IEC Stainless steel encapsulated motors - Installation, operation, maintenance and safety manual
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MANUAL | JUNE 2018 IEC Stainless steel encapsulated motors Installation, operation, maintenance and safety manual For other manuals: abb.com/motors-generators/iec-low-voltage-motors/manuals
Contents 1. Introduction.............................................................................................................................................4 1.1 Declaration of Conformity.............................................................................................................................. 4 1.2 Validity................................................................................................................................................................ 4 2. Safety considerations............................................................................................................................. 5 3. Handling...................................................................................................................................................6 3.1 Reception........................................................................................................................................................... 6 3.2 Motor description............................................................................................................................................ 6 3.3 Transportation and storage............................................................................................................................7 3.4 Lifting..................................................................................................................................................................7 3.5 Motor weight......................................................................................................................................................7 4. Installation and commissioning............................................................................................................8 4.1 General............................................................................................................................................................... 8 4.2 Insulation resistance check............................................................................................................................ 8 4.3 Foundation........................................................................................................................................................ 8 4.4 Balancing and fitting coupling halves and pulleys.................................................................................... 9 4.5 Mounting and alignment of the motor........................................................................................................ 9 4.6 Radial forces and belt drives.......................................................................................................................... 9 4.7 Drain plugs for condensation........................................................................................................................ 9 4.8 Cabling and electrical connections..............................................................................................................10 4.8.1 Connections for different starting methods............................................................................................. 11 4.8.2 Connections of auxiliaries.............................................................................................................................13 4.9 Terminals and direction of rotation.............................................................................................................13 5. Operation............................................................................................................................................... 14 5.1 General..............................................................................................................................................................14 6. Low voltage motors in variable speed operation............................................................................. 15 6.1 Introduction.....................................................................................................................................................15 6.2 Winding insulation..........................................................................................................................................15 6.2.1 Selection of filters for ABB converters........................................................................................................15 6.2.2 Selection of filters with all other converters.............................................................................................15 6.3 Thermal protection.........................................................................................................................................15 6.4 Bearing currents..............................................................................................................................................15 6.4.1 Elimination of bearing currents with ABB converters..............................................................................15 6.4.2 Elimination of bearing currents with all other converters......................................................................15 6.5 Cabling, grounding and EMC........................................................................................................................15 6.6 Operating speed..............................................................................................................................................16 2 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS
6.7 Motors in variable speed applications........................................................................................................16
6.7.1 General..............................................................................................................................................................16
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control.............................................16
6.7.3 Motor loadability with AC_5_ _ – series of converter...............................................................................16
6.7.4 Motor loadability with other voltage source PWM-type converters.....................................................16
6.7.5 Short time overloads......................................................................................................................................16
6.8 Rating plates.................................................................................................................................................... 17
6.9 Commissioning the variable speed application........................................................................................ 17
7. Maintenance........................................................................................................................................... 18
7.1 General inspection..........................................................................................................................................18
7.1.1 Standby motors...............................................................................................................................................18
7.2 Lubrication.......................................................................................................................................................18
7.2.1 Lubricants.........................................................................................................................................................19
8. After Sales Support...............................................................................................................................20
8.1 Spare parts...................................................................................................................................................... 20
8.2 Dismantling, re-assembly and rewinding.................................................................................................. 20
8.3 Bearings........................................................................................................................................................... 20
9. Environmental requirements............................................................................................................... 21
9.1 EU Directive 2012/19/EU (WEEE).................................................................................................................21
9.1.1 Marking of the products................................................................................................................................21
9.1.2 For private households..................................................................................................................................21
9.1.3 For professional users in the European Union..........................................................................................21
9.1.4 For disposal in countries outside of the European Union......................................................................21
10. Figures.................................................................................................................................................... 22
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 31. Introduction
1.1 Declaration of Conformity
NOTE! The conformity of the end product according to Directive
2006/42/EC (Machinery) has to be established by the
These instructions must be followed to ensure safe
commissioning party when the motor is fitted to the
and proper installation, operation and maintenance
machinery.
of the motor. They should be brought to the attention
of anyone who installs, operates or maintains the
1.2 Validity
motor or associated equipment.
These instructions are valid for the following ABB electrical
The motor is intended for installation and use by machine types, in both motor and generator operation:
qualified personnel, familiar with health and safety • series M3MA
requirements and national legislation. Ignoring these • in frame sizes 71-80-90-100-112
instructions may invalidate all applicable warranties.
i.e. motors for washdown duty for Food & Beverage, design
with stainless steel frame and components, and with
windings encapsulated in epoxy resin.
4 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS2. Safety considerations
The motor is intended for installation and use by qualified
WARNING! personnel, who are familiar with health and safety
requirements and national legislation.
Emergency stop controls must be equipped with
restart lockouts. After an emergency stop, a new
Safety equipment necessary for the prevention of accidents
start command can take effect only after the restart
at the installation and operating site must be provided in
lockout has been intentionally reset.
accordance with local regulations.
Points to be observed:
• Do not step on the motor.
• The temperature of the outer casing of the motor may be
hot to the touch during normal operation and especially
after shut-down.
• Some special motor applications may require additional
instructions (e.g. when supplied with frequency convert-
ers).
• Mind the rotating parts of the motor.
• Do not open the terminal boxes while energized.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 53. Handling
3.1 Reception 3.2 Motor description
Immediately upon receipt, check the motor for external The following parts are visible on the motor when received:
damage (e.g. shaft-ends, flanges and finished surfaces) and, 1. Lifting lug (some motors, e.g. generation A motors, do
if found, inform the forwarding agent without delay. not have a pre-installed lifting lug like this) (*) (**)
2. Drain plugs available on four sides (only the two on top
Check all rating plate data, in particular voltage and winding of the motor are shown in the picture)
connections (star or delta). The type of bearing is specified 3. Drain plug for use when motors are mounted vertically,
on the rating plate of the motor. with the shaft upside (in generation A motors it is on
the rear face of the motor)
In the case of a variable speed drive application, check the 4. Long drain plug, only for motors equipped with feet,
maximum loadability allowed according to frequency. due to difficulties in the tightening/removal of the stan-
dard plug with this type of mounting
5. Drain plug for use when motors are mounted vertically,
(*) Remove the lifting lug after with shaft downside (in generation A motors this is not
mounting, since it is not in stain-
less steel. Motors are provided available)
with a Stainless steel plug to 6. Drain plug for use when the motor is coupled to a gear-
put in place of the lifting lug
box to remove possible condensed water between mo-
(**) Motors with generation code A tor and gearbox
Lifting lug
are provided with a “lifting lug kit”.
To mount the lifting lug, remove 7. Fixing screw for the terminal box cover
the drain plug “2” in figure” and
8. Threaded hole for cable gland, closed with a plastic plug
tighten the lifting lug. Take care to
Washer screw in the “lifting lug kit” without 9. Gamma ring seal on DE flange
removing its pre-mounted nut
Nut and washer to avoid damaging the
10. Fan cover (only frame size 100 and above)
threaded hole of the drain plug.
8. 7. 1. 2. 9. 2. 5. 10. 8. 7.
3. 4. 5. 6. 3.
All motor types, both with Only motors with flanges Only fan cooled motors
feet and with flanges
6 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS3.3 Transportation and storage 3.5 Drain plugs for condensation
The motor should always be stored indoors (above –40 °C), Motors have several drain plugs, to be used to remove
in dry, vibration-free and dust-free conditions. During possible condensed water from inside the motor. To remove
transportation, shocks, falls and humidity should be such water, the bottommost plug must be unplugged.
avoided. In other conditions, please contact ABB. For motors that are equipped with flanges only and do not
have feet, there is one drain plug for each of the four
It is recommended that shafts are rotated periodically (one possible orientation sides of the motor, i.e. with terminal
time per quarter) by hand to prevent grease migration. box oriented upside, left, right or downside.
There is also one drain plug on the NDE side of the motor in
The motor must not be subject to any external vibrations at case of vertical mounting with the shaft upside and one
standstill so as to avoid causing damage to the bearings. drain plug on the DE end shield or flange for motors that are
mounted with the shaft downwards.
3.4 Lifting
All ABB motors above 25 kg are equipped with lifting lugs or Finally, for motors equipped with flanges that can be
eyebolts. coupled, for example, to a gearbox, there is an additional
drain plug for removing possible condensed water in the
Only the main lifting lugs or eyebolts of the motor should be volume between the motor and the gearbox itself. Please
used for lifting the motor. They must not be used to lift the note that for motors mounted horizontally, this plug will be
motor when it is attached to other equipment. in the bottommost part of the motor only when the motor is
mounted with the terminal box on top of the motor. In case
Because of different outputs, mounting arrangements and the motor is mounted with the terminal box in a horizontal
auxiliary equipment, motors with the same frame may have position (left or right), this plug becomes unusable unless
a different center of gravity. the flange is dismounted and rotated accordingly (this is an
operation that can be done only by authorized personnel or
Damaged lifting lugs must not be used. Check that the in factory).
eyebolts are undamaged before lifting.
3.6 Motor weight
Lifting eyebolts must be tightened before lifting. The total weight of the motor can vary within the same
frame size (center height) depending on its output,
Ensure that proper lifting equipment is used and that the mounting arrangement and auxiliaries.
sizes of the hooks are suitable for the lifting lugs.
The following table shows estimated maximum weights for
Care must be taken not to damage auxiliary equipment and machines in their basic versions as a function of frame
cables connected to the motor. material.
Remove eventual transport jigs fixing the motor to the The actual weight of a motor is shown on the rating plate.
pallet.
Frame size Weight kg
Specific lifting instructions are available from ABB. 71 20
80 25
90 45
WARNING! 100 62
112 64
During lifting, mounting or maintenance work, all
necessary safety considerations shall be in place and
If the motor is equipped with any accessories, contact ABB
special attention to be taken that nobody will be
for the weight, if not available on the nameplate.
subject to lifted load.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 74. Installation and commissioning
If the reference resistance value is not attained, the winding
WARNING! is too damp and must be oven dried. The oven temperature
should be 90 °C for 12–16 hours followed by 105 °C for 6–8
Disconnect and lock out before working on the motor
hours.
or the driven equipment.
If fitted, drain hole plugs must be removed during heating.
After heating, make sure the plugs are refitted.
4.1 General
All rating plate values must be carefully checked to ensure 4.3 Foundation
that the motor protection and connection will be properly The end user has full responsibility for preparing the
done. foundation.
When starting the motor for the first time or after it has Metal foundations should be made out of stainless steel to
been in storage more than six months, manually rotate the avoid corrosion.
shaft for some turns in both directions.
Foundations must be even and sufficiently rigid to
4.2 Insulation resistance check withstand possible short circuit forces.
Measure insulation resistance (IR) before commissioning, or
after long periods of standstill or storage, if you suspect They must be designed and dimensioned to avoid the
dampness in the windings IR must be measured directly on transfer of vibration to the motor and vibration caused by
the motor terminals with the supply cables disconnected in resonance. See figure.
order to avoid them affecting the result. 1. Ruler
2. Note! Height difference shall not exceed ± 0,1mm re-
Insulation resistance should be used as a trend indicator to ferred to any other motor foot
determine changes in the insulation system. In new 3. Foot location
machines, the IR is usually thousands of Mohms and
therefore it is important to follow changes in IR so as to
know the condition of the insulation system. Typically, the IR 1. 2.
should not be below 10 MΩ and in no case should it be below
1 MΩ (measured with 500 or 1000 VDC and corrected to 25
°C). The insulation resistance value is halved for each 20 °C
increase in temperature.
Figure 1, in chapter 11, can be used for the insulation
correction to the desired temperature.
WARNING!
To avoid risk of electrical shock, the motor frame
3.
must be grounded and the windings should be
discharged against the frame immediately after each
measurement.
8 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS4.4 Balancing and fitting coupling halves and pulleys Do not exceed permissible loading values for bearings as
As standard, balancing of the motor has been carried out stated in the product catalogs.
using a half key.
Check that the motor has sufficient airflow.
Coupling halves or pulleys must be balanced after machining Ensure that no nearby objects or direct sunshine radiate
the keyways. Balancing must be done in accordance with the additional heat on the motor.
balancing method specified for the motor.
For flange mounted motors (e.g. B14, B5, B35, V1), make sure
Coupling halves and pulleys must be fitted on the shaft with that the construction allows sufficient air flow on the outer
the appropriate equipment and tools that do not damage surface of the flange. To be compliant with Hygienic Design,
the bearings and seals. only hexagonal head bolts are allowed, preferably in
stainless steel.
Never fit a coupling half or pulley by hammering or removing
it by using a lever pressed against the body of the motor. 4.6 Radial forces and belt drives
Belts must be tightened according to the instructions of the
4.5 Mounting and alignment of the motor supplier of the driven equipment.
Ensure that there is enough space for free airflow around
the motor. For motors equipped with a fan, it is
recommended to have clearance between the fan cover and WARNING!
the wall etc. of at least half of the air intake of the fan cover.
Excessive belt tension will damage bearings and can
Additional information may be found from the dimension
cause shaft damage.
drawings available on our web pages: www.abb.com/
motors&generators.
Correct alignment is essential to avoid bearing damage, 4.7 Drain plugs for condensation
vibration, and possible shaft failures. During operation, all drain holes can be either closed or
opened; the only condition when drain plugs must be tightly
Mount the motor on the foundation using the appropriate closed is during washing operations, to ensure IP69
bolts or studs and place shim plates between the foundation protection.
and the feet. To be compliant with hygienic design, only In any case, to remove possible condensed water from inside
hexagonal head bolts are allowed, preferably in stainless the motor, at least the bottommost plug must be unplugged
steel.
Align the motor using the appropriate methods.
If applicable, drill locating holes and fix the locating pins
into position.
Mounting accuracy of coupling half: check that clearance b is
less than 0.05 mm and that the difference a1 to a2 is also
less than 0.05 mm. See figure 2.
Re-check the alignment after the final tightening of the
bolts or studs.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 94. Installation and commissioning
4.8 Cabling and electrical connections We recommend using cables of up to a maximum of 16 mm
The terminal box has a terminal block inside and it is that are compatible with the following IP69 cable glands (or
provided with: equivalent):
1. One earth terminal (M4 stainless steel or brass screw). • ABB FSCG-M251 M25X1.5 D12-17 mm (FNB CG M25 12.0-17.0
2. Two thermal sensor terminals (T1 T2) SS – 7TCA303080R0072)
3. Three winding terminals (U1-V1-W1) for power line sup- • Lapp SKINTOP INOX M25X1,5 D9X17 (53806743)
ply • Harting Han CGM-P M25X1,5 D.13-18mm black
4. Three winding terminals (U2-V2-W2) to be used to create (19000005193)
both star or delta connections • Hummel HSK-INOX-Ex-d / Metr. M25X1,5 D9-16mm
(1.632.2500.51)
Motors are intended for fixed installation only. Unless
otherwise specified, cable entry threads are metric. The IP
class of the cable gland must be the same as the motor, i.e.
IP69.
1.
WARNING!
2.
For consistency with the motor, only cable glands
with IP protection level IP69 can be considered as
3. appropriate. Cable glands shall be selected according
to the type and diameter of the cable.
4. We recommend using cables of up to a maximum of 16 mm
that are compatible with the following IP69 cable glands (or
equivalent):
• ABB FSCG-M251 M25X1.5 D12-17 mm (FNB CG M25 12.0-17.0
SS – 7TCA303080R0072)
• Lapp SKINTOP INOX M25X1,5 D9X17 (53806743)
The terminal block is with male faston tabs 6.45 X 7.9 X0.8 • Harting Han CGM-P M25X1,5 D.13-18mm black
mm, for both power connection and for thermal sensors. (19000005193)
Cables must be provided with suitable female faston tabs • Hummel HSK-INOX-Ex-d / Metr. M25X1,5 D9-16mm
(ABB uses the following code from TE for an internal (1.632.2500.51)
connection not accessible by Customers: 60650-2, or
equivalent). Motors are intended for fixed installation only. Unless
otherwise specified, cable entry threads are metric. The IP
The terminal box has only one cable entry suitable for an class of the cable gland must be the same as the motor, i.e.
M25 cable gland. Due to this, the power cables must be with IP69.
at least six conductors:
• Three conductors for L1, L2, L3 power supply phases
• One conductor for PE
• Two conductors for the thermal sensor
10 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORSAfter connection, make sure that water cannot enter the
WARNING! terminal box: the O-ring must be in place in the terminal box
cover slot and greased to avoid pinching during mounting.
For consistency with the motor, only cable glands
The cables must enter the terminal box cover through an
with IP protection level IP69 can be considered as
IP69 cable gland. A leak could lead to penetration of dust or
appropriate. Cable glands shall be selected according
water, creating a risk of flashover to live elements.
to the type and diameter of the cable.
4.8.1 Connections for different starting methods
The terminal box contains six winding terminals and at least
Earthing must be carried out according to local regulations one earth terminal. This enables the use of DOL- or Y/D –
before the motor is connected to the supply voltage. starting.
The earth terminal on the frame is always inside the terminal
box and has to be connected to PE (protective earth) with a The voltage and connection are stamped on the rating plate.
cable as shown, e.g. in Figure 24 of IEC 60034-25.
Direct-on-line starting (DOL):
Minimum cross-sectional area of protective conductors Y or D winding connections may be used.
Cross-sectional area of Cross-sectional area of the
For example, 400 VY, 230 VD indicates Y-connection for 400
phase conductors of the corresponding protective
installation S [mm2] conductor S [mm2] V and D-connection for 230 V.
4 4
6 6 Star/Delta (Wye/Delta) starting (Y/D):
The supply voltage must be equal to the rated voltage of the
In addition, earthing or bonding connection facilities on the motor when using a D-connection.
outside of electrical apparatus must provide effective
connection of a conductor with a cross-sectional area of at To supply the motor at 400 VY, create the star center as
least 4 mm². shown in the figure.
The cable connection between the network and motor To make the star center three wires with crimped fastons
terminals must meet the requirements stated in the national need to be connected together and inserted in the U2, V2,
standards for installation or in the standard IEC/EN 60204-1 W2 terminals; connection of the wires maybe done by a
according to the rated current indicated on the rating plate. clamp (figure) or they may be soldered together, but in this
case the welded terminal must be isolated (use a heat
shrinking sleeve).
NOTE!
When the ambient temperature exceeds +50 °C, NOTE!
cables having permissible operating temperature of
+90 °C as minimum shall be used. Also all other ABB provides only the fastons.
conversion factors depending on the installation
conditions shall be taken into account while sizing
the cables.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 114. Installation and commissioning
Color code shown for cables is according to IEC 60445 To make the Delta connection three wires with crimped
(2010) but it is not mandatory: fastons need to be connected together and inserted in the
1. L1 = U1 = Brown U2, V2, W2 terminals as shown in the figure; connection of
2. L2 = V1 = Black the wires maybe done by a one clamp for each phase or they
3. L3 = W1 =Grey may be soldered together, but in this case the welding must
be isolated (use a heat shrinking sleeve).
To supply motors with 230 VD connect the cables as shown
in figure.
NOTE!
1. 2. 3. ABB provides only the fastons.
Color code shown for cables is according to IEC 60445
(2010) but it is not mandatory:
1. L1 = U1 = Brown
2. L2 = V1 = Black
3. L3 = W1 =Grey
To supply motors with 230 VD connect the cables as shown
in figure.
1. 2. 3.
Wire lenght: approx. 3 cm
12 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORSOther starting methods and severe starting conditions:
4.8.2 Connections of auxiliaries
All motors are by default equipped with 3 PTC thermistors
connected in series; they have a threshold value of 150 ºC
and are encapsulated into the stator winding, to monitor the
motor temperature and provide a signal in case the
maximum temperature is exceeded. These thermistors do
not cut power supply to the motor, i.e. they are not
connected in series with the windings.
It is up to the user whether they wish to connect and use
those thermistors or not, however, it is recommended they
be used and connected by the appropriate means: ABB
provides eight (8) female faston tabs in the terminal box,
two of which can be used to connect the thermistors.
The maximum measuring voltage for the thermistors is 2.5 V.
Using a higher measuring voltage or current may cause
errors in readings or a damaged temperature detector.
The insulation of thermal sensors fulfills the requirements of
basic insulation.
4.9 Terminals and direction of rotation
The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence
- L1, L2, L3 - is connected to the terminals as shown in figure 3.
To alter the direction of rotation, interchange any two
connections on the supply cables.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 135. Operation
5.1 General
Unless otherwise stated on the rating plate, the motors are WARNING!
designed for the following conditions:
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
• Motors are to be installed in fixed installations only.
the use of the motor.
• Storage temperature and startup should not be below
-40°C;
• Normal ambient working temperature range is from -40 °C
to +40 °C, provided that a pre-heating cycle as described
above has been carried out.
• Maximum altitude is 1000 m above sea level.
• The variation of the supply voltage and frequency may not
exceed the limits mentioned in relevant standards. Toler-
ance for supply voltage is ±5 %, and for frequency ±2 % ac-
cording to the figure 4 (EN / IEC 60034-1, paragraph 7.3,
Zone A). Both extreme values are not supposed to occur at
the same time.
The motor can only be used in applications for which it is
intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In addition,
all requirements of this manual and other related
instructions and standards must be followed.
If these limits are exceeded, motor data and construction
data must be checked. Please contact ABB for further
information.
14 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS6. Low voltage motors in variable speed
operation
6.1 Introduction 6.4.1 Elimination of bearing currents with ABB converters
This part of the manual provides additional instructions for In case of ABB frequency converter, e.g. AC_8_ _- and AC_5_
motors used in conjunction with frequency converters. The _-series with a diode supply unit, the methods according to
motor is intended to operate from a single frequency table 6.1 must be used to avoid harmful bearing currents in
converter supply and not motors running in parallel from motors.
one frequency converter. Instructions given by the converter
manufacturer shall be followed. PN < 100 kW
UN ≤ 500 V Standard motor
Additional information may be required by ABB to decide on 500V < UN ≤ 690V (any Standard motor
cable length) + dU/dt –filter (reactor)
the suitability of the motor for use in special applications or
with special design modifications. Table 6.1 Selection of filters for ABB converters
6.2 Winding insulation Please contact ABB for more information on resistor braking
Variable speed drives create higher voltage stresses than and converters with controlled supply units.
the sinusoidal supply on the winding of the motor.
Therefore, when needed, the filter at the converter output
must be dimensioned according to the following
NOTE!
instructions.
Insulated bearings that have aluminum oxide coated
6.2.1 Selection of filters for ABB converters inner and/or outer bores or ceramic rolling elements
In the case of ABB, e.g. AC_8_ _-series and AC_5_ _-series are not suitable for SSE motors. Changing the
single drives with a diode supply unit (uncontrolled DC bearing type or insulation method without ABB’s
voltage), filters can be selected in accordance with table 6.1. permission is prohibited.
6.2.2 Selection of filters with all other converters
The voltage stresses must be limited to below accepted 6.4.2 Elimination of bearing currents with all other
limits. Please contact the system supplier to ensure the converters
safety of the application. The influence of possible filters The user is responsible for protecting the motor and driven
must be taken into account when dimensioning the motor. equipment from harmful bearing currents. Instructions
described in chapter 6.4.1 can be used as guideline, but their
6.3 Thermal protection effectiveness cannot be guaranteed in all cases.
SSE motors covered by this manual are by default equipped
with 3 PTC thermistors connected in series; they have a 6.5 Cabling, grounding and EMC
threshold value 150 ºC and are encapsulated into the stator Symmetrical and shielded cables are highly recommended,
winding to monitor the motor temperature and provide a even if not mandatory. Make the 360° grounding
signal in case the maximum temperature is exceeded. arrangement at all the cable entries as described in the
It is recommended to connect them to the frequency instructions for the glands. Twist the cable shields into
converter. Read more in chapter 4.8. bundles and connect to the nearest ground terminal/bus bar
inside the terminal box, converter cabinet, etc.
6.4 Bearing currents
Common mode filters and suitable cabling and grounding
methods must be used according to the following
instructions and using table 6.1.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 156. Low voltage motors in variable speed
operation
NOTE! NOTE!
In addition to the IP69 protection characteristics, The maximum speed of the motor and application
proper cable glands providing 360° bonding must be may not be exceeded!
used at all termination points such as motor,
converter, possible safety switch, etc.
6.7.3 Motor loadability with AC_5_ _ – series of converter
The loadability curves presented in Figures 6a – 6b are valid
More information about grounding and cabling of variable for AC_5_ _ -series converters. The figures show the
speed drives can be found in the manual “Grounding and approximate maximum continuous output torque of the
cabling of the drive system” (Code: 3AFY 61201998). motors as a function of supply frequency. The output torque
is given as a percentage of the nominal torque of the motor.
6.6 Operating speed The values are indicative and exact values are available on
For speeds higher than the nominal speed stated on the request.
motor’s rating plate or in the respective product catalog,
ensure that either the highest permissible rotational speed
of the motor or the critical speed of the whole application is NOTE!
not exceeded. For 2 pole motors, the maximum speed is
The maximum speed of the motor and application
6000 r/min; for 4 pole motors the maximum speed is 4000
may not be exceeded!
r/min.
6.7 Motors in variable speed applications
6.7.1 General 6.7.4 Motor loadability with other voltage source PWM-
With ABB’s frequency converters, the motors can be type converters
dimensioned using ABB’s DriveSize dimensioning program. For other converters with an uncontrolled DC voltage and
The tool is downloadable from the ABB website (www.abb. minimum switching frequency of 3 kHz (200…500 V), the
com/motors&generators). dimensioning instructions as mentioned in chapter 6.7.3 can
be used as guidelines. However, please note that the actual
For applications supplied by other converters, the motors thermal loadability can also be lower. Please contact the
must be dimensioned manually. For more information, manufacturer of the converter or the system supplier.
please contact ABB.
The loadability curves (or load capacity curves) are based on NOTE!
nominal supply voltage. Operation in under or over voltage
conditions may have an influence on the performance of the The actual thermal loadability of a motor may be
lower than shown by guideline curves.
application.
6.7.2 Motor loadability with AC_8_ _ – series of converters
with DTC control 6.7.5 Short time overloads
The loadability curves presented in Figures 5a – 5d are valid ABB motors can usually be temporarily overloaded as well as
for ABB AC_8_ _-series converters with uncontrolled DC- used in intermittent duties. The most convenient method to
voltage and DTC-control. The figures show the approximate dimension such applications is to use the DriveSize tool.
maximum continuous output torque of the motors as a
function of supply frequency. The output torque is given as a
percentage of the nominal torque of the motor. The values
are indicative and exact values are available on request.
16 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS6.8 Rating plates
The use of ABB’s motors in variable speed applications does
not usually require additional rating plates. The parameters
required for commissioning the converter can be found from
the main rating plate.
6.9 Commissioning the variable speed application
The commissioning of the variable speed application must
be done according to the instructions of the frequency
converter and local laws and regulations. The requirements
and limitations set by the application must also be taken
into account.
All parameters needed for setting the converter must be
taken from the motor rating plates. The most often needed
parameters are:
• nominal voltage
• nominal current
• nominal frequency
• nominal speed
• nominal power
NOTE!
In case of missing or inaccurate information, do not
operate the motor before ensuring the settings are
correct!
ABB recommends using all the suitable protective features
provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):
• minimum speed
• maximum speed
• acceleration and deceleration times
• maximum current
• maximum torque
• stall protection
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 177. Maintenance
better evacuation of the condensed water. Check the O-ring
WARNING! status of the removed drain plugs and if you notice any
damage or wear, replace them. Once finished, drain plugs
Voltage may be connected at standstill inside the
must be tightened ensuring that their O-rings are properly
terminal box for heating elements or direct winding
installed in their seats.
heating.
7.1.1 Standby motors
If the motor is in standby mode for a longer period of time
7.1 General inspection on a ship or other vibrating environment, the following
1. Inspect the motor at regular intervals, at least twice a measures have to be taken:
year. The frequency of checks depends on, for example,
the amount of washing cycles per day and their tough- 1. The shaft must be rotated regularly every two weeks (to
ness, the type of food in contact with the motors etc. be reported) by means of starting up of the system. In
This can initially be determined experimentally and must case a start-up is not possible, for any reason, at least
then be strictly adhered to. the shaft has to be turned by hand in order to achieve a
2. Keep the motor clean and ensure free ventilation airflow different position once a week. Vibrations caused by
(for fan cooled motors). If the motor is used in a dusty or other vessel’s equipment will cause bearing pitting
very dirty environment with a lot of food debris, the ven- which should be minimized by regular operation/hand
tilation system must be regularly checked and cleaned. turning.
3. Remove condensed water frequently by unplugging the 2. All vibrations must be avoided to prevent a bearing from
bottommost drain plug of the motor. failing. All instructions in the motor instruction manual
4. Check the condition of shaft seals (the external V-ring) for commissioning and maintenance have to be fol-
and replace if necessary. lowed. The warranty will not cover any damage to the
5. Check the condition of connections (by opening the ter- winding and bearings if these instructions have not
minal box cover and inspecting the faston tabs) and been followed.
mounting and assembly bolts. Once opened, check the
status of the o-ring seal and if damaged, replace it. Be- 7.2 Lubrication
fore closing the cover, apply grease on the O-ring - food
grade grease approved by US FDA.
6. Check the bearing condition by listening for any unusual WARNING!
noise, vibration measurement, bearing temperature,
Beware of all rotating parts!
leakage of grease etc. Pay special attention to bearings
when their calculated rated life time is coming to an end.
When signs of wear are noticed, dismantle the motor, check
the parts and replace if necessary. When bearings are WARNING!
changed, replacement bearings must be of the same type as
Grease can cause skin irritation and eye
those originally fitted (H1 food grade grease). The shaft
inflammation. Follow all safety precautions specified
seals have to be replaced with seals of the same quality and
by the manufacturer of the grease.
characteristics as the originals when changing bearings
(food grade rubber seals).
It is recommended to periodically open the drain plugs in
order to ensure that the way out for condensation is not
blocked and allows condensation to escape from the motor.
This operation must be done when the motor is at a
standstill and has been made safe to work on. To do so,
remove the bottom plug and possibly also the top one, for a
18 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORSBearing types are specified on the rating plate of all motors. 7.2.1 Lubricants
Bearings are in stainless steel and are permanently greased
with H1 food grade grease and do not need regreasing. WARNING!
Bearings are of the type 2Z, 2RS or equivalent. In case of
Do not mix different types of grease.
replacement, it is mandatory to use bearings with this kind
of grease. Incompatible lubricants may cause bearing damage.
Duty hours for permanently greased bearings at ambient
temperatures of 25 °C and 40 °C are: In case of bearing replacement, bearings with H1 food grade
grease with the following properties must be used:
Duty hours Duty hours
Frame size Poles at 25° C at 40° C
• good quality grease with Aluminum complex soap and
71-80-90-100-112 2 100 000 65 000
with PAO-oil
71-80-90-100-112 4-6 100 000 96 000
• base oil viscosity 150 cST at 40 °C
• temperature range -40 °C – +120 °C, continuously
Data is valid up to 60 Hz.
The above mentioned grease specification is valid if the
ambient temperature is above -40 °C or below +55 °C, and
NOTE! the bearing temperature is below 110 °C; otherwise, consult
ABB regarding suitable grease.
An increase in the ambient temperature raises the
temperature of the bearings correspondingly. The
The above grease is marked as VT378 by SKF
interval values should be halved for a 15 °C increase in
bearing temperature and may be doubled for a 15 °C
Grease with the correct properties is available from all major
decrease in bearing temperature.
lubricant manufacturers. As an example, the following H1
Food grade greases can be used:
Higher speed operation, e.g. in frequency converter • Bechem Berolub FG-H 2 SL
applications, or lower speed with heavy load will lead to less • Mobil Mobilgrease™ FM Series (101, 222)
duty hours. • Mobil Mobil SHC Polyrex™ Series (005, 221, 222, 462)
• Shell CASSIDA GREASE GTS 2
• Klüber Klüberfood NH1 94-402
WARNING! • Total NEVASTANE XMF
The maximum operating temperature of the grease If other lubricants are used, check with the manufacturer
and bearings, +110 °C, must not be exceeded. The
that the qualities correspond to those of the above
designed maximum speed of the motor must not be
mentioned lubricants (H1 Food Grade greases are
exceeded.
mandatory).
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 198. After Sales Support
8.1 Spare parts
Unless otherwise stated, spare parts must either be original NOTE!
parts or ones approved by ABB.
Any repair by the end user, unless expressly approved
by the manufacturer, releases the manufacturer from
When ordering spare parts, the motor serial number, full
responsibility to conformity.
type designation and product code, as stated on the rating
plate, must be specified. Replacing the bearings only without replacing also
the external gamma ring and the internal simmering
8.2 Dismantling, re-assembly and rewinding can cause serious damages and loss of IP69
Motors cannot be rewound. characteristics of the motors
8.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by heating
or using special tools. When replacing a DE bearing, external
gamma ring and internal Simmering must also be replaced.
Bearing replacement is described in detail in a separate
instruction leaflet available from the ABB Sales Office.
Any directions placed on the motor, such as labels, must be
followed. The bearing types indicated on the rating plate
must not be changed.
20 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS9. Environmental requirements
9.1 EU Directive 2012/19/EU (WEEE) Disposing of this product correctly will help save valuable
EU Directive 2012/19/EU (WEEE) gives end-users the resources and prevent any potential negative effects on
necessary information on how to treat and dispose of EEE human health and the environment, which could otherwise
(Electrical and Electronic Equipment) waste after it has been arise from inappropriate waste handling.
removed from service and is to be recycled.
9.1.4 For professional users in the European Union
9.1.1 Marking of the products The crossed –out wheeled bin symbol on the product(s) and
Products that are marked with the crossed-out wheeled bin / or accompanying documents means that used electrical
symbol as below and/or the symbol is included in its and electronic equipment (WEEE) should not be mixed with
documentation shall be handled in the following way: general household waste.
If you wish to discard electrical and electronic equipment
(EEE), please contact your dealer or supplier for further
information.
Disposing of this product correctly will help save valuable
resources and prevent any potential negative effects on
human health and the environment, which could otherwise
9.1.2 For private households arise from inappropriate waste handling.
The crossed–out wheeled bin symbol on the product(s) and
/ or accompanying documents means that used electrical 9.1.5 For disposal in countries outside of the European
and electronic equipment (WEEE) should not be mixed with Union
general household waste. For proper treatment, recovery The crossed–out wheeled bin symbol is only valid in the
and recycling, please take this product(s) to a designated European Union (EU) and means that used electrical and
collection point where it will be accepted free of charge. electronic equipment (WEEE) should not be mixed with
Alternatively, in some countries, you may be able to return general household waste.
your products to your local retailer upon purchase of an
equivalent new product. If you wish to dispose of this product, please contact your
local authorities or dealer for the correct method of
Disposing of this product correctly will help save valuable disposal.
resources and prevent any potential negative effects on
human health and the environment, which might otherwise Disposing of this product correctly will help save valuable
arise from inappropriate waste handling. resources and prevent any potential negative effects on
Please contact your local authority for further details of your human health and the environment, which could otherwise
nearest designated collection point. arise from inappropriate waste handling.
Depending on your national legislation, incorrect disposal of
this waste may incur a penalty in your country.
9.1.3 For professional users in the European Union
The crossed –out wheeled bin symbol on the product(s) and
/ or accompanying documents means that used electrical
and electronic equipment (WEEE) should not be mixed with
general household waste.
If you wish to dispose of electrical and electronic equipment
(EEE), please contact your dealer or sup-plier for further
information.
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 2110. Figures
Figure 1 Figure 2
Diagram illustrating the insulation resistance dependence Mounting of half-coupling or pulley
from the temperature and how to correct the measured
insulation resistance to the temperature of 40 °C.
100
50
10
5
1.0
0.5
0.1
0.05
Figure 3
-10 0 10 20 30 40 50 60 70 80 90 100
Connection of terminals for main supply
Key
X-axis: Winding temperature, Celsius Degrees
Y-axis: Insulation Resistance Temperature Coefficient, ktc
1) To correct observed insulation resistance, Ri,
to 40 ºC multiply it by the temperature coefficient ktc.
Ri 40 ºC = Ri x.
22 3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORSFigure 4 Figure 5a
Voltage and frequency deviation in zones A and B Converter with DTC control, 50 Hz, temperature rise B
IC410 Non ventilated natural air flow, IEC frame sizes 80-90
IC411 Self ventilated, IEC frame size 100
Figure 5b
Converter with DTC control, 60 Hz, temperature rise B
3GZF500930-876 REV C EN 06-2018 | ABB MOTORS AND GENERATORS 23For more information and contact details:
www.abb.com/motors&generators
3GZF500930-76 Rev C EN 06-2018
© Copyright 2018 ABB. All rights reserved.
Specifications subject to change without notice.You can also read
