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Summary of Contents for Vascat ID Series
- Page 1 OPERATION AND MAINTENANCE MANUAL ID MOTORS...
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Page 2: Table Of Contents
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 2 CONTENTS 1. LEGAL NOTES AND SAFETY INSTRUCTIONS ____________________________________________________________ 5 Justification ___________________________________________________________________________________ 5 Users and purpose _____________________________________________________________________________ 5 Hazards and warning signs _______________________________________________________________________ 6 Intended use __________________________________________________________________________________ 7 Qualified personnel _____________________________________________________________________________ 7 Disclaimer ____________________________________________________________________________________ 8 Scope of the documentation and external references ___________________________________________________ 8 2. - Page 3 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 3 3.7.3 Power-supply conditions ____________________________________________________________________27 3.7.4 Standard thermal protection _________________________________________________________________28 3.7.5 Optional thermal sensors ___________________________________________________________________28 3.7.6 Anti-condensation heaters __________________________________________________________________29 3.7.7 Fan and pressure gauge ___________________________________________________________________30 Accessories __________________________________________________________________________________ 31 3.8.1 Feedback sensors ________________________________________________________________________31 3.8.2 Parking brake ____________________________________________________________________________32 3.8.3 Noise level ______________________________________________________________________________33...
- Page 4 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 4 6.2.5 Replacement of motor brushes ___________________________________________________________________55 6.2.6 Cleaning the collector area ______________________________________________________________________56 Replacing the encoder/tacho _____________________________________________________________________ 56 Replacing the brake and/or lining _________________________________________________________________ 58 Original spares _______________________________________________________________________________ 59 Operating faults _______________________________________________________________________________ 61 6.6.1 Electrical faults ___________________________________________________________________________61 6.6.2...
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Page 5: Legal Notes And Safety Instructions
ID motors and avoid hazards that may cause serious injury. This manual is for any person or individual working with the motors to which it refers or who assume responsibility for their operation. All individuals working with ID series C.C. motors must have this manual at their disposal and they must follow the relevant instructions and indications. -
Page 6: Hazards And Warning Signs
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 6 1.3 Hazards and warning signs This manual contains the information required for personal safety and the prevention of material damages. All the information that refers to personal safety is highlighted in general with a warning triangle; however, the informative notes (to avoid only material damages) are not. -
Page 7: Intended Use
1.4 Intended use WARNING VASCAT motors are to be used in industrial installations. They comply with the requirements of the harmonised standards of the EN 60034 series. Said units are parts designed to be mounted on machines in accordance with the current machines directive. Start-up is not allowed until the end product is checked and found to be compliant with said directive (please see, among others, the EN 60204-1 standard). -
Page 8: Disclaimer
The indications that refer to procedures and the connection details included in this manual must be considered only as proposals and whether or not they are applicable must be studied for each case in particular. VASCAT does not guarantee their appropriateness in any case. -
Page 9: Declarations Of Conformity
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 9 2. DECLARATIONS OF CONFORMITY CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019 Subject to technical changes without prior notice... - Page 10 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 10 CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019 Subject to technical changes without prior notice...
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Page 11: Product Description
PAGE: 11 3. PRODUCT DESCRIPTION VASCAT ID motors are direct current separately excited electrical machines with square laminated steel frame and forced cooling. They have been specially designed to work in high-dynamics applications that require speed variation. They must be powered exclusively by AC/DC or DC/DC converters. -
Page 12: Reference Standards
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 12 3.2 Reference standards The ID motors are designed and manufactured according to the Low Voltage Directive 2006/95/CE and they have been designed for their use in industrial applications as an incomplete machine or as a machine component as provided for in the 2006/46/CE Machinery Directive. -
Page 13: Definitions
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 13 The data given in all the documentation provided by VASCAT includes tolerances regarding the most relevant parameters shown on the table 3: Maximum Power Efficiency Inertia Noise level Speed Power Torque Pn < 150 kW -15% (1-η) -
Page 14: Mounting
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 14 3.3.2 Mounting The following are some of the mounting types applicable to the ID motors, labelled in accordance with the IEC/EN 60034/7 standard. Mounting Diagram Assembly Mounting Diagram Assembly IM B3 Foot-mounting on IM V1 With flange shaft IM1001... -
Page 15: Ip Protection Rating
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 15 3.3.3 IP protection rating The protection rating of electrical machines is defined in accordance with IEC/EN 60034-5. Said standard specifies the protection rating of each machine using an ‘IP’ code, which comprises two digits: - First digit: Indicates the protection rating for contact and solid bodies. -
Page 16: Ic Cooling Method
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 16 3.3.4 IC Cooling Method The type of cooling used in electrical machines is regulated by the IEC/EN 60034-6 standard. In order to identify the type of cooling used in each motor, it is also given a code similar to the IP protection rating. There are two types of code: full indication (e.g. -
Page 17: Balancing And Vibration Level
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 17 3.3.5 Balancing and vibration level The EN 60034-14 standard specifies the test procedures for the acceptance of vibration at factory and the vibration limits for certain electrical machines in specific conditions when they are disconnected from a power machine or charge The standard defines two possible vibration levels for the shaft: type ‘A’... -
Page 18: Insulation Class
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 18 3.3.6 Insulation class The insulation rating of an electrical machine is identified on the motor specifications plate by means of a letter in accordance with the IEC/EN 60034-18 standard. The following table summarises the maximum allowed temperature in the installation of a winding in accordance with its insulation rating: Class Maximum temperature... -
Page 19: Nameplate
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 19 3.4 Nameplate All ID motors are provided with the following nameplate: Figure 1: ID motor nameplate The following table contains a description of the different fields of the plate: Pos. Description Pos. Description Motor type Serial No. -
Page 20: General Specifications
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 20 3.5 General specifications 3.5.1 Motor code ID series motors are coded as follows: Motor type Series Size Length Armature winding Field winding IP23 – IC06 Radial fan IP 23 – IC06 Radial fan... - Page 21 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 21 Figure 2: Derating factor for an S2-duty service CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019 Subject to technical changes without prior notice...
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Page 22: Mechanical Specifications
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 22 3.6 Mechanical specifications 3.6.1 Types of construction Available construction types for ID motors are detailed in the table below: Frame size EN 60034-7 IM B3 IM 1001 IM V5 IM 1011 IM V6 IM 1031 IM B5 IM 3001... -
Page 23: Degree Of Protection Ip
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 23 3.6.2 Degree of protection IP ID motors are defined with the following IP degrees: Standard Optional Motor version ratings IP23 IP44 / 54 Table 15: Degree of protection of ID motors For motors that comply with the IP23 protection rating, due precautions must be taken if they are installed in environments that are dusty, damp or subject to adverse weather. -
Page 24: Cooling Method
Tabla16: Available cooling methods for ID motors 3.6.4 Balancing and vibration level VASCAT motors from ID series are defined as A-grade vibration level machines (according to EN 60034-14). Balances for class B can also be supplied to order. CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019... -
Page 25: Bearings
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 25 3.6.5 Bearings ID motors include different bearings types depending on their frame size (shaft height). The following table summarises the bearings that are considered standard for each model: max n L10h max P max X max Fr Motor Type... - Page 26 A motor may need some type of special work (considered as non-standard) that includes a bearing different to those specified above. In said case, the customer must check with VASCAT to make sure that he has all the relevant information.
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Page 27: Electrical Specifications
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 27 3.7 Electrical specifications 3.7.1 Windings and insulation ID motor coil windings are made up of copper wires and plates with two coats of polyamide varnish > 220°C and/or THEIC- Polyesterimide with Amide-Imide > 200°C, rated with H-type insulation class. They are impregnated using single-component epoxy resins that polymerise on the basis of temperature, also class H. -
Page 28: Standard Thermal Protection
PT100 sensors on the windings and/or bearings, which would monitor the operating temperature at all times. The following graphs correspond to said sensors. Please check with VASCAT for each specific case. CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019... -
Page 29: Anti-Condensation Heaters
As an option (on request), one or two heating elements can be installed on the main and/or auxiliary coils to prevent condensation on the motor windings when the motor is to be installed at a site with high relative humidity (> 85%). The standard VASCAT model is 50 W 230 VAC. CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019... -
Page 30: Fan And Pressure Gauge
PAGE: 30 3.7.7 Fan and pressure gauge ID series motors are air-cooled using a forced ventilation system that includes an electric fan powered independently from the motor. The fan on the ID series motors can be installed in the following positions:... -
Page 31: Accessories
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 31 3.8 Accessories 3.8.1 Feedback sensors ID series motors can be fitted with different types of feedback sensors. As standard models, VASCAT offers the following incremental optical encoders Specifications Type A Type B Type C... -
Page 32: Parking Brake
3.8.2 Parking brake ID series motors can be fitted, as an option, with an electromagnetic parking brake to immobilise the motor load safely and in a way that is 100% external to the operation of the motor itself. On certain occasions, this is necessary for safety reasons, e.g. when it is necessary to block the movement of the machine to work on the interior safely or when there is a fault in the converter power supply or other mechanical devices of the installation. -
Page 33: Noise Level
The technical data sheets VASCAT provides for each motor show the noise level in dB issued by each model. Optionally, motors can be fitted with a kit to reduce the level of noise emissions. Please check with VASCAT for more details. -
Page 34: Shipment, Reception, Transport And Storage
Otherwise, a claim must be filed immediately with VASCAT for the faults that have been seen or for an incomplete shipment. -
Page 35: Transport
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 35 4.3 Transport The machine must be transported always in accordance with the following instructions: WARNING Transport and lifting of the machine by the eyebolts only For the correct handling of the motor, several eyebolts have been fitted on the top of the housing exclusively for said purpose. Therefore, do not lift the motor using the shaft or the fan casing under any circumstances. -
Page 36: Storage
Before packaging the motor, VASCAT applies a thin film of blue removable lacquer on the end of the shaft and the machined surfaces. This product protects the materials against corrosion. If it is to be stored for a long period, do not remove the protective film. -
Page 37: Installation And Start-Up
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 37 5. INSTALLATION AND START-UP PRECAUTION Damage caused to bearings as a result of long storage periods If the machine has been stored for more than 3 years in good conditions (dry, dust-free place, etc.), the grease on the bearings must be changed, if they need re-greasing, or the bearing should be changed if it is a bearing with lubrication for its entire service life. -
Page 38: Mounting
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 38 5.1.2 Mounting Correct mounting is essential to guarantee a long service life for the motor. The following are essential issues that need to be taken into account when anchoring the motor correctly: IM B3 Foot-mounting: a) Ensure that the support base is correctly levelled: the motors must be mounted on a solid, flat base that is perfectly level. -
Page 39: Machine Coupling
The customer is responsible for ensuring the correct alignment of both shafts. VASCAT motors and rotors are dynamically balanced using a half-key on the end of the shaft (in accordance with the 60034-14 standard). To ensure the correct balance of the entire transmission unit, all the parts of the transmission system must also be balanced (pulley, coupling, etc.). - Page 40 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 40 Figure 8: Fitting the coupling PRECAUTION Damages to the motor bearings If the motor shaft is knocked, the bearings may be damaged. If belts are used for the transmission of the torque or a gear with radial load, make sure that the admissible radial load is not exceeded on the motor shaft.
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Page 41: Electrical Connections
Before the connection, check the status of the insulation elements of the windings with regard to earth, since long or inappropriate storage or transport may have caused the motor to absorb humidity, which affects the capacity for insulation. The insulation reference values considered safe by VASCAT are as follows: Parameters... -
Page 42: Terminal Boxes And Connector Strips
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 42 5.2.1 Terminal boxes and connector strips The motor has a terminal box with the corresponding electrical connection strip and connection bolts for the current of each motor. The table below summarises the different types of terminal boxes, strips and terminals that correspond to the standard execution of each shaft height of the ID motors. -
Page 43: Connection Diagrams
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 43 5.2.2 Connection diagrams The connection schematics of the terminals in the terminal box for standard versions of the ID motors are as follows: CONEXIÓN TERMINALES TERMINAL CONNECTION 1 Tuerca / Nut 2 Arandela bloqueo / Blocking washer 3 Arandela / Washer 4 Terminal / Terminal 5 Puente / Bridge... -
Page 44: Power Cables
The inputs of the power cables that are to be connected on the motor terminal box strip and the converter terminals must comply with current regulations. For the protection rating, type of cable-laying, allowed cable diameter, connection, etc., VASCAT recommends the use of symmetrical structure screened cables in accordance with technical specification IEC TS 60034-25. -
Page 45: Connections For The Fan, Thermal Sensors And Accessories
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 45 The earth protection conductor must be connected to the terminal indicated for said function. DANGER A poor earth connection involves a severe risk of electrocution through accidental contact with the motor surface. 5.2.4 Connections for the fan, thermal sensors and accessories The fan motor cables must be connected in accordance with the specified voltage or that given on the fan motor nameplate (ID... -
Page 46: Final Checks
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 46 5.2.5 Final checks Before closing the terminal box, check that: The electric connections in the terminal box are fastened tight in accordance with the above and the fastening torques given in Table 22. There are no protruding wire ends. -
Page 47: Start-Up
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 47 5.3 Start-up 5.3.1 Preliminary checks Before starting the motor, check the following: - The motor is correctly aligned, fastened and coupled (the belt tension is correct in the case of belt transmission or the radial profile and tooth flank profile is adequate in the case of gear transmission). -
Page 48: Start-Up
4- Check that the manifold switches cleanly and evenly 5- After several hours in operation, check that the thermal behaviour of the motor corresponds to the motor service type. If in doubt, please contact VASCAT. CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019... -
Page 49: Maintenance
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 49 6. MAINTENANCE This chapter describes the preventive maintenance operations for ID motors. VASCAT declines all responsibility for faulty maintenance performed by the end user. 6.1 Safety instructions WARNING Qualified personnel All the cleaning and maintenance work must be carried out by qualified personnel in observance of the safety regulations that apply to the machine coupled to the motor and when the motors are completely stopped and isolated from the mains. -
Page 50: Basic Inspection
If faults are found during the inspection, they must be corrected immediately. Besides this basic inspection, a number of maintenance tasks must be carried out to ensure that the motor has a long service life. The maintenance operations recommended by VASCAT are as follows: 6.2.2 Cleaning of the fan and air filter It is important to keep the fan wheel as clean as possible. - Page 51 PAGE: 51 The air inlets of ID series motors are fitted with NGB 290/4-type particle filters, which require regular cleaning. The frequency of this operation will depend on the environment in which the motor is located and the frequency with which it is used.
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Page 52: Re-Greasing Of The Bearings
Factor that will depend on the re-greasing frequency (0.002 weekly, 0.003 monthly and 0.004 annually). VASCAT recommends re-greasing every 500 hours or once a month. The greasing nipples VASCAT fits to its motors comply with the DIN 71412 standard and are zinc-coated. The types used in standard procedures are as follows:... -
Page 53: Replacement Of Bearings
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 53 6.2.4 Replacement of bearings Both the bearings that have been greased for all their service life and those that need to be greased regularly, as well as hermetic parts that are subjected to wear and tear (seals and joints, etc.), where applicable, must be replaced after 20,000 operating hours. - Page 54 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 54 4. Remove the rotor from the interior of the stator, taking care not to damage the windings. Figure 15: Replacing bearings on ID motors (step 4) 5. Put the rotor in a stable place so that it does not turnover. 6.
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Page 55: Replacement Of Motor Brushes
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 55 6.2.5 Replacement of motor brushes The brush-holders are only accessible through the inspection windows, as shown by the following figures: Figure 17: Access to motor brush holder. In order to access the brushes on the lower position, it will be necessary to rotate the brush-holders ring, as there is not enough space below to access and remove these brushes: Figure 18: Detail of the rotation to access the lower brushes. -
Page 56: Cleaning The Collector Area
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 56 3. Remove the pressure spring from each brush. 4. Loosen the screw of each wire. 5. Insert the new brush, fasten the screws, reposition the spring, place the brush-holders back in its original position and tighten and adapt the brushes to the collector using a polishing stone. - Page 57 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 57 Figure 19: Replacing the encoder/tacho on ID motors (solid shaft type) CODE: CTT52 EDITION: 03 RELEASE: APRIL 2019 Subject to technical changes without prior notice...
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Page 58: Replacing The Brake And/Or Lining
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 58 6.4 Replacing the brake and/or lining The procedure for replacing the brake must be carried out as follows: Remove the entire stator from the brake (a) 2. Then remove the protection ring (c) 3. -
Page 59: Original Spares
OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 59 6.5 Original spares VASCAT supplies subunits of the complete motor as original spares for ID motors. The spare subunits that are available are listed in the following table: Spares Subunits Stator subunit... - Page 60 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 60 When a specific original spare is required for an ID or IDX series motor, the following information must be provided: 1. Motor type (by default, ID). 2. Series (ID or IDX). 3. Size (in reference to shaft height). 4.
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Page 61: Operating Faults
If faults appear during the operation of the motor, first of all check the possibility of the errors given in the following tables. If the fault cannot be eliminated with any of the following measures, please contact the technical service at VASCAT. - Page 62 OPERATION AND MAINTENANCE MANUAL ID MOTORS PAGE: 62 Fault Probable cause Corrective action Converter output voltage too high, Check adjustments on drive and perform auto-tuning frequency too low Overheating Fans stopped or turning in opposite Connect fan. Invert phase sequence in case of inverse during load-free direction rotation.
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Page 63: Mechanical Faults
Determine cause and eliminate it. Realign machine Table 28 : Mechanical faults 6.7 Technical support and service For more information or specific technical support, please contact: VASCAT, S.A. P.I. Mas les Vinyes, C/ De l’Esquirol, s/n Apartado 142 08570 Torelló (Barcelona) Tel. - Page 64 CTT 51 – ED – Terminal box – Conductor fR P material terminal Mt – Motor box S – Cable terminals – screen – Earth Earth terminal – cable Cable screen – Motor body – Screen bracket G – EMC –...
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