to the driven load:

Place shims under the feet of the motor to position it vertically and to preventstress/distortion. The number of shims should be kept as low as possible, so stack thelowest possible number of strong ones as opposed to several thinner ones.

For horizontal positioning, push the motor sideways onto the foundation. Pay attention tomaintaining the axial position.

When positioning the motor, ensure that a uniform axial gap is maintained around thecoupling.

5.5 Mounting the motor securelyRequirements

Preconditions for smooth, vibration-free operation:

Stable foundation or stable machine suspension in the case of flange-mounted motors. Precise motor alignment. Correct balancing of parts to be fitted to the shaft extension.

Secure mounting of different motor variants Use fixing bolts with the necessary ISO 898-1 classification (e.g. 10.9) to secure the

machine and safely transmit forces resulting from torque.

On motors with an upward oriented shaft extension, make sure that no water canpenetrate the top bearing.

Machines that are attached to the wall by their mounting feet because of their type mustbe supported from below by a wall strip, for example, or pinned.

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Assembling

5.6 Pushing on the power output elements


Install motors with a belt output on clamping bars. This will ensure the correct belttension.

5.6 Pushing on the power output elementsBalance quality

The rotors are balanced dynamically. For shaft extensions with featherkeys, the balancingtype is specified using the following coding on the face of the drive end of the shaft:

"H" means balancing with a half feather key "F" means balancing with a whole feather key.

Pushing on the power output elements Make sure that the balancing method of the output element is correct! If the power output element is shorter than the feather key with balancing type "H", then

you must machine off the section of feather key protruding from the shaft contour andoutput element in order to maintain the balance quality.

Power output elements may only be pushed on or pulled off with the correct equipment.WARNING

The feather key can fall outThe featherkeys are only secured during transport to prevent them from falling out. If amachine with two shaft extensions does not have an output element on one shaft

extension, the feather key can fall out during operation.Death or serious injury can result.

On shaft extensions without output element, make sure that the feather key cannot fallout and shorten it by approximately half for balance type "H".

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Connection 66.1 GeneralSafety notes

Please observe the five safety regulations when working with the motor. All of the work must

be carried out by qualified, skilled personnel.

ConnectionThe machine is connected to the supply in the terminal box. Supplementary connections forauxiliary circuits with terminal strips for cable cross-sections of up to 2.5 mm2 are provided.Terminal post insulators or Terminal Boards (depending on construction type) are providedfor connecting the excitation circuit.

Terminal boxes can also be rotated by 90 in each case depending on the connectingdirection. Please ensure that winding feeder cables are relaid correctly. In this case, theinsulator plate does not need to be repositioned. Under difficult conditions, e.g. with largecross sections or a large number of cables, it might not always be possible to reposition a

terminal box or special adaptation measures may need to be taken. The connection must be made in such a way that a permanent, safe electrical connection

is maintained. Depending on their design, the connecting parts may be suitable forconnection with or without cable lugs. Use the matching cable end pieces.

Make sure the protective conductor connection is secure. Make sure that you follow the rating plate data and the terminal diagram in the terminal

box when making the electrical connections.

Choosing the connecting leads When choosing connecting leads, you must take into account the rated current and the

plant-specific conditions (e.g. ambient temperature, cable installation, etc. to IEC /EN 60204-1).

Terminal designationAccording to IEC / EN 60034-8, the following basic definitions apply to the terminaldesignations on DC motors:

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Connection

6.2 Cable entry


Table 6-1 Terminal designations in example B1

B 1 Designationx Code letter for winding parts (A, B, C, D, E, F)

x Identification number showing winding start (1), end (2), or tapping if there is more than

one connection per winding

The terminal diagram pasted into the terminal box shows only the conditions required tomake the mains connection, i.e. with detailed representation of inner connections or windingcomponents.

6.2 Cable entryCable entry and routing

1.

The screw-mounted entry plate is not normally supplied with holes. Make sure the type,number, and size of the screw connections are appropriate to the specific cablingrequirements.

2. Only use guide elements which meet the following requirements: Guide elements must be adapted to suit the type and diameter of the cables. Guide elements must guarantee IP55 degree of protection. The same applies to

insertion points, where sealing rings and adhesive should be used.

Guide elements must be appropriate to cable installation conditions. For example, usecable grips where cables are not securely installed.

3. Connecting leads and, in particular, protective conductors in the terminal box should belaid out in an open arrangement, preferably with spare length to prevent chafing of the

cable insulation.

4. Close unused cable entries with suitable seal inserts. Please ensure the following: The seals are made of resistant, approved material. The degree of protection is guaranteed. Use sealing rings or adhesive, if necessary Cable entries can only be opened with a tool.

6.3 Connecting the main circuitRequirements

Remove the insulation from the conductor ends so that the remaining insulation is almostlong enough to reach the cable lug.

Insulate the cable lug sleeves to ensure air clearances are maintained.

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Connection

6.3 Connecting the main circuit


WARNINGShort circuits caused by projecting wire endsThe specified air insulation clearance can be reduced by projecting wire ends, resulting

in short circuits. This could result in death, serious injury or material damage.

Remove protruding cables. Ensure that air insulation clearances as specified in the tablebelow are maintained.

Table 6-2 Air insulation clearances

Voltage Air clearanceUp to 600 V > 8 mm

Up to 800 V > 10 mm

Up to 1200 V > 14 mm

Connecting using cable lugs Select the cable lugs corresponding to the required cable cross-section and the specified

dimensions of the terminal connection.

Tighten the contact and fastening nuts to the torque specified in the table below:Table 6-3 Terminal box connection data

Terminals 1XB7 gk 602 / gk 604 gk 702 / gk 704Terminal size M16 M10 M12

Tightening torque 83 Nm 13 Nm 20 Nm

Main terminals

Connectable cable cross-section 6 x 240 mm2 2 x 35 mm2 2 x 70 mm2

Terminal size M6 M4 M4

Tightening torque 4 Nm 1.2 Nm 1.2 Nm

Auxiliaryterminals

Connectable cable cross-section 35 mm2 6 mm2 6 mm2

Figure 6-1 Connection of main terminals with cable lug

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Connection

6.4 Connecting the earthing conductor


Figure 6-2 Connection of auxiliary terminals with cable lug

If the fittings for connection to busbars are not supplied, use only approved fittings, e.g. toDIN 43673 - corrosion-proof hexagon bolts (minimum strength class 5.6) with hexagonalnuts and spring elements, e.g. spring lock washers to DIN 128.

Connection without cable lugsIf terminal box size gk 602 or gk 702 is mounted on the machine, you can also connect thecables without cable lugs.

Figure 6-3 Connection without cable lugs

The design of the terminals makes it possible to connect finely stranded conductorswithout the use of wire end ferrules.

Only use end sleeves after first applying sufficient force to the conductor to ensure it isable to bear almost all the transferred binding power. Stiff wire end ferrules, which have

not yet been placed under pressure, reduce the binding power exerted on the conductor,thereby affecting the quality of the contact.

6.4 Connecting the earthing conductorThe grounding conductor cross-section of the motor must be in full conformance with theinstallation specifications, e.g. in accordance with IEC / EN 60204-1.

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Connection

6.4 Connecting the earthing conductor


CAUTIONDamage resulting from protective conductor currentsWhen the machine is operated on a converter with current limiter, but without ground-faultmonitoring, protective conductor currents of up to 1.7 times the external conductor currentcan arise if there is a ground fault on the output side. Neither the PE conductors of normallyrated multi-core connecting cables nor the PE connecting points of normal terminal boxesare suitable for this purpose. This results in material damage.

Install an adequately sized parallel protective conductor and connect this to the groundterminal on the motor housing. Use only the screws supplied.

Connecting the grounding conductorA hexagon bolt with spring lock washer and flat washer or a ground terminal is provided at

the designated grounding conductor connection points. The hexagon bolt can be used forconnecting stranded conductors with cable lugs or ribbon cables with an appropriatelyshaped conductor end.

When making connections, ensure the following:

the connecting surface is bare and protected against corrosion using a suitablesubstance, e.g. acid-free Vaseline

the flat and spring washers are located under the bolt head. The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not

exceeded

The minimum required screw-in depth and the tightening torque comply with the valuesspecified in the tables below. These differ depending on whether cable lugs or groundterminals are used.

Table 6-4 Tightening torque of screws with cable lugs

Bolt Screw-in depth Tightening torqueM12 x 25 > 16 mm 38 Nm

M16 x 35 > 20 mm 92 Nm

Table 6-5 Tightening torque of screws with ground terminals

Bolt Screw-in depth Tightening torqueM6 > 9 mm 8 Nm

M8 > 12 mm 20 Nm

M10 > 15 mm 40 Nm

Equipotential bondingTerminals are provided on the bearing shield for the connection of an equipotential bondingconductor.

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Connection

6.5 Internal equipotential bonding


6.5 Internal equipotential bondingThe equipotential bonding between the protective conductor terminal in the terminal box andthe motor housing is established through the terminal box fixing screws. These screws arerated and designed as an "equivalent conductive connection" in relation to the protective

conductor cross-section specified for the phase conductor in standard (IEC / EN 60034-1).

Equipotential bondingIn order to guarantee the current carrying capacity of the connection via the retaining bolts inthe event of a short circuit, make sure that the following conditions are fulfilled:

Use only original gaskets. The contact points underneath the bolt heads or spring lock washers must be bare metal

and protected against corrosion.

The standard cover fixing screws are an adequate equipotential bonding connectionbetween the terminal box cover and terminal box housing.

WARNINGElectric shockIf the equipotential bonding connection fails, parts of the machine may become live. Ifyou touch them, you will receive an electric shock. This could result in death, seriousinjury or material damage.

When performing any installation work you must always take care to ensure that allequipotential bonding connections remain effective.

6.6 Connecting auxiliary circuitsAuxiliary circuit

Terminal strips for cable cross-sections of up to 2.5 mm2 are provided for connectingauxiliary circuits (e.g. temperature sensor or anti-condensation heater).

The information required to connect the auxiliary circuits is provided in the connectiondiagram, located on the inside of the terminal box cover, and in the machine documentation.

The required length of stripped insulation on conductors for auxiliary terminals varies: From 6mm to 9 mm depending on the terminal type. When the length is correct, the bare conductormust reach the center stop in the terminal and at the same time the conductor insulation

must reach the contact part of the terminal.

Brush monitoringSignal transmitters for brush monitoring may be installed depending on the machine design.

The brush monitoring device senses the brush height limit value. When a brush heightreaches approximately 2 mm above the specified minimum height limit, a signal is generatedvia a microswitch. For normal operation at average speeds, this corresponds to a residualoperating period of about 500 to 1,000 operating hours. The carbon brushes must bereplaced punctually.

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Connection

6.7 Connecting an external fan


The electrical connection requirements are shown on the terminal diagram pasted into theterminal box.

Speed sensorWith add-on speed sensors, the electrical connection is made on the line side. Please followthe supplementary operating instructions in this respect.

Temperature monitoringOn machines with temperature sensors, design the temperature evaluation and controlcircuits such that any risk of unexpected, automatic restart of the installation after it hascooled down following a temperature monitor response can be completely precluded.

WARNINGTemperature monitoringIf the temperature monitoring system fails to prevent the machine from restartingautomatically after it has cooled, there is a risk of death or serious physical injury topersonnel caused by hazardous voltage and rotating parts if they are working on themachine when it restarts unexpectedly.

On machines with temperature sensors, design the temperature evaluation and controlcircuits in such a way that it is impossible for the machine to restart automatically.

6.7 Connecting an external fanProcedure

1. Connect the external fan motor in accordance with the terminal connection diagrampasted in the associated terminal box and in accordance with any information provided onplates and operating instructions.

2. The direction of rotation of the external fan must match the arrow indicating the directionof rotation. The fan impeller is visible through the air inlet point in the fan cowl on themotor. If the direction of rotation is incorrect, change it by swapping over two of the phaseconductors in the terminal box of the fan motor.

3. A protective circuit must be provided for electric machines with an external fan to ensurethat the main machine cannot be switched on when the fan unit is not in operation.

6.8 Final measuresChecks prior to closing the terminal box

1. Before closing the terminal box, please check that: The cables and links match the terminal diagram inside the terminal box cover.

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Connection

6.8 Final measures


The electrical connections in the terminal box are tight and fully comply with thespecifications in the chapters above.

The inside of the terminal box is clean and free of any cable debris. All of the clamping bolts and entry parts are securely tightened (this also applies to

unused terminals). Minimum air clearances have been respected. The connecting leads are laid in an open arrangement, and the cable insulation

cannot be damaged.

Any unused entry points are sealed. The sealing elements can only be removed with atool.

All of the seals/gaskets and sealing surfaces of the terminal box are in a goodcondition. If the joins are sealed purely by metal sealing surfaces, these must becleaned and lightly greased again.

The right cable guides are fitted with respect to degree of protection, method of laying,permissible cable diameter, etc., as stated in the specifications.

With a U-shaped terminal box casing, the entry plate is aligned and secured in such away that the seat for the box cover seal is continuous all the way round.

2. Then close the terminal box. Tightening torque for the cover fixing screws is 22 Nm.

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Commissioning 77.1 Safety informationQualified personnel

Only qualified personnel should be allowed to commission and operate this device. In the

safety instructions provided in this manual, qualified persons are those who have thenecessary authorization to commission, ground, and identify equipment, systems, andcircuits in accordance with the relevant safety standards.

Please note the general safety information in the chapter titled "Safety notes (Page 11)".

WARNINGRotating and live partsCovers prevent contact with live or rotating parts, or are used for proper air routing and thuseffective cooling of the motor.

Removing the covers during operation can result in death, serious injury, and material

damage.Never open covers during operation.

WARNINGFaults in operationAll deviations from normal operation, such as higher power consumption, highertemperatures and vibration levels, unusual noises and odors and tripped monitoringdevices, are indications that the motor is no longer functioning correctly.

In this case, maintenance personnel must be notified immediately to prevent disturbancesthat could either directly or indirectly lead to severe personal injury or substantial material

damage.If in doubt, switch off the drive in question immediately.

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Commissioning

7.2 Measures to be performed prior to startup


DANGEROverspeedWhen the exciter circuit is deactivated, the machine can reach dangerously high speeds.

Death, serious injury, or material damage will result.The control must be interlocked in such a way that the armature circuit can be connectedonly when the exciter circuit is energized. If the exciter circuit fails, switch off the armaturecircuit immediately.

7.2 Measures to be performed prior to startupThis list below does not claim to be complete. It may be necessary to perform additionalchecks and tests in accordance with the situation specific to the particular place ofinstallation.

ChecksOnce the system has been correctly installed, you should check the following prior tocommissioning:

All electrical and mechanical connections are securely seated and functioning properly. The motor has been assembled and aligned properly. The cover sheets have been remounted correctly to ensure effective cooling of the motor. The operating conditions correspond to the data specified on the rating plate. Any supplementary motor monitoring devices and equipment have been correctly

connected and are fully functional.

Appropriately configured control and speed monitoring functions ensure that the motorcannot exceed the permissible speeds specified on the rating plate.

The power output elements have the proper setting conditions according to type, forexample:

Couplings are aligned and balanced. The belt tension is properly adjusted if there is a belt drive. Gear tooth flank play and gear tooth tip play, as well as radial play, are properly

adjusted if there is a gearwheel output.

The minimum insulation resistance values are maintained. The grounding and equipotential bonding connections have been established correctly. All fixing screws, connecting elements and electrical connections are firmly tightened. The rotor can spin without coming into contact with the stator. All touch protection measures for moving and live parts have been taken. If the second shaft extension has not been used, its featherkey has been secured to

prevent it from being thrown out.

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Commissioning

7.3 Checking the insulation resistance


All external fans are ready for operation and have been connected so that they rotate inthe direction specified.

The flow of cooling air is not impeded. All brakes are operating correctly. Carbon brushes and brush levers can move freely in the brush guides. The spring action

is identical on all carbon brushes.

The machine is connected up appropriately for the specified direction of rotation.

Commissioning converters Before the motor is commissioned, the converter must be commissioned as described in

its operating instructions. Be aware of the motor parameters.

Make sure any work done is documented on the correct checklist.

7.3 Checking the insulation resistanceChecking the insulation resistance of the winding

The insulation resistance check on the winding relative to frame with DC voltage must beperformed prior to commissioning and again after any extended periods of storage or idletime.

WARNINGHazardous voltageDangerous voltages are sometimes present on the terminals during and immediately aftermeasurement of the winding insulation resistance. Contact with the terminals can result indeath, serious personal injury and damage to property.

If any power cables are connected, check them to ensure that no supply voltage can begenerated. Once you have measured the insulation resistance, discharge the winding byconnecting the ground potential.

Measuring the insulation resistance Before you begin measuring the insulation resistance, please read the manual for the

insulation resistance meter you are going to use.

The measuring voltage for insulation resistance measurements on electrical componentsmust never exceed 500 V. As an exception, a measuring voltage of 1000 V may be usedto test new windings on condition that they are insulation-tested beforehand with ameasuring voltage of max. 500 V and the measurement result is not below the minimumpermissible insulation value.

When measuring, wait until the full-scale resistance value is reached. This is the caseafter approximately one minute.

After measuring, ground the electrical components to discharge them.

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Commissioning

7.4 Power on


Limit values of winding insulation resistanceTable 7-1 Winding insulation resistance at 25 C

Rated voltageUN < 2 kV

Measuring circuit voltage 500 V (at least 100 V)

Minimum insulation resistance with new, cleanedor repaired windings

10 M

Critical specific insulation resistance after a longoperating time

0.5 M/kV

Dry, new windings have insulation resistance of between 100 and 2000 M, or possiblyvalues that are even higher. If the insulation resistance is close to the minimum value,then the cause could be humidity and/or pollution.

Over its operating lifetime, the motor winding insulation resistance can drop due toambient and operational influences. The critical insulation resistance value for a winding

temperature of 25 C can be calculated, depending on the rated voltage, by multiplyingthe rated voltage (kV) by the specific critical resistance value.

Example:

Critical resistance for UN of 400 V:

0.4 kV x 0.5 M/kV = 0.2 M

NOTICECritical insulation resistance is reached or insufficientIf the critical insulation resistance is reached or is insufficient, damage to the insulationand flashover voltages can result.

Dry the windings or clean and dry them thoroughly, having first removed the rotor. If the clean windings have not cooled to 25 C after drying, a lower insulation

resistance will be measured. The insulation resistance can only be properlyassessed after conversion to the reference temperature of 25 C. Allow the windingsto cool to 25 C or convert the insulation resistance using 25 C as the referencetemperature.

If the measured value is close to the critical value, you must check the insulationresistance at appropriately frequent intervals subsequently.

7.4 Power onTrial run

If the period between installation and commissioning is expected to be fairly long, make surethat water-cooled machines undergo a test run without water cooling.

Procedure Start up the motor without a load, temporarily. Check the direction of rotation at this point.

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Commissioning

7.5 Deactivating


As the motor is coasting down, check the mechanical operation for noise and vibration atthe bearings and bearing shields.

Where the motor is running without any mechanical problems, switch it back on again.Continue to the maximum speed allowed (according to the rating plate).

If the motor is not running smoothly or is emitting abnormal noises, switch it off anddetermine the cause of the fault as the motor coasts down. If the mechanical operation improves immediately after the motor is switched off, then the

cause is magnetic or electrical.

If mechanical operation does not improve immediately after switching the motor off, thenthe cause is mechanical (e.g. imbalance of electrical machines, etc.).

If the motor is running perfectly, switch on the cooling equipment. Observe the motor for a while during no-load operation.

NOTICEOverheating during test runs without water coolingThe motor can overheat without water cooling. Reduce the ON duration accordingly ifthe water cooler is not to be operated during a test run.

If it runs perfectly, connect a load. Check whether it is running smoothly. Record the voltage, current, and power values. As far as possible, record the corresponding values of the driven machine. Monitor and record the temperatures of the bearings, windings, and so on until the

system reaches a steady state.

See alsoStarting check list (Page 88)

7.5 DeactivatingIn most cases, the motor will be shut down by an automatic control system. If switch-off isnot performed by the correct control system, please proceed as follows:

1. Switch the machine off.2. Switch off any external fans.3. Switch off the coolant supply. Follow the operating instructions provided by the

manufacturer.

4. Switch on the anti-condensation heating.

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Commissioning

7.6 Final measures


7.6 Final measuresThis list below does not claim to be complete. It may be necessary to perform additionalchecks and tests in accordance with the situation specific to the particular place ofinstallation.

Measures to be performed prior to commissioning the plantAfter proper installation, and prior to commissioning the plant, the following measures andchecks must be performed:

The installation and operating conditions comply with the specifications on the ratingplate.

The manufacturer has been consulted if the motor is to be operated continuously underlight-load conditions (I < 50% IN), due to the risk of high brush wear or commutatorproblems.

The bearings have been regreased as appropriate for the model. If the bearings are insulated, the insulation has not been bridged. If an air-to-water heat exchanger is installed, the water cooler is connected, filled, air

bled, and ready to run. This also applies after long outage periods.

Make a record of all work undertaken.

See alsoCommissioning check list (Page 89)

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Operation 88.1 Safety information

DANGEROverspeedWhen the exciter circuit is deactivated, the machine can reach dangerously high speeds.Death, serious injury, or material damage will result.

The control must be interlocked in such a way that the armature circuit can be connectedonly when the exciter circuit is energized. If the exciter circuit fails, switch off the armaturecircuit immediately.

WARNINGRotating or live partsCovers prevent contact with live or rotating parts, or are used for proper air routing and thuseffective cooling of the motor.

Removing the covers during operation can result in death, serious injury, and materialdamage.

Never open covers during operation.

WARNINGFaults in operationAll deviations from normal operation, such as higher power consumption, highertemperatures and vibration levels, unusual noises and odors and tripped monitoringdevices, are indications that the motor is no longer functioning correctly.

Keep maintenance personnel fully informed to prevent faults that could directly or indirectlycause serious injury to personnel or damage to equipment.

If in doubt, switch off the drive in question immediately.

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Operation

8.2 Switch on


NOTICEOperating the motor at the natural installation frequencyOperating the motor at the natural installation frequency can lead to damage to both themotor and the foundation.

Never operate the motor at the natural installation frequency.

WARNINGRisk of burnsSome parts of the frame of electrical machines can reach temperatures in excess of 100C.

Serious burn injuries can be caused by touching components when the machine is inoperation.

Do not touch frame parts while the machine is in operation or immediately after machine

operation. Let frame parts cool off before starting any work.

8.2 Switch onProcedure

1. If at all possible, run the machine without load and check that it is running smoothly.2. If it runs perfectly, connect a load.3. If it is possible using the available measuring equipment, check the bearing and stator

winding temperatures.

Vibration magnitudesThe vibration characteristics of the system at the installation site are affected by factors suchas power output elements, alignment, installation and external vibration and may in turnincrease the level of vibration on the motor.

In the interests of achieving perfect commutation, very low brush wear and long service lifeof bearings, the level of motor vibration must not exceed the limits specified inDIN ISO 10816-3 as given in the table below.

Table 8-1 Vibration magnitude as a function of vibration frequency

Vibration magnitude valuesibration frequency[Hz]

Vibration magnitudesFrame size 280

and lowerFrame size

355 andhigher

< 6.3 Hz Vibration displacement s [mm] 0,1 0,16

6.3 to 63 Hz Vibration speed Vrms[mm/s] 2,8 4,5

> 63 Hz Vibration acceleration a [m/s2] 1,6 2,55

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8.3 Deactivating


If higher levels of vibration than the above specified occur in operation, then specialmeasures must be taken. For more information, please contact your local Siemens salesoffice.

8.3 DeactivatingMeasures when switching off

If the corresponding control action does not take place automatically, switch on the anti-condensation heating if present. This prevents damage to the winding insulation.

If this does not happen automatically, switch off any external fans or coolers.

8.4 Special operating conditionsOperating under light-load conditions

If a motor is operated continuously or over a prolonged period under light-load conditions, atapproximately half rated current or less, then problems with high brush wear or commutatormalfunctions may occur. For more information, please refer to chapter "Faults (Page 44)".

Consult the manufacturer if the motor is to be operated continuously under light-loadconditions.

Loading at standstillStationary DC motors may be loaded with armature current only for short periods so as toprotect the commutator against damage.

The permissible current and time values for loading at standstill can be obtained from themanufacturer.

8.5 StoppagesNecessary measures when motors are at standstill and ready for operation

Keep the motor dry using anti-condensation heating. After prolonged idle time and when commissioning at very low ambient temperatures ( 0

C), the inside of the motor should receive additional heat to de-ice and dry it out. Thisshould be done by heating the exciter winding with 30% rated exciter current, withoutventilation, for a period of at least 30 minutes. This cannot be achieved by the anti-condensation heater alone.

Take care with motors using water cooling to avoid possible problems with corrosion andfreezing. Follow the operating instructions provided by the water cooler manufacturer.

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8.6 Faults


Operate the motor regularly, at least once monthly, in the event of lengthy downtimes.Alternatively, turn the rotor as a minimum.

NOTICEBearing damage due to external factorsWhere cylindrical-roller bearings are used, bearing damage can be caused by externalvibration in standby mode.

Consult the manufacturer for details of suitable corrective action.

Prolonged outage periods If the motor is out of operation for a prolonged period, suitable measures must be taken

with respect to anti-corrosion protection, mothballing, packaging and drying, as describedin chapter "Transport and storage" (Page 18).

When restarting the motor after a long downtime, carry out the measures recommendedin chapter "Commissioning" (Page 35).

8.6 Faults

8.6.1 Safety notes during operationSafety notes

WARNINGFaults in operationAll deviations from normal operation (e.g. higher power consumption, higher temperaturesor vibration levels, unusual noises or odors, tripped monitoring devices, etc.) are indicationsthat the motor is no longer functioning correctly. This can cause faults which can result ineventual or immediate death, serious injury, or material damage.

Immediately inform the maintenance personnel. If you are in doubt, immediately shut downthe motor, being sure to observe the system-specific safety conditions.

Correct the cause of the fault as specified in the remedial measures section. Repair any

damage to the machine. Ensure that the skilled personnel responsible investigate thecause and remedy the error.

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8.6 Faults


WARNINGDo not remove covers when the machine is runningRotating or live parts are dangerous. Death, serious injury, or material damage can result if

the required covers are removed during operation.De-energize the machine first, if you need to remove any covers. Ensure that any coverswhich are designed to prevent active or rotating parts from being touched, or which arenecessary to ensure correct air guidance and thus effective cooling, remain closed duringoperation.

The tables of faults below can be used as troubleshooting and repair guides in the event ofelectrical or mechanical faults. Consult the manufacturer if necessary.

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8.6 Faults


8.6.2 Faults in operationTable 8-2 Faults in operation

Symptoms of fault General uneven running of machine

Vibrating brushes

High temperature rise (general)

Severe brush sparking

Possible causes of faults Remedial measuresPlant fault

X Coupled motor out of balance Check coupling, rebalance systemX X Poor alignment Align motor setX X X Resonance in system Improve installation conditions or reduce

excitation of vibrationOperating mode or operating error

X Continuous light-load duty (partial load) Change number of brushes and/or materialX Temporary overload Correct current limit on converterX Continuous overload Correct current limit on converter/reduce

down periods of rest

Cooling faultX Cooling air-flow rate too low (commutator

temperature too high)Improve ventilation circuit

Component defectX Interturn fault Repair winding

X X Out-of-round commutator Rework commutatorX Rotor imbalance Balance rotorX Bearing damage Repair or replace bearing

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8.6 Faults


8.6.3 Rolling-contact bearing faultsNoteDamage to rolling

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