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SIMOTICS
Drive technology
1FE1 synchronous built-in motors
Hardware Installation Manual
12/2016
610.43000.40b
Introduction
Fundamental safety
instructions
1
Description
2
Motor components
3
Preparing for use
4
Mechanical mounting
5
Connecting
6
Commissioning
7
Operation
8
Service and maintenance
9
Decommissioning and
disposal
10
Spare Parts/Accessories
11
List of abbreviations
A
Document order number: 610.43000.40b
Ⓟ
02/2017 Subject to change
Copyright © Siemens AG 2010 - 2016.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 5
Introduction
Keeping the documentation safe
This documentation should be kept in a location where it can be easily accessed and made
available to the personnel responsible.
Target group
This Hardware Installation Manual addresses installation technicians, commissioning
engineers, service and maintenance personnel.
About this Hardware Installation Manual
This Hardware Installation Manual applies to SIMOTICS M-1FE1 synchronous built-in
motors, called "1FE1" in the following text.
The Hardware Installation Manual explains how to handle the 1FE1 from delivery to disposal.
The Hardware Installation Manual provides information about the components that enable
the target group to install, set up, test, commission, operate, and troubleshoot the products
and systems correctly and safely.
● Before you start using the motor, you must read this Hardware Installation Manual. This
will ensure safe, problem-free operation and maximize the service life of the motor.
● Always follow the safety instructions and notices in this Hardware Installation Manual.
This Hardware Installation Manual complements the relevant Siemens Configuration Manual.
Siemens strives continually to improve the quality of information provided in this Hardware
Installation Manual.
● If you find any mistakes or would like to offer suggestions about how this document could
be improved, contact the Siemens Service Center.
The warning notice system is explained on the rear of the inside front.
Introduction
1FE1 synchronous built-in motors
6 Hardware Installation Manual, 12/2016, 610.43000.40b
Text features
In addition to the notes that you must observe for your own personal safety as well as to
avoid material damage, in this document you will find the following text features:
Operating instructions
Operating instructions with the specified sequence are designated using the following
symbols:
The arrow indicates the start of the operating instructions.
The individual handling steps are numbered.
1. Execute the operating instructions in the specified sequence.
The square indicates the end of the operating instruction.
Operating instructions without a specified sequence are identified using a bullet point:
● Execute the operating instructions.
Enumerations
● Enumerations are identified by a bullet point without any additional symbols.
– Enumerations at the second level are hyphenated.
Notes
Notes are shown as follows:
Note
A Note is an important item of information about the product, h
andling of the product or the
relevant section of the document. Notes provide you with help or further suggestions/ideas.
More information
Information on the following topics is available under the link:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
More information (https://support.industry.siemens.com/cs/de/en/view/108998034)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
docu.motioncontrol@siemens.com
Introduction
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 7
Internet address for products
Products (http://www.siemens.com/motioncontrol)
My support
The following link provides information on how to create your own individual documentation
based on Siemens content, and adapt it for your own machine documentation:
My support (https://support.industry.siemens.com/My/de/en/documentation)
Note
If you want to use this function, you must first register.
Later, you can log on with your login data.
Training
The following link provides information on SITRAIN - training from Siemens for products,
systems and automation engineering solutions:
SITRAIN (http://siemens.com/sitrain)
Technical Support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
Technical Support (https://support.industry.siemens.com/sc/ww/en/sc/2090)
Websites of third parties
This publication contains hyperlinks to websites of third parties. Siemens does not take any
responsibility for the contents of these websites or adopt any of these websites or their
contents as their own, because Siemens does not control the information on these websites
and is also not responsible for the contents and information provided there. Use of these
websites is at the risk of the person doing so.
Introduction
1FE1 synchronous built-in motors
8 Hardware Installation Manual, 12/2016, 610.43000.40b
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 9
Table of contents
Introduction ............................................................................................................................................. 5
1 Fundamental safety instructions ............................................................................................................ 13
1.1 General safety instructions ..................................................................................................... 13
1.2 Handling electrostatic sensitive devices (ESD) ...................................................................... 18
1.3 Industrial security .................................................................................................................... 19
1.4 Residual risks of power drive systems .................................................................................... 20
2 Description ............................................................................................................................................ 21
2.1 Special safety notices for handling built-in motors ................................................................. 21
2.2 Correct usage ......................................................................................................................... 22
2.3 Overview of the motors ........................................................................................................... 23
2.4 Technical features and environmental conditions .................................................................. 24
2.4.1 Directives and standards ........................................................................................................ 24
2.4.2 Technical characteristics......................................................................................................... 26
2.4.2.1 Weights and moments of inertia ............................................................................................. 28
2.4.2.2 Magnetic forces that occur ...................................................................................................... 30
2.4.3 Rating plate data ..................................................................................................................... 32
2.4.4 Structure of the article number ............................................................................................... 33
3 Motor components ................................................................................................................................ 35
3.1 Thermal motor protection ........................................................................................................ 35
3.2 Cooling .................................................................................................................................... 36
3.3 Encoder ................................................................................................................................... 39
4 Preparing for use .................................................................................................................................. 41
4.1 Safety instructions for electromagnetic and permanent-magnetic fields ................................ 41
4.2 Shipping and packaging ......................................................................................................... 44
4.3 Transportation and storage ..................................................................................................... 47
5 Mechanical mounting ............................................................................................................................ 51
5.1 Safety instructions ................................................................................................................... 51
5.2 Mounting instructions .............................................................................................................. 55
5.3 Mounting/dismantling the rotor ............................................................................................... 56
5.3.1 Tools and resources ............................................................................................................... 56
5.3.2 Preparation ............................................................................................................................. 60
5.3.3 Mounting the rotor ................................................................................................................... 62
5.3.4 Compensating mechanical stresses and deformations of the spindle shaft........................... 64
5.3.5 Balancing ................................................................................................................................ 67
5.3.6 Dismantling the rotor ............................................................................................................... 69
Table of contents
1FE1 synchronous built-in motors
10 Hardware Installation Manual, 12/2016, 610.43000.40b
5.4 Mounting the stator with the spindle housing ......................................................................... 73
5.4.1 Production equipment, assembly tools and other resources ................................................. 73
5.4.2 Mounting preparation ............................................................................................................. 74
5.4.3 Mounting the stator with cooling jacket .................................................................................. 76
5.4.4 Mounting the stator without cooling jacket ............................................................................. 82
5.5 Mounting the motor spindle .................................................................................................... 86
5.5.1 Preparation ............................................................................................................................. 86
5.5.2 Acting magnetic forces ........................................................................................................... 86
5.5.3 Mounting the motor spindle with IPM rotor ............................................................................ 87
5.5.4 Mounting the motor spindle with APM rotor ........................................................................... 88
5.6 Installation .............................................................................................................................. 92
5.6.1 Placement of the motor spindle ............................................................................................. 92
5.6.2 Permissible motor vibrations .................................................................................................. 92
6 Connecting ........................................................................................................................................... 95
6.1 Connecting the cooling .......................................................................................................... 95
6.1.1 Warning of the consequences of unqualified work ................................................................ 95
6.1.2 Safety instructions .................................................................................................................. 95
6.1.3 Connecting the water cooling ................................................................................................. 98
6.1.4 Connecting the air cooling ..................................................................................................... 99
6.2 Electrical connection ............................................................................................................ 100
6.2.1 Safety information ................................................................................................................ 100
6.2.2 High-voltage test .................................................................................................................. 100
6.2.3 Electrical equipment ............................................................................................................. 101
6.2.4 Connection cables ............................................................................................................... 101
6.2.5 Cable cross-sections and outer diameter of the connecting cables .................................... 103
6.2.6 Information on cable routing ................................................................................................ 107
6.2.7 Connecting to a converter .................................................................................................... 108
6.2.8 Connection overview ............................................................................................................ 108
6.2.9 Grounding ............................................................................................................................ 109
6.2.10 Connecting the temperature sensors ................................................................................... 110
6.2.11 Temperature evaluation using NTC thermistors (universal protection, option) ................... 113
6.2.12 Temperature evaluation using the PTC thermistor triplet (full motor protection, option) ..... 114
6.2.13 Voltage limitation .................................................................................................................. 115
7 Commissioning .................................................................................................................................... 119
7.1 Safety instructions ................................................................................................................ 119
7.2 Checklists for commissioning ............................................................................................... 122
7.3 Test the insulation resistance .............................................................................................. 125
7.4 Commutation angle and pole position identification ............................................................ 126
7.4.1 Commutation angle .............................................................................................................. 126
7.4.2 Pole position identification variants ...................................................................................... 127
7.5 Commissioning the cooling circuit........................................................................................ 128
7.6 Switching on and switching off ............................................................................................. 128
Table of contents
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 11
8 Operation ............................................................................................................................................ 129
8.1 Safety instructions ................................................................................................................. 129
8.2 Operation .............................................................................................................................. 132
8.3 Faults .................................................................................................................................... 133
8.4 Stoppages ............................................................................................................................. 135
9 Service and maintenance .................................................................................................................... 137
10 Decommissioning and disposal ........................................................................................................... 139
10.1 Safety instructions ................................................................................................................. 139
10.2 Decommissioning .................................................................................................................. 140
10.3 Disposal ................................................................................................................................ 141
10.3.1 Disposal - Introduction .......................................................................................................... 141
10.3.2 Guidelines for disposal.......................................................................................................... 141
10.3.3 Disposal of 1FE1 rotors ........................................................................................................ 142
10.3.4 Disposal of packaging ........................................................................................................... 142
11 Spare Parts/Accessories ..................................................................................................................... 143
A List of abbreviations ............................................................................................................................ 145
Index................................................................................................................................................... 147
Table of contents
1FE1 synchronous built-in motors
12 Hardware Installation Manual, 12/2016, 610.43000.40b
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 13
Fundamental safety instructions
1
1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
• Only work on electrical devices when you are qualified for this job.
• Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
– Switch off the machine.
– Wait until the discharge time specified on the warning labels has elapsed.
– Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
– Check whether the existing auxiliary supply circuits are de-energized.
– Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or
short-circuiting or closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
• Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
Fundamental safety instructions
1.1 General safety instructions
1FE1 synchronous built-in motors
14 Hardware Installation Manual, 12/2016, 610.43000.40b
WARNING
Danger to life when live parts are touched on damaged motors/devices
Improper handling of motors/devices can damage them.
For damaged motors/devices, hazardous voltages can be present at the enclosure or at
exposed components.
• Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
• Do not use any damaged motors/devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
• As a minimum, connect cable shields and the conductors of power cables that are not
used (e.g. brake cores) at one end at the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
• Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
• Only open plug connections when the equipment is in a no-voltage state, unless it has
been explicitly stated that they can be opened in operation.
Fundamental safety instructions
1.1 General safety instructions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 15
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This
can result in damage due to fire, device defects or malfunctions.
• Tighten all power connections with the specified tightening torques, e.g. line supply
connection, motor connection, DC link connections.
• Check all power connections at regular intervals. This applies in particular after
transport.
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction, influence the
functional safety of machines therefore putting people at risk or causing material damage.
• Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.
WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
• Check that the warning labels are complete based on the documentation.
• Attach any missing warning labels to the components, in the national language if
necessary.
• Replace illegible warning labels.
Fundamental safety instructions
1.1 General safety instructions
1FE1 synchronous built-in motors
16 Hardware Installation Manual, 12/2016, 610.43000.40b
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to serious injury or death.
• Observe the information in the appropriate product documentation before
commissioning.
• Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
• Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
• Perform a function test.
• Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the
Safety I
ntegrated manuals.
WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment,
such as transformers, converters, or motors.
People with pacemakers or implants are at particular risk in the immediate vicinity of this
equipment.
• If you have a heart pacemaker or implant, maintain the minimum distance specified in
chapter "Correct usage" from such motors.
WARNING
Danger to life from permanent-magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk
for persons with heart pacemakers or implants if they are close to converters/motors.
• If you have a heart pacemaker or implant, maintain the minimum distance specified in
chapter "Correct usage".
• When transporting or storing permanent-magnet motors always use the original packing
materials with the warning labels attached.
• Clearly mark the storage locations with the appropriate warning labels.
• IATA regulations must be observed when transported by air.
Fundamental safety instructions
1.1 General safety instructions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 17
WARNING
Risk of injury caused by moving parts or parts that are flung out
Touching moving motor parts or drive output elements and loose motor parts that are flung
out (e.g. feather keys) in operation can result in severe injury or death.
• Remove any loose parts or secure them so that they cannot be flung out.
• Do not touch any moving parts.
• Safeguard all moving parts using the appropriate safety guards.
WARNING
Danger to life due to fire if overheating occurs because of insufficient cooling
Inadequate cooling can cause overheating resulting in death or severe injury as a result of
smoke and fire. This can also result in increased failures and reduced service lives of
motors.
• Comply with the specified coolant requirements for the motor.
WARNING
Danger to life due to fire as a result of overheating caused by incorrect operation
When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire
and smoke. This can result in severe injury or death. Further, excessively high
temperatures destroy motor components and result in increased failures as well as shorter
service lives of motors.
• Operate the motor according to the relevant specifications.
• Only operate the motors in conjunction with effective temperature monitoring.
• Immediately switch off the motor if excessively high temperatures occur.
CAUTION
Risk of injury due to touching hot surfaces
In operation, the motor can reach high temperatures, which can cause burns if touched.
• Mount the motor so that it is not accessible in operation.
Measures when maintenance is required:
• Allow the motor to cool down before starting any work.
• Use the appropriate personnel protection equipment, e.g. gloves.
Fundamental safety instructions
1.2 Handling electrostatic sensitive devices (ESD)
1FE1 synchronous built-in motors
18 Hardware Installation Manual, 12/2016, 610.43000.40b
1.2
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged
individual components, integrated circuits, modules or devices.
• Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
• Only touch components, modules and devices when you are grounded by one of the
following methods:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
• Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).
Fundamental safety instructions
1.3 Industrial security
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 19
1.3
Industrial security
Note
Industrial security
Siemens
provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement
– and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions only represent one component of such a
concept.
The customer is responsible for preventing unauthorized access to its plants, systems,
ma
chines and networks. Systems, machines and components should only be connected to
the enterprise network or the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Addit
ionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported,
and failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).
WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
• Keep the software up to date.
• Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
• Make sure that you include all installed products into the holistic industrial security
concept.
• Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
Fundamental safety instructions
1.4 Residual risks of power drive systems
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20 Hardware Installation Manual, 12/2016, 610.43000.40b
1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Unintentional movements of driven machine or system components during
commissioning, operation, maintenance, and repairs caused by, for example,
– Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
– Response times of the control system and of the drive
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
– External influences/damage
– X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
– Component failure
– Software errors
– Operation and/or environmental conditions outside the specification
– External influences/damage
3. Hazardous shock voltages caused by, for example:
– Component failure
– Influence during electrostatic charging
– Induction of voltages in moving motors
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too
close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 21
Description
2
2.1
Special safety notices for handling built-in motors
Components with permanent magnets
For the 1FE1 built-in motor described in this manual, the permanent magnets are located in
the rotor.
Risk to persons as a result of strong magnetic fields
WARNING
Danger to life as a result of permanent magnet fields
Even when not installed, the permanent-magnetic fields of electric motors represent a
potential risk for persons with heart pacemakers or implants if they are close to motors.
• If you are an affected person, maintain a minimum separation of 500 m.
• When transporting or storing permanent magnet motors always use the original packing
materials with the warning labels attached.
• Clearly mark the storage locations with the appropriate warning labels.
WARNING
Electrical shock hazard
Each movement of the rotor in relation to the stator or vice versa induces a voltage. If you
use defective cable ports, you could suffer an electric shock.
• Do not touch the cable ports.
• Connect the motor cable ports correctly, or insulate them properly.
Material damage caused by strong magnetic fields
NOTICE
Data loss caused by strong magnetic fields
If you are close to the rotor (< 100 mm) any magnetic or electronic data medium as well as
electronic devices that you are carrying can be destroyed. For example, credit cards, USB
sticks, floppy disks and watches are at risk.
• Do not carry any magnetic/electronic data media and no electronic devices when you
are close to a rotor!
Description
2.2 Correct usage
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22 Hardware Installation Manual, 12/2016, 610.43000.40b
2.2
Correct usage
WARNING
Danger to life and material damage when incorrectly used
If you do not use the motors correctly, there is a risk of death, severe injury and/or material
damage.
• Only use the motors for their intended purpose.
• Make sure that the conditions at the location of use comply with all the rating plate data.
• Make sure that the conditions at the location of use comply with the conditions specified
in this documentation. When necessary, take into account deviations regarding
approvals or country-specific regulations.
WARNING
Danger to life caused by magnetic and electrical fields to persons with active implants
Electric motors represent a danger for people with active implants who come close to the
motors.
• If you are an affected person, maintain a minimum separation of 500 m to motors.
If you wish to use special versions and design variants whose specifications vary from the
motors described in this document, then contact your local Siemens office.
If you have any questions regarding the intended usage, please contact your local Siemens
office.
WARNING
Danger to life through the use of an incomplete machine
If you use a machine that does not conform to the 2006/42/EU decree, there is the danger
of death, severe injury and/or material damage.
• Commission the machine only when it conforms to the regulations of the EU
2006/42/EU machine decree and the conformity has been declared.
Synchronous built-in motors are components for installation in machines and for deployment
in industrial or business plants.
Any other application of the motor is considered to be incorrect usage.
The observance of the specifications contained in the Hardware Installation Manual and the
Configuration Manual is part of the correct usage.
● Observe the data on the rating plate.
Conditions at the location of use must comply with the specifications on the rating plate.
Description
2.3 Overview of the motors
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 23
The 1FE1 is designed for operation in sheltered areas under normal climatic conditions, such
as those found on shop floors.
The 1FE1 is not permitted to be operated in hazardous areas.
The 1FE1 motor is only certified for operation through a converter.
The 1FE1 is a three-phase motor for low voltage.
The motor is deployed for machine tool main spindle drives.
A motor spindle unit results after installing the rotor and the stator in the machine tool
spindle.
2.3
Overview of the motors
Table 2- 1 Motor types
IPM rotor (rotor with internal permanent magnets)
APM rotor (rotor with external permanent mag-
nets)
1FE105☐-4W
1FE105☐-4H
1FE107☐-
4
W 1FE110☐-
4
1FE108☐-4W
1FE112☐-4
1FE109☐-4W
1FE104☐-6
1FE105☐-6W
1FE114☐-8
1FE106☐-6W
1FE108☐-6W
1FE109☐-6W
1FE111☐-6W
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
24 Hardware Installation Manual, 12/2016, 610.43000.40b
2.4
Technical features and environmental conditions
2.4.1
Directives and standards
Standards that are complied with
SIMOTICS S, SIMOTICS M, SIMOTICS L, SIMOTICS T, SIMOTICS A motors -
subsequently called the "SIMOTICS motor series " - comply with the following standards:
● EN 60034-1 - Rotating electrical machines – Dimensioning and operating behavior
● EN 60204-1 - Safety of machinery – Electrical equipment of machines; general
requirements
Where applicable, the SIMOTICS motor series are in conformance with the following parts of
IEC / EN 60034:
Feature
Standard
Degree of protection
IEC / EN 60034-5
Cooling 1) IEC / EN 60034-6
Type of construction
IEC / EN 60034-7
Connection designations IEC / EN 60034-8
Noise levels
1)
IEC / EN 60034-9
Temperature monitoring
IEC / EN 60034-11
Vibration severity levels
1)
IEC / EN 60034-14
1) Standard component, e.g. cannot be applied to built-in motors
Relevant directives
The following directives are relevant for SIMOTICS motors.
European Low-Voltage Directive
SIMOTICS motors comply with the Low-Voltage Directive 2014/35/EU.
European Machinery Directive
SIMOTICS motors do not fall within the area of validity covered by the Machinery Directive.
However, the use of the products in a typical machine application has been fully assessed
for compliance with the main regulations in this directive concerning health and safety.
European EMC Directive
SIMOTICS motors do not fall within the area of validity covered by the EMC Directive. The
products are not considered as devices in the sense of the directive.
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 25
Eurasian conformity
SIMOTICS motors comply with the requirements of the customs union
Russia/Belarus/Kazakhstan (EAC).
China Compulsory Certification
SIMOTICS motors do not fall within the area of validity covered by the China Compulsory
Certification (CCC).
CCC product certification
(https://support.industry.siemens.com/cs/document/93012735/allgemeine-produktzulassung-
ccc?lc=de-WW&pnid=13347)
Underwriters Laboratories
SIMOTICS motors are generally in compliance with UL and cUL as components of motor
applications, and are appropriately listed.
Specifically developed motors and functions are the exceptions in this case. Here, it is
important that you carefully observe the contents of the quotation and that there is a cUL
mark on the rating plate!
Quality systems
Siemens AG employs a quality management system that meets the requirements of ISO
9001 and ISO 14001.
Certificates for SIMOTICS motors can be downloaded from the Internet at the following link:
Certificates for SIMOTICS motors
(https://support.industry.siemens.com/cs/products?dtp=Certificate&mfn=ps&pnid=13347&lc=
de-WW)
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
26 Hardware Installation Manual, 12/2016, 610.43000.40b
2.4.2
Technical characteristics
Type of motor
Synchronous motor with permanent-magnet excited rotor (4, 6 or 8-pole)
Type of construction Individual components (IM 5110 acc. to IEC 60034-7)
Stator, rotor
Degree of protection IP00 (acc. to DIN IEC 60034, Part 5): Stator, rotor
Cooling
Water cooling with T
H2O
= 25° C acc. to EN 60034-1
Standard protection - temperature
monitoring
Two KTY 84 or Pt1000 PTC thermistors in the stator winding (1x reserve)
Full protection (optional) In addition to the standard protection 1 x PTC thermistor triplet (3 sensors in series)
Can be evaluated, e.g. using a thermal motor protection unit:
Order No.: 3RN1013-1GW10
Universal protection (optional)
Full protection + NTC PT3-51-F + NTC K227
Winding insulation Temperature class 155 (F) acc. to EN 60034 permits an average winding tempera-
ture rise of 105 K. The power data is valid for a cooling water temperature of +5° -
25° C.
Balance quality of the rotor (acc. to
ISO 1940-1)
• Rotor with sleeve:
Depending on the particular version, pre-balanced, balance quality G 2.5
reference speed 3600 rpm or non-
balanced for complete balancing after mounting
and installation
• Rotor without sleeve:
Not pre-balanced
Motor voltage
(terminal voltage)
regulated: Maximum 3 AC 430 Vrms
Non-regulated: Maximum 3 AC 460 V
rms
Supply voltage of the SINAMICS
S120 drive system
ALM 400 V → VDC link ≦ 600 V
SLM 400 V → VDC link ≦ 600 V
SLM 480 V → VDC link ≦ 650 V
Note: For ALM 480 V infeed, a change must be made to "Smart Mode operation".
Type of connection Free single cables U1, V1, W1 (cables freely brought out);
Length 0.5 m (preferred version) or 1.5 m
Torque ripple
1FE1 ... -6W
1FE1 ... -8W
1FE1 ... -4W
≦ 1% at 20 rpm and MN/2 referred to the rated torque
≦ 1% at 20 rpm and MN/2 referred to the rated torque
≦ 2% at 20 rpm and M
N
/2 referred to the rated torque
UL marking With a few exceptions, motors are UL-1004 approved, see Chapter "Directives and
standards (Page 24)"
Note
Technical data is system data and is applicable only in conjunction with the specified system
comp
onents (1FE1 built-in motor, SINAMICS S120, VPM, IVP, etc.).
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 27
Motor parts
Note
Special versions and construction variants may differ in the scope of delivery with respect to
certain technical aspects.
Rotor
with IPM (internal permanent magnets)
with APM (external permanent magnets)
without sleeve
with sleeve
without sleeve
with sleeve
Stator
with cooling jacket without cooling jacket (available only on special motor re-
quest)
4 O-ring seals
Rating plate
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
28 Hardware Installation Manual, 12/2016, 610.43000.40b
2.4.2.1
Weights and moments of inertia
Table 2- 2 Weights and moments of inertia
Motor article number
Order code
Rotor
Stator weight
[kg]
Rotor weight
[kg]
Moment of inertia
[kg * m2]
6-pole built-in motors
1FE1041–6W☐☐☐–☐BA☐
-
2.50
0.35
0.00019
1FE1042–6W☐☐☐–☐BA☐
-
4.00
0.60
0.00033
1FE1051–6W☐☐☐–☐BA☐
-
4.00
1.20
0.00106
1FE1051–6W☐☐☐–☐BC☐
-
4.00
1.90
0.00152
1FE1052–6W☐☐☐–☐BA☐
-
6.00
2.20
0.00195
1FE1052–6W☐☐☐–☐BC☐
-
6.00
3.10
0.00248
1FE1054–6W☐☐☐–☐BA☐
-
10.00
4.30
0.00380
1FE1061–6W☐☐☐–☐BA☐
-
4.00
1.10
0.00141
1FE1061–6W☐☐☐–☐BB☐
-
4.00
2.10
0.00242
1FE1062–6W☐☐☐–☐BB☐
6.50
2.20
0.00283
1FE1064–6W☐☐☐–☐BA☐
-
11.50
4.30
0.00553
1FE1082–6W☐☐☐–☐BA☐
-
12.00
3.60
0.01048
1FE1082–6W☐☐☐–☐BB☐
-
12.00
7.70
0.01841
1FE1082–6W☐☐☐–☐BN☐
T34
12.00
7.70
0.01841
1FE1082–6W☐☐☐–☐BC☐
-
12.00
6.80
0.01710
1FE1082–6W☐☐☐–☐BN☐
T37
12.00
6.80
0.01710
1FE1082–6W☐☐☐–☐BD☐
-
12.00
6.10
0.01604
1FE1083–6W☐☐☐–☐BA☐
-
17.00
5.70
0.01659
1FE1083–6W☐☐☐–☐BB☐
-
17.00
10.60
0.02535
1FE1084–6W☐☐☐–☐BA☐
-
22.00
7.10
0.02067
1FE1084–6W☐☐☐–☐BB☐
-
22.00
13.60
0.03959
1FE1084–6W☐☐☐–☐BC☐
-
22.00
12.20
0.03068
1FE1091–6W☐☐☐–☐BA☐
-
14.00
2.60
0.00814
1FE1091–6W☐☐☐–☐BB☐
-
14.00
5.40
0.01423
1FE1091–6W☐☐☐–☐BC☐
-
14.00
4.50
0.01293
1FE1092–6W☐☐☐–☐BA☐
-
21.00
5.00
0.01566
1FE1092–6W☐☐☐–☐BB☐
-
21.00
9.10
0.02398
1FE1092–6W☐☐☐–☐BC☐
-
21.00
7.50
0.02155
1FE1092–6W☐☐☐–☐BN☐
1)
T37
21.00
8.30
0.02289
1FE1093–6W☐☐☐–☐BA☐
-
28.00
7.40
0.02317
1FE1093–6W☐☐☐–☐BB☐
-
28.00
12.70
0.03346
1FE1093–6W☐☐☐–☐BC☐
-
28.00
10.50
0.03017
1FE1093–6W☐☐☐–☐BN☐
1)
T06
28.00
10.50
0.03017
1FE1113–6W☐☐☐–☐BA☐
-
43.00
9.70
0.04765
1FE1113–6W☐☐☐–☐BD☐
-
43.00
19.80
0.07747
1FE1113–6W☐☐☐–☐BE☐
-
43.00
14.50
0.06512
1FE1114–6W☐☐☐–☐BA☐
-
54.00
12.70
0.06239
1FE1114–6W☐☐☐–☐BB☐
-
54.00
24.90
0.09843
1FE1114–6W☐☐☐–☐BC☐
-
54.00
19.60
0.08650
1FE1114–6W☐☐☐–☐BN☐
1)
T46
54.00
22.40
0.09342
1FE1114–6W☐☐☐–☐BN☐
1)
T49
54.00
20.80
0.08971
1FE1114–6W☐☐☐–☐BN☐
1)
T52
54.00
18.60
0.08353
1FE1114–6W☐☐☐–☐BN☐1)
T55
54.00
17.90
0.08279
1FE1115–6W☐☐☐–☐BC☐
-
65.00
23.80
0.10503
1FE1116–6W☐☐☐–☐BA☐
-
73.00
18.90
0.09285
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 29
Motor article number
Order code
Rotor
Stator weight
[kg]
Rotor weight
[kg]
Moment of inertia
[kg * m2]
1FE1116–6W☐☐☐–☐BB☐
-
73.00
35.80
0.14152
1FE1116–6W☐☐☐–☐BC☐
-
73.00
28.20
0.12445
8-pole built-in motors
1FE1143–8W☐☐☐–☐BA☐
68.00
10.40
0.08627
1FE1144–8W☐☐☐–☐BA☐
-
82.00
14.50
0.11447
1FE1144–8W☐☐☐–☐BC☐
-
82.00
24.00
0.18349
1FE1145–8W☐☐☐–☐BC☐
-
96.00
28.30
0.21636
1FE1145–8W☐☐☐–☐BD☐
-
96.00
34.00
0.24759
1FE1145–8W☐☐☐–☐BE☐
-
96.00
41.50
0.28115
1FE1147–8W☐☐☐–☐BC☐
-
124.00
37.70
0.28823
1FE1147–8W☐☐☐–☐BD☐
-
124.00
45.20
0.32915
4-pole built-in motors
1FE1051–4W☐☐☐–☐BA☐
-
4.50
0.70
0.00057
1FE1051–4H☐☐☐–☐BA☐
-
4.50
0.60
0.00045
1FE1052–4W☐☐☐–☐BA☐
-
7.00
1.35
0.00110
1FE1052–4H☐☐☐–☐BA☐
-
7.00
1.15
0.00087
1FE1053–4W☐☐☐–☐BA☐
-
9.50
2.00
0.00163
1FE1053–4H☐☐☐-☐BA☐
-
9.50
1.70
0.00128
1FE1072–4W☐☐☐–☐BA☐
-
12.50
2.20
0.00287
1FE1073–4W☐☐☐–☐BA☐
-
16.00
3.30
0.00430
1FE1074–4W☐☐☐–☐BA☐
-
19.50
4.40
0.00573
1FE1075–4W☐☐☐–☐BA☐
-
23.00
5.50
0.00741
1FE1082–4W☐☐☐–☐BA☐
-
15.00
3.10
0.00559
1FE1083–4W☐☐☐–☐BA☐
-
20.00
4.70
0.00847
1FE1084–4W☐☐☐–☐BA☐
-
25.00
6.20
0.01118
1FE1085–4W☐☐☐–☐BA☐
-
30.00
7.70
0.01388
1FE1092–4W☐☐☐–☐BR☐
-
26.00
3.80
0.00916
1FE1093–4W☐☐☐–☐BA☐
-
33.00
7.50
0.01694
1FE1093–4W☐☐☐–☐BR☐
-
33.00
5.60
0.01350
1FE1094–4W☐☐☐–☐BA☐
-
40.50
9.60
0.02168
1FE1094–4W☐☐☐–☐BR☐
-
40.50
7.50
0.01808
1FE1095–4W☐☐☐–☐BA☐
-
48.00
11.70
0.02642
1FE1095–4W☐☐☐–☐BR☐
-
48.00
9.30
0.02242
1FE1096–4W☐☐☐–☐BA☐
-
55.50
13.90
0.03139
1FE1096–4W☐☐☐–☐BR☐
-
55.50
11.20
0.02700
1FE1103–4W☐☐☐–☐BA☐
-
35.00
5.30
0.01589
1FE1104–4W☐☐☐–☐BA☐
-
43.00
7.00
0.02098
1FE1105–4W☐☐☐–☐BA☐
-
52.00
8.70
0.02608
1FE1106–4W☐☐☐–☐BA☐
-
60.00
10.50
0.03147
1FE1124–4W☐☐☐–☐BA☐
-
58.00
12.10
0.05112
1FE1125–4W☐☐☐–☐BA☐
-
69.50
15.00
0.06337
1FE1126–4W☐☐☐–☐BA☐
-
81.00
18.00
0.07604
1) As an alternative, Z is also valid for N.
Note
Rotor weights
The weights of special version
s are specified on the rating plate.
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
30 Hardware Installation Manual, 12/2016, 610.43000.40b
2.4.2.2
Magnetic forces that occur
Table 5-5 Magnetic forces of attraction
Acting magnetic forces of attraction
①
Spindle shaft with rotor core
②
Stator core with spindle housing
Fa
Axial attractive force
Fr
Radial attractive force
Figure 2-1 Attractive_forces_motor_spindle
Motor type
Axial attractive force Fa [N]
Radial attractive force Fr [N]
Rotors with internal permanent magnets (IPM)
1FE1051-4W
189
290
1FE1052-4W
580
1FE1053-4W
870
1FE1072-4W
260
700
1FE1073-4W
1050
1FE1074-4W
1400
1FE1075-4W
1750
1FE1082-4W
300
850
1FE1083-4W
1275
1FE1084-4W
1700
1FE1085-4W
2125
1FE1092-4W
180
1000
1FE1093-4W
1500
1FE1094-4W
2000
1FE1095-4W 2500
1FE1096-4W
3000
1FE1051-6W
180
200
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 31
Motor type
Axial attractive force Fa [N]
Radial attractive force Fr [N]
1FE1052-6W
400
1FE1054-6W 800
1FE1061-6W
250
250
1FE1062-6W 500
1FE1064-6W
1000
1FE1082-6W
350
700
1FE1083-6W
1050
1FE1084-6W
1400
1FE1091-6W
360
350
1FE1092-6W
700
1FE1093-6W
1050
1FE1113-6W
450
1300
1FE1114-6W
1700
1FE1115-6W
2200
1FE1116-6W
2600
Rotors with external permanent magnets (APM)
1FE1051-4H
200
150
1FE1052-4H
300
1FE1053-4H
450
1FE1103-4W
250
750
1FE1104-4W 1000
1FE1105-4W
1250
1FE1106-4W
1500
1FE1124-4W
350
1800
1FE1125-4W
2300
1FE1126-4W
2800
1FE1041-6W 180
200
1FE1042-6W
400
1FE1143-8W
700
1800
1FE1144-8W
2400
1FE1145-8W
3000
1FE1147-8W
4200
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
32 Hardware Installation Manual, 12/2016, 610.43000.40b
2.4.3
Rating plate data
Figure 2-2 1FE1 rating plate (example)
Note
All data applies only in conjunction with the associated rotor.
Position
Description / technical data
1
Motor type / designation (article number)
2 Motor serial number
3
Rated current I
N
[A]
4
Rated speed nN [rpm]
5
Maximum speed n
max
[rpm]
6
Induced voltage UIN [V] at nN
7
Type of construction
8
Temperature class
9
Degree of protection
10
Technical data for S1 and S6 40% 2 minutes
11
ID, temperature sensor
12
2D code contains the motor data
13
Standards and regulations
14
Data regarding water cooling
15
Maximum torque M
max
[Nm]
16
Maximum induced voltage VImax [V]
17
Stator and rotor mass m [kg]
18
Maximum current I
max
[A]
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 33
2.4.4
Structure of the article number
The article number comprises a combination of digits and letters. It is divided into three
hyphenated blocks.
Possible combinations, see Catalog NC 62.
Please note that not every theoretical combination is available.
Description
Position of the article number
1
2
3
4
5
6
7
-
8
9
10
11
12
-
13
14
15
16
-
Z
SIMOTICS M-1FE1 synchronous
built-in motors
Standard type with water cooling,
machine tools - main spindle drive
1
F
E
1
Frame size
0
4
0
5
0
6
0
7
0
8
0
9
1
0
1
1
1
2
1
4
Overall length
1
2
3
4
5
6
7
Lamination
4-pole
4
6-pole
6
8-pole
8
Cooling
Water cooling
W
H
Air cooling
L
Winding versions, e.g. C, D, E, F, G, H, J, K, L, M, N, P, Q, R, S, T, U, V, Y
☐
Winding design
1) Impregnated winding with standard protection (2 tem-
perature sensors)
0
Cast winding with standard protection (2 temperature
sensors)
1
Cast winding with full protection (standard protection +
PTC thermistor triplet)
3
Cast winding with universal protection (full protection +
NTC-PT3-51F + NTC K227)
5
Description
2.4 Technical features and environmental conditions
1FE1 synchronous built-in motors
34 Hardware Installation Manual, 12/2016, 610.43000.40b
Description
Position of the article number
1
2
3
4
5
6
7
-
8
9
10
11
12
-
13
14
15
16
-
Z
Voltage limitation
Operation without VPM module
0
Operation with VPM module
1
Scope of delivery
Stator and rotor; 2 KTY temperature sensors
1
Spare part: Stator only (W in rotor version); 2 KTY temperature
sensors
2
Spare part: Rotor only (W in stator version)
3
Stator and rotor; 2 Pt1000 temperature sensors
6
Spare part: Stator only (W in rotor version); 2 Pt1000 temperature
sensors
7
Stator version
Stator without cooling jacket
A
Stator with cooling jacket
1)
W
Stator with special cooling jacket
2)
N
Replacement rotor; the stator has no significance
W
Rotor version (with differ-
ent bore versions)
Without rotor sleeve; for di, see dimensions table
A
R
With rotor sleeve; for d*, see dimensions table (only for
1FE1061/1FE108/1FE109)
W
With rotor sleeve, for d**, see dimensions table (only for
1FE1051/1FE1052/1FE108/1FE109)
C
With rotor sleeve, for d**, see dimensions table (only for 1FE1082)
D
With special rotor sleeve
2)
N
Replacement stator, rotor has no significance
W
Connection type
Free cable ends, length
1.5 m
Cable outlet at large outer diameter of cooling jacket
0
Cable outlet at small outer diameter of cooling jacket
(on request)
1
Free cable ends, length
0.5 m
Cable outlet at large outer diameter of cooling jacket
2
Cable outlet at small outer diameter of cooling jacket
(on request)
3
1) Temperature sensors, see scope of delivery
2) Available only on request; contact your local Siemens office
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 35
Motor components
3
3.1
Thermal motor protection
The thermal motor protection is available in three versions:
Standard protection:
Temperature sensors (2x KTY 84-130 or 2x Pt1000)
Full protection (option):
Temperature sensors + PTC thermistor triplet (3 sensors in s
e-
ries) (2x KTY
84-130 or Pt1000 + 1x PTC180 C)
see Chapter "
Temperature evaluation using the PTC thermistor
triplet (full motor protection, option) (Page 114)"
Universal protection (o
p-
tion):
Temperature sen
sors + PTC thermistor triplet + NTC thermistor
(2x KTY
84-130 or Pt1000 + 1x PTC180 C + NTC PT3-51F +
NTC
K227/33k/A1)
see Chapter "
Temperature evaluation using NTC thermistors
(universal protection, option) (Page 113)"
The stator core has two temperature sensors to monitor the winding; one of these is a
reserve.
Note
Temperature sensors of the same type are always installed in one particular mo
tor.
The type of temperature sensor installed is stamped on the rating plate.
Motor components
3.2 Cooling
1FE1 synchronous built-in motors
36 Hardware Installation Manual, 12/2016, 610.43000.40b
Two temperature sensor types are integrated:
Table 3- 1 Features and technical data
Type
KTY 84-130
Pt1000
Temperature sensors KTY 84 are
ESD components. When delivered,
they are short-circuited with a termi-
nal.
Pt1000 temperature sensors are not
ESD components.
Resistance when cold
(20° C)
Approx. 580 Ω Approx. 1090 Ω
Resistance when hot
(100° C)
Approx. 1000 Ω Approx. 1390 Ω
Connection
Via signal cable
Via signal cable
Response temperature Prewarning < 150° C
Alarm/trip at max. 170° C ±5° C
Prewarning < 150° C
Alarm/trip at max. 170° C ±5° C
High short-term overload conditions require additional protective measures as a result of the
thermal coupling time of the temperature sensor.
3.2
Cooling
Note
The manufacturer of the motor spindle is responsible for the design and construction of the
cooling.
Information about the materials and components in the cooling circuit is contained in the
Configuration Manual.
Please observe the spindle manufacturer's project requirements.
Equipotential bonding
WARNING
Danger to life by incorrectly routing cooling water pipes
If electrically conductive cooling water pipes come into contact with live parts, this can
cause an electric shock leading to death or severe injury.
• Ensure adequate insulation.
• Securely fasten the pipes.
● Provide all components in the cooling system (motor, heat exchanger, piping system,
pump, pressure equalization tank, etc.) with equipotential bonding.
● Implement the equipotential bonding using a copper rail or finely stranded copper cable
with the appropriate conductor cross-sections.
Motor components
3.2 Cooling
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 37
Preventing cavitation
NOTICE
Motor damage caused by cavitation and abrasion
An excessive pressure drop at the motor can cause motor damage as the result of
cavitation and/or abrasion.
• Operate the motor so that the pressure drop at a converter or motor in continuous
operation does not exceed 0.2 MPa.
Coolant inlet temperature
NOTICE
Motor damage caused by condensation formation
Water condensation can cause motor damage.
• Select the coolant inlet temperature so that condensation does not form on the surface
of the motor. Tcooling > Tambient - 5 K.
• Interrupt the supply of coolant for a longer motor standstill.
The motors are designed for full-load operation at maximum +25° C coolant inlet
temperature.
Operation up to +40° C coolant inlet temperature is possible with derating (reduced power).
Note
Derating
The spindle manufacturer is responsible for the derating.
Motor components
3.2 Cooling
1FE1 synchronous built-in motors
38 Hardware Installation Manual, 12/2016, 610.43000.40b
Coolant specification
As coolant, use only water that complies with the "water specification for coolant".
Note
If possible, use deionized water with reduced conductivity (5 ... 10 μS/cm) as the coolant.
Table 3- 2 Coolant water specifications
Quality of the water used as coolant for motors with alumi-
num, stainless steel tubes + cast iron or steel jacket
Chloride ions
< 40 ppm, can be achieved by adding deionized water.
Sulfate ions
< 50 ppm
Nitrate ions
< 50 ppm
pH value
6 ... 9 (for aluminum 6 ... 8)
Electrical conductivity
< 500 μS/cm
Total hardness
< 170 ppm
Dissolved solids
< 340 ppm
Size of entrained particles
< 100 μm
Corrosion protection
0.2 to 0.25% inhibitor, Nalco TRAC100 (previously 0GE056)
Anti-freeze protection
When required, 20 - 30% Tyfocor
The values specified for the water as a coolant are the requirements for a closed cooling
circuit. Not all of the specified concentrations will occur in the water at the same time.
When necessary, contact your water utility for the values.
Note
Inhibitor is not required if a Tyfocor concen
tration > 20% is ensured.
Derating is not required for antifreeze protection components <
30%.
Using a different coolant
Other coolants (e.g. cooling-lubricating medium, water-oil mixtures with 10% oil and higher)
can reduce the power of the motor.
Note
Power reduction when using a different coolant
Derating is required for water
-oil mixtures with more than 10% oil.
Measures for frost danger
If there is danger of frost, adopt frost protective measures for complete or preassembled
motor spindle units.
● Replenish antifreeze for operation (see Table "Coolant water specifications").
Motor components
3.3 Encoder
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 39
Note
•
Avoid mixing different antifreeze products.
•
Use and dose the antifreeze according to the manufacturer’s specifications.
Maintenance and service for assembled motor spindles
Check at least once annually
● the filling level,
● for any discoloring and
● the cooling-water specification
Note
Use cooling water only with the permitted specification.
In case of cooling water loss, refill with a previously deployed mixture of deionized water and
inhibitor or Antifrogen N.
3.3
Encoder
The encoder is not included in the scope of delivery.
The spindle manufacturer is responsible for the selection and assembly.
Note
Additional information about the encoder is contained in the
associated Configuration
Manual
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 41
Preparing for use
4
4.1
Safety instructions for electromagnetic and permanent-magnetic
fields
WARNING
Risk of death and crushing as a result of permanent magnet fields
Severe injury and material damage can result if you do not take into consideration the
safety instructions relating to permanent magnet fields.
• Observe the information in Chapter Special safety notices for handling built-in motors
(Page 21).
Safety measures for electromagnetic and permanent-magnetic fields
● Observe the relevant nationally applicable health and safety regulations.
● Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
● Keep the motor components in their individual packaging until installation.
● Mark the storage location with the warning and prohibition signs from the following tables.
● Avoid being crushed when handling the rotor core.
● Place the unpacked rotor core on a safe non-magnetic surface. Secure the rotor core with
non-magnetic devices.
● Avoid contact of the rotor core with ferromagnetic objects.
● Use tools made of non-magnetic materials. Ferromagnetic assembly tools must have low
mass.
Attaching warning signs
Any danger areas must be identified by well visible warning and prohibition signs
(pictograms) in the immediate vicinity of the danger.
Note
The text
for the warning signs should be written in the language of the country of use.
Preparing for use
4.1 Safety instructions for electromagnetic and permanent-magnetic fields
1FE1 synchronous built-in motors
42 Hardware Installation Manual, 12/2016, 610.43000.40b
Identification of dangers using warning and prohibition signs:
Table 4- 1 Warning signs according to ISO 7010 and their meaning
Sign
Meaning
Sign
Significance
Warning - magnetic
field
(W006)
Warning - hand injuries
(W024)
Warning for electrical
voltage
(W012)
Warning - hot surface
(W017)
Table 4- 2 Prohibition signs according to ISO 7010 and their meaning
Sign
Significance
Sign
Significance
No access for persons
with pacemakers or
defibrillator implants
(P007)
No access for persons
with metal implants
(P014)
No metal objects or
watches
(P008)
UN number 2807 is allocated to permit magnets as hazardous item.
Preparing for use
4.1 Safety instructions for electromagnetic and permanent-magnetic fields
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 43
WARNING
Danger to life if devices are packed, stored or transported incorrectly.
Risk of death, injury and/or material damage can occur if the devices are packed, stored, or
transported incorrectly.
• Always follow the safety instructions for storage and transport.
• Before transporting or lifting machines or machine parts, lock the rotary axes so they
cannot accidentally rotate. This is necessary, as the axes are not self locking.
• Always correctly and carefully carry out storage, transport and lifting operations.
• Only use suitable devices and equipment that are in perfect condition.
• Only use lifting devices, transport equipment and suspension equipment that comply
with the appropriate regulations.
• IATA regulations must be observed when components are transported by air.
• Mark locations where rotors are stored with warning and prohibit signs according to the
tables in Chapter "Supplied pictograms".
• Observe the warning instructions on the packaging.
• Always wear safety shoes and safety gloves.
• When working with permanent magnets, keep the following tools and aids available to
free any trapped body parts:
– A hammer made of non-magnetizable material
– Two pointed wedges (wedge angle approx. 10° to 15°) made of non-magnetizable
material (e.g. hard wood)
• Take into account the maximum loads that personnel can lift and carry.
• Transport and store built-in motors only in their packed state.
– Replace any defective packaging. Correct packaging offers protection against
sudden forces of attraction that can occur in their immediate vicinity. Further, when
correctly packaged you are protected against hazardous motion when storing and
moving rotors.
–
Use only undamaged original packaging.
Preparing for use
4.2 Shipping and packaging
1FE1 synchronous built-in motors
44 Hardware Installation Manual, 12/2016, 610.43000.40b
4.2
Shipping and packaging
Transport
Note
Observe the country
-specific regulations.
The 1FE1 synchronous built-in motors are supplied as motor components in individual or
bulk packaging according to the delivery contract.
Note
The standard packaging of 1FE1 motors is suitable for transport by road, rail and sea.
● Please pay attention to the symbols on the packaging in which the motor is delivered.
Symbol
Meaning
Symbol
Meaning
Fragile
(0621)
Keep dry
(0626)
Top
(0623)
Stack limitation based
on the count
(2403)
● Transport the motor carefully and, when possible, in its original packaging.
● Fasten the load suspension device to the provided locations of the packaging or the
motor.
● Avoid any jerky and oscillating movements during transport.
Preparing for use
4.2 Shipping and packaging
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 45
Notes regarding air transportation (IATA)
Observe the maximum permissible field strengths in accordance with IATA packaging
instructions for the air transport of products that contain permanent magnets.
Note
The magnetic field strengths listed in the table always apply to the values for
the constant
magnetic field from the IATA packaging instructions
953.
Shipping must be approved, notified or marked for magnetic field strengths above those
specified below.
Subject to approval Shipping a product whose largest determined field
strength at 4.6 m distance is larger than 0.418 A/m.
This product may be transported only
with approval by the responsible na-
tional authorities of the dispatching
country and the air transportation com-
pany's base country.
Notification and marking
approval required
Shipping a product whose largest determined field
strength at 2.1 m distance is greater than or equal to
0.418 A/m.
Notification and marking
approval not required
Shipping a product whose largest determined field
strength at 2.1 m distance is less than 0.418 A/m.
The shipping of original-packed 4-pole built-in motors requires notification and marking
approval.
The shipping of original-packed 6-pole and 8-pole built-in motors does not require notification
and marking approval.
Preparing for use
4.2 Shipping and packaging
1FE1 synchronous built-in motors
46 Hardware Installation Manual, 12/2016, 610.43000.40b
Checking the delivery for completeness
Scope of delivery of a synchronous built-in motor
1A
Rotor core without sleeve or
1B
Rotor core with sleeve
2
Stator core with cooling jacket (optional, without cooling jacket)
3
4 O-ring seals (for version with standard cooling jacket)
4
Rating plate
Safety notes / product information (without figure)
Circuit diagram (without figure)
● Upon receipt of the delivery, check immediately whether the items delivered are in
accordance with the accompanying documents.
Note
Siemens will not accept any claims relating to items missing from the delivery and which
are submitted at a later date.
● Register a complaint about
– any apparent transport damage with the delivery agent immediately.
– any apparent defects or missing components with the appropriate SIEMENS office
immediately.
The safety instructions are included in the scope of delivery.
Note
Store the safety instructions so they are always
available.
Note
Special versions and construction variants may differ in the technical details and scope of
delivery.
Preparing for use
4.3 Transportation and storage
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 47
4.3
Transportation and storage
Transport and store the built-in motors in the original packaging.
Transporting
Note
Observe the co
untry-specific regulations.
● Fasten the load suspension device to the provided locations of the packaging or the
motor.
● Transport the motor carefully.
● Avoid any jerky and oscillating movements during transport.
If a motor is not installed immediately after the delivery, it must be stored appropriately.
Observe the following storage conditions.
Storage
Storage conditions
Store the motor in a dry, dust-free and vibration-free indoor storage facility.
Adhere to the following values:
● vrms < 0.2 mm/s
● Max. temperatures: -15° C ... 70° C
● Relative humidity: 5% ... 85%
Identification of the storage location
Mark the storage location clearly with warning notices as per the packaging of the built-in
motors.
Note
This identification must also be visible after re
moval of the external packaging.
Preparing for use
4.3 Transportation and storage
1FE1 synchronous built-in motors
48 Hardware Installation Manual, 12/2016, 610.43000.40b
Label on the rotor packaging
1
Warning about a hazardous location
2
Warning - hand injuries
3
Warning - magnetic field
4
Prohibition for people with a pacemaker
Figure 4-1 Warnings on the packaging
Please observe the warning instructions on the packaging and labels.
Long-term storage
Check the correct state of the machine every six months.
● Check the motor for any damage.
● Perform any necessary maintenance work.
● Check the state of the dehydrating agent and replace when necessary.
● Record the preservation work so that all preservation coating can be removed prior to the
commissioning.
Preparing for use
4.3 Transportation and storage
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 49
Condensation
The following ambient conditions encourage the formation of condensation:
● Significant fluctuations of the ambient temperature
● Direct sunshine
● High air humidity during storage
Avoid these ambient conditions.
Use a desiccant and a hygroscope in the packaging.
NOTICE
Risk of motor damage by voltage discharges resulting from condensation
If the stator winding is damp, its insulation resistance decreases. This can cause voltage
discharges that damage the windings.
• Keep the drain holes free so that condensation can escape freely.
NOTICE
Risk of motor damage by corrosion resulting from condensation
Condensation that does not escape can cause corrosion and motor damage.
• Keep the drain holes free so that condensation can escape freely.
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 51
Mechanical mounting
5
5.1
Safety instructions
Safety measures for electromagnetic and permanent-magnetic fields
Note
Only qualified, suitably trained personnel who clearly understand the special hazards
involved may work with and on permanent
-magnet rotor cores.
Note
Apply safety marking in accordance with the country
-specific regulations at the assembly
stations for rotor cores.
● Observe the relevant nationally applicable health and safety regulations.
● Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
● Keep the motor components in their original packaging until installation.
● Mark the storage location with the symbol for magnetic danger.
● Place the unpacked rotor core in a safe place. Secure the rotor core with non-magnetic
devices.
● Avoid contact of the rotor core with ferromagnetic bodies.
● Preferably use tools made of non-magnetic materials. Ferromagnetic assembly tools
must have low mass. Work carefully!
Attaching warning signs
Any danger areas encountered during normal operation, maintenance, and servicing must
be identified by well visible warning and prohibition signs (pictograms) in the immediate
vicinity of the danger.
The associated texts must be provided in the language of the country in which the product is
used.
Mechanical mounting
5.1 Safety instructions
1FE1 synchronous built-in motors
52 Hardware Installation Manual, 12/2016, 610.43000.40b
Identification of dangers using warning and prohibition signs:
Table 5- 1 Warning signs according to ISO 7010 and their meaning
Sign
Significance
Sign
Significance
Warning - magnetic
field
(W006)
Warning - hand injuries
(W024)
Warning for electrical
voltage
(W012)
Warning - hot surface
(W017)
Table 5- 2 Prohibition signs according to ISO 7010 and their meaning
Sign
Significance
Sign
Significance
No access for persons
with pacemakers or
defibrillator implants
(P007)
No access for persons
with metal implants
(P014)
No metal objects or
watches
(P008)
WARNING
Danger to life when lifting and transporting
Incorrect lifting and transport operations, as well as devices and equipment that are
unsuitable or damaged can result in death, severe injury and/or material damage.
• Lifting devices, industrial trucks, and load suspension devices must comply with the
regulations.
• The maximum capacity of the lifting equipment and the load suspension device must
correspond to the weight of the motor parts (see the rating plate) or of the (partially)
mounted motor spindle.
• Do not attach any additional loads to the lifting equipment.
• To hoist the motor, use suitable cable-guidance or spreading equipment (particularly if
the motor is equipped with built-on assemblies).
• Fasten the lifting equipment only in the provided threaded holes and never at the
balancing disk.
• Do not lift and transport the motor with the motor cables.
• Do not stand in the slewing range of hoisting gear or under suspended loads.
• Observe the country-specific regulations.
Mechanical mounting
5.1 Safety instructions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 53
WARNING
Danger to life from permanent magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk
for persons with heart pacemakers or implants if they are close to converters/motors.
• If you have a heart pacemaker or implant, maintain a minimum distance of 50 cm.
• When transporting or storing permanent magnet motors always use the original packing
materials with the warning labels attached.
• Clearly mark the storage locations with the appropriate warning labels.
• IATA regulations must be observed when transported by air.
NOTICE
Data loss or damage caused by magnetic fields
Magnetic fields can lead to a loss of data on magnetic or electronic data media and
damage watches.
• Keep magnetic or electronic data media (e.g. credit cards, memory cards) and watches
outside magnetic fields (> 100 mm).
WARNING
Danger of crushing caused by the strong attractive forces of permanent magnets
The strong attractive forces on magnetizable materials and tools when working near motors
with permanent magnets (distance less than 100 mm) can cause severe injuries that result
from crushing.
• Do not underestimate the strength of the attractive forces.
• Wear protective gloves.
• Always work at least as a pair.
• Remove the packaging of the motor components only immediately before assembly.
• Do not carry any objects made of magnetizable materials (e.g. watches, steel or iron
tools) and/or permanent magnets close to the motor with permanent magnets.
• Never place components with permanent magnets directly next to each other.
• To free any trapped body parts (hand, finger, foot, etc.), keep available:
– A hammer (about 3 kg) made of solid, non-magnetizable material
– Two pointed wedges (wedge angle approx. 10° to 15°) made of solid, non-
magnetizable material (e.g. hard wood)
Mechanical mounting
5.1 Safety instructions
1FE1 synchronous built-in motors
54 Hardware Installation Manual, 12/2016, 610.43000.40b
First aid in the case of accidents involving permanent magnets
● Stay calm.
● Press the emergency stop switch and, where necessary, switch off the main switch if the
machine is live.
● Administer FIRST AID. Call for further help if required.
● To free jammed body parts (e.g., hands, fingers, feet), pull apart components that are
clamped together.
– To do this, use a hammer to drive a wedge into the separating rift
– Release the jammed body parts.
● If necessary, call for an EMERGENCY DOCTOR.
WARNING
Danger to life caused by damage to the insulation of the connection cables during mounting
Damaged insulation of the motor cables can cause an electric shock that can lead to death
or severe injuries.
• Perform the mounting without exerting force on the connecting cables.
• Ensure that the minimum bending radii are not exceeded.
• Connect the connection cables with an effective strain relief.
CAUTION
Risk of injury due to touching hot surfaces
The hot surfaces associated with warm shrinking can cause injuries.
• Do not touch any hot surfaces.
• Wear heat-resistant gloves, safety goggles and closed work clothes.
Mechanical mounting
5.2 Mounting instructions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 55
5.2
Mounting instructions
The mounting instructions in the following chapters are recommendations.
The spindle manufacturer can specify different actions, and tools and resources needed for
mounting.
Tools and resources needed for mounting are not included in the scope of delivery. The
spindle manufacturer is responsible for their provision.
To mount/dismantle the motor parts, ensure the following ambient conditions:
● A draught-free room
● Technically dust-free and dry environment. The permissible relative air humidity lies
within the range 5% to 85%.
● The occupational safety equipment required is specified in the appropriate work stages.
NOTICE
Danger of damage to the rotor banding
APM rotors have a banding (composite fiber) around the external diameter of the rotor
that must not be damaged.
• Keep the protective film until mounting the rotor.
• Remove the protective film only for balancing or immediately before mounting.
• Check the banding for damage before mounting.
• Mount the APM rotor centered in the spindle box using a mounting device.
• Use an assembly film.
Mechanical mounting
5.3 Mounting/dismantling the rotor
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56 Hardware Installation Manual, 12/2016, 610.43000.40b
5.3
Mounting/dismantling the rotor
5.3.1
Tools and resources
You require the following assembly tools and other resources:
● Occupational safety equipment
– Face protection shield
– Protective gloves
– Closed protective clothing for protection against any oil leaks and high or low surface
temperatures
● Fixture for checking the radial runout of the spindle shaft
● For the joining, you require the following assembly tools and resources depending on the
deployed version:
WARNING
Danger to life through the use of a different coolant for the cold process
Liquid oxygen or liquid air can cause explosions and death or severe injuries.
• Use only liquid nitrogen for the cold process.
Joining with the hot process
(shrink fit)
Joining with the cold process
(stretch fit)
Cold-hot process
• Hot-air oven with tempera-
ture monitoring - suitable
for temperatures specified
in the "Mounting tempera-
tures" table
• Oven volume appropriate
for the rotor type, place-
ment of the oven in the
immediate vicinity of the
workplace
• Air-conditioned room or
cold chamber for temper-
ing the spindle shaft and
rotor core
• Dewar vessel with liquid
nitrogen N2 (-195.8° C)
• For a small workspace: good
ventilation
• Hot-air oven with tempera-
ture monitoring - suitable
for temperatures specified
in the "Mounting tempera-
tures" table
• Oven volume appropriate
for the rotor type, place-
ment of the oven in the
immediate vicinity of the
workplace
• Cold chamber for temper-
ing the spindle shaft and
rotor core
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 57
● Hoisting gear, gripper, load suspension device (see "Examples for transporting
components" figure)
– Carrying capacity dependent upon the weight or the rotor core and/or spindle shaft,
refer to the rating plate
– Preferably with a device for quick lowering
1
Rotor with a smaller diameter with gloves
2
Rotor with a larger diameter with a gripper tool
3
Spindle shaft with lifting eyes and lifting lug
Figure 5-1 Transporting the rotor components (examples)
Mechanical mounting
5.3 Mounting/dismantling the rotor
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58 Hardware Installation Manual, 12/2016, 610.43000.40b
● Mounting device depending on the rotor mounting arrangement
The rotor can be mounted in two ways:
– Version A: The rotor is mounted on the spindle shaft.
– Version B: The spindle shaft is inserted in the rotor.
①
Rotor core
②
Spindle shaft
③
Stable support with opening
④
Mounting fixture (non-magnetic, resistant to heat and cold, thermally insulating)
Figure 5-2 Arrangement for mounting the rotor
● Suitable oil-pressure hand pump with manometer for relieving stress or dismantling the
rotor with sleeve for “oil press fit“ device version.
Figure 5-3 Oil pressure hand pump
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 59
● Fixture for relieving stress and dismantling
①
Connection hydraulic hand pump
②
Connector nipple
③
Extension tube
④
Slotted nut (only for relieving stress)
⑤
Spacer sleeve (only for relieving stress)
⑥
Non-magnetic fixture (prism)
⑦
Non-magnetic tray
A
Dimension for the axial relative movement for dismantling, 90 mm
Figure 5-4 Fixture for relieving stress and dismantling
● Accessories:
– Connector with nipple (1, 2), e.g. type SKF 1077454
– Extension tube (3), e.g. type SKF1077453
– Non-magnetic fixture (prism, 6)
– Slotted nut (4), spacing sleeve (5)
– Non-magnetic tray (7) for catching oil, e.g. made from aluminum
– Pressure oil for relieving stress, e.g. SKF LHMF 300 (viscosity 300 mm²/s at 20° C)
– Pressure oil for dismantling, e.g. SKF LHDF 900 (viscosity 900 mm²/s at 20° C)
● Balancing machine for balancing the rotor (fine or complete balancing)
● Detergent, e.g. Loctite 7061 or Loctite 7063; bolt locking compound, e.g. Loctite 243
Mechanical mounting
5.3 Mounting/dismantling the rotor
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5.3.2
Preparation
Perform the following work before starting mounting:
1. Check that the components to be joined are correct and complete.
2. Clean the surfaces to be joined as a prerequisite for the separation and reuse of the
components later. The surfaces to be joined must be free from contamination, rust, sharp
edges, damage and machining marks.
3. Clean the oil connection holes in accordance with the following description.
– Remove the grub screws from the connection holes.
– Remove oil, grease or other contaminants from the grub screws and holes (e.g. with
Loctite 7061 or 7063).
Note
Observe the manufacturer's instructions for the cleaning products used.
Ensure adequate ventilation for solvent
-based products.
4. Measure and record the radial runout of the spindle to the reference plane, see
measurement plane "R"
①
Spindle shaft
②
Position of the rotor core
③
Oiled surface (mounting without stress relief)
R
Reference plane for radial runout check
Y
Measured value (before and after mounting)
A-B
Spindle shaft axis (reference axis)
Figure 5-5 Checking the radial runout
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 61
5. If the stress of the rotor core is not relieved after mounting, rub dismantling oil in the
joined surfaces ③ e.g. SKF LHMF 300.
6. The rotor core and spindle shaft are mounted using thermal joining.
NOTICE
Damage to the permanent magnets of the rotor
If the rotor temperature exceeds 150° C (140° C for APM rotors), the permanent
magnets in the rotor will be demagnetized irreversibly.
• Ensure the rotor is not heated above 150° C (140° C for APM rotors) by checking the
rotor temperature with a temperature-reactive dye or a temperature measuring
device.
• Inductive heating of the rotor is not permissible.
NOTICE
Danger of damage to the rotor banding caused by impermissible temperatures
APM rotors have a banding (composite fiber) around the external diameter of the rotor
that can be damaged by impermissible temperatures during mounting.
• Comply with the permissible temperatures during mounting.
NOTICE
Danger of bearing damage on the spindle shaft
Low temperatures can damage the bearing of the spindle shaft.
• Use the cold process only when the bearing lubricant is certified for low
temperatures.
Note
A hot box or Dewar vessel must be kept in the immediate vicinity of the mounting
location.
Three processes are deployed.
Hot process (shrinkage)
Cold process (stretching)
Combined cold-hot process
The tempered spindle shaft is
inserted into the rotor core
that has been heated up.
The rotor core is inserted over
the spindle shaft that has been
cooled down.
The heat rotor core is inserted
over the spindle shaft that has
been cooled down.
Mechanical mounting
5.3 Mounting/dismantling the rotor
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Temper the components in accordance with the mounting version at the following
temperatures:
Joining process
Rotor temperature
Spindle shaft temperature
Hot process
(shrinkage) 1)
IPM rotors:
145° ... max. 150° C
APM rotors:
135° ... max. 140° C
10° ... 20° C
Cold process
(stretching)
2)
20° ... 40° C -160° ... -196° C
Cold-hot process IPM rotors:
145° ... max. 150° C
APM rotors:
135° ... max. 140° C
-40° ... -30° C
1)
For frame size < 1FE108□ do not use, use the cold-hot process or cold process
2) After joining the rotor with the shaft, dry for 2 to 3 hours at approx. 60° C
5.3.3
Mounting the rotor
Mounting the rotor
WARNING
Risk of injury caused by hot/cold surfaces
During mounting, the components are very hot or very cold and can cause burns or frost
bite.
• Do not touch any components with unprotected hands.
• Wear heat-resistant gloves, safety goggles and closed work clothes.
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 63
Procedure
Select joining process A or B
Perform the following operations for mounting:
A Joining the rotor
B Joining the spindle shaft
1 Rotor
4 Rigid support
2 Spindle shaft
5 Oil connection hole
3 Non-magnetic assembly fixture
1. Check that the resources function properly.
Note
Avoid positioning errors
•
Perform the joining procedure without delay.
•
Observe the position of the pressure oil connections for the rotor with sleeve.
2. Position the components, see the "Joining the rotor" figures.
3. Join without delay the rotor core or the spindle shaft at its final position.
4. Allow the joined parts to assume room temperature.
5. Measure the radial runout at the reference level and mark the position of largest
deviation, see the "Checking the radial runout" figure.
You have mounted the rotor.
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
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5.3.4
Compensating mechanical stresses and deformations of the spindle shaft
The thermal joint causes stresses (pressing) by the fit interference of the spindle shaft.
These stresses can deform the spindle shaft.
Note
The following stress compensation is possible only for mounted rotors with sleeve.
After joining, a destressing of the spindle shaft with oil pressure for stress compensation or
for reducing the spindle deformation is recommended.
WARNING
Danger to life caused by oil under high pressure
The spurting of oil and/or mechanical damage at the hydraulic system can cause death or
severe injuries.
• Use only intact devices and resources for destressing.
• Observe the prescribed pressures.
Forcing oil between the spindle shaft and the rotor core releases the step press fit.
If the pressure is sufficient, the spindle shaft will slide off the rotor core.
● Prevent axial relative movements during the destressing (see "Mechanical stress
compensation" figure).
Safety measures for the stress equalization
● Check the pump and accessories for functional safety.
● Operate the pump only with manometer.
● Do not make any changes to the device and its safety equipment.
● Observe the notes contained in the oil press pump operating instructions.
● Wear a face protective mask and closed work clothes.
● Vent the hydraulic system.
The oil pressure is built up manually.
● Do not exceed the maximum permissible oil pressure See the following table.
Table 5- 3 Maximum permissible oil pressure
Motor type
Maximum oil pressure Pmax [MPa]
1FE105□-6W
100
1FE106□-6W, 1FE108□-6W, 1FE109□-4W,
1FE109□-6W, 1FE111□-6W, 1FE114□-8W,
80
1FE1 Rotor cores without rotor sleeves
No oil press fit
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 65
Note
Please consult your local Siemens office for special versions with rotor
sleeve.
Oil that can be used for the stress equalization
Viscosity
300 mm
2
/s at 20° C
e.g. type SKF LHMF 300
Stress equalization
NOTICE
Danger to the environment caused by escaping oil
The forcing of oil can cause oil to escape and result in environmental damage.
• Catch any escaping oil.
• Bind the escaping oil with a suitable oil binding agent.
• Dispose of the oil and oil binding agent in accordance with the legal regulations.
Procedure
Perform the following operations for stress equalization and realignment:
①
Connection hydraulic hand pump
②
Connector nipple
③
Extension tube
④
Slotted nut
⑤
Spacing sleeve
⑥
Supporting fixture (prism)
⑦
Catchment tray
⑧
Manual oil pump
Figure 5-6 Compensating mechanical stresses
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
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1. Unscrew both grub screws from the rotor core sleeve.
2. Wrap the threaded shoulder on the extension tube and the second grub screw with Teflon
sealing tape.
3. Screw the extension tube firmly into the sleeve of the rotor core.
4. Place the rotor core with spindle shaft, slotted nut and the spacing sleeve on the prism.
5. Attach the oil hand pump.
6. Vent the hydraulic system.
7. Screw the second grub screw with Teflon sealing tape tightly into the sleeve thread.
8. Force the oil with the hand pump slowly until the pressure of approx. 50 MPa (500 bar) is
reached.
9. Allow the oil to act for approximately 15 minutes.
→ The oil penetrates the fitting gaps and distributes itself.
10.Increase the pressure to approx. 60 to 70 MPa (600 to 700 bar).
→ The unit floats.
The rotor is prevented from sliding off by the slotted nut and the spacing sleeve.
11.Reduce the oil pressure at the pump.
12.Check the radial runout at the reference mark (see the "Checking the radial runout"
figure).
13.If the required accuracy is not attained, repeat the pressure operation.
→ The rotor core and the shaft are rotated against each other.
14.Remove the extension pipe.
15.Place the "rotor - spindle shaft" system vertical.
→ Allow the oil to drip from the sleeve.
16.Store the unit for 24 hours.
→ Collect the escaping residual oil in the sump.
The "rotor - spindle shaft" system is fully loadable again after 24 hours.
17.Degrease the threaded holes and grub screws with e.g. Loctite 7061.
18.To secure the grub screw, apply Loctite 243 or similar to the threaded hole.
19.Screw the grub screws into the threaded hole.
20.Mark on the face the position of the rotor to the spindle.
You have removed tensions in the rotor.
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 67
5.3.5
Balancing
In accordance with the requirements for smooth running, the rotor core with the spindle shaft
must be implemented with the appropriate vibration severity level.
● Remove the protective film before balancing the rotor core.
● Balance the mounted rotor core as described below.
Note
The spindle manufacturer is responsible for performing and providing proof of the balancing
procedure.
NOTICE
Risk of motor damage caused by remaining drilling chips
Ferrite chips stick to the rotor core. During balancing by drilling the balancing disks, chips
can damage the rotor core and pre-mounted bearing.
• Ensure an effective chip removal.
• Protect the bearing from contaminations.
NOTICE
Risk of damage to the rotor core banding
The protective film must be removed before balancing the rotor core. Careless handling of
the rotor core can damage banding made of composite fiber.
• Handle the rotor core carefully.
• Prevent damage to the rotor core banding (composite fiber).
● After balancing the rotor, reattach a protective film to the rotor banding.
Rotor core with sleeve
Depending on the variant, the manufacturer delivers the rotor cores with sleeve either pre-
balanced or not pre-balanced.
Note
The rotor core must not be modifi
ed.
● The pre-balanced rotor cores with sleeve in the delivered state conform with ISO 1940:
G2.5 (reference speed 3600 rpm).
● After mounting, fine balancing of the "spindle shaft - rotor core" system may be
necessary.
● The "spindle shaft - not pre-balanced rotor core" system must be balanced.
To do this, use the balancing planes provided by the spindle manufacturer on the spindle
axis provided for this purpose.
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
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● Drilling holes on the balancing disks of the rotor core ① are permissible only for fine
balancing.
● Observe the specifications from the following figure and table when balancing.
①
Balancing disk
②
Rotor core
③
Sleeve
④
Spindle shaft
⑤
Restricted area (drilling holes for balancing is not permitted here)
Figure 5-7 Fine balancing a spindle shaft and rotor with sleeve
Motor type
a [mm]
t1 [mm]
w [mm]
t2 [mm]
1FE105□-6
4
5
6
3
1FE109□-6
5
1FE111□-6
5
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 69
Rotor core without sleeve
● The rotor core is not pre-balanced by the manufacturer.
● The "spindle shaft - rotor core without sleeve" system must be balanced, e.g. with
balancing disk.
To do this, use the balancing planes provided by the spindle manufacturer on the spindle
axis provided for this purpose.
①
Balancing disk (not included in scope of delivery)
②
Rotor core
③
Spindle shaft
Figure 5-8 Balancing a spindle shaft and rotor core without sleeve
5.3.6
Dismantling the rotor
Note
The rotor can be dismantled only for variants with sleeve.
The rotor core is dismantled from the spindle shaft using the oil pressing procedure, e.g. for
a bearing change.
The oil pressing procedure causes a high level of mechanical stress in the components.
WARNING
Danger to life caused by oil under high pressure
The spurting of oil and/or mechanical damage at the hydraulic system can cause death or
severe injuries.
• Use only intact devices and resources for destressing.
• Observe the prescribed pressures.
Forcing oil between the spindle shaft and the rotor core releases the step press fit.
If the pressure is sufficient, the spindle shaft will slide off the rotor core.
The necessary section is specified by the construction of the stepped press fit. The section is
specified by dimension A in the "Rotor core dismantling" table.
The non-magnetic fixture must permit movement of the rotor core.
Mechanical mounting
5.3 Mounting/dismantling the rotor
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Safety measures for dismantling
● Check the pump and accessories for functional safety.
● Operate the pump only with manometer.
● Do not make any changes to the device and its safety equipment.
● Observe the notes contained in the oil press pump operating instructions.
● Wear a face protective mask and closed work clothes.
● Vent the hydraulic system. The oil pressure is built up manually.
● Do not exceed the maximum permissible oil pressure See the following table.
Table 5- 4 Maximum permissible oil pressure
Motor type
Maximum oil pressure Pmax [MPa]
1FE105□-6W
100
1FE106□-6W, 1FE108□-6W 1FE109□-4W,
1FE109□-6W 1FE111□-6W, 1FE114□-8W
80
Oil that can be used for dismantling
Viscosity 900 mm2/s at 20° C e.g. type LHDF 900
Dismantling
NOTICE
Danger to the environment caused by escaping oil
The forcing of oil can cause oil to escape and result in environmental damage.
• Catch any escaping oil.
• Bind the escaping oil with a suitable oil binding agent.
• Dispose of the oil and oil binding agent in accordance with the legal regulations.
Mechanical mounting
5.3 Mounting/dismantling the rotor
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 71
Procedure
Table 5- 5 Dismantling the rotor core
Position before loosening
Position after loosening
①
Hydraulic hand pump connection
②
Connector nipple
③
Extension tube
④
Supporting fixture (prism)
⑤
Catchment tray
A Movement dimension = 55
mm, for the 1FE114□-8 = 80 mm
A' Distance after loosening
1. Unscrew both grub screws from the rotor core sleeve.
2. Wrap the threaded shoulder on the extension tube and the second grub screw with Teflon
sealing tape.
3. Screw the extension tube firmly into the sleeve of the rotor core.
4. Place the rotor core with spindle shaft, slotted nut and the spacing sleeve on the prism.
5. Attach the oil hand pump.
6. Vent the hydraulic system.
7. Screw the second grub screw with Teflon sealing tape tightly into the sleeve thread.
8. Force the oil with the hand pump slowly until the pressure of approx. 50 MPa (500 bar) is
reached.
9. Allow the oil to act for approximately 15 minutes.
→ The oil penetrates the fitting gaps and distributes itself.
Mechanical mounting
5.3 Mounting/dismantling the rotor
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10.Increase the pressure to approx. 60 to 70 MPa (600 to 700 bar) until the oil escapes at
both sides of the press fit. If the oil escapes only at one side, retain pressure by
repumping.
→ The rotor core slides off the spindle of its own accord.
Note
A few oil drops can spurt out in the axial direction.
The rotor movement is limited by the prism.
If necessary,
support the loosening of the rotor core by tapping lightly, for example, with a
soft
-faced hammer.
Consult your Siemens representative if dismantling is not successful.
11.Check the joint surfaces for scratches or marks in the longitudinal direction.
Note
Scratches or marks in the longitudinal direction inhibit the pressure build
-up in
subsequent dismantling operations and consequently the release of the joined
components.
You have dismantled the rotor core.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 73
5.4
Mounting the stator with the spindle housing
5.4.1
Production equipment, assembly tools and other resources
Ensure the ambient conditions from Chapter Mounting instructions (Page 55).
Provide the following production equipment, assembly tools and other resources:
1
Appropriate axial stops (examples)
2
Lifting accessories (examples)
3
Eyebolts
4
Spacing sleeves
5
Plastic-covered support arm for horizontal mounting (example)
6
Internal tensioning spindle (example)
● Occupational safety equipment:
– Face protection shield
– Protective gloves
– Closed protective clothing for protection against high surface temperatures
● Hoisting gear with suitable load suspension device for the stator core
● Eyebolts or ring nuts and spacing sleeves
● Axial stop for cooling jacket/stator core without cooling jacket
● Internal tensioning spindle for the laminated stator core
● Plastic-covered support arm (for horizontal mounting)
● Anti-corrosion agent for steel surfaces
● Grease or talcum as lubricants for Viton O-ring seals
For the leak test with liquid:
● Water connection, maximum test pressure 0.7 MPa (7 bar).
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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For joining by heating the spindle housing (shrink fit):
● Hot-air oven with temperature monitoring
– Oven volume appropriate for the stator type
– Placement of the oven in the immediate vicinity of the workplace
● Device for cooling the heated-up cooling jacket.
5.4.2
Mounting preparation
Procedure
1. Check that the components are correct and complete.
2. Check the insulation resistance before mounting stators that have been stored for a
longer period. See Chapter "Test the insulation resistance (Page 125)".
3. Clean the surfaces to be joined①.
1
Joining surfaces for the stator to be coated with anti-corrosion agent.
2
Four slots for the O-ring seals for sealing the stator
3
Center slots for discharge in the drain holes
4
Cooling thread
Figure 5-9 Surfaces and slots for the stator with water cooling
All surfaces must be free from contamination, rust, sharp edges, shrink holes, damage
and machining marks, in particular:
– The ring slots for the O-ring seals
– The cooling thread on the cooling jacket (for the stator with cooling jacket variant)
– The spindle housing
– The cable duct in the spindle housing
– The drain holes
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 75
4. Apply a suitable anti-corrosion agent for steel to the stator and spindle housing surfaces
that do not come into contact with the cooling fluid.
①
Stator core with cooling jacket
②
Spindle housing
③
O-ring seal
④
Surface coated with anti-corrosion agent
⑤
Drain hole
Figure 5-10 Applying anti-corrosion agent (the figure shows the fully mounted stator).
5. To improve sliding, rub the O-ring seals with an appropriate grease or talcum.
2
The slots for the O-ring seals
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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6. Insert the O-ring seals in the slots.
7. Screw the eyebolts, if necessary with spacer sleeves, into the front face of the cooling
jacket for the attachment of the hoisting gear.
You have made preparations for mounting.
5.4.3
Mounting the stator with cooling jacket
There are several variants for joining the stator with the spindle housing.
Note
The spindle manufacturer is responsible for selecting and executing the joining process.
NOTICE
Damage to power and sensor cables
The power and sensor cables can be damaged during mounting.
• Position the cables so they are not damaged during mounting.
• Avoid tensions on the cables.
• Do not crush the cables.
Note
The spindle housing seals the cooling thread of the cooling jacket from the exterior.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 77
Examples for the vertical mounting of the spindle housing
Example A: Vertical mounting of the stator in the spindle housing
Use this joining procedure when the connection cables exit from the larger cooling jacket
diameter.
Procedure
1
Stator with cooling jacket
5
Cable entry
2
O-ring seals (four)
6
Connection cables
3
Axial stop
7
Spacing sleeves (example)
4
Spindle housing
8
Lifting lug / eyebolts
Figure 5-11 Vertical mounting of the stator in the spindle housing, steps 1, 7 and 8
1. Place the spindle housing at the axial stop.
2. Remove the lifting lug and the eyebolts.
3. Check that the four O-ring seals are fitted correctly.
4. Fasten the eyebolts, possibly with spacer sleeves, to the cooling jacket.
5. Take the stator at the lifting lug.
6. Position the stator so that you can route the connection cables through the cable gland of
the spindle housing or the bearing shield later.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
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7. Insert the stator from above into the spindle housing.
Note
•
In necessary, push the stator by hand to the final position.
•
When joining, ensure that the O-ring seals remain in the stator slots.
8. Remove the lifting lug and the spacer sleeves from the stator.
9. Push the connection cables through the cable gland of the spindle housing or the bearing
shield in accordance with the project specifications.
10.Attach the bearing shield.
11.Bolt the bearing shield or mounting shield onto the cooling jacket. See Chapter "Mounting
the motor spindle (Page 86)".
– First tighten all bolts with half the maximum tightening torque.
– Then tighten the bolts with a torque wrench diagonally to the maximum tightening
torque. See "Tightening torques" table.
12.Use a liquid medium to check whether the spindle housing is sealed properly. Test
pressure 0.7 MPa (7 bar).
– Turn the spindle housing so that the drain holes are facing downwards.
13.If the spindle housing leaks, dismantle the spindle housing.
– Replace the O-ring seals.
– Debur any sharp edges.
14.Remount the spindle housing.
You have mounted the spindle housing.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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Example B: Vertical mounting of the spindle housing over the stator
Use this joining procedure when the connection cables exit from the smaller cooling jacket
diameter.
Procedure
1
Stator with cooling jacket
5
Cable entry
2
O-ring seals (four)
6
Connecting cables
3
Axial stop
7
Internal tensioning spindle
4
Spindle housing
8
Lifting lug / eyebolts
Figure 5-12 Vertical mounting of the spindle housing over the stator, steps 2, 3 and 5
1. Check that the four O-ring seals are fitted correctly.
2. Position the stator on the axial stop.
3. Remove the internal tensioning spindle from the stator.
4. Position the spindle housing so that you can route the electrical cables through the cable
gland of the spindle housing or the bearing shield later.
5. Place the spindle housing over stator from above.
Note
•
If necessary, push the the spindle housing by hand to the final position.
•
When joining, ensure that the O-ring seals remain in the stator slots.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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6. Remove the lifting lug and the eyebolts from the spindle housing.
7. Push the connection cables through the cable gland of the spindle housing or the bearing
shield in accordance with the project specifications.
8. Attach the bearing shield.
9. Bolt the bearing shield or mounting shield onto the cooling jacket. See Chapter "Mounting
the motor spindle (Page 86)".
– First tighten all bolts with half the maximum tightening torque.
– Then tighten the bolts with a torque wrench diagonally to the maximum tightening
torque. See "Tightening torques" table.
10.Use a liquid medium to check whether the spindle housing is sealed properly. Test
pressure 0.7 MPa (7 bar).
– Turn the spindle housing so that the drain holes are facing downwards.
11.If the spindle housing leaks, dismantle the spindle housing.
– Replace the O-ring seals.
– Debur any sharp edges.
12.Remount the spindle housing.
You have mounted the spindle housing.
Example for the horizontal mounting of the stator in the spindle housing
Procedure
1
Plastic-covered support arm
4
Spindle housing
2
Stator
5
Bearing shield
3
O-ring seals (four)
6
Bolt
Figure 5-13 Horizontal mounting of the stator in the spindle housing, steps 3, 4 and 7
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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1. Check that the four O-ring seals are fitted correctly.
2. Take the stator at the support arm.
3. Position the spindle housing so that you can route the electrical cables through the cable
gland of the spindle housing or the bearing shield.
4. Insert the stator horizontally in the spindle housing. When inserting, ensure that the O-
ring seals remain in the stator slots.
5. Thread the connection cables through the cable gland.
6. Attach the bearing shield.
7. Bolt the bearing shield or mounting shield onto the cooling jacket. See Chapter "Mounting
the motor spindle (Page 86)".
– First tighten all bolts with half the maximum tightening torque.
– Then tighten the bolts with a torque wrench diagonally to the maximum tightening
torque. See "Tightening torques" table.
Use a liquid medium to check whether the spindle housing is sealed properly. Test
pressure 0.7 MPa (7 bar).
– Turn the spindle housing so that the drain holes are facing downwards.
8. If the spindle housing leaks, dismantle the spindle housing.
– Replace the O-ring seals.
– Debur any sharp edges.
9. Remount the spindle housing.
You have mounted the spindle housing.
Tightening torques
Use bolts with at least property class 8.8 μtot = 0.14
Diameter [mm]
Tightening torque [Nm]
M5
6
M6 10
M8
25
Mechanical mounting
5.4 Mounting the stator with the spindle housing
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5.4.4
Mounting the stator without cooling jacket
The stator is connected with the spindle housing of the spindle manufacturer by warm
shrinking.
There are several variants for joining the stator with the spindle housing.
Note
The spindle manufacturer is responsible for selecting and executing the joining process.
Note
Perform the joining procedure without delay.
Example A: Mounting the stator in the spindle housing
Procedure
1
Axial stop for stator
4
Stator without cooling jacket
2
Spindle housing
5
Connection cables
3
Cable entry
6
Internal tensioning spindle
Figure 5-14 Mounting the stator without cooling jacket in the spindle housing, steps 3, 6 and 7
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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1. Clean contaminants and chips from the subassemblies ② and ④.
NOTICE
Risk of damage to the winding and insulation
Excessive temperatures can damage the winding and insulation.
• Ensure that the temperatures when joining spindle housings do not exceed 160° C.
2. Warm up the spindle housing.
3. Place the heated spindle housing on the mounting support.
4. Remove without delay the lifting lug and the eyebolts.
5. Take the stator without cooling jacket with the inner tensioning spindle.
6. Insert without delay the stator in the spindle housing using the internal tensioning spindle.
Ensure the correct position of the connection cables at the cable gland in the spindle
housing.
NOTICE
Damage to the power and signal cables caused by a hot spindle housing
The insulation can be damaged if the power and signal cables come into contact with
the hot spindle housing.
• Avoid the cables making contact with the hot spindle housing.
Note
•
If necessary, push the stator with the internal tensioning spindle by hand to the final
position.
7. Remove the internal tensioning spindle plug.
8. Let the hot spindle housing cool down.
9. Push the connection cables through the cable gland of the spindle housing or the bearing
shield in accordance with the project specifications.
10.Attach the bearing shield.
11.Bolt the bearing shield onto the spindle housing.
– First tighten all bolts with half the maximum tightening torque.
– Then tighten the bolts with a torque wrench diagonally to the maximum tightening
torque. See "Tightening torques" table.
You have mounted the stator in the spindle housing.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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Example B: Mounting the spindle housing over the stator
Figure 5-15 Mounting the spindle housing over the stator without cooling jacket, steps 2, 3 and 7
1. Clean contaminants and chips from the subassemblies ② and ④.
NOTICE
Risk of damage to the winding and insulation
Excessive temperatures can damage the winding and insulation.
• Ensure that the temperatures when joining spindle housings do not exceed 160° C.
2. Place the stator on the mounting support.
3. Remove the internal tensioning spindle from the stator.
4. Warm up the spindle housing.
5. Mount without delay the lifting lug and the eyebolts.
6. Take the heated spindle housing at the lifting lug.
Mechanical mounting
5.4 Mounting the stator with the spindle housing
1FE1 synchronous built-in motors
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7. Push without delay the spindle housing over the stator.
Ensure the correct position of the connection cables at the cable gland in the spindle
housing or bearing shield.
NOTICE
Damage to the power and signal cables caused by a hot spindle housing
The insulation can be damaged if the power and signal cables come into contact with
the hot spindle housing.
• Avoid the cables making contact with the hot spindle housing.
Note
•
If necessary, push the the spindle housing by hand to the final position.
8. Let the hot spindle housing cool down.
9. Push the connection cables through the cable gland of the spindle housing or the bearing
shield in accordance with the project specifications.
10.Attach the bearing shield.
11.Bolt the bearing shield onto the spindle housing.
– First tighten all bolts with half the maximum tightening torque.
– Then tighten the bolts with a torque wrench diagonally to the maximum tightening
torque. See "Tightening torques" table.
You have mounted the spindle housing over the stator.
Tightening torques
Use bolts with at least property class 8.8 μtot = 0.14
Diameter [mm]
Tightening torque [Nm]
M5
6
M6
10
M8
25
Mechanical mounting
5.5 Mounting the motor spindle
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5.5
Mounting the motor spindle
5.5.1
Preparation
Stator core with spindle enclosure and spindle shaft with rotor core are mounted to form a
complete motor spindle.
Production equipment and other resources required
● Hoisting gear with suitable load suspension device
● Eyebolts
● Centering assembly fixture
● Assembly film (only for APM rotors)
● Personnel protective equipment
5.5.2
Acting magnetic forces
The higher magnetic forces present as a result of the permanent magnets in the rotor can
draw the spindle into the stator bore.
①
Spindle shaft with rotor core
②
Stator core with spindle housing
Fa
Axial attractive force
Fr
Radial attractive force
Figure 5-16 Attractive_forces_motor_spindle
The magnitude of the present magnetic forces is motor-specific.
Mechanical mounting
5.5 Mounting the motor spindle
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 87
The present magnetic forces are contained in the table in Chapter "Magnetic forces that
occur (Page 30)".
Note
The specified radial forces are the maximum values that occur if the rotor comes into contact
with the stator at one side.
For an ideally centric rotor (no eccentricity), the resulting radial
force is zero.
The radial force between a centric rotor and the rotor in contact with the stator can be
linearly converted (calculated air gap, 0.5 mm) depending on the eccentricity.
Depending upon the relative position and the weight of the rotor core, an additional axial
mounting force of about 300 N is required.
5.5.3
Mounting the motor spindle with IPM rotor
Procedure
1. Clean contaminants and chips from the subassemblies ①②.
①
Spindle shaft with rotor core
②
Stator core with spindle housing
Figure 5-17 Mounting the motor spindle
2. Lower the spindle shaft with the rotor core onto the stator core.
Mechanical mounting
5.5 Mounting the motor spindle
1FE1 synchronous built-in motors
88 Hardware Installation Manual, 12/2016, 610.43000.40b
3. Bolt on the bearing shield as specified in Chapter Mounting the stator with cooling jacket
(Page 76). This may necessitate overcoming the radial force Fr.
①
Encoder (separate mounting instructions)
⑦
Bearing shield NDE
②
Housing bolts
⑧
Drain hole
③
Stator core with cooling jacket
⑧
Coolant connection
④
Rotor core
⑧
Spindle housing
⑤
Free cable ends
⑧
Spindle shaft with bearings
⑥
Flexible tube
⑧
Bearing shield DE
Figure 5-18 Complete_motor_spindle
4. Complete the motor spindle in accordance with the project.
5. Fasten the rating plate, supplied as a loose item, securely to the spindle box in a clearly
visible position.
You have mounted the motor spindle.
5.5.4
Mounting the motor spindle with APM rotor
NOTICE
Danger of damage to the rotor banding
The banding (composite composite fiber) must not be damaged and must not come into
contact with the stator bore.
• Remove the protective film only immediately before mounting.
• Use an assembly film.
• Always use a centering assembly fixture for mounting.
Mechanical mounting
5.5 Mounting the motor spindle
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 89
Procedure
Carry out the mounting according to the following sequence:
1. Clean contaminants and chips from the subassemblies ①②.
2. Remove carefully the protective film from the rotor (in the scope of delivery for some
variants).
1
Spindle shaft with rotor core
2
Stator core with spindle housing
3
Centering assembly fixture for stator core
4
Centering assembly fixture for rotor core
5
Stable support
6
Assembly film
7
Bolts for attaching the bearing shield
Figure 5-19 Mounting the motor spindle
3. Place the required assembly film in the stator bore.
Mechanical mounting
5.5 Mounting the motor spindle
1FE1 synchronous built-in motors
90 Hardware Installation Manual, 12/2016, 610.43000.40b
4. Using the hoisting gear, ease the spindle shaft with rotor core ① slowly and carefully into
the stator core ②.
Note
Depending upon the relative position and the weight of the rotor core, an additional axial
mounting force of about 300 N is required.
5. Bolt on the bearing shield.
6. Rotate the premounted motor spindle through 180°.
6
Assembly film
Mechanical mounting
5.5 Mounting the motor spindle
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 91
7. Remove the assembly film.
①
Encoder (separate mounting instruc-
tions)
⑦
Bearing shield NDE
②
Housing bolts
⑧
Drain hole
③
Stator core with cooling jacket
⑧
Coolant connection
④
Rotor core
⑧
Spindle housing
⑤
Free cable ends
⑧
Spindle shaft with bearings
⑥
Flexible tube
⑧
Bearing shield DE
Figure 5-20 Complete motor spindle
8. Complete the motor spindle in accordance with the project.
9. Fasten the rating plate, supplied as a loose item, securely to the spindle box in a clearly
visible position.
You have mounted the motor spindle.
Mechanical mounting
5.6 Installation
1FE1 synchronous built-in motors
92 Hardware Installation Manual, 12/2016, 610.43000.40b
5.6
Installation
5.6.1
Placement of the motor spindle
NOTICE
Danger of component destruction caused by contact with hot surfaces
If temperature-sensitive components and cables come into contact with hot motor surfaces,
they can be damaged or destroyed.
• Install temperature-sensitive components and cables so they cannot come into contact
with the hot motor surface.
● Observe the project specifications of the spindle manufacturer.
● Observe the technical data on the motor housing rating plate or the details contained in
the machine documentation of the spindle manufacturer.
● Check whether the rating plate details match the conditions pertaining at the installation
location.
● Observe the permitted maximum radial and axial vibration values.
● Ensure that the motor spindle mounting (e.g. foot-flange or mounting foot) has even
contact with the mounting surface. Stresses of the motor spindle are not permitted.
● Turn the output elements by hand.
If a grinding noise occurs, rectify the cause or contact the manufacturer.
Emissions
The motors are certified for a wide range of mounting and operating conditions.
The installation and operating conditions can affect the motor noise.
5.6.2
Permissible motor vibrations
The following effects can increase motor vibration values:
● The on-site system vibration characteristics depend on factors such as the output
elements, mounting conditions, alignment and installation.
● Effects of external vibration
Ensure that the vibration values conform to project specifications and the following tables are
not exceeded at the specified measuring points on the motor.
Observe the notes for measuring points, measurement and evaluation according to ISO
10816.
Mechanical mounting
5.6 Installation
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 93
If necessary, balance the rotor with the drive system completely.
Table 5- 6 Maximum permitted radial vibration values
Vibration frequency
Vibration values
< 6.3 Hz
Vibration displacement s ≤ 0.16 mm
6.3 - 250 Hz Vibration velocity vrms ≤ 4.5 mm/s
> 250 Hz
Vibration acceleration a ≤ 10 m/s
2
Table 5- 7 Maximum permitted axial vibration values
Vibration velocity
Vibration acceleration
vrms = 4.5 mm/s apeak = 2.25 m/s2
Figure 5-21 Maximum permissible vibration velocity taking into account the vibration displacement
and vibration acceleration
Measure the vibration velocity using appropriate measuring equipment.
The vibration acceleration is evaluated as a peak value in the frequency band 10 to 2000 Hz.
Note
If vibration excitations in excess of 2000 Hz (e.g. gear teeth meshing frequencies) can be
expected, the measurement range must be adapted accordingly.
The permitted maxim
um values remain unchanged.
Mechanical mounting
5.6 Installation
1FE1 synchronous built-in motors
94 Hardware Installation Manual, 12/2016, 610.43000.40b
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 95
Connecting
6
6.1
Connecting the cooling
6.1.1
Warning of the consequences of unqualified work
WARNING
Defective work on the cooling circuit
Defective work on the cooling circuit can cause injury and/or damage to property.
• Only qualified personnel may assemble, install, and commission the cooling circuit.
• Perform installation or service work on the cooling circuit only when the system is de-
energized.
6.1.2
Safety instructions
WARNING
Danger to life caused by an electric shock
Electrical conducting parts of the machine that touch parts of the cooling system can cause
death or injuries.
• Prepare for shutdown and notify all those who will be affected by the procedure.
• Before performing any work on the cooling system, de-energize the motor and the
auxiliary circuits.
• Check that the cabinet is de-energized.
• Take measures to prevent reconnection of the energy sources.
Connecting
6.1 Connecting the cooling
1FE1 synchronous built-in motors
96 Hardware Installation Manual, 12/2016, 610.43000.40b
WARNING
Danger to life caused by short-circuit to a frame in a fault situation
The spindle housing must be electrically connected to the cooling jacket.
In a fault situation, lethal voltage can be present at the spindle housing that causes death or
severe injuries because of an electric shock.
• Ground the complete motor spindle in accordance with the regulations.
WARNING
Danger to life caused by rotation of the assembled spindle shaft
The rotating of an assembled built-in motor produces induction that causes lethal voltages
at the cable ends of the motor.
The voltages can cause death or severe injuries because of an electric shock.
• Do not touch any bare cable ends.
• Prevent assembled built-in motors from turning.
• Insulate the terminals and cores of bare cable ends.
WARNING
Danger to life caused by high leakage currents
High leakage currents can cause death or injuries as result of an electric shock.
• Satisfy the requirements placed on protective conductors in accordance with EN 61800-
5-1.
WARNING
Danger to life caused by high residual voltages
When the power supply voltage is switched-off, active components of the motor can have
an electrical charge of more than 60 μC.
The residual voltages that occur at the connections of the built-in motor several seconds
after power-down can cause death or severe injuries as result of an electric shock.
• Do not touch any bare connections.
• Protect bare connections and active components against inadvertent contact.
• Ground the motor properly.
Connecting
6.1 Connecting the cooling
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 97
WARNING
Danger to life when the cooling system bursts
The motor will overheat if it is operated without cooling. When cooling water enters the hot
motor, this immediately and suddenly generates hot steam that escapes under high
pressure. This can cause the cooling water system to burst, resulting in death, severe injury
and material damage.
• Never operate the motor without cooling.
• Only commission the cooling water circuit when the motor is in a cool condition.
CAUTION
Danger of burns a result of touching hot surfaces
In operation, the motor housing can reach high temperatures, which can cause burns if
touched.
• Do not touch any hot surfaces.
• Allow the motor to cool down before starting any work.
• Use the appropriate personnel protection equipment, e.g. gloves.
NOTICE
Material damage due to the effect of electrochemical series
When using different conductive materials, material damage can occur as a result of the
electrochemical series.
• Do not use any zinc in the cooling circuit.
• Use brass, stainless steel or plastic for pipes and fittings.
NOTICE
Motor damage due to lack of cooling
if you operate the motor without water cooling, the motor will be damaged or destroyed.
• Only operate the motor with a closed cooling water loop with heat exchange equipment.
Connecting
6.1 Connecting the cooling
1FE1 synchronous built-in motors
98 Hardware Installation Manual, 12/2016, 610.43000.40b
6.1.3
Connecting the water cooling
Note
Lay the cooling water supply intake and drain outlet connections according to project
requirements.
Preconditions
● Ensure that the cooling water complies with the required cooling water specification. See
Chapter "Cooling (Page 36)".
● Ensure that cooling water with the required flow volume is available. See rating plate
(type plate).
Procedure
1. Connect the cooling water pipes for intake and drainage according to project
requirements.
1
Drain holes
2
Connections for the cooling water pipes
2. Set for the inlet a maximum permitted operating pressure of 0.7 MPa.
NOTICE
Risk of motor damage by voltage discharges resulting from condensation
If the stator winding is damp, its insulation resistance decreases. This can cause voltage
discharges that damage the windings.
• Keep the drain holes free so that condensation can escape freely.
NOTICE
Risk of motor damage by corrosion resulting from condensation
Condensation that does not escape can cause corrosion and motor damage.
• Keep the drain holes free so that condensation can escape freely.
Connecting
6.1 Connecting the cooling
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 99
3. Check that the drain holes are free so that condensation can escape freely.
4. Check the water cooling for leaks.
You have connected the water cooling.
6.1.4
Connecting the air cooling
Air-cooled motors are special versions. Connection is in accordance with the spindle
manufacturer's project requirements.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
100 Hardware Installation Manual, 12/2016, 610.43000.40b
6.2
Electrical connection
6.2.1
Safety information
NOTICE
Motor destruction caused by incorrect connection
The direct connection to the three-phase line supply damages the motor.
• Connect the motor only at the configured converters.
• Observe the correct phase sequence.
6.2.2
High-voltage test
DANGER
Lethal voltage hazards
A dangerous voltage is present at the motor during a high-voltage test. Death or serious
injury can result when live parts are touched.
• Do not touch any live parts.
• Adhere to the fundamental safety instructions.
NOTICE
Destruction of electronic components and damage to the insulation
A high-voltage test on the motor can damage the insulation of the motor and destroy
electronic components, e.g. temperature sensors.
• Use maximum 80% of the test voltage in accordance with EN 60034-1.
• Prior to the test, short-circuit the cable ends of the temperature sensors.
Before being shipped, the stators of the built-in motors are subject to a high-voltage test in
compliance with EN 60034-1.
However, the Standards Commission recommends that when electrical components (such
as built-in motors) are installed, a new high-voltage test according to EN 60034-1 should be
performed after the final assembly has been completed.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 101
6.2.3
Electrical equipment
The following equipment is provided by the spindle manufacturer:
● Terminal box or connectors, variant with at least IP54 according to EN 60034
● Flexible tube
● Ground cable with cable lug
6.2.4
Connection cables
In the standard version, the stator core has the following connection cables:
● Power connection marked U1, V1, W1
● Two cables for the temperature sensor (one reserve), two-wire with color coding, each
cable cross-section 0.22 mm².
Note
Electrical connection via terminal box or power connector
The power cables of the motor are not suitable as direct electrical interface of the spindle.
The electrical connection of the sp
indle must be made via the terminal box or power
connector.
● Feed out the free cable ends from the spindle box in a suitable protective tubing with
cable gland to a terminal box provided by the customer.
● Ensure effective strain relief. Maintain the required minimum bending radii (3 to 4 x the
outer cable diameter).
● To connect the motor to a converter, use MOTION-CONNECT cables or shielded
connecting cables from the spindle box interface.
Note
The maximum length of the connecting cable is 50
m with and without VPM.
● Due to the high voltages, use cables for higher mechanical requirements in combination
with a connection socket and VPM.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
102 Hardware Installation Manual, 12/2016, 610.43000.40b
The spindle manufacturer installs the following cable connections:
1. Power connection
2. Internal protective ground cable (protection from dangerous shock currents)
3. Connection for the temperature sensors
Two types of temperature sensors can be installed.
KTY 84
Pt1000
ESD component
No ESD component
Ensure proper polarity
+ = brown connection cable
- = white connection cable
No polarity: 2 yellow connection cables
Example circuits for additional temperature evaluations are contained in the following
chapters:
Temperature evaluation using the PTC thermistor triplet (full motor protection, option)
(Page 114)
Connect the temperature sensor to the flanged connection socket of the encoder.
4. Encoder connection
Example for connecting with terminal box
1
Power connection U, V, W
2
Internal protective conductor
3
Connection for internal and external protective conductors
4 Connection for temperature sensors. The color coding depends on the installed temperature
sensor, see table above.
Figure 6-1 Terminal box (example)
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 103
6.2.5
Cable cross-sections and outer diameter of the connecting cables
Table 6-2 Cable cross-sections (Cu) and outer diameter of the connecting cables
Motor type
L = 0.5 m 1)
L = 1.5 m 2)
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
6-pole built-in motors
1FE1041-6WM□□
2.5
3)
4.4
3)
2.5
3)
4.4
3)
1FE1041-6WU□□ 2.53) 4.43) 2.53) 4.43)
1FE1042-6WN□□
2.5
3)
4.4
3)
2.5
3)
4.4
3)
1FE1042-6WR□□
2.5
3)
4.4
3)
2.5
3)
4.4
3)
1FE1042-6WT□□
2.5
3)
4.4
3)
2.5
3)
4.4
3)
1FE1051-6WK□□
2.5
4.4
2.5
4.4
1FE1051-6WN□□
2.5
4.4
2.5
4.4
1FE1052-6WK□□
4.0
5.5
4.0
5.5
1FE1052-6WN□□
2.5
4.4
2.5
4.4
1FE1052-6WY□□
2.5
4.4
2.5
4.4
1FE1054-6WN□□
6.0
3)
6.3
3)
6.0
3)
6.3
3)
1FE1054-6WR□□
4.0
5.5
6.0
6.3
1FE1061-6WH□□
2.5
4.4
2.5
4.4
1FE1061-6WV□□
2.5
4.4
2.5
4.4
1FE1061-6WY□□
2.5
4.4
2.5
4.4
1FE1062-6WQ□□
2.5
4.4
2.5
4.4
1FE1064-6WN□□
6.0
3)
6.3
3)
6.0
3)
6.3
3)
1FE1064-6WQ□□
4.0
5.5
6.0
6.3
1FE1082-6WE□□
2.5
4.4
2.5
4.4
1FE1082-6WP□□
10.0
7.9
10.0
7.9
1FE1082-6WQ□□ 6.0 6.3 10.0 7.9
1FE1082-6WS□□
4.0
5.5
6.0
6.3
1FE1082-6WW□□
2.5
4.4
2.5
4.4
1FE1083-6WP□□
10.0
7.9
10.0
7.9
1FE1084-6WR□□
6.0
6.3
10.0
7.9
1FE1084-6WU□□
4.0
5.5
6.0
6.3
1FE1084-6WX□□
2.5
4.4
2.5
4.4
1FE1091-6WN□□
2.5
4.4
2.5
4.4
1FE1091-6WS□□
2.5
4.4
2.5
4.4
1FE1092-6WN□□
6.0
6.3
10.0
7.9
1FE1092-6WR□□
4.0
5.5
6.0
6.3
1FE1093-6WN□□
10.0
7.9
16.0
9.0
1FE1093-6WS□□
6.0
6.3
10.0
7.9
1FE1093-6WV□□
4.0
5.5
6.0
6.3
1FE1093-6WX□□
2.5
4.4
2.5
4.4
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
104 Hardware Installation Manual, 12/2016, 610.43000.40b
Motor type
L = 0.5 m 1)
L = 1.5 m 2)
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
1FE1113-6WU□□
6.0
6.3
10.0
7.9
1FE1113-6WX□□
4.0
5.5
6.0
6.3
1FE1114-6WR□□ 16.0 9.0 25.0 11.0
1FE1114-6WT□□
10.0
7.9
16.0
9.0
1FE1114-6WW□□
6.0
6.3
10.0
7.9
1FE1115-6WT□□
10.0
7.9
16.0
9.0
1FE1115-6WW□□
6.0
6.3
10.0
7.9
1FE1116-6WR□□
16.0
9.0
25.0
11.0
1FE1116-6WT□□
10.0
7.9
16.0
9.0
1FE1116-6WW□□
6.0
6.3
10.0
7.9
1FE1116-6WY□□
4.0
5.5
6.0
6.3
1) According to EN 46200 can only be used in the motor spindle
2) Notes on
using cables is provided in VDE 0298, Part 3 and Part 4
3) Teflon cable
Motor type
L = 0.5 m 1)
L = 1.5 m 2)
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
8-pole built-in motors
1FE1143-8WM□1
25.0
11.0
25.0
11.0
1FE1143-8WQ□1
10.0
7.9
16.0
9.0
1FE1144-8WL□1
25.0
11.0
2 * 16
2 * 9
1FE1144-8WQ□1
16.0
9.0
25.0
11.0
1FE1144-8WT□1
16.0
9.0
16.0
9.0
1FE1144-8WV□1
10.0
7.9
10.0
7.9
1FE1145-8WE□1
10.0
7.9
16.0
9.0
1FE1145-8WN□1
2 * 16
2 * 9
2 * 16
2 * 9
1FE1145-8WQ□1
2 * 10
2 * 7.9
2 * 16
2 * 9
1FE1145-8WS□1 25.0 11.0 25.0 11.0
1FE1147-8WM□1
2 * 16
2 * 9
2 * 25
2 * 11
1FE1147-8WN□1 2 * 16 2 * 9 2 * 16 2 * 9
1FE1147-8WQ□1
2 * 10
2 * 7.9
2 * 16
2 * 9
1FE1147-8WS□1
25.0
11.0
25.0
11.0
1)
According to EN 46200 can only be used in the motor spindle
2) Notes on using cables is provided in VDE 0298, Part 3 and Part 4
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 105
Motor type
L = 0.5 m 1)
L = 1.5 m 2)
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
4-pole built-in motors
1FE1051-4HC□0
2.5
4.4
2.5
4.4
1FE1051-4HF□1 2.5 4.4 2.5 4.4
1FE1051-4WN□1
2.5
4.4
2.5
4.4
1FE1052-4HD□0 6.0 6.3 6.0 6.3
1FE1052-4HG□1
4.0
5.5
6.0
3)
6.3
3)
1FE1052-4WK□1
2.5
4.4
4.0
5.5
1FE1052-4WN□1
2.5
4.4
2.5
4.4
1FE1053-4HH□1
4.0
5.5
6.0
6.3
1FE1053-4WJ□1
4.0
5.5
4.0
5.5
1FE1053-4WN□1
2.5
4.4
2.5
4.4
1FE1072-4WH□1
6.0
6.3
10.0
7.9
1FE1072-4WL□1
4.0
5.5
6.0
6.3
1FE1072-4WN□1
2.5
4.4
4.0
5.5
1FE1072-4WV□1
2.5
4.4
2.5
4.4
1FE1073-4WL□1
10.0
3)
7.9
3)
16.0
3)
9.0
3)
1FE1073-4WN□1
6.0
6.3
10.0
7.9
1FE1073-4WT□1
2.5
4.4
2.5
4.4
1FE1074-4WM□1
16.0
3)
9.0
3)
16.0
3)
9.0
3)
1FE1074-4WN□1
10.0
7.9
16.0
9.0
1FE1074-4WR□1
6.0
6.3
10.0
7.9
1FE1074-4WT□1 6.0 6.3 6.0 6.3
1FE1074-4WV□1
4.0
5.5
6.0
6.3
1FE1075-4WQ□1
6.0
6.3
10.0
7.9
1FE1082-4WF□1
10.0
7.9
16.0
9.0
1FE1082-4WK□1
6.0
6.3
10.0
7.9
1FE1082-4WN□1
4.0
5.5
6.0
6.3
1FE1082-4WP□1 2.5 4.4 2.5 4.4
1FE1082-4WR□1
2.5
4.4
2.5
4.4
1FE1083-4WN□1
10.0
7.9
16.0
9.0
1FE1084-4WN□1
16.0
9.0
25.0
11.0
1FE1084-4WP□1
10.0
7.9
16.0
9.0
1FE1084-4WQ□1
10.0
7.9
16.0
9.0
1FE1084-4WT□1
6.0
6.3
10.0
7.9
1FE1084-4WV□1
4.0
5.5
6.0
6.3
1FE1085-4WN□1
16.0
9.0
25.0
11.0
1FE1085-4WQ□1
10.0
7.9
16.0
9.0
1FE1085-4WT□1
6.0
6.3
10.0
7.9
1FE1092-4WP□1
4.0
5.5
6.0
6.3
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
106 Hardware Installation Manual, 12/2016, 610.43000.40b
Motor type
L = 0.5 m 1)
L = 1.5 m 2)
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
Cable cross-section
per phase [mm2]
Cable outer
diameter [mm]
1FE1092-4WV□1
2.5
4.4
2.5
4.4
1FE1093-4WH□1
10.0
7.9
16.0
9.0
1FE1093-4WM□1 6.0 6.3 10.0 7.9
1FE1093-4WN□1
6.0
6.3
10.0
7.9
1FE1094-4WK□1
16.0
9.0
25.0
11.0
1FE1094-4WL□1
10.0
7.9
16.0
9.0
1FE1094-4WS□1
6.0
6.3
10.0
7.9
1FE1094-4WU□1
4.0
5.5
6.0
6.3
1FE1095-4WN□1
16.0
9.0
25.0
11.0
1FE1096-4WN□1
16.0
9.0
25.0
11.0
1FE1103-4WN□1
10.0
7.9
16.0
9.0
1FE1103-4WQ□1
10.0
7.9
10.0
7.9
1FE1103-4WT□1
6.0
6.3
10.0
7.9
1FE1104-4WL□1
2 * 10
2 * 7.9
2 * 16
2 * 9
1FE1104-4WN□1
16.0
9.0
25.0
11.0
1FE1105-4WN□1
16.0
9.0
25.0
11.0
1FE1105-4WQ□1
16.0
9.0
16.0
9.0
1FE1105-4WS□1
10.0
7.9
16.0
9.0
1FE1106-4WN□1
2 * 10
2 * 7.9
2 * 16
2 * 9
1FE1106-4WR□1
25.0
11.0
2 * 16
2 * 9
1FE1106-4WS□1
25.0
11.0
25.0
11.0
1FE1106-4WY□1 6.0 6.3 10.0 7.9
1FE1124-4WN□1
25.0
11.0
2 * 16
2 * 9
1FE1124-4WQ□1
25.0
11.0
25.0
11.0
1FE1125-4WN□1
2 * 16
2 * 9
2 * 16
2 * 9
1FE1125-4WP□1
25.0
11.0
2 * 16
2 * 9
1FE1125-4WQ□1
16.0
9.0
25.0
11.0
1FE1126-4WN□1
2 * 16
2 * 9
2 * 16
2 * 9
1FE1126-4WP□1
2 * 16
2 * 9
2 * 16
2 * 9
1FE1126-4WQ□1
25.0
11.0
2 * 16
2 * 9
1) According to EN 46200, can b
e used only within the motor spindle.
Observe IEC / EN 60364-5-52 and IEC / EN 60204-1.
2) Notes on using cables is provided in VDE 0298, Part 3 and Part 4
3) Teflon cable
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 107
6.2.6
Information on cable routing
Cable selection
● Select the connecting cables appropriate for the rated dynamic currents and the plant-
specific conditions, e.g. ambient temperature, routing type.
Note
As a result of the converter operation, high
-frequency current and voltage oscillations in
the motor feeder cables can cause electromagn
etic interference.
Only use shielded power and signal cables.
● Use shielded cables whose shields have a large-area conductive connection with the
terminal box of the motor via EMC cable glands.
● Use prefabricated cables from Siemens. These cables reduce the installation time and
costs and increase operational reliability.
● Use EMC cable glands for permanently installed entry fittings.
Information on cable routing
● Lay loose connection cables so that the insulation is not damaged.
● Make sure that the minimum bending radii are not exceeded. Minimum radius for fixed
installation: R = 4 x D
(D = outer cable diameter).
● Only remove insulation from the cable ends so that the insulation reaches up to the cable
lug, terminal, or wire end ferrule.
● Use cable lugs or wire end ferrules appropriate for the dimensions of the terminal board
connections and the cable cross-section. If necessary, install parallel connection cables.
● Ensure that the inside of the terminal box or connector is clean and free of cable cuttings
and moisture.
● Tighten all of the screws for the electrical connections (terminal board connections, with
the exception of the terminal strips) to the torque specified by the spindle manufacturer.
● Observe the minimum air clearances for the connection and for the laying of internal
connection cables.
Supply voltage [V]
Minimum air clearance [mm]
< 500
4.5
500 - 600
6
● Avoid protruding cable ends.
● Close the terminal boxes and cable entries in accordance with the configured degree of
protection.
● Ensure that connecting cables cannot rotate, are not subject to strain and pushing force,
and also provide anti-kink protection.
● Plug in or remove the connector only when the system is de-energized.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
108 Hardware Installation Manual, 12/2016, 610.43000.40b
6.2.7
Connecting to a converter
To connect the motor to a converter, use MOTION-CONNECT cables or shielded connecting
cables.
The braided shielding must have good electrical conductivity. Prefer braided shielding made
of copper or aluminum.
The shield must be connected at both ends to the motor and the converter; unshielded cable
ends must be kept as short as possible.
Attach the shielding with a large area as 360° contact to the converter and to the motor. Use
for instance, EMC glands at the cable entries.
6.2.8
Connection overview
The circuit diagram contains information about wiring and connecting the motor winding.
1
Ground connection
2
Temperature sensor (1 x reserve)
3
Encoders
4
VP module (if required)
Figure 6-2 Circuit diagram with SIMODRIVE (example)
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 109
1
Power cable
2
Signal line, trailable or only conditionally trailable
3 Signal connector, 17 pole, external thread, MLFB 6FX2003-1CF17
Optional assembly flange for retrofitting MLFB 6FX2003-7DX00
4
DRIVE-CLiQ cable 6FX☐002-2DC10_☐☐☐, trailable or only conditionally trailable
5
SME120, encoder, motor side, connector kits 6FX2003-0SA12, 12-pin
6
Encoder
7
Temperature sensor (+1 reserve)
8
Ground connection
9
Voltage limiting (VPM, IVP), only if EMF > 820 V
Figure 6-3 Circuit diagram with SINAMICS (example)
Note
Connect a rotary encoder according to the project requirements.
6.2.9
Grounding
Ground the 1FE1 according to the project requirements.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
110 Hardware Installation Manual, 12/2016, 610.43000.40b
6.2.10
Connecting the temperature sensors
NOTICE
Risk of damage to temperature-sensitive components
Some parts of the electrical motor housing can reach temperatures that exceed 100° C. If
temperature-sensitive components, e.g. electric cables or electronic components, come into
contact with hot surfaces, these components could be damaged.
• Ensure that no temperature-sensitive components are in contact with hot surfaces.
Connecting the KTY
NOTICE
Risk of destroying temperature sensors when the ESD notes are ignored
Temperature sensors KTY 84 are ESD components. When delivered, they are short-
circuited with a terminal.
• Observe the ESD notes.
• Remove the terminal only when the temperature sensor is connected.
NOTICE
Risk of destroying the KTY 84 temperature sensor because of incorrect polarity
Incorrect polarity destroys the KTY 84 temperature sensor.
• Connect the KTY 84 with the correct polarity.
Connect the KTY 84 as follows:
● Brown cable: positive polarity (temperature)
● White cable: negative polarity (temperature)
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 111
Figure 6-4 KTY temperature monitoring with PTC thermistor triplet (example)
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
112 Hardware Installation Manual, 12/2016, 610.43000.40b
Connecting the Pt1000
Pt1000 temperature sensors are not ESD components.
Connect the Pt1000 temperature sensor independent of the polarity with two-wire yellow
cables.
Figure 6-5 Pt1000 temperature monitoring with PTC thermistor triplet (example)
Circuit diagrams
Note
SMC20
For additional information on connecting and operating the SMC20, refer to the
documentation in the SINAMICS Function Manual 1 and List Manual 1.
Note
Before the motor is commissioned, carefully check that the shutdown circuit via the PLC
(programmable logic controller) functions correctly.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 113
6.2.11
Temperature evaluation using NTC thermistors (universal protection, option)
Note
Temperature evaluation using
the NTC K227 and NTC PT3-51F thermistors does not
guarantee full motor protection.
The K227 and PT3-51F NTC thermistors are used if the drive system cannot evaluate the
KTY 84 or Pt1000 PTC thermistor.
The NTC thermistors are provided for operating the motor on third-party systems.
The NTC thermistor should be connected in accordance with the configuration and operating
instructions of the third-party system.
The drive system senses and evaluates the motor temperature using the sensor signal (refer
to the drive system documentation).
Table 6- 1 Technical data, NTC K227 and NTC PT3-51
Designation
Technical data
NTC K227
NTC PT3-51F
PTC thermistor resistance (25°
C)
Approx. 32.8 kΩ Approx. 49.1 kΩ
Resistance when hot (100° C)
Approx. 1800 Ω
Approx. 3300 Ω
Cable cross-section
Outer diameter
0.14 mm2
0.8 mm
0.14 mm2
0.8 mm
Temperature characteristic
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
114 Hardware Installation Manual, 12/2016, 610.43000.40b
6.2.12
Temperature evaluation using the PTC thermistor triplet (full motor protection,
option)
For special applications (e.g. when a load is applied with the motor stationary or for
extremely low speeds), the temperature of all of the three motor phases must be additionally
monitored using a PTC thermistor triplet.
Note
I
f water-cooled synchronous built-in motors are operated for longer than one minute in
standstill with the standstill torque, a phase can be thermally loaded overproportionately.
•
Reduce the permanent standstill torque to 20%.
•
Protect the winding thermally with a thermistor triplet (PTC) with an external trip unit or
with an I2t monitoring of the drive system.
The PTC thermistor triplet must be evaluated using an external tripping/evaluation unit (this
is not included in the scope of delivery). This means that the sensor cable is monitored for
wire breakage and short-circuit by this unit.
The motor must be de-energized within 1 second when the response temperature is
exceeded.
Table 6- 2 Technical data for the PTC thermistor triplet
Designation
Technical data
Type (acc. to DIN 44082–M180)
PTC thermistor triplet
Thermistor resistance (20° C)
≤ 750 Ω
Resistance when hot (180° C)
≥ 1710 Ω
Connection
Via an external trip unit
Cable cross-section/outer diameter
0.14 mm
2
/0.9 mm
Response temperature
180° C
Note:
PTC thermistors do not have a linear characteristic curve and are, therefore, not suitable for
determining the instantaneous temperature.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 115
6.2.13
Voltage limitation
Note
EMF (Electro Motive Force) > 820 V
In a fault situation, a voltage limitation of the DC
-link voltage on the converter is required.
The voltage limitation depends on the maxi
mum EMF (induced chained voltage peak > 820
V).
A voltage limitation is required when the mot
or is operated with speed n > nmax inv.
If the line voltage fails at maximum motor speed or if the drive converter pulses are canceled
as a result of the power failure, the synchronous motor regenerates a high voltage back into
the DC link. The voltage protection detects a DC-link voltage that is too high (> 820 VDC)
and short-circuits the three motor supply cables. The energy remaining in the motor is
converted into heat as a result of the short-circuit and causes the motor to quickly brake.
The VPM (Voltage Protection Module) is deployed as voltage limiter for SINAMICS S120.
Operation without voltage limiting
NOTICE
Danger of motor damage caused by exceeding the maximum speed
If a motor with EMF > 820 V is operated without voltage limitation, the maximum permitted
speed must be reduced.
• Never operate the motor without voltage limitation.
• Do not exceed the maximum permissible speed.
Calculate the maximum permissible speed for operation without voltage limitation with the
following equation:
kE = voltage constant, see Chapter "Technical data and characteristic curves" in the
Configuration Manual.
Voltage limitation with the Voltage Protection Module (VPM)
The Voltage Protection Module (VPM) is not included with the 1FE1 built-in motors.
● The VPM ordering information is contained in Catalog NC 62.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
116 Hardware Installation Manual, 12/2016, 610.43000.40b
WARNING
Danger to life caused by the incorrect use of the VPM
The VPM can be used up to a maximum motor EMF of 2 kV. The use of motors with higher
EMC can cause death or severe injury.
• Deploy the VPM only for motors with an EMF greater than 800 V to maximum 2 kV.
• The connection of motors with an EMF > 2 kV on the VPM is prohibited.
Integration and system prerequisites of the VPM
Integration
The VPM is located between the motor and the drive system. The maximum distance to the
drive system is 1.5 m.
Note
No switching elements may be added to the U, V, W connection cables between the drive
system, VPM and motor.
Connect the VPM with shielded motor supply cables.
System requirements:
● SINAMICS S120 booksize (6SL31xx-xxxxx-xxxx3)
● SINUMERIK 840D sl as of software release 1.3
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 117
Technical data
Table 6- 3 Technical data VPM
Designation
VPM 120
VPM 200
Article number for metric gland
6SN1113-1AA00-1JA1
6SN1113-1AA00-1KA1
Dimensions (H x W x D) [mm] 300 x 150 x 180 300 x 250 x 190
Drive system connection (cable cross-
section)
U3, V3, W3; M50
(max. 50 mm²)
U3, V3, W3; 2 x M50
(max. 2 x 50 mm²)
Motor side connection (cable cross-
section)
U4, V4, W4; M50
(max. 50 mm²)
U4, V4, W4; 2 x M5
(max. 2 x 50 mm²)
Cable lug
Crimp-type cable lug M6
Crimp-type cable lug M8
Signaling contact 1 x M16
Max. cable cross-section
1 x NC contact (floating) 24 VDC
≤ 1.5 mm²
1 x NC contact (floating) 24
VDC
≤ 1.5 mm²
Rated current
≤ 3 AC 120 A
eff
≤ 3 AC 200 A
eff
Max. permissible short-circuit current
90 A
200 A
Short-time loading
2 x I
N
for approx. 500 ms
3 x I
N
for approx. 500 ms
Connection length, drive system
≤ 1.5 m
≤ 1.5 m
Connection length, motor side
≤ 50 m
≤ 50 m
Power loss
• Normal operation
• Short-circuit operation with IN
approx. 0 W
approx. 360 W (max. 2 min)
approx. 0 W
approx. 1.1 kW (max. 2 min)
Tripping voltage
830 VDC +/- 1%
830 VDC +/- 1%
Degree of protection
IP20
IP20
Ambient temperature
0° ... 50° C
0° ... 50° C
Installation altitude 1000 m above sea level
(otherwise power reduction)
1000 m above sea level
(otherwise power reduction)
Vibratory load (according to DIN EN
60721)
Up to 1 g Up to 1 g
Shock load (according to DIN EN 60721)
Up to 10 g
Up to 10 g
Max. permissible braking duration
≤ 2 min
≤ 2 min
Weight
approx. 6 kg
approx. 11 kg
Capacity of the drive system with VPM
To ensure in a fault situation that a defined DC-link voltage is not exceeded and the voltage
gain speed is limited, the DC link must have a minimum capacitance.
The DC-link minimum capacitance is calculated using the following equation:
CDC-link min [µF] = INmotor [A] x 33.33
Consider the calculated DC-link capacitance when configuring the system.
Connecting
6.2 Electrical connection
1FE1 synchronous built-in motors
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1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 119
Commissioning
7
WARNING
Danger to life through the use of an incomplete machine
If you use a machine that does not conform to the 2006/42/EU decree, there is the danger
of death, severe injury and/or material damage.
• Commission the machine only when it conforms to the regulations of the EU
2006/42/EU machine decree and the conformity has been declared.
7.1
Safety instructions
WARNING
Danger to life as a result of hazardous voltages when connected to inadequately grounded
line supplies
In the case of a fault, connecting a motor to an inadequately grounded line supply can
result in death, severe injury and motor damage.
• Connect motors, as part of the drive system, to TN and TT line supplies with a grounded
neutral point or to IT line supplies.
• Ensure that the SINAMICS devices and motors are compatible with the residual current
device according to EN 61800-5-1 before you connect the devices and motors to the
line supply using residual current devices (RCDs).
• For line supplies with grounded line conductor, e.g. TT line supplies, use an isolating
transformer with grounded neutral point (on the secondary side) between the line supply
and the drive system, so that the motor insulation is not overstressed.
• When connected to IT line supplies, a monitoring device must signal the first fault
between an active part and ground. Remove this fault immediately.
Commissioning
7.1 Safety instructions
1FE1 synchronous built-in motors
120 Hardware Installation Manual, 12/2016, 610.43000.40b
WARNING
Danger to life caused by dangerous voltage while testing the insulation resistance
During the measurement and immediately afterwards, high voltages can be present at the
terminals that can cause death or severe injury as result of an electric shock.
Contact to live parts causes electric shocks.
• Work on power installations must only be carried out by specialists.
• Before you begin measuring the insulation resistance, read the operating manual for the
insulation resistance meter you are going to use.
• Never touch the terminals when making measurements or immediately after the
measurement.
• Check the connected supply feeder cables to ensure that the line supply voltage cannot
be connected.
WARNING
Danger to life caused by rotating rotors or ejected parts
Rotating rotors and the resulting ejected parts can cause death or injury.
• Secure rotating output elements using the appropriate safety guards.
• Secure loose parts, e.g. featherkeys to prevent the ejection.
WARNING
Danger to life caused by machine movement and loose objects
Machine movement and loose objects that can fall out or be ejected can cause death or
severe injury.
• Ensure that the machine has been completely installed and all of the setting work
completed.
• Ensure that nobody is at risk at switch on.
• Before switching on, check that there are no loose objects in or on the motor that can
fall or be flung off.
WARNING
Danger to life when the cooling system bursts
The motor will overheat if it is operated without cooling. When cooling water enters the hot
motor, this immediately and suddenly generates hot steam that escapes under high
pressure. This can cause the cooling water system to burst, resulting in death, severe injury
and material damage.
• Never operate the motor without cooling.
• Only commission the cooling water circuit when the motor is in a cool condition.
Commissioning
7.1 Safety instructions
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 121
CAUTION
Burns as a result of touching hot surfaces
In operation, the motor housing can reach high temperatures, which can cause burns if
touched.
• Do not touch any hot surfaces.
• Allow the motor to cool down before starting any work.
• Use the appropriate personnel protection equipment, e.g. gloves.
NOTICE
Motor damage caused by overheating as result of missing cooling
If the cooling fails or the motor is operated briefly without cooling, the motor overheats. This
can cause motor damage.
Never operate the motor without activated cooling.
Monitor the permitted water inlet temperatures and the cooling air supply.
Operate the motor only in conjunction with an effective temperature control.
NOTICE
Thermal damage to temperature-sensitive parts
Some parts of the electrical motor enclosure can reach temperatures that exceed 100° C. If
temperature-sensitive parts, e.g. electric cables or electronic components, come into
contact with hot surfaces, these parts could be damaged.
• Ensure that no temperature-sensitive parts are in contact with hot surfaces.
NOTICE
Motor damage when the maximum speed is exceeded
The maximum speed nmax is the highest permissible operating speed. The maximum speed
is specified on the rating plate.
The motor can be damaged if operated at inadmissible speeds.
• Ensure that the maximum permissible speed is not exceeded. Realize this using a
suitable control system or activate the speed monitoring function in the drive.
NOTICE
Motor damage caused by uneven running or abnormal noise
The motor can be damaged by improper handling during transport, storage or installation. If
a damaged motor is operated, this can damage the winding or bearings and could even
destroy the system.
• In case of uneven running or abnormal noise, switch off the motor.
• Identify the cause.
Commissioning
7.2 Checklists for commissioning
1FE1 synchronous built-in motors
122 Hardware Installation Manual, 12/2016, 610.43000.40b
7.2
Checklists for commissioning
Note
Required checks
The lists below do not claim to be complete. It may be necessary to perform additional
checks and tests appropriate for the situation specific to the particular system.
Before commissioning the system, check that it is properly mounted and connected.
Commission the drive system according to the operating instructions of the converter or
inverter being used.
Checklists for commissioning 1FE1 motors
Thoroughly familiarize yourself with the safety instructions and observe the checklists below
before starting any work.
Table 7- 1 Checklist (1) - general checks
Check
OK
Are all of the necessary components of the configured drive line-up available, correctly
dimensioned, installed and connected?
Is the manufacturer documentation for the system components (e.g. drive system,
encoder, cooling system, brake) and the "SIMOTICS M-1FE1 built-in motors" Configu-
ration Manual available?
If the 1FE1 motor is to be operated on the SINAMCIS S120 drive system:
Is the following, current SINAMICS documentation available?
• SINAMICS S120 Commissioning Manual
• Getting Started S120
• S120 Function Manual
• S120/150 List Manual
If the 1FE1 motor should be operated on the SINAMCIS S120 drive system:
Was the Chapter "Checklists for commissioning SINAMICS S" in the SINAMICS S120
Commissioning Manual carefully observed?
Is the motor type to be commissioned known?
(e.g. 1FE1 _ _ _ – _ _ _ _ _ – _ _ _ _)
Are the environmental conditions in the permissible range?
Commissioning
7.2 Checklists for commissioning
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 123
Table 7- 2 Checklist (2) - checks regarding the mechanical system
Check
OK
Have all touch protection measures for moving and live parts been implemented?
Has the motor been correctly mounted and aligned?
Can you rotate the rotor without it touching the stator?
Do the operating conditions correspond to the data specified on the rating plate?
Have all fastening screws, fastening elements, and electrical connections been tight-
ened with the prescribed torques and properly attached?
Do the output elements have the correct setting conditions according to type?
Examples:
• Have the couplings been aligned and balanced?
• Has the belt drive tension been correctly adjusted?
• Have the gear tooth flank and gear tooth tip play as well as radial play been cor-
rectly adjusted for geared outputs?
Is the rating plate visible and fastened permanently on the spindle box?
Table 7- 3 Checklist (3) - checks regarding the electrical system
Check
OK
Has the motor been connected so that it rotates in the specified direction?
Have the minimum insulation resistance values been maintained?
Have the grounding and equipotential bonding connections been correctly estab-
lished?
Is the specified limit speed n
max
maintained during the operation on the converter?
Table 7- 4 Checklist (4) - Monitoring equipment checks
Check
OK
Has it been ensured that speeds higher than the maximum speed nmax cannot be
reached?
Have all supplementary motor monitoring devices been correctly connected and are
they working properly?
Commissioning
7.2 Checklists for commissioning
1FE1 synchronous built-in motors
124 Hardware Installation Manual, 12/2016, 610.43000.40b
Table 7- 5 Checklist (5) - Cooling system checks
Check
OK
Water cooling
Has the cooling water supply been connected and is it ready for operation?
Coolant circuit (example)
1 Cooling unit
2 Flow rate indicator (optional)
3 Filter (optional)
4 Set the flow rate (optional)
5 Pump
6 Coolant container
7 Compressor / recooling unit
8 Coolant temperature measurement
Is the cooling water circulation (flow direction, flow rate, temperature) in compliance
with the specifications?
Is the seal between the spindle housing and the cooling jacket tight? No coolant may
escape from the drain holes.
Air cooling (special version)
Is the air cooling operational?
Is the air circulation (flow rate, temperature) in compliance with the specifications?
Table 7- 6 Checklist (7) - checks regarding roller bearings
Check
OK
Are the roller bearings OK?
Commissioning
7.3 Test the insulation resistance
1FE1 synchronous built-in motors
Hardware Installation Manual, 12/2016, 610.43000.40b 125
7.3
Test the insulation resistance
After long storage or shutdown periods, you must check the insulation resistance of the
windings with respect to ground using a DC voltage.
● Always measure the insulation resistance of the winding to the motor housing when the
winding temperature is between 20° and 30° C.
● When measuring, wait until the final resistance value is reached. This will take
approximately one minute.
Limit values
The table below specifies the measuring circuit voltage as well as the limit values for the
minimum insulation resistance and the critical insulation resistance with a rated motor
voltage of VN < 2 kV:
Table 7- 7 Stator winding insulation resistance at 25° C
Rated voltage VN < 2 kV
Measurement voltage
500 V (minimum, 100 V)
Minimum insulation resistance with new, cleaned, or repaired
windings
10 MΩ
Critical specific insulation resistance after a long operating
time
0.5 MΩ/kV
Note the following:
● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ.
Note
Measured value of the insulation resistance near the critical value
If the measured value lies near the cri
tical value, the insulation resistance must be
checked in shorter intervals.
Values apply to the measurement at a winding temperature of 25° C.
● The insulation resistance of the motor winding can reduce during the course of its service
life due to ambient and operational influences (moisture, contamination).
● Calculate the critical insulation resistance at a winding temperature of 25° C by
multiplying the rated voltage (kV) by the specific critical resistance value (0.5 MΩ/kV).
Example: critical resistance for the rated voltage (VN) = 0.6 kV:
0.6 kV x 0.5 MΩ/kV = 0.3 MΩ
Commissioning
7.4 Commutation angle and pole position identification
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Measures on overshooting or undershooting the critical insulation resistance
If the critical insulation resistance is less than or equal to this value, then the windings must
be dried or, if the fan is removed, cleaned thoroughly and dried.
Note
Lower resistance
Note that the insulation resistance of dried, clean windings is lower than that of warm
windings. The correct insulation resistance must be achie
ved for a winding that has been
cooled down to room temperature (approx. 20° to 30° C).
Commission the motor only when the insulation resistance has achieved the specified
values.
7.4
Commutation angle and pole position identification
7.4.1
Commutation angle
Note
With synchronous spindles, the commutation angle must be determined or entered when the
spindle is first commissioned or when the spindle is replaced!
The stator magnetic field must be aligned to the rotor magnetic field for the optimum torque
development (synchronized).
This reference is established by a pole position identification (PLI) and the subsequent
traversing of the encoder zero mark. The associated determined commutation angle offset is
stored in the drive system.
Determining the pole position identification / commutation angle with STARTER for SINAMICS
1. Select the Motor Module and select the (closed-loop) control type "Speed control with
encoder".
2. Select the synchronous built-in motor in the motor selection list. Press the "Next" key.
3. Select the speed encoder (hollow shaft incremental encoder, 1 Vpp). Press the "Enter
data" key.
4. The pole position identification routine provides coarse synchronization. A zero mark
exists in the encoder. When the zero mark traversed, the pole position can be matched
automatically with the zero mark position (fine synchronization). The zero mark position
must be electrically adjusted (p0431).
We recommend a fine synchronization (p0404.15 = 1). It prevents measurement
scattering and allows an additional test of the determined pole position.
5. Select the "Pole position identification" under coarse synchronization in the encoder data
mask.
Commissioning
7.4 Commutation angle and pole position identification
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Select "Zero marks" for the fine synchronization. The other fields are already
preassigned. The "Saturation-based 1st harmonic" is selected and acknowledged using
"Pole position ID parameter".
6. The configuration is completed when the wizard is closed and the data has been loaded
into the drive. The correct pole position identification technique (p1980) is preassigned
with the motor-specific identification currents (p0325, p0329) and their selection (p1982).
7. Check the control direction of the drive, i.e. the encoder in r0061 must return a positive
actual speed value for a clockwise motor, before you determine the commutation angle
offset.
8. Select p1990 = 1 to determine the correct commutation angle offset (p0431). In the expert
list, switch-on the drive using the commissioning tool (control panel) (PLI will be
performed). p1990 = 1.
9. Enter a small speed setpoint. After the zero mark has been crossed for the first time, the
determined commutation angle offset is automatically entered into p0431. Alarm A07971
is output during the determination routine. p1990 is automatically set to the value of 0 at
the end of the measurement.
10.Check whether the automatically determined value in p0431 is plausible. Several
techniques are recommended in the parameter description for p1990 (see SINAMICS
S120/S150 List Manual LH1).
If the angle is already known (e.g. final acceptance report), use this value to check the
determined value.
Note
Deviations > 5°
For deviations
> 5°, the authorized technical personnel of the manufacturer must be
contacted.
7.4.2
Pole position identification variants
The pole position identification is available in two variants.
Motion-based pole position identification
Induction-based pole position identification
Precondition The rotor must be able to freely rotate. • The rotor can rotate freely or be blocked
• The pole position identification requires a
minimum current. The rated current (S1
current) of the motor module must be ≥
50% of the rated motor current.
Accuracy of determining the
rotor position.
High, independent of the magnetic proper-
ties
Dependent on the magnetic motor charac-
teristics
Effect of series reactors The deployment of series reactors has no
effect on the result.
When using series reactors or for motors
with a low degree of saturation, the accuracy
when determining the rotor position is low or
the pole position identification does not pro-
vide any result at all.
Commissioning
7.5 Commissioning the cooling circuit
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7.5
Commissioning the cooling circuit
● To prevent contamination to the cooling water pipes, flush them before you connect the
motor and the converter to the cooling circuit.
● Commission the cooling circuit before performing the electrical commissioning.
7.6
Switching on and switching off
Note
EMERGENCY OFF
To
avoid accidents, inform yourself about the EMERGENCY OFF function before you switch
on the system.
The motor is switched on and off using the converter.
● Read about this topic in the converter operating instructions.
Before switching on
● Ensure that the converter is correctly parameterized.
● Use the appropriate commissioning tools, e.g. "Drive ES" or "STARTER".
● Switch on the cooling system.
Switching on
1. Switch-on the motor at the converter.
2. Ensure smooth motor operation.
3. Check the function of the motor cooling system.
4. Check the function of the safety equipment.
5. Check whether the motor reaches the required parameters
Switching off
● Switch-off the motor at the converter.
The motor has been commissioned.
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Operation
8
8.1
Safety instructions
WARNING
Danger to life caused by machine movement and loose objects
Machine movement and loose objects that can fall out or be ejected can cause death or
severe injury.
• Ensure that the machine has been completely installed and all of the setting work
completed.
• Ensure that nobody is at risk at switch on.
• Before switching on, check that there are no loose objects in or on the motor that can
fall or be flung off.
• Before switching on, check that all safety guard covers are installed and all safety
equipment functions correctly.
WARNING
Danger to life caused by a rotating rotor or ejected parts
Rotating rotors and the resulting ejected parts can cause death or injury.
• Secure rotating output elements using the appropriate safety guards.
• Secure loose parts, e.g. featherkeys to prevent the ejection.
WARNING
Danger to life when the forced ventilation of the motor draws in hair and articles of clothing
Hair, ties or loose objects sucked into the air inlet can cause death or severe injury.
• Secure hair, ties and loose objects from being sucked in.
WARNING
Danger to life when the cooling system bursts
The motor will overheat if it is operated without cooling. When cooling water enters the hot
motor, this immediately and suddenly generates hot steam that escapes under high
pressure. This can cause the cooling water system to burst, resulting in death, severe injury
and material damage.
• Never operate the motor without cooling.
• Only commission the cooling water circuit when the motor is in a cool condition.
Operation
8.1 Safety instructions
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CAUTION
Burns as a result of touching hot surfaces
In operation, the motor housing can reach high temperatures, which can cause burns if
touched.
• Do not touch any hot surfaces.
• Allow the motor to cool down before starting any work.
• Use the appropriate personnel protection equipment, e.g. gloves.
NOTICE
Motor damage caused by overheating as result of missing cooling
If the cooling fails or the motor is operated briefly without cooling, this can cause it to
overheat. This can cause motor damage.
• Never operate the motor without activated cooling.
• Monitor the permitted water inlet temperatures, the cooling water circulation and the
cooling air supply.
• Operate the motor only in conjunction with an effective temperature control.
• Keep the air ducting free.
• Do not remove any air ducting.
NOTICE
Thermal damage to temperature-sensitive parts
Some parts of the electrical motor enclosure can reach temperatures that exceed 100° C. If
temperature-sensitive parts, e.g. electric cables or electronic components, come into
contact with hot surfaces, these parts could be damaged.
• Ensure that no temperature-sensitive parts are in contact with hot surfaces.
NOTICE
Motor damage when the maximum speed is exceeded
The maximum speed nmax is the highest permissible operating speed. The maximum speed
is specified on the rating plate.
The motor can be damaged if operated at inadmissible speeds.
• Ensure that the maximum permissible speed is not exceeded. Realize this using a
suitable control system or activate the speed monitoring function in the drive.
Operation
8.1 Safety instructions
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NOTICE
Motor damage caused by uneven running or abnormal noise
The motor can be damaged by improper handling during transport, storage or installation. If
a damaged motor is operated, this can damage the winding or bearings and could even
destroy the system.
• In case of uneven running or abnormal noise, switch off the motor.
• Identify the cause.
CAUTION
Gearbox faults can cause injuries or gearbox damage
Changes to the gearbox during operation can cause injuries or gearbox damage.
• If deviations from normal operation (e.g. unusual noise, unusual temperature rise) occur,
switch off the drive unit immediately.
• If possible, determine the cause of the fault using the fault table (Page 133).
• Rectify any faults or contact the Siemens Service Center.
Operation
8.2 Operation
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8.2
Operation
Note
EMERGENCY OFF
To avoid accidents, inform yourself about the EMERGENCY OFF function before you switch
on the system.
The motor is switched on and off using the converter.
● Read about this topic in the converter operating instructions.
Before switching on
● Ensure that the converter is correctly parameterized.
● Switch on the cooling system.
Switching on
1. Switch-on the motor at the converter.
2. Ensure smooth motor operation.
3. Check the function of the motor cooling system.
4. Check the function of the safety equipment.
5. Check whether the motor reaches the required parameters
The motor is switched on.
Operation
While the motor is operating, ensure that the specified parameters are maintained.
Observe the following during operation:
● The power consumption lies in the specified range.
● The motor is cooled.
– With water cooling: Check the liquid level and coolant circulation.
– With air cooling: Check that the heat can dissipate freely.
● The motor runs without any unusual noise.
● The motor temperature lies in the specified range.
Note
Observe the maintenance intervals
Maintain the motor as specified in the project specifications of the spindle manufacturer.
Switching off
● Switch-off the motor at the converter.
Operation
8.3 Faults
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8.3
Faults
Note
Correct the cause of the fault as specified in the remedial measures section.
Repair any damage to the machine / motor spindle.
Note
When operating the motor spindle with a converter, refer also to the Operating Instructions of
the frequency converter if electrical faults occur.
If there are deviations from normal operation or if faults occur, initially proceed according to
the following list. In this regard, observe the relevant chapters in the documentation
associated with the components of the complete drive system.
Even in test operation, never disable protective functions or devices.
Table 8- 1 Possible faults
Fault
Cause of fault (see key table)
Motor spindle does not start
A
B
E
Motor spindle starts slowly
A
C
E
F
Rumbling noise during startup
C
E
F
Rumbling noise during operation
A
C
E
F
Overheating during no-load opera-
tion
D G
H I
Overheating with load
A
C
G
H
I
High temperature rise of individual
winding sections
E F
Uneven running
J
K
Grinding sound, bearing noise L
Radial vibrations
M
N
O
Axial vibrations O
Water is escaping
P
Operation
8.3 Faults
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Table 8- 2 Key to causes of faults and remedial measures
No.
Cause of fault
Remedial measures
A
Overload
Reduce load
B Interruption of a phase in the supply ca-
ble
Check frequency converter and supply cables
C Interruption of a phase in the supply after
switching on
Check frequency converter and supply cables
D Converter output voltage too high, fre-
quency too low
Check the settings on the frequency converter, perform automatic motor
identification
E
Stator winding incorrectly connected
Check winding connections
F Winding short-circuit or phase short-
circuit in stator winding
Measure the winding resistances and insulation resistances, repair after
consultation with manufacturer
G Cooling water not connected / switched
off
Check cooling water connection / switch on cooling water
Water connection / pipes defective
Locate leaks and seal as necessary, or consult the manufacturer
H
Cooling water flow rate too low
Increase cooling water flow rate
Inlet temperature too high
Set correct inlet temperature
I Heat dissipation impeded by deposits Clean the surface of the drives and ensure that the cooling air can flow
in and out unimpeded
Cooling air inlet/outlet is blocked by for-
eign bodies
Remove the block and ensure that the cooling air can flow in and out
unimpeded
Fan motor does not start up
Make sure that the fan motor works properly
J Insufficient shielding for motor and/or
encoder cable
Check the shielding and grounding
K Excessive drive controller gain Adjust the controller
L
Rotating parts are grinding
Determine cause and adjust parts
Foreign bodies within the motor
Send to manufacturer for repair
Bearing damage
Send to manufacturer for repair
M
Rotor not balanced
Decouple rotor and rebalance
N
Rotor out of true, shaft bent
Consult the manufacturer
O
Poor alignment
Align motor unit, check coupling
P Cooling water pipe / water connection
defective
Locate leaks and seal as necessary, or consult the manufacturer
Operation
8.4 Stoppages
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8.4
Stoppages
Measures for longer non-operational periods
Note
Damage due to improper storage
The motor can be dama
ged if it is not stored properly.
•
If the motor is out of service for extended periods of time, implement suitable anti-
corrosion, preservation, and drying measures.
•
When recommissioning the motor after longer stoppages, perform the measures
recommended in Chapter "Commissioning".
● Disconnect the motor from the cooling water system.
● Remove any cooling water from the motor.
● Blow out the cooling ducts with compressed air to dry them.
● Observe the instructions for storage contained in Chapter "Transportation and storage
(Page 47)".
● If the motor is not operational for extended periods of time, run it at regular intervals
(roughly once a month) or spin the rotor by hand.
● Refer to the Chapter "Commissioning (Page 119)" before switching on for
recommissioning.
Operation
8.4 Stoppages
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Service and maintenance
9
Note
Carry out maintenance and servicing in accordance with the spindle manufacturer's project
requirements.
Service and maintenance
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Decommissioning and disposal
10
10.1
Safety instructions
Removing the motor from the machine
WARNING
Danger to life caused by falling machine parts
The machine partially comprises heavy individual components. When removing the
machine, these components can fall. This can result in death, serious injury or material
damage.
• Secure the machine components that are being released so that they cannot fall.
WARNING
Injury as a result of suspended loads
When being dismantled and transported, the motor can cause injury as a result of its
movement.
• Only use perfectly functioning hoisting and load suspension equipment dimensioned to
carry the motor load.
• Pay careful attention to possible movement when the motor is released.
• Do not stand under suspended loads or in their slewing range.
• When placing down the motor, ensure that it cannot roll.
CAUTION
Injuries caused by liquids when draining and environmental pollution
When draining, liquids can cause injuries, such as burns, chemical burns, irritation. Spilt oil
can make floor surfaces slippery and pollute the environment.
• Allow the liquid to cool down.
• Use a sufficiently large collection container.
• Avoid liquids coming into contact with the skin. Use suitable personnel protection
equipment, e.g. protective eyewear, gloves.
• Have materials on hand to soak up leaked liquids and prevent areas from being
slippery.
Decommissioning and disposal
10.2 Decommissioning
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10.2
Decommissioning
Removing the motor
The motor must only be removed by qualified personnel with the appropriate technical know-
how.
Contact a certified waste disposal organization in your vicinity.
Procedure
1. Disconnect all of the electrical connections
2. Remove all liquids such as oil, water.
3. Release all of the supply lines
4. Remove all cables.
5. Remove the fixing elements from the motor.
6. Transport the motor to a suitable location for storage.
Refer also to the information in the section headed "Maintenance (Page 137)".
You have removed the motor.
Note
Dismantling the motor
The motor must be dismantled by an authorized company or the man
ufacturer.
Decommissioning and disposal
10.3 Disposal
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10.3
Disposal
10.3.1
Disposal - Introduction
The product must be disposed of in the normal recycling process in compliance with national
and local regulations.
10.3.2
Guidelines for disposal
WARNING
Injury or material damage if not correctly disposed of
If you do not correctly dispose of direct drives or their components (especially components
with permanent magnets), then this can result in death, severe injury and/or material
damage.
• Ensure that direct drives and their associated components are correctly disposed of.
Main constituents of a proper disposal procedure
● Complete demagnetization of the components that contain permanent magnets
● Components that are to be recycled should be separated into:
– Electronics scrap (e.g. encoder electronics, Sensor Modules)
– Electrical scrap (e.g. motor windings, cables)
– Scrap iron (e.g. laminated cores)
– Aluminum
– Insulating materials
● No mixing with solvents, cold cleaning agents, or residue of paint, for example
Decommissioning and disposal
10.3 Disposal
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10.3.3
Disposal of 1FE1 rotors
WARNING
Risk of death and crushing as a result of permanent magnet fields
Severe injury and material damage can result if you do not take into consideration the
safety instructions relating to permanent magnet fields.
• Observe the information in Chapter Special safety notices for handling built-in motors
(Page 21).
Disposing of and demagnetizing 1FE1 rotors
The magnetized rotors must be subject to a special thermal treatment so they do not pose
any risk during or after disposal.
● Dispose of magnetized rotors by an appropriately specialized disposal company.
● For transport, pack the rotors individually in the original rotor packaging.
Demagnetizing rotors
Rotors are demagnetized in a special furnace at minimum 300° C for at least 30 minutes.
10.3.4
Disposal of packaging
Packaging materials and disposal
The deployed packaging and packing aids contain no problematic materials. With the
exception of wooden materials, they can all be recycled and should always be disposed of
for reuse. Wooden materials should be thermally recovered.
Note
Original rotor packaging
Retain the original rotor packaging for transport to the disposal company.
Only recyclable plastics are used as packing aids:
● Code 02 PE-HD (polyethylene)
● Code 04 PE-LD (polyethylene)
● Code 05 PP (polypropylene)
● Code 04 PS (polystyrene)
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Spare Parts/Accessories
11
Note
Spare parts can be ordered in our Service Center based on the motor designation.
Please also refer to th
e scope of delivery described in section Technical Support
(
https://support.industry.siemens.com/sc/ww/en/sc/2090).
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List of abbreviations
A
APM
Rotor with external permanent magnets and banding
BGR
Health and safety at work regulations
BGV
Health and safety at work regulations
CE
Conformité Européenne - compliance with EU directives
DIN
Deutsche Industrie Norm (German Industry Standard)
DRIVE-CLiQ
Drive Component Link with IQ - for installation with SINAMICS components
EGB
Electrostatic Sensitive Devices
EMF
Electromotive force
EMC Electromagnetic compatibility
EN
European standard
IATA
International Air Transport Association
IPM
Rotor with internal permanent magnets
IEC
International Electrotechnical Commission
IP
International Protection
ISO
International Organization for Standardization
IVP
Internal Voltage Protection
KTY
Silicon temperature sensor - temperature sensor with progressive, almost linear characteristic curve
MLFB
Machine-Readable Product Code
NTC
Negative Temperature Coefficient - temperature sensor with negative temperature coefficient
Pt1000
Platinum temperature sensor with rated value of 1000 Ω at 0° C
PTC
Positive Temperature Coefficient - temperature sensor with positive temperature coefficient
SME
Sensor Module External
VDE
Association of Electrical Engineering, Electronics and Information Technology (Germany)
VPM
Voltage Protection Module
List of abbreviations
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Index
A
Accessories, 59
Accidents
First aid, 54
Anti-corrosion agent for stator, 75
B
Banding, 88
C
Cables, 108
Certificates
EAC, 25
EC Declaration of Conformity, 25
UL and cUL, 25
Commissioning, 122
Cooling water supply, 98
Correct usage, 22
D
Disposal, 141
F
Fine balancing, 68
H
Hotline, 7
I
IATA, 45
Insulation resistance, 125
J
Joining process, 82
K
KTY, 36
L
Leak test, 78, 80, 81
M
Magnetic fields
First aid in the case of accidents, 54
Manufacturer declaration, 22, 119
Measuring the radial runout, 60
Motor
Disposal, 141
N
NTC K227, 113, 113
NTC PT3-51, 113
NTC PT3-51F, 113
NTC thermistor, 113
O
Occupational safety equipment, 56, 73
Oil pressing procedure, 69
P
Packaging, 43, 142
Polarity, 110
Prohibition signs, 42, 52
Pt1000, 36
R
Recommissioning, 135
Removing the motor, 140
Rotor mounting, 58
Index
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S
Safety instructions
Disposal, 141
Packaging, 43
Storage, 43
Transport, 43
Siemens Service Center, 7
Storage, 43
Stress equalization, 64
T
Target group, 5
Technical Support, 7
Thermal joining, 61
Thermal motor protection, 35, 36
NTC thermistor, 113
PTC thermistor triplet, 114
Training, 7
Transport, 43
Type of construction, 26
V
VPM, 115
W
Warm shrinking, 82
Warning signs, 42, 52
Water cooling, 95
Z
Zero-speed monitoring, 114