Induction motor

SIMOTICS M-1PH8
Type 1PH818., 1PH822., 1PH828. forced ventilated

Operating Instructions / Installation Instructions 03/2012

21.03.2012 15:08
 Introduction 1

Safety notes 2

Description 3
Induction motor
Preparations for use 4
SIMOTICS M-1PH8
1PH8 Assembling 5

Electrical connection 6
Operating Instructions
Installation Instructions
Commissioning 7

Operation 8

Maintenance 9

Spare parts 10

Disposal 11

Service and Support A

Quality documents B

Additional documents C

Edition 03/2012
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

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

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

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

CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:

WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Order number: A5E03555811A AB Copyright © Siemens AG 2012.

Industry Sector Ⓟ 03/2012 Technical data subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents

1 Introduction.................................................................................................................................................13
2 Safety notes................................................................................................................................................15
2.1 Information for the nominated person in control of the electrical installation...............................15
2.2 The five safety rules:...................................................................................................................15
2.3 Qualified personnel......................................................................................................................16
2.4 Safe handling...............................................................................................................................16
2.5 Electrostatic sensitive devices.....................................................................................................18
2.6 Electromagnetic compatibility......................................................................................................19
2.7 Interference immunity..................................................................................................................19
2.8 Interference voltages when operating the converter...................................................................20
2.9 Electromagnetic fields when operating electrical power engineering installations......................20
3 Description..................................................................................................................................................21
4 Preparations for use...................................................................................................................................29
4.1 Safety-related aspects to consider when configuring the plant...................................................29
4.2 Interlock circuit for the external fan..............................................................................................29
4.3 Rotational speed limit values.......................................................................................................30
4.4 System-inherent frequencies.......................................................................................................31
4.5 Torsional loading of the shaft assembly due to faults in the electrical supply.............................31
4.6 Thermal motor protection............................................................................................................31
4.7 Transport and storage.................................................................................................................32
4.7.1 Checking the delivery..................................................................................................................32
4.7.2 Requirements for safe lifting and transporting.............................................................................32
4.7.3 Lifting and transporting................................................................................................................34
4.7.4 Transporting a force-ventilated motor that has already been in operation..................................35
4.7.5 Transporting the machine set......................................................................................................36
4.7.6 Storage........................................................................................................................................37
4.7.7 Protection against corrosion........................................................................................................39
4.8 Ensure the cooling of force-ventilated motors.............................................................................39
4.9 Cooling air quality........................................................................................................................42
4.10 Converter operation.....................................................................................................................42
4.10.1 Reducing bearing currents..........................................................................................................42
5 Assembling.................................................................................................................................................45
5.1 Safety instructions.......................................................................................................................45
5.2 Insulation resistance and polarization index................................................................................45

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5.3 Testing the insulation resistance and polarization index.............................................................46

5.4 Preconditions for correct alignment and secure attachment ......................................................48
5.5 Vibration severity.........................................................................................................................48
5.6 Aligning the machine...................................................................................................................50
5.7 Securing the machine..................................................................................................................51
5.8 Tightening torques for screw and bolt connections.....................................................................52
5.9 Mounting the output elements.....................................................................................................53
5.10 Opening condensation drain holes (option).................................................................................55
5.11 Refitting the external fan..............................................................................................................56
6 Electrical connection...................................................................................................................................57
6.1 Connecting the grounding conductor at the force-ventilated motor.............................................57
6.2 Circuit diagram............................................................................................................................58
6.3 Terminal designation...................................................................................................................58
6.4 Laying cables...............................................................................................................................59
6.5 Electrical connection data............................................................................................................59
6.6 Connection with cable lugs..........................................................................................................60
6.7 Connecting aluminum conductors...............................................................................................62
6.8 Stepless mating face for the seal in the terminal box cover........................................................62
6.9 Completing connection work.......................................................................................................63
6.10 Internal equipotential bonding.....................................................................................................63
6.11 Auxiliary circuits...........................................................................................................................64
6.11.1 Selecting cables..........................................................................................................................64
6.11.2 Connecting an external fan..........................................................................................................64
6.11.3 Connecting the speed encoder....................................................................................................68
6.11.4 Connect the holding brake...........................................................................................................69
6.11.5 Connecting the temperature sensor............................................................................................69
6.11.6 Connection to a converter...........................................................................................................70
6.11.7 Converter operation on a grounded network...............................................................................71
7 Commissioning...........................................................................................................................................73
7.1 Safety instructions.......................................................................................................................73
7.2 Magnetic field when the brake is open........................................................................................73
7.3 Insulation resistance and polarization index................................................................................74
7.4 Checks to be carried out prior to commissioning ........................................................................74
7.5 Switching on................................................................................................................................76
7.6 Setting values for the bearing temperature monitoring (option)..................................................77
8 Operation....................................................................................................................................................79
8.1 Safety notes during operation......................................................................................................79

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8.2 Operation.....................................................................................................................................81
8.3 Switching-off force-ventilated motors..........................................................................................81
8.4 Switching on again after an emergency switching-off.................................................................81
8.5 Stoppages...................................................................................................................................81
8.5.1 Avoidance of damage to roller bearings during stoppages.........................................................82
8.5.2 Measurement of the insulation resistance after an extended stoppage......................................82
8.6 Decommissioning the machine....................................................................................................83
8.7 Re-commissioning the machine..................................................................................................83
8.8 Faults...........................................................................................................................................83
8.8.1 Inspections in the event of faults.................................................................................................83
8.8.2 Electrical faults at force-ventilated motors...................................................................................84
8.8.3 Mechanical faults.........................................................................................................................84
8.8.4 Rolling-contact bearing faults......................................................................................................85
8.8.5 Holding brake faults.....................................................................................................................86
9 Maintenance...............................................................................................................................................87
9.1 Observe the operating instructions of the components...............................................................87
9.2 Inspection and maintenance........................................................................................................87
9.2.1 Inspections in the event of faults.................................................................................................87
9.2.2 Initial inspection...........................................................................................................................88
9.2.3 General inspection.......................................................................................................................88
9.2.4 Rolling-contact bearing inspection...............................................................................................89
9.2.5 Changing bearings when using permanently lubricated rolling-contact bearings.......................89
9.2.6 Maintenance................................................................................................................................90
9.2.6.1 Safety instructions.......................................................................................................................90
9.2.6.2 Maintenance intervals..................................................................................................................91
9.2.6.3 Rolling-contact bearings..............................................................................................................91
9.2.6.4 Lubrication...................................................................................................................................92
9.2.6.5 Cleaning the spent grease chamber............................................................................................97
9.2.6.6 Force-ventilated motors...............................................................................................................98
9.2.6.7 Maintaining terminal boxes........................................................................................................100
9.3 Repair........................................................................................................................................101
9.3.1 Safety instructions.....................................................................................................................101
9.3.2 Dissembling a force-ventilated motor........................................................................................101
9.3.3 Removing and installing the protecting ring...............................................................................102
9.3.4 Removing and mounting end shields of force-ventilated motors...............................................103
9.3.5 Installing the machine................................................................................................................103
9.3.6 Sealing (type 1PH828.).............................................................................................................105
9.3.7 Relocating the external fan (type 1PH828.)...............................................................................106
9.3.8 Removing the external fan.........................................................................................................106
9.3.9 Removing and mounting the speed sensor...............................................................................108
9.3.10 Connecting the speed encoder..................................................................................................110
9.3.11 Replacing the DRIVE-CLiQ interface (encoder module)...........................................................111
9.3.12 Touch up any damaged paintwork............................................................................................112
10 Spare parts...............................................................................................................................................113
10.1 Ordering data.............................................................................................................................113

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10.2 Spare parts kits..........................................................................................................................113

10.3 Ordering spare parts via the Internet.........................................................................................114
10.4 Spare parts force-ventilated motor............................................................................................115
10.4.1 Force-ventilated motor, complete..............................................................................................115
10.4.2 External fan...............................................................................................................................116
10.4.3 Roller bearing cartridge DE with radial shaft sealing ring with regreasing................................117
10.4.4 Roller bearing cartridge DE, belt coupling.................................................................................118
10.4.5 Roller bearing cartridge DE, coupling output, with regreasing..................................................119
10.4.6 Roller bearing cartridge DE, coupling output, with permanent lubrication.................................120
10.4.7 Roller bearing cartridge NDE, with permanent lubrication.........................................................121
10.4.8 Roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.).................................122
10.4.9 Roller bearing cartridge NDE, with regreasing (type 1PH828.).................................................123
10.4.10 Roller bearing cartridge NDE, "Performance"...........................................................................124
10.5 Spare parts holding brake.........................................................................................................124
10.6 Terminal box..............................................................................................................................125
10.7 Speed encoder (type 1PH818., 1PH822.).................................................................................126
10.8 Speed encoder (type 1PH828.).................................................................................................127
11 Disposal....................................................................................................................................................129
11.1 Introduction................................................................................................................................129
11.2 Preparing for disassembly.........................................................................................................129
11.3 Dismantling the machine...........................................................................................................129
11.4 Disposal of components............................................................................................................130
A Service and Support.................................................................................................................................131
A.1 Siemens Service Center............................................................................................................131
B Quality documents....................................................................................................................................133
B.1 EC Declaration of Conformity 2006/95/EC................................................................................135
C Additional documents...............................................................................................................................137
C.1 Reader notes for the operating instructions of the holding brake..............................................137
C.2 Operating instructions, holding brake........................................................................................138
C.3 Reader notes for the operating instructions of the external fan.................................................161
C.4 Operating instructions, external fan...........................................................................................161
Index.........................................................................................................................................................203

Tables

Table 3-1 Elements on the rating plate........................................................................................................22

Table 3-2 Machine design .........................................................................................................................23
Table 3-3 Technical data of the holding brake.............................................................................................25
Table 3-4 Roller bearing versions .............................................................................................................26

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Table 3-5 Minimum radial forces.................................................................................................................27

Table 4-1 Tightening torque for rotor shipping brace ................................................................................35
Table 4-2 Pressure drop in motors with pipe connection ..........................................................................42
Table 5-1 Stator winding insulation resistance at 40℃...............................................................................47
Table 5-2 Maximum permitted radial vibration severity...............................................................................49
Table 5-3 Maximum permitted axial vibration severity.................................................................................49
Table 5-4 Permissible deviations when aligning the motor..........................................................................51
Table 5-5 Tightening torques for bolted connections with a tolerance of ±10%..........................................53
Table 6-1 Terminal designations using the 1U1-1 as an example...............................................................58
Table 6-2 Data for electrical connection......................................................................................................60
Table 7-1 Guidelines for setting the tripping temperature of slot thermometers..........................................77
Table 8-1 Electrical faults .........................................................................................................................84
Table 8-2 Mechanical faults ......................................................................................................................84
Table 8-3 Rolling-contact bearing faults .................................................................................................85
Table 9-1 Checks after installation or repair ...............................................................................................88
Table 9-2 Maintenance measures...............................................................................................................91
Table 9-3 Criteria for selecting roller bearing greases.................................................................................92
Table 9-4 Roller bearing greases for vertical and horizontal types of construction ....................................93
Table 9-5 Alternative greases with NLGI class 2 for motors with a horizontal type of construction............93
Table 9-6 Lubricating grease for the Performance version (Option L37).....................................................94
Table 10-1 Motor, complete .......................................................................................................................115
Table 10-2 Spare parts for external fan.......................................................................................................116
Table 10-3 Spare parts for rolling-contact bearing bush drive end with mounted gearing, with regreasing 117
Table 10-4 Spare parts for rolling-contact bearing bush drive end with belt coupling, with regreasing.......118
Table 10-5 Spare parts for rolling-contact bearing bush drive end, with coupling output, with regreasing 119
Table 10-6 Spare parts for rolling-contact bearing bush drive end, with coupling output, with permanent
lubrication .................................................................................................................................120
Table 10-7 Spare parts for roller bearing cartridge, non-drive end, permanent lubrication ........................121
Table 10-8 Spare part, roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.) ..............122
Table 10-9 Spare part, roller bearing cartridge NDE, with regreasing (type 1PH828.) ...............................123
Table 10-10 Spare parts for rolling-contact bearing bush non-drive end with regreasing.............................124
Table 10-11 Spare parts for terminal box .....................................................................................................125
Table 10-12 Spare part, speed encoder (type 1PH818., 1PH822.)...............................................................126
Table 10-13 Spare part, speed encoder (type 1PH828.) .............................................................................127
Table A-1 Service numbers........................................................................................................................131
Table C-1 Technical data of the holding brake...........................................................................................137

Figures

Figure 3-1 Schematic layout of rating plate..................................................................................................21

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Figure 4-1 Lifting the machine (schematic representation)...........................................................................34

Figure 4-2 Rotor shipping brace...................................................................................................................35
Figure 4-3 Air guidance from the DE to the NDE (schematic representation, types 1PH818. and 1PH822.)40
Figure 4-4 Bypass for 1PH822. for IP23 ......................................................................................................41
Figure 4-5 Air guidance from the NDE to the DE (schematic representation, type 1PH828.)......................41
Figure 5-1 Max. permissible vibration velocity, taking into account the vibration displacement and vibration
acceleration.................................................................................................................................49
Figure 5-2 Aligning the machine...................................................................................................................51
Figure 5-3 Balancing type on the drive-end side..........................................................................................53
Figure 5-4 Water drain hole (type 1PH818., 1PH822.).................................................................................55
Figure 6-1 Detailed view: Connection point ① for ground conductor...........................................................58
Figure 6-2 Connection with cable lug at the terminal box 1XB7 322 / 1XB7 422.........................................61
Figure 6-3 Connection with cable lug at the terminal box 1XB7 700 / 1XB7 712.........................................61
Figure 6-4 Connection in the external fan terminal box................................................................................65
Figure 6-5 External fan terminal box ① (schematic representation)............................................................66
Figure 6-6 External fan terminal box ① (schematic circuit diagram)...........................................................67
Figure 6-7 Detailed view: Plug-in connection ...............................................................................................68
Figure 6-8 Sensor Module ① mounted on the terminal box........................................................................69
Figure 9-1 Flat grease nipple ① and ② (schematic circuit diagram for types 1PH818. and 1PH822.)......96
Figure 9-2 Flat grease nipple ① and ② (schematic circuit diagram for type 1PH828.)..............................96
Figure 9-3 Fitting the protecting ring...........................................................................................................103
Figure 9-4 Sealing gap between the enclosure and bearing shields (schematic representation)..............105
Figure 9-5 Installing the rotary shaft seal....................................................................................................106
Figure 9-6 Unscrewing the external fan (1PH818., 1PH822.).....................................................................107
Figure 9-7 Unscrewing the external fan (1PH828.).....................................................................................107
Figure 9-8 Detailed view of the speed encoder..........................................................................................108
Figure 9-9 Electrical connection of the speed sensor ................................................................................111
Figure 10-1 Schematic representation of the motor, complete.....................................................................115
Figure 10-2 Spare parts for external fan (type 1PH818., 1PH822.) ............................................................116
Figure 10-3 Rolling-contact bearing bush drive end with mounted gearing, with regreasing.......................117
Figure 10-4 Rolling-contact bearing bush drive end with belt coupling, with regreasing..............................118
Figure 10-5 Rolling-contact bearing bush drive end, with coupling output, with regreasing.........................119
Figure 10-6 Rolling-contact bearing bush drive end, with coupling output, with permanent lubrication.......120
Figure 10-7 Roller bearing cartridge, non-drive end, permanent lubrication ................................................121
Figure 10-8 Roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.).................................122
Figure 10-9 Roller bearing cartridge NDE, with regreasing (type 1PH828.).................................................123
Figure 10-10 Rolling-contact bearing bush non-drive end with regreasing ...................................................124
Figure 10-11 Terminal box..............................................................................................................................125
Figure 10-12 Speed encoder..........................................................................................................................126

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Figure 10-13 Speed encoder (type 1PH828.).................................................................................................127

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12 Operating Instructions 03/2012 A5E03555811A AB
Introduction 1
These operating instructions are valid for 1PH8 induction motors in shaft heights 180 ... 280
in the force-ventilated version.
● 1PH818.1 and 1PH818.3
● 1PH822.1 and 1PH822.3
● 1PH828.1
The serial number of the motor can be found on the rating plate.

These instructions describe the machine and explain how to handle it, from initial delivery to
final disposal of the equipment. Keep these instructions for later use.
Read these operating instructions before you handle the machine and follow the instructions.
to become familiar with its design and operating principles and thus ensure safe, problem-free
machine operation and long service life.
If you have suggestions for improving the document, please contact our Service Center
(Page 131).

Text format features

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

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

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Introduction

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14 Operating Instructions 03/2012 A5E03555811A AB
Safety notes 2
2.1 Information for the nominated person in control of the electrical
installation
This electric machine has been designed and built in accordance with the specifications
contained in Directive 2006/95/EC ("Low-Voltage Directive") and is intended for use in
industrial plants. Please observe the country-specific regulations when using the electric
machine outside the European Community.
Follow the local and industry-specific safety and setup regulations.
The persons responsible for the plant must ensure the following:
● Planning and configuration work and all work carried out on and with the machine is only
to be done by qualified personnel.
● The operating instructions must always be available for all work.
● The technical data as well as the specifications relating to the permissible installation,
connection, ambient and operating conditions are taken into account at all times.
● The specific setup and safety regulations as well as regulations on the use of personal
protective equipment are observed.

Note
Use the services and support provided by the appropriate Service Center (Page 131) for
planning, installation, commissioning, and servicing work.

In the individual chapters of this document, you will find safety instructions that must be obeyed
absolutely, for your own safety, to protect other people and to avoid damage to property.
Observe the following safety instructions for all activities on and with the machine.

2.2 The five safety rules:

For your personal safety and to prevent material damage when working on the machine, always
observe the safety instructions and the following five safety rules, according to EN 50110‑1
("Working in a voltage-free state). Apply the five safety rules in the order stated before starting
work at the machine.

Five safety rules

1. Disconnect the system.
Disconnect the auxiliary circuits, for example anti-condensation heating
2. Prevent reconnection.
3. Make sure that the equipment is at zero voltage

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Safety notes
2.4 Safe handling

4. Ground and short-circuit

5. Cover or isolate nearby components that are still live.
To energize the system, apply the measures in reverse order.

2.3 Qualified personnel

All work at the machine must be carried out by qualified personnel only. For the purpose of
this documentation, qualified personnel is taken to mean people who fulfill the following
requirements:
● Through appropriate training and experience, they are able to recognize and avoid risks
and potential dangers in their particular field of activity.
● They have been instructed to carry out work on the machine by the appropriate person
responsible.

2.4 Safe handling

Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
● General safety regulations applicable in the country where the machine is deployed.
● Manufacturer-specific and application-specific regulations
● Special agreements made with operator
● Separate safety instructions supplied with the machine
● Safety symbols and instructions on the machine and its packaging

WARNING
Live parts
Electric machines contain live parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed
or if the machine is not handled, operated, or maintained properly.
● Always observe the "five safety rules (Page 15)" when carrying out any work on the
machine.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.
● Regularly and correctly maintain the machine.

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 Safety notes
2.4 Safe handling

WARNING
Rotating components
Electric machines contain dangerous rotating parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed
or if the machine is not handled, operated, or maintained properly.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.
● Perform regular maintenance on the machine.
● Secure free-standing shaft ends.

WARNING
Hot surfaces
Electric machines have hot surfaces. Do not touch these surfaces. They could cause burns.
● Allow the machine to cool before starting work on the machine.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.

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

CAUTION
Flammable substances
Chemical substances required for the setup, operation and maintenance of machines may
be flammable.
Burns and other damage to health and material may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.

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Safety notes
2.5 Electrostatic sensitive devices

WARNING
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
work place. which can cause hearing damage.
Take steps to reduce noise, such as introducing covers and protective insulation or adopting
hearing protection measures, so that the machine can be operated safely within your system.

2.5 Electrostatic sensitive devices

ESD protective measures

CAUTION
Electrostatic discharge
Electronic modules contain components that can be destroyed by electrostatic discharge.
These modules can be easily destroyed by improper handling.
To protect your equipment against damage, follow the instructions given below.
● Never touch electronic modules unless absolutely necessary in the course of maintenance
and repair procedures.
● If the modules have to be touched, the body of the person concerned must be
electrostatically discharged immediately beforehand and be grounded.
● Electronic modules should not be brought into contact with electrically insulating materials
such as plastic film, plastic parts, insulating table supports or clothing made of synthetic
fibers.
● Always place electrostatic sensitive devices on conductive bases.
● Always pack, store and transport electronic modules or components in conductive
packaging, e.g. metallized plastic or metal containers, conductive foam material or
domestic aluminum foil.

The necessary ESD protective measures for electrostatic sensitive devices are illustrated once
again in the following drawings:

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 Safety notes
2.7 Interference immunity

d d d
b b
e e
f f f f f

c a c a c a
(1) (2) (3)

(1) Sitting (2) Standing (3) Standing/sitting

a = conductive floor surface b = ESD table c = ESD shoes
d = ESD overall e = ESD wristband f = cabinet ground connection

See also
Replacing the DRIVE-CLiQ interface (encoder module) (Page 111)

2.6 Electromagnetic compatibility

This machine is designed in accordance with IEC/EN 60034 and, when used as prescribed, it
satisfies the requirements of European Directive 2004/108/EG on electromagnetic
compatibility.

2.7 Interference immunity

The machine fulfills the requirements regarding interference immunity in conformity with IEC/
EN 61000‑6‑2.
When using machines with integrated sensors (e.g. PT100, PTC thermistors), the
manufacturer of the overall system must himself ensure sufficient interference immunity by
selecting suitable sensor signal leads and evaluation units.

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Safety notes
2.9 Electromagnetic fields when operating electrical power engineering installations

2.8 Interference voltages when operating the converter

WARNING
Interference voltages when operating the converter
When a converter is in operation, the emitted interference varies in strength depending on
the converter (manufacturer, type, interference suppression measures undertaken). On
motors with integrated sensors (e.g. PTC thermistors), interference voltages caused by the
converter may occur on the sensor lead. This can cause faults which can result in eventual
or immediate death, serious injury, or material damage.
In order to avoid exceeding the limit values set in IEC/EN 61000-6-3 for the drive system
(motor and converter), the EMC information provided by the converter manufacturer must be
observed. You must put appropriate EMC measures in place.

2.9 Electromagnetic fields when operating electrical power engineering

installations

WARNING
Interference with electronic devices caused by electromagnetic fields when operating
electrical power engineering installations
Electromagnetic fields are generated during operation of electrical power engineering
installations. Electromagnetic fields can interfere with electronic devices,
resulting in malfunctioning of those devices. The operation of heart pacemakers can be
impaired, potentially leading to damage to a person's health or even death. It is therefore
forbidden for persons with heart pacemakers to come into the vicinity of the machine. Data
may be lost from magnetic or electronic data media. As the operator of the installation, you
must take the following measures:
● Ensure that the personnel working in these areas are adequately protected from any harm
by making appropriate arrangements, such as erecting identifying markings, safety
barriers and warning signs and giving safety talks.
● Observe the nationally applicable health and safety regulations.
● Do not carry any magnetic or electronic data media with you.

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Description 3
Application range
The motors of the 1PH818., 1PH822., 1PH828., series are used as industrial drives. They
have been designed to address a wide range of drive applications exclusively fed from
converters.
They are characterized by their high power density, ruggedness, long lifetime, and overall
reliability.

WARNING
Explosion hazard
This machine is not designed for use in hazardous areas. An explosion can occur if the motor
is switched on in these areas. This can result in death, serious injury, or material damage.
Never operate this machine in hazardous areas.

Rating plate
The rating plate shows the identification data and the most important technical data. The data
on the rating plate and the contractual agreements define the limits of proper usage.

 1R1  

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8 1 9 , 1 $ 31 N: I 1 +] Q 1 PLQ &2'(
         

        

        



        

  QPD[ PLQ 

 
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Figure 3-1 Schematic layout of rating plate

SIMOTICS M-1PH8
Operating Instructions 03/2012 A5E03555811A AB 21
Description

Table 3-1 Elements on the rating plate

No. Description No. Description

010 MLFB 200 Rated current IN (3)
012 Consecutive number, part of serial number 210 Rated power PN (3)
020 Serial number 220 Power factor (3)
025 UL approval 230 Rated frequency fN (3)
026 (empty) 240 Rated speed nN (3)
030 Type of construction 250 Operating mode (3)
035 (empty) 255 Code for operating point 3
036 (empty) 260 Rated voltage VN (4)
040 Degree of protection 261 Switching mode 4
045 Type of balancing 270 Rated current IN (4)
049 Power factor (asynchronous) 280 Rated power PN (4)
050 Rated voltage VN (1) 290 cosinus φ (4)
051 Switching mode 1 300 Rated frequency fN (4)
060 Rated current IN (1) 310 Rated speed nN (4)
070 Rated power PN (1) 320 Operating mode (4)
080 Power factor (1) 325 Code for operating point 4
090 Rated frequency fN (1) 335 Weight
100 Rated speed nN (1) 330 Maximum current IMAX
110 Operating mode (1) 340 Maximum torque MMAX
115 Code for operating point 1 350 Maximum speed nMAX
120 Rated voltage VN (2) 360 Temperature sensor
121 Switching mode 2 370 Tachometer/resolver
130 Rated current IN (2) 380 Cooling method
140 Rated power PN (2) 390 Throughput l/min (m3/s)
150 Power factor (2) 400 System pressure
160 Rated frequency fN (2) 410 Maximum coolant temperature
170 Rated speed nN (2) 420 Options (I)
180 Operating mode (2) 430 Options (II)
185 Code for operating point 2 440 Optional customer information
190 Rated voltage VN (3) 450 Anti-condensation heater / place holder
191 Switching mode 3

Rotor
This machine is an induction motor for low voltage with squirrel-cage induction motor and
integrated cooling circuit.

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22 Operating Instructions 03/2012 A5E03555811A AB
 Description

Machine design
The regulations and standards used as basis for designing and testing this machine are
stamped on the rating plate. The machine design basically complies with the following
standards:

Table 3-2 Machine design

Feature Standard
Dimensions and operation characteristics IEC / EN 60034-1
Degree of protection IEC / EN 60034-5
Cooling IEC / EN 60034-6
Type of construction IEC / EN 60034-7
Terminal markings and direction of rotation IEC/EN 60034-8
Noise emission IEC / EN 60034-9
Mechanical vibrations IEC / EN 60034-14
IEC‑standard voltages IEC/DIN IEC 60038
Vibration limit values DIN ISO 10816-3

Drive
The speed of the machine is controlled by a frequency converter.

CAUTION
Destruction of the machine when operated directly from the line supply
The machine will be destroyed if it is directly connected to the line supply. Only operate the
machine with a frequency converter.

Types of construction
The type construction can be found on the rating plate.
The motor is supplied with two attached lifting eyes. For IM V5 and IM V15 types of construction
with "shaft extension pointing downward", the motor is equipped with two additional Vario eye
bolts.

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Description

Cooling with external fan

The motor has an open design with cooling method IC 416 to IEC / EN 60034-6. The separately
driven fan unit and the terminal box can be mounted in a different position depending on the
order.

WARNING
Operating instructions, external fan
Improper use of the external fan can result in death, serious injury, and material damage.
Observe and follow the operating instructions of the external fan.

CAUTION
Minimum clearance for built-on accessories
If the required cooling air flow cannot be maintained, then the machine can overheat. Material
damage can result.
Maintain a minimum clearance of 300 mm for customer-supplied built-on accessories at the
air intake opening and at the air discharge openings to ensure the required cooling air flow.

See also
Operating instructions, external fan (Page 161)

EC external fan from the Ziehl-Abegg company

Ziehl-Abegg EC-external fans are installed in the 1PH8 air-cooled motors. This are especially
designed fan units for this motor series, with a permanently set operating speed.
For shaft heights 180 and 225, EC motors with frame size "B" are used, for shaft height 280
(option) frame size "D" is used.
Terminals GND; 10V; D1; I1; A1 and A2 must not be connected and are therefore equipped
with insulators.

CAUTION
The use in IT systems is not permitted.

CAUTION
The external fan may not be cleaned with a water jet. This results in material damage.

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24 Operating Instructions 03/2012 A5E03555811A AB
 Description

Degree of protection
Depending on the version, the machine has degree of protection IP23 or IP55.

Supplementary devices
A KTY 84 temperature sensor is installed (Page 69) in the stator winding for winding control.
Depending on the order options, various supplementary devices such as encoder systems can
be either installed or mounted.

Holding brake
Depending on the order, a special version of a holding brake from the Stromag company is
mounted. Various types of holding brake are mounted depending on the shaft height.

CAUTION
Technical data for the special version of the holding brake
The following technical data apply to the special version of the mounted holding brake. The
corresponding data in the manufacturers operating instructions do not apply.

Table 3-3 Technical data of the holding brake

Technical data NFF-A 63 NFF-A 100

Holding torque MStat [Nm] 1000 1600

Max. no-load speed N0 [rpm] 3000 2800
Rated switching speed Nzn [rpm] 1600 1300
Air gap min. / max. 0.6 / 1.5 0.6 / 1.6
Rated switching power S4 - 40% Pvn [kW] 0.249 0.27
ED
Ground mbrake [kg] 75 95
Moment of inertia of the rotating Jbrake [kgm2] 0.025 0.059
parts
Supply voltage Usupply [V] 230 (AC) 230 (AC)
Coil voltage Ucoil [V] 103 (DC) 103 (DC)
Power consumption P [W] 227 278
Current consumption I [A] 2.21 2.7

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Description

Note
Notes for the reader
● Regarding Chapter 4.2: The shaft end is magnetized when the holding brake is opened.
● Regarding Chapter 9: Only frame sizes 63 and 100 are relevant in the table.
● Regarding Chapter 9.2: Only frame sizes 63 and 100 are relevant in the table.

See also
Operating instructions, holding brake (Page 138)

Ambient conditions
The standard machines are not suitable for use in corrosive atmospheres, atmospheres with
a high salt content, or outdoor applications.

Roller bearings
The machines are equipped with different types of roller bearings depending on the version
and the operating conditions described in the order. If the machine is equipped with a
regreasing system, you will find the relevant data on the machine's lubricant plate.
The following standard roller bearing versions are available:

Table 3-4 Roller bearing versions

Design Bearings
Standard design and Drive end deep-groove ball bearing as spring-loaded floating
"Performance" bearing
Non-drive end deep-groove ball bearing as fixed bearing
Version for increased radial forces Drive end cylindrical-roller bearing as floating bearing
Non-drive end deep-groove ball bearing as fixed bearing

CAUTION
Maintain the minimum radial forces
Operating cylindrical roller bearings without a load can damage them. Maintain the minimum
radial forces specified when using cylindrical-roller bearings.

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26 Operating Instructions 03/2012 A5E03555811A AB
 Description

Table 3-5 Minimum radial forces

Type Minimum radial force

1PH818. 4 kN
1PH822. 5 kN
1PH828. 9 kN

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Description

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28 Operating Instructions 03/2012 A5E03555811A AB
Preparations for use 4
Good planning and preparation of machine applications are essential in terms of keeping
installation simple and avoiding errors, ensuring safe operation, and allowing access to the
machine for servicing and corrective maintenance.
This chapter outlines what you need to consider when configuring your plant in relation to this
machine and the preparations you need to make before the machine is delivered.

4.1 Safety-related aspects to consider when configuring the plant

A number of residual risks are associated with the machine. These are described in the chapter
titled "Safety information" and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.

Observing the operating mode

Observe the machine's operating mode. Use a suitable control system to prevent overspeeds,
thus protecting the machine from damage.

4.2 Interlock circuit for the external fan

For machines with external fans, install an interlock circuit that prevents the main machine
being switched on if the external fan is not operational.

See also
Operating instructions, external fan (Page 161)

Force-ventilated 1PH818. and 1PH822. motors are equipped as standard with an external fan
with electronically commutated motor (EC motor); this is optional for 1PH828. motors.

CAUTION
Voltage fluctuations
The electronics of the external fan equipped with EC motor can be damaged as a result of
voltage fluctuations. Supply the external fan with power from the line supply and not via a
frequency converter.

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Preparations for use
4.3 Rotational speed limit values

CAUTION
Periodic duty
For all operating modes, operate the external fan according to DIN EN 60034-1. Also for non-
periodic operation, the machine can be thermally overloaded. This can result in damage to
the machine.
In the case of extended non-operational periods, the fan should be in operation until the
machine has approximately reached the temperature of the coolant, see S2-operation in
DIN EN 60034‑1.
Use a suitable circuit to ensure that the external fan is appropriately operated.

WARNING
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
work place. which can cause hearing damage.
Take steps to reduce noise, such as introducing covers and protective insulation or adopting
hearing protection measures, so that the machine can be operated safely within your system.

4.3 Rotational speed limit values

WARNING
Permissible speed
Excessive rotational speed can lead to serious damage to the machine. This can result in
death, serious injury, or material damage.
The controller must ensure that operation at impermissible speeds is prevented. Observe the
information about the speeds on the rating plate.

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 Preparations for use
4.6 Thermal motor protection

4.4 System-inherent frequencies

CAUTION
System-inherent frequencies
The system consisting of the foundation and machine set must be configured and matched
in such a way that no system resonances can arise and result in the permissible vibration
levels being exceeded.
Excessive vibrations can damage the machine set.
DIN 4024 must be taken into account when constructing the machine foundation. The limit
values to DIN ISO 10816-3 must not be exceeded.

4.5 Torsional loading of the shaft assembly due to faults in the electrical
supply
In the event of faults in the electrical connection during operation, excessive air gap torques
can lead to additional mechanical torsional load on the line shaft.

WARNING
Serious damage to the machine
If the configuration does not correctly recognize the mechanical torsional loadings of the shaft
assembly, this can lead to serious damage to the machine. This can result in death, serious
injury or material damage.
When planning the system, consider the configuration data in the catalog.

Note
The system planner is responsible for the entire shaft assembly.

4.6 Thermal motor protection

The machine is equipped as standard with a KTY 84 temperature sensor, optionally with PTC
thermistors to directly monitor the motor temperature to protect the machine against overload
in operation. Plan a corresponding circuit for monitoring.

See also
Connecting the temperature sensor (Page 69)

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Preparations for use
4.7 Transport and storage

4.7 Transport and storage

When carrying out any work on the machine, observe the general safety instructions and the
specifications contained in DIN EN 50110‑1 as regards working safely with and on electrical
machines.

4.7.1 Checking the delivery

Checking the 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 items delivered are in accordance with the
accompanying documents. Siemens will not accept any claims relating to items missing from
the delivery and which are submitted at a later date.
● Report any apparent transport damage to the delivery agent immediately. Never
commission a damaged motor.
● Report any apparent defects/missing components to the appropriate Siemens office
immediately.
These safety instructions are part of the scope of supply; keep them in a location where they
can be easily accessed.

4.7.2 Requirements for safe lifting and transporting

● Personnel operating cranes and fork-lift trucks must be appropriately qualified.
● When lifting the machine, use only approved and undamaged sling guides and spreaders
of sufficient rated capacity. Check these before using them. The weight of the machine is
shown on the rating plate.
● When lifting the machine, refer to the information on the lifting plate.
– Comply with the specified spreading angles.
– Do not exceed the maximum lifting acceleration and lifting speed specified on the lifting
plate. Lift the machine without jerking it.
Acceleration a ≤ 0.4 g
Speed v ≤ 20 m/min
● When lifting, use only the load handling attachments on the stator casing, such as load
stands or eye bolts.

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 Preparations for use
4.7 Transport and storage

WARNING
Transporting or lifting the motor
The machine or the machine set may be lifted and transported only using the load handling
attachments at the intended positions. Otherwise, the machine may tip over, slip in the
direction of lifting or fall.
This can result in death, serious injury or material damage.
1. Only use the load handling attachments on the stator frame to lift the motor.
2. Use suitable rope guiding or spreading devices. The weight of the machine is shown on
the rating plate.

WARNING
Center of gravity when transporting or lifting the motor
If the center of gravity of a load is not located centrally between the attachment points, the
motor can tip over or slip out of the lifting equipment when it is being transported or lifted.
This can result in death, serious injury or material damage.
1. Comply with the handling instructions on the machine when transporting it.
2. Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
3. Always take account of the center of gravity when transporting or lifting the motor. If the
center of gravity is not located centrally between the attachment points, then position the
hoisting hook above the center of gravity.

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Preparations for use
4.7 Transport and storage

4.7.3 Lifting and transporting

There are two lifting eyebolts for horizontal transport of the motor. Always transport and lift the
motor by the lifting eyebolts.
● Only lift the motor at the lifting eyebolts on the bearing end shields. To hoist the motor, in
particular if there are built-on assemblies, use suitable cable-guidance or spreading
equipment.
● Pay attention to the lifting capacity of the hoisting gear. The weight of the motor is specified
on the rating plate.

Figure 4-1 Lifting the machine (schematic representation)

Lifting force-ventilated motor in type of construction IM V5 with side-mounted terminal box

Proceed as follows if you wish to lift a machine with type of construction IM V5 and with side-
mounted terminal box:
1. Screw off the external fan.
2. Screw in the eyebolts supplied and use these to lift the machine.
3. Screw on the external fan again after the work has been completed.

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 Preparations for use
4.7 Transport and storage

Rotor shipping brace

Machines ordered with the "Increased radial force" option are equipped with cylindrical-roller
bearings and a rotor shipping brace.

CAUTION
Transport 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 securely
attached during transportation.
● Only remove it before pushing on the drive element.
● When the motor has to be transported after the drive element is pushed on you must take
other appropriate measures to fix the axial position of the rotor.

཰
ཱ

① Sleeve
② Shaft screw

Figure 4-2 Rotor shipping brace

Table 4-1 Tightening torque for rotor shipping brace

Type Thread in the shaft end Tightening torque Preload

1PH818. M20 50 Nm 12 kN
1PH822. M20 50 Nm 12 kN
1PH828. M24 100 Nm 20 kN

4.7.4 Transporting a force-ventilated motor that has already been in operation

If you have already operated the motor and now want to transport it, proceed as follows:
1. Allow the motor to cool down.
2. Remove the connections provided by the customer.
3. Fit the rotor shipping brace.
4. Only use the eyebolts on the bearing shields to transport and lift the motor.

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Preparations for use
4.7 Transport and storage

Note
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.

4.7.5 Transporting the machine set

WARNING
Transporting the machine set
The lifting lugs on the machine are designed only for the weight of the machine. If a machine
set is lifted and transported by a single machine, this can lead to mechanical failure of the
lifting lug. The machine or machine set may fall.
Death, serious injury or material damage may result.
● Do not lift machine sets by attaching lifting tackle to the individual machines.
● Use only the equipment provided, e.g. the openings or lugs on the base plates, for
transporting machine sets. Note the maximum capacity of the lifting lug.

Note
Place the machine in a secure and raised position
In order to obtain easy and safe access to the underside of the machine, place the machine
in a secure and raised position.

DANGER
Never remain under a suspended load
If the lifting gear or load handling attachments were to fail, the machine could fall.
This can result in death, serious injury, or material damage. Never remain under the machine
when it is raised.

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 Preparations for use
4.7 Transport and storage

4.7.6 Storage
The motors can be stored for up to two years in dry, dust-free and vibration-free rooms without
reducing the specified storage time.

CAUTION
Seizure damage to bearings
If the motors are stored incorrectly there is a risk of bearing seizure damage such as brinelling,
for example as a result of vibrations.
Read the following storage instructions.

Preparation
● Fit the rotor shipping brace.
● Apply a preserving agent such as Tectyl to bare external components such as shaft ends,
if this has not already been applied in the factory.

Storing indoors

CAUTION
Damage caused as a result of outdoor storage
Storing the machine outdoors can result in it being damaged. Ensure that the machine is only
stored in areas that comply with the following conditions.

● Store the motor in an area that meets the following criteria:

– Dry, dust-free, frost-free and vibration-free The relative air humidity should be lower than
60% and the temperature should not drop below -15 °C in accordance with EN 60034-1.
– It must be well ventilated.
– Offers protection against extreme weather conditions
– The air in the storage area must not contain any harmful gases.
● Protect the motor from shocks and humidity.
● Cover the motor properly.
● Avoid contact corrosion:
– Every three months, remove the shipping brace and rotate the shaft end by hand.
– Then reattach the rotor shipping brace.

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Preparations for use
4.7 Transport and storage

Protection against humidity

● If a dry storage area is not available, then take the following precautions:
– Wrap the motor in humidity-absorbent material and then wrap it in film to create an air-
tight unit.
– Include several bags of desiccant in the seal-tight packaging. Check the desiccant and
replace as required.
– Place a humidity meter in the seal-tight packaging to indicate the level of air humidity
inside it.
– Inspect the motor regularly.

Long-term storage
If you are storing a machine for more than six months, you must check its condition every six
months.
● Check the machine for damage.
● 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 air-conditioning for the storage room.

Condensation
Condensation can collect in the machine as a result of sharp fluctuations in ambient
temperature, exposure to direct sunlight, high levels of humidity in the storage location or
intermittent operation/variations in load during operation.

CAUTION
Damage caused by condensation
If the stator winding is damp, its insulation resistance is reduced. This results in voltage
flashovers, which can destroy the winding. Condensation can also cause rusting inside the
machine.

Water drain holes (optional)

Depending on the order concerned, the bearing shields at the DE and NDE feature water
drainage holes in the foot area and opposite the regreasing system. Make sure that the
condensation can always drain away freely.

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 Preparations for use
4.8 Ensure the cooling of force-ventilated motors

The plug that has been inserted into the water drainage holes allows the condensation to drain
away. Do not remove the plug, otherwise the machine's degree of protection will be affected.

CAUTION
In IM B3, IM B35, IM B5 types of construction, water drain holes are only functional when
mounted horizontally.

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

4.7.7 Protection against corrosion

If the machine is stored in dry conditions, then apply the subsequently listed anti-corrosion
measures:
● Storage up to six months:
Apply a coat of corrosion protective compound to all accessible bare metal parts such as
the 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 if
necessary.
Document all preservation measures taken so that they can be reversed before the machines
are put back into service.

4.8 Ensure the cooling of force-ventilated motors

Note
Note also the technical specifications on the rating plates on the motor enclosure.

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Preparations for use
4.8 Ensure the cooling of force-ventilated motors

Preconditions for adequate cooling

● In the case of motors that are cooled by the ambient air, the cooling air must be able to flow
unimpeded to and from the motors. Hot exhaust air should not be inducted again.
● The requirements of the IP degree of protection must be observed.
Higher requirements regarding the IP degree of protection may necessitate the installation
of suitable filters and special arrangement of the intake and outlet openings.
● Equipment and leads must be connected without strain.

CAUTION
Minimum clearance for built-on accessories
If the required cooling air flow cannot be maintained, then the machine can overheat. Material
damage can result.
Maintain a minimum clearance of 300 mm for customer-supplied built-on accessories at the
air intake opening and at the air discharge openings to ensure the required cooling air flow.

Figure 4-3 Air guidance from the DE to the NDE (schematic representation, types 1PH818. and
1PH822.)

A bypass is available for 1PH822. with IP23 degree of protection.

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40 Operating Instructions 03/2012 A5E03555811A AB
 Preparations for use
4.8 Ensure the cooling of force-ventilated motors

Figure 4-4 Bypass for 1PH822. for IP23

Figure 4-5 Air guidance from the NDE to the DE (schematic representation, type 1PH828.)

External fan
The code for the external fan is the eleventh position of the order number, e.g. 1PH8......0. For
details of the order number, which also tells you which type of external fan is installed (pressure
or extraction), please refer to the motor rating plate.

Machines with pipe connection

You must mount and connect pipes and a fan of suitable type and dimensioning to machines
that are intended for the connection of pipes and/or for operation with a separately driven fan.
An adapter is not included in the scope of supply.
Please observe the following when connecting pipes:
● Additional pressure drop in the system.
● Shipping covers on the ventilation openings must have been removed.
For machines with a pipe connection, the potential pressure drop inside the machine is given
in the following table:

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Preparations for use
4.10 Converter operation

Table 4-2 Pressure drop in motors with pipe connection

Type Degree of Flow rate Pressure drop Flow resistance

protection
1PH818. IP23 0,21 m3/s 450 Pa 10204 Ns2/m8
IP55 0,17 m /s
3
550 Pa 19030 Ns2/m8
1PH822. IP23 0,33 m3/s 600 Pa 5510 Ns2/m8
IP55 0,31 m /s
3
650 Pa 6760 Ns2/m8
1PH828. IP23 0,52 m3/s 600 Pa 2220 Ns2/m8
IP55 0,42 m3/s 600 Pa 3400 Ns2/m8

4.9 Cooling air quality

The cooling air is only permitted to have weak chemically aggressive properties and must only
have low levels of oil or dust.

4.10 Converter operation

4.10.1 Reducing bearing currents

Selecting and connecting the cable

● Use Motion Connect cables or symmetrically constructed, shielded cables to connect the
motor to a converter. The cable shielding, made up of as many strands as possible, must
have good electrical conductivity. Braided shields made of copper or aluminum are well
suited.
● The shield must be connected at both ends to the motor and the converter; unshielded
cable ends must be kept as short as possible.
● To ensure effective discharge of high-frequency currents, make the shield contact over the
largest possible area, i.e. as a 360° contact on the converter and motor, e.g. using EMC
glands at the cable entry points.

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 Preparations for use
4.10 Converter operation

Measures to reduce bearing currents

To specifically reduce and prevent damage caused by bearing currents, you must consider
the system as a whole, which comprises the motor, converter, and driven machine. The
following precautions help to prevent bearing currents:
● Setting up a properly meshed grounding system in the system as a whole, with low
impedance for high-frequency currents
● No potential difference between the motor, converter, and working machine.
– Use symmetrical, shielded connecting cables.
– Connect the cable shield at both ends over the greatest possible surface area (360°
contact).
– Use equipotential bonding conductors between the motor and the driven machine as
well as between the motor and the converter
● Use iron cores mounted above the motor connecting cable at the converter output. These
help to reduce common-mode components. The Siemens sales representative is
responsible for selection and dimensioning.
● Limit the voltage rate of rise by using an output filter to dampen harmonic components in
the output voltage

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Preparations for use
4.10 Converter operation

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44 Operating Instructions 03/2012 A5E03555811A AB
Assembling 5
5.1 Safety instructions
When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

CAUTION
Heat-resistant mounting parts
The motor components get very hot during operation. High temperatures can damage
mounting parts such as the cable insulation.
● Temperature-sensitive parts such as normal cables or electronic components must not
rest against or be attached to these.
● Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the ambient temperature.

CAUTION
Loss of CE conformity
Unauthorized changes or modifications to the motor will result in the loss of the CE conformity,
warranty will then become null and void.

5.2 Insulation resistance and polarization index

Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:

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5.3 Testing the insulation resistance and polarization index

● Can the machine be put into operation?

● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"

5.3 Testing the insulation resistance and polarization index

WARNING
Hazardous voltage at the terminals
During and immediately after measuring the insulation resistance or the polarization index
(PI) of the stator winding, hazardous voltages may be present at some of the terminals.
Contact with these can result in death, serious injury or material damage.
● If any power cables are connected, check to make sure line supply voltage cannot be
delivered.
● Discharge the winding after measurement until the risk is eliminated, e.g. using the
following measures:
– Connecting the terminals with ground potential until the recharge voltage drops to a
non-hazardous level
– Connecting the connecting cable

Measure the insulation resistance

1. Before you begin measuring the insulation resistance, please read the manual for the
insulation resistance meter you are going to use.
2. Disconnect any connected main-circuit cables from the terminals before measuring the
insulation resistance.
3. Measure the insulation resistance of the winding in relation to the machine housing and the
winding temperature. The winding temperature should not exceed 40°C during the
measurement. Convert the measured insulation resistances to the reference temperature
of 40°C according to the formula in the following table. This thereby ensures that the
minimum values specified can be compared.
4. Read out the insulation resistance 1 minute after applying the measuring voltage.

Measuring the polarization index

1. To determine the polarization index, measure the insulation resistances after 1 minute and
10 minutes.
2. Express the measured values as a ratio:
PI = Rinsul 10 min / Rinsul 1 min
Modern measuring devices display these values automatically following the measurement.

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5.3 Testing the insulation resistance and polarization index

Limit values for insulation resistance and polarization index of the stator winding
The following table indicates the measuring voltage and limit values for the insulation
resistance and PI. These values correspond to recommendations in IEEE 43‑2000. In addition,
a critical insulation resistance is specified for the stator winding, which is the minimum
requirement for further operation e.g. following a long-term machine downtime.

Table 5-1 Stator winding insulation resistance at 40℃

Urated Umeas RC RC, operation RT PI

[V] [V] [MΩ] [MΩ] [MΩ]
U ≤ 1000 500 ≥5 0.2 MΩ/kV 5&
57 
(≈0.5 MΩ/kV at 25°C)  7  2.0
1000 ≤ U ≤ 2500 500 (max. 1000) 100 1.8 MΩ/kV
2500 < U ≤ 5000 1000 (max. 2500) (≈5 MΩ/kV at 25°C)
5000 < U ≤ 12000 2500 (max. 5000)
U > 12000 5000 (max. 10000)

Urated = rated voltage, see the rating plate

Umeas = DC measuring voltage
RC = critical or minimum insulation resistance at reference temperature of 40°C
RC = minimum insulation resistance after cleaning/repair at 40°C
RC, operation = critical insulation resistance during operation at 40°C
RT = insulation resistance converted to current measuring/winding temperature
PI = polarization index Rinsul 10 min / Rinsul 1 min. (T < 40°C)
T = current measuring/winding temperature

Note the following:

● When measuring at winding temperatures other than 40 °C, the measured value must be
converted to the reference temperature of 40 °C. The value is calculated using the formula
specified in the table from IEEE 43‑2000. In this case, doubling or halving the insulation
resistance at a temperature change of 10 K is used as the basis.
– The insulation resistance halves every time the temperature rises by 10 K.
– The resistance doubles every time the temperature falls by 10 K.
● Dry, new windings have an insulation resistance of between 100 ... 2000 MΩ, or even higher
values, if required. Insulation resistance close to the minimum value could be due to
humidity and/or dirt accumulation. However, the size of the winding, the rated voltage and
other characteristics affect the insulation resistance and may need to be taken into account
when determining measures.
● Over its operating lifetime, the motor winding insulation resistance can drop due to ambient
and operational influences. Depending on the rated voltage, the critical insulation resistance
value is to be calculated by multiplying the rated voltage (kV) by the specific critical
resistance value and then converted to the current winding temperature at the time of the
measurement, see previous table.

Example calculation
Critical resistance for a rated voltage (VN) of 3.3 kV:

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5.5 Vibration severity

3,3 kV x 1,8 MΩ / kV = 6 MΩ at 40° C.

A winding temperature of T = 25°C during the measurement, results in a critical insulation
resistance of 16.5 MΩ.

CAUTION
Critical insulation resistance reached or undershot
If the critical insulation resistance is reached or undershot, this can damage the insulation
and cause voltage flashovers.
● Contact your Siemens Service Center.
● If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.

5.4 Preconditions for correct alignment and secure attachment

Detailed specialist knowledge of the following measures is required in order to correctly align
and securely fit the equipment.
● Preparing the foundation
● Selecting and mounting the coupling
● Measuring the concentricity and axial eccentricity tolerances
● Positioning the machine
If you are not familiar with the prescribed measures and procedures, then you can make use
of the services offered by the local Service Center (Page 131).

5.5 Vibration severity

Due to the influencing variables listed below, the vibration response of the system at the site
of operation can lead to increased vibration severity at the motor:
● Transmission elements
● Assembly conditions
● Alignment and installation
● Effects of external vibrations
Under certain circumstances, the rotor may have to be balanced completely with the output
element.
Please take care to ensure that the vibration severity specified to ISO 10816 is not exceeded
at the defined measuring points on the motor. By doing this, you can ensure problem-free
operation and a long service life.

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5.5 Vibration severity

Maximum permitted vibration severity

The values for the maximum permitted radial and axial vibration severity must both be
maintained.

Table 5-2 Maximum permitted radial vibration severity

Vibration frequency Vibration values1)

< 6.3 Hz Vibration displacement s ≤ 0.25 mm
6.3 to 63 Hz Vibration velocity vrms ≤ 7.1 mm/s
> 63 Hz Vibration acceleration a ≤ 4.0 m/s2

Table 5-3 Maximum permitted axial vibration severity

Vibration velocity Vibration acceleration

vrms = 7.1 mm/s apeak = 3.55 m/s2
P

Dื
P


 


P

Vื

Vt

 

Figure 5-1 Max. permissible vibration velocity, taking into account the vibration displacement and
vibration acceleration

To evaluate the vibration velocity, the measuring equipment must fulfill the requirements of
ISO 2954.
The vibration acceleration must be measured as a peak value in the time range in a frequency
band of 10 to 2000 Hz.
If excitation in excess of 2000 Hz (e.g. meshing frequencies) is to be expected, the
measurement range must be adapted accordingly. This does not alter the maximum
permissible values.

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5.6 Aligning the machine

5.6 Aligning the machine

Vertical and horizontal alignment

The following measures are required in order to compensate any radial offset at the coupling
and to horizontally adjust the electric motor with respect to the driven load:
● Place shims under the motor feet to position it vertically and to prevent stress/distortion.
The number of shims should be kept as low as possible, so use as few thicker shims as
possible, instead of several thinner shims.
● For horizontal positioning, push the motor sideways on the foundation Pay attention to
maintaining the axial position.
● When positioning the motor, ensure that a uniform axial gap is maintained around the
coupling.

Note
Alignment accuracy
Remember to take account of data concerning the alignment accuracy of the driven load
and the coupling.

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5.7 Securing the machine

Alignment accuracy
1. Align the motors with coupling output in such a manner that the center lines of the shafts
are parallel with no offset. This ensures that no additional forces affect their bearings during
operation.
2. Perform the fine adjustments with plates under the entire motor foot.

 

š'

Figure 5-2 Aligning the machine

Table 5-4 Permissible deviations when aligning the motor

Permissible deviations Radial shaft offset [x] Axial shaft offset [y]
Flexible coupling 0.05 mm 0.05 mm

5.7 Securing the machine

Fixing by means of motor feet

● The contact surfaces of the motor feet must lie on one plane. If the motor needs to be
aligned, position metal shims underneath the feet in order to prevent machine deformation.
The number of shims should be kept as low as possible i.e. stack as few as possible.
● Select foot screws as per ISO 898-1 in compliance with the loading conditions and machine
type:

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5.8 Tightening torques for screw and bolt connections

● Use foot screws with a minimum property class of 8.8.

● Pin the mounting feet to the customer foundation for motors with types of construction B6,
B7, B8, V5 and V6.
Type Foot screw size
1PH818. M12
1PH822. M16
1PH828. M20

Flange mounting
The flange is only used to transfer the torque. Due to the empty weight or as a result of
vibrations that arise if the flange is too soft, the motor can be damaged if it is only fastened via
the flange.
1. Fasten the flange-mounted motors via a stable motor suspension and support them via the
end shield feet (foot flange type of construction).
2. During commissioning, ensure that the permitted vibration values are maintained in
accordance with ISO 10816‑3.
If the motor is to be only flange mounted, then the maximum speed nmax is reduced for rigid
foundations according to the following table:
Type Maximum speed nmax
1PH818. 3000 1/min
1PH822. 2500 1/min
1PH828. 2000 1/min

Maximum speed for a rigid foundation and flange mounting

5.8 Tightening torques for screw and bolt connections

Bolt locking devices
● Refit nuts or bolts that are mounted together with locking, resilient, and/or force-distributing
elements with identical, fully-functional elements when re-assembling. Always renew keyed
elements.
● When screwing together threads secured with a liquid adhesive, use a suitable medium
such as Loctite 243.
● Always use suitable securing devices or removable adhesives (e.g., Loctite 243) when
installing fixing bolts with a clamping length of less than 25 mm. The clamping length is
taken as the distance between the head of the bolt and the point at which the bolt is screwed
in.

Tightening torques
The bolted connections with metal contact surfaces, such as end shields, bearing cartridge
parts, terminal box parts bolted onto the stator frame, should be tightened to the following
torques, depending on the thread size:

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5.9 Mounting the output elements

Table 5-5 Tightening torques for bolted connections with a tolerance of ±10%.

Case M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48 M56
A 1,2 2,5 4 8 13 20 40 52 80 150 - - - - Nm
B 1,3 2,6 4,5 11 22 38 92 180 310 620 1080 1700 2600 4200 Nm
C 3 5 8 20 40 70 170 340 600 1200 2000 3100 4700 7500 Nm

Applications
The above-mentioned tightening torques apply for the following applications:
● Case A
Applies to electrical connections in which the permissible torque is normally limited by the
bolt materials and/or the current carrying capacity of the insulators, with the exception of
the busbar connections in case B.
● Case B
Applies to bolts screwed into components made from lower-strength materials (e. g.
aluminum) and to bolts of strength class 8.8 to ISO 898-1.
● Case C
Applies to bolts of strength class 8.8 or A4-70 to ISO 898-1, but only to bolts screwed into
components made from higher-strength materials (e. g. gray cast iron, steel or cast steel).

Note
Non-standard tightening torques
Different tightening torques for electrical connections and bolted connections for parts with
flat seals or insulating parts are specified in the relevant sections and drawings.

5.9 Mounting the output elements

Balance quality
The rotor is dynamically balanced. For shaft extensions with featherkeys, the balancing type
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.

Figure 5-3 Balancing type on the drive-end side

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5.9 Mounting the output elements

Pushing on the power output elements

● Prerequisites:
– The coupling and/or the output element must be appropriately dimensioned for the
operating case at hand.
– Comply with the coupling manufacturer's instructions.
– Make sure that the balancing type of the transmission element correctly matches the
type of balance of the rotor.
– Use only ready drilled and balanced transmission elements. Check the hole diameters
and the balancing status before pulling them on. Thoroughly clean the shaft extension.
● Pulling on:
– Warm up the transmission elements to expand them before pulling them on. Select the
temperature difference for the heating process to suit the coupling diameter, fit and
material. See the coupling manufacturer's instructions.
– Power output elements may only be pushed on or pulled off with the correct equipment.
The transmission element must be pulled on in one continuous operation via the front
thread holes in the shaft or pushed on by hand.
– Do not strike it with a hammer, as this would damage the bearings.

Shaft extensions with feather key

To maintain the balancing quality, you have the following options:
● If the transmission element is shorter than the feather key with balancing type "H", then you
must machine off the section of feather key protruding from the shaft contour and
transmission element in order to maintain the balance quality.
● If the output element is mounted up to the shaft shoulder for motors with full-key balancing
"F", or if the output element is longer than the motor shaft extension, then when balancing
the coupling or belt pulley, take into account that the feather key does not completely fill
the slot in the hub.

WARNING
The feather key can fall out
The feather keys are only locked against falling out during shipping. If a machine 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.
● Do not operate the machine unless the transmission elements have been pulled on.
● On shaft extensions without output element, make sure that the feather key cannot fall
out and shorten it by approximately half for balance type "H".

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5.10 Opening condensation drain holes (option)

Note
Type of balancing
In the case of shaft extensions with feather keys, the type of balancing is also included on
the rating plate next to the CE mark.

5.10 Opening condensation drain holes (option)

For types 1PH818. and 1PH822., a water drain hole with plugs is available in the DE bearing
shield. For type 1PH828., there are water drain holes without plugs at the DE and NDE.

Figure 5-4 Water drain hole (type 1PH818., 1PH822.)

● Make sure that the condensation can always drain away freely.
● The plug that has been inserted into the water drainage holes allows the condensation to
drain away. Do not remove the plug, otherwise the machine's degree of protection will be
affected.
● If you have any questions, contact the Siemens Service Center (Page 131).

CAUTION
Damage caused by condensation
If the stator winding is damp, its insulation resistance is reduced. This results in voltage
flashovers, which can destroy the winding. Condensation can also cause rusting inside
the machine.
Make sure that the condensation can always drain away freely.

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5.11 Refitting the external fan

5.11 Refitting the external fan

If you want to subsequently move the external fan from the non-drive end to the drive end or
vice versa, please contact the Siemens Service Center (Page 131).

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Electrical connection 6
When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

Note
Service Center
If you require support when electrically connecting up the motor, please contact the Service
Center (Page 131) .

CAUTION
Electrostatically sensitive devices
The DRIVE-CLiQ interface contains components that are susceptible to electrostatic
charging. Touching connections with electrostatically charged hands or tools can cause
malfunctions.
Maintain the ESD protective measures (Page 18) as well as the five safety rules (Page 15).

6.1 Connecting the grounding conductor at the force-ventilated motor

The grounding conductor of the motor must be in full conformance with the installation
regulations, e.g. in accordance with IEC/EN 60204-1.

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6.3 Terminal designation

● Connect the ground conductor to the end shield of the motor. There is a fixing lug ① for
the ground conductor at the designated connection point.
– The fixing lug ① is suitable for grounding high-frequency currents using HF ribbon cable
with appropriately formed conductor ends.

Figure 6-1 Detailed view: Connection point ① for ground conductor

● When making connections, ensure the following:

– the connecting surface is bare and protected against corrosion using a suitable
substance, e.g. acid-free Vaseline
– the flat and spring washers are located under the bolt head.

6.2 Circuit diagram

Data on the connection and connecting the motor winding can be found in the circuit diagram
in the cover of the terminal box.

6.3 Terminal designation

With the terminal designations according to IEC / EN 60034‑8, the following definitions apply
to three-phase machines:

Table 6-1 Terminal designations using the 1U1-1 as an example

1 U 1 - 1 Designation
x Index for pole assignment on pole-changing motors where applicable. A lower
index signifies a lower speed. Special case for split winding.
x Phase designation U, V, W
x Index for winding start (1) or end (2) or if there is more than one connection per
winding
x Additional indices for cases in which it is obligatory to connect parallel power feed
cables to several terminals with otherwise identical designations

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6.5 Electrical connection data

6.4 Laying cables

● Lay cables in accordance with IEC / EN 60364-5-52.
● Use EMC cable glands for permanently installed entry fittings. Screw the EMC cable glands
into the threaded holes in the entry plate, which can be unscrewed.
● Use shielded cables whose shields are conductively connected to a large area of the
terminal box of the motor via EMC cable glands.
● Arrange the exposed connecting cables in the terminal box so that the PE conductor has
excess length and the insulation of the cable strands cannot be damaged.
● Close off unused bushings with a metal threaded plug. This is the way to achieve a high
frequency-proof shielding.

6.5 Electrical connection data

Cable entry and technical connection data depend on the mounted terminal box. You can find
more information on the terminal box that is mounted in the ordering documentation or in the
catalog.

 
   








 

1XB7 322 1XB7 422

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6.6 Connection with cable lugs

  
 
















1XB7 700 1XB7 712

① main terminal ③ signal connection terminal
② ground terminal ④ signal connection

Table 6-2 Data for electrical connection

Terminal box type 1XB7 322 1XB7 422 1XB7 700 1XB7 712
Cable entry 2 x M50 x 1,5 2 x M63 x 1,5 3 x M75 x 1,5 4 x M75 x 1,5
Max. poss. cable outer diameter 38 mm 53 mm 68 mm 68 mm
Number of main terminals 3 x M12 3 x M12 3 x 3 x M12 3 x 4 x M16
Max. cross-section per terminal 2 x 50 mm2 2 x 70 mm2 3 x 150 mm2 4 x 185 mm2
Max. current per terminal ① 210 A 270 A 700 A 1150 A
Number of ground terminals 4 x M6 4 x M8 Klemmlasche 4 x M16
①
Current carrying capacity based on IEC / EN 60204-1or IEC / EN 60364-5-32

6.6 Connection with cable lugs

● To connect the cables to the main terminals, select cable lugs that match the necessary
cable cross-section and appropriate screw size.
The connectable cable cross section is determined by the cable lug size for example.
– Cable lug in accordance with DIN 46234, from 35 mm2 to 185 mm2,
– Cable lug in accordance with DIN 46235, from 35 mm2 to 185 mm2.
Observe the possible outer diameter of the connecting cable in the chapter entitled
"Electrical connection data".
● Remove the insulation from the conductor ends so that the remaining insulation is almost
long enough to reach the cable lug.

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6.6 Connection with cable lugs

● If necessary, insulate the cable lug sleeves in order to maintain the minimum clearances
in air of 10 mm and the 20 mm creepage distance normally present.
● The tightening torque for contact nuts and fixing screws depends on the size of the screw,
see Case A in the table in ChapterTightening torques for screw and bolt connections
(Page 52).

Connection with cable lug at the terminal box 1XB7 322 / 1XB7 422

① Customer connecting cable

② Internal motor connecting cable
③ Copper spacer ring

Figure 6-2 Connection with cable lug at the terminal box 1XB7 322 / 1XB7 422

Connection with cable lug at the terminal box 1XB7 700 / 1XB7 712

① Customer connecting cable

② Connection bar

Figure 6-3 Connection with cable lug at the terminal box 1XB7 700 / 1XB7 712

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6.8 Stepless mating face for the seal in the terminal box cover

See also
Electrical connection data (Page 59)

6.7 Connecting aluminum conductors

If you are using aluminum conductors, comply in addition with the following:
● Use only cable lugs that are suitable for connecting aluminum conductors.
● Immediately before inserting the aluminum conductor, remove the oxide layer from the
contact areas on the conductor and/or the mating piece, by brushing or filing.
● Then grease the contact areas immediately using neutral Vaseline in order to avoid re-
oxidation.

CAUTION
The aluminum flow is determined by contact
The aluminum flow is determined by contact following installation. The connection with
the clamping nuts can loosen as a result. The contact resistance would increase and the
current-carrying be impeded; as a consequence the terminal box and the surrounding
components could burn. This could result in material damage to the machine or even in
total failure, which could in turn lead to indirect material damage to the system.
Retighten the clamping nuts after approximately 24 hours and then again after
approximately four weeks. Make sure that the terminals are de-energized before you
tighten the nuts.

6.8 Stepless mating face for the seal in the terminal box cover
The sealing face of the terminal box cover is formed by the terminal box enclosure and the
cable entry element. Therefore make sure these parts are correctly aligned, so as to ensure
the seal and hence the degree of protection.
Align the cable entry support and the cable entry plate to the terminal box enclosure so that
the sealing surface between the terminal box and the terminal box cover form a flat face. There
must be no steps in the sealing area.

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6.10 Internal equipotential bonding

6.9 Completing connection work

1. Before closing the terminal box, please check that:
– The electrical connections in the terminal box are tight and are in full compliance with
the specifications above.
– The required clearances in air of 10 mm are maintained.
– Wire ends do not protrude.
– The inside of the terminal box is clean and free of any cable debris.
– All seals and sealing surfaces are undamaged.
– The connecting cables are arranged so that they do not come into contact with the
machine, and the cable insulation cannot be damaged.
– unused entry points are sealed. The sealing elements are firmly screwed in, i.e. they
can only be removed with a tool.
– The cable/conductor glands are fitted compliant with the specifications regarding degree
of protection, cable routing type, permissible cable diameter etc.
2. Then close the terminal box with the terminal box cover fixing screws.

See also
Tightening torques for screw and bolt connections (Page 52)

6.10 Internal equipotential bonding

The internal equipotential bonding between the grounding terminal in the box enclosure and
the motor frame is established through the terminal box retaining bolts. The contact locations
underneath the bolt heads are bare metal and protected against corrosion.
The standard cover fixing screws are sufficient for equipotential bonding between the terminal
box cover and terminal box housing.

Note
Connecting points are provided on the enclosure or end shield to allow an outer PE conductor
or equipotential bonding conductor to be connected; see "Connecting the grounding
conductor".

See also
Connecting the grounding conductor at the force-ventilated motor (Page 57)

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6.11 Auxiliary circuits

6.11 Auxiliary circuits

6.11.1 Selecting cables

Take the following criteria into account when selecting the connecting cables for the auxiliary
circuits:
● Rated current
● Rated voltage
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Requirements to IEC / EN 60204‑1

6.11.2 Connecting an external fan

Preconditions
● Only use cables that comply with the relevant installation regulations regarding voltage,
current, insulation material, and load-carrying capacity.
● Before connecting the device, make sure that the line voltage matches the device voltage.
● Check whether the data on the fan rating plate matches the connection data.
● Cable glands are not included in the scope of delivery. Close unused cable entries,
otherwise, the degree of protection is not maintained.
Type Supply voltage Current consumption
1PH818. 1 AC 200 V … 277 V / 50Hz, 60 Hz (± 10 %) 1,45 ... 1,05 A
1PH822. 1 AC 200 V … 277 V / 50Hz, 60 Hz (± 10 %) 2,3 ... 1,6 A
1PH828. 3 AC 400 V / 50 Hz (± 10 %) 2,55 A
3 AC 400 V / 60 Hz (± 10 %) 2,50 A
3 AC 480 V / 60 Hz (± 10 %) 2,50 A

Connection values for external fans

● The line voltage must fulfill the quality criteria stipulated by DIN EN 50160 and the defined
standard voltages specified in DIN IEC 60038.

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6.11 Auxiliary circuits

Procedure
1. Open the terminal box of the external fan and route the cables into it. The cables are not
included in the scope of delivery.
2. Connect the protective conductor (PE).
3. Connect the other cables to the relevant terminals, refer to the connection diagram.
Connection cables must not be subject to excessive tensile stress.

Note
For fans equipped with EC motor, the fan motor starts with a delay after the line voltage
is connected.

Figure 6-4 Connection in the external fan terminal box

External ground connection

Motors with a power rating of more than 100 kW must be grounded via the additional grounding
screw M12 at the mounting flange. Use a cable lug in accordance with DIN 46234.

Protection against humidity

Protect the device against humidity. Water must not be allowed to run along the cables and
into the terminal box.

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6.11 Auxiliary circuits

● Use suitable cables at the connection cable gland on the terminal box.
● Ensure the terminal box cover is properly mounted and completely closed.

WARNING
Voltages at the internal motor connections
The motor may continue running, e.g. due to airflow, or may run on after being shut down.
This means that dangerous voltages of over 50 V can occur at the internal motor
connections. Death, serious injury or material damage can result.
● For safety reasons, it is not permissible to make any unauthorized modifications or
changes to the fan.
● Due to the way it functions, the fan switches on and off automatically.
● After a power failure or when the power has been disconnected, the fan starts up
automatically again when the voltage is restored.
● Wait until the fan has come to a standstill before approaching it.
● Provide a protective circuit that prevents the main motor from being switched on when
the external fan is not in operation.

See also
Operating instructions, external fan (Page 161)

Connecting an external fan (type 1PH818., 1PH822.)

The external fan is connected in the external fan terminal box. If necessary, you can rotate the
external fan through 90°.

Figure 6-5 External fan terminal box ① (schematic representation)

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6.11 Auxiliary circuits

CAUTION
Rotating the external fan
If you rotate the external fan through 90°, then it is not permissible that the cable outlet faces
upwards. Water that accumulates at the cable glands can result in a short circuit.
Rotate the terminal box cover of the external fan through 180°.

See also
Interlock circuit for the external fan (Page 29)

Connecting an external fan (type 1PH828.)

The external fan is connected in the external fan terminal box.

Figure 6-6 External fan terminal box ① (schematic circuit diagram)

CAUTION
An external fan is only suitable for one direction of rotation
The separately-driven fan unit is only designed for one direction of rotation corresponding to
the direction of rotation arrow. Operation with the wrong direction of rotation can cause
overheating or destruction of the motor.
Ensure that the external fan is operated in the proper direction of rotation. The direction-of-
rotation arrow and the direction of movement of the fan impeller are indicated on the rear
side of the blower.
If necessary, change the direction of rotation by interchanging two phase conductors in the
external fan terminal box.

See also
Interlock circuit for the external fan (Page 29)

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Electrical connection
6.11 Auxiliary circuits

6.11.3 Connecting the speed encoder

The speed encoder is connected at the terminal box using a plug connection ①. This is located
on the terminal box enclosure.

Figure 6-7 Detailed view: Plug-in connection

Note
The plug-in connection may differ from the standard layout in the case of special orders. For
versions without speed encoder, connection thread M16x1.5 is located here.

Connecting a speed encoder via DRIVE-CLiQ

The signal connection between the motor and the converter is established via the DRIVE‑CLiQ
cable MOTION‑CONNECT.
● Always use prefabricated cables from Siemens. These cables reduce the mounting/
installation time and costs and increase operational reliability.
● Push the connector of the DRIVE‑CLiQ cable into the socket until the catch spring latches
into place. Pay attention to the coding of the connector.

Cable outlet directions

The sensor module is mounted on the motor terminal box. The sensor module can be rotated
through approximately 235°. You can change the cable outlet directions by rotating the sensor
module, as shown in the diagram below.

CAUTION
Damage to the sensor module
You can damage the sensor module if you turn it with a pipe wrench, a hammer, or similar
tools.
Turn the sensor module by hand. The typical torque is approx. 4 ... 8 Nm.

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 Electrical connection
6.11 Auxiliary circuits

r 


Figure 6-8 Sensor Module ① mounted on the terminal box

CAUTION
Modifying the cable outlet direction
Changing the cable outlet direction by any improper means will damage the connecting
cables.
The permissible rotation range must not be exceeded. A maximum of ten changes to the
rotation angle of the Sensor Module are permissible within the rotation range.

6.11.4 Connect the holding brake

Information for electrically connecting the holding brake can be found in the operating
instructions supplied by the manufacturer in the (Page 138) appendix.

6.11.5 Connecting the temperature sensor

● The temperature sensor is connected to the signal connector together with the speed
encoder signal.
● For the version without speed encoder, the temperature sensor is connected at the terminal
strip.
● The motor has a reserve temperature sensor, which is also connected at the auxiliary
terminal strip. Reconnect the temperature sensor as needed, e.g. if the previous
temperature sensor fails.

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Electrical connection
6.11 Auxiliary circuits

6.11.6 Connection to a converter

Selecting and connecting the cable

● Use Motion Connect cables or symmetrically constructed, shielded cables to connect the
motor to a converter. The cable shielding, made up of as many strands as possible, must
have good electrical conductivity. Braided shields made of copper or aluminum are well
suited.
● The shield must be connected at both ends to the motor and the converter; unshielded
cable ends must be kept as short as possible.
● To ensure effective discharge of high-frequency currents, make the shield contact over the
largest possible area, i.e. as a 360° contact on the converter and motor, e.g. using EMC
glands at the cable entry points.

Measures to reduce bearing currents

To specifically reduce and prevent damage caused by bearing currents, you must consider
the system as a whole, which comprises the motor, converter, and driven machine. The
following precautions help to prevent bearing currents:
● Setting up a properly meshed grounding system in the system as a whole, with low
impedance for high-frequency currents
● No potential difference between the motor, converter, and working machine.
– Use symmetrical, shielded connecting cables.
– Connect the cable shield at both ends over the greatest possible surface area (360°
contact).
– Use equipotential bonding conductors between the motor and the driven machine as
well as between the motor and the converter
● Use iron cores mounted above the motor connecting cable at the converter output. These
help to reduce common-mode components. The Siemens sales representative is
responsible for selection and dimensioning.
● Limit the voltage rate of rise by using an output filter to dampen harmonic components in
the output voltage

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 Electrical connection
6.11 Auxiliary circuits

6.11.7 Converter operation on a grounded network

CAUTION
Damage resulting from protective conductor currents
When the machine is operated on a converter with current limiter, but without ground-fault
monitoring, protective conductor currents of up to 1.7 times the external conductor current
can arise if there is a ground fault on the output side. Neither the PE conductors of normally
rated multi-core connecting cables nor the PE connecting points of normal terminal boxes
are suitable for this purpose. Material damage can result.
● Use an appropriately sized PE conductor.
● Connect the PE conductor to the grounding terminal on the motor enclosure.

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6.11 Auxiliary circuits

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Commissioning 7
7.1 Safety instructions
When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

7.2 Magnetic field when the brake is open

WARNING
Magnetic field when the holding brake is open
If the motor is equipped with a holding brake, then the shaft extension is magnetized when
the holding brake is open, i.e. if a voltage is connected to it.
Magnetic objects will then be suddenly attracted as a result of this magnetic field. This can
result in death, severe injury or material damage.
Working in the vicinity of the shaft extension is only permitted in exceptional circumstances.
Clear and obvious access rules must be established as a result of the magnetic fields
prevailing at the workplace. Clearly mark the boundaries of the areas where standing is
permitted.
People who need to use electronic or magnetic medical aids such as pacemakers, hearing
aids, implants or similar devices, are at particularly high risk. Such persons must undergo an
occupational health assessment.
Observe the following measures.

Personal protective measures

● Ensure that you never wear or carry any of the following objects and that they are kept a
safe distance from the machine:
– All kinds of magnetic metal parts such as, keys, glasses, tools, knives, scissors, tape
measures, etc.
– Magnetic jewelry such as rings, chains, needles, watches, etc.
– Electronic devices and data carriers such as service cards, check cards, credit cards,
calculators, cell phones, etc.
– Wallets or other iron-containing objects
– Electrically conductive foreign bodies
● Do not use any magnetic tools or lifting devices.
● Wear only occupational safety items without magnetic metal parts, e.g. occupational safety
shoes with non-magnetic protective caps and soles.

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Commissioning
7.4 Checks to be carried out prior to commissioning

● Keep your shoes and clothing free from chips and waste containing iron.
● Exercise caution when installing accessories. Ensure that no parts fall into the inside of the
machine.
● Do not perform any cutting at the machine, e.g. drilling threaded holes. Any exceptions
require written approval from the manufacturer.

7.3 Insulation resistance and polarization index

Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"

7.4 Checks to be carried out prior to commissioning

Once the system has been correctly installed, you should check the following prior to
commissioning:

Note
Checks to be carried out prior to commissioning
The following list of checks to be performed prior to commissioning does not claim to be
complete. It may be necessary to perform further checks and tests in accordance with the
specific situation on-site.

● The machine is undamaged.

● The machine has been correctly installed and aligned, the transmission elements are
correctly balanced and adjusted.

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7.4 Checks to be carried out prior to commissioning

● All fixing screws, connection elements, and electrical connections have been tightened to
the specified tightening torques.
● The operating conditions match the data provided in accordance with the technical
documentation, such as degree of protection, ambient temperature, etc..
● Moving parts such as the coupling move freely.
● If the second shaft extension is not in use, its feather key is secured to prevent it from being
thrown out, and cut back to roughly half its length if the rotor has balancing type "H"
(standard type).
● All touch protection measures for moving and live parts have been taken.

● The rotor can spin without coming into contact with the stator.
● The bearing insulation is not bridged.

● The grounding and equipotential bonding connections have been made correctly.
● The machine is connected so that it rotates in the direction specified.
● Appropriately configured control and speed monitoring functions ensure that the motor
cannot exceed the permissible speeds specified in the technical data. For this purpose,
compare the data on the rating plate or, if necessary, the system-specific documentation.
● The minimum insulation resistance values are within tolerance.
● Minimum air clearances have been maintained.
● Any supplementary motor monitoring devices and equipment have been correctly
connected and are functioning correctly.
● All brakes and backstops are operating correctly.
● At the monitoring devices, the values for "Warning" and "Shutdown" are set.

See also
Setting values for the bearing temperature monitoring (option) (Page 77)

● While being operated on the converter, the motor cannot exceed the specified upper speed
limit nmax or undershoot the lower speed limit nmin.
If the design of the motor requires connection to a particular converter type, the rating plate
will contain corresponding additional information.
● The converter is correctly parameterized. The parameterization data is specified on the
rating plate of the machine. Information about the parameters is available in the operating
instructions for the converter.

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Commissioning
7.5 Switching on

● If the motor has been stored for more than two years in a dry, dust-free and vibration-free
room, prepare for commissioning as follows:
– Replace the rolling-contact bearings on motors with lifetime lubrication.
– Replace the grease in motors with re-greasing system.
● If stored under less favorable conditions, replacement of bearings or re-greasing must be
carried out after a storage period of approx. 18 months.

● Appropriately configured control and speed monitoring functions ensure that the the
permissible speeds specified on the rating plate cannot be exceeded.
● Any supplementary motor monitoring devices and equipment have been correctly
connected and are fully functional.

Force-ventilated motors
● All external fans fitted are ready for operation and have been connected so that they rotate
in the direction specified.
● The flow of cooling air is not impeded.

7.5 Switching on
● See the operating instructions of the frequency converter for switching on.
● Before you switch on the motor, ensure that the parameters of the frequency converter
have been assigned correctly.
● Use appropriate commissioning tools, such as "Drive ES" or "STARTER".

CAUTION
Operation noise or abnormal noises
The motor can be damaged by improper handling during transport, storage or set up. If a
damaged motor is operated damage to the winding, bearings or, complete destruction of
the motor can be the result.
If the motor is not running smoothly or is emitting abnormal noises, de-energize it, and
determine the cause of the fault as the motor runs down.

Maximum speed
The maximum rotational speed nmax is the highest permissible operating speed. The maximum
rotational speed is specified on the rating plate.

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 Commissioning
7.6 Setting values for the bearing temperature monitoring (option)

Commission the machine after assembly or inspection as follows:

● Start up the machine without a load. To do this, close the circuit breaker and do not, if at
all possible, switch off prematurely.
● Switching the machine off again while it is starting up and still running at slow speed should
be kept to a bare minimum, for example for checking the direction of rotation or for checking
the required dimensions. Allow the machine to run down before switching it on again.
● Check the machine for noises or vibrations on the bearings or bearing shields as it runs.
● If the machine is not running smoothly or is emitting abnormal noises, de-energize it, and
determine the cause of the fault as the motor runs down.
– If the mechanical operation improves immediately after the machine is switched off, then
the cause is magnetic or electrical.
– If the mechanical operation is not improved after switching off, then the cause is
mechanical. This can be an imbalance in the electrical machines or in the driven
machine, poor alignment of the machine unit, operation of the machine with the system
resonating (system = motor, base frame, foundation etc.).
● Continue to observe the motor for a while in no-load operation.
● If it runs perfectly, connect a load. Check whether it is running smoothly. Read off the values
for voltage, current, and output and log them. If possible, read and log the corresponding
values for the working machine.

CAUTION
Keep within the vibration values
The vibration values encountered during operation must be satisfied in accordance with
DIN ISO 10816-3, as otherwise the motor could be damaged or destroyed.

● Monitor and log the temperatures of the bearings, windings, etc., until the system reaches
the steady state, in as much as this is possible with the available measuring equipment.

7.6 Setting values for the bearing temperature monitoring (option)

Before the first machine run, set the tripping temperatures of the monitoring system.
The tripping temperatures of slot thermometers differ depending on the temperature class of
the machine. The temperature class can be found on the rating plate.

Table 7-1 Guidelines for setting the tripping temperature of slot thermometers

Set value Temperature class F/B Temperature class F/F

Prior to for shutdown T0 = 120°C T0 = 140°C
commissioning
During operation for warning T1 = T + 10 K (max. 135°C) T1 = T + 10 K (max. 150℃)
for shutdown T2 = T + 15 K (max. 140°C) T2 = T + 15 K (max. 155℃)

T = temperature in steady state (°C)

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Commissioning
7.6 Setting values for the bearing temperature monitoring (option)

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Operation 8
When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

8.1 Safety notes during operation

WARNING
All terminal boxes must be closed
Terminal boxes contain live electrical parts. Death, serious injury or material damage can
result if terminal box covers are removed.
When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and de-energized.

WARNING
Do not remove covers when the motor is running
Rotating or live parts are dangerous. Death, serious injury or material damage can result if
the required covers are removed.
All covers that are designed to prevent live electrical or rotating parts from being touched,
ensure compliance with a particular degree of protection, or that are required for ensuring
proper air flows and hence effective cooling must not be opened during operation.

WARNING
Fire hazard resulting from hot surfaces
Certain parts of the machine become hot during operation. Severe burns can result from
contact with these parts.
● Check the temperature of the parts before touching them and take appropriate protective
measures if necessary.
● Allow the machine to cool down before starting work on the machine.

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Operation
8.1 Safety notes during operation

WARNING
Faults in operation
Deviations from normal operation such as increased power consumption, temperatures or
vibrations, unusual noises or odors, tripping of monitoring devices, etc., indicate that the
machine is not functioning properly. This can cause faults which can result in eventual or
immediate death, serious injury or material damage.
● Immediately inform the maintenance personnel.
● If you are in doubt, immediately switch off the motor, being sure to observe the system-
specific safety conditions!

CAUTION
Risk of corrosion due to condensate
Humid air can condense inside the machine during operation as a result of intermittent duty
or load fluctuations. Condensate can collect inside the motor. Damage such as rust can result.
Make sure that any condensation can drain away freely.

See also
Opening condensation drain holes (option) (Page 55)

CAUTION
Periodic duty
For all operating modes, operate the external fan according to DIN EN 60034-1. Also for non-
periodic operation, the machine can be thermally overloaded. This can result in damage to
the machine.
In the case of extended non-operational periods, the fan should be in operation until the
machine has approximately reached the temperature of the coolant, see S2-operation in
DIN EN 60034‑1.
Use a suitable circuit to ensure that the external fan is appropriately operated.

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 Operation
8.5 Stoppages

8.2 Operation
● After starting the motor, observe it for a while to see if it is running smoothly and check the
monitoring devices.
● Monitor operation and the monitoring devices regularly and record the values you read off.

CAUTION
Speed monitoring
The motor is designed for a certain speed range.
If a motor is operated at impermissible speeds damage to the winding, bearings, or
complete destruction of the motor can be the result.
Ensure that the speeds specified on the rating plate are not exceeded by appropriately
configuring controller and speed monitoring components.

8.3 Switching-off force-ventilated motors

● When switching-off, also observe the converter operating instructions.
● Switch off the external fan during longer standstill periods. Leave the fan on for
approximately 30 minutes after switching off the motor to avoid overheating of the motor.
● If a standstill heating unit is available, switch it on.

8.4 Switching on again after an emergency switching-off

● Check the motor before restarting the driven machine after an emergency off.
● Eliminate all the causes that have led to the emergency off

8.5 Stoppages

The stoppage is a shutdown for a period of time, during which the machine is stopped but
remains at the location of use.
Under normal ambient conditions, e. g. the stopped machine is not exposed to any vibration,
no increased level of corrosion, etc. in general, the following measures are necessary during
stoppages.

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Operation
8.5 Stoppages

Measures when motors are at standstill and ready for operation

● For longer periods when the motor is not being used, either energize the motor at regular
intervals (roughly once a month), or at least spin the rotor.
● Please refer to the section"Switching on" (Page 76) before switching on to recommission
the motor.

CAUTION
Damage due to improper storage
The motor can be damaged if it is not stored properly. If the motor is out of service for
extended periods of time, implement suitable anti-corrosion, preservation, and drying
measures.
When recommissioning the motor after a long period out of service, carry out the measures
recommended in the chapter entitled "Commissioning (Page 73)".

8.5.1 Avoidance of damage to roller bearings during stoppages

Extended stoppages at the identical or almost identical resting position of the roller bearings
can lead to damage such as brinelling or formation of corrosion.
● During stoppages, regularly start the machine up for a brief period once a month, or at least
turn the rotor over several times.
If you have uncoupled the machine from the driven machine and secured the rotor with a
rotor shipping brace, then remove this before turning the rotor over or starting the machine
up.
Make sure that the resting position of the roller bearings after the rotor has been turned
over is different from what it previously had been. Use the fitted key or the coupling halves
as reference markers.
● During re-commissioning, refer to the information in the "Commissioning" section.

8.5.2 Measurement of the insulation resistance after an extended stoppage

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

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 Operation
8.8 Faults

● Is the winding head insulation conductively contaminated?

● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index"

8.6 Decommissioning the machine

CAUTION
Damage as a result of an extended period out of service
If the machine is going to be out of service for longer than six months, then perform the
necessary measures for anti-corrosion protection, preservation, packaging and drying.
Otherwise damage to the machine will result.

Record the decommissioning steps. This log will be useful upon recommissioning.

8.7 Re-commissioning the machine

When you re-commission the machine, proceed as follows:
● Study the record made when the machine was decommissioned, and reverse the measures
that were taken for conservation and storage.
● Perform the measures listed in the "Commissioning" section.

8.8 Faults

8.8.1 Inspections in the event of faults

Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.

Correct the cause of the fault as described in the respective remedial measures section. Repair
any damage to the machine.

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Operation
8.8 Faults

8.8.2 Electrical faults at force-ventilated motors

Note
When operating the machine with a converter, also refer to the operating instructions of the
frequency converter if electrical faults occur.

Table 8-1 Electrical faults

↓ Motor fails to start

↓ Motor accelerates sluggishly
↓ Humming noise when starting
↓ Humming noise in operation
↓ High temperature rise during no-load operation
↓ High temperature rise under load
↓ High temperature rise of individual winding sections
Possible causes of faults Remedial measures
X X X X Overload Reduce the load.
X Interruption of a phase in the Check frequency converters and supply cables.
supply cable
X X X X Interruption of a phase in the Check frequency converters and supply cables.
supply after switching on
X X X X Winding short circuit or phase Determine the winding and insulation resistances.
short circuit in stator winding Contact the Service Center.
X Converter output voltage too Check the settings at the frequency converter and
high, frequency too low perform the automatic motor identification.
X External fan is not running Check the external fan and its connections.
X Reduced air intake Check the air ducts; clean the machine.

8.8.3 Mechanical faults

Table 8-2 Mechanical faults

↓ Grinding noise
↓ Overheating
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults Remedial measures
X Rotating parts are grinding Establish the cause and realign the parts.
X Rotor not balanced Decouple the rotor and then rebalance it.
X Rotor out of true, shaft bent Contact the Service Center.
X X Poor alignment Align the machine set and check the coupling. 1)
X Coupled machine not balanced Rebalance the coupled machine.
X Shocks from coupled machine Examine the coupled machine.

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 Operation
8.8 Faults

↓ Grinding noise
↓ Overheating
↓ Radial vibrations
↓ Axial vibrations
Possible causes of faults Remedial measures
X X Resonance with the foundation Stabilize the foundation following consultation.
X X Changes in foundation Determine the cause of the changes and, if
necessary, rectify. Realign the machine.
1)
Take into account possible changes which may occur during overheating.

8.8.4 Rolling-contact bearing faults

Note
Damage to rolling-contact bearings can be difficult to detect in some cases. If in doubt, replace
the bearing. Use other bearing designs only after consulting the manufacturer.

Table 8-3 Rolling-contact bearing faults

↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
Possible causes of fault Remedial measures
X High coupling pressure Align the machine more accurately.
X Belt tension too high Reduce the drive belt tension.
X Bearing contaminated Clean the bearing or replace it. Check the seals.
X High ambient temperature Use a suitable high-temperature grease.
X X Insufficient lubrication Grease the bearings as instructed.
X X Bearing canted Properly install the bearing.
X X Insufficient bearing play Only after consultation with the manufacturer: Fit a bearing with
greater play.
X Excessive bearing play Only after consultation with the manufacturer: Fit a bearing with
lower play.
X X Bearing corroded Replace the bearing. Check the seals.
X Too much grease in bearing Remove surplus grease.
X Wrong grease in the bearing Use the correct grease.
X Friction marks on raceway Replace the bearing.
X Scoring (brinelling) Replace the bearing. Avoid any vibration at standstill

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Operation
8.8 Faults

8.8.5 Holding brake faults

Information on holding brake faults can be found in the manufacturer's operating instructions
in the (Page 138) appendix.

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Maintenance 9
When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

Note
Service Center
Please contact the Service Center, if you require support with servicing, maintenance or
repair.

9.1 Observe the operating instructions of the components

When carrying out any maintenance and repair work, always carefully observe the
manufacturer's operating instructions for additional components.

See also
Operating instructions, holding brake (Page 138)
Operating instructions, external fan (Page 161)

9.2 Inspection and maintenance

Through careful and regular maintenance, inspections, and overhauls you can detect faults at
an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).

9.2.1 Inspections in the event of faults

Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.

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Maintenance
9.2 Inspection and maintenance

9.2.2 Initial inspection

Perform the following checks after approximately 500 operating hours or at the latest after six
months:

Table 9-1 Checks after installation or repair

Check When the At

motor is standstill
running
The electrical parameters are maintained. X
The smooth running characteristics and machine running noise have not X
deteriorated.
The motor foundation has no cracks and indentations. (*) X X

(*) You can perform these checks while the motor is running or at a standstill.
Additional checks may also be required according to the system-specific conditions.

CAUTION
If you detect any deviations during the inspection, you must rectify them immediately. They
may otherwise damage the motor.

9.2.3 General inspection

Inspection interval
Perform the following checks after approx. 16,000 operating hours or two years, whichever
comes first.

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 Maintenance
9.2 Inspection and maintenance

Implementation
● While the motor is running, check that:
– The stated electrical characteristics are being observed
– The smooth running characteristics and machine running noise have not deteriorated
● Once the machine has been shut down, check that:
– The motor foundation has no indentations or cracks
– The machine is aligned within the permissible tolerance ranges
– All the fixing bolts/screws for the mechanical and electrical connections have been
securely tightened
– The winding insulation resistances are sufficiently high
– Any bearing insulation has been fitted as shown on plates and labeling.
– Cables and insulating parts and components are in good condition and there is no
evidence of discoloring

CAUTION
If you detect any defects or malfunctions during the inspection, you must rectify them
immediately. They may otherwise cause damage to the machine.

9.2.4 Rolling-contact bearing inspection

Inspections in the event of faults

Perform an inspection immediately in the event of faults or exceptional operating conditions
indicating an electrical or mechanical overload, e.g., overload, short circuit.

Regreasing intervals

CAUTION
Observe the regreasing intervals for the rolling-contact bearings
The regreasing intervals for roller bearings are different from the servicing intervals for the
machine. Failure to regrease the rolling-contact bearings at the specified intervals can result
in them sustaining damage. Comply with the regreasing intervals for roller bearings, the
regreasing intervals are specified on the lubricant plate.

9.2.5 Changing bearings when using permanently lubricated rolling-contact bearings

The replacement of the permanently lubricated roller bearing is determined by the number of
operating hours and is required around every three years.

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Maintenance
9.2 Inspection and maintenance

9.2.6 Maintenance

9.2.6.1 Safety instructions

When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

WARNING
Perform maintenance work on the machine only when it is stopped
Electric machines have live parts and rotating parts. Fatal or serious injuries and substantial
material damage can occur if maintenance work is performed on the machine when it is not
stopped or not de-energized.
● Perform maintenance work on the machine only when it is stopped. The only operation
permissible while the machine is rotating is regreasing the roller bearings.
● When performing maintenance work, comply with the five safety rules (Page 15).

WARNING
Damage resulting if the machine is not maintained
If the machine is not maintained it can suffer damage. This can cause faults which can result
in eventual or immediate death, serious injury, or material damage.
Perform regular maintenance on the machine.

CAUTION
Personal protective measures when working with compressed air
When cleaning with compressed air, dust, metal chips, or cleaning agents can be whirled up.
Injuries can result.
When cleaning using compressed air, make sure you use suitable extraction equipment and
wear protective equipment (safety goggles, protective suit, etc.).

CAUTION
Cleaning with compressed air
If cleaning is performed using compressed air, chips of metal can be blown into the winding
head. This can damage the insulation, and result in clearances and creepage distances less
than the minimum allowable. This may cause damage to the machine extending to total failure.
When cleaning with compressed air, ensure there is adequate extraction.

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CAUTION
Foreign bodies in and on the machine
Foreign bodies such as dirt, tools or loose components, such as screws etc., can be left by
accident inside the machine after maintenance is performed. These can cause short circuits,
reduce the performance of the cooling system or increase noise in operation. They can also
damage the machine.
● When carrying out maintenance work, make sure that no foreign bodes are left in or on
the machine.
● Securely attach all loose parts again once you have completed the maintenance
procedures.
● Carefully remove any dirt.

Note
Operating conditions and characteristics can vary widely. For this reason, only general
intervals for inspection and maintenance measures can be specified here.

9.2.6.2 Maintenance intervals

Perform the following maintenance measures after the operating time or the intervals specified
in the following table elapse.

Table 9-2 Maintenance measures

Maintenance measures Maintenance intervals

Initial inspection After 500 operating hours, at the latest after six months
Regreasing See the lubricant plate
Permanent lubrication (with coupling Replace bearings after approximately 20,000 operating hours,
output) at the latest after three years
Cleaning Depending on the degree of pollution
Main inspection After approximately 16,000 operating hours, at the latest after
two years

9.2.6.3 Rolling-contact bearings

The motors have rolling-contact bearing bushes for grease lubrication. Depending on the
version, the motors are permanently lubricated or are equipped with a regreasing device.
Depending on the type of load, a deep-groove ball bearing or a cylindrical-roller bearing is
fitted as a floating bearing on the drive end.
The DE bearing contains built-in compression springs that help to rebalance the axial play of
the external bearing rings.

See also
Description (Page 21)

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9.2.6.4 Lubrication
The specified grease data apply for the data specified on the rating plate data and for high-
quality grease in accordance with the specifications in these operating instructions. These
greases exceed the requirements according toDIN 51825 and ISO 6743‑9 significantly, thereby
permitting the specified relubrication intervals.

Initial lubrication
For initial lubrication of the bearings (when delivered), the lubricating grease ESSO / Unirex N
(standard version) or Lubcon / Sintono GPE702 (Performance version) is used.

Grease selection criteria

High qualityISO‑L‑X BDEA3 grease according to ISO 6743-9 and K3N‑20 grease according
to DIN 51825 with lithium soap as a thickener and an upper service temperature of at least
+140 °C / +284 °F are permissible for standard applications without special requirements.
When selecting the lubricating grease, ensure that the technical data of the grease are suitable
for the application.
The lubricating grease must satisfy the criteria listed in the table below and must match the
operating conditions.

Table 9-3 Criteria for selecting roller bearing greases

Criteria Standard Property, characteristic value Unit

Type of base oil - Mineral oil -
Thickener - Lithium -
Consistency according to NLGI class DIN 51818 ● 3 for vertical and horizontal types of construction -
● 2 alternatively for horizontal type of construction
with reduced lubrication interval
Worked penetration DIN ISO 2137 220–295 0.1 mm
Operating temperature range - At least -20 °C ... +140 °C °C
Dropping point DIN ISO 2176 At least +200 °C °C
Basic oil viscosity DIN 51562-1 ● Approx. 100 mm²/s at 40 °C mm²/s
● Approx. 10 mm²/s at 100 °C
Additive - ● Antioxidation (AO), Anti-Wear (AW) -
● No solid lubricants
● Alternative: Extreme-pressure (EP) only after
consultation with grease and bearing
manufacturers
FE9 test: A/1500/6000 DIN 51821-1/-2 F10 ≥ 50 h at +140 °C h
F50 ≥ 100 h at +140 °C
Behavior with respect to water DIN 51807 0 or 1 at a test temperature of +90 °C -
Corrosive effect on copper DIN 51811 0 or 1 at a test temperature of +140 °C Corr. °
Resistance to corrosion (EMCOR) DIN 51802 / 0 - 0 (0 - 1, permissible for special greases) Corr. °
ISO 11007

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Criteria Standard Property, characteristic value Unit

Solid matter content, particle sizes > DIN 51813 < 10 mg/kg mg/kg
25 µm
Suitability of bearings - Suitable for the built-in motor bearings, seals and -
Speed characteristic nxdm these speeds mm/min

If different special lubricating greases are stated on the lubricant plate, then different criteria apply.

CAUTION
Other ambient temperatures and operating conditions
For other ambient temperatures and operating conditions, alternative grease to the one stated
on the lubricant plate may only be used after prior consultation with the manufacturer.
Otherwise the roller bearing could be damaged.

CAUTION
Use of other greases
If other greases are used, there can be no guarantee of compatibility with the overall system.
Otherwise the roller bearing could be damaged.
If you use greases that satisfy only the minimum requirements of DIN 51825 or ISO 6743-9,
then reduce the lubrication intervals by half or adapt them as appropriate. If in doubt, consult
the manufacturer.

Recommended greases for roller bearings

For standard applications, the following high-quality greases are recommended for roller
bearings for vertical and horizontal motor types of construction due to their technical properties:

Table 9-4 Roller bearing greases for vertical and horizontal types of construction

Manufacturer Grease type

ExxonMobil Unirex N3
Esso
Fuchs Renolit H443 HD88
Lubcon Turmoplex 3
FAG Arcanol Multi 3

For motors with a horizontal type of construction, you can alternatively use greases with NLGI
class 2. However, this reduces the lubrication interval by 20%.

Table 9-5 Alternative greases with NLGI class 2 for motors with a horizontal type of construction

Manufacturer Grease type

ExxonMobil Unirex N2
Esso
Castrol Longtime PD2
Lubcon Turmogrease L 802 EP plus

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Manufacturer Grease type

Shell Retinax LX2
FAG Arcanol Multi 2

Table 9-6 Lubricating grease for the Performance version (Option L37)

Manufacturer Grease type

Lubcon Sintono GPE702

For the Performance version, only this special lubricating grease may be used.

CAUTION
Damage caused by mixing lubrication types
Mixing different greases adversely affects the lubricating properties and must therefore be
avoided. Only the manufacturer can provide a guarantee as to whether certain creases can
be mixed.

Regreasing
Regreasing data are stamped on the lubricant plate of the machine:
● Relubrication intervals in operating hours
● Regreasing amount in grams
● Grease type
Irrespective of the actual number of operating hours, the machine must be regreased every
12 months at the latest.

CAUTION
Relubrication intervals
The relubrication intervals for roller bearings are different from the servicing intervals for the
machine. Failure to observe the relubrication intervals can result in damage to roller bearings.
Pay attention to the instructions on the lubricant plate.

Grease replacement intervals

The grease replacement intervals in these Operating Instructions or the relubrication intervals
indicated on the plate apply for the following conditions:
● Normal load
● Operation at speeds in accordance with rating plate
● Low-vibration operation
● Neutral ambient air
● High-quality roller bearing greases

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In the case of unfavorable operating conditions, the relubrication intervals must be reduced
after consultation with the manufacturer.

Regreasing
The shaft must rotate during regreasing, so that the new grease can be distributed throughout
the bearing. For motors that are be operated at a converter, regreasing should be carried out
at low-to-medium speed where possible (nmin = 250 rpm, nmax = 3600 rpm) to ensure an even
distribution of grease.

WARNING
Rotating parts
When regreasing, pay attention to all rotating components. This can result in death, serious
injury or material damage.

Clean the grease nipples before regreasing and then gradually press in an appropriate type
and amount of grease, as described on the lubricant plate and by the specifications in these
Operating Instructions.
The roller bearing temperature rises sharply at first, then drops to the normal value again after
the excess grease has being expelled from the bearing.
The used grease collects outside each bearing in a spent grease chamber. If the specifications
on the lubricant plate are observed, the spent grease chamber will provide capacity for a
calculated service life of at least 20 000 operating hours (approx. 2.5 years).

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Lubricating using the regreasing system

A flat grease nipple in accordance with DIN 3404, size M10x1, is provided at both the DE ①
and the NDE ② for regreasing.

Figure 9-1 Flat grease nipple ① and ② (schematic circuit diagram for types 1PH818. and 1PH822.)

Figure 9-2 Flat grease nipple ① and ② (schematic circuit diagram for type 1PH828.)

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1. Clean the grease nipples at the DE and NDE.

2. Press in the type and quantity of grease specified (see lubrication instruction plate). The
shaft should rotate so that the new grease can be distributed throughout the bearing.
The bearing temperature rises sharply at first, then drops to the normal value again after
the excess grease has been displaced out of the bearing.

9.2.6.5 Cleaning the spent grease chamber

The rolling-contact bearing's spent grease chamber only has room for a limited amount of
spent grease. When the spent grease chamber is full, the spent grease must be removed,
otherwise it will penetrate into the interior of the machine. The information on the amount of
grease to be used when regreasing can be found on the lubricant plate. When changing the
bearings remove the spent grease that has collected in the spent grease chamber and in the
outer bearing cover.
To remove the spent grease, proceed as follows:
1. Remove the transmission element.
2. Remove the spent grease:
– At the DE, unscrew the outer bearing cover and empty the spent grease from the outer
bearing cover.
– At the NDE, remove the cover of the speed sensor and the cover of the spent grease
chamber. Empty the spent grease chamber.

Note
For types 1PH818. and 1PH822., you must remove the fan before removing the speed
encoder cover. At the NDE, remove the fan and then the speed encoder cover.

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9.2.6.6 Force-ventilated motors

Cleaning the cooling air passages

● Regularly clean the cooling air passages through which the ambient air flows, e.g. using
dry compressed air.

CAUTION
Cleaning intervals depend on the degree of fouling
The frequency of the cleaning intervals depends on the local degree of fouling. The
machine can overheat if the cooling air passages are fouled and the cooling air cannot
flow without obstruction.
Check for fouling regularly and clean the cooling air passages through which the ambient
air flows.

Servicing the external fan

● Check the external fan in accordance with DIN ISO 10816 every 12 months for mechanical
vibrations. The maximum permissible vibrational severity is 2.8 mm/s measured on the end
shield of the impeller-side motor bearing.
● Regularly clean and inspect the fan. Impeller and frame are subject to natural wear
depending on the area of application and displacement medium.

WARNING
Impeller can crack
Due to deposits and the resulting imbalance there is a hazard of fatigue fracture of the
impeller. The impeller can crack in operation. Death, serious injury, or material damage
can result.
Regularly clean and inspect the fan.

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WARNING
Voltages at the internal motor connections
The motor may continue running, e.g. due to airflow, or may run on after being shut down.
This means that dangerous voltages of over 50 V can occur at the internal motor
connections. Death, serious injury, or material damage can result.
● For safety reasons, it is not permissible to make any unauthorized modifications or
changes to the fan.
● Due to the way it functions, the fan switches on and off automatically.
● After a power failure or when the power has been disconnected, the fan starts up
automatically again when the voltage is restored.
● Wait until the fan has come to a standstill before approaching it.
● Provide a protective circuit that prevents the main motor from being switched on when
the external fan is not in operation.

Cleaning the fan

If the fan blades need to be cleaned, the following points must be observed:

DANGER
Danger of shearing
During maintenance work on the forced ventilation unit (e.g. when cleaning the fan blades),
the fan must be at a standstill. The circuit for the forced ventilation unit must be open and a
safeguard must be provided to prevent unintentional reclosing.

CAUTION
Avoid the effects of excessive force
If excessive forces are present, this can damage the fan blades.

The fan should be cleaned with a suitable cloth or brush, and steps should be taken to prevent
moisture from entering the motor.
● Once the voltage has been disconnected on all poles, wait for five minutes before touching
the device.
● Never open the device during operation.
● Never loosen any fixing screws for the ventilation unit during operation.

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Changing the filter mat of the external fan (option)

Check the state of the filter mat regularly depending on the prevailing conditions. Change it if
it is dirty.
1. Unscrew the fan guard and remove the old filter mat.
2. Insert the new filter mats and screw the fan guard back into position.
You can order the filter mat as a spare part.
● Spare parts, external fan (Page 116)
● Spare parts kits (Page 113)
● Ordering spare parts via the Internet (Page 114)

9.2.6.7 Maintaining terminal boxes

Requirement
The machine is de-energized.

Checking the terminal box

● Terminal boxes must be regularly checked for tightness, undamaged insulation, and tight
terminal connections.
● If dust or humidity have infiltrated the terminal box, this should be cleaned and dried
(particularly the insulators).
Check all the seals and sealing surfaces and address the cause of the leakiness.
● Check the insulators, connectors and cable connections in the terminal box.
● Replace the damaged components if necessary.

WARNING
Short-circuit hazard
Damaged components can cause short circuits, possibly resulting in death, serious
injuries and property damage.
Replace damaged components.

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9.3 Repair

9.3.1 Safety instructions

When carrying out any work on the machine, observe the general safety instructions
(Page 15) and the specifications contained in DIN EN 50110‑1 as regards working safely with
and on electrical machines.

Note
If the motor has to be transported, please observe the information and instructions in the
"Transport" (Page 34) section.

9.3.2 Dissembling a force-ventilated motor

The drawings and parts lists do not contain any detailed information about the type and
dimensions of fixing elements, etc.

CAUTION
Installing and removing the impeller
For some motor versions the stator link has an interior diameter that is smaller than the
impeller diameter. When removing the rotor the stator coil connection can be damaged.
Only install the impeller in the direction on which a stator link is not attached. Contact the
Siemens Service Center (Page 131), if necessary.

CAUTION
Dismantling centered parts
Centered parts can be damaged if dismantled improperly with unsuitable tools.
Use pullers or suitable devices to disassemble parts and components attached to the motor
shaft.

Removing
1. Ensure you do not damage insulation when dismantling the device. Check the insulation
for possible damage prior to re-installing.
2. To disassemble the motor, disconnect the connecting cables from the terminals and the
entry plate from the terminal box housing.
In this way, the respective positioning of the cables in relation to one another and the sealing
of the cables in the cable entries are to a large extent maintained.

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3. Remove the connecting cables in the terminal box of the fan motor, and if necessary the
cable on the ground terminal and the cables laid out on the motor.
4. Pull out the connector of the speed sensor.

Links
The circuit diagram (Page 58) shows the relationships required when connecting to the line
supply.

Component assignment
When dismantling or assembling the bearing pay attention to the proper arrangement of the
components particularly if the bearing is the same size on the DE side and NDE side, for
example:
● Bearing shield
● Bearings
● Compression springs
● Spacer washers,
● Covers with different centering length, etc.

9.3.3 Removing and installing the protecting ring

The protecting ring acts as an outer bearing seal. It sits on the shaft outside the bearing end
shield.

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Disassembly
● Once the coupling is detached, you can remove the protective ring from the shaft. After it
has been removed, the protective ring will be deformed and must be replaced.

Assembly
● Push the protecting ring over the end of the shaft. Make sure that the outer collar is placed
at a spacing of 1 mm from the bearing end shield.

ཱ
= PP

Figure 9-3 Fitting the protecting ring

9.3.4 Removing and mounting end shields of force-ventilated motors

1. Unscrew the belt pulleys. The belt pulleys may be jammed or distorted, in which case you
should lever them off carefully.
2. Remove the bearing shield.
When removing the bearing shields, take care that the windings are not damaged.
For assembly, proceed in reverse order.

9.3.5 Installing the machine

Strictly ensure the greatest possible care and cleanliness when repairing the machine.

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Mount the machine on an alignment plate. This ensures that the contact surfaces of the motor
feet are all on the same level.

CAUTION
Do not damage windings
Windings protrude from the stator housing and can be damaged when attaching the end
shield. This can damage the motor.
When mounting the end shield, ensure that the windings that project from the stator housing
are not damaged.

Sealing the motor

● Clean bare joints between parts before re-assembling (e.g. between enclosures, end
shields and the active parts of bearings).
● Brush the bare joints with the non-hardening sealing agent " Hylomar M".
Firma W. Kopp Marston Bentley Domsel GmbH
Schlesierstrasse 9 Bergheimer Str. 15
D-97268 Kirchheim D-53909 Zülpich

Addresses to purchase sealing agents

● Note that these joints between parts (e.g. the sealing gap on the active part of the bearing)
must also be resealed with a suitable, silicone-free sealant during assembly.
● Check the sealing elements fitted (e.g. at the terminal boxes) and replace them if they do
not provide an adequate seal.
● Follow the manufacturer's application and safety instructions when using the sealant.
● Replace parts that are subject to wear such as the adjusting springs.

Installing the active parts of the bearings

1. First position the parts that must be arranged on the shaft within the bearing.
2. To fit the bearings on the shaft, heat them up to about 80 °C in oil or air.
3. Then push the bearings onto the shaft up to its shoulder. Avoid any heavy blows that might
damage the bearings.
4. Fill the bearing to the top with the specified lubricating grease.

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9.3.6 Sealing (type 1PH828.)

Sealant must be used due to the higher requirements for degree of protection IP55. In addition
to the previous instructions, please note the following:
1. When assembling, seal the joints between parts, such as the sealing gap between the
enclosure and bearing shield, using suitable, silicon-free sealing compound.
2. Seal the gap ② using a non-hardening sealant, which remains permanently plastic, before
screwing on the bearing shields, for example "Hylomar M".
3. Check all sealing elements/gaskets, such as those on the terminal boxes, for elasticity,
aging or damage, and renew them if they are no longer effective.

ໂ
ໃ

① End shields ③ Housing

② Sealing gap ④ Protective tube
Figure 9-4 Sealing gap between the enclosure and bearing shields (schematic representation)

Installing the active parts of the bearings

● Follow the instructions given in the previous section "Installing the machine (Page 103)".
● When installing/replacing the bearing, ensure that an insulated bearing is again installed
at the NDE.
● If rotary shaft seals without helical springs are installed, the replacement part must also be
installed without a spring.

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Sealing the bearings

The outer bearing seal comprises a rotary shaft seal. When installing the bearings, make sure
that the seat of the shaft is not greased.
The correct axial position of the rotary shaft seal is reached when the outer edges of the bearing
cap end face ① and rotary shaft seal ② are flush.

① Bearing cap end face

② Rotary shaft seal
③ Seat of shaft

Figure 9-5 Installing the rotary shaft seal

9.3.7 Relocating the external fan (type 1PH828.)

If you want to subsequently move the external fan from the non-drive end to the drive end or
vice versa, please contact the Siemens Service Center (Page 131).

9.3.8 Removing the external fan

WARNING
Live parts
Contact with live parts can cause death, serious injury or material damage.
1. Before carrying out any maintenance work on the device, disconnect it from the line
supply, particularly before opening the terminal box.
2. Make sure that the device cannot be switched back on.

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Removing the external fan

1. Before carrying out any maintenance work on the device, disconnect it from the line supply.
2. Unscrew the screws ① and remove the external fan.

Figure 9-6 Unscrewing the external fan (1PH818., 1PH822.)




Figure 9-7 Unscrewing the external fan (1PH828.)

For assembly, proceed in reverse order.

See also
Operating instructions, external fan (Page 161)

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9.3.9 Removing and mounting the speed sensor

CAUTION
Electrostatic discharge
Electronic modules contain components that can be seriously damaged by electrostatic
discharge. These modules can easily be destroyed unless they are handled properly.
To protect your equipment against damage, follow the instructions given in the section
headed "Electrostatic Sensitive Devices" (Page 18).

CAUTION
To prevent damage, remove the encoder prior to disassembling the machine.

Preparation
For 1PH818. and 1PH822. motors, the speed encoder can only be removed and replaced if
the external fan (Page 106) has been removed.

① Shaft ③ Speed encoder

② Torque arm ④ Encoder cover

Figure 9-8 Detailed view of the speed encoder

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1. Unscrew the cover of the speed encoder.

2. Detach the electrical connection.
– Pull the cable carefully out of its holder.
– Pull out the connector.
3. Remove the screwed union connections for the speed encoder from the bearing shield.

Separating the speed encoder

The following options are available for the purpose of separating the speed encoder from the
shaft by means of a clamping screw:

Disassembling the speed encoder - Version A

0[

0[
ໂ
0[

1. Unscrew screw M5x50 (①).

2. In succession, screw in the M5x10 and M6x70 screws. This releases the encoder cone in
the motor shaft (②).
3. Remove the speed encoder.

Removing the speed encoder - version B

ແ
FD¡¡

0

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1. Loosen the retaining screw (①).

2. Using the M10 screw, apply pressure to the original screw. This will then drop out (②).
3. Remove the speed encoder.

Mounting the speed encoder

1. Screw the torque arm to the speed encoder, tightening the two screws by hand.
2. Use the M5x50 screw to secure the speed encoder over the internal cone, ensuring a
tightening torque of 5 Nm at the shaft extension.
3. Secure the torque arm to the bearing shield with a tightening torque of 3 Nm.
4. Loosen the torque arm screws, so that they are stress-relieved and tighten them across
diagonals to a tightening torque of 0,6 Nm.
5. Establish the electrical connection.
6. Screw on the cover of the speed encoder.

9.3.10 Connecting the speed encoder

CAUTION
Electrostatic discharge
Electronic modules contain components that can be seriously damaged by electrostatic
discharge. These modules can easily be destroyed unless they are handled properly.
To protect your equipment against damage, follow the instructions given in the section
headed "Electrostatic Sensitive Devices" (Page 18).

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1. Insert the connector into the socket.

2. Press the cable into the holder provided for it.
3. Screw on the sensor cover. Take care that you do not catch the cable as you screw it in.

཰ ཰

Figure 9-9 Electrical connection of the speed sensor

9.3.11 Replacing the DRIVE-CLiQ interface (encoder module)

Only trained Siemens service engineers are authorized to replace the DRIVE-CLiQ interface
(sensor module).

CAUTION
Electrostatic discharge
Electronic modules contain components that can be destroyed by electrostatic discharge.
These modules can be easily destroyed by improper handling.
To protect your equipment against damage, follow the instructions given in the chapter ESD
Guidelines (Page 18).

WARNING
Motor-specific sensor module
The Sensor Module contains motor-specific and sensor-specific data and an electronic
nameplate.
If you operate a different Sensor Module on the motor, this can result in serious injury or
death, or cause considerable material damage.
Only operate the sensor module on the original motor. Do not install the sensor module on
other motors. Do not replace the sensor module with a sensor module from a different motor.

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9.3.12 Touch up any damaged paintwork

If the paint is damaged, it must be repaired in order to protect the unit against corrosion.

CAUTION
Paint system
Contact the Service Center before you repair any paint damage. They will provide you with
more information about the correct paint system and methods of repairing paint damage.

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Spare parts 10
10.1 Ordering data
When ordering spare parts, in addition to the precise designation of the spare part, specify the
motor type and the serial number of the motor. Ensure that the spare part designation matches
the designation in the spare part lists and add the associated part number.

Example:

Spare part Spare parts kit, drive-end bearing (Part 3.00)

Machine type 1PH81841JD202FA1
Serial number N-W91246206010001
The machine type and the serial number are indicated on the rating plate and in the technical
data, and are also embossed on the drive end of the shaft.

Note
Bar code on rating plate
You can also read the machine type and serial number from the bar code on the rating plate.

Note
The graphics in this chapter are schematic representations of the basic versions. They are
used for spare parts definitions. The supplied version may differ in details from these
representations.

10.2 Spare parts kits

The spare parts are bundled with the necessary wearing parts in a logical way so as to create
spare parts kits. The spare parts kits for the bearings also contain the bearing grease.
The following spare parts kits are available for you to order:

3.00 Spare parts kit, non-drive-end bearing (complete)

4.00 Spare parts kit, drive-end bearing (complete)
32.00 Spare parts kit, separately driven fan (only force-ventilated motors)
55.00 Spare parts kit, relevant version of speed encoder
Additional spare parts are available on request.
For an overview of the services available from Technical Support, please visit:
Technical Support (http://support.automation.siemens.com/WW/view/en/16605654)

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Operating Instructions 03/2012 A5E03555811A AB 113
Spare parts
10.3 Ordering spare parts via the Internet

If you wish to submit a service request directly, you can do so via the following page:
http://www.siemens.com/automation/support-request (http://www.siemens.com/automation/
support-request)

10.3 Ordering spare parts via the Internet

Spare parts can be ordered online from the spare parts service "Spares on Web":
Spares on Web (https://b2b-extern.automation.siemens.com/spares_on_web).
You can use "Spares on Web" to determine the order numbers for motor spare parts quickly
and easily.
A short description of how to use "Spares on Web" is available on the Internet.
Guide for Spares on Web (http://support.automation.siemens.com/WW/news/en/25248626).

Note
DRIVE-CLiQ interface
If you order a DRIVE-CLiQ interface, please specify when ordering from Spares on Web that
the DRIVE-CLiQ interface must be described along with the motor data.

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 Spare parts
10.4 Spare parts force-ventilated motor

10.4 Spare parts force-ventilated motor

10.4.1 Force-ventilated motor, complete














 

Figure 10-1 Schematic representation of the motor, complete

Table 10-1 Motor, complete

Number Designation Number Designation

3.00 Spare parts kit, NDE bearing 10.00* Stator housing (with laminated core
and winding)
4.00 Spare parts kit, DE bearing 10.35* Eyebolt
5.00* Bearing shield, DE 20.00* Terminal box
6.00* Bearing shield, NDE 32.00 External fan
8.00* Rotor, complete 55.10 Spare parts kit, speed encoder

* On request

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Spare parts
10.4 Spare parts force-ventilated motor

10.4.2 External fan









Figure 10-2 Spare parts for external fan (type 1PH818., 1PH822.)

Table 10-2 Spare parts for external fan

Part Description Part Description

32.00 Fan 34.31 External grill cover
34.21 Filter element * 34.33 Inside basket

* Option for type 1PH828.

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116 Operating Instructions 03/2012 A5E03555811A AB
 Spare parts
10.4 Spare parts force-ventilated motor

10.4.3 Roller bearing cartridge DE with radial shaft sealing ring with regreasing














Figure 10-3 Rolling-contact bearing bush drive end with mounted gearing, with regreasing

Table 10-3 Spare parts for rolling-contact bearing bush drive end with mounted gearing, with
regreasing

Number Designation Number Designation

3.00 Spare parts kit, drive-end bearing 3.60* Inner bearing cover
● Deep-groove ball bearing
(floating bearing)
● Radial shaft sealing ring
● Inner ring
3.20* Outer bearing cover 3.80* Grease nipple
3.45* Corrugated spring/compression
springs

* On request

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Spare parts
10.4 Spare parts force-ventilated motor

10.4.4 Roller bearing cartridge DE, belt coupling











Figure 10-4 Rolling-contact bearing bush drive end with belt coupling, with regreasing

Table 10-4 Spare parts for rolling-contact bearing bush drive end with belt coupling, with regreasing

Number Designation Number Designation

3.00 Spare parts kit, drive-end bearing 3.60* Inner bearing cover
● Cylindrical-roller bearing (floating
bearing)
● Protecting ring (rotating)
3.20* Outer bearing cover 3.80* Grease nipple

* On request

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 Spare parts
10.4 Spare parts force-ventilated motor

10.4.5 Roller bearing cartridge DE, coupling output, with regreasing













Figure 10-5 Rolling-contact bearing bush drive end, with coupling output, with regreasing

Table 10-5 Spare parts for rolling-contact bearing bush drive end, with coupling output, with regreasing

Number Designation Number Designation

3.00 Spare parts kit, drive-end bearing 3.60* Inner bearing cover
● Deep-groove ball bearing
(floating bearing)
● Protecting ring (rotating)
3.20* Outer bearing cover 3.80* Grease nipple
3.45* Corrugated spring

* On request

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Operating Instructions 03/2012 A5E03555811A AB 119
Spare parts
10.4 Spare parts force-ventilated motor

10.4.6 Roller bearing cartridge DE, coupling output, with permanent lubrication







Figure 10-6 Rolling-contact bearing bush drive end, with coupling output, with permanent lubrication

Table 10-6 Spare parts for rolling-contact bearing bush drive end, with coupling output, with permanent
lubrication

Number Designation
3.00 Spare parts kit, drive-end bearing
● Deep-groove ball bearing (floating bearing)
● Protecting ring (rotating)
3.45* Corrugated spring/compression springs

* On request

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 Spare parts
10.4 Spare parts force-ventilated motor

10.4.7 Roller bearing cartridge NDE, with permanent lubrication







Figure 10-7 Roller bearing cartridge, non-drive end, permanent lubrication

Table 10-7 Spare parts for roller bearing cartridge, non-drive end, permanent lubrication

Number Designation
4.00 Spare parts kit, NDE bearing
● Deep-groove ball bearing (locating bearing)
● Retaining ring
4.60* Inner bearing cover

* On request

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Spare parts
10.4 Spare parts force-ventilated motor

10.4.8 Roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.)










Figure 10-8 Roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.)

Table 10-8 Spare part, roller bearing cartridge NDE, with regreasing (type 1PH818., 1PH822.)

Number Designation Number Designation

4.00 Spare parts kit, NDE bearing 4.80* Grease nipple
● Deep-groove ball bearing
(locating bearing)
● Retaining ring
4.60* Inner bearing cover 4.90* Cover of spent grease chamber

* On request

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122 Operating Instructions 03/2012 A5E03555811A AB
 Spare parts
10.4 Spare parts force-ventilated motor

10.4.9 Roller bearing cartridge NDE, with regreasing (type 1PH828.)











Figure 10-9 Roller bearing cartridge NDE, with regreasing (type 1PH828.)

Table 10-9 Spare part, roller bearing cartridge NDE, with regreasing (type 1PH828.)

Number Designation Number Designation

4.00 Spare parts kit, NDE bearing 4.80* Grease nipple
● Deep-groove ball bearing 4.60* Inner bearing cover
(locating bearing)
● Retaining ring

* On request

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Spare parts
10.5 Spare parts holding brake

10.4.10 Roller bearing cartridge NDE, "Performance"










Figure 10-10 Rolling-contact bearing bush non-drive end with regreasing

Table 10-10 Spare parts for rolling-contact bearing bush non-drive end with regreasing

Number Designation Number Designation

4.00 Spare parts kit, non-drive-end 4.80* Grease nipple
bearing
● Deep-groove ball bearing
(locating bearing)
● Shrink ring
4.60* Inner bearing cover 4.90* Cover of spent grease chamber

* On request

10.5 Spare parts holding brake

Contact your Service Center for spare parts for the holding brake.

See also
Operating instructions, holding brake (Page 138)

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124 Operating Instructions 03/2012 A5E03555811A AB
 Spare parts
10.6 Terminal box

10.6 Terminal box








Figure 10-11 Terminal box

Table 10-11 Spare parts for terminal box

Number Designation Number Designation

20.20* Enclosure 20.50* Entry plate
20.30* Cover 20.60* Adapter plate (optional)

* On request

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Spare parts
10.7 Speed encoder (type 1PH818., 1PH822.)

10.7 Speed encoder (type 1PH818., 1PH822.)







Figure 10-12 Speed encoder

Table 10-12 Spare part, speed encoder (type 1PH818., 1PH822.)

Part Description
55.00 Spare parts kit, speed encoder
● Speed encoder
● Torque arm
6.80* Cover

* On request

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126 Operating Instructions 03/2012 A5E03555811A AB
 Spare parts
10.8 Speed encoder (type 1PH828.)

10.8 Speed encoder (type 1PH828.)







Figure 10-13 Speed encoder (type 1PH828.)

Table 10-13 Spare part, speed encoder (type 1PH828.)

Part Description Part Description

6.80 Cover 55.63 Torque arm
55.12 Speed encoder

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Operating Instructions 03/2012 A5E03555811A AB 127
Spare parts
10.8 Speed encoder (type 1PH828.)

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Disposal 11
11.1 Introduction
Protecting the environment and preserving its resources are corporate goals of the highest
priority for us. Our worldwide environmental management system to ISO 14001 ensures
compliance with legislation and sets high standards in this regard. Environmentally friendly
design, technical safety and health protection are always firm goals even at the product
development stage.
Recommendations for the environmentally friendly disposal of the machine and its components
are given in the following section. Be sure to comply with local disposal regulations.

11.2 Preparing for disassembly

Disassembly of the machine must be carried out and/or supervised by qualified personnel with
appropriate expert knowledge.
1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in
terms of the quality of dismantling the machine and provision of the components.
2. Follow the five safety rules (Page 15).
3. Disconnect all electrical connections and remove all cables.
4. Remove all liquids such as oil, cooling liquids, …
5. Detach the machine fixings.
6. Transport the machine to a suitable location for disassembly.

See also
Maintenance (Page 87)

11.3 Dismantling the machine

Dismantle the machine using the general procedures commonly used in mechanical
engineering.

WARNING
Machine parts can fall
The machine is made up of heavy parts. These parts are liable to fall during dismantling. This
can result in death, serious injury, or material damage.
Secure the machine parts being dismantled to prevent them falling.

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Disposal
11.4 Disposal of components

11.4 Disposal of components

Components
The machines consist for the most part of steel and various proportions of copper and
aluminum. Metals are generally considered to be unlimitedly recyclable.
Sort the components for recycling according to whether they are:
● Iron and steel
● Aluminum
● Non-ferrous metal, e.g. windings
The winding insulation is incinerated during copper recycling.
● Insulating materials
● Cables and wires
● Electronic waste

Process materials and chemicals

Sort the process materials and chemicals for recycling according to whether they are for
example:
● Oil
● Grease
● Cleaning substances and solvents
● Paint residues
● Anti-corrosion agent
Dispose of the separated components according to local regulations or via a specialist disposal
company. The same goes for cloths and cleaning substances which have been used while
working on the machine.

Packaging material
● If necessary, contact a suitable specialist disposal company.
● Wooden packaging for sea transport consists of impregnated wood. Observe the local
regulations.
● The foil used for water-proof packaging is an aluminum composite foil. It can be recycled
thermically. Dirty foil must be disposed of via waste incineration.

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130 Operating Instructions 03/2012 A5E03555811A AB
Service and Support A
A.1 Siemens Service Center

Contact for further information

Details regarding the design of this electrical machine and the permissible operating conditions
are described in these operating instructions.

Service numbers
If you wish to request local field service or order spare parts, or if you require answers to
technical queries or any additional information, please contact the relevant service number
below.
Please have the following machine data ready:
● Machine type
● Machine number
You can find this data on the rating plate of the machine.

Table A-1 Service numbers

Local field service Phone +49 (0)911 895 7444

Fax +49 (0)911 895 7445
Technical queries or additional Phone +49 (0)911 895 7448
information Fax +49 (0)911 895 7449
Spare parts and repairs Phone +49 (0)911 895 7222
Fax +49 (0)911 895 7223

Contact:
● http://www.siemens.com/automation/support-request (http://www.siemens.com/
automation/support-request)
● [email protected] (mailto:[email protected])

SIMOTICS M-1PH8
Operating Instructions 03/2012 A5E03555811A AB 131
Service and Support
A.1 Siemens Service Center

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132 Operating Instructions 03/2012 A5E03555811A AB
Quality documents B

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Operating Instructions 03/2012 A5E03555811A AB 133
Quality documents

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134 Operating Instructions 03/2012 A5E03555811A AB
 Quality documents
B.1 EC Declaration of Conformity 2006/95/EC

B.1 EC Declaration of Conformity 2006/95/EC

SIMOTICS M-1PH8
Operating Instructions 03/2012 A5E03555811A AB 135
Quality documents
B.1 EC Declaration of Conformity 2006/95/EC

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136 Operating Instructions 03/2012 A5E03555811A AB
Additional documents C
If you have any questions or problems, contact your Siemens service center (Page 131).

C.1 Reader notes for the operating instructions of the holding brake

Holding brake
Depending on the order, a special version of a holding brake from the Stromag company is
mounted. Various types of holding brake are mounted depending on the shaft height.

CAUTION
Technical data for the special version of the holding brake
The following technical data apply to the special version of the mounted holding brake. The
corresponding data in the manufacturers operating instructions do not apply.

Table C-1 Technical data of the holding brake

Technical data NFF-A 63 NFF-A 100

Holding torque MStat [Nm] 1000 1600

Max. no-load speed N0 [rpm] 3000 2800
Rated switching speed Nzn [rpm] 1600 1300
Air gap min. / max. 0.6 / 1.5 0.6 / 1.6
Rated switching power S4 - 40% Pvn [kW] 0.249 0.27
ED
Ground mbrake [kg] 75 95
Moment of inertia of the rotating Jbrake [kgm2] 0.025 0.059
parts
Supply voltage Usupply [V] 230 (AC) 230 (AC)
Coil voltage Ucoil [V] 103 (DC) 103 (DC)
Power consumption P [W] 227 278
Current consumption I [A] 2.21 2.7

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Additional documents
C.2 Operating instructions, holding brake

Note
Notes for the reader
● Regarding Chapter 4.2: The shaft end is magnetized when the holding brake is opened.
● Regarding Chapter 9: Only frame sizes 63 and 100 are relevant in the table.
● Regarding Chapter 9.2: Only frame sizes 63 and 100 are relevant in the table.

C.2 Operating instructions, holding brake

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 Additional documents
C.2 Operating instructions, holding brake

Stromag Dessau
safety in motion

Service Instructions

NFF
Electromagnetic -
Double - Face
Spring - Applied Brake

These operating instructions are intended to

enable the user to operate the Stromag Dessau
Stromag Dessau GmbH
product safely and effectively, to use it sensibly Dessauer Str. 10
and to maintain it properly so as to exclude the
possibility of any damage or incorrect operation.
D-06844 Dessau-Roßlau
Telefon: 0340-2190-0
Telefax: 0340-2190-201
E-mail: [email protected]
Internet: http://www.stromag-dessau.de

SIMOTICS M-1PH8
Operating Instructions 03/2012 A5E03555811A AB 139
Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

Contents Chapter Page

Technical data 1 2
Nameplate data 1.1 2
Torque, speed, and other technical data 1.2 2
Bore and keyway dimensions, connections 1.3 3
Application range and utilization as per specification 1.4 3
Safety guidelines 2 4
Symbol for safety at work 2.1 4
Instructions "Caution" 2.2 4
Safety instructions for working 2.3 4
Electromagnetic compatibility 2.4 5
Transportation 3 5
Packing 3.1 5
Pre-mounting condition 3.2 5
Sensitivity 3.3 5
In – process stocking 3.4 6
Delivery extent 3.5 6
Construction, functioning, construction characteristics 4 7
Designation of individual components 4.1 7
Functioning and design characteristics of the standard versions 4.2 8
Mechanical release by means of emergency release screws 4.3 8
Mechanical release by means of hand lever (optional) 4.4 9
Current supplies and electrical connections 4.5 9
Assembly and dismantling 5 9
Assembly 5.1 10
Mounting accuracy 5.2 10
Dimensions, space requirement and mass 5.3 10
Dismantling 5.4 10

Initial setting into service 6 11

Operation 7 11
Operating conditions 7.1 11
Protection classes 7.2 12
Duty cycle and switching frequency 7.3 13
Trouble shooting 7.4 13
Maintenance 8 14
Maintenance and inspection works 8.1 14
Measurement of the air gap 8.2 14
Wear re-adjustment 8.3 14
Replacement of the friction disc 8.4 15
Variants (optional) 9 16
Execution with micro switch 9.1 17
Execution with adjusting ring to reduce the brake torque 9.2 17
Hand lever emergency with self locking 9.3 18
Execution with condensation heater 9.4 18
Speedometer installation 9.5 18
Spare parts stocking, after-sales service 10 19
Spare parts stocking 10.1 19
Data for spare parts stocking 10.2 19
Address of after-sales service 10.3 19
Listed standard and regulations 11 20
Appendix 12 21

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 Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

1 Technical data

1.1 Nameplate data

The following data is stated on the nameplate (73). It is provided on the front side of the brake.

Series / Size
Order – Ref. – No.
Delivery date month /year
Nominal voltage V DC
Nominal wattage W
Nominal current A
Brake torque Nm
Connexion on V AC
Airgap “off” norm. mm
max. mm

This data must comply with the identifications of the order acknowledgement.

1.2 Torque, speed, and other technical data

Table 1

W
size Mdyn Mstat n0 nzn Un * Pk Airgap PVN J m
-1 -1 2
NFF Nm Nm min min V-DC W min/max KJ kW kgm kg
2 20 22 5300 3000 103 89,9 0,6/1,0 25 0,080 0,00040 6,3
4 40 44 4900 3000 103 90,7 0,6/1,0 30 0,067 0,00043 10,4
6,3 63 70 4500 3000 103 113,9 0,6/1,2 65 0,103 0,00080 13
10 100 110 4100 2500 103 110,4 0,6/1,2 75 0,110 0,00125 14
16 160 175 3800 2400 103 115,8 0,6/1,2 120 0,124 0,00340 21
25 250 275 3500 2100 103 136,6 0,6/1,2 150 0,149 0,00430 30
40 400 440 3200 1800 103 212,9 0,6/1,3 250 0,170 0,01212 40
63 630 700 3000 1600 103 227,3 0,6/1,5 320 0,249 0,01463 68
100 1000 1100 2800 1300 103 277,6 0,6/1,6 450 0,270 0,04171 85,5
160 1600 1750 2200 1000 103 353,5 0,6/1,6 450 0,325 0,14821 133
250 2500 2750 1900 900 207 367,0 0,6/1,8 700 0,400 0,23515 176
400 4000 4400 1600 ** 207 400,9 0,6/1,8 ** 0,482 0,43412 278
630 6300 7000 1400 ** 207 489,6 0,6/1,6 ** 0,601 1,01607 367
1000 10000 11000 1200 ** 207 535,5 0,6/1,6 ** 0,587 1,56099 491

* other voltages on request

** on request

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Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

Mdyn dynamic torque (friction torque, nominal value for working brake)
applies to dry operation with an oil- and grease-free friction lining after running-in
Mstat static torque (torque of adhesion)
no maximum idling speed
nzn nominal switching speed
Pk excitation output at 20°C
Pvn nominal breaking capacity (S4-40% I.O.)
W switch work per switching operation for z = 1-5 h-1
J mass moment of inertia of rotating parts
m weight
Protection class IP 66 in accordance with DIN 40050
Mode of operation S1, S4 - 40% I.O.
thermical class 155 ‘F’ in accordance with DIN VDE 0580
The main parameters are also given on the nameplate
AC control via rectifier

The max. admissible speed as well as the other technical data are stated on the dimensional
drawing which is binding for the pertinent order and can be inquired at our after-sales service;
address is given in chap. 10.3.

1.3 Bore and keyway dimensions, connections

The binding dimensions for the bore, keyway and connections are stated on the dimensional
drawing as mentioned in chap. 1.2.

1.4 Application range and utilization as per specification

in docks:
in harbour cranes, container loading facilities for crane, hoisting and trolley travel gears.

Operating conditions:

Protection class IP 66 in accordance with DIN 40050 (VDE 0470). Electrical design of brakes in
accordance with DIN VDE 0580 in thermical class 155 (F). The brake corresponds to Directive
93/68/EEC (Low Voltage Directive).
The Directive 89/336/EEC (EMC) must be ensured by the user, taking into account the
instructions given by the manufacturer.
The products are marked accordingly.
Mode of operation S1, S4.
Horizontal installation. Vertical operation after consultation with manufacturer.
With the friction combination steel/ organic friction lining the brake may only be used for dry
running under the conditions described in chapters 7.1 and 7.3
In addition, compliance with the assembly, dismantling, commissioning and maintenance
conditions specified by the manufacturer must be ensured.
Non-compliance with these conditions or any use beyond this shall be deemed use not in
accordance with the specification.
The manufacturer shall not be liable for any such use, the risk shall be exclusively borne by the
user.

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 Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

If the brake is to be used outside this contractual scope of operation, contact Stromag Dessau
for further details (Address see Chapter 10.3).

2 Safety guidelines

2.1 Symbol for safety at work

This symbol denotes all the safety instructions in this manual which deal with danger to life and
limb of personnel. These instructions must be adhered to and particular caution exercised in
these cases. All users must be familiarised with the safety instructions.

2.2 Instructions Caution!

The term "Caution!" denotes those sections in this manual which require special attention, in
order that the guidelines, recommendations and correct procedures are complied with to
prevent damaging or destroying the brake.

2.3 Safety instructions for working

The following recommendations are of particular importance:

The brake has been manufactured to the highest up to date standard and is operationally safe.
However, the brake can become a risk to safety when used improperly by untrained personnel
or for an application it is not designed for.
Every person involved in assembling, disassembling, commissioning, operating and maintaining
(inspecting, servicing and repairing) the brake must be authorised, adequately trained and
instructed. Each such person must have read and understood this instruction manual, especially
in respect to the safety instructions.
We do not accept liability for damage or malfunctioning, resulting from non - adherence to this
manual.

Repair and maintenance works must be carried - out by skilled and trained workmen only
meeting the minimum requirements for aptitude and qualification according to DIN VDE 1000-
10.
Any work process involving the brake which impairs safety is to be avoided.
The user is obliged to inform the supplier immediately of any change occurring to the brake
which adversely affects safety; address see chap. 10.3.
The user is obliged to only operate the brake when it is functioning correctly.
Unauthorised changes and modifications which impair safety, as well as the use of non -
authentic components is not permitted.
To exclude any danger to people, domestic animals and goods by parts in motion, the user has
to take protective measures according to DIN 31000 / VDE 1000.
As protection against hazardous shock currents, the user has to take protective measures
according to DIN VDE 0100 - 410 and DIN EN 50274.
To avoid dangerous influences due to heating of the units and in case of a failure, the user has
to take suitable protective measures according to DIN 31000 / VDE 1000 and DIN VDE 0100 -
420.
To exclude any danger to people, domestic animals and goods by direct or indirect effect of
electromagnetic fields, the user has to take suitable measures according to DIN V VDE V 0848-
4/A3.

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Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

Caution! In every case the local safety and accident prevention regulations are also
applicable, the user must ensure that these are complied with.

We reserve the right to make modifications of a technical nature to this manual if required for
brake development.
We recommend that these instructions are incorporated into the service manual of the user
(machine manufacturer).

2.4 Electromagnetic Compatibility

The Electromagnetic Compatibility of Equipment Act (EMVG) demands to meet defined

protective requirements when using electrical equipment so that this equipment can operate in
its electromagnetic environment without mutual impairment of function.
Machine manufacturers, system and plant constructors must assure that the product is installed
as required and that the installation of the pertinent current supply is made correctly in order to
adhere to the protective requirements of the EMVG.
Please inquire our leaflet "EMC - notes", No. 900 - 00001 at Stromag Dessau GmbH; address
as per chap. 10.3.

3 Transportation

3.1 Packing

The type of packing complies with the agreements with the orderer as stated in the order
acknowledgement. If no type of packing has been agreed, it depends on the transportation
route. The symbols marked on the packing must be adhered to.

3.2 Pre-mounting conditions

The brakes will be supplied completely mounted and with all settings made. The pinion (15) is
supplied as a loose part. If a hand lever is required (4) it is loosely attached and has to be
mounted.

3.3 Sensitivity

Caution!

Make sure to avoid damage as a result of shocks or impacts during transportation. Special care
should be exercised with regard to the radial connecting cable (version without terminal box).
For direct transportation or assembly of the brake, from size 16 there are threaded bores
provided in the coil body (1) for screwing of supporting eyes, see figure 1.

Caution!

The support eye shall not be used for transport and for mounting of the unit motor with mounted
brake.
Make sure to avoid the generation of condensation water as a result of strong temperature
fluctuations.

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144 Operating Instructions 03/2012 A5E03555811A AB
 Additional documents
C.2 Operating instructions, holding brake

Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

3.4 In - process stocking

All parts are made of stainless material or are provided with a surface protection by gas
nitrocarburizing. In addition they are prined with a zinc phosphate painting.
Bore and keyway of the driving hub (15) are supplied greased.
Should it be intended to stock the brake in - process, another protection against corrosion has
to be provided. Please consult our after - sales service (address given in chapter 10.3).

3.5 Delivery extent

On receipt check the consignment for completeness (see packing list).

Possible damage during transportation and/or missing parts must be advised immediately and
in writing.

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Electromagnetic Double Face Spring – Applied Brake 01.06.2009

4 Construction, functioning, construction characteristics

Fig. 1

4.1 Designation of individual components

(shown size NFF 16 with option speedometer installation)

1 Coil body with coil 30 condensation heater

2 friction lining assy. 40 screw for tacho flange
3 terminal box assy. 41 brake mounting screw
4 hand lever assy. 42 cylindric screw
10 armature disc 46 mounting screw for hand release end cap
11 brake flange 47 screw for locating dog
12 tacho flange 49 emergency release screw
13 outer body 50 cap screw for emergency release
14 adjusting ring 52 screw for lockable hand release
15 hub 60 seal ring for tacho
20 shim 61 seal ring for brake flange
21 compression spring 63 counter nut for micro switch
22 locating doc 64 set screw (micro switch)
23 terminal box spacer 65 cap screw for airgap measurement
24 brass pin 67 gland
25 hand release end cap 73 nameplate
26 hand release pivot pin 74 metal tack (to mount identification plate)
27 grooved ball bearing 76 adhesive
28 micro switch 78 washer for pos. 52
81 seal ring for pos. 50

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Electromagnetic Double Face Spring – Applied Brake 01.06.2009

4.2 Functioning and design characteristics of the standard version

The brake NFF is a spring-loaded electromagnetic double-face brake which brakes without
current and is released electromagnetically.
The brake type NFF meets highest requirements with regard to fatigue strength and robustness
and is seawater-proof. The brakes are manufactured and tested in accordance with DIN VDE
0580.
The brake is screwed to a motor or any other machine part by means of cyl. screws (mounting
screws pos. 41).

The coil body contains a coil which is potted with a synthetic resin compound in accordance
with thermical class 155 (F), (max. limit of temperature 155°C).

If the coil is not excited, the springs (21) press the armature disc (10) against the friction disc
(2), which is firmly clamped between the torsion-protected armature disc (10) and the brake disc
(11) and thus prevented from rotating. The braking effect is transmitted from the geared friction
disc (2) via the hub (15) and a fitting key to the shaft. If the coil is connected to a direct voltage
as specified on the identification plate (73), the magnetic force will draw the armature disc (10)
to the coil body (1) overcoming the spring pressure. The friction disc (2) is released, the braking
effect is cancelled and the brake is released.

4.3 Mechanical release by means of emergency release screws

Fig. 2

1 coil body with coil

11 brake flange
13 outer body
49 emergency release screw
50 cap screw for axial emergency release
81 seal ring

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Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

For the mechanical release in case of emergency of the system use red marked screws (49)
which have to be removed of its position (coil body (1) – outer body (13) – brake flange (11)) (up
to size NFF 10 loosely attached) – up to size NFF 63-2 screws, up size NFF 100 –3 screws).
For release, unscrew the cap screws (50) from the coil body (1). In the now free holes, screw in
the release screws (49). The release is made by alternating clockwise turning of the screws until
the braking effect is cancelled.

Caution!

The emergency release is self-locking; for normal operation it must be re-turned into the initial
position, i.e. the screws (49) are re-turned counter-clockwise. Then re-screw the release screws
(49) into the original threaded hole (coil body (1) – outer body (13) – brake flange (11)). Then
screw the cap crews (50) into the coil body (1). We recommend to seal the threaded holes with
hylomar.

Take care that the seal rings (81) are also re-fitted. This is necessary to assure the full electrical
operation and sealing effect (IP 66).

Manual emergency release shall not be used to maintain temporary operation!

4.4 Mechanical release by means of hand lever (optional)

By pulling the hand lever (4) at approx. 30° towards the back of the brake the armature disc (10)
is moved axially until it is lying against the coil body (1) thus the friction disc lining (2) may rotate
freely.

Manual emergency release shall not be used to maintain temporary operation!

4.5 Current supplies and electrical connections

Make sure that the electrical connection is performed by expert personnel taking into account
the installation regulations (such as DIN IEC 92).

The coil has been designed for 100% duty factor and connection to D.C. supply only, given on
the identification plate (residual ripple< 0.5).
According to DIN VDE 0580 the permanently admissible voltage change is +5% to –10% of the
nominal voltage.
To protect the coil or the power supply unit it is recommended to connect a varistor of the
corresponding operating A.C. voltage range and with the required power to the rectifier output.

5 Assembly and dismantling

(individual parts with Item-No. see chap. 4.1)

Caution! The brake must only be operated, maintained and repaired by accordingly
authorized, trained and instructed people. Each such person must have read and
understood the complete instruction manual and must have been informed in particular
about possible risks and danger.

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IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

5.1 Assembly

The assembly to the motor is simple, no dismantling of the brake is required.

- Check the connecting dimensions for compatibility with the brake.

- Remove any existing transportation or bearing protections devices, as well as any burr
or impact damage.
- Check face run out of the flange mounting surface relative to the shaft to be braked
(tolerance class N in accordance with DIN 42955 should not be exceeded).
- Slightly grease shaft and fitting key with assembly paste. Mount pinion (15) and secure it
axially.
- Use suitable slings (shackles or equivalent) to move the brake cautiously across the
pinion (15) and turn the shaft or swivel the brake to engage pinion teeth with the mating
teeth of the friction disc (2). (The friction disc is pre-centered during the final acceptance
of the brake).

Caution!

Do not use force! Do not tilt! Pay attention of the cable!

- offer brake onto the motor in the position specified

- tighten the mounting screws (41) to correct bolt tightening torque (as specified on the
drawing)
- To prevent mechanical blocking of the stainless steel screws (41) we recommend to
grease these screws with Klüber paste HEL 46-54
- Make sure that the electrical connection is performed by expert personnel taking into
account the installation regulations (such as DIN IEC 92).

Caution!

When mounting always assure that all seal rings and sealings are properly lying in the
accordingly provided positions (IP 66).

5.2 Mounting accuracy

The concentric run of the shaft piece on which the driving hub (15) is fixed as well as the
coaxiality and the run - out of the fixing flange must comply with tolerance class "N" of DIN
42955.

5.3 Dimensions, space requirement and mass

The binding dimensions, the mass (weight) and the other technical data are stated on the
dimensional drawing which is binding for the pertinent order. This drawing can be inquired at
our after - sales service; address is given in chap. 10.3.

5.4 Dismantling

Dismantling is subject to the same instructions and regulations as installation. Carry out the
operations in inversed order of succession!
Important note!

Check up: The brake must be torque-free on the output side.

Before removing the brake, disconnect it from the mains and secure with slings.

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IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

6 Initial setting into service

(Single parts with item designation as per chap. 4.1)

Before the initial setting into service, the following test measures are necessary:
• As the new friction lining does not yet dispose of optimum friction characteristics, some
electric releases have to be carried - out to smooth the friction face pinpoints.
• The electric connection values on the nameplate (73), see chap. 1.1, must comply with the
values at site
• The brake must be undamaged, i.e. it must not have any damage generated during
transportation, stocking, etc.
• The prescribed service conditions (chap. 7.1) must comply with those ones at site
• Not only the emergency manual release as per chap. 4.3 but also the hand lever emergency
release as per chap. 4.4 or 9.3 must not be active.

7 Operation

Notwithstanding any instructions given below, operation of the brake must

always comply with local mandatory safety and accident prevention rules. Compliance with
these rules shall be ensured by the user.

7.1 Operating conditions

The operating conditions to be maintained for a faultless operation of the brake are given below:

- The operating temperature should not be below –30°C and not above +50°C.

- In the case of higher and/or lower ambient temperatures, please contact our after-sales
service (for address see Chapter 10.3).

- Air humidity may be 100%.

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Electromagnetic Double Face Spring – Applied Brake 01.06.2009

7.2 Protection classes

In completely mounted condition and under consideration of the following hints

assembled, the brake as standard execution (as shown in fig 3) complies with
protection class IP 66, in accordance with DIN 40050 and DIN VDE 0530.
When using original Stromag accessory, such as terminal box, cable glands (see Fig. 1)
the type of protection is maintained. The same applies when the speed encoder is rigidly
connected to the cover by means of a flange gland which is sealed by round ring.
Sealings of through-shafts (by means of shaft seal ring), reduce the type of protection in
relation to the execution. Please consult the manufacturer.

Fig. 3

Important note!

The contact surfaces of the brake to the motor, as well as the surfaces of the
"speedometer connection" option shall be sealed with suitable means (e.g. Hylomar or
sealing ring) to guarantee the protection class.

The user has to provide a sealing element on the shaft in direction to the motor side in
order to prevent the penetration of grease from the motor bearing.

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IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

7.3 Duty cycle, switching frequency

The design as well as admissible loads on brakes as per braking torque, speed,
switching capacity are given under „Technical Data“ (see Chapter 1) and the
dimensional drawing (appendix). If any of these data are exceeded consult the
manufacturer.

7.4 Trouble shooting (individual parts with Item-No. see chapter 4)

Störungen Mögliche Ursachen Erforderliche Maßnahmen

Insufficient braking Friction surfaces are not free from replace friction disc (2)
effect grease
Max. Air gap “off” exceeded due to re-adjust brake (chapter 8.3.), if
wear of friction lining necessary replace friction disc (2)

Let brake run in

Brake not completely run-in
Replace brake
Brake has been overloaded
Dismantling of brake contact
Spring rupture manufacturer

No braking effect Manual release (4) has been See Chapter 4.3
actuated and not re-set
Brake does not release Max. Air gap „off“ too large due to Re-adjust brake (chapter 8.3.) if
wear of friction lining necessary replace friction disc (2)
Replace friction disc (2) and pinion (15)
Friction disc (2) is stuck on pinion (chapter 8.4.)
(15)
Replace brake (chapter 5)
Armature disc (10) distorted
Check DC voltage supply
Coil connecting voltage too low
Replace brake (chapter 5)
Coil defective
Renew feed line
Feed line defective
Re-tighten contact points
Contact points loose
Dismantling of brake, contact
foreign particles in the air gap (e.g. manufacturer
spring rupture)
when micro switch is Armature plate is not being Re-adjust brake (chapter 8.3.) if
used: attracted against the coil body necessary replace friction disc (2)
because of:
No operational switch - max. air gap has been exceeded Check position of micro switch under
indication consideration of adjustment procedure of
- foreign particles in the air gap micro switch

Dismantle and clean the brake

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Electromagnetic Double Face Spring – Applied Brake 01.06.2009

8 Maintenance

8.1 Maintenance and inspection work

Make sure to comply with Chapter 2 "Safety guidelines" during all maintenance and
inspection work.

As the brakes work under varying operating conditions, it is not possible to pre-define wear
check, inspection, maintenance and repair intervals.
Higher loads on the brake (e.g. as a result of torque, speed, switching frequency, ambient
temperature etc.) require shorter maintenance intervals.
Therefore it is first of all necessary to observe the brake with regard to safety and wear, and
then adapt the maintenance intervals in accordance with the observations made.
Wear of the friction lining will result in a greater air gap „off“.
Depending on the load on the brake, the air gap must be checked from time to time. This will be
done by measuring the air gap according to chapter 8.2.
If the max. air gap as determined in chap. 1.1. is reached please readjust the air gap described
in chap.8.3.

Caution!

If wear re-adjustment is not carried out early enough, both the transmission of the rated load
torque and the lifting of the brake will not be ensured.

8.2 Measurement of the air gap

The measurement of the air gap between coil body (1) and armature disc (10) can only be done
when the coil is currentless.
The measurement of the air gap must be taken on two places be opposited 180°. Therefore
remove the two cap screws (65) in the outer body and control with a finger gauge. The air gap
between the armature disc (10) and coil body (1) must be between „off min.“ and „off max.“
described in chap.1.1.
After the measurement the thread hole must be closed with cap screw (65) and sealing ring for
protection of IP 66.

8.3 Wear re-adjustment

When the maximum ‘air gap off’ has been reached in brakes (chap.1.1) a onetime wear re-
adjustment is possible.

Important! Check up: the brake must be torque-free on the output side.

Disconnect the brake from current.

Proceed as follows (fig. 1)

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Electromagnetic Double Face Spring – Applied Brake 01.06.2009

- Remove the mounting screws (41) and (42)

- dismantle the complete coil body assembly with outer body (13) from the brake flange (11)
taking care not to damage armature disc (10)
- remove shim (20) and re-assemble in inversed order coil body assembly and outer body.
- offer brake onto the motor in the position specified
- tighten the mounting screws (41) to correct bolt tightening torque (as specified on the
drawing)

To simplify maintenance works the armature disc (10) may be retained in position by using the
emergency release screws (49). Ensure these are removed before setting into operation.

Note: If the shim (29) has previously been removed, a new friction disc (2), see chap. 8.4.,
together with shim (20) has to be fitted.

Attention: On assembling the brake or replacing the friction disc, care should be taken that the
linings do not come in contact with grease etc. Greasy substances if any, can be removed by
suitable degreasing agents. Never use petrol or paraffin.

8.4 Replacement of the friction disc

Proceed as follows:

Important ! Check up: The brake must be torque-free on the output side.

- Remove the mounting screws (41) and (42)

- dismantle the complete coil body assembly with outer body (13) from the brake flange (11)
taking care not to damage armature disc (10)
- take the friction disc (2) from the pinion (15)
- clean the brake
- push the friction disc (2) onto the toothing of the pinion (15)
- fit the shim (20)
- mount in inversed order coil body assembly (1) and outer body (13)
- offer brake onto the motor in the position specified
- tighten the mounting screws (41) to correct bolt tightening torque (as specified on the
drawing)

To simplify maintenance works the armature disc (10) may be retained in position by using the
emergency release screws (49). Ensure these are removed before setting into operation.

The new friction linings on the friction disc will transmit the full braking torque only
after a certain run-in period.

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9 Variants (optional)

Micro switch to Micro switch for Without terminal box;

Condensation heater monitor switching states wear monitoring 1m flying lead

98
64 X
PG 11

Electrical connection
via terminal block
within terminal box
Options:
rectifier, quick

M
switching unit

L
6
x6
0°
6 0 = 36
° 0°
Ø 85 G7
Ø 100

J
6 x M6, 8 mm thread length

adjustable Brake handle End cover with tacho Emergency hand

brake torque support provision; bore Ø85 G7 release lever
Q

Fig. 4

Brake Size 2 4 6.3 10 16 25 40 63 100 160 250 400 630 1000

M 115.5 128.5 128 125 151 165 179 196 238 260 290 327 364 420
K 179.5 198 201 216 251 276 300 343 408
J 20.9 28 29 29 32 39 40 45 54 Refer to Stromag Dessau
L 95 110 110 123 140 150 170 200 220
X 19 33.75 33.75 38 48 62 83 86 113 125.5 133.5 168 172 182
Q 110 110 110 110 110 150 150 250 500

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Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

9.1 Execution with micro switch

If the switching condition of the brake should be controlled, a micro switch (28) could be used.
When the armature disc (10) is moved against the coil body (1) as a result of the
electromagnetic force of the coil or the actuation of the mechanical emergency release device,
(chap. 4.3), it will operate a micro switch (28) via set screw (64). The micro switch (28) may be
included in the control circuit of the motor contactor as a normally open or normally closed
contact.

The micro switch is preset in our works and should not require adjustment. If
replacement of the micro switch is required this must be done by our agreed procedure
(096-701:181)

9.2 Execution with adjusting ring to reduce the brake torque

The torques given in the technical data

(chap. 1.1.) were obtained only by fully tightening
the adjusting ring (14). By turning the adjusting ring
(14) this changes the pre-load of the cylindrical
pressure springs (21) and the brake torque is
altered accordingly.

The table shown here below indicates the

dimension X and the respective torque rating.

These are approx. figures only

Fig. 5

Brake 100% 90% 80% 70% 60% 50% 40% 30% 20% 10%
size X(mm) X(mm) X(mm) X(mm) X(mm) X(mm) X(mm) X(mm) X(mm) X(mm)
2 0 0.7 1.4 2.1 2.8 3.5 4.2 4.9 5.6 6.3
4 0 1.1 2.2 3.3 4.4 5.5 6.6 7.7 8.8 9.9
6.3 0 0.95 1.9 2.85 3.8 4.75 5.7 6.65 7.6 8.55
10 0 1.3 2.6 3.9 5.2 6.5 7.8 9.1 10.4 11.7
16 0 1.3 2.6 3.9 5.2 6.5 7.8 9.1 10.4 11.7
25 0 0.7 1.4 2.1 2.8 3.5 4.2 4.9 5.6 6.3
40 0 0.55 1.1 1.65 2.2 2.75 3.3 3.85 4.4 4.95
63 0 2.2 4.4 6.6 8.8 11.0 13.2 15.4 17.6 19.8
100 0 1.03 2.06 3.09 4.12 5.15 6.18 7.21 8.24 9.27
160 0 1.05 2.10 3.15 4.20 5.25 6.3 7.35 8.4 9.45

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IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

9.3 Hand lever emergency with self locking

Optionally the brake can be equipped with a self -

locking hand lever release allowing the manual
release in case of emergency, e.g. current failure.
By pulling the hand lever (4) at approx. 30°
towards the back of the brake the armature disc
(10) is moved axially until it is lying against the coil
body (1) thus the friction disc lining may rotate
freely. The handle (4) must be screwed in at this
position to operate the locking mechanism. Please
ensure brake is fully released. Then screwed out to
release.

Please note: the cap screws (50) can be removed

and the emergency release screws can be fitted
(see chapt. 4.3) to release brake (this is
recommended method of brake release).

Fig. 6

Manual emergency release shall not be used to maintain temporary operation!

Please note: this is a Fail Safe Brake and “fails to safety” when there is a power failure.
When locking handles are used this disables the Fail Safe system and we do not
recommend using them.

9.4 Execution with condensation heater

If strong temperature fluctuations are expected, a condensation heater (30) may be used to
prevent the generation of condensation water. A special feed line will be provided accordingly.
In case of questions please contact the manufacturer.

9.5 Speedometer installation

If a speedometer connection is required for the brake, the brake is provided with a tacho flange
(12) with connecting bores in accordance with „Euro dimensions“ (Diameter 85/100).

It is recommended to connect the tachometer or the encoder to the shaft through a plug-type
coupling.

Caution!

The type of protection only maintains when the speed encoder is rigidly connected to the cover
by means of a flange gland which is sealed by round ring.

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Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

10 Spare parts stocking, after-sales service

10.1 Spare parts stocking
Stocking of spare and parts subject to wear is an important precondition for permanent and
reliable functioning of the brake.
Friction disc (2), armature disc (10), brake flange (11) and pinion (15) (for item see Chapter 4.1)
are parts subject to wear.

Warranty will be provided only for the original spare parts supplied by us. We expressly state
that the installation or use of spare parts other than the original ones supplied by us will
negatively affect the design characteristics of the brake and thus have an impact on active
and/or passive safety.
Stromag Dessau GmbH shall have no warranty obligations for any damage caused by the use
of spare parts or accessories other than the original ones supplied by us.
Please bear in mind that often particular manufacturing and delivery specifications exist for
parts manufactured by us or bought from others, and that we offer spare parts to the up-dated
technical conditions and the up-dated legal prescriptions.

10.2 Data for spare parts orders

Please specify the following details when ordering spare parts:

- Series and size of brake
- article code
- Location and designation of spare part (see chapt. 4.1. and fig. 1)
- Number of pieces

10.3 Address of after-sales service

This is our address for after-sales service and spare parts distribution:

Stromag Dessau GmbH

Dessauer Str. 10
D-06844 Dessau-Roßlau

Telefon : +49 (340) 2190-203

Telefax : +49 (340) 2190-201
E-Mail : [email protected]
Internet : http://www.stromag-dessau.de

If you require a service engineer, please contact our "Technical after-sales service" under the
above address.

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Service Instructions NFF Stromag Dessau

IP 66 safety in motion

Electromagnetic Double Face Spring – Applied Brake 01.06.2009

11 Listed standards and regulations

DIN 6885 Sheet 1 Fitting keys

DIN 40050 (VDE 0470) Protection classes
DIN 42948 Fastening flanges for electrical machines
DIN 42955 Concentricity of shaft ends, co-axial and true running of
fastening flanges of rotating electrical machines
DIN IEC 92 Electrical equipment on ships
DIN VDE 0530 Rotating electrical machines
DIN VDE 0580 Regulations for electrical devices
VDE 0660 T 200/09.82, Section 4.2.4, Table 1 - Inductive load
89/336/EEC (EMC) Electromagnetic compatibility
93/68/EEC Low Voltage Directive

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NFF – Service Instruction Stromag Dessau

safety in motion

air gap
Brake size 2 4 6.3 10 16 25 40 63 100 160 250 400 630 1000
Brake torque Nm 20 40 63 100 160 250 400 630 1000 1600 2500 4000 6300 10000
Nom. speed min-1 5300 4900 4500 4100 3800 3500 3200 3000 2800 2200 1900 1600 1400 1200
Moment of Inertia
kgm2 0.0004 0.00043 0.00080 0.00125 0.00340 0.00430 0.01212 0.01463 0.04171 0.14821 0.23515 0.43412 1.0161 1.5610
B side
Weight kg 6.3 10.4 13 14 21 30 40 68 85,5 133 167 278 367 491
Nom. voltage V DC 103 103 103 103 103 103 103 103 103 103 207 207 207 207
Nom. power W 89,9 90,7 113,9 110,4 115,8 136,6 212,9 227,3 277,6 353,5 367 400,9 489,6 535,5
Nom. current A 0,87 0,88 1,11 1,07 1,12 1,37 2,07 2,21 2,70 3,43 357 3,89 4,75 5,2
Air gap norm. mm 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Air gap max. mm 1 1 1.2 1.2 1.2 1.2 1.3 1.5 1.6 1.6 1.8 1.8 1.6 1.6
a mm 150 165 175 190 225 250 270 314 350 440 500 560 650 750
b mm 135 152 162 175 205 225 250 292 325 418 472 530 620 710
c H8 mm 120 140 140 160 180 200 220 240 270 340 390 460 530 600
d max H7 mm 25 30 40 40 45 50 60 60 80 110 120 130 140 160
e mm 53 55 55 65 76 78.5 90 96 100 200 215 240 270 300
f mm 47 80 80 65 80 90 105 120 158 220 255 280 320 330
g mm 19 33,7 33,75 38 48 62 83 86 113 125,5 133,5 168 172 182
h mm 30 33 31 26 29 30 32 32 32 33 33 33 33 33
i mm 73.5 89.6 92.8 95.3 104 121 141 145 168 182.6 191 226 225 265
j mm 20,9 28 29 29 32 39 40 45 54 On request
6 screws k mm M5 M6 M6 M6 M8 M8 M8 M10 M10 M12 M16 M16 M16 M20
l mm 95 110 110 123 140 150 170 200 220 On request
m mm 10.5 7.8 13 14 14 13 14.2 19.5 19 24.4 21.4 26.3 30 30
n mm 2.5 2.5 2.5 3.5 3.5 3.5 4 4 5 5.5 5 5 6 6
p mm 24 28 30 30 35 45 45 55 75 125 130 150 185 210
q mm 110 110 110 110 110 150 150 250 500 On request
r mm 115,5 128,5 128 125 151 165 179 196 238 260 290 327 364 420
s mm 8.5 10.5 10 10 10 10 10 12 10 10 10 10 10 10
t mm 123 140 150 146 168 172 184 230 255 270 280 320 340 380
u mm 179,5 198 201 216 251 276 300 343 408 On request

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C.4 Operating instructions, external fan

C.3 Reader notes for the operating instructions of the external fan

EC external fan from the Ziehl-Abegg company

Ziehl-Abegg EC-external fans are installed in the 1PH8 air-cooled motors. This are especially
designed fan units for this motor series, with a permanently set operating speed.
For shaft heights 180 and 225, EC motors with frame size "B" are used, for shaft height 280
(option) frame size "D" is used.
Terminals GND; 10V; D1; I1; A1 and A2 must not be connected and are therefore equipped
with insulators.

CAUTION
The use in IT systems is not permitted.

CAUTION
The external fan may not be cleaned with a water jet. This results in material damage.

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english

ECblue Basic
EC-fans and motors with highest efciency
Assembly instructions

Software version: D1583...87A, D1680A from Version 1.00

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Content
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Structure of the assembly instructions . . . . . . . . . . . . . . . . . . . . 4
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Explanations of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Requirements placed on the personnel / due diligence . . . . . . . 6
2.6 In the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Working on device / Hazards through “residual voltage” . . . . . . 7
2.8 Modications / interventions in the device . . . . . . . . . . . . . . . . . 8
2.9 Operator’s obligation of diligence . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Employment of external personnel . . . . . . . . . . . . . . . . . . . . . . . 8

3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Application operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Ziehl-Abegg design criteria for long service life . . . . . . . . . . . . . 9
3.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Waste disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Connection lead & terminal box . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Installation of axial fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.1 Fan designs A, D, K, S and W (without nozzles) . . . . . . . . 12
4.3.2 Installation in an exhaust air stack, design T . . . . . . . . . . . 13
4.4 Mounting of centrifugal fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4.1 Mounting of centrifugal fans, RH design . . . . . . . . . . . . . . 15
4.4.2 Erecting the equipment: Design ER...-..N... / ER...-..K... / GR...
16
4.4.3 Optimal installation distances according to for RH../ ER../ GR..
fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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4.5 Mounting of motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.6 Outdoor fans in a humid atmosphere . . . . . . . . . . . . . . . . . . . . . 17
4.7 Motorheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.1 Motor size “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.2 Motor size “D” and “G” . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 EMC-compatible installation of control lines . . . . . . . . . . . . . . . . 21
5.4 Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.1 Line voltage for 1~ types . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.2 Line voltage for 3~ types . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.3 Required quality attributes for the mains voltage . . . . . . . . . 22
5.4.4 Use in IT-System only in special version . . . . . . . . . . . . . . 22
5.5 Residual-current-operated protective device . . . . . . . . . . . . . . . . 22
5.6 Motor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7 Analog input (0...10 V) for setting fan speed . . . . . . . . . . . . . . . 23
5.8 Output voltage +10 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.9 Voltage supply for external devices, only motor sizes “D”, “G”
(+24 V, GND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.10 Enable, device ON / OFF (Digital In 1 = D1) . . . . . . . . . . . . . . . 24
5.11 Relay output (K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.12 Output A1 Status Out OC (motor size “B”) . . . . . . . . . . . . . . . . . 25
5.13 Output A2 Operation Out OC (motor size “B”) . . . . . . . . . . . . . . 25
5.14 Potential at control voltage connections . . . . . . . . . . . . . . . . . . . 25
5.15 Add-on modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 27

7 Diagnostics / Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Status Out with ash code . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Behaviour in rotation by air current in reverse direction . . . . . . . 31

8 Service work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Repairs / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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9 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.3 EC Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.5 Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.6 Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Assembly instructions ECblue Basic General notes

1 General notes
1.1 Structure of the assembly instructions
Before installation and start-up, read this assembly instructions carefully to en-
sure correct use!
We emphasize that these assembly instructions apply to specic units only, and
are in no way valid for the complete system!
Use these assembly instructions to work safely with and on the device. They contain
safety instructions that must be complied with as well as information that is required for
failure-free operation of the device.
Keep these assembly instructions together with the device. It must be ensured that all
persons that are to work on the device can refer to the assembly instructions at any time.
Keep the assembly instructions for continued use. They must be passed-on to all
successive owners, users and nal customers.

1.2 Target group

The assembly instructions address persons entrusted with planning, installation, com-
missioning and maintenance and servicing and who have the corresponding qualica-
tions and skills for their job.

1.3 Exclusion of liability

Concurrence between the contents of these assembly instructions and the described
hardware and software in the device has been examined. It is still possible that non-
compliances exist; no guarantee is assumed for complete conformity. To allow for future
developments, construction methods and technical data given are subject to alteration.
We do not accept any liability for possible errors or omissions in the information con-
tained in data, illustrations or drawings provided.
Ziehl-Abegg AG is not liable for damage due to misuse, incorrect use, improper use or
as a consequence of unauthorized repairs or modications.

1.4 Copyright
These assembly instructions contain copyright protected information. The assembly
instructions may be neither completely nor partially photocopied, reproduced, translated
or put on data medium without previous explicit consent from Ziehl-Abegg AG. Infringe-
ments are liable for damages. All rights reserved, including those that arise through
patent issue or registration on a utility model.

2 Safety information
This chapter contains instructions to prevent personal injury and property damage.
These instructions do not lay claim to completeness. In case of questions and problems,
please consult our company technicians.

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Assembly instructions ECblue Basic Safety information

2.1 Intended use

Attention!
• The fans are only intended for the conveyance of air or mixtures similar to
air.
• Other uses which do not coincide with, or which exceed those specied will
be deemed unauthorised unless contractually agreed. Damages resulting
from such unauthorised uses will not be the liability of the manufacturer.
The user will assume sole liability.
• They must not be used in hazardous areas for the transfer of gas, mist
vapours or mixtures. Nor must they be used for the transfer of solid compo-
nents in the transfer medium.
• Reading these document and complying with all contained instructions -especially
the safety notications contained therein -are considered part of intended use.
• To consider is also the documentation of attached components.

2.2 Improper use

Improper use / reasonably foreseeable misuse
• Conveyance of aggressive and explosive gaseous media.
• Use in an explosive atmosphere.
• Operation with iced up fan impeller.
• Conveyance of abrasive or adhesive media.
• Conveyance of liquid media.
• Use of the fan and add-on parts (e.g. safety grille) as a resting surface or climbing
aid.
• Unauthorised constructional modications to the fan.
• Operation of the fan as a safety component or for the performance of safety-
relevant functions in the sense of DIN EN ISO 13849-1.
• Blocking or braking of the fan by inserting objects.
• Loosening of the impeller from the motor.
• All applications not listed in the intended use.
Not the manufacturer, rather the operator of the frequency inverter is liable for any
personal harm or material damage arising from non-intended use.

2.3 Explanations of symbols

Safety instructions are highlighted with warning triangles and are depicted according to
the degree of hazard as follows.
Attention!
Hazardous area. Death or severe injury or signicant property damage can occur if
the corresponding precautions are not taken!

Danger owing to electric current

Danger owing to electric current or voltage.

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Information
Important information and advice for user.

2.4 Product safety

The device conforms to the state of the art at the time of delivery and is fundamentally
considered to be reliable. The device and its accessories must only be used in a awless
condition and installed and operated in compliance with the assembly instructions and/or
operating instructions. Operating outside the device's technical specications (F rating
plate and attachment / technical data) can lead to a defect in the device and additional
damage!
A separate fault and performance monitoring-system with an alarm signal function
is necessary in order to prevent personal injuries and material damages during
malfunctions and in case the device fails. Substitute operation must be taken into
consideration! The design and installation of the system must comply with local
regulations and directives.

2.5 Requirements placed on the personnel / due diligence

Persons entrusted with the planning, installation, commissioning and maintenance and
servicing in connection with the frequency inverter must have the corresponding qual-
ications and skills for these jobs.
In addition, they must be knowledgeable about the safety regulations, EU directives,
rules for the prevention of accidents and the corresponding national as well as regional
and in-house regulations. Personnel to be trained or instructed and apprentices are only
permitted to work on the device under the supervision of an experienced person. This
also applies to personnel undergoing general training. Comply with the legal minimum
age.
This device is not intended to be used by people (including children) who have restricted
mental, sensory or intellectual abilities or who have a lack of experience and/or knowl-
edge.

2.6 In the Operation

Danger owing to electric current
• Any faults detected in the electric system/modules/operating equipment must be
corrected immediately. If these faults are not corrected, the device/system is
potentially very dangerous. The device/system must therefore not be operated
when it is faulty.
• Fuses must always be replaced only, never repaired or bridged. The specications
for maximum prefusing must always be adhered to (F Technical data). Only fuses
cited in the electrical circuit diagram may be used.

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Attention, danger of being sucked in!

• Danger of being sucked in: Do not wear loose or hanging clothing, long hair,
jewellery, etc.

2.7 Working on device / Hazards through “residual voltage”

Information
Mounting, electrical connection, and start-up operation may only be carried out by
an electrical specialist in accordance with electrotechnical regulations (e.g. DIN
EN 50110 or DIN EN 60204)!

Danger owing to electric current

• It is forbidden to carry out work on electrically live parts. Protection class of
the device when open is IP 00! It is possible to inadventently touch compo-
nents carrying hazardous voltages.
• The rotor is not protected by insulation nor grounded to earth in accordance
with DIN EN 60204-1, and for this reason the system constructor must
provide protection by casing in accordance with DIN VDE 0100-410, before
the motor is connected to a power source. This protection can be achieved
for example by a protection grating (F Product overview: Application opera-
tional area and Installation: General).
• When the motor runs independently due to air owing through or if it
continues to run down after being turned off, dangerous voltages of over
50 V can arise on the motor internal connections through operation of the
generator.
• The safe isolation from the supply must be checked using a two-pole voltage
detector.
• Even after disconnecting the mains voltage, life-threatening charges can appear
between the protective earth “PE” and the mains connection.
• The protective earth is routed over high discharge currents (irrespective of the
clock frequency, current-source voltage and motor capacity). Earthing in
compliance with VDE specications shall therefore be observed even for testing
and trial conditions (EN 50 178, Art. 5.2.11). Without earthing, dangerous voltages
can be present on the motor housing.
• Maintenance work may only be carried out by suitably qualied personnel.
Waiting period at least 3 minutes!
Through use of capacitors, danger of death exists even after switching off the
device through directly touching the energized parts or due to parts that have
become energized due to faults.
The controller housing may only be removed or opened when the power line has
been switched off and a period of three minutes has elapsed since switching it off.

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Assembly instructions ECblue Basic Safety information

Attention, automatic restart!

• The fan / motor may switch on and off automatically for functional reasons.
• After power failure or mains disconnection an automatic restart of the fan takes
place after voltage return!
• Wait for the fan to come to a complete standstill before approaching it!
• In the AC external rotor motor the external rotor turns during operation!
Attention, hot surface!
• Temperatures of above 85 °C can occur on the motor surfaces, especially on the
controller housing!

2.8 Modications / interventions in the device

Attention!
For reasons of safety, no unauthorized interventions or modications may be made on
the device. All planned modications must be authorized by the manufacturer in writing.

Use only genuine spare parts / genuine wearing parts / genuine accessories from Ziehl-
Abegg.These parts were specically designed for the device. There is no guarantee that
parts from non-original sources are designed and manufactured in correspondence with
load and safety requirements.
Parts and optional equipment not supplied by Ziehl-Abegg are not approved by Ziehl-
Abegg for use.

2.9 Operator’s obligation of diligence

• The contractor or owner must also ensure that the electric systems and equipment
are operated and maintained in accordance with electro-technical regulations.
• The owner is obliged to ensure that the device are operated in perfect working
order only.
• The device may only be used as intended (F “Application”).
• You must periodically examine the safety equipment for their properly functioning
condition.
• The assembly instructions and/or operating instructions are always readily avail-
able at the location where the device is being used, are complete and are in
legible condition.
• These persons are regularly instructed in all applicable questions regarding occu-
pational safety and environmental protection and are knowledgeable regarding
the assembly instructions and/or operating instructions and, especially, are famil-
iar with the safety instructions contained therein.
• All safety and warning notices attached to the frequency inverter are never
removed and remain legible.

2.10 Employment of external personnel

Maintenance and service work are frequently carried out by external employees who
often do not recognize the specic situations and the thus resulting dangers.These
persons must be comprehensively informed about the hazards in their area of activity.

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Assembly instructions ECblue Basic Product overview

You must monitor their working methods in order to intervene in good time if necessary.

3 Product overview
3.1 Application operational area
The fans / motors are not ready-for-use products, but conceived as components for
ventilation systems (type designation Ftype label). The fans may only then be operated
when they are installed in accordance with their intended use, and safety has been
secured through protective devices in accordance with DIN EN ISO 13857 (DIN EN ISO
12100) or other structural protective measures.

Information
This assembly instructions describes the combination of motor and controller. Dependent
on application and version of the fan absolutely the resuming specications are to be
considered!

3.2 Functional description

ECblue stands for EC fans and motors with maximum efciency. Highly efcient, elec-
tronically commutated motors with permanent magnets are used the speed of which is
controlled by the integrated controller.
The devices are constructed in accordance with the general requirement in DIN EN
61800-2 for adjustable speed electrical power systems and is intended for one-quadrant
drives.
ECblue fans and motors in different models and sizes are described in this assembly
manual. Connection, structure and technical details depend partly on the motor size.
The three used motor sizes (B = 096, D = 116, G = 152) are recognisable from the type
designation.

Motors Type Example for fans with motor size “B”

MK096 -_ I _ . _ _ . _ _ Axial fans type: Centrifugal fans type:
MK116 -_ I _ . _ _ . _ _ • F _ _ _ _-_ I _. B _._ _ _ • RH _ _ _-_ I _. B _._ _
MK152 -_ I _ . _ _ . _ _ _ • GR _ _ _-_ I _. B _._ _
• ER _ _ _-_ I _. B _._ _

3.3 Ziehl-Abegg design criteria for long service life

The service life of devices with power electronics is decisively dependent on the ambient
temperatures. The longer electronic components are exposed to high ambient temper-
atures, the faster the deterioration and the more probable the failures.
The device is designed with a service life amounting to at least 40.000 h when S1
operated at full power in the maximum permissible ambient-temperature environ-
ment.
In order to achieve this, the device protects itself by active temperature management.

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Assembly instructions ECblue Basic Product overview

3.4 Transport
Attention!
• Ziehl-Abegg fans and motors are packed in the factory in accordance with the
respective, agreed, form of transportation.
• Always observe the weight specications and the permissible carrying loads of
the means of transport.
• Transport the fan(s) either in their original packing or larger fans on the transport
devices provided (axial fans: holes drilled in support arms, wall ring plates and
motor block ; radial fans: holes drilled in the motor block, fastening brackets and
support plates) with suitable means of transport. Observe the weight specica-
tions on the rating plate.
• Wear safety shoes and gloves for handling!
• Do not transport the fan by the connecting cable!
• Avoid shocks and impacts to the device during the transport.
• Avoid extreme heat or cold (temperature range for storage and transportF Techni-
cal data).
• Be on the alert for any damage to the packaging or the fan.
• Radial impellers or built-in fans type ER../GR.. are generally delivered on euro-
pallets, and can be transported using lift trucks.
• Fix pallets during transport.
• Do not stack pallets.
• Only handle with suitable hoisting gear.
• Construction ER../ GR..: Fan unit may only be lifted and transported when using
a suitable hoisting device (load spreader). Ensure sufcient cable or chain length.
• Position the lifting beam transversely to the motor axis. Pay attention to adequate
width of the lifting beam.
• Never stand underneath the suspended fan because defective transport
equipment could cause death.

3.5 Storage
• Store the fan / motor in the original packaging in a dry area protected from the
weather and protect it from dirt and weather until nal installation.
• Do not stack pallets!
• Avoid extreme heat or cold (temperature range for storage and transportF Techni-
cal data).
• Inspect the motor bearings for proper operation prior to installation.
• Avoid prolonged storage; we recommend a maximum of one year (consult the
manufacturer before starting if stored for longer).

3.6 Waste disposal / recycling

Disposal must be carried out professionally and environmentally friendly in accordance
with the legal stipulations.

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Assembly instructions ECblue Basic Mounting

4 Mounting
4.1 General notes
Attention!
• Installation are only to be performed by trained service personnel. The system
manufacturer or the machine builder and/or the user is responsible that the
inherent installation and security information are harmonized with the valid stand-
ard and guidelines (DIN EN ISO 12100 / 13857).
• Lift the fan out of the packing with a hoisting unit (lifting beam). Only use the holes
in the motor block and the fastening brackets of the fan and the hook or fastening
bracket (depending on the design of the fan) as attachment points.
• The chain/rope may not touch the fan wheel when lifting with the lifting beam.
Other damage is possible.
• Check the fan for damage, e.g. transport damage, cracks or dents or damage to
the electric cables, before assembly.
• At a weight greater than 25 kg for men / 10 kg for women, the fan should be lifted
out by two persons (according to REFA). The values may differ from country to
country.
• Do not allow drilling chips, screws and other foreign bodies to reach the device
interior!
• Prior to installing the fan, it is to be checked whether the safety zone as per DIN
EN ISO 13857 and in household appliances as per DIN EN 60335 are met. If the
installation height (danger zone) above the reference level is greater than or equal
to 2700 mm and is not reduced by auxiliary means such as chairs, ladders, work
platforms or bases on vehicles, a protection grating against accidental contact is
not necessary at the fan.
• If the fan is located in danger zone, then the manufacturer or operator shall ensure
that hazards shall be prevented by appropriare protective constuctions which
meet the requirements to DIN EN ISO 13857.
• Custom designs must suit the prevailing conditions.
• Tighten the fastenings with the specied torques.
• Any use below -10 °C is dependent on not being subjected to unusual, sudden or
mechanical loads or stresses on the material (min. ambient temperature F Tech-
nical data).

4.2 Connection lead & terminal box

Information
In demanding environments (wet areas, open air installation) all connections must
incorporate water drainage curves. To ensure that water cannot penetrate through to the
controller housing from the connections install a terminal box lower than ventilator.

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4.3 Installation of axial fans

4.3.1 Fan designs A, D, K, S and W (without nozzles)

For attachment to xed motor ange use screws with property class 8.8 or A2-70
(stainless steel) to DIN EN ISO 4014 and provide with suitable screw locking.

Permissible tightening torques MA

Motor size B D D G
M6
Thread size M6 (Special application M8 M10
with 5-pitch)
Property class 8.8, friction coefcient 9 Nm 9.5 Nm 23 Nm 40 Nm
µges = 0.12
Stainless steel A2-70, friction coef-
7 Nm 7 Nm 17 Nm 33 Nm
cient µges = 0.12
Screw penetration ≥ 1.07 x d ≥ 1.5 x d ≥ 1.5 x d ≥ 1.5 x d

When using screws with different friction values or strength classes, different tightening
torques may be necessary.

Information
• Pay attention to a sufcient screw-in length in the motor ange.
• Motor size B: Excess screw length of max. 3 mm is permissible.
• Motor size “D” + “G”: Excess screw length not permissible and it may result in the
rotor being brushed against or blocked.
• Every screwing case is different. The tightening torque adapted to it must be
determined by the appropriate screw tests.
• Avoid structural damage or stress with installation. Make sure the surface is at
and even.
• In the case of a vertical motor axis, the respective lower condensation drain hole
must be open.
• Fasten the fan connecting cable using cable ties to the guard grille or motor
braces.
A minimum head gap “A” of 2 mm in all installation
positions but especially in installation position H (hor-
izontal motor shaft) is necessary. Distortion due to
uneven surface may lead to fan failure due to brush-
ing against the fan wheel.

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4.3.2 Installation in an exhaust air stack, design T

Mark the mounting bracket (4) in accordance with g. 1

in the chimney (3) using a 4x90° template, drill hole
center distance “a” in accordance with the mounting
bracket (4).

gure 1

Adjustable diameter area

Fan size
min. max.
F_063 640 660
F_071 725 745
F_080 815 835
F_091 915 935

Tighten the mounting bracket (4) and the support bracket (5) g. 2 with screws (6) only
so far that the mounting bracket and support bracket do not dig into the chimney wall (3).
Self-locking nuts (7) are used for securing the screws. The enclosed protective caps (8)
are to be pushed onto the ends of the fan supports (1), g. 2.

4 9/10 1 8 1

5
7
6

3
ai_kl_1905_1

gure 2

gure 3

Feed the fan (1) into the chimney in accordance with g. 3, and center it in the mounting
bracket (4). In addition, the support is to be secured in accordance with g. 2 by using
bolts (9/10).

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The four support clamps (5) are used as support eyelets for additional xings (e.g. by
standing ropes) in order to relieve the chimney of the weight of greater fans.

Installation set (Part.-No. 00291545)

Pos. Naming Each

1 Axial fan -
3 Chimney -
4 Mounting bracket 4
5 Support bracket 4
6 M8x70 screws DIN EN ISO 4014 8
7 M8 nuts DIN EN ISO 10511 self-locking 8
7a 8.4 washer DIN EN ISO 7089 8
8 Protective cap 4
9 M8x30 screws DIN EN ISO 4017 4
10 M8 nuts DIN EN ISO 10 511 self-locking 4
10a 8.4 washer DIN EN ISO 7089 4

All fastening elements made of stainless steel

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4.4 Mounting of centrifugal fans

4.4.1 Mounting of centrifugal fans, RH design

For attachment to xed motor ange use screws with property class 8.8 to DIN EN ISO
4014 and provide with suitable screw locking.

Permissible tightening torques MA

Motor size B D D G
M6
Thread size M6 (Special application M8 M10
with 5-pitch)
Property class 8.8, friction coefcient 9 Nm 9.5 Nm 23 Nm 40 Nm
µges = 0.12
Screw penetration ≥ 1.07 x d ≥ 1.5 x d ≥ 1.5 x d ≥ 1.5 x d

When using screws with different friction values or strength classes, different tightening
torques may be necessary.

Information
• Pay attention to a sufcient screw-in length in the motor ange.
• Motor size B: Excess screw length of max. 3 mm is permissible.
• Motor size “D” + “G”: Excess screw length not permissible and it may result in the
rotor being brushed against or blocked.
• Every screwing case is different. The tightening torque adapted to it must be
determined by the appropriate screw tests.
• Avoid structural damage or stress with installation. Flange and mounting bracket
must be xed at on a level surface.
• In the case of a vertical motor axis, the respective lower condensation drain hole
must be open.
• The fan must be securely mounted, with vibration dampers if necessary.

Ensure that the clearance (gap) “a” see g. be-

tween the fan impeller and the stationary housing
section is constant. Distortion due to uneven sur-
face may lead to fan failure.

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4.4.2 Erecting the equipment: Design ER...-..N... / ER...-..K... / GR...

• To avoid the transference of disruptive vibrations, we recommend de-coupling the
entire plug fan to avoid sounds transmitted through solids. (Spring and/or attenu-
ation units are not a constituent part of the standard scope of delivery). Look at
our catalogue for positioning the decoupling elements or request a dimensions
sheet stating the type designation and Part.-No.
• Attention: All contact points must be xed securely. If the xing is inad-
equate there is a risk of the fan overturning.
• Erect in the open air only if this is expressly mentioned and conrmed in the
ordering information. There is a risk of damage to the bearings if the fan remains
stopped in a moist environment. Avoid corrosion by suitable protective measures.
Roong is required.
• Making your own alterations/conversions on the fan module is unacceptable -
safety risk.
• In the case of a vertical motor axis, the respective lower condensation drain hole
(if available) must be open.

4.4.3 Optimal installation distances according to for RH../ ER../ GR.. fans

• Distance on suction side: LA ≥ 0.5 x DSa*

• Distance on the pressure side: LD ≥ 1 x DSa
• Impeller blade external-diameter : Ø DSa
• Housing wall distances: A = 1.8 x DSa (A = B)
* In the case of disturbance ow (per example curved pipe at the suction side, aps etc.)
LA ≥ 1 x DSa

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4.5 Mounting of motors

EC-motors design MK
Fastening to xed motor angeF assembly of axial fans / fans of design A, D .. and
assembly of radial fans of design RH
• If the motor is used to drive fan impellers or other components, please note the
maximum permissible speeds of the impeller or the component to be driven.
• The max. permissible mass of the impeller ort he component to be driven must be
inquired from and conrmed in writing by Ziehl-Abegg.

Design K (with rotor ange) or D (with offset rotor ange) as a drive for fans:
• During assembly of the fan impellers or other components, no inadmissible force
may be applied to the motor bearing.
• Centre the fan impeller accurately and mount without tension on the rotor ange,
the fan wheel must lie at.
• Use suitable screws for fastening the fan impeller on the rotor ange and t as
suitable screw lock.
• Every screwing case must be tested for suitability.
• The permissible area pressing of the rotor ange may never be exceeded (de-
pending on the contact surface).
• Too great a screw overhang is not permitted and can lead to scraping or blocking
of the rotor on the xed motor ange.
• Motors are not balanced as standard, a complete balancing with mounted fan
impeller is necessary. The balancing must be done on the fan impeller. The
pertinent regulations must be observed.

Permissible tightening torques MA

Motor size B D G
Thread size M6 M6 M8
Property class 8.8, friction coefcient µges = 0.12 9.5 Nm 9.5 Nm 23 Nm
Screw penetration ≥ 0.83 x d ≥ 0.83 x d ≥ 0.83 x d
Max. permissible screw overhang 3.0 mm 1.0 mm 1.5 mm

4.6 Outdoor fans in a humid atmosphere

Information
If a fan is stationary for long periods in a humid atmosphere, it should be switched
ON for minimum of two hours every month to remove any moisture that may have
condensed within the motor.

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4.7 Motorheating
To prevent a stationary ventilator in a cold environment from jamming or freezing, the
Motorheating becomes automatically active at a controller interior temperature of -19 °C.

5 Electrical installation
5.1 Safety precautions
Danger owing to electric current
• Work on electric components may only be carried out by trained electricians
or by persons instructed in electricity under the supervision of an electrician
in accordance with electrical engineering regulations.
• The 5 electrical safety rules must be observed!
• It is forbidden to carry out work on electrically live parts. Even after discon-
nection, the dc-link is still live. Always wait at least 3 minutes.
• A second person must always be present when working on energized parts
or lines who disconnects in case of emergency.
• Connect fan only to electrical circuits that can be disconnected with an all-
pole isolating switch.
• The device owner is responsible for the EMC of the entire plant according to
the locally applicable standards.
• Inspect electrical equipment periodically: retighten loose connections –
immediately replace damaged lines and cables.

5.2 Connection
Information
The respective connections are represented in the enclosure of this assembly
instructions (F Connection diagram)!

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5.2.1 Motor size “B”

Fans with cable connection (type: _ _ _ _ _-_ I _. B _._ _ _ _)

17.11.2009
v_anschl_ecblue_096.vsd

0.6 m

0.6 m

RD = 10 V DC Out

GN = D1 Digital In

BU = GND

GY = A2 Status Out OC

YE = E1 Analog In

WH = A1 Tacho Out OC
2

1
GNYE = PE

BU = N

BN = L1

WH = 11

WH = 14

1 Connection line and relay: light plastic-sheathed cable 18 AWG (length ca. 0.6 m)
2 Connection control: light plastic-sheathed cable 22 AWG (length ca 0.6 m)
3 Connection cover

Information
An exchange of the motor / fan should always take place with the connection leads!
The connection cover may not be opened!

• The leads in this illustration are assigned to terminal designations with reference
to their function. Some of these are used in the following chapters.
• Extension through separate connecting box for each connecting line only.
• Connecting boxes and connectors are not included in the package contents.

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5.2.2 Motor size “D” and “G”

Fans with connection box (type: _ _ _ _ _-_ I _. D _._ _ _ _), (type: F _ _ _ _-_ I _. G _._
_ _ _)

1 Cover of controller housing

2 Cable glands + seal insert for two cables (applicable only if necessary)
- motor size “D”: 3 x M16 + 1 x seal insert with two holes 5 mm
- motor size “G”: 3 x M20 + 1 x seal insert with two holes 6 mm
3 Cable entry points with plastic fastener
4 Mains connection
5 Connection alarm relay
6 Connection contols
7 Slot for add-on module

Procedure:
1. Remove the cover from the controller housing for the connection.
2. All 3 cable entry points are in a sealed condition at delivery. Remove plastic
fastener if necessary, and insert enclosed cable glands, entry points that are not
used must remain sealed!
3. When using the seal insert for two cables it is not permissible to use the corre-
sponding cable gland with only one cable.
4. Insert and connect lines correctly.
5. Attach cover of controller housing again carefully in correct position before start-
up.

Attention!
• Temperatures up to 85 °C can be present on the controller housing.
• To connect, always use heat resistant wires or, as an alternative, silicon tubes.
• Remants from installation und foreign object may not remain on the inside!

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Permissible tightening torques MA

Thread size Tightening tor- Remark

que MA
Cable gland M16 2.5 Nm Sealing area for cable diameter 4…10 mm
Cable gland M20 4 Nm Sealing area for cable diameter 6…12 mm
Locking screw M16 + M20 1.25 Nm Phillips screwdriver
Locking screw M16 + M20 2.5 Nm Flat screwdriver
Cover of controller
housing M4 2.3 Nm
Protective earth con-
nection M4 2.5 Nm
Add-on modul M4 1.3 Nm

Max. cross section of terminals

Mains connection: L1, N and/ or L1, L2, L3 max. 2.5 mm2 and/or AWG12
Connection control: +24 V, +10 V, GND, D1, E1, K1 max. 1.5 mm2 and/or AWG16
Add-on modules: 1.5 mm2 (0.75 mm2 with wire end sleeve)
and/or AWG16

5.3 EMC-compatible installation of control lines

Pay attention to sufcient distance from powerlines and motor wires to prevent interfer-
ences. The control cable may not be longer than 30 m. Screened control cables must be
used when the cable length is longer than 20 m. When using a shielded cable connect
the shielding to one side only, i.e. only to the device with the protective earth (keep cable
short and with as little inductance as possible!).

5.4 Mains connection

5.4.1 Line voltage for 1~ types

Mains connection: PE, L1, and N. Here, it must be strictly observed that the mains
voltage lies within the allowable tolerance specications (F technical data).

Alternatively a supply of DC voltage is possible (F Technical data).

The polarities on “L1” and “N” are irrelevant.

5.4.2 Line voltage for 3~ types

Mains connection: PE, L1, L2 and L3. Here, it must be strictly observed that the mains
voltage lies within the allowable tolerance specications (F technical data).

Alternatively a supply of DC voltage is possible (F Technical data).

Connect to any two terminal clips for “L1”, “L2” and “L3”, the polarity is irrelevant.

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5.4.3 Required quality attributes for the mains voltage

Danger owing to electric current
The mains voltage must comply with the DIN EN 50160 quality characteristics and
the dened standard voltages in IEC 60038!

5.4.4 Use in IT-System only in special version

Information
Employment in the IT-System only in special version “IT” possible.
In the IT-System the neutral point of voltage supply is not grounded; in the case of
a short-circuit between a phase (e.g. “L1”) and protective earth “PE” becomes the
protective earth potential = L1.

In order to ensure a trouble free operation in IT-System the “GND” potential of the
control ports have to be connected with the protective earth potential.
As consequence of the connection between “GND” potential of the control ports
with protective earth potential, the following must be considered (exception oat-
ing relay contacts):
1. connection only with wires, suitable for mains voltage and surrounding area.
2. connection with suitable isolated ampliers only.

5.5 Residual-current-operated protective device

For 1 ~ fan types

Residual current circuit breaker (type A)

To ensure as high a degree of reliability as possible we recommend a release current of 300
mA, where a residual current circuit breaker (type A) is used.

Danger owing to electric current

Exception: Mains connection between two phase conductors for supply networks 3 ~
230 V
For an installation of r.c.d. protection, it shall be observed that this must be of “universal-
current sensitivity”. In accordance with EN 50 178, Section. 5.2. other types of current-
operated protective devices may not be used.

For 3 ~ fan types

Residual current circuit breaker (type B)

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Danger owing to electric current

For an installation of r.c.d. protection, it shall be observed that this must be of
“universal-current sensitivity”. In accordance with EN 50 178, Section. 5.2. other
types of current-operated protective devices may not be used. To ensure as high a
degree of reliability as possible , we recommend a tripping current of 300 mA.

5.6 Motor protection

Integrated overload protection, preceding motor protection device unnecessary (max.
prefusing FTechnical details).

5.7 Analog input (0...10 V) for setting fan speed

The unit has an analog input 0...10 V for setting fan speed.
Connection “GW E1 Viive” / “GND” (Analog In 1).
Alternatively speed setting with a PWM-signal is possible.

Attention!
Ensure correct polarity!
Never apply line voltage to analog inputs!

Possibilities for speed setting

• Control via external setting signal 0...10 V
GND E1 • By external wiring with a resistor (499 Ω / 0,25 W) between the
terminals “E1” and “GND” parallel to the input signal, activation
+ with a 0...20 mA signal is possible.
0...10 V • The “AM-Modbus” communication module enables a inverted
set-point signals to be programmed (10...0 V).

10V GND E1

• Speed setting by 10 kΩ potentiometer at terminals “+10 V” and

“GND” pick-off at terminals “E1”.
10 kΩ

24V 10V GND E1

E1
10 V

GND

10 kΩ

PWM
• Control by external setting signal PWM (connection “24 V” only
E1
24 V

f = 1...10 kHz for motor sizes “D” and “G” available).

E1
GND

- +

15...28 V

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Diagram Setting signal and fan speed (Idealized principle diagram)
nM

100 %

Si
0 1 2 3 4 5 6 7 8 9 10 0 – 10 V
0 10 20 30 40 50 60 70 80 90 100 0 – 100 % PWM

20.04.2009
v_nmotor@0_10v_pwm.vsd

nM Fan speed
Si Speed setting signal 0...10 V / 0...100 % PWM

5.8 Output voltage +10 V

Voltage supply e.g. for speed setting by external potentiometer.
Connection: “DC Out” - “GND” (Imax 10 mA).
It is not permissible to connect outputs of several devices to each other!

5.9 Voltage supply for external devices, only motor sizes “D”, “G”
(+24 V, GND)
Integrated voltage supply for external devices. Terminals “+ 24 V”(FTechnical data).
It is not permissible to connect outputs of several devices to each other!
During an overload or short-circuit (24 V - GND), the control voltage (and thus the device)
is disconnected . Automatic start after elimination of the cause of error.

5.10 Enable, device ON / OFF (Digital In 1 = D1)

Electronic ON / OFF control via oating contact at terminals “D1” - “+24V” /
“+10V”
• Device “ON” for closed contact.
• Device “OFF” with opened contact.
Relay “K1” remains energized, connections 11 - 14 bridged.
Status Out with ash code: |1 | (F Diagnostics / Faults).

Attention!
• No disconnection (isolation) when turned off by remote, in accordance with
VBG4 §6)!
• Never apply line voltage to the digital input!
• It is not permissible to connect inputs of several devices to each other!

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5.11 Relay output (K1)

An external fault indicator is available over the potential-free contact of the built-in relay
(max. contact rating FTechnical data and connection diagram).
For operation the relay is energized, connections “11” and “14” are bridged. For fault the
relay is de-energized (FDiagnostics / faults).
When switching off via enable (D1 = Digital In 1), the relay remains energized.

5.12 Output A1 Status Out OC (motor size “B”)

Depending on the operating state of the device, the output “A1 Status Out OC” is

Out OC
DC Out
switched to GND potential for a certain number of pulses until there is a longer

Status
pause.
The status of the device can be displayed by this digitally coded signal. 10V A1

With the output voltage “+10 V” a standard LED / low-power LED can be
controlled by using a pull-up resistor. Pull Up
This lights when the output “A1 Status Out OC” (OC = Open-Collector) is on GND
potential.
The details of which pull-up resistor needs to be used depend on the specication 09.02.2011
v_ecblue_096_status_oc

on the LED that is used.

Explanation of ash codes F Diagnostic / faults: Status Out with ash code.

5.13 Output A2 Operation Out OC (motor size “B”)

Via the output “A2 Operation Out OC” an operating message is possible in motor

Operation
size “B”.

Out OC
With the output voltage “+10 V” a standard LED / low-power LED can be DC Out

controlled by using a pull-up resistor. 10V A2

This lights when the output “A2 Operation Out OC” (OC = Open-Collector) is on
GND potential. Pull Up

In operation without faults the output “A2” is switched to GND potential (also
when switched off by the enable at “D1 Digital In 1”).
The details of which pull-up resistor needs to be used depend on the specication 09.02.2011
v_ecblue_096_operation_oc

on the LED that is used.

5.14 Potential at control voltage connections

The control voltage connections (< 50 V) relate to the joint GND potential (Exception:
Relay contacts are potential free). There is a potential separation between the control
voltage connections and the protective earth. It must be ensured that the maximum
external voltage at the control voltage connections cannot exceed 50V (between “GND”
terminals and “PE” protective earth). If necessary, a connection to the protective earth
potential can be established, install bridge between “GND” terminal and the “PE” con-
nection (terminal for screening).

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5.15 Add-on modules

The assembly instructions and/or operating instructions available here describe the
“Basic Version”.
If required, an auxiliary module can be retrotted to the designated slot for motor size
“D”, “G”. The auxiliary module is installed automatically. Manual installation or parameter-
isation is not required!
For fans of motor size “B” separate versions with integrated add-on modules are
available.
The extended scope of function is specied in the documentation for the auxiliary
module.
The range of additional modules is constantly being extended and adapted to market
requirements. The currently available additional modules can be requested from Ziehl-
Abegg.

Examples for currently available additional modules

Type Part.-No. Function

AM-MODBUS 349045 Communication module
(for motor size “D” Over the “AM-MODBUS” module can be communicated with
and “G”) the controller of the fan. The module can be put in temporarily
for programming of desired functions during start-up or for
diagnostics. The connection to the control terminal is made by
a connecting cable or wirelessly by means of radio.
The module is left in the slot if it is to be integrated into a
module bus system or networked to several devices. The
addressing of ECblue fans takes place automatically, i.e. it is
not necessary to manually enter individual network addresses
for each fan.
AM-PREMIUM 349046 Premium Module
(for motor size “D” When the “AM-PREMIUM” is plugged in the controller in the
and “G”) fan is extended to become a full-grade multipurpose controller.
The “Premium module” provides not only an integrated module
bus interface, it also enables sensors to be connected straight
to the fan.
The module also comes with two analogue inputs and one
analogue output.

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Assembly instructions ECblue Basic Start-up

6 Start-up
6.1 Prerequisites for commissioning
During commissioning, unexpected and hazardous conditions can arise in the entire
installation due to defective adjustments, defective components or incorrect electrical
connections. Remove all persons and objects from the hazardous area.

Attention!
• Before rst-time start-up, check the following:
1. Installation and electrical connection have been properly completed?
2. Has any leftover installation material and other foreign material been removed
from the fan area?
3. That safety devices -if necessary- are mounted (EN ISO 13857)?
4. The impeller is out of reach?
5. Installation position and the arrangement of condensation water drains
correspond to each other?
6. Connection data complies with the specications on the type plate?

• Commissioning may only take place if all safety instructions have been
checked and danger can be excluded.
– Check the direction of rotation (F rotation direction arrow on the fan blade,
impeller base plate or on the fan housing).
– Check for quiet, low vibration operation. Strong vibrations due to erratic
operation (unbalanced), e.g. caused by transportation damage or improper use,
can lead to failure.
– A-rated sound power levels of over 80 dB(A) are possible, see product
catalogue.
– Check for mechanical vibrations after installation into the system. If the
tolerances according to DIN Iso 10816-1 are exceeded, it is possible to exclude
certain speed ranges (F Motor Setup or add-on module).

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Assembly instructions ECblue Basic Diagnostics / Faults

7 Diagnostics / Faults
7.1 Trouble shooting
Type of error Possible cause Remedial measures
Fan does not Failure line voltage check line voltage
run (anymore) Failure of one phase
Under - or overvoltage
Earth fault Check motor connection and line voltage
Short circuit winding Replace fan
Thermal motor protection Check for free air passages; remove foreign bodies if nec-
has triggered (motor is over- essary
heated) F "Impeller blocked or dirty"
Check temperature of supply air
check voltage
Impeller blocked or dirty - Switch off power to the motor and secure against switch-
ing back on
- check safe isolation from supply
- Remove safety grille
- Remove foreign bodies or soiling
- Remount the safety grille
- Further procedure as in the chapter “Start-up”
fan will not start Temperature too low for Insert bearing with cold greasing
bearing grease
Air stream wrong direction Check air stream
(Motor turns in wrong direc-
tion at high speed)
F "Fan does not run"
Fan turns too Impeller / blade scrapes / Clear foreign bodies/dirt from the fan
slowly brushes
Active temperature manage- Check for free air passages; remove foreign bodies if nec-
ment effective essary
(Motor or electronics over- F "Impeller blocked or dirty"
heated) Check temperature of supply air
Check installation space (air speed over heat sink)
Air ow to low Fan turns too slowly F
Airways blocked check for free air passages (supply/exhaust air vents, l-
ters)
F "Impeller blocked or dirty"
Pressure loss different to Check fan selection
planned
Vibrations Imbalance Check blades for damage, soiling or ice F "Impeller
blocked or dirty"
No or wrong vibration damp- Install correct vibration dampers
ers (only in radial)
Unusual noises Bearing damaged / worn Change bearings
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Assembly instructions ECblue Basic Diagnostics / Faults

Type of error Possible cause Remedial measures

Impeller / blade scrapes / Clear foreign bodies / dirt from the fan F "Impeller blocked
brushes or dirty"
Operation beyond stall point check for free air passages (supply/exhaust air vents, l-
(for axial fans) ters)
Wrong overlap on nozzle Observe the installation instructions
(for centrifugal fans)

7.2 Status Out with ash code

OFF

ON

1x

2x

3x

4x
For motor size “D” and “G” Status LED
5x
integrated in cover.
6x
For motor size “B” connection for external 7x
Status LED (F Electrical installation: output
8x
A1 Status Out OC).
9x
11.02.2009
v_flash_explain.VSD

LED Code Relays K1 Cause Reaction of Controller

(programmed Explanation Adjustment
function at fac-
tory: Fault indica-
tion not inverted)
Line voltage available?
de-energized, 11 Unit switches OFF and automatically
OFF no line voltage
- 14 interrupted ON when the voltage has been re-
stored
energized, 11 - 14
ON Normal operation without fault
bridged
no enable = OFF
energized, 11 - 14 Switch OFF by external contact (F
1x
bridged Terminals “D1” - “24 V / 10 V” (Digital digital input).
In 1) not bridged.

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Assembly instructions ECblue Basic Diagnostics / Faults

LED Code Relays K1 Cause Reaction of Controller

(programmed Explanation Adjustment
function at fac-
tory: Fault indica-
tion not inverted)
Active temperature management
The device has an active tempera-
ture management to protect it from
damage due to too high inside tem-
peratures. In case of a temperature
rise above the xed limits, the modu- At sinking temperature the modula-
energized, 11 - 14
2x lation is reduced linearly. To prevent tion rises again llinear.
bridged
the complete system being switched Check cooling of the controller
off externally (in this operation per-
missible for the controller) in case of
reduced operation due to too high an
internal temperature, no fault mes-
sage is sent via the relay.
HALL-IC Controller turns the motor off. Auto-
de-energized, 11
3x Incorrect signal from the Hall-ICs, matic restart if no more fault is recon-
- 14 interrupted
error in the commutation. gized.
Line failure (only for 3 ~ types)
The device is provided with a built-in Following a shutoff, a startup attempt
phase-monitoring function for the is made after approximately 15 sec-
mains supply. In the event of a mains onds, if the voltage supply is high
de-energized, 11
4x interruption (failure of a fuse or enough. This keeps occurring until
- 14 interrupted
mains phase) the unit switches off all 3 supply phases are available
after a delay (approx. 200 ms). again.
Function only when load for the con- Checking power supply
troller is high enough.
EC-Controller switches off, renewed
attempt to start after about 2.5 sec.
Motor blocked
Final shutoff, when fourth starting
de-energized, 11 If after 8 seconds cummutation no
5x test fails. It is then necessary to have
- 14 interrupted speed is measured > 0, the fault
an reset by disconnecting the power
“Motor blocked” is released.
supply.
Check if motor is freely rotatable.
EC-Controller switches off, renewed
attempt to start after about 60 sec. F
Code 9
IGBT Fault Final shutoff, if - following a second
de-energized, 11
6x Short circuit to earth or short circuit starting test – a second fault detec-
- 14 interrupted
of the motor winding. tion is detected within a period of 60
seconds.
It is then necessary to have an reset
by disconnecting the line voltage.

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Assembly instructions ECblue Basic Diagnostics / Faults

LED Code Relays K1 Cause Reaction of Controller

(programmed Explanation Adjustment
function at fac-
tory: Fault indica-
tion not inverted)
If the intermediate circuit voltage
rises again within 75 seconds above
DC undervoltage the limit, an automatic starting test is
de-energized, 11 If the intermediate circuit voltage run.
7x drops below a specied limit, the de- If the intermediate circuit voltage re-
- 14 interrupted
vice is shutoff. mains below the limit for more than
75 seconds, the device is shutoff
with a fault message.
If the intermediate circuit voltage
DC overvoltage drops again within 75 seconds below
If the intermediate circuit voltage in- the limit, an automatic starting test is
de-energized, 11 creases above the specied limit the run.
8x
- 14 interrupted motor is switched off. If the intermediate circuit voltage re-
Reason for excessively high input mains above the limit for more than
voltage or alternator motor operation. 75 seconds, the device is shutoff
with a fault message.
IGBT cooling down period
IGBT cooling down period for approx.
energized, 11 - 14
9x 60 sec.
bridged
Final shutoff after 2 cooling-off inter-
vals F Code 6

7.3 Behaviour in rotation by air current in reverse direction

In the STOP state (no release, no preset signal, no voltage supply) the motor controller
does not intervene when the fan turns in the wrong direction (e.g. due to a draught).
If the fan is started while being driven in the opposite direction to that set, the speed is
reduced controlled to “0” and restarted in the set direction of rotation.
The higher the speed to be reduced, the longer this process lasts.
In cases in which the fan is driven very powerfully in the wrong direction, it may not be
possible to start the fan with the set direction of rotation.

Information
Safe starting of fans is not guaranteed if it is started in reverse. If the application
demands safe starting, the machine manufacturer or owner must prevent reverse driving
rotation by suitable measures.

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Assembly instructions ECblue Basic Service work

8 Service work
8.1 Repairs / maintenance
Attention!
• Allow maintenance work to be carried out by trained specialists only.
• Please observe the safety regulations and the worker´s protection rules by
all maintenance and service work (DIN EN 50 110, IEC 364).
• Before working on the fan, this must be disconnected from the power supply
and secured against switching back on!
• Keep the airways of the fan free - danger because of objects dropping out!
• No maintenance work at running fan!
• Watch out for vibration free motion!
• Depending on the application and the transfer medium the impeller has a
natural wear. Deposits on the impeller can lead to imbalance and thus to
damages (danger of endurance fracture). The impeller can disintegrate!
• Maintenance interval in accordance with the degree of contamination of the
impeller!
• In case of imbalance: Rebalance the impeller.
• Check the impeller, in particular the weld-seams, for possible cracks.
• Repair, e.g. by welding is prohibited!
• The fan or motor is maintenance-free due to the use of ball bearings with “life-long
lubrication”. At the end of the grease life (F Technical Data) it is necessary to
change the bearing. Please consult our Service Department in this case as for all
other damage (e.g. to the coil or electronics).
• Bolted-on wheels and/or wings may only be replaced by authorised Ziehl-Abegg
AG staff. The manufacturer shall not be liable for damage caused through
improper repair work.
• Regular inspection, and cleaning is necessary to prevent imbalance due to ingress
of dirt.

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Assembly instructions ECblue Basic Enclosure

8.2 Cleaning
Danger owing to electric current
Voltage supply for motor must be interrupted and secured against restoration!

Attention!
• Do not use any aggressive, paint solvent cleaning agents when cleaning.
• Cleaning with a water jet:
– Make sure that no water gets into the inside of the motor and electronics, note
protection class (IP).
– Do not hold the jet spray directly on the motor openings and seals.
– During cleaning work using a jet spray, no guarantee is assumed regarding
corrosion formation / paint adhesion for unpainted / painted fans.
– After the cleaning process, the fan must be operated for 30 minutes at 80 to
100 % of maximum speed for drying purposes!

9 Enclosure
9.1 Technical data
Line voltage* AC: 1 ~ 200...277 V (+/- 10 % ), DC: 280...400 V (+/- 10 % )
(F Rating-plate) 50/60 Hz
AC: 3 ~ 200...240 V (+/- 10 % ), DC: 280...340 V (+/- 10 % )
50/60 Hz
AC: 3 ~ 380...480 V (+/- 10 % ), DC: 500...680 V (+/- 10 % )
50/60 Hz
Special version for IT-System:
AC: 3 ~ 400 V (-15 up to +10 % ), 50/60 Hz
Maximal line fuse 16 A for all types 1 ~ and 3 ~
Max. cut-in current 126 A
Max. load limit integral of cut-in 1.22 A2s
current
Switching Freq. 16 kHz
Input resistance for signal set for Ri > 100 kΩ
the rotational speed
Specication speed setting sig- Voltage: 15...28 VDC
nal PWM Switching Frequency: 1...10 kHz
On-off ratio: 0...100 %
Voltage supply for external devi- + 10 V, I max 10 mA (short-circuit-proof)
ces +24 V ±20 %, Imax 70 mA (only for motor size “D”, “G”)

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Assembly instructions ECblue Basic Enclosure

Permissible minimal and maxi- -25 °C...60 °C (up to 70 °C **)

mal ambient temperature for op- Please see the technical documentation of the product for the minimum
eration and maximum ambient temperature valid for the respective fan; These
may deviate from the specied permissible ambient temperatures.
To avoid condensation the drive must be continuously energized due to
the application of heat, with interruptions such that cooling to the point of
condensation does not occur.
Max. permissible installation height 1000 m amsl without derating
height
Permissible rel. humidity 85 % no condensation
Permissible temperature range -30...+80 °C
for storage and transport
Electromagnetic compatibility for Interference emission EN 61000-6-3 (domestic household applications)
the standard voltage 230 / 400 By special version for IT-System according to EN 61000-6-4 (industrial
V according to DIN IEC 60038 applications)
Interference immunity EN 61000-6-2 (industrial applications)
Harmonics current according For 1 ~ types
Active power factor adjustment for sinusoidal input current (PFC = Power
- Factor - controller), harmonic current in accordance with EN 61000-3-2
are guaranteed.
For 3 ~ types
EN 61000-3-2 for a “professional unit”.
Please ask Ziehl-Abegg for the individual harmonic oscillation levels of
the current as a percentage of the fundamental oscillation of the rated
current.
Contact rating of the internal AC 250 V 2 A
relay
Max. leakage current according < 3.5 mA
to the dened networks of DIN
EN 60990
dB(A) values F product catalog
Ball bearings crease service-life during standard usage ca. 30 - 40,000 h
Protection class of motor ac- IP 54
cording DIN EN 60529

* Regarding the mains connection, the devices are to be classied as category “C2” devices
according to the relevant DIN EN 61800-2 The increased requirements placed on electrical
interference for category “C1” devices are complied with in addition.
** In case of a temperature increase above the predetermined threshold values modulation is
linearly reduced by active temperature management.

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Assembly instructions ECblue Basic Enclosure

9.2 Connection diagram

Motor size “B” (type: _ _ _ _ _-_ I _. B _._ _ _ _)

ECblue Basic (_ _ _ _ _-_I_.B_._ _ _ _)

5
Kontaktbelastung
Contact rating
K1 max. AC 250 V 2 A

1 1
11 - L1 N A2 GND 10V - - - -

14 - - PE E1 D1 A1 - - - -

WH
GN
RD

GY
BU

YE
GNYE
WH

WH

BN

BU

10V D1 GND A2 E1 A1

10 V DC Out (Imax = 10 mA)

10V RD
+ D1 Digital In 1
Eingang D1 GN
Input 4 GND
11 14 L1 N PE 0...10 V GND BU
Netz A2 Operation Out OC
A2 GY
Line
1 ~ 200...277 V 10 kΩ E1 Analog In 1
E1 YE
50/60 Hz
A1 Status Out OC
1 A1 WH
Externe Drehzahlvorgabe
External speed setting
3
E1
10 V

GND

10 kΩ
E1
GND

- +
KT00044A
15...28 V 08.03.2011
PWM
f = 1...10 kHz
2

1 Line voltage 1 ~ 200...277 V, 50/60 Hz

2 PWM input, f = 1...10 kHz
3 External speed setting
4 Input 0...10 V
5 Contact rating max. AC 250 V 2 A

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Assembly instructions ECblue Basic Enclosure

Motor size “D” and “G” (type: _ _ _ _ _-_ I _. D _._ _ _ _), (type: _ _ _ _ _-_ I _. G _._ _ _ _)

ECblue Basic (_ _ _ _ _-_I_.D_._ _ _ _), (_ _ _ _ _-_I_.G_._ _ _ _)

Kontaktbelastung
(Imax = 70 mA)

(Imax = 10 mA)

2 Contact rating

Analog In 1
Digital In 1
max. AC 250 V 2 A
DC Out

DC Out

L1 N

24V 10V GND D1 E1 11 14 L1 L2 L3

K1

PE PE L1 L2 L3/N
Netzspannung Leistungsschild
Externe Drehzahlvorgabe 10 kΩ
Line voltage Rating-plate
External speed setting
3 3 ~ Typ nur in Sonderausführung
für IT-System geeignet
+ 3 ~ type only in special version
Eingang suitable for IT-System
4 Input 1
0...10 V
E1
10 V

GND

10 kΩ

PWM
E1
24 V

f = 1...10 kHz
5 MOEA03K0
08.03.2011
E1
GND

- +

15...28 V

1 Line voltage F rating plate (3 ~ type only in special version suitable for IT-System)
2 Contact rating max. AC 250 V 2 A
3 External speed setting
4 Input 0...10 V
5 PWM input, f = 1...10 kHz

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Assembly instructions ECblue Basic EC Declaration of Incorporation

9.3 EC Declaration of Incorporation ZA87-GB-12/09 Index 000

00296702-GB
as dened by the EC Machinery Directive 2006/42/EC,
Annex II B

The design of the incomplete machine:

• Axial fan FA.., FB.., FC.., FE.., FS.., FT.., FH.., FL.., FN.., VR.., VN..
• Centrifugal fan RA.., RD.., RE.., RF.., RG.., RH.., RK.., RM.., RR.., RZ.., GR..,
ER..
• Cross ow fan QK.., QR.., QT.., QD.., QG..

Motor type:
• Induction internal or external rotor motor (also with integrated frequency inverter)
• Electronically commutated internal or external rotor motor (also with integrated EC
controller)

complies with the requirements in Appendix I, Articles 1.1.2, 1.1.5, 1.4.1, 1.5.1 in
EC Machinery Directive 2006/42/EC.

The manufacturer is the Ziehl-Abegg AG

Heinz-Ziehl-Strasse
D-74653 Kuenzelsau

The following standards are applied:

EN 60204-1:2006 Safety of machinery; electrical equipment of machines; Part 1: Gen-
eral requirements
EN ISO Safety of machinery; basic concepts, general principles for design
12100:2003
EN ISO Safety of machinery; safety distances to prevent danger zones being
13857:2008 reached by the upper limbs
Note: The maintenance of the EN ISO 13857:2008 relates only to the
installed accidental contact protection, provided that it is part of the
scope of delivery.

The specic technical documentation in accordance with Appendix VII B has been
written and is available in its entirety.

The person authorised for compiling the specic technical documentation is: Dr. O. Sadi,
address see above.
The specic documentation will be transmitted to the ofcial authorities on justied
request. The transmission can be electronic, on data carriers or on paper. All industrial
property rights remain with the above-mentioned manufacturer.

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Assembly instructions ECblue Basic EC Declaration of Incorporation

It is prohibited to commission this incomplete machine until it has been secured
that the machine into which it was incorporated complies with the stipulations of
the EC Machinery Directive.

Künzelsau, 29-Dec-2009 Dr. O. Sadi - Technical Manager Ventilation Technology

i.V.

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9.4 Index

A Motors Type 9
air current 31
O
B one-quadrant 9
Outdoor fans 17
Bearing 28
P
C
PWM-signal 23
change the bearing 32
Chimney 14
R
cleaning 33
condensation drain hole 12, 15 relay 25
control cable 21 Relay output 25
current-operated protective Residual current circuit
devices 23 breaker 22

D S
DC voltage 21 S1 operated 9
service life 9
E Setting signal 24
sound power levels 27
Enable 24
Switching Freq. 33
G
T
grease life 32
Technical data 3, 33
temperature management 30
I
Imbalance 28
Input resistance 33
IT-System 22

L
leakage current 34

M
motor ange 17
motor size 9
Motorheating 18

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Assembly instructions ECblue Basic Index

9.5 Manufacturer reference

Our products are manufactured in accordance with the relevant international regulations.
If you have any questions concerning the use of our products or plan special uses,
please contact:
Ziehl-Abegg AG
Heinz-Ziehl-Straße
74653 Künzelsau
Telephone: +49 (0) 7940 16-0
Telefax: +49 (0) 7940 16-504
[email protected]
http://www.ziehl-abegg.de

9.6 Service information

If you have any technical questions while commissioning or regarding malfunctions,
please contact our V-STE support department for control systems - ventilation technol-
ogy.
Our worldwide contacts are available in our subsidiaries for deliveries outside of Ger-
many. F www.ziehl-abegg.com.
If you make returns for inspections or repairs we need certain information in order to
facilitate focused trouble shooting and fast repair. Please use our repair tickets for this. It
is provided to you after you have consulted our support department.
In addition, you can download it from our homepage. Download - Ventilation Technology
- Topic: Control Engineering - Document type: General documents.

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Index
Corrosion protection, 39
Creepage distance, 61
A
Aligning
Prerequisites, 48
D
Alignment accuracy, 51 Damage during transportation
Aluminum conductors, 62 Prevention, 35
Application range, 21 Degree of protection, 25
Disassembly
Disposal, 129
B External fan, 107
Disposal
Balance quality, 53
Chemicals, 130
Bearing currents, 43, 70
Components, 130
Bearing seizure damage, 37
DRIVE-CLiQ, 57, 111
Bearing shield
Assembly, 103
Disassembly, 103
Bolt locking device, 52
E
Electromagnetic compatibility, 19
Electromagnetic fields, 20
C EMC cable glands, 59
Emergency off, 81
Cable lug, 60
Emitted interference, 20
Cable outlet direction, 68
Environmental requirements, 26
CE conformity, 45
Equipotential bonding, 63
Center of gravity, 33
Equipotential bonding conductor, 43, 70
Checks to be carried out prior to commissioning, 74
ESD guidelines, 18
Circuit diagram, 58
Explosion hazard, 21
Cleaning, 91
External fan, 24, 29, 116
Cooling air passages, 98
Connection, 64, 66, 67
Spent grease chamber, 97
Filter mat, 100
Cleaning intervals, 98
Maintenance, 98
Condensate, 80
Refitting, 56, 106
Condensation, 38, 55
Connecting cables
Selection of, 64
Connection
F
Electrical, 59 Fan
External fan, 64 Cleaning, 99
Holding brake, 69 Faults, 80
Speed encoder, 68 Electrical, 84
Temperature sensor, 69 Holding brake, 86
Connection data, 59 Inspection , 83, 87
Contact, 131 Mechanical, 84
Cooling, 40 Roller bearings, 85
Cooling air quality, 42 Feather key, 54
Cooling method, 24 Five safety rules, 15
Corrective maintenance Flammable substances, 17
Initial inspection, 88 Flange-mounted motors, 52

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Index

Frequency converter, 23 Minimum radial forces, 26

Mounting
Flange, 52
H Motor feet, 51
Mounting parts, 45
Hazardous substances, 17
Hearing damage, 18, 30
Holding brake, 25, 137
Connection, 69
N
Faults, 86 Noise emissions, 18, 30
Magnetic field, 73
Spare parts, 124
Hot surfaces , 17 O
Operating mode, 29
Output element, 54
I Overspeeds, 29
Initial inspection, 91
Inspection
Faults, 83, 87 P
Installation
Paint system, 112
Initial inspection, 88
Paintwork damage, 112
Insulation resistance, 45, 74, 82
Permanent lubrication , 91
Critical, 48
Pipe connection, 41
measure, 46
Polarization index, 45, 74, 82
Interference immunity, 19
Pressure drop, 42
Interference voltages, 20
Protecting ring, 102
Interlocking circuit
Protective conductor, 71
External fan, 29

Q
L
Qualified personnel, 16
Lifting, 33
Limit speed, 75
Live parts, 16
Local field service
R
Service numbers, 131 Rating plate, 21
Long-term storage, 38 Bar code, 113
Low-Voltage Directive, 15 Re-commissioning, 83
Regreasing, 95
Regreasing , 91
M Regreasing device, 91
Regreasing intervals, 89
Machine
Regreasing system, 96
Aligning, 50
Residual risks, 29
Machine design, 23
Roller bearings
IEC, 23
faults, 85
Main inspection, 88, 91
Versions, 26
Maintenance
Rotating components, 17
Maintenance intervals, 87
Rotor, 22
Maximum speed, 76
Rotor shipping brace, 35, 39
Flange mounting, 52
Tightening torque, 35
Minimum clearances in air, 61

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 Index

S T
Safety information Technical information
Flammable substances, 17 Service numbers, 131
Hazardous substances, 17 Temperature sensor
Hot surfaces, 17 Connection, 69
Live parts, 16 Terminal box, 59
Rotating components, 17 Maintaining, 100
Safety instructions Sealing, 63
Maintenance work, 90 Terminal designation, 58
Sealing, 62 Thermal motor protection, 31
Sealing agent, 104 Tightening torques
Sensor module, 111 Bolted connection, 52
Service numbers Torsional loadings, 31
Local field service, 131 Transporting, 33, 34
Spare parts, 131 Type of balancing, 53, 55
Technical information, 131
Shaft assembly, 31
Spare parts, 113 V
Holding brake, 124
Vibration response of the system, 48
Motor, 115
Vibration severity, 48
Ordering, 114
Vibration values, 31, 77
Roller bearing cartridge NDE, 121, 122, 123
Rolling-contact bearing bush, drive end, 117, 118,
119, 120
Rolling-contact bearing bush, non-drive end, 124
W
Service numbers, 131 Water drain hole, 38, 55
Speed encoder, 126, 127
Terminal box, 125
Spare parts kits, 113
Spare parts ordering, 113
Spares on Web, 114
Speed, 30
Speed encoder
Connection, 68
Electrical connection, 111
Mounting, 110
Separating, 109
Speed monitoring, 81
Spent grease chamber, 97
Stoppages, 81
Roller bearings, 82
storage
Indoor, 37
Switching off, 81
Switching on, 76, 77
System resonances, 31
System-inherent frequencies, 31

SIMOTICS M-1PH8
Operating Instructions 03/2012 A5E03555811A AB 205
Index

SIMOTICS M-1PH8
206 Operating Instructions 03/2012 A5E03555811A AB
AG EG Konformitätserklärung 1PH8 18/22/28
AA BA STROMAG Haltebremse U705
AA BA Ziehl-Abegg Lüfter 1PH8 U726
Siemens AG
Industry Sector
Drive Technologies and Industry Automation
P.O. Box 4848
90327 NUREMBERG
GERMANY

www.siemens.com/automation