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Siemens LOHER CHEMSTAR 1PS5 Operating Instructions & Installation Instructions

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For employment in zone 1 or zone 2 (IEC/EN 60079-10-1)
II 2G Ex d IIC/IIB T. Gb
0102
LOHER CHEMSTAR
Induction motor
Type 1PS5
Operating Instructions / Installation Instructions N-R 601d
Edition
03/2014
Answers for industry.

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  • Page 1 For employment in zone 1 or zone 2 (IEC/EN 60079-10-1) II 2G Ex d IIC/IIB T. Gb 0102 LOHER CHEMSTAR Induction motor Type 1PS5 Operating Instructions / Installation Instructions N-R 601d Edition 03/2014 Answers for industry.
  • Page 2 11.03.2014 02:49 V4.00...
  • Page 3 Introduction Safety notes Description Induction motor Preparations for use LOHER CHEMSTAR 1PS5 Assembling Electrical connection Operating Instructions Installation Instructions Commissioning Operation Maintenance Spare parts Disposal Service and Support For employment in zone 1 or zone 2 (IEC/EN Technical data and drawings 60079-10-1) II 2G Ex d IIC/IIB T.
  • Page 4 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.

  • Page 5: Table Of Contents

    Attaching the rotor shipping brace prior to storage..............32 4.10.5 Storage for up to two years......................33 4.10.5.1 Storage conditions........................33 4.10.5.2 Storing motors with water cooling down to -20 °C..............33 4.10.6 Storage for between two and four years..................33 4.10.7 Storage at low temperatures.......................34 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 6 Connecting the machine for a specific direction of rotation............59 6.2.8 Terminal box..........................59 6.2.9 Minimum air clearances......................60 6.2.10 Cable ends with wire end sleeves....................61 6.2.11 Connection with terminal board....................61 6.2.12 Tightening torques for cable glands ...................62 6.2.13 Connecting aluminum conductors....................63 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 7 Regreasing intervals and types of grease for operating rolling-contact bearings.......90 9.1.7.6 Alternative types of grease for the operation of roller bearings...........92 9.1.7.7 Cleaning the cooling air passages....................93 9.1.7.8 Maintenance and repair for machines of protection type "Ex d" ..........93 9.1.7.9 Maintaining terminal boxes......................95 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 8 Service and Support..........................125 Siemens Service Center......................125 Technical data and drawings........................127 Tightening torques for screw and bolt connections..............127 Quality documents............................129 IECEx certificate........................129 EC Declaration of Conformity....................130 EC Declaration of Conformity, Zone 21 or 22................133 Data............................135 Index.................................137 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 9 Schematic representation of a tandem drive................40 Figure 5-1 Balancing type on the drive-end side..................46 Figure 6-1 Conductor connection.........................61 Figure 6-2 Conductor connection.........................62 Figure 10-1 E-AN000-0007...........................101 Figure 10-2 E-AN000-0008...........................102 Figure 10-3 E-AN000-0009...........................104 Figure 10-4 E-DN000-0010..........................106 Figure 10-5 E-9-101_162-0002........................108 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 10 Table of contents Figure 10-6 E-9-108_213-0001........................110 Figure 10-7 E-9-108_213-0002........................112 Figure 10-8 E-9-101_208-0002........................114 Figure 10-9 E-9-101_285-0002........................115 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 11: Introduction

    – 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 12 Introduction LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 13: Safety Notes

    Disconnect the auxiliary circuits, for example anti-condensation heating. 2. Secure against reconnection. 3. Verify absence of operating voltage. 4. Carry out earthing and short-short-circuiting. 5. Provide protection against adjacent live parts. To energize the system, apply the measures in reverse order. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 14: Qualified Personnel

    ● Always observe the "five safety rules (Page 13)" 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 15 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 16: Use In Hazardous Areas

    1999/92/EC directives as well as in the IEC / EN 60079 series of standards. If a third-party certification is available for the machine, then carefully comply with the technical data defined in it and any special conditions. The certificate must be available before commissioning. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 17: Electrostatic Sensitive Devices

    (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 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 18: Electromagnetic Compatibility

    In order to avoid exceeding the limit values set for the drive system (machine and converter) in IEC/EN 61000-6-3, the EMC information provided by the converter manufacturer must be observed. You must put appropriate EMC measures in place. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 19: Electromagnetic Fields When Operating Electrical Power Engineering Installations

    ● On the vertical type of machine construction with air intake from above, protect the air inlets from the ingress of foreign bodies and water. ● If the shaft extension is facing upwards, liquid must be prevented from entering by moving along the shaft. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 20 Safety notes 2.11 Ventilation LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 21: Description

    EC type examination certificate or in the IECEx certificate of conformity. Operation with a converter must be certified. It is essential that you observe the separate manufacturer's information and instructions. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 22: Table 3-1 Marking For Machines With Type Of Protection Ex D For Zone 1

    Ex d ib IIC T3 to T6 Gb Ex d ib IIB T3 to T6 Gb Ex d e ib IIC T3 to T6 Gb Ex d e ib IIB T3 to T6 Gb LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 23: Table 3-2 Marking For Machines With Ex Tb Type Of Protection For Zone 21

    Noise emission IEC/EN 60034‑9 Starting characteristics, rotating electrical machines IEC/EN 60034‑12* Vibration severity grades IEC/EN 60034‑14 Vibration limits DIN ISO 10816-3 * For machines in line operation only See also Quality documents (Page 129) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 24: Table 3-5 Motor Version With Type Of Explosion Protection Ex T

    The stator frame has a double jacket that is split and through which the cooling water flows. As a consequence, there is a good heat dissipation and there is less risk of the suspended solids in the water being deposited. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 25 For larger machines, an additional terminal box can be optionally mounted. You can see the number of available terminals in the circuit diagrams. Paint finish The machine is painted according to the instructions in your order. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 26 Anti-condensation heating The machine can be fitted with anti-condensation heating. The connection data is listed on an additional plate on the machine. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 27: Preparations For Use

    Here, only use a suitable grease to guarantee protection against corrosion. Ensuring adequate cooling Ensure that the machine is sufficiently cooled by the cooling air flow at the installation site: LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 28: Thermal Motor Protection

    ● Only operate anti-condensation heating when the machine is switched off. Interlock circuit for the external fan motor For machines with external fans, install an interlock circuit that prevents the main machine being switched on if the external fan is not operational. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 29: Noise Emissions

    (i.e. 0.58 times the rated motor current) is to be taken as a basis. If such a circuit is not possible, then additional protective measures are required (e.g. thermal motor protection). LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 30: System-Inherent Frequencies

    ● Report any apparent transport damage to the delivery agent immediately. ● Immediately report any apparent defects/missing components to your contact partner. These Operating Instructions are part of the scope of delivery; keep them in a location where they can be easily accessed. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 31: Lifting And Transportation

    3. Be aware of the possibility of different loads on the sling ropes or lifting straps and the carrying capacity of the lifting equipment. Note Store the rotor locking device Be sure to store the rotor locking device. It must be remounted for possible disassembly and transport. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 32: Attaching The Rotor Shipping Brace Prior To Storage

    If the customer has already mounted parts, for example coupling, belt pulley, etc., the bearing can be damaged during transport. ● In this case, make sure that the customer uses a rotor shipping brace. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 33: Storage For Up To Two Years

    4.10.6 Storage for between two and four years If machines are to be stored for between 2 and 4 years, then also observe the following: When ordering, the manufacturer must know the storage time. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 34: Storage At Low Temperatures

    – Caps filled with grease attached to the shaft output gland to provide protection against the ingress of dust and moisture are still effective. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 35: Commissioning After Storage

    ● For machines with regreasing systems, briefly lubricate both bearings after commissioning with the motor running as a precautionary measure. ● Grease type, grease quantity and relubrication intervals for the regreasing system are stamped on a supplementary plate attached to the machine. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 36: 4.10.10.4 Regreasing Roller Bearings After Storage Periods Of Between 2 And 4 Years

    4.11 Converter operation When controlling explosion-protected machines from a converter, carefully observe R-No. 20000 (Page 135) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 37 If the motor design requires a special converter assignment, you can find the appropriate additional data stamped on the rating plate. • Correctly parameterize the converter. The parameterization data is specified on the rating LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 38: Reducing Bearing Currents During Operation On The Converter

    – To ensure good discharging of high-frequency currents, provide contacting over a large surface area: with 360° contacting at the converter, at the motor for instance with EMC screw fastenings at the cable entries. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 39: Insulated Bearings When Operating The Converter

    ● In the overall system, set up a properly meshed grounding system with low impedance for high-frequency currents. ● Use the common-mode filter (damping cores) at the converter output. The Siemens sales representative is responsible for selection and dimensioning. ● Limit the rise in voltage by using output filters. This dampens the harmonic content in the output voltage.

  • Page 40: Figure 4-2 Schematic Representation Of A Tandem Drive

    Bearing damage If the coupling between the motors of the tandem drive is not insulated, bearing currents can cause damage to the drive-end bearings of both motors. Use an insulated coupling to link the motors. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 41 The voltage is up to 1000 V, depending on the converter type. Ensure that the five safety rules are followed before working on the motor. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 42 Preparations for use 4.11 Converter operation LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 43: Assembling

    ● Where necessary, use suitable steps when performing installation work on the machine. ● Do not stand on cables or attachments during installation. Do not use attachments as steps. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 44: Requirements For Installation

    ● Temperature-sensitive parts such as normal cables or electronic components must not rest against or be attached to mounted machine parts. ● Only use heat-resistant mounting parts. The connecting cables and cable entries must be suitable for the ambient temperature. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 45: Lift The Machine To Where It Will Be Installed, And Position It

    Note Store the rotor locking device Be sure to store the rotor locking device. It must be remounted for possible disassembly and transport. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 46: Mounting The Output Elements

    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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 47: Lifting And Transportation

    ● 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 stated on the rating plate. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 48 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 or in the immediate vicinity of the machine when it is raised. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 49: Setting Down The Machine

    ● Stable foundation design as per DIN 4024 ● Precise alignment of the machine ● Correct balancing of parts to be fitted to the shaft end. ● Maintaining the vibration velocity according to ISO 10816-3 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 50: Aligning The Machine To The Driven Machine And Mounting

    3. Position the machine so that its axis is aligned with that of the driven machine, but not yet quite touching. Advance the machine slowly towards the driven machine; advancing too quickly risks damaging the centering. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 51: Vertical Types Of Construction With Flange

    Observe the required alignment accuracy of the coupling manufacturer in all cases when aligning the machine. Table 5-1 Recommended alignment accuracy Speed [ Parallel offset [mm] Angular offset [mm per 100 mm coupling diameter] 0.09 0.09 1500 0.06 0.05 3000 0.03 0.025 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 52: Axial And Radial Forces

    5.4 Cooling water supply for machines with water cooling 5.3.4 Axial and radial forces You can obtain the permissible values for axial and radial forces by contacting the Siemens Service Center or referring to the machine catalog. NOTICE Damage to bearings or the shaft Large output masses and their centers of gravity outside the shaft extensions can lead to resonance in operation.
  • Page 53 If the cooling ducts are not completely filled with water, sufficient machine cooling cannot be guaranteed and the machine may overheat. Ensure that the air is bled from the cooling ducts during filling and that the cooling ducts are completely filled with water. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 54 Assembling 5.4 Cooling water supply for machines with water cooling LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 55: Electrical Connection

    Take the following criteria into account when selecting the connecting cables: ● Rated current ● Rated voltage ● If required, service factor ● System-dependent conditions, such as ambient temperature, routing type, cable cross- section as defined by required length of cable, etc. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 56: Connecting

    The intrinsically safe circuits are safely galvanically isolated from all non-intrinsically safe circuits up to a peak value for the rated voltage of 1000 V. Please refer to the additional plate on the machine for the maximum values for "intrinsically safe power circuits". LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 57: Terminal Boxes With Type Of Protection "Ex D

    An explosion may occur during operation. This can result in death, serious injury or material damage. The damaged seal may only be repaired with original sealing material. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 58: Connecting The Grounding Conductor

    Vaseline. 6.2.5 Circuit diagram in the terminal box cover Data on the connection and connecting the motor winding can be found in the circuit diagram in the cover of the terminal box. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 59: Terminal Designation

    ● If you are using cable glands, use only appropriately certified cable glands with strain relief. Comply with the installation and operation conditions specified in the certificate for these cable glands and check that they have been fully complied with. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 60: Minimum Air Clearances

    When determining the required minimum air clearance, the voltage value in the table may be increased by a factor of 1.1, so that the rated input voltage range is taken into account during general use. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 61: Cable Ends With Wire End Sleeves

    U shape. Alternatively, with multi-stranded and finely-stranded conductors, evenly divide the conductor (into two parts) and lay in a straight line under the U-shaped terminal clamps. See sketch! Figure 6-1 Conductor connection LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 62: Tightening Torques For Cable Glands

    Cable gland for Ex e / Ex d IIC TypeHSK-M Type ADE 1F, ADE 4F R... / B... Union nut Connection thread Union nut / connection Union nut / connection thread thread M12 x 1.5 M16 x 1.5 12.5 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 63: Connecting Aluminum Conductors

    Replace any damaged O-ring seals. O-ring seals can be present on the following components, for instance: ● Tapers ● Cable glands ● Bearing seals LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 64: Finishing Connection Work

    Internal equipotential bonding The equipotential bonding between the ground terminal in the terminal box enclosure and the motor frame is established via the terminal box metallic contact faces. The contact faces are protected against corrosion. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 65 The equipotential bonding is achieved by means of a stranded wire. A copper braided strip, a stranded wire or a metal contact is used to ensure potential equalization between the cable entry plate and the terminal box enclosure. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 66 Electrical connection 6.2 Connecting LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 67: Commissioning

    ● All touch protection measures for moving and live parts have been taken. WARNING If the openly accessible shaft sealing rings are damaged, the degree of protection is at risk. This can result in death, serious injury, or material damage. Replace damaged components immediately. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 68 You must contact the Service Center. Electrical connection ● The grounding and equipotential bonding connections have been made correctly. ● The machine is connected so that it rotates in the direction specified. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 69: 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" LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 70: Testing The Insulation Resistance And Polarization Index

    Limit values for insulation resistance and polarization index of the stator winding The following table shows the measuring voltage and limit values for the insulation resistance and polarization index. These values correspond to the recommendations of IEEE 43‑2000. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 71: Table 7-1 Stator Winding Insulation Resistance At 40° C

    Example calculation Critical resistance for a rated voltage (V ) of 3.3 kV: 3.3 kV x 1.8 MΩ / kV = 6 MΩ at 40 °C LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 72 Limit values of the anti-condensation heating insulation resistance The insulation resistance of the anti-condensation heating with respect to the machine housing should not be lower than 1 MΩ when measured at 500 V DC. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 73: Operation

    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! LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 74 This can result in material damage. ● Make sure that the anti-condensation heating is switched off before the machine is switched on. ● Only operate anti-condensation heating when the machine is switched off. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 75: Switching On The Machine

    8.6.1 Switching on the anti-condensation heater If the machine has anti-condensation heating, then switch it on when the machine is not in operation. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 76: Avoidance Of Frost And Corrosion Damage In The Cooling System

    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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 77: Decommissioning The Machine

    Correct the cause of the fault as described in the respective remedial measures section. Repair any damage to the machine. 8.9.2 Electrical faults Note If you are operating the motor with a converter, the operating instructions of the converter must also be observed if electrical faults occur. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 78: Mechanical Faults

    Rebalance the coupled machine. Shocks from coupled machine Investigate the coupled machine. Uneven running of gear unit Fix the gearing. Resonance of the overall system Stabilize the foundation following consultation. comprising motor and foundation LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 79: Roller Bearing Faults

    Too much grease in bearing Remove surplus grease. Wrong grease in the bearing Use the correct grease. Friction marks on raceway Replace the bearing. Scoring (brinelling) Replace the bearing. Avoid any vibration at standstill LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 80: Faults At The External Fan

    Switch on the cooling water supply. Cooling water contains frost or anti- Use cooling water of the agreed quality. corrosion additives Leaks in the cooling system Consult the manufacturer. Defective cooling water connection Find the leak and seal it. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 81: Maintenance

    ● 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 82 ● 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 83 Do not use compressed air to clean plastic parts in an explosive atmosphere. When cleaning the machine, make sure that the air in the vicinity of the motor is free of gas and dust. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 84: Inspections In The Event Of Faults

    16 000 operating hours or at the latest after two years: Table 9-2 Checks that have to be performed during the general inspection Checking When the motor is standstill running The electrical parameters are maintained The permissible bearing temperatures are not exceeded LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 85: Servicing The Roller Bearings

    Bolt grade for ambient temperature T ≥ -40 °C -55 °C ≤ T < -40 °C Standard Stainless steel bolts Standard 071, 080, 090, 100, 112, 132, A4-70 A4-70 160, 180, 200, 225, 250, 280, 315 180.B A4-80 A4-80 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 86: Mechanical Explosion Protection For Roller Bearings

    – The nominal roller bearing service life of machines which are not subject to any forces is at least 40 000 hours. ● For roller bearings with external oil supply, monitor that lubrication is maintained. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 87: Maintenance

    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 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 88 ● 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" LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 89: Grease Service Life And Fill Quantities

    Horizontal type of construction (B) Vertical type of construction (V) Permanent Relubricatio lubrication 3000 1500 ≤1000 3000 1500 ≤1000 2000 2800 5600 8000 4000 5600 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 90: Regreasing Intervals And Types Of Grease For Operating Rolling-Contact Bearings

    Observe the regreasing intervals for the roller bearings The regreasing intervals for roller bearings are different from the service/inspection intervals for the machine. Failure to regrease the roller bearings at the specified intervals can result in bearing damage. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 91 ‑20 °C, the permissible type of grease is indicated on the lubricant plate. Note Grease quantity control The grease quantity control only operates correctly if the specified greases are used. This is specified on plates attached to the machine. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 92: Alternative Types Of Grease For The Operation Of Roller Bearings

    To do this, thoroughly grease the bearing when the machine is running with about twice the amount of grease until spent grease has been removed from the greasing ducts. Then regrease 4x at intervals of ¼ of the LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 93: Cleaning The Cooling Air Passages

    This includes the following operations, for example: ● Repairs to the stator or rotor windings and to the terminals ● Repairs to the ventilation system ● Repairs to the bearings LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 94 Live electrical parts are dangerous. Contact with them can cause death, serious injury or material damage. Before carrying out any maintenance work on the external fan, disconnect it from the mains, particularly before opening the terminal box. Make sure that the device cannot be switched back on. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 95: Maintaining Terminal Boxes

    ● 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. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 96: Touch Up Any Damaged Paintwork

    ● Limit the surface resistance of the paint used: – IIB, IIC, III: Surface resistance ≤ 1 GΩ for motors of groups II and III (gas and dust) ● Breakdown voltage ≤ 4 kV for explosion group III (dust only) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 97: Repair

    If the motor has to be transported, please observe the information and instructions in the "Transport" section. Note Service Center Please contact the Service Center, if you require support with servicing, maintenance or repair. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 98: Anti-Condensation Heating Spare Parts

    9.2.2 Insulated roller bearings If roller-contact bearings with an insulated design are installed, use roller bearings of the same type as spare parts. This will prevent any bearing damage being caused by bearing currents. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 99: Spare Parts

    If roller-contact bearings with an insulated design are installed, use roller bearings of the same type as spare parts. This will prevent any bearing damage being caused by bearing currents. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 100: Using Commercially Available Spare Parts

    Repairing and mounting the anti-condensation heating and the subsequent routine testing must always be undertaken by experts from the Service Center (Page 125), because this work requires extensive specialist knowledge. Only authorized and tested spare parts may be used. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 101: Spare Parts List, Frame Sizes 071 To 132

    Spacer washer Shaft with rotor 201.20 Gamma ring End shield, drive end Roller bearings, NDE Flange plate Bearings, NDE End shield, non-drive end 301.10 Spacer washers 301.20 Gamma ring Fan cover Terminal box Protective cover LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 102: Spare Parts List, Frame Sizes 160 To 280

    Spare parts 10.6 Spare parts list, frame sizes 160 to 280 10.6 Spare parts list, frame sizes 160 to 280 Figure 10-2 E-AN000-0008 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 103 End shield, non-drive end 301.04 Outer grease chamber cover 301.06 Grease slinger Fan cover 301.10 Spacer washers Adapter screw 301.20 Gamma ring Protective cover Grease nipple Feather key Regreasing assembly Roller bearing, DE Terminal box Bearings, DE LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 104: Spare Parts List, Frame Size 315

    Spare parts 10.7 Spare parts list, frame size 315 10.7 Spare parts list, frame size 315 Figure 10-3 E-AN000-0009 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 105: Spare Parts List, Frame Size 355

    End shield, non-drive end 301.03 Grease chamber cover 301.06 Grease slinger Fan cover 301.20 Gamma ring Adapter screw Grease nipple Protective cover Regreasing assembly Feather key Terminal box 10.8 Spare parts list, frame size 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 106: Figure 10-4 E-Dn000-0010

    Fan cowl, complete 4.01 Bearing DE 5.04 Fan hub NDE 4.05 Bearing NDE 5.11 Protective cover 4.10 Grease chamber cover DE, outer 5.56 Fan, complete 4.12 Grease chamber cover DE, inner 6.00 Terminal box, complete LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 107 Spare parts 10.8 Spare parts list, frame size 355 Parts Designation Parts Designation Number Number 4.13 Grease slinger DE 4.24 Sealing ring DE, outer LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 108: Spare Parts List For Terminal Boxes With Type Of Protection "Ex E", Frame Sizes 071-160

    10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 071-160 10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 071-160 Figure 10-5 E-9-101_162-0002 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 109 Spare parts 10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 071-160 Parts Designation Parts Designation Number Number Terminal box base Additional terminals Terminal board Terminal box cover LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 110: Spare Parts List For Terminal Boxes With Type Of Protection "Ex D", Frame Sizes 071-160

    10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 071-160 10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 071-160 Figure 10-6 E-9-108_213-0001 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 111 10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 071-160 Parts Designation Parts Designation Number Number Gland plate Additional terminals Terminal box base Terminal box cover Terminal board LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 112: Spare Parts List For Terminal Boxes With Type Of Protection "Ex D", Frame Sizes 180-225

    10.11 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 180-225 10.11 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 180-225 Figure 10-7 E-9-108_213-0002 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 113 10.11 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 180-225 Part Designation Parts Designation number Number Gland plate Additional terminals Terminal box base Terminal box cover Terminal board LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 114: Spare Parts List For Terminal Boxes With Type Of Protection "Ex E", Frame Sizes 180-225

    Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 180-225 Figure 10-8 E-9-101_208-0002 Part Designation Parts Designation number Number Terminal box base Additional terminals Terminal board Terminal box cover LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 115: Spare Parts List For Terminal Boxes With Type Of Protection "Ex D", Frame Sizes 250 To 355

    10.13 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 10.13 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 Figure 10-9 E-9-101_285-0002 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 116 10.13 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 Part Designation Parts Designation number Number Gland plate Additional terminals Terminal box base Gland plate Terminal board Terminal box cover LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 117: Spare Parts List For Terminal Boxes With Type Of Protection "Ex D", Frame Sizes 250 To 355

    10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 118 Spare parts 10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 119 10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 Parts Designation Parts Designation Number Number Terminal box base Additional terminals Sealing washer Terminal box cover Terminal board LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 120 Spare parts 10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 121: Disposal

    4. Remove all liquids such as oil and cooling liquids. Collect the liquids separately and dispose of them in a professional manner. 5. Detach the machine fixings. 6. Transport the machine to a suitable location for disassembly. See also Maintenance (Page 81) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 122: Dismantling The Machine

    ● Coolant additives such as inhibitors, antifreeze or biocides Dispose of the separated components according to local regulations or via a specialist disposal company. The same applies for cloths and cleaning substances which have been used while working on the machine. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 123 ● 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 thermally. Dirty foil must be disposed of via waste incineration. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 124 Disposal 11.4 Disposal of components LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 125: Service And Support

    Technical queries or additional Phone +49 (0)911 895 7448 information +49 (0)911 895 7449 Spare parts and repairs Phone +49 (0)911 895 7222 +49 (0)911 895 7223 Contact: ● http://www.siemens.com/automation/support-request (http://www.siemens.com/ automation/support-request) ● ld-service.i-cs@siemens.com (mailto:ld-service.i-cs@siemens.com) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 126 Service and Support A.1 Siemens Service Center LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 127: Technical Data And Drawings

    Table B-1 Tightening torques for bolted connections with a tolerance of ±10%. Case 1080 1700 2600 4200 1200 2000 3100 4700 7500 Applications The above-mentioned tightening torques apply for the following applications: LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 128 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. See also Finishing connection work (Page 64) LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 129: Quality Documents

    1. Enter the IECEx ID in the "Quick access" field. You then have access to the certificate. 2. If you scroll down completely to the bottom of the page shown, you can open the certificate as a PDF file and download it. LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 130: Ec Declaration Of Conformity

    Quality documents C.2 EC Declaration of Conformity EC Declaration of Conformity LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 131 BVS 11 ATEX E 025 X T3 - T6 1MD*31*-*****-**** BVS 12 ATEX E 051 X T3 - T6 DJS*-315**-** 1PS*31*-*****-**** anti-friction BVS 12 ATEX E 077 X T3 - T6 Rev. Q-1 Seite 2 von 3 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 132 BVS 11 ATEX E 170 X T3 - T6 D*Q*-800**-** 1PS*80*-*****-**** sleeve PTB 06 ATEX 1049 X T3 - T6 D*Q*-910**-** 1PS*91*-*****-**** sleeve BVS 10 ATEX E 103 X T3 - T6 Rev. Q-2 Seite 3 von 3 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 133: Ec Declaration Of Conformity, Zone 21 Or 22

    Quality documents C.3 EC Declaration of Conformity, Zone 21 or 22 EC Declaration of Conformity, Zone 21 or 22 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 134 1MD*22*-*****-**** BVS 12 ATEX E 103 X A***-250**-** 1PS*25*-*****-**** BVS 11 ATEX E 034 E***-250**-** 1PS*25*-*****-**** BVS 11 ATEX E 030 X D***-250**-** 1MD*25*-*****-**** BVS 11 ATEX E 045 X Seite 2 von 2 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 135: Data

    Dr. Klaus Neupert $pUn".,Ilr .. Ughlll��'u: " � ... ! . " ..: ... : ... , ... " ..• .." 0,0' •. 0.> •. • o. e '.> I.! .. ) J:\LGR08\QM\QME\PrOffeld\FORM\r·nr\r·nr.20000h_EN.doc LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 136 Quality documents C.4 Data LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...

  • Page 137: Index

    Converter documentation, 39 Cooling system, 80 Cooling system Electric, 78 faults, 80 Inspection , 77, 84 Faults, 80 Roller bearings, 79 Cooling water supply, 52 Feather key, 47 Correct usage, 24 Filling , 53 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 138 External fan, 28 Intrinsically safe circuits, 56 Qualified personnel, 14 Lifting eye, 31, 47, 48 Limit speed, 69 Local field service Service numbers, 125 Radial force, 52 Lubricant plate, 90 Rating plate, 24 Re-commissioning, 77 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 139 Service numbers, 125 Spare parts ordering, 99 Standard cable glands, 62 Standard flange, 50, 51 Stoppages, 75, 76 Roller bearings, 76 Storage, 33 Switching off, 75 Switching on, 75 System resonances, 30 System-inherent frequencies, 30 LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 140 Index LOHER CHEMSTAR 1PS5 Operating Instructions 03/2014...
  • Page 141 AC EC-Declaration of Conformity (U161) AB EC-Declaration of Conformity (U163) AA R-No.20000h (U165)
  • Page 142 Siemens AG Industry Sector Drive Technologies and Industry Automation P.O. Box 4848 90327 NUREMBERG GERMANY www.siemens.com/drives...

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