Lenze AC Motor
Lenze AC Motor
0.75 kW ... 55 kW
Operating instructions EN
Three−phase AC motors
Ä.UñIä
.UñI
Please read these instructions before you start working!
Follow the safety instructions enclosed.
Note!
For safety−rated built−on accessories, the manufacturer’s operating
instructions have to be observed!
0Fig. 0Tab. 0
Contents i
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 General safety instructions for drive components . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Application as directed ................................................ 10
2.3 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Residual hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 Motor name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.2 Motor code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.3 Encoder code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.4 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 General data and operating conditions .................................. 19
5 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4 Assembly of built−on accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.5 Spring−applied brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.6 Locking of the manual release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Three−phase AC motor operation on a frequency inverter . . . . . . . . . . . . . . . . . . . . 28
6.3 EMC−compliant wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.1 Power connections on the terminal board . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.2 Brake connection to terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.3 Feedback system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 Plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.1 Motor plug connection assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.2 Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4.3 Feedback system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5 Terminal box HAN connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8 Maintenance/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2.1 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2.2 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2.3 Spring−operated brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3 Maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.1 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.2 Spring−operated brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3.3 Checking the component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3.4 Checking the rotor thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3.5 Checking the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3.6 Release / voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3.7 Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3.8 Rotor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4 Installation of a spring−applied brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4.1 Brake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4.2 Installation of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4.3 Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4.4 Assembly of the friction plate, sizes 06 to 16 . . . . . . . . . . . . . . . . . . . . . . 49
8.4.5 Assembly of the flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4.6 Assembly of the cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.1 Technical data as specified by ordinances (EU) No. 4/2014 and (EC) No. 640/2009 52
Contents
¯ The present documentation is intended for safe working on and with the drives. It
contains safety instructions that must be observed.
¯ All persons working on and with the drives must have the documentation at hand
during work and observe the information and notes relevant for it.
¯ The documentation must always be complete and in a perfectly readable state.
If the information and notes provided in this documentation do not meet your
requirements, please refer to the gearbox documentation.
Tip!
Information and tools concerning the Lenze products can be found in the
download area at
www.lenze.com
Validity
This documentation is valid for three−phase AC motors:
Type Name
m500−P Three−phase AC motors (squirrel−cage induction motor)
m540−P
m550−P
Target group
This documentation is directed at qualified skilled personnel according to IEC 60364.
Qualified skilled personnel are persons who have the required qualifications to carry out
all activities involved in installing, mounting, commissioning, and operating the
product.
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Layout of the safety instructions:
Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent
dangerous situations)
voltage
Danger! Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures are
not taken.
Danger of personal injury through a general source of
danger
Danger! Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures are
not taken.
Application notes
2 Safety instructions
At the time of dispatch, the drive components are in line with the latest state of the art
and can be regarded as operationally safe.
Scope
The following general safety instructions apply to all Lenze drive and automation
components.
The product−specific safety and application notes given in this documentation must be
observed!
General hazards
Danger!
Disregarding the following basic safety measures may lead to severe
personal injury and damage to material assets!
¯ Only qualified skilled personnel are permitted to work with or on Lenze drive and
automation components.
According to IEC 60364 or CENELEC HD 384, these are persons ...
... who are familiar with the installation, assembly, commissioning and operation of
the product,
... possess the appropriate qualifications for their work,
... and are acquainted with and can apply all the accident prevent regulations,
directives and laws applicable at the place of use.
Storage
¯ In a dry, low−vibration environment without aggressive atmosphere;
¯ In the original packaging;
¯ Protect against dust and impacts;
¯ Observe climatic conditions according to the technical data.
Storage conditions
¯ Up to one year:
– Shafts and uncoated surfaces are delivered with rust protection. Aftertreatment
is required where the corrosion protection has been damaged.
¯ More than one year, up to two years:
– Apply a long−term corrosion preventive (e.g. Anticorit BW 366 from the Fuchs
company) to the shafts and uncoated surfaces before storing the motor away.
Transport
Before transport
¯ Check that all components are securely mounted;
¯ Check that all components with a loose fastening are secured or removed;
¯ Tighten all transport aids (eye bolts or support plate).
Stop!
Danger by tipping or falling loads!
Observe carrying capacity!
¯ The carrying capacity of the hoists and load handling devices must be
at least the weight of the load, weights catalogue.
¯ Secure the load to prevent it from tipping over or falling down.
¯ Standing beneath suspended loads is prohibited!
Risk of breakage!
The motors mounted to the gearbox are partly equipped with transport
eyebolts that are solely intended for mounting/dismounting the motor
to/from the gearbox and that must not be used for transport of the
geared motor!
Danger!
Completely screw in transport aids (such as eye bolts or bearing plates),
they must be flat and applied over their entire surface!
If possible, the transport aids (such as eye bolts or bearing plates) must
be stressed vertically in the direction of the screw axis! Angular tension or
tension to the sides reduces the payload! Observe the information
provided in DIN 580!
Use additional appropriate lifting aids, if required, to achieve a direction
of loading which is as vertical as possible (highest payload). Secure lifting
aids against shifting!
Corrosion protection
Lenze offers paints with different resistance characteristics for drive systems. Since the
resistance may be reduced when the paint coat is damaged, defects in paint work (e.g.
through transport or assembly) must be removed professionally to reach the required
corrosion resistance.
Mechanical installation
¯ Provide for careful handling and avoid mechanical overload. During handling
neither bend components, nor change the insulation distances.
Electrical installation
¯ Carry out the electrical installation according to the relevant regulations (e. g.
cable cross−sections, fusing, connection to the PE conductor). Additional notes are
included in the documentation.
¯ Only plug in or remove pluggable terminals in the deenergised state!
Commissioning
¯ If required, you have to equip the system with additional monitoring and
protective devices in accordance with the respective valid safety regulations (e. g.
law on technical equipment, regulations for the prevention of accidents).
¯ Before commissioning remove transport locking devices and keep them for later
transports.
All products which this documentation applies to are no household appliances but are
exclusively intended as components for re−utilisation for commercial use or
professional use in terms of IEC/EN 61000−3−2. They meet the requirements of the
Low−Voltage Directive 2006/95/EC and the requirements of the harmonised standards
of the IEC/EN 60034 series.
Only use the products under the operating conditions and power limits specified in this
documentation.
Do not use the brakes installed as fail−safe brakes. It cannot be ruled out that the braking
torque is reduced by disruptive factors which cannot be influenced.
Low−voltage machines with IP23 protection or less are only intended for outdoor use
when applying special protective features.
Products included in the scope of application of the EU regulations (EG) 640/2009
and (EU) 4/2014 (and hence ErP Directive 2009/125/EG) and which did not comply
with minimum efficiency requirements when first put into circulation, are not CE
compliant and will not receive CE marking. The product is for exclusive use outside
the European Economic Area (EEA) only.
Note!
Increased surface and corrosion protection can be achieved by using
adapted coating systems.
Protection of persons
¯ The motor surfaces can become very hot. Danger of burns when touching!
– Provide protection against accidental contact, if necessary.
¯ Danger of unintentional starting or electrical shocks
– Connections must only be made when the equipment is deenergised and the
motor is at standstill.
– Installed brakes are no fail−safe brakes.
Motor protection
¯ Installed thermal detectors are no full protection for the machine.
– Installed overload protection does not prevent an overload under any
conditions.
¯ Installed brakes are no fail−safe brakes.
– The torque may be reduced by disruptive factors that cannot be influenced such
as contamination by oil.
¯ Fuses are no motor protection.
– Use current−dependent motor protection switches at average operating
frequency.
– Use installed thermal detectors at high operating frequency.
¯ Too high torques cause a fraction of the motor shaft.
– The maximum torques according to catalogue must not be exceeded.
¯ Lateral forces from the motor shaft may occur.
– Align shafts of motor and driving machine exactly to each other.
¯ If deviations from normal operation occur, e.g. increased temperature, noise,
vibration, determine the cause and, if necessary, contact the manufacturer. If in
doubt, switch off the motor.
Fire protection
¯ Fire hazard
– Prevent contact with flammable substances.
2.5 Disposal
Sort individual parts according to their properties. Dispose of them as specified by the
current national regulations.
3 Product description
3.1 Identification
Three−phase AC motors
m550−P
B3 type B5 type B14 type
Each motor has a motor name and a motor code. In the sales documents, the motors are
identified by the motor name. The technical documentation and nameplate show the
motor code.
The table below shows a list of the motor names and the first eleven digits of the
corresponding motor code:
m500−P
Motor name Motor code
m500−P132M4 M50AP132M04
m500−P132L4 M50AP132L04
m500−P160M4 M50AP160M04
m500−P160L4 M50AP160L04
m500−P180M4 M50AP180M04
m500−P180L4 M50AP180L04
m500−P180V4 M50AP180V04
m500−P500M4 M50AP500M04
m500−P225M4 M50AP225M04
m500−P225L4 M50AP225L04
m540−P
Motor name Motor code
m540−P90/M4 M54AP090M04
m540−P90/L4 M54AP090L04
m540−P100/M4 M54AP100M04
m540−P100/L4 M54AP100L04
m540−P112/M4 M54AP112M04
m540−P132/M4 M54AP132M04
m540−P132/L4 M54AP132L04
m540−P160/M4 M54AP160M04
m540−P160/L4 M54AP160L04
m540−P180/M4 M54AP180M04
m540−P180/L4 M54AP180L04
m540−P200/M4 M54AP200M04
m540−P225/M4 M54AP225M04
m540−P225/L4 M54AP225L04
m540−P250/M4 M54AP250M04
m550−P
Motor name Motor code
m550−P80/M4 M55AP080M04
m550−P90/M4 M55AP090M04
m550−P90/L4 M55AP090L04
m550−P100/M4 M55AP100M04
m550−P100/L4 M55AP100L04
m550−P112/M4 M55AP112M04
m550−P132/M4 M55AP132M04
m550−P132/L4 M55AP132L04
m550−P160/M4 M55AP160M04
m550−P160/L4 M55AP160L04
m550−P180/M4 M55AP180M04
m550−P180/L4 M55AP180L04
m550−P180/V4 M55AP180V04
m550−P200/M4 M55AP200M04
m550−P225/M4 M55AP225M04
m550−P225/L4 M55AP225L04
Note!
If feedback systems for safety functions are used, the manufacturer’s
documentation must be observed!
3.1.4 Nameplate
L 1 15
Hz 16.1 26
2 21 kW 16.2
15
3 18 16.4
V
4 17 16.4 19
5.1 5.2 23
5.3 5.4 16.5 13
A
6 7.1 7.2 16.5 14.1
8.1 8.2 8.3 r/min 16.3 14.2
9 h% 16.7 14.3
cos j 16.6 27
10.2 10.3 C86 22
11 20.1
L 1 9 43 15
23 13 14.2
2 14.1 21 14.3 Hz 16.1
3 18 kW 16.2
4 17 16.4
5.1 V
5.2 16.4
5.3 5.4 30 16.5
A
6 7.1 7.2 16.5
8.1 8.2 8.3 33.1 33.2 r/min 16.3
20.1 h% 16.7
11 cos j 16.6
10.2 10.3 C86 22
L 1
9
15
Pos. Contents
1 Manufacturer / production location
2 Type of motor / standard
3 Gearbox type
4 Motor type
5 Technical data
5.1 Ratio
5.2 Rated torque
5.3 Rated speed
5.4 Rated frequency
6 Position of system modules / mounting position
7 Lubricant details
7.1 Lubricant amount
7.2 Lubricant type
8 Brake data
8.1 Type
8.2 AC/DC brake voltage
8.3 Braking torque, electrical power input
9 For feedback / pulse encoder or resolver data, 16
10 Production data
10.2 Material number
10.3 Serial number
11 Bar code
13 Information with regard to the operating mode
14 Additional motor specifications
14.1 Temperature class
14.2 Enclosure
14.3 Motor protection
15 Applicable conformities, approvals and certificates
16 Rated data for various frequencies
16.1 Hz = frequency
16.2 kW = motor power
16.3 rpm = motor speed
16.4 V = motor voltage
16.5 A = motor current
16.6 cos j = motor power factor
16.7 h = motor efficiency: at a rated power of 100%
17 Application factor / load capacity
18 Year of manufacture / week of manufacture
19 UL file number
20 Customer data
20.1 Additional customer data
21 UL category (e.g. inverter duty motor)
22 C86 = motor code for inverter parameterisation (code 0086)
23 Efficiency class
24 Partial load efficiencies for 50Hz operation at a rated power of 50% and 75%
26 CC number Department of Energy (optional)
27 Permissible ambient temperature (e.g. Ta £ 40°C)
30 Weight
43 Internal key: QR code
4 Technical data
General data
The applicable approvals for the product you have ordered require labelling and are
specified on the nameplate.
Operating conditions
Ambient conditions
Climatic
Transport IEC/EN 60721−3−2 2K3 (−20 °C ... +70 °C)
Storage IEC/EN 60721−3−1 1K3 (−20 °C ... +60 °C) < 3 months
1K3 (−20 °C ... +40 °C) > 3 months
Operation IEC/EN 60721−3−3 3K3 (−20 °C ... +40 °C) Without brake
3K3 (−10 °C ... +40 °C) With brake
> +40 °C With power reduction, see
catalogue
Site altitude < 1000 m amsl − without power reduction
> 1000 m amsl < 4000m amsl with power reduction, see
catalogue
Humidity Relative humidity £ 85 %, without condensation
Mechanical
IEC/EN60721−3−3 3M6
5 Mechanical installation
Danger!
Some of the motors mounted to the gearboxes are equipped with
transport aids. They are only intended for the mounting/dismounting of
the motor to the gearbox and must not be used for the entire geared
motor!
¯ Only move the drive with means of transport or hoists that have sufficient
load−bearing capacity.
¯ Ensure safe fixing.
¯ Avoid shocks!
Stop!
Observe the maximally permissible screw−in depth for B14 flange!
C
S
c max. s
[mm] [mm]
M55AP0800 FT100 10 M6
FT130 12 M8
M55AP0900 FT115 16 M8
FT130 12 M8
M55AP1000 FT130 12 M8
M55AP1120 FT130 12 M8
5.2 Preparation
Remove the corrosion protection from the shaft ends and flanges. If necessary, remove
dirt using standard cleaning solvents.
Stop!
Bearings or seals must not come into contact with the solvent − material
damages.
After a long storage period (> 1 year) you have to check whether moisture has
entered the motor. For this purpose, measure the insulation resistance (measuring
voltage 500 VDC). In case of values £1kWper volt of rated voltage, dry the winding.
5.3 Installation
¯ The mounting surface must be dimensioned for the design, the weight, and the
torque of the motor.
¯ The foot and flange faces must rest flat on the mounting surface.
– An insufficient alignment of the motor shortens the service life of the roller
bearings and the transmission elements.
Blows to shafts can cause damage to the bearings.
¯ Do not exceed the permissible range of ambient operating temperature ( 19).
¯ Securely fasten the motor.
¯ Ensure unobstructed ventilation. The exhaust air, also that of adjacent
aggregates, must not be inlet again immediately.
¯ During operation, surface temperatures of up to 140 °C are possible! Protect
against contact!
Note!
From the air inlet to other component parts, a minimum distance of 10%
of the outer diameter of the fan cover must be complied with!
Ensure an even surface, solid foot or flange mounting and exact alignment if a direct
clutch is connected. Avoid resonances with the rotational frequency and double supply
frequency which may be caused during assembly.
Only mount or remove transmission elements using appropriate means. In order to
facilitate handling, heat them beforehand. Cover belt pulleys and clutches with a touch
guard.
Stop!
Ensure a correct belt tension!
The machines are halfkey balanced. The clutch must be halfkey balanced, too. The
visible jutting out part of the key must be removed.
Designs with shaft end at the bottom must be protected with a cover at the N−end,
preventing the ingress of foreign particles into the fan.
Follow these instructions carefully. Please note that the warranty and product liability
will become void in the event of impermissible alterations or modifications to the
motors.
¯ Mount the transmission elements:
– Shocks and impacts must be avoided! They could destroy the motor.
– For mounting always use the centre bore in the motor shaft as specified by DIN
332−DR−M...
– Tolerances of the shaft ends:
£ Æ 50 mm: ISO k6, > Æ 50 mm: ISO m6.
¯ Only use an extractor for the disassembly.
¯ When using belts for torque/power transmission:
– Tension the belts in a controlled manner.
– Provide protection against accidental contact! During operation, surface
temperatures of up to 140°C are possible.
Important notes
As an option, the motors can be fitted with a brake. The installation of brakes (in or on
the motor) increases the length of the motor.
Note!
The brakes used are not fail−safe because interference factors which
cannot be influenced (e.g. oil ingress) may lead to a reduction in torque.
The brakes are used as holding brakes and serve to hold the axes at standstill or in the
deenergised state.
Emergency stops at higher speeds are possible but high switching energy increases
wear on the friction surfaces and the hub, ( 42).
The spring−applied brakes work on the basis of the closed−circuit principle, i.e. the brake
is closed in the deenergised state. The brakes for DC supply can be fed with a
bridge−rectified DC voltage (bridge rectifier) or with a smoothed DC voltage. The
permissible voltage tolerance is ±10 %.
In case of long motor cables the voltage drop must be checked due to increasing
conductor resistance and compensated for by higher input voltage if necessary.
The following applies to Lenze system cables:
ƪ
U *+ U B ) 0.08W
m @ L @ I B
ƫ U* [V]
UB [V]
Resulting supply voltage
Rated voltage of the brake
l [m] Cable length
IB [A] Rated current of the brake
Stop!
If no suitable voltage (incorrect value, incorrect polarity) is applied to the
brake, the brake will be applied and can be overheated and destroyed by
the motor continuing to rotate.
The shortest operating times of the brakes are achieved by DC switching of the voltage
and an external suppressor circuit (varistor or spark suppressor). Without suppressor
circuit, the operating times may increase. A varistor/spark suppressor limits the
breaking voltage peaks. It must be ensured that the power limit of the suppressor circuit
is not exceeded. This limit depends on the brake current, brake voltage, disengagement
time and the switching operations per time unit.
Furthermore the suppressor circuit is necessary for interference suppression and for
increasing the service life of the relay contacts (external, not integrated into the motor).
For permissible operating speeds and characteristics, please see the motor catalogue
applicable in each case. Emergency stops at higher speeds are possible, but high
switching energy increases wear on the friction surfaces and the hub.
Stop!
The friction surfaces must always be free from oil and grease because
even small amounts of grease or oil will considerably reduce the braking
torque.
The formula below provides a simplified way to calculate friction energy per switching
cycle which must not exceed the limit value for emergency stops that depends on the
operating frequency (
motor catalogue; Lenze drive solutions: formulas,
dimensioning, and tables).
Q [J] Friction energy
MK
Q + ½ @ J tot @ Dw 2 @ Jtot [kgm2] Total mass inertia (motor + load)
MK * ML
Dw [1/s] Angular velocity w=2p n/60, n= speed [rpm]
MK [Nm] Characteristic torque
ML [Nm] Load torque
Depending on the operating conditions and possible heat dissipation, surface
temperatures can be up to 130 °C.
Scope of supply
GT−GNG−GST−010.iso/dms GT−GXX−012.iso/dms
GT−GXX−013.iso/dms
Mounting
1
2
4
GT−GXX−014.iso/dms
Handling
Stop!
¯ Lock the manual release only for service work!
¯ The manual release must not be locked during operation, otherwise
the brake could be damaged!
¯ Always secure the terminal block against loosening in every position
with cheese head screw and nut!
GT−GXX−015.iso/dms GT−GXX−016.iso/dms
6 Electrical installation
Danger!
Hazardous voltage on the power connections even when disconnected
from mains: residual voltage >60 V!
Before working on the power connections, always disconnect the drive
component from the mains and wait until the motor is at standstill.
Verify safe isolation from supply!
Stop!
Electrical connections must be carried out in accordance with the
national and regional regulations!
Tightening torques
CuZn
m500−P / m550−P
[Nm]
Material M12x1.5 M16x1.5 M20x1.5 M25x1.5 M32x1.5 M40x1.5 M50x1.5
Plastics 0.7 1 1 2.5 3 3 3
Metal 3 3 4 6 8 10 14
m540−P
[Nm]
Material M12x1.5 M16x1.5 M20x1.5 M25x1.5 M32x1.5 M40x1.5 M50x1.5
Plastics 4 4 4 4 6 6 6
Metal 8 10 12 12 18 18 20
Tab. 1 Locking screws and cable glands
m500−P, m540−P, and m550−P three−phase AC motors are optimised and qualified for
the use on Lenze frequency inverters and can be combined without any restrictions.
When actuating the motors on a third−party inverter, the voltage peaks (Vpk) at a
given rise time (tR) that are shown in the diagram must not be exceeded.
1.8
1.6 1.56 kV
1.4
1.2
Upk (kV)
1.0
0.8
0.6
0.4
0.2
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
tr (ms)
MT−m500−001.des
Motor
Multivoltage motors
M50AP, M55AP M54AP
U2 V2 W2 U2 V2 W2 U2 V2 W2 U2 V2 W2
U5 V5 W5 U5 V5 W5 U3 V3 W3 U3 V3 W3
U1 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
MT_MXXXX_001.iso/dms
Temperature monitoring
Separate fan 1~
Terminal board
Contact Meaning Note
U1 Connection to L1 − mains
V1 / U2 Connection to N − mains
Resolver
Contact Name Meaning
B1 + Ref Transformer windings
B2 − Ref (reference windings)
B3 Not assigned
B4 +COS Stator winding cosine
B5 −COS
B6 +SIN Stator winding sine
B7 −SIN
B8 Not assigned
Stop!
¯ Tighten the coupling ring of the connector.
¯ If plugs without SpeedTec bayonet nut connectors are used, the
connector boxes for the power / encoder / fan connections must be
secured by O−rings if loadings by vibration occur:
– M17 connector box with O−ring 15 x 1.3 mm
– M23 connector box with O−ring 18 x 1.5 mm
Plug−in connectors (plug/connector box) with SpeedTec bayonet nut
connectors are vibration−proof.
¯ If SpeedTec bayonet nut connectors are used, O−rings must be
removed (if any)!
¯ Never disconnect plugs when voltage is being applied! Otherwise, the
plugs could be destroyed! Inhibit the inverter before disconnecting the
plugs!
When connecting the cable connector to the motor connector, make sure that the aids
to orientation (pos. 1) are facing each other. Only then trouble−free operation is ensured.
Note!
When making your selection, the motor data and permissible currents of
the cables according to the "System cables" system manual must be
observed.
PE PE conductor 3
D
3 W Power phase W C 4
4 V Power phase V
B
Thermal sensor 1
A
A TB1 / TP1 / R1 TCO / PTC / + KTY
B TB2 / TP2 / R2 TCO / PTC / − KTY
Connection variant ICN 8B − switching contact of the rectifier for DC switching. Rectifier
supply via motor terminal board. Only possible during mains operation!
Fan
Only for m500−P / m550−P
ICN, 7−pole
Single−phase (external view of poles)
Contact Name Meaning M17
PE PE conductor
6
1 U1
2 U2 AC fan 1
5
3 Not assigned
4 U+ 4 2
5 U− DC fan
6 Not assigned
3
Incremental encoder / sin/cos absolute value encoder Hiperface (external view of poles)
Contact Name Meaning M23
1 B Track B / + SIN
2 A Track A inverse / − COS
3 A Track A / + COS
4 + UB Supply +
5 GND Mass
6 Z Zero track inverse / − RS485
7 Z Zero track / + RS485
8 Not assigned
9 B Track B inverse / − SIN
10 Shield Encoder housing shield
11 + KTY
Thermal detector KTY
12 − KTY
Circular connector
4−pole
Incremental encoder (external view of poles)
Contact Name Meaning M12
1 + UB Supply +
2 B Track B
3 GND Mass
4 A Track A MT plug−in
connector−001.iso/dms
ICN, 8−pole
Incremental encoder (external view of poles)
Contact Name Meaning M12
1 B − SIN
2 B + SIN
6 5 4
3 A − COS
4 A + COS 7 3
5 Z + RS485 8
6 Z − RS485 1 2
7 GNG Mass
8 + UB Supply +
HAN−GTM−007.iso HAN−GTM−004.iso
HAN−GTM−008.iso HAN−GTM−004.iso
Terminal box
Module Contact Name Meaning
a 1 U1 Terminal board
2 V1 Terminal board
3 W1 Terminal board
b Blind module
c 1 +KTY / PTC / TCO Thermal sensor
2 + / AC Brake
3 − / AC Brake
4 Switching contact Rectifier
5
6 −KTY / PTC / TCO Thermal sensor
HAN−GTM−007.iso HAN−GTM−004.iso
Terminal box
Contact Name Meaning
1 U1 Terminal board
2 V1
3 W1
4 + / AC Holding brake
5 − / AC
6 W2 Terminal board
7 U2
8 V2
9 +KTY / PTC / TCO Thermal sensor
10 −KTY / PTC / TCO
Note!
Carry out the wiring in or in the counter plug:
¯ − wiring: 6−7−8
¯ − wiring: 1−6/2−7/3−8
For trial run without output elements, lock the featherkey. Do not deactivate the
protective devices, not even in a trial run.
Check the correct operation of the brake before commissioning motors with brakes.
Note!
Before switch−on, you must ensure that the motor starts with the
intended direction of rotation.
Lenze motors rotate CW (looking at the driven shaft) if a clockwise
three−phase field L1 U1, L2 V1, L3 W1 is applied.
Stop!
¯ Fire hazard! Do not clean or spray motors with flammable detergents
or solvents.
¯ Avoid overheating! Deposits on the drives impede the heat dissipation
required and have to be removed regularly.
Danger!
During operation, motor surfaces must not be touched. According to the
operating status, the surface temperature for motors can be up to 140°C.
For the protection against burn injuries, provide protection against
contact, if necessary. Observe cooling−off times!
During operation, carry out inspections on a regular basis. Pay special attention to:
¯ Unusual noises
¯ Oil spots on drive end or leakages
¯ Irregular running
¯ Increased vibration
¯ Loose fixing elements
¯ Condition of electrical cables
¯ Speed variations
¯ Impeded heat dissipation
– Deposits on the drive system and in the cooling channels
– Pollution of the air filter
In case of irregularities or faults: ( 51).
8 Maintenance/repair
Danger!
Hazardous voltage on the power connections even when disconnected
from mains: residual voltage >60 V!
Before working on the power connections, always disconnect the drive
component from the mains and wait until the motor is at standstill.
Verify safe isolation from supply!
Shaft sealing rings and roller bearings have a limited service life.
Regrease bearings with relubricating devices while the low−voltage machine is running.
Only use the grease recommended by the manufacturer.
If the grease drain holes are sealed with a plug, (IP54 drive end; IP23 drive and nondrive
end), remove plug before commissioning. Seal bore holes with grease.
Inspections
¯ If the machine is exposed to dirt, clean the air channels regularly.
8.2.1 Motor
8.2.2 Encoder
Stop!
Repair work or replacement of defective safety encoders must only be
carried out by Lenze service personnel!
After a service life of 10 years, an inspection of the metal elastomer torque plate is
required for the AS1024−8V−K, AS1024−8V−K2; AM1024−8V−K, and AM1024−8V−K2
encoders. If no replacement is required, an inspection interval of max. 5 years has to be
observed.
To ensure safe and trouble−free operation, spring−applied brakes must be checked and
maintained at regular intervals. Servicing can be made easier if good accessibility of the
brakes is provided in the plant. This must be considered when installing the drives in the
plant.
Primarily, the necessary maintenance intervals for industrial brakes result from the load
during operation. When calculating the maintenance interval, all causes for wear must
be taken into account, (( 43). For brakes with low loads such as holding brakes with
emergency stop, we recommend a regular inspection at a fixed time interval. To reduce
the cost, the inspection can be carried out along with other regular maintenance work
in the plant if necessary.
If the brakes are not maintained, failures, production losses or damage to the system
may occur. Therefore, a maintenance concept adapted to the particular operating
conditions and brake loads must be defined for every application. For the spring−applied
brakes, the maintenance intervals and maintenance operations listed in the below
table must be provided. The maintenance operations must be carried out as described
in the detailed descriptions.
8.3.1 Motor
Stop!
¯ Make sure that no foreign bodies can enter the inside of the motor!
¯ Do not remove plugs when voltage is being applied!
Danger!
¯ Only work on the motor when it is deenergised!
¯ Hot motor surfaces of up to 140 °C. Observe cooling times!
¯ Remove loads acting on motors or secure loads acting on the drive!
The brake is mounted to the N−end shield of the motor. Remove the fan cover or blower
unit or the encoder, if available, to check, maintain, or set the brake.
Note!
Brakes with defective armature plates, cheese head screws, springs or
counter friction faces must always be replaced completely.
Generally observe the following for inspections and maintenance works:
¯ Remove oil and grease linked impurities using brake cleaning agents, if
necessary, replace brake after identifying the cause of the
contamination. Dirt deposits in the air gap between stator and
armature plate impair the function of the brake and must be removed.
¯ After replacing the rotor, the original braking torque will not be
reached until the run−in operation of the friction surfaces has been
completed. After replacing the rotor, run−in armature plates and
counter friction faces have an increased initial rate of wear.
Stop!
Dimension "s" must be maintained! Check air gap "sL"!
( operating instructions)
Danger!
When the rotor thickness is checked, the motor must not run.
1. Check the air gap "sL" near the fixing screws between the armature plate and
stator using a feeler gauge ( 46).
2. Compare air gap measured to maximally permissible air gap "sL max." ( 46).
3. If required, set air gap to "sLN" ( 45).
Danger!
The rotating rotor must not be touched.
Danger!
Live connections must not be touched.
1. Observe the brake’s function while the drive is being operated. The armature
plate must be tightened and the rotor must move free of residual torque.
2. Measure the DC voltage on the brake.
– The DC voltage measured after the overexcitation time ( operating
instructions, forced voltage rectifier) must equal the voltage for the holding. A
deviation of up to ±10 % is permissible.
Danger!
The brake must be free of residual torque.
Stop!
For the flange design, please observe the following if the flange is
mounted with additional screws:
Clearing holes in the end shield must be provided behind the threaded
holes in the flange that are designed for the screws. Without clearing
holes, the minimum rotor thickness cannot be utilised fully. In no case
must the screws press against the end shield.
Danger!
The brake must be free of residual torque.
Brake size sLN sLmax. sLmax. Max. adjustment, Rotor thickness Tightening torque
+0.1 mm service brake holding brake permissible wear of the fixing
−0.05 mm path screws
[mm] [mm] [mm] [mm] min. 1) [mm] max. [mm] [Nm]
06 4.5 6.0 3.0
08 0.2 0.5 0.3 1.5 5.5 7.0 5.9
10 7.5 9.0 10.1
12 2.0 8.0 10.0 10.1
14 0.3 0.75 0.45 2.5 7.5 10.0 24.6
16 3.5 8.0 11.5 24.6
18 3.0 10.0 13.0 24.6
0.4 1.0 0.6
20 4.0 12.0 16.0 48.0
25 0.5 1.25 0.75 4.5 15.5 20.0 48.0
Stop!
¯ Check the state of the end shield (15). It must be free from oil and
grease.
15
4
K14.0502/8
1. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand
(Fig. 3).
Stop!
Please note the following for the version "brake with shaft sealing ring in
torque adjustment ring":
9
15
1
10
KL458−012−a
1. Check air gap near the screws (10) using a feeler gauge and compare the values to
the data for "sLrated" in the table, 46.
Note!
Do not insert feeler gauge further than 10 mm between the armature
plate (2) and stator (1)!
If "sL" ( 46) is not within the tolerance, readjust the air gap.
Danger!
Disconnect voltage. The brake must be free of residual torque.
9 −
1
10
+
KL458−013−a
If the measured value "sL" is outside the tolerance of "sLrated", set the dimension:
15
27
KL458−009−a
1. Put a friction plate (27) or flange (6) against the end shield (15).
Note!
The flanged edge of the friction plate must remain visible!
15
6
6.1
KL458−008−a
1. Hold the flange (6) against the end shield (15) and check the pitch circle and
retaining screw drill hole threading.
2. Fasten the flange (6) on the end shield (15) with the screws (6.1).
3. Tighten the cheese head screws (6.1) evenly, (tightening torques ( 46).
4. Check the height of the screw heads. The screw heads may not be higher than the
minimum rotor thickness. We recommend using screws according to DIN 6912,
dimensions ( 46).
1.2 15 1 2 13 27 13 6 10 15
1 12
10
13
KL458−010−a KL458−007−a
8.5 Repair
¯ We recommend having all repairs carried out by the Lenze customer service.
Note!
Also observe the corresponding chapters in the operating instructions for
the other components of the drive system.
If the fault cannot be remedied using one of the listed measures, please contact the
Lenze Service.
Fault Cause Remedy
Motor too hot Insufficient cooling air, blocked air Ensure unimpeded circulation of cooling air
ducts.
Can only be evaluated by Preheated cooling air Ensure a sufficient supply of fresh cooling air
measuring the surface Overload, with normal mains voltage Use larger drive (determined by power measurement)
temperature: the current is too high and the speed
¯ Non−ventilated motors too low
> 140 °C Rated operating mode exceeded (S1 to Adjust rated operating mode to the specified operating conditions.
¯ Externally ventilated or S8 IEC/EN 60034−1) Determination of correct drive by expert or Lenze customer service
self−ventilated motors Loose contact in supply cable Tighten loose contact
> 110 °C (temporary two−phase operation!)
Fuse has blown (two−phasing!) Replace fuse
Overload of the drive Check load and, if necessary, reduce by means of longer ramp−up
times
Check winding temperature
Heat dissipation impeded by deposits Clean surface and cooling fins of the drives
Motor does not start Voltage supply interrupted Check error message on the inverter
Check electrical connection, 26
Inverter inhibited Check display on the inverter
Check inverter enable
Fuse has blown Replace fuse
Interrupted encoder cable Check error message on the inverter
Check encoder cable
Brake does not release Check electrical connection, 26
Check air gap, brake documentation
Check continuity of magnetic coil
Drive blocks Check components for easy movement, remove foreign particles if
necessary
Motor cable with reverse polarity Check electrical connection, 26
Motor suddenly stops and Overload monitoring of the inverter is Check inverter settings
does not restart activated Reduce load caused by longer acceleration times
Incorrect rotating direction Motor cable with reverse polarity Check and correct polarity
of the motor
Motor rotates normally but Motor cable interchanged cyclically Connect the phases at the motor cable connection correctly
does not reach the expected Not all motor phases connected
torque
Motor turns in one direction Motor cable interchanged cyclically Check motor connector and correct it if necessary
at maximum speed in an
uncontrolled manner Polarity of encoder cable reversed Check encoder connection and correct it if necessary
Motor rotates slowly in one Polarity of motor cable and encoder Check and correct polarity
direction and cannot be cable reversed
influenced by the inverter
Irregular running Insufficient shielding of motor or Checking shielding and earth connection
resolver cable
Drive inverter gain too large Adjust the gains of the inverters (see operating instructions for
drive inverter)
Vibrations Insufficiently balanced coupling Rebalance
elements or machine
Inadequate alignment of drive train Realign machine unit, check foundation if necessary
Loose fixing screws Check and tighten screw connections
Running noises Foreign particles inside the motor Repair by manufacturer if necessary
Bearing damage
Surface temperature > 140°C Overload of the drive Check load
Check winding temperature
Heat dissipation impeded by deposits Clean surface and cooling fins of the drives
10 Appendix
This chapter includes the technical data in compliance with the specifications laid down
by ordinances (EU) No. 4/2014 and (EC) No. 640/2009.
Annex 1 Clause 2 of ordinance (EC) No. 640/2009 stipulates the publication of the
following technical data in the fixed order 1 ... 12:
No. Meaning
1 Rated efficiency (h) at 100 %, 75 % and 50 % of the rated load and rated voltage (Urated)
2 Efficiency level: "IE2" or"IE3"
3 Year of manufacture
4 Name or trademark, official registration number and manufacturer’s place of establishment
5 Model number of the product
6 Number of poles of the motor
7 Rated output power(s) or rated output power interval [kW]
8 Rated input frequency (frequencies) of the motor [Hz]
9 Rated voltage(s) or rated voltage interval [V]
10 Rated speed(s) or rated speed interval [rpm]
11 Relevant information for the disassembly, recycling or disposal after the final decommissioning
12 Information regarding the range of operating conditions for which the motor is specially designed:
i) Altitudes above sea level
ii) Ambient air temperatures, also for motors with air cooling
iii) Cooling fluid temperature at the inlet of the product
iv) Maximum operating temperature
v) Hazardous areas
Appendix
10
53
10
54
Appendix
h75% [%] 84.7 85.9 87 88.9 89.2 90 91.1 91.8 92.3 93.1 93.6 94.2 94.5 94.9 95.1
h50% [%] 83.4 84.9 85.9 87.9 88.6 89.4 90.8 91.2 91.5 93 93.6 94.2 94.4 95.1 95
2 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3 IE3
3 For year of manufacture and week of manufacture see nameplate: 17
4 Lenze Drives GmbH, Breslauer Straße 3, D−32699 Extertal, GERMANY, HR Lemgo B 6478
5 Motor code M54AP M54AP M55AP M54AP M54AP M54AP M54AP M54AP M54AP M54AP M54AP M54AP M5AP M54AP M54AP
090M04 090L04 100M04 100L04 112M04 132M04 132L04 160M04 160L04 180M04 180L04 200M04 225M04 225L04 250M04
6 Number of poles 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
7 Prated [kW] 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55
8 fr [Hz] 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
9 Vrated [V] 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400
10 nr [rpm] 1440 1445 1465 1460 1460 1470 1465 1475 1475 1470 1470 1470 1478 1478 1482
11 Information regarding the disposal: 12
12
i) Permissible installation height: 19
ii) Permissible ambient air temperatures: 19
iii) Not relevant, since motors are not liquid−cooled.
iv) Maximum operating temperature: 155 C (temperature class F)
v) Operation in hazardous areas prohibited.
Lenze ¯ BA 33.0008 ¯ 3.0
Notes !
Lenze Service GmbH
Breslauer Straße 3, D−32699 Extertal
Germany
0080002446877 (24 h helpline)
+49515482−1112
service@lenze.com
10 9 8 7 6 5 4 3 2 1