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MEZ Zone 2 Installation, Operation & Maintenance Instructions Manual

Hazardous area electric motors
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Installation, Operation & Maintenance Instructions
Hazardous Area Electric Motors
Zone 2
Zone 22
Zone 2 & 22

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Summary of Contents for MEZ Zone 2

  • Page 1 Installation, Operation & Maintenance Instructions Hazardous Area Electric Motors Zone 2 Zone 22 Zone 2 & 22...

  • Page 3: Legal Information

    Note the following: WARNING MEZ 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 Van Houcke. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 4: Machine Types

    Standard Efficiency IE1 Premium Efficiency IE3 Ex tC IIIB (Ex Zone 22) High Efficiency IE2 Standard Efficiency IE1 Premium Efficiency IE3 Ex nA IIC T3 (Ex Zone 2) High Efficiency IE2 Standard Efficiency IE1 Premium Efficiency IE3 Motor frame size to to Poles Voltage &...

  • Page 5: Safety Notes

    Safety notes Safety notes Information for those responsible for the plant or system This electric machine has been designed and built in accordance with the specifications contained in Directive 2006/95/EC up to April 19, 2016 - and from April 20, 2016 according to Directive 2014/35/EU ("Low-Voltage Directive") and is intended for use in industrial plants.

  • Page 6: The Five Safety Rules

    Safety notes Additional information: Information for plant managers (ATEX) This machine has been designed and built in accordance with Directive 94/9/EC until April 19, 2016 and from April 20, 2016 in accordance with Directive 2014/34/EU ("Explosion Protection Directive”), and it is intended for use in industrial plants with a potentially explosive atmosphere.

  • Page 7: Qualified Personnel

    Safety notes Qualified personnel All work at the machine must be carried out by qualified personnel only. For the purpose of this documentation, qualified personnel is taken to mean people who fulfill the following requirements: ● Through appropriate training and experience, they are able to recognize and avoid risks and potential dangers in their particular field of activity.
  • Page 8 Safety notes WARNING Live parts Electric machines contain live parts. Fatal or severe injuries and substantial material damage can occur if the covers are removed or if the machine is not handled, operated, or maintained properly. Always observe the “five safety rules" (Page 78) when carrying out •...
  • Page 9 Safety notes CAUTION Hazardous substances Chemical substances required for the setup, operation and maintenance of machines can present a health risk. Poisoning, skin damage, cauterization of the respiratory tract, and other health damage may result. Read the information in these operating instructions and the product •...

  • Page 10: Interference Voltages When Operating The Converter

    Safety notes Interference voltages when operating the converter WARNING Interference voltages when operating the converter When a converter is in operation, the emitted interference varies in strength depending on the converter (manufacturer, type, interference suppression measures undertaken). On machines with integrated sensors (e.g. PTC thermistors), interference voltages caused by the converter may occur on the sensor lead.
  • Page 11 Description Additional languages If you require additional language versions, please contact Van Houcke. Intended use of the machines These machines are intended for industrial installations. They comply with the harmonized standards of the series EN / IEC 60034 (VDE 0530). It is prohibited that these motors are used in hazardous zones if the marking on the rating plate does not explicitly permit line or converter operation.
  • Page 12 Description Table 3-1 Applicable general regulations Feature Standard Dimensioning and operating behavior EN / IEC 60034-1 Procedure for determining the losses and the efficiency of EN / IEC 60034-2-1 rotating electrical machines and inspections EN / IEC 60034-2-2 EN / IEC 60034-2-3 Degree of protection EN / IEC 60034-5 Cooling...
  • Page 13 Description Feature Standard Potentially explosive atmosphere - Part 31: Device dust EN / IEC 60079-31 explosion protection by enclosure "t" Electrical equipment for use in the presence of combus- EN / IEC 60079-17 tible dust - Part 17: Inspection and maintenance of elec- trical systems in hazardous areas (except underground excavation) Directive on the approximation of the laws of the Member...
  • Page 14 Description Table 3-4 Regulations applied for explosion-protected machines Feature Standard Electrical equipment for hazardous EN / IEC 60079-0 GOST 30852 0 - 2002 gas atmospheres, Part 0: General requirements Electrical equipment for hazardous EN / IEC 60079-7 GOST 30852 8 - 2002 gas atmospheres, Part 7: Increased safety "e"...

  • Page 15: Forced Ventilation (Optional)

    Machines intended for use in Zone 1 (type of protection Flameproof Enclosure "d" or Increased Safety "e") or in Zone 2 (type of protection "n") are designed with IP 55 degree of protection. Machines intended for use in Zone 21 have IP 65 degree of protection. Machines...

  • Page 16: Environmental Conditions

    Marking explosion-proof machines Table 3-5 Zone 1 with Ex e IIC Gb type of protection (increased safety "e") 0158 Table 3-6 Zone 2 with type of protection Ex nA IIC Gc, (non sparking) Table 3-7 Zone 21 0158 IIIC T125°C...

  • Page 17: Preparing For Use

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

  • Page 18: Transport And Storage

    Preparing for use Transport and storage When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. WARNING Risk of dropping and swinging when transported suspended If you transport the motor suspended from cables or ropes, the cables or ropes can break, e.g.
  • Page 19 Preparing for use 4.4.1 Storage Storing outdoors NOTICE Damage to the motor Damage can occur if incorrectly stored. Take all precautions to protect the motor under extreme climatic conditions, e.g. salt-laden and/or dusty, moist/humid atmospheres. Choose a dry storage location which is safe from flooding and free from vibration. Repair any damage to the packaging before putting the equipment into storage if this is necessary to ensure proper storage conditions.
  • Page 20 Preparing for use Explosion hazard during commissioning, if stored incorrectly WARNING Risk of explosion due to damaged sealing materials Storing the machine at temperatures that do not fall within the specified limits can damage the material of the seals and cause them to fail. As a result, a potentially explosive gaseous atmosphere can enter the machine and be ignited during commissioning.

  • Page 21: Electromagnetic Compatibility

    Preparing for use Closed bearings ● For sealed bearings, replace the DE and NDE bearings after a storage time of 48 months. NOTICE Storage The motor can be damaged if you use it or store it unprotected outdoors. Protect the motor against intensive solar radiation, rain, snow, ice and dust. Use •...

  • Page 22: Parameterizing The Converter

    Preparing for use Converter operation 4.7.1 Parameterizing the converter ● If the design of the motor requires connection to a particular converter type, the rating plate will contain corresponding additional information. ● Correctly parameterize the converter. Parameterizing data can be taken from the machine rating plate (not the supplementary rating plate with the operating data when connected to a converter).
  • Page 23 Preparing for use ● To ensure good discharging of high-frequency currents, provide contacting over a large surface area: – as contact established through 360° at the converter – at the motor, for instance with EMC glands at the cable entries ●...

  • Page 24: Insulated Bearings When Operated With A Converter

    Preparing for use Note Converter documentation The operating instructions for the converter are not part of this documentation. Refer also to the configuration information for the converter. 4.7.3 Insulated bearings when operated with a converter If the machine is operated from a low-voltage converter, insulated bearings are fitted at the NDE and an insulated encoder with insulated bearings (option).
  • Page 25 Preparing for use Tandem operation If you connect two motors in series in "tandem operation", install an insulated coupling between the motors. ① ④ Driving machine Insulated bearings ② ⑤ Motor Insulated tachometer fitting ③ ⑥ Coupling Insulated coupling Figure 4-2 Schematic representation of a tandem drive NOTICE Bearing damage...

  • Page 26: Preparing For Installation

    Installation When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. Note Loss of conformity with European directives In the delivery state, the machine corresponds to the requirements of the European directives.

  • Page 27: Insulation Resistance And Polarization Index

    Installation Note Note also the technical data on the rating plates on the motor enclosure. NOTICE Damage to the motor To avoid material damage, before commissioning, check whether the correct direction of rotation of the machine has been set on the customer side, e.g. by decoupling from the driven load.

  • Page 28: Testing The Insulation Resistance And Polarization Index

    Installation 5.1.2.2 Testing the insulation resistance and polarization index WARNING Hazardous voltage at the terminals During and immediately after measuring the insulation resistance or the polarization index (PI) of the stator winding, hazardous voltages may be present at some of the terminals. Contact with these can result in death, serious injury or material damage.
  • Page 29 Installation Limit values for the stator winding insulation resistance The following table specifies the measuring voltage and limit values for the insulation resistance. These values correspond to IEEE 43-2000 recommendations. Table 5-1 Stator winding insulation resistance at 40° C [MΩ] Meas U ≤...
  • Page 30 Installation ● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ, or possibly even higher values. An insulation resistance value close to the minimum value could be due to moisture and/or dirt accumulation. The size of the winding, the rated voltage and other characteristics affect the insulation resistance and may need to be taken into account when determining measures.
  • Page 31 Installation Installation 5.2.1 Installation of explosion-proof machines ● Only use explosion-protected machines in appropriate areas in accordance with directive 1999/92/EG . If the certification is supplemented by an X, please note the special conditions in the EC type test certificate.Special conditions for explosion-proof machines (Page 82) ●...
  • Page 32 Installation 5.2.2 Cooling WARNING Overheating and failure of the motor Death, severe injury or material damage can occur if you do not carefully observe the following points. Do not obstruct ventilation. • Prevent the air expelled by neighboring equipment from being immediately •...
  • Page 33 Installation 5.2.3 Balancing The rotor is dynamically balanced. The balancing quality corresponds to vibration severity grade "A" for the complete machine as standard. The optional vibration severity grade "B" is indicated on the rating plate. The declaration regarding the type of featherkey for balancing is generally marked on the rating plate and optionally on the face of the shaft end.
  • Page 34 Installation Alignment and mounting Observe the following when aligning and mounting: ● Ensure a flat and uniform contact surface for foot and flange mounting. ● Precisely align the machine when couplings are used. ● Ensure that the mounting surfaces are clean and free of any dirt. ●...

  • Page 35: Electrical Connection

    Electrical connection When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. Connecting the machine DANGER Hazardous voltages Death, injury or material damage can occur. Note the following safety information before connecting-up the machine: Only qualified and trained personnel should carry out work on the •...
  • Page 36 Electrical connection The following features make this type of electrical connection different from that for standard machines: ● For machines marked with Zone A, maintain area A in EN / IEC 60034-1 (VDE 0530-1) (±5 % voltage or ±2 % frequency deviation, waveform, line supply symmetry) so that the temperature rise remains within the permissible limits.

  • Page 37: Terminal Box

    Electrical connection 6.1.1 Terminal box DANGER Hazardous voltage Electric motors have high voltages. When incorrectly handled, this can result in death or severe injury. Switch off the machine so that it is in a no-voltage condition before you open the terminal box. NOTICE Damage to the terminal box If you incorrectly carry out work on or in the terminal box, this can result in material...

  • Page 38: Protruding Connection Cables

    Electrical connection 6.1.1.2 Protruding connection cables WARNING Risk of short-circuit and voltage hazard A short circuit can occur if connecting cables are clamped and crushed between parts of the enclosure and the cover plate. This can result in death, severe injury and material damage. During disassembly and particularly when installing the cover plate, •...
  • Page 39 Electrical connection 6.1.1.3 Thread sizes Table 6-1 Thread sizes in the cast iron terminal box Frame Type Type of protection / Standard thread Additional size Zone thread with mounting parts Size Size 71 ... 90 1TE1 Non sparking "n" M 25x1.5 M 16x1.5 Zone 21 Zone 22...
  • Page 40 Electrical connection...

  • Page 41: Tightening Torques

    Electrical connection Tightening torques 6.2.1 Electrical connections - Termincal board connections Table 6-3 Tightening torques for electrical connections on the terminal board Thread ∅ M 3,5 M 10 M 12 M 16 Nm min 6.2.2 Cable glands Note Avoid damaging the cable jacket. Adapt the tightening torques to the cable jacket materials.

  • Page 42: Terminal Boxes, End Shields, Grounding Conductors, Sheet Metal Fan Covers

    Electrical connection 6.2.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers If no other tightening torques are specified, then the values in the following table apply. Table 6-5 Tightening torques for screws on the terminal box, end shields, screw- type grounding conductor connections Thread ∅...

  • Page 43: Connecting The Grounding Conductor

    Electrical connection Connecting the grounding conductor The machine's grounding conductor cross-section must comply with EN / IEC 60034- Please also observe installation regulations such as those specified in EN / IEC 60204-1. 6.3.1 Grounding connection type Enclosure grounding method Cable cross- section [mm²] …...

  • Page 44: Conductor Connection

    Electrical connection Table 6-7 Minimum cross-sectional area of grounding conductor Minimum cross-sectional area of phase Minimum surface area of associated conductor for installation grounding connection [mm²] [mm²] S ≤ 16 16 < S ≤ 35 S > 35 0.5 S Table 6-8 Screw size of the grounding cable, external grounding Frame size...
  • Page 45 Electrical connection Table 6-10 Max. conductor connection for explosion-proof machines (with the exception of Zone 22) and VIK standard version Frame size Max. connectable conductor cross-section [mm²] 63 ... 112 16,0 10,0 180 (1LG4, 1LG6) 16,0 200 ... 225 50,0 250 ...

  • Page 46: Type Of Conductor Connection

    Electrical connection 6.4.1 Type of conductor connection Terminal board Con- ductor cross- section [mm²] Connection with cable DIN 46 234 ... 25 Bend down the cable lug for the connection. Connection of an indi- vidual conductor with terminal clamp ... 10 Connection of two conductors of approxi- mately the same thick-...
  • Page 47 Electrical connection Terminal board Conductor cross- section [mm²] Bend down the cable lug for the connection! 1MA618. … 10 1MA620. … 35 Connection of an indi- vidual conductor with terminal clamp 1MA618..20. … 25 Connection of two conductors of the same thickness with terminal clamp 1MA618.

  • Page 48: Connecting Converters

    Electrical connection Connection terminal 1MA6, 1MB153., 1MB163. and 1LG4/6 in type Conductor of protection Ex nA. cross- section Frame [mm²] size/option 18..22. 2,5 … 25 25..28. 10 … 95 25 … 135 31. + L00 / R50 50 …...
  • Page 49 Electrical connection WARNING Machine overheating Operating explosion-protected machines at the converter without using the appropriate protective equipment can result in death or severe injury. Always use PTC thermistor monitoring when operating explosion-protected machines at the converter. Tripping units according to directive 94/9/EC are always necessary when using PTC thermistor monitoring.

  • Page 50: Final Checks

    Electrical connection Final checks Before closing the terminal box/terminal base of the machine enclosure, check the following: ● Establish the electrical connections in the terminal box in accordance with the details in the sections above and tighten with the correct torque. ●...

  • Page 51: Setpoint Values For Monitoring The Bearing Temperature

    Commissioning When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. Setpoint values for monitoring the bearing temperature Prior to commissioning If the machine is equipped with bearing thermometers, set the temperature value for disconnection on the monitoring equipment before the first machine run.

  • Page 52: Measures Before Commissioning

    Commissioning Measures before commissioning NOTICE Damage to the machine In order to avoid material damage, check the following points before commissioning the motor: Using appropriate measures, check whether the correct direction of rotation of • the motor has been set by the customer, e.g. by decoupling from the driven load.
  • Page 53 Commissioning ● Corresponding to the control and speed monitoring functions implemented, ensure that the machine cannot exceed the permissible speeds specified on the rating plate. ● Ensure the correct setting conditions of the drive output elements depending on the type (e.g. alignment and balancing of couplings, belt forces in the case of a belt drive, tooth forces and tooth flank backlash/play in the case of gear wheel output, radial and axial clearance in the case of coupled shafts).

  • Page 54: Operation

    Operation When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. Switching on the machine DANGER Hazardous voltages Electrical machines are at hazardous voltage levels. Contact with these can result in death, serious injury or material damage.
  • Page 55 Operation WARNING Faults in operation Changes with respect to normal operation indicate that there is an impaired function. This can cause faults which can result in eventual or immediate death, severe injury or material damage. For instance, observe the following signs that could indicate a malfunction: Higher power drawn than usual •...

  • Page 56: Safety Information For Explosion-Protected Machines In Operation

    Only install machines with type of protection increased safety "e", and machines for Zone 2 in hazardous areas, according to the regulations laid down by the responsible regulatory body. They are responsible for determining the hazard level of each area (division into zones).

  • Page 57: Safety Instructions For Cleaning

    Operation Safety instructions for cleaning Cleaning To ensure problem-free machine cooling, the air ducts (ventilation grilles, channels, cooling fins, tubes) must be free of pollution. WARNING Risk of explosion when cleaning with compressed air If you clean the machine with compressed air, plastic components may become statically charged and ignite a potentially explosive atmosphere;...

  • Page 58: Fault Tables

    Operation Lubricating before recommissioning NOTICE Dry running bearings Bearings can be damaged if they do not have sufficient grease. Re-grease the bearings if they have been out of service for more than one year. • The shaft must rotate so that the grease can be distributed in the bearings. Observe the data on the lubricant plate.
  • Page 59 Operation Table 8-1 Electrical influences Electrical fault characteristics ↓ Machine will not start up ↓ Machine starts up reluctantly ↓ Rumbling noise during startup ↓ Rumbling noise during operation ↓ Overheating during no-load operation ↓ Overheating when under load ↓ Overheating of individual winding sections Possible causes of faults Remedial measures Overload...
  • Page 60 Operation Table 8-2 Mechanical effects Mechanical fault characteristics ↓ Grinding noise ↓ Overheating ↓ Radial vibrations ↓ Axial vibrations Possible causes of faults Remedial measures Rotating parts are grinding Determine cause and adjust parts concerned Reduced air supply, fan possibly Check airways, clean machine rotating in the wrong direction Rotor not balanced.

  • Page 61: Safety Instructions For Inspection And Maintenance

    Maintenance When carrying out any work on the machine, observe the general safety instructions (Page 77) and the specifications contained in EN 50110-1 regarding safe operation of electrical equipment. Safety instructions for inspection and maintenance WARNING Rotating and live parts Electric machines contain live and rotating parts.
  • Page 62 Maintenance NOTICE Damage to insulation If metal swarf enters the winding head when cleaning with compressed air, this can damage the insulation. Clearance and creepage distances can be undershot. This may cause damage to the machine extending to total failure. When cleaning with compressed air, ensure there is adequate extraction.

  • Page 63: Preparation And Notes

    Maintenance Preparation and notes 9.2.1 Paint finish resistant to sea air WARNING Risk of explosion as a result of processes with high levels of electrostatic charging Carefully observe the appropriate precautionary measures in order to avoid death or severe injury. For paint finish "resistant to sea air"...
  • Page 64 Maintenance – IIA, IIB: Total paint coating thickness ≤ 2 mm – IIC: Overall coating thickness ≤ 0.2 mm for motors of group II (gas) ● Limit the surface resistance of the paint used: – Surface resistance ≤ 1 GΩ for motors of groups II and III (gas and dust) ●...
  • Page 65 Maintenance Note When servicing a three-phase machine, it is generally not necessary to dismantle it. The machine only has to be dismantled if the bearings are to be replaced. Maintenance 9.4.1 Re-greasing For machines with regreasing system, relubrication intervals, grease quantity and grease grade are provided on the lubricant plate.

  • Page 66: Drain Condensate

    Maintenance 9.4.2 Cleaning Cleaning the grease ducts and spent grease chambers The spent grease collects outside each bearing in the spent grease chamber of the outer bearing cap. When replacing bearings, remove the spent grease. Note Dismantle the bearing cartridges to replace the grease in the lubrication duct. Cleaning the cooling air ducts Regularly clean the cooling air ducts through which the ambient air flows.
  • Page 67 Maintenance WARNING Hazardous voltage The winding can be damaged if objects are introduced into the condensation holes (optional). This can lead to death, serious injury or material damage. Note the following to maintain the degree of protection: Switch off the machine so that it is in a no-voltage condition before •...
  • Page 68 Maintenance WARNING Explosion hazard due to increased surface temperature Components within the motor may be hotter than the maximum permissible surface temperature for the enclosure. In an explosive atmosphere, dust can ignite and an explosion occur. This can result in death, serious injury or material damage. Do not open the motor in an explosive and dusty atmosphere when it is still at •...

  • Page 69: Replacing Bearings In Explosion-Proof Machines

    Replacing bearings in explosion-proof machines ● When changing the bearings, renew the sealing rings and only use original MEZ spare parts. ● For radial sealing rings with dust protection lip (DIN 3760-AS), completely fill the spaces (100%) in the sealing ring as well as in the bearing shield hub with a suitable grease.
  • Page 70 Maintenance ● Locate the arms of the pulling tool in the the breakout openings and slightly tension the pressure screw of the tool. ● Simultaneously release the two snap-in lugs of the fan from the shaft groove Keep the snap-in lugs in this position. ●...

  • Page 71: Fitting Bearings

    Maintenance 9.7.1 Fitting bearings Sealing the bearings Note the following details: ● Shaft sealing rings are used to seal machines at the rotor shaft. – For V rings, comply with the assembly dimension. ● Use the specified bearings. ● Ensure that the bearing sealing disks are in the correct position. ●...

  • Page 72: Mounting Fans

    Maintenance Mounting dimension "x" of V rings Motor Frame size types [mm] 4.5 ±0.6 Standard design 80 ... 112 6 ±0.8 132 ... 160 7 ±1 180 ... 200 1MA6 1FP1 180 ... 200 11 ±1 Special design 1MA622 180 ... 225 11 ±1 1MB1 1MA6...

  • Page 73: Spare Parts

    ● Order number and serial number of the machine Spare parts information and database Using the MEZ order number and the associated serial number, you can download spare parts information from a database for almost all current motors. Service & support If you have any technical queries or you require additional information, please contact MEZ Technical Support At Van Houcke NV.
  • Page 74 However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Van Houcke nv Vlamingveld 32 8490 Jabbeke Belgium Registered in Belgium. Company Reg. No. 0423055206 Tel: +32 (0)50 25 04 90 Fax: +32 (0)50 25 04 99 Email: mez@vanhoucke.be Website: www.mezmotorenbelgium.be www.vanhoucke.co.uk...

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