be370007 bfp atex-3gd - buehler technologies...fluidcontrol installation and operation instructions...

Fluidcontrol

Installation and Operation Instructions

Original instructions

Circulation pumps

BFP ATEX-3GD

BE37000703/2019

Bühler Technologies GmbH, Harkortstr. 29, D-40880 RatingenTel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20

E-Mail: [email protected]: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 RatingenTel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20Internet: www.buehler-technologies.comE-Mail: [email protected]

Read this instruction carefully prior to installation and/or use. Pay at-tention particularly to all advises and safety instructions to prevent in-juries. Bühler Technologies can not be held responsible for misusingthe product or unreliable function due to unauthorised modifications.

All rights reserved. Bühler Technologies GmbH 2019

Document informationDocument No..........................................................BE370007Version......................................................................... 03/2019Part No. ............................................................. 998BE370007

BFP ATEX-3GD

Contents1 Introduction..................................................................................................................................................................................................................... 2

1.1 Intended Use......................................................................................................................................................................................................... 21.2 Model key............................................................................................................................................................................................................... 21.3 Type plate .............................................................................................................................................................................................................. 21.4 Scope of delivery .................................................................................................................................................................................................. 2

2 Safety instructions......................................................................................................................................................................................................... 32.1 Important notices................................................................................................................................................................................................ 32.2 General hazard warnings ................................................................................................................................................................................. 5

3 Transport and storage .................................................................................................................................................................................................. 7

4 Installation and connection ........................................................................................................................................................................................ 84.1 Installation site requirements......................................................................................................................................................................... 84.2 Installing the pump ............................................................................................................................................................................................ 84.3 Hydraulic connection ......................................................................................................................................................................................... 84.4 Electrical connections ........................................................................................................................................................................................ 9

5 Operation and control ................................................................................................................................................................................................. 115.1 Before startup ..................................................................................................................................................................................................... 115.2 During startup .................................................................................................................................................................................................... 11

6 Maintenance................................................................................................................................................................................................................... 126.1 Maintenance schedule...................................................................................................................................................................................... 13

7 Service and repair......................................................................................................................................................................................................... 147.1 Troubleshooting ................................................................................................................................................................................................ 14

8 Disposal ............................................................................................................................................................................................................................ 15

9 Calculations ................................................................................................................................................................................................................... 169.1 Calculating viscosity......................................................................................................................................................................................... 169.2 Table of operational viscosity for VG oil ..................................................................................................................................................... 169.3 Calculating the pressure loss......................................................................................................................................................................... 16

10 Pressure loss in straight pipes................................................................................................................................................................................... 17

11 Appendices..................................................................................................................................................................................................................... 1811.1 Technical data .................................................................................................................................................................................................... 18

11.1.1 BFP 8 / BFP 15........................................................................................................................................................................................ 1911.1.2 BFP 30 / BFP 40 ................................................................................................................................................................................... 2011.1.3 BFP 60..................................................................................................................................................................................................... 2111.1.4 BFP 90.................................................................................................................................................................................................... 22

11.2 Installation torques and clamping range for cable fitting ................................................................................................................... 2311.3 User book (Please make copies) .................................................................................................................................................................... 24

12 Attached documents ................................................................................................................................................................................................... 2512.1 Declaration of conformity............................................................................................................................................................................... 2512.2 Statement of Conformity ................................................................................................................................................................................ 2712.3 Motor operating instructions (Leroy-Somer) ............................................................................................................................................ 3412.4 RMA - Decontamination statement.............................................................................................................................................................. 71

iBühler Technologies GmbHBE370007 ◦ 03/2019

BFP ATEX-3GD

1 Introduction

1.1 Intended UseBFP circulation pumps are used to convey oils in hydraulic and lubrication circuits. Their scope is indicated by their specifica-tions. Various combinations of the equipment can be marketed.

The pumps are solely intended for proper and designated use in systems for industrial purposes and typical industrial atmo-spheres (without aggressive substances). They may only be used in accordance with the technical documentation and the spe-cifications on the type plate. Any other applications require the prior approval of Bühler Technologies GmbH.

Non-compliance will void any and all warranty and manufacturer liability.

1.2 Model key

Temperature class T3ATEX mark

BFP 8-4-0.75kW-Atex-3GDT3-BPx

If a bypass is desired, the information is added to the to the type designation:

Bypass version BPx

Bypass valveBypass rate in bar

Number of motor contactsPump output per litre

Motor power

BFP 8-4-0.75kW-Atex-3GDT3-BPx } not for BFP 60 and BFP 90

1.3 Type plate

Example:

BFP 15-4-0,75kW-ATEX-3GD-T33715075ATEX3GDT3

Manufacturer including address

II 3G Ex h IIC T3 Gc

230/400V50Hz / 276/480V 60Hz-15°C ≤ Ta ≤ 40°CRef: 13 ATEX 0010 XYear: 2016

Type designationSerial no., item no.

Explosion prevention markExplosion prevention mark (optional)

VoltageTemperature specifications

Tech File Ref.Year of manufacture

II 3D Ex h IIIB T125 °C Dc

1.4 Scope of delivery– BFP ATEX Circulation Pump

– Product documentation

2 Bühler Technologies GmbH BE370007 ◦ 03/2019

BFP ATEX-3GD

2 Safety instructions

2.1 Important noticesBefore installing the equipment, verify the application parameters for your pump meet the specifications and the approved am-bient parameters. Further check if all contents are complete. Please also note the motor operating instructions in the appendix.

This unit may only be used if:

– The product is being used under the conditions described in the operating- and system instructions, used according to thenameplate and for applications for which it is intended. Any unauthorized modifications of the device will void the warrantyprovided by Bühler Technologies GmbH,

– The specifications and markings in the type plate are observed,

– The threshold values in the data sheet and the instructions are observed,

– Monitoring equipment / protection devices are connected correctly,

– Service and repair work not described in these instructions are performed by Bühler Technologies GmbH,

– Genuine spare parts are used,

– All special requirements in the enclosed type examination certificate are observed.

Erecting electrical systems in explosive areas requires compliance with regulations EN 60079-14 and EN 60079-17.

Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be observed.

These operating instructions including the instructions for add-on parts (e.g. motor) are a part of the entire equipment. Themanufacturer reserves the right to change performance-, specification- or technical data without prior notice. Please keep theseinstructions for future reference.

Signal words for warnings

DANGERSignal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.

WARNINGSignal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if notavoided.

CAUTIONSignal word for a hazardous situation with low risk, resulting in damaged to the device or the property orminor or medium injuries if not avoided.

NOTICESignal word for important information to the product.

Warning signsIn this manual, the following warning signs are used:

Warning against hazardous situations Warning against high pressure

Warning against electrical voltage General notice

Warning against hot surface Disconnect from mains

Warning against environmental hazard Wear protection gloves

Warning against potentially explosive atmospheres

3Bühler Technologies GmbHBE370007 ◦ 03/2019

BFP ATEX-3GD

General explosion prevention information:

The equipment complies with the applicable standards and regulations and meet the requirements of directive 2014/34/EU.

Depending on the designation, the equipment may be used as follows:a) In zone 2 (Gas-Ex, Category 3G) in explosion groups IIA, IIB and IIC

(hydrogen only)b) In zone 22 (Dust-Ex, Category 3D) in explosion groups IIIA (lint)

and IIIB (non-conductive dusts)The surface temperature qualification is T3. The equipment has no ignition sources for any gasses, vapours and mistswith an ignition temperature > 200 °C. The same applies to areas with a dust explosion hazard for dusts with an ignitiontemperature > 188 °C.

Always note the explosion prevention mark in the name plate of your equipment (and all add-on parts).

Installing add-on parts beyond the as-delivered condition may cause a rise in temperature. Be sure these do not exceed the tem-perature class marking.

Dust environment requirementsThe pump may only be used in areas with an explosive dust atmosphere if the glow temperatures of the dust layers and the ig-nition temperatures of the dust atmosphere are higher than the following temperatures:

VersionT 125 °C

Glow temperature(5 mm dust layer)

≥ 200 °C

Dust atmosphere ignitiontemperature

≥ 188 °C

Always note the explosion prevention mark in the name plate of your equipment (and all add-on parts).

Operating fluid requirementsIn temperature class T3 or T125 °C only convey fluids with a flash point ≥ 200 °C through the cooler.

ATEX marking on standard equipmentThe ATEX mark depends on the version of the equipment and provides information on equipment category, equipment group,ex-atmosphere, ignition protection type. Please refer to the chart below for possible and complete markings.

Version for Marking ExplanationGas II 3G Ex h IIC T3 Gc Zone 2 (IIC hydrogen only)

Temperature class T3Dust II 3D Ex h IIIB T125 °C Dc Zone 22

max. surface temperature 125 °C

Gas and dust atmosphere must not be present at the same time.

Vibrations: Bühler pumps are subject to vibration testing per EN 14986. During use, however, external vibration or (in the eventof a malfunction) vibration produced by the unit itself could result in premature damage to the motor mount. This can result inhigh, incendive temperatures or sparks on the motor mounts.

The equipment must be installed on a solid and vibration-free surface. Select an installation site so vibrations and resonanceswill not have a negative impact.

Please pay attention to any turbulent operation and unusual noise in all equipment. These can indicate damage to the motorbracket. The equipment must then immediately be put out of operation and replaced by Bühler. Please refer to the Serviceschedule for inspection intervals.


BFP ATEX-3GD

2.2 General hazard warningsThe equipment must be installed by a professional familiar with the safety requirements and risks.

Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Preventmalfunctions and avoid personal injuries and property damage.

The operator of the system must ensure:– Safety notices and operating instructions are available and observed,

– The respective national accident prevention regulations are observed,

– The permissible data and operational conditions are maintained,

– Safety guards are used and mandatory maintenance is performed,

– Legal regulations are observed during disposal,

– compliance with national installation regulations.

Maintenance, RepairPlease note during maintenance and repairs:

– Repairs to the unit must be performed by Bühler authorised personnel.

– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.

– Always use genuine spare parts.

Always observe the applicable safety and operating regulations in the respective country of use when performing any type ofmaintenance.

DANGER Electrical voltage

Electrocution hazard.

a) Disconnect the device from power supply.

b) Make sure that the equipment cannot be reconnected to mains unintentionally.

c) The device must be opened by trained staff only.

d) Regard correct mains voltage.

DANGER Electrostatic propagating brush discharge

Propagating brush discharges are strong sources of ignition with a high energy content.The unit must not be used in processes generating high loads.

DANGER Explosion hazard when exceeding the flash point of the fluid

The fluid may ignite when exceeding the flash point.In temperature class T3 or T125 °C only convey fluids with a flash point ≥ 200 °C throughthe pump.

DANGER Explosion hazard due to igniting dust layers

Dust accumulations can raise the equipment temperatures to prohibited levels.Dust layers > 2 mm are prohibited and must therefore be cleaned regularly. When doingso, be sure not to cause dust clouds, which could ignite. Only clean insulating surfaceswith a damp cloth.

WARNING Hot surface

Risk of burnsDepending on the operating parameters and type, the housing temperature may reachup to 100 °C during operation.Allow the unit to cool down before performing maintenance. Wear suitable protectivegloves.


BFP ATEX-3GD

CAUTION High pressure

Hazard of injury due to flung off parts or oil, environmental hazard due to oil.

a) Before starting any maintenance or repair to the oil circuit, make sure that the deviceis depressurized. This applies to the locking screws as well.

b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oilcircuit.

c) Use drip pans.


BFP ATEX-3GD

3 Transport and storageThe products should be transported only in its original packaging or a suitable replacement. Secure device for transportation.

When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and dust-free room at ambienttemperature.


BFP ATEX-3GD

4 Installation and connection

4.1 Installation site requirementsBe absolutely sure to only install equipment and accessories with EX classifications meeting the prevailing EX zones / categor-ies.

Be absolutely sure to comply with the applicable national erection regulations (e.g. EN 1127-1, EN 60079-14, EN 61241-14) duringinstallation/assembly.

On principle a potential equalization must be established in the system. Also observe the erection regulations in the country ofuse (e.g. VDE 0100 Part 540, IEC 364-5 54). Be sure no vagrant currents are conveyed through the pumps (e.g. produced throughwelding systems or motors in inverter operation). The pumps must not be used in systems with cathodic corrosion protection.

Ensure adequate ventilation. Be sure the hose is stable against negative pressure, e.g. steel wire reinforced.

4.2 Installing the pump

DANGER Explosion hazard due to:

Failure to observe equipment specificationsExplosion hazard if operated outside the equipment specification. All pumps may onlybe operated within the specifications indicated. Please note the type plate and the spe-cifications in these instructions.ImpactStrong blows to the housing can produce sparks, which can ignite an EX atmosphere.Protect the equipment from external impact. Damaged / deformed housing parts mustbe replaced immediately.

The pumps are mounted in the installation site using four screws.

To protect the pumps and system from damage, the connections to the pump must be stress free. We recommend using flexiblehoses.

When installing outdoors, be sure to consider the IP protection class of the motor and provide sufficient weather protection. Lowoutdoor temperatures can result in high starting pressures due to the higher viscosity of the oil. In this case you should considerusing a bypass valve or / and heater.

Avoid possible leaks in the circuit to prevent environmental damages. If necessary, use an oil pan. Never install the pumps abovehot parts, which could ignite leaking fluid / operating liquid. Select an installation site for your pump so that even in the eventof a malfunction (e.g. pump or line leak) fluid / operating liquid will not be ignited by nearby hot parts.

4.3 Hydraulic connectionArrows on the motor housing indicate the flow direction (FLOW) and the direction of motor rotation (M). Connect the lines stressand vibration free, so typically using hoses. Be sure to use suitable lines (with regard to fluid resistance, environmental influ-ences, fire) when connecting to the hydraulic-, lubricant circuit.

Contaminated fluids impact the life of the pump, we therefore recommend a purity class of 23/19/13 per ISO 4406.

If your hydraulic system is equipped with control or shut-off valves, we urgently recommend protecting the pump with a pres-sure relief valve.

The distance between the pump (pump suction side) and tank should be as short as possible.

There should be no difference between the vertical height of the tank and pump / cooling system. The pump / the cooling sys-tem can also be installed below this level.

If the aggregate can only be installed above this level, the pump will have a constant suction pressure of 0.4 bar (atmosphere).Depending on the oil viscosity and temperature, this will result in a different suction lift. A difference in value of 2 m can beused as a guide.

Until the oil is heated to operating temperature, a suction pressure of 0.6 bar is permissible temporarily.

The diameter of the intake pipe should not be smaller than specified in the data sheet. We recommend a max. flow rate of 1.5 m/s.

When first starting up a hydraulic system with a long intake pipe can cause problems due to excess air in the intake pipe. In thiscase we suggest filling the suction pipe with oil and using a suction valve without spring.


BFP ATEX-3GD

Oil is sprayed into the pump housing during the assembly process at our factory. This is necessary to seal the gerator from thehousing with an oil film. During extended periods of storage the pump housing may not have enough oil anymore to create thisoil film when switching on the pump. The pump may then completely lose suction. Before connecting the suction pipe we re-commend spraying some oil into the pump housing to prevent this.

The pump may be exposed to max. 0.5 bar of pressure on the suction side.

The pump head of all pumps can be mounted turned in 90° increments to align with the line routing. Please note the offsetfrom the centre of the motor.

The connection threads are manufactured to ISO 228. The screw-in surfaces are finished and suitable for the use of soft seals. Werecommend using screwed plugs per ISO 1179-2.

4.4 Electrical connections

CAUTION Electric voltage

An incorrect mains voltage can destroy the unitThe connection must be made by a trained professional. Observe the mains voltage in-dicated on the type plate. Make sure the cables have sufficient strain relief.FusingFusing must comply with applicable standards!PolarityPlease note the direction of rotation of the motor when connecting: The direction of ro-tation is indicated on the pump head with “M” and an arrow.

The electrical circuits must be installed in accordance with the applicable erection specifications (by professionals). Electricity isconnected via the terminals in the motor housing. Ensure proper installation and maintaining IP protection!

On principle the motor must always be connected under zero potential.

In EX areas, the electric circuits of the motor connection may only be put into operation by professionals with qualifications sim-ilar to a qualified person according to TRBS 1203. The specifications on the type plate must absolutely be observed.

Please also note the motor manufacturer’s operating instructions.

DANGER Potential equalization/static charge

Static charges can result in incendive sparking.Avoid static charges. Any conductive pump parts must be grounded!The housing or terminal box has a connection for an earth/equipotential bonding con-ductor. Ensure the housing is adequately earthed (minimum conductor cross-section 4mm2).Particularly observe the requirements of EN 60079-14!

Use the applicable local regulations to determine the safety values and the cross-sections of connection leads. The motor and, ifequipped, starting devices must be connected to protective earth.

Connect the protective earth of the motor to the protective earth on site. Protective earth per DIN VDE 0100 must be connectedto the marked earth lead terminal.

DANGER Motor connection, operation and maintenance

Improper handling of the motor poses an explosion hazard.Be sure to observe the separate instructions of the motor manufacturer.

Motor monitoringLead fuses protect the cables in case of a short circuit, but are not sufficient to protect the motor coils from overheating/burningdue to overload. Therefore, install an adequate motor circuit breaker with high precision range of adjustment for thermal pro-tection to protect the motor against overload and operation with two phases

Adjust the motor circuit breaker according to the nominal current specified on the type plate of the motor. Operation outsidethe specified mains voltage and frequency range limits is prohibited.

The operator of the equipment is responsible for ensuring lightning protection.


BFP ATEX-3GD

Connection– Open the motor connection box and install the bridge circuits according to the voltage for the connection in star or delta con-

nection.

– Connect the power supply to U1/V1/W1.

– Close the terminal box.

Star connection - high voltage

Earth connection U1 V1 W1

Delta connection - low voltage

Earth connection U1 V1 W1

Change the direction of rotation by switching any two leads.


BFP ATEX-3GD

5 Operation and control

5.1 Before startup

Before startup, check:– the operating instructions for the motor (see appendix) were observed.

– No parts are damaged .

– The pump is not being operated outside the specifications (observe specification on type plate, in the data sheet, in the oper-ating instructions).

– The Ex classification of the equipment (per type plates) is suitable for use in the prevailing explosive area.

– Voltage and frequency match the mains values specified on the type plate.

– All connection cables are installed without strain.

– All required protective measures have been taken (e.g. earthing + potential equalisation, motor circuit breaker, fluid filter.

– All cable glands are sealed properly.

– All valves or other parts which must be open during startup were opened.

– The hose- and electrical connections are installed correctly and undamaged.

– Applicable Ex regulations are met (e.g. EN 60079-14).

5.2 During startup

DANGER Explosion hazard due to oil pump dry running

Dry running the pump causes excessive temperatures or sparks. These can ignite an ex-plosive atmosphere.Dry running is prohibited during normal operation. Dry running is only permitted briefly(< 30s) when starting the pump up and under supervision. Regularly check the pump foroil leaks (see maintenance schedule).Monitor the fluid level in your hydraulic system.Monitoring circuits used to ensure excess fluid of the pump must at a minimum meet PLa per EN 13849-1.

DANGER Explosion hazard due to particles / solid objects in the fluid

Particles / solid objects inside the fluid to be conveyed can damage and overheat the oilpump.Ensure fluid flowing through the pump is filtered adequately (grade of filtration ≤25µm).

First, check that the pump rotates counter clockwise. The direction is marked on the pump housing with M and directional ar-row.

If equipment malfunctions occur, immediately put it out of operation and correct the malfunction (see chapter “Troubleshoot-ing”).

Noise levelOur pump is supplied with a low noise. If the noise level increases significantly check if the suction line has the right dimensionand if the pump works in the appropriate temp/viscosity range. Ask Bühler Technologies GmbH for technical advice.


BFP ATEX-3GD

6 Maintenance

DANGER Electrostatic charge (sparking)

Cleaning housing parts can result in an electrostatic charge of the surfaces.Always clean housing parts with insulating surfaces with a damp cloth.

DANGER Explosion hazard due to excessive temperatures

Contamination, ageing or corrosion of fluids can cause excessive oil pump temperatures.The values may then exceed those in the type plate and potentially ignite an explosiveatmosphere.

a) Please note the maximum life of the fluids being conveyed.

b) Maintain the prescribed intervals for replacing fluids.

During maintenance, remember:

– The equipment must be maintained by a professional familiar with the safety requirements and risks.

– Only perform maintenance work described in these operating and installation instructions.

– When performing maintenance of any type, observe the respective safety and operation regulations.

The coolers must regularly be maintained and cleaned (see maintenance schedule). The intervals must be determined and ad-justed by the operator according to environmental exposure.

Always observe the applicable safety and operating regulations when performing any type of maintenance. Maintenance workmust always be performed by personnel with qualifications comparable to a qualified person per the Technical Rules for Operat-ing Safety (TRBS 1203).

Only perform conversion-, maintenance or installation work described in these operating and installation instructions. Anyother work on the unit must be performed by personnel authorised by Bühler.

Only perform maintenance and cleaning when there is no explosive atmosphere or outside the explosive area. If this is not pos-sible, equivalent contingency measures (e.g. non-arcing tools) must be taken.

Furthermore, it’s important the pump is also earthed again using the earthing connection on the motor (see chapter “ElectricalConnections”) after being maintained.


BFP ATEX-3GD

6.1 Maintenance scheduleComponent Interval Work to be performed To be performed byMotor See motor operating instructionsMotor Bi-monthly – Check for turbulent operation

– Acoustic inspection for unusual noise

Customer

4 screws for the motorflange

After 200 h Retighten the screws to 6 Nm Customer

Complete pump Bi-monthly – Check for prohibited heating using suitablemeasuring devices, and for unusual noise

– Visual inspection for intactness / leaks

– Remove dust deposits > 2 mm

Customer

Electrical components 8000 h or annually* Detailed inspection for intactness and functionality CustomerComplete pump After 25000 h or 5 years – Inspection at Bühler

– Replace motor bearings

– Replace pump bearings

Bühler Technologiesservice technician

Operating fluids Per manufacturer spe-cifications

Replace or treat per manufacturer specifications Customer

Maintenance schedule for normal ambient conditions / *whichever occurs first.

Special measures:1. Also observe the maintenance notes in the motor instructions.

2. If unusual events occur, e.g. short-circuit, emergency shutdown, period duty or overload cut-off, a visual inspection is re-quired before restarting the unit!

3. Replacing the motor bearings: The motor bearings must be replaced by Bühler Technologies authorized persons or a motormanufacturer certified shop.

4. The lifetime calculation is based on a typical mixed application at 25 % of the life at full-load operation and 75 % of the life atleft-load operation of the motor.


BFP ATEX-3GD

7 Service and repairThis chapter contains information on troubleshooting and correction should an error occur during operation.

Repairs to the unit must be performed by Bühler authorised personnel.

Please contact our Service Department with any questions:

Tel.: +49-(0)2102-498955 or your agent

If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspectedby the manufacturer. Please send the equipment inside suitable packaging to:

Bühler Technologies GmbH

Werk 2 – Service-

Halskestr. 23

40880 Ratingen

Germany

Please also attached the completed and signed RMA decontamination statement to the packaging. We will otherwise be unableto process your repair order.

You will find the form in the appendix of these instructions, or simply request it by e-mail: [email protected].

7.1 Troubleshooting

DANGER Risk due to defective unit

Personal injury or property damage may occur.Correct defects to the unit immediately. Switch the unit off and disconnect from themains. Discontinue use of the device until the defect has been corrected.

Problem / malfunction Possible cause ActionInsufficient pump capacity – Reversed direction of motor rotation – Correct connection, see chapter "Electrical

Connections"– Motor doesn’t start – Correct connection, see chapter "Electrical

Connections"– Oil flow too low – Correct connection, see chapter "Electrical

Connections"– Oil circuit blocked – Open valves and cocks– Excessive suction pressure, reducing the oil

flow rate– Reduce suction lift

– Excess back-pressure in the pressure pipe.Motor is being overloaded and throttled

– Select a larger cross-section

No oil flow – insufficient oil in the pump housing afterprolonged standstill, thus no suction

– spray some oil into the housing before con-necting the oil ling

Loud pump – Negative intake pressure too high – Select a large enough suction hose– Reduce suction lift

– Bracket damage – Shut equipment down immediately and con-tact Bühler Technologies service

Tab. 1: Troubleshooting


BFP ATEX-3GD

8 DisposalDispose of the parts in such a way that does not present a danger to other people’s heath or to the environment. Observe thelegal requirements in the country of use for the disposal of electrical components and oils and coolants.


BFP ATEX-3GD

9 Calculations

9.1 Calculating viscosityValid for VG-oil between 10 - 100 °C at an exactness from ± 5 %.

Definitions Example: oil VG 46V40 oil viscosity at 40 °C in cst V40 46 cstT temperature in °C T 25 °Cʋ viscosity in cst

9.2 Table of operational viscosity for VG oil

10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °CVG 46 264,45 131,96 73,58 46,00 29,13 20,04 14,43 10,78 8,32VG 68 444,77 210,85 112,61 68,00 41,63 27,86 19,58 14,32 10,84VG 220 2.120,17 861,60 404,31 220,00 121,71 74,99 49,00 33,61 24,01VG 320 3.489,92 1.350,22 607,96 320,00 171,40 102,85 65,66 44,12 30,94

Viscosity given in cst (mm2/s)

9.3 Calculating the pressure lossValid for smooth straight piping per meter at laminar current.

Definitions Example: oil VG 46ʋ Viscosity in cst ʋ 97,35 cstρ spec. gravity in kg/dm3 ρ 0,8817 kg/dm³DN tube diameter in mm DN 20 mmV flow in m/s V 3,18 m/s (60 l/min for tube DN 20)PV pressure loss in bar

NOTICE

Pressure loss increases significantly for bends and fittings.It might be necessary in some cases to determine the final shape of the suction line onsite under specific conditions.

Please do not hesitate to contact us for help to calculate the pressure loss of the suction line for you specific application.


BFP ATEX-3GD

10 Pressure loss in straight pipesPressure loss (bar) per metre in straight tubing with laminar flow of mineral oil:

BFP 8 8 l/min – DN 25VG 46 VG 68 VG 120 VG 160 VG 220 VG 320 VG 460 VG 680

10 °C 0.03 0.05 0.11 0.17 0.25 0.42 0.68 1.1420 °C 0.02 0.03 0.05 0.07 0.10 0.16 0.25 0.4030 °C 0.01 0.01 0.02 0.03 0.05 0.07 0.11 0.1740 °C 0.01 0.01 0.01 0.03 0.03 0.04 0.05 0.0850 °C 0.01 0.01 0.01 0.02 0.01 0.02 0.03 0.0460 °C – 100 °C < 0.03 bar


10 °C 0.02 0.04 0.08 0.12 0.19 0.31 0.50 0.8520 °C 0.01 0.02 0.04 0.10 0.08 0.12 0.19 0.3030 °C 0.01 0.01 0.02 0.05 0.04 0.05 0.08 0.1240 °C 0.01 0.01 0.01 0.01 0.02 0.03 0.04 0.0650 °C 0.01 0.01 0.01 0.01 0.01 0.02 0.01 0.0360 °C – 100 °C < 0.02 bar


10 °C 0.04 0.07 0.15 0.22 0.33 0.54 0.88 1.4820 °C 0.02 0.03 0.06 0.09 0.13 0.21 0.33 0.5230 °C 0.01 0.02 0.03 0.04 0.07 0.09 0.14 0.2240 °C 0.01 0.01 0.02 0.02 0.03 0.05 0.07 0.1050 °C 0.01 0.01 0.01 0.01 0.02 0.03 0.04 0.0660 °C – 100 °C < 0.03 bar


10 °C 0.03 0.06 0.12 0.18 0.28 0.45 0.74 1.2420 °C 0.02 0.03 0.05 0.08 0.11 0.18 0.27 0.4330 °C 0.01 0.01 0.03 0.04 0.05 0.08 0.12 0.1840 °C 0.01 0.01 0.02 0.02 0.02 0.04 0.06 0.0850 °C 0.01 0.01 0.01 0.01 0.02 0.02 0.03 0.0560 °C – 100 °C < 0.03 bar

BFP 90 86 l/min – DN 40LVG 46 VG 68 VG 120 VG 160 VG 220 VG 320 VG 460 VG 680

10 °C 0.05 0.09 0.19 0.27 0.42 0.68 1.11 1.8720 °C 0.03 0.04 0.08 0.12 0.17 0.26 0.41 0.6530 °C 0.02 0.02 0.04 0.06 0.08 0.12 0.18 0.2740 °C 0.01 0.01 0.02 0.03 0.04 0.06 0.09 0.1350 °C 0.01 0.01 0.01 0.02 0.02 0.03 0.05 0.0760 °C – 100 °C < 0.04 bar

Note: Values in blue exceed the suction operation limit of -0.4 bar.


BFP ATEX-3GD

11 Appendices

11.1 Technical data

Technical DataPump housing: Anodised and impregnated cast aluminiumMotor housing: Aluminium die castingMotor flange: Grey cast ironGerotor: Sintered steelOperating fluids: Mineral oils per DIN 51524

Gear oil per DIN 51517-3Operating pressure: 8/16/29 L/min – max. 8 bar

42 L/min – max. 6 bar58/88 L/min – max. 8 bar

Operating oil temperature: max. 80 °CSeal: VitonAmbient temperature: -15 to 40 °C

Electric motorsVoltage / frequency: 230 / 400 V - 50 Hz ± 5 %

277 / 480 V - 60 Hz ± 5 %Thermal stability: Class of insulation FDesign: Three-phase asynchronous squirrel-cage induction motor totally enclosed, fan cooledColour: RAL 7031Protection class: IP 55The motors comply with standards IEC 60079-0, IEC 60079-7, IEC 61241-0, IEC 61241-1

Please also observe the operating manual for the motor! All pumps are supplied with cable gland inside the motor terminalbox.

Pump selection information:When selecting the pump model, choose the motor output according to the oil viscosity to be used. Motor output informationrefers to the maximum oil viscosity at maximum operating pressure.

The BFP 8 to BFP 40 are also available as a special version with a 6 bar internal bypass valve for protection. This does not changethe dimensions.

Installation information:The pump head of all pumps can be mounted turned in 90° increments to align with the line routing. Please note the offsetfrom the centre of the motor.

The connection threads are manufactured to ISO 228. The screw-in surfaces are finished and suitable for the use of soft seals. Werecommend using screwed plugs per ISO 1179-2.

Please note:Especially note the dimension of the suction pipe. The cross-sections should not be smaller than specified. In most cases, loudnoise indicates the cross-section was reduced too much.

Please refer to the notices in the operating instructions.


BFP ATEX-3GD

11.1.1 BFP 8 / BFP 15BFP 8-4-0.75 kW BFP 15-4-0.75 kW BFP 15-4-1.5 kW

Item number 3708075ATEX3GDT3 3715075ATEX3GDT3 3715150ATEX3GDT3Motor power 0.75 kW 0.75 kW 1.5 kWMax. oil viscosity 1500 cSt 300 cSt 2000 cStAt max. operating pressure 8 barNumber of poles 4Max. power input (400 V/50 Hz) approx. 1.65 A approx. 1.65 A approx. 3.35 ANominal delivery volume at 50/60 Hz

5.8 cm3/U 11.7 cm3/U 11.7 cm3/U8/10 L/min 16/20 L/min 16/20 L/min

Suction side connection G3/4 – DN20 G1 1/4 – DN32 G1 1/4 – DN32Pressure side connection G1/2 – DN16 G1 – DN25 G1 – DN25Suction pressure for all types briefly up to

-0.4 bar-0.6 bar

Acoustic power per ISO 3744 56 dB(A) 59 dB(A) 59 dB(A)Weight 18.5 kg 18.1 kg 23.6 kgDimensions

A 96.5 96.5 100B 324 324 376C 96 96 120D 82 70 70E 71 60 60F 80 80 90G 218 218 236H 125 125 140J 152 152 177K 77 77 87L 100 100 125

M 4xØ10 4xØ10 4xØ10

Inlet Outlet

L/min

Flow rate

BFP 8-4-0.75 kWBFP 15-4-0.75 kW

bar


BFP ATEX-3GD

11.1.2 BFP 30 / BFP 40BFP 30-4-0.75 kW BFP 30-4-1.5 kW BFP 40-4-1.5 kW

Item number 3730075ATEX3GDT3 3730150ATEX3GDT3 3740150ATEX3GDT3Motor power 0.75 kW 1.5 kW 1.5 kWMax. oil viscosity 100 cSt 1000 cSt 700 cStAt max. operating pressure 6 bar 8 bar 6 barNumber of poles 4Max. power input (400 V/50 Hz) approx. 1.65 A approx. 3.35 A approx. 3.35 ANominal delivery volume at 50/60 Hz

20.4 cm3/U 20.4 cm3/U 30.6 cm3/U29/35 L/min 29/35 L/min 42/50 L/min

Suction side connection G1 1/4– DN32Pressure side connection G1 – DN25Suction pressure for all types briefly up to

-0.4 bar-0.6 bar

Acoustic power per ISO 3744 61 dB(A) 61 dB(A) 62 dB(A)Weight 18.8 kg 24.3 kg 24.8 kgDimensions

A 95 98.5 108B 323 375 384C 96 120 120D 80 90 90E 218 236 236F 125 140 140G 152 177 177H 77 87 87J 100 125 125K 4xØ10 4xØ10 4xØ10

Inlet Outlet

L/min

Flow rate

bar

BFP 40-4-1.5 kWBFP 30-4-1.5 kWBFP 30-4-0.75 kW


BFP ATEX-3GD

11.1.3 BFP 60BFP 60-4-2.2 kW BFP 60-4-3 kW

Item number 3760220ATEX3GDT3 3760300ATEX3GDT3Motor power 2.2 kW 3 kWMax. oil viscosity 300 cSt 900 cStAt max. operating pressure 8 barNumber of poles 4Max. power input (400 V/50 Hz) approx. 4.8 A approx. 6.5 ANominal delivery volume at 50/60 Hz

40.8 cm3/U58/70 L/min

Suction side connection G1 1/2– DN40Pressure side connection G1 1/4– DN32Suction pressure for all types briefly up to

-0.4 bar-0.6 bar

Acoustic power per ISO 3744 64 dB(A)Weight 40.3 kg 49.3 kgDimensions

A 172 172B 471 501C 128 158D 140 140E 97 97F 100 100G 160 160H 193 193J 255 255K 4xØ12 4xØ12

Inlet Outlet

L/min

Flow rate

BFP 60-4-2.2 kWBFP 60-4-3 kW

bar


BFP ATEX-3GD

11.1.4 BFP 90BFP 90-4-2.2 kW BFP 90-4-3 kW

Item number 3790220ATEX3GDT3 3790300 ATEX3GDT3Motor power 2.2 kW 3 kWMax. oil viscosity 100 cSt 300 cStAt max. operating pressure 8 barNumber of poles 4Max. power input (400 V/50 Hz) approx. 4.8 A approx. 6.5 ANominal delivery volume at 50/60 Hz

61.2 cm3/U88/105 L/min

Suction side connection G1 1/2– DN40Pressure side connection G1 1/4– DN32Suction pressure for all types briefly up to

-0.4 bar-0.6 bar

Acoustic power per ISO 3744 65 dB(A)Weight 41.3 kg 50.3 kgDimensions

A 184.5 184.5B 505 535C 128 158D 140 140E 97 97F 100 100G 160 160H 193 193J 255 255K 4xØ12 4xØ12

Inlet Outlet

L/min

Flow rate

BFP 90-4-3 kWBFP 90-4-2.2 kW

bar


BFP ATEX-3GD

11.2 Installation torques and clamping range for cable fitting

SizeStrain relief clamping

range (mm)Installation torque (Nm)

M12x1,5 3-6 1,5M16x1,5 5-9,5 2,5M20x1,5 8-13 3,5M25x1,5 11-17 5M32x1,5 15-21 5M40x1,5 19-28 7,5M50x1,5 27-35 7,5M63x1,5 32-42 13


BFP ATEX-3GD

11.3 User book (Please make copies)Maintained on Unit no. Operating hours Remarks Signature


BFP ATEX-3GD

12 Attached documents

12.1 Declaration of conformity


BFP ATEX-3GD

12.2 Statement of Conformity


BFP ATEX-3GD

12.3 Motor operating instructions (Leroy-Somer)


FluidControl

Excerpt from the original instructions of the manufacturer

Motor Documentation

VEM

350030EN03/2017



Bühler Technologies GmbH, Harkortstr. 29, D-40880 RatingenTel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20Internet: www.buehler-technologies.comE-Mail: [email protected]

Read this instruction carefully prior to installation and/or use. Pay at-tention particularly to all advises and safety instructions to prevent in-juries. Bühler Technologies can not be held responsible for misusingthe product or unreliable function due to unauthorised modifications.

All rights reserved. Bühler Technologies GmbH 2017

Document informationDocument No......................................................... 350030ENVersion..........................................................................03/2017

Edition 04.2016 VEM-Ident-No. 68238 01

Installation, operating and maintenance instructions

Three-phase asynchronous motors with squirrel-cage rotor for low voltage applications

Three-phase asynchronous motors with slip-ring rotor for low voltage applications

Translation

KP./KPE./K1../K2../KU../KV../K4../K8.. BP./BPE./B1../B2../BU../BV../BE../BR.

WE../W2../W4../WU../G1../G2../GS1.. YP./YPE./Y1../Y2../YE../YU..

S(R)../SG../SP./SPE./S1../S8.. CP./CPE./C1../R1../R2../RE.. AR./A1../A2../AU../AV../AE..

Motors that comply with the Regulation 2005/32/EC and the order No. 640/2009 receive the marking IEx before the type designation, whereas x= 1,2,3 (acc. to EN 60034-30). (Example IE1-K21R 132 S4)

Installation, Operating and Maintenance Instructions (Translation) English

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1. General To prevent damage to motors and the driven equipment the procedures laid down in the Operating and Maintenance Instructions must be followed. Especially to avoid risk of injury, the separately enclosed Safety Regulations must be adhered to strictly. Since for reasons of clarity the Operating and Maintenance Instructions cannot contain specific information with regard to all conceivable special applications and areas with special requirements, the user himself has to make appropriate protection arrangements during the installation process. 1.2. Qualified personnel Installation work, commissioning and operation of motors must only be done by qualified personnel. Installation work shall only be done by qualified personnel who is skilled because of a technical education, expertise and schooling of knowledge about

security regulations, accident prevention regulations, standards and approved rules of technique (for example VDE-regulations, standards).

The qualified personnel must have the ability to assess the assigned job, identify possible dangers and avoid them. The qualified personnel must be authorized by the person in charge for security of the plant to carry out the necessary work and tasks. 1.3. Intended use This motor is only approved for the intended use given by the manufacturer in his catalogue and the corresponding technical documentation. Other or additional use is not intended. This includes consideration of all corresponding product documents. Changes or reconstruction of the motor are not allowed. External products and components that shall be used together with the motor must be approved or recommended by the manufacturer. 1.4. Disclaimer Observance of this manual and the conditions and methods used for installation, operation, use and maintenance of the electric motor can not be monitored by the manufacturer. An improper installation can result in property damage and thus result in personal injuries. We therefore do not accept responsibility and liability for losses, damages or costs resulting from improper installation, improper or wrong use and maintenance or connected with this in any kind. We strive to improve our products continuously. Consequently technical data and illustrations remain subject to change without prior notice. Specifications may only be considered binding after written confirmation by the supplier. EC motor regulation (EC) No. 640/2009 Since June 2011 the regulation (EC) no. 640/2009 of the European Commission for electric motors has become into force. This regulation specifies the eco design requirements for 2-, 4- and 6-pole low-voltage three-phase asynchronous motors in the output range from 0.75 kW to 375 kW. The individual eco design requirements are scheduled as follows:

After 16th June 2011 all motors must have at least the efficiency class IE2 specified in attachment I/no. 1 of

the regulation.

After 1st January 2015 all motors with rated output 7.5 kW to 375 kW must have either the efficiency class

IE3 specified in attachment I/no. 1 of the regulation or the efficiency class IE2 specified in attachment I/no. 1 of the regulation but operating with speed control.

After 1st January 2017 all motors with rated output 0.75 kW to 375 kW must have either the efficiency class

IE3 specified in attachment I/no. 1 of the regulation or the efficiency class IE2 specified in attachment I/no. 1 of the regulation but operating with speed control.

The regulation permits the user to choose either an IE3-motor (fixed or variable speeds) or an IE2-motor operating in connection with a speed control. The user is responsible to observe the specifications of the EC regulation. The motor manufacturer labels his products accordingly. The detailed scope and exemptions for special designs have to be taken directly from regulations (EC) No. 640/2009 and (EC) No. 4/2014.


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2. DescriptionThe motors have been manufactured in accordance with IEC 34-1, EN 60034-1 and other appropriate European standards. Motors can also be supplied complying with special regulations (e.g. classification regulations, regulations for explosion protection). Separate additional instructions apply for the following motor versions:

Roller table motors Motors in explosion protected design

The details on the relevant order confirmation constitute the scope of supply.

3. EfficiencyThe efficiency is determined according to the specifications of EN 60034-2-1. For motors < 1kW the direct measurement method is used. The measurement uncertainty of this method is rated „low“. For motors ≥ 1kW the individual loss method is used. The additional losses of this method are determined from the residual losses. The measurement uncertainty of this method is also rated as “low”. Efficiency and Efficiency class complying with EN 60034-30 are listed on the name plate of energy saving motors.

4. Degree of ProtectionThe degree of protection of the motors is indicated on their rating plate. The degree of protection of additional devices fitted to the motor can be different than the degree of protection of the motor. This needs to be taken into

consideration during the installation of the motors. If motors are installed in the open (degree of protection IP 44), they should be protected against direct effects of the climate (freezing of the fan due to direct fall of rain, snow and formation of ice).

5. Type of ConstructionThe type of construction of the motors is indicated on the rating plate. The motors can be used in different types of construction only with permission of the manufacturer and if necessary after modification carried out in accordance with the manufacturer’s instructions. Especially with types of construction with vertical shaft the user has to ensure that foreign particles cannot fall into the fan cowl.

6. Transport & StorageIf possible the motors should only be stored in closed and dry rooms. Outdoor storage under cover is permitted for a short time only and requires adequate protection against all harmful effects of the climate. The motors also have to be protected against mechanical damage. Never transport or store the motors resting on their fan cowls. The eye bolts/attachment eyes of the motors together with appropriate lifting tackle must be used for transport. The eye bolts/attachment eyes are intended for the lifting of the motors only, without any additional parts such as bed plates, gears etc. If eye bolts/attachment eyes are removed after installation, the tapped holes must be blanked off permanently according to the Protection Standard. For longer periods of storage a low vibration environment shall be provided so that bearing damages due to downtime can be avoided. After a storage period of more than 12 months the condition of the grease must be checked before putting the motor into operation.

8. Installation and FittingSince during normal operation of electric motors, temperatures in excess of 100 °C can occur on their surface, any contact with them must be prevented if the motors are installed in accessible areas. Because of this temperature sensitive parts must never be fitted to them or have contact with them.

In types of construction IM B14 and IM B34 it must be ensured that the maximum usable screw depth specified in the table below is not exceeded, otherwise the winding will be damaged. Vent holes must be kept free and the minimum distances stated in the dimensional drawings must be maintained so that the flow of cooling air is not obstructed. Care must be taken that the discharged warmed up cooling medium is not sucked up again. For constructions with shaft end upwards the user must prevent liquid entry from the shaft!


4

The key in the shaft end is secured by the shaft protective sleeve for transport and storage only. Because of the danger that the key may be thrown aside, a start-up or a trial run with the key protected by the shaft sleeve only is strictly forbidden.

Transmission components (such as couplings, pinions or belt pulleys) should be drawn onto the shaft by means of pull-on devices or by heating-up the part to be drawn onto the shaft. For the purpose of drawing the transmission components onto the shaft, the shaft ends are provided with tapped centering holes according to DIN 332 Part 2. Transmission components must never be driven onto the shaft using hammer blows because the shaft, the bearings and other components of the motor could be damaged. All components that are to be fitted to the shaft end must be balanced dynamically according to the balancing system of the motor (full or half key). The rotors of the motor are balanced with half key; this is indicated by letter H after the serial number on the rating plate. Motors with letter F after the serial number are balanced with full key. If possible the motors are to be installed in such a way that they are free from vibrations. With precision balanced motors special instructions are to be followed. When the installation is completed the user must ensure protection of movable parts and safety of operation. Direct coupling to the driven machine requires a particularly accurate alignment. The shafts of both machines must be in alignment. The shaft height is to be adjusted to that of the driven machine using appropriate shims. Belt drives put a lot of stress on the motor because of relatively high radial forces. When dimensioning belt drives, apart from the instructions and calculation programmes issued by the manufacturers of the belts, it must be ensured that the radial force permissible at the shaft end of the motor as stated in our data is never exceeded by the pull and pre-tensioning of the belt. When pre-tensioning the belt during installation the instructions of the belt manufacturers must be strictly adhered to.

Relatively large radial forces or masses can be taken up at the end of the motor shaft by the use of cyclindrical roller bearings (“heavy bearing arrangement” VL). The minimum radial force at the shaft end must be a quarter of the permissible radial force. The permissible shaft end load is to be taken into account. The information can be taken from the tables and diagrams in the design selection data.

If the radial force falls below the minimum value, damage to the bearings can be caused within a few hours. Test runs in no-load state only permissible for a short period.

The threaded holes of the flange types listed in the table are through holes (type IMB14, IMB34). To avoid damage to the winding overhang of the motor winding, observe the maximum permissible tap depths in conformity with the following table.

Flange type (EN 50347)

Old flange type (DIN 42948)

Tap depth (mm)

FT65 C80 6,5

FT75 C90 8

FT85 C105 8,5

FT100 C120 8

FT115 C140 10

FT130 C160 10

FT165 C200 12

FT215 C250 12

If a motor of type IMB34 without flanged attachments is used, the user has to take appropriate measures at the through holes to maintain the specified degree of protection.

9. Insulation Check & Replacement of Grease / BearingsWhen the motor is first commissioned and especially after extended storage, the insulation resistance of the winding is to be measured to earth and between phases. The check must take place using the rated voltage, but at least 500 V.

During and immediately after the measurements dangerous voltages are present at the terminals. Therefore never touch the terminals and follow the operating instructions of the insulation resistance meter closely!

Depending on the rated voltage UN, the following minimum values must be maintained with a winding temperature

of 25 °C:


5

Rated Power PN in kW

Insulation Resistance referred to Rated

Voltage in k/V

1 < PN 10 6,3

10 < PN 100 4

100 < PN 2,5

If the minimum values are lower, the winding must be dried properly until the insulation resistance corresponds to the required value. When the motor is commissioned after a prolonged period of storage inspect the bearing grease visually and replace it if hardening and other irregularities occur. If the motors are to be commissioned by the manufacturer after more than three years following their delivery then the bearing grease must always be replaced. With motors fitted with covered or sealed bearings the bearings must always be replaced with new bearings of the same type after a storage period of four years.

10. Motor connectionThe connection has to be done by qualified personnel according to the valid security regulations. Outside of Germany the required national standards must be applied. Name plate designations have to be observed under all circumstances!

Take extra care when connecting the supply cables in the terminal box of the motor. The nuts of the connection screws have to be fastened without force. Before connecting the power line, the existing motor connections must eventually be retightened.

Terminal box overview

Terminal box type Terminal board

Rated current Connecting thread

Tightening torque

[A] [Nm]

KA 05 K1M4 30 M4 1,8 0,2

KA 05-13 K1M4 30 M4 1,8 0,2

KA 05-13 K1M5 30 M5 2,4 0,2

KA 25 A SB 5 25 M5 2,5 0,5

KA 25 A SS SB 5 25 M5 2,5 0,5

K 63/25 A SB 5 25 M5 2,5 0,5

KK 63 A SB 6 63 M6 4 1

KK 100 A SB 8 100 M8 7,5 1,5

KK 200/100 A SB 8 100 M8 7,5 1,5

KK 200 A SB 10 200 M10 12,5 2,5

KK 400 A SB 12 400 M12 20 4

KK 400 B KM 12 400 M12 20 4

KK 400 B KM 16 630 M16 30 4

KK 630 A KLP 630-16 630 M16 30 4

KK 630 A KLP 630-20 630 M20 30 4

KK 1000 A KLSO 1000 1000 current bar -

11. CommissioningPlease follow the Safety Regulations closely. All work is to be carried out only when there is no voltage on the motor. The installation must be carried out according to the valid regulations by qualified skilled personnel. Initially the mains conditions (voltage and frequency) must be compared with the data on the rating plate of the motor. The dimensions of the connecting cables must be adjusted in line with the rated currents of the motor. The connection points of the motor are marked in accordance with EN 60034-8 (VDE 0530 Part 8). In Section 19 of these instructions the most common circuit diagrams for three phase motors in basic design are provided, according to which the connection will be implemented. For all other versions, the special circuit diagrams are glued to the inside of the terminal box cover or placed in the terminal box. An additional terminal box can be provided for the connection of auxiliary and protection devices (e.g. anti-condensation heaters); the same regulations apply as for the main terminal box.


6

Always start the motors with an over-current protection device that is set in accordance with the relevant nominal

values of the motor (1,05 Inom). Otherwise warranty claims with respect to damaged windings become void. Before the motor is connected for the first time it is recommended to check the insulation resistances between winding and earth and between phases (see Section 9). After prolonged storage it is absolutely essential that the insulation resistance is measured. Before coupling the motor to the driven machine, check the direction of rotation of the motor to prevent possible damage being caused to the driven machine. If the power lines are connected with the phase sequence L1, L2, L3 to U, V, W, the direction of rotation is clockwise (view to shaft end on drive side DS). If two terminals are changed, the direction of rotation is counterclockwise (i.e. L1, L2, L3 to V, U, W). For machines with only one direction of rotation the required sense of rotation is marked by an arrow on the machine. For the permissible tightening torques for the terminal board bolts refer to the table below:

Tightening torques for bolts (terminal box, end shield, bearing cover)

Series W.. and K.. 63 to 132T, W.. and K.. 56 to 100

Type Type of construction

End shield Fixed bearing cover

Terminal box

W.. and K..

W.. and K..

DS NS DS NS or adapter cover

Bolts/tightening torque for bolts MA

63… 56…

all

M 4 2,0 Nm

M 4 2,0 Nm

M 4 1,5 Nm

(for W.. and K.. 100 L

M 5 2,0 Nm)

M 4 1,5 Nm

M 4 2,5 Nm

M 5 1,0 Nm

71… 63…

80… 71… M 5 4,0 Nm

M 5 4,0 Nm 90… 80…

100 L 90… M 6 7,0 Nm

M 6 7,0 Nm

100 LX,112…

100…

B3 M 8

10,0 Nm

M 8 10,0 Nm

M 5 2,0 Nm

M 5 2,0 Nm

B5, B14 M 8

15,0 Nm

132 S…T -

B3, B14-FT130

M 8 10,0 Nm

M 4 2,0 Nm B5, B14

M 8 15,0 Nm


Series W.. and K.. 112 to 355

Thread Ø M5 M6 M8 M10 M12 M16 M20

End shield - - 25 45 75 170 275

Bearing cover 5 8 15 20 20 - -

Terminal box - 4 7,5 12,5 - 20 -

Before closing the terminal box make absolutely sure that: - the connection has been made in accordance with the wiring diagram - all terminal box connections are tightened - all minimum values of air paths are maintained (larger than 8 mm up to 500 V, larger than 10 mm up to 750 V, larger than 14 mm up to 1000 V) - the interior of the terminal box is clean and free from foreign particles - unused cable entries are blanked off and the threaded plugs with seals are tightened - the seal in the terminal box cover is clean and tightly glued and all sealing surfaces are in the correct state to ensure that the relevant degree of protection is maintained.

Before starting up the motor check that all safety regulations are strictly adhered to, that the machine is correctly installed and aligned, that all fixing parts and earthing connections are tightened, that the auxiliary and additional devices are functionally and correctly connected and if a second shaft end is fitted that the key is secured against being thrown aside. If possible the motor is to be connected without load. If the motor is running smoothly and without any abnormal noises, the load of the driven machine is to be applied onto the motor. When the motor is started up it is recommended to monitor the current consumption if the motor is loaded with its driven machine so that any possible overloads and asymmetries occurring in the mains can be recognised immediately. The starter must always be in the starting position during starting. With slip ring motors the correct running of the brushes must be monitored. They must be absolutely spark-free.


7

For mountings like encoders, brakes and others please observe the corresponding operating and maintenance instructions of the manufacturer.

12. MaintenanceYou are once again referred to the Safety Regulations, in particular to isolation, to securing against reconnection, to checking whether all components connected to a voltage source are in dead state. If it is necessary to disconnect the motor from the mains for maintenance work particular care must be taken to ensure that any possibly existing auxiliary circuits (e.g. anti-condensation heaters, forced ventilators, brakes) are also disconnected from the mains. If the motor is to be dismantled during maintenance work, the sealing compound on the centering shoulders is to be removed. When re-assembling the motor these need to be re-sealed using a suitable motor sealing compound. Existing copper sealing washers must always be refitted.

Careful and regular maintenance, inspections and revisions are necessary to detect and clear faults in time, before consequential damages will happen. As individual operating conditions can not be defined for all applications the listed terms represent a general advice for undisturbed operation. Individual local conditions (degree of pollution, load, etc.) must be taken into account when adjusting these terms.

What to do? Time period Terms

First inspection After about 500 operating hours ½ year at the latest

Control of air circulation and surface of motor

Depending on local environmental pollution

Relubrication (as option) See name plate or relubrication sign

Main inspection After about 10,000 operating hours Once a year

Remove condensate water Depending on the local environmental conditions

12.2 Inspektions 12.2.1 Initial inspection According to the requirements an initial inspection of the motor must be organised after approximately 500 hours of operation, but not later than half a year after start of operation. The following examinations will be done at standstill of the motor:

a) Check of the foundations. There must be no cracks or other damages like depressions.The following examinations will be done when the motor is running:

a) Check of the electric characteristics.b) Check of the bearing temperatures. It is examined if the permissible bearing temperatures will be exceeded

during operation of the motor.c) Check of the running noises. When the motor is running, it is checked if the quiet running has changed for

the worse.If the examination results in differences from the values specified in the mainenance manual or if there are other faults or damages detected, than these must be corrected immediately.

12.2.2 Main inspection According to the requirements a main inspection of the motor must be organised annually after approximately 10,000 hours of operation. The following examinations will be done at standstill of the motor:

a) Check of the foundations. There must be no cracks or other damages like depressions.b) Check of the motor alignment. The motor alignment must be within the given tolerances.c) Check of the fastening bolts. All bolts used for fixing mechanical and electrical connections must be tight

(see also the table for tightening torques for bolts in chapter 11. Commissioning).d) Check of the cables and the insulation material. The examination must check if the cables and used

insulation materials are in good conditions. They must not be discoloured or even burnt and they must notbe broken, cracked or faulty in any other way.

e) Check of the insulation resistance. The insulation resistance of the winding must be measured. Therequirements in the maintenance manual (chapter 9) must be kept.

f) According to the grease quality and bearing type of the motor it can be necessary to change the greaseafter 10,000 working hours (see chapter 13 Bearings and Lubrication). Apart from that the necessaryrelubrication periods for friction bearings must be observed, because they differ from the inspectionperiods.

The following examinations will be done when the motor is running: a) Check of the electric characteristics.


8

b) Check of the bearing temperatures. It is examined if the permissible bearing temperatures will be exceededduring operation of the motor.

c) Check of the running noises. When the motor is running, it is checked if the quiet running has changed forthe worse.

If the examination results in differences from the values specified in the mainenance manual or if there are other faults or damages detected, than these must be corrected immediately.

13. Bearings and LubricationThe anti-friction bearings of the motors in standard design are filled with anti-friction bearing grease in the factory (or with sealed bearings by the bearing manufacturer) according to DIN 51825 in compliance with the table below:

Motor type Designation of grease Design. acc. to DIN 51825

Temperature range in °C

Thermal class F Thermal class H rise F Standard, TII, AS, NS, VL, LL Marine design (SS) Smoke exhaust design FV, FV1, FV2 (up to 300°C/1h)

Asonic GHY 72 KE2R-40 -40 up to +180

For low temperatures Asonic GLY 32 KPE2N-50 -50 bis +140

For high temperatures, Thermal class H rise H Roller table motors ARB, ARC Smoke exhaust design FV3 (up to 300°C/2h)

Berutox FH 28 KN KHC1R-30 -30 bis +180

Power plant design Motors complying with VIK with relubrication device

HIGH- LUB LM 3 EP KP3N-30 -30 bis +140

For very high ambient temperatures Barrierta L55/3 HV - -25 bis 260

Customer request Only after consultation with design department of VEM

Under normal load and climatic conditions, the quality of grease guarantees an operation of the motor for approx. 10,000 service hours with two pole design and 20,000 service hours with multipole design. If not otherwise agreed the grease of anti-friction bearing must never be refilled during this period. However, the condition of the grease should be checked occasionally even before this time limit. The bearing itself or the grease of permanently lubricated bearings should be changed after approximately 3 years independent of operating hours. This is due to the reduction of lubrification properties of the grease. The indicated number of service hours is only valid for operation at rated speed. When using inverter feeding the indicated relubrication periods are reduced by 25% because of the higher temperature increase. If during operation of the motor via an inverter the nominal speed is exceeded then the regreasing period reduces approximately in the opposite ratio to the increase in the motor speed. Regrease the bearings only after a thorough cleaning using suitable solvents. The same type of grease must be used. When replacing the grease only the equivalent types specified by the motor manufacturer can be used. Please bear in mind that the bearings should only be filled up to about 2/3 of their free space. A complete filling of the bearings and bearing covers with grease leads to increased bearing temperature and therefore to increased wear. The regreasing of bearings with regreasing facility is carried out at the grease nipple when the motor is running using the grease quantity required for the respective motor. For the re-greasing intervals please refer to the table below:

Frame size

Series IEC/DIN Series Transnorm

2-pole design Design with 4-poles and more

132 bis 280 100 bis 250 2.000 h 4.000 h

315 280 bis 315 2.000 h 4.000 h

355 - 2.000 h 3.000 h

The quantities of grease required for the re-greasing are stated in the below table (Please note that for the first re-greasing approx. twice the amount of grease is required because the grease lubrication pipes are still empty). The used grease is collected in the grease chamber of the external bearing cap. After approx. 5 re-greasings this old grease should be removed, e.g. as part of inspection work.


9

Series Trans-norm

Overall length

pole number

Quantity of grease in cm

3Series

IEC/DIN

Overall length pole number

Quantity of grease in cm

3

Size D-end N-end Size D-end N-end

112 alle 10 10 132 M4, MX6 17 17

132 alle 17 17 160 L2, MX2, L4, 6, 8 23 20

160 alle 23 20 180

M2, L4 23 23

180 2 23 23 M4, L6, 8 23 20

4 31 31 200

L2, L4, 6, 8, LX 6 31 23

200 2 31 31 LX2 31 31

4 35 31 225

M2 31 31

225

2 35 35 M4, 6, 8, S4, 8 35 31

4 41 35 250

M2 35 35

250

2 41 41 M4, 6, 8 41 35

4 52 41 280

2 41 41

280 2 52 52 4 52 41

4 57 52

315

S,M2 52 52

315

S2 57 52 S,M 4, MX2 57 52

M,L,LX2 57 57 MY,L,LX2 57 57

S4, 6, 8 64 52 MX4, 6, 8 64 52

M,L,LX4, 6, 8

78 57 MY,L,LX4, 6, 8 78 57

355

2 57 57

355

2 57 57

4 90 57 4, 6, 8 90 57

6,8 90 57

The necessary relubrication periods for roller bearings differ from the inspection periods and must be observed separately!

The motors up to size 315M are equipped as standard with anti-friction bearings with life-time lubrication. From size 315MX upwards they are equipped with relubrication devices which can be ordered for smaller motors as option. Information about bearings and relubrication can be found in the general installation, maintenance and operation manual or on the name plate or relubrication sign.

Maintenance works (without relubrication) has to be done at standstill of the motor. It has to be assured that the machine is secured against re-connection and labelled with an appropriate sign.

In addition the security advices and accident prevention regulations of the manufacturers for the use of oils, lubricants and detergents has to be observed!

Adjacent live parts have to be covered or secured! It has to be assured that the auxiliary circuits like anti-condensation heating are dead (zero potential).

For design versions with condensate drain hole please observe that the drain plug screw has to be lubricated with a suitable sealant (for example Epple 28) before relocking.

14. Long term storage (more than 12 months)Long term storage must be done indoors in vibration-free, dry rooms with temperatures not below -20°C and not above +40°C. The storage environment must not contain aggressive gas, vapours, dusts and salts. Preferably motors shall be moved and stored only in original packing. Storage and transport with motors standing on their fan covers is not allowed. Additionally unprotected metal surfaces like shaft ends and flanges must be protected with a medium for long-time corrosion protection in addition to the exisiting factory-provided temporary corrosion protection. If there is a risk of motors being covered by moisture from condensation, please provide precautionary measures against humidity. Than a special packing in airtight sealed plastic foil is necessary or as alternative packing in plastic foil with desiccants. Please put desiccant bags in the terminal box as well. For the transport please use the eye bolts/attachment eyes of the motors together with suitable lifting accessories. The eye bolts/attachment eyes must only be used for lifting the motors without additional mountings like foundation plates, gears and others. Motors with reinforced bearings are supplied with a transportation safety device. The transportation safety device at the shaft end must only be removed during installation of the motor and before switching on.


10

16. Draining of condensation waterOn installation sites where formation of dew and thus occurrence of condensation water can be expected inside the motor, the accumulated condensation water has to be drained at regular intervals through the opening at the lowest point of the end shield. Subsequently the opening must be closed up again.

17. CleaningSo that the effects of cooling air are not interferred with, all parts of the motor must be cleaned at regular intervals. In the majority of cases it is sufficient to clean the machine with compressed air that is free from water and oil. Especially the vent holes and the spaces between the ribs must be kept clean. The dust generated by natural wear and deposited in the interior of the motor or in the slip ring space must be removed at regular intervals. It is recommended to include the electric motors in the regular routine inspections of the driven machine.

18. Auxiliary devicesAs option the motors can be equipped with auxiliary devices.

18.1 Motors with Thermal Winding Protection For monitoring the stator winding temperature it is possible to have thermo couples installed in the motor (PTC thermistors, KTY or PT100). For their connection suitable auxiliary clamps for auxiliary circuits are available in the main terminal box or in additional terminal boxes. The connection is done according to the attached connection diagram.

A continuity test of the thermistor sensor circuit using a test lamp, a hand generator and such like is strictly prohibited because this would destroy the sensors immediately. If it becomes necessary to verify the cold

resistance of the sensor circuit (at approx. 20C) then the measuring voltage must never exceed 2.5 V DC. It is recommended to carry out the measurement using a Wheatsone bridge with a 4.5 V DC supply voltage. The cold resistance of the sensor circuit must never exceed 810 Ohms; a measurement of the hot resistance is not necessary.

With motors that are fitted with thermal winding protection, care must be taken that when the thermal winding protection responds and after the cooling down of the motor, no hazards can occur due to spurious automatic reconnection.

18.2 Anti-condensation heating The input supply voltage is indicated on the name plate of the motor. For their connection either in the main terminal box or in the auxiliary terminal boxes suitable clamps for auxiliary circuits are provided. The connection is done according to the attached connection diagram. The anti-condensation heating has to be switched on only after disconnection of the motor. It shall not be switched on while the motor is in operation.

18.3 Forced ventilation unit The forced ventilation unit is dissipating the lost heat at operation of the main motor. During operation of the main motor the motor of the forced ventilation unit has to be switched on. After disconnection of the main motor the forced ventilation has to continue depending on the temperature. For motors with forced ventilation units that are dependent of the sense of rotation, the sense of rotation has to be observed unconditionally (see rotation mark). Only manufacturer approved forced ventilation units shall be used. The forced ventilation unit has to be connected according to the connection diagram that is supplied inside of the terminal box.


11

19. Warranty, Repair, Spare Parts Unless expressly agreed otherwise only our contractual workshops are permitted to carry out repairs during the warranty period. Other repairs that may potentially be required can also be carried out by skilled personnel in these workshops. Details about Customer Service network can be obtained from the manufacturer on request. The spare parts are listed in Section 24 of these Operating & Maintenance Instructions. Maintenance carried out appropriately (provided it is as described in Section “Maintenance”) does not constitute a breach of warranty provisions. The contractual warranty liability on the part of the manufacturer is not prejudiced by this. 20. Electromagnetic Compatibility The motors, as non-independently working unit, have been checked with regard to their conformity with the EMC Standards. It is the responsibility of the equipment operator to ensure by suitable measures that the apparatus or plant in their entirety comply with the relevant electromagnetic compatibility standards. 21. Trouble Shooting General mechanical and electrical faults are to be rectified according to the Schedule in Section 25. All Safety Regulations must be strictly observed when rectifying faults. 22. Terminal board circuits For a machine with only one shaft end or with two shaft ends that have different diameters, the sense of rotation is that rotational direction which is seen, if a person looks at the front end of the only or thicker shaft end.

For each motor the correct connection diagram is attached. The connection must be done accordingly. For the connection of auxiliary circuits please see the additional connection diagram, which is also attached. 23. Disposal When disposing of the motors please observe applicable national law. In addition please take care that all oil and grease is disposed according to the ordinance of waste oils (Altölverordnung). They must not be contaminated with solvents, cold cleaners and paint residues. Before recycling the individual materials must be separated. Most important components are grey cast iron (housing), steel (shaft, stator and rotor sheets, consumables), aluminium (rotor), copper (windings) and plastics (insulation materials like for example Polyamide, Polypropylene and others). Electronic components like printed circuit boards (inverter, encoder, etc.) must be recycled separately.


12

Single speed squirrel-cage motors: Single speed squirrel-cage motors:

low voltage Y high voltage

Star-delta switch connection:

For star-delta switch without bridges, connection according to the switch scheme

Motor with thermal winding protection

Terminal board connection as above

The connection will be implemented according to the connecting diagramme of the tripping device

Slip ring motor Stator

low voltage Y high voltage

Rotor

Rotor connection according to type either to rotor terminals or brush holders

to the starter


17

25. Trouble shooting 25.1 Electrical Faults

Motor doesn't start

Motor runs up heavily

Humming noise during start

Humming noise during operation

Hum in time of the double slip frequency

Excessive warming up at no-load

operation

Excessive warming up at rated output

Excessive warming up of individual winding sections

Possible cause of fault Remedial measure

Overload Decrease the load

Interruption of a phase in the supply conductor check the switch and the supply conductor

Interruption of a phase in the supply conductor after switching-on check the switch and the supply conductor Mains voltage too low, frequency too high check the mains conditions

Mains voltage too high, frequency too low check the mains conditions

Stator winding misconnected check the winding connections Turn-to-turn fault check the winding and the insulation resistance,

repair in authorized service workshop Phase-to-phase short circuit check the winding and the insulation resistance,

repair in authorized service workshop Interruption in the squirrel cage winding repair in authorized service workshop


18

25. 2 Mechanical Faults

Dragging noise

Excessive warming up

Strong vibrations

Bearing warming up excessively

Bearing noises

Possible cause of fault Remedial measure

Rotary parts are dragging Determine the cause, re-align parts Air supply reduced Check the ventilation passages Unbalance of the rotor Take rotor off, re-balance it Rotor not circular, shaft deformed Take rotor off, co-ordinate further measures with the

manufacturer Imperfect alignment Align motor & driven machine, check the coupling Unbalance of the coupled machine Re-balance coupled machine Shocks from the coupled machine Check the coupled machine Irregularities from the gear Check and repair the gear Resonance with the foundation Stiffen the foundation after consultation Changes in the foundation Determine the cause, eliminate it and re-align the machine Too much grease in the bearing Remove excess grease Coolant temperature higher than 40 °C Regrease bearing with suitable grease V-type rotary seal or gamma ring are

dragging Replace V-type rotary seal or gamma ring, maintain the prescribed installation clearance

Lubrication insufficient Lubricate according to instructions Bearing is corroded Replace bearing Bearing clearance too small Use bearing with larger bearing clearance Bearing clearance too large Use bearing with smaller bearing clearance Chatter marks in the bearing track Replace bearing Standstill marks Replace bearing Cylindrical roller bearing operated at

low load Change the bearing according to manufacturer’s instructions

Coupling pushes or pulls Re-align motor & driven machine Belt tension too high Adjust the belt tension according to instructions

Bearing not aligned or stressed Check the bearing bore, consult the manufacturer


19


20

VEM motors GmbH

Carl-Friedrich-Gauß-Straße 1 D-38855 Wernigerode fon: +49-(0)39 43-68-0 fax: +49-(0)39 43-68-21 20

email: [email protected] web: www.vem-group.com VEM motors Thurm GmbH

Äußere Dresdner Strasse 35 D-08066 Zwickau fon: +49-(0)375-427-0 fax: +49-(0)375-427-383

email: [email protected] web: www.vem-group.com


Additional Installation, Operating and Maintenance Instructions

Explosion-protected three-phase asynchronous motors with

squirrel-cage rotor for low voltage

Type of protection increased safety „e” Type of protection „n“

Type of protection by enclosure „t“

Translation

Design series (IE*-)K...

(IE*-)W..R

For energy-efficient design the mark IE*- is added to the type designation, whereas x= 1,2,3 (acc. to IEC/EN 60034-30). (Example IE3-K11R 132S 4 Ex e II T3)

Additional Installation, Operating and Maintenance Instructions (Translation) English


2

General Attention! Read installation, operation and maintenance instructions, connection diagram, additional connection diagram and safety regulations before transportation, installation, start-up, maintenance and repair. Mind the information!

The existing additional operation and maintenance manual is valid together with the already mentioned doc-uments and the operation and maintenance manual for standard motors, where the basic specifications for connection, installation, operation and maintenance as well as the spare parts lists are included. This manual shall help the user to ease the secure and proper transportation, installation, start-up and maintenance of the explosion-protected electric machine. The compliance of this manual and the conditions and methods for installation, operation, usage and maintenance of the electric motor can not be controlled by the manufacturer. An incorrect installation can result in damage to property and thus can lead to risks for persons. Therefore we do not assume responsibil-ity and warranty for losses, damages or costs resulting directly or indirectly from incorrect installation, faulty operation or usage and maintenance. Technical drawings and pictures are simplified illustrations. Due to improvements and changes it might hap-pen that they do not correspond in detail with the supplied electric machine. Our policy is one of constant product improvement. Therefore we reserve the right to change the product, technical data or installation, operating and maintenance instructions without prior notice. Designs, technical data and illustrations are not binding until confirmed in writing by the supplier’s works. Symbols In this manual three symbols will be used, that indicate important passages:

Security and warranty advices, possible damage to persons included.

Warning against electric voltage, danger of life. Advice that damages to the electrical machine and/or the auxiliary devices can happen.

Additional advice for electrical Ex-motors of Group II of category 2 (zone 1, 21) or Group II of category 3 (zone 2, 22).

Security regulations The security regulations, accident prevention regulations, standards and approved rules of technique must be observed unconditionally! The non-observance of the security advices can result in endangering people and/or damaging of the ma-chine. Operation according to regulations This manual is valid for explosion-protected, surface-cooled, low voltage electric machines. The type of pro-tection according to IEC/EN 60034, part 5 is at least IP 54 for motors for operation in zones 1 and 2, at least IP 55 for operation in zone 22 and IP 65 for operation in zones 21 and 22 with conducting dust. For combinations always the highest required type of protection has to be used. The type of protection is always declared on the name plate of the motor. In areas with risk of explosion only electric motors with the permitted type of protection may be used.

Electric machines of Group II, category 2 (assigned to zones 1, 21) or Group II, category 3 (assigned to zones: 2, 22)

Other or different operations are not classified in accordance to the regulations. For damages and operational disturbances that results from faults at installation, ignorance of this manual or improper repair no warranty can be claimed. Areas with risk of explosions Which areas outdoors or indoors have to be considered at risk of explosion according to the relevant rules and regulations must be left at the responsibility of the operator or the supervisory authority if there is any doubt about the localisation of areas with risk of explosion. The responsibilities for the operator of such plants are described in the regulation 99/92/EG – ATEX 153 (former ATEX 118a and 137), occupational health and safety regulation. The directive 94/9/EG – ATEX 114 (former ATEX 100a and 95) contains the fundamentals for explosion-protected products.


Edition 02.2016 VEM-Ident-No. 50229 01 3

The requirements for products for operation in areas with risk of explosion are determined in this directive. They will be supported by corresponding regulations (see below). Explosion-protected electrical machines, that will be covered by this manual, have been designed according to the regulations of series IEC/EN 60034 (VDE 0530), IEC/EN 60079-0, IEC/EN 61241-0 and the regulation for the corresponding type of protection IEC/EN 60079-7, IEC/EN 60079-15, IEC/EN 61241-1 or IEC/EN 60079-31. They shall only be put into operation according to the measures of the appropriate supervisory authority.

Type of protection, temperature class and characteristics have to be taken from the name plate of the motor.

- Group II, category 2 (assigned zones: 1, 21) In this category electrical machines of type of protection „increased safety“„e“ and „flame-proof enclosure” „d“ can be found. In addition electrical machines for operation in areas with combustible dusts and type of pro-tection - protection by enclosure “tc” are included in this group. - Group II, category 3 (assigned zones: 2, 22) In this category electrical machines with type of protection “n” and electrical machines for operation in areas with combustible dusts and type of protection - protection by enclosure “tb” can be found.

If the certification number includes the letter X, special requirements have to be observed that are listed in the corresponding type examination certificate.

Characterisation of explosion-protected motors QS certificiation with NB 0637 … IBExU Freiberg

Designation acc. to directive 94/9/EC

Designation acc. to Designation acc. to

EU No. NB

Group/ category/ G (gas) or D (dust)

IEC 60079-0:2004/EN 60079-0:2006 and/or

IEC 61241-0:2004/EN 61241-0:2006, IEC 60079-0:2007/EN 60079-0:2009

0637 II 2G Ex e II T1/T2, T3 or T4 Ex e IIC T1/T2, T3 or T4 Gb

II 3G Ex nA II T2, T3 or T4 Ex nA IIC T2, T3 or T4 Gc

0637 II 2D Ex tD A21 IP65 T125°C Ex tb IIIC T125°C Db

II 3D Ex tD A22 IP55 T125°C (IP 65 combustible dust)

Ex tc IIIB T125°C Dc (Ex tc IIIC T125°C Dc, combustible dust)

0637 II 2G

II 2D

Ex e II T2, T3 or T4 Ex tD A21 IP65 T125°C

Ex e IIC T1/T2, T3 or T4 Gb Ex tb IIIC T125°C Db

0637 II 2G

II 3D

Ex e II T2, T3 or T4 Ex tD A22 IP55 T125°C (IP 65 combustible dust)

Ex e IIC T1/T2, T3 or T4 Gb Ex tc IIIB T125°C Dc (Ex tc IIIC T125°C Dc, combustible dust)

0637 II 3G

II 2D

Ex nA II T2, T3 or T4 Ex tD A21 IP65 T125°C

Ex nA IIC T2, T3 or T4 Gc Ex tb IIIC T125°C Db

II 3G

II 3D

Ex nA II T2, T3 or T4 Ex tD A22 IP55 T125°C (IP 65 combustible dust)

Ex nA IIC T2, T3 or T4Gc Ex tc IIIB T125°C Dc (Ex tc IIIC T125°C Dc, combustible dust)

[When indicating a maximum surface temperature: for zone 2 (gas): total surface including rotor and wind-ings; for zone 21,22 (dust): outer surface (enclosure, shaft)!]


Edition 02.2016 VEM-Ident-No. 50229 01 5

Efficiency classes The specification of the efficiency class (IE class) according to IEC/EN 60034-30 is allowed for explosion protected motors. Indicated are IE class and rated efficiency. The determination of the motor efficiency is done with direct measurement complying with IEC/EN 60034-2-1 for motors up to 1 kW (chapter 8.1.1) and with the summation of losses method and determination of residual losses for motors > 1kW (chapter 8.2.2.5.1). The type designation is extended with a prefix (example IE3-K11R 132 M2…).

Installation and electrical connection At installation and start of operation the security advices that are enclosed with the motor have to be ob-served. Installation work shall only be done by qualified personnel who is skilled because of a technical edu-cation, expertise and schooling of knowledge about

security regulations, accident prevention regulations, standards and approved rules of technique

(for example VDE-regulations, standards).

The qualified personnel must have the ability to assess the assigned job, identify possible dangers and avoid them. The qualified personnel must be authorized by the person in charge for security of the plant to carry out the necessary work and tasks. In Germany the construction of electrical systems in areas with risk of explosion is liable to the following reg-ulations:

BetrSichV ”Operational Safety Act”, TRBS “Technical rules for industrial safety” GefStoffV ”Hazardous Goods Regulations” IEC/EN 60079-14 ”Explosive atmospheres - Part 14: Electrical installations design, selection

and erection”

Outside of Germany the correct national regulations have to be observed.

Non-ventilated motors without self-ventilation are cooled by free convection with rib cooling at the motor housing. Unacceptable warming is avoided by reducing the output / winding design and this is checked with type testing and certification. To ensure the selected temperature class is kept at all times, please always ensure free convection. The motor must not be encased.

Environmental effects The permissible coolant temperature (room temperature at place of installation) according to IEC/EN 60034-1 is max. 40°C/min. –20°C without labelling and the permissible altitude of site is up to 1000 m above sea level (other than the given values have to be specified on the name plate of the motor and must be certified separately if necessary).

Please make sure that the cooling air can enter and leave the air in/outlet without hindrance and without getting sucked in again. Inlet and outlet openings have to be protected against pollution and dirt particles. The direct intake of discharged air from neighbouring aggregates must be prevented by suitable measures. The minimum distance of air inlet of the fan cover against any obstacles (dimension BI) has to be observed under all circumstances.

Size Bl [mm]

63, 71 14

80, 90 16

100, 112 20

132, 160, 180, 200 40

225, 250 90

280 … 315 100

355 110



6

It must be prohibited that foreign particles and liquids can fall into the fan of motors with vertical shaft orienta-tion. This shall be done as follows: Shaft end directed downwards: The protection cover of the fan is equipped with a protective roof (supplied condition). Shaft end directed upwards: For type of constructions with shaft end upwards the operator has to ensure that no foreign substances can fall inside from above. For shaft ends directed upwards it must be prohibited that water or other liquids can penetrate into the motor next to the shaft. During installation of surface cooled motors it has to be observed that the condensate drain holes are locat-ed at the lowest possible place. If the condensate drain holes are closed, the screws must be reinserted with a sealant after drainage of condensation water. If the condensate drain holes are open, the direct contact with a jet or gush of water must be avoided. A careful installation of the motors on an exactly level support has to be ensured to avoid strain when tightening the machine. Machines that shall be coupled must be ad-justed exactly. If possible elastic couplings shall be used. Motor connection The connection has to be done by qualified personnel according to the valid security regulations. Outside of Germany the required national standards must be applied. Name plate designations have to be observed under all circumstances! Compare current type, mains voltage and frequency!

Mind connection type! Mind rated current for motor protection switch setting! For motors with type of protection „increased safety“„e“ the tE- time has to be observed! Connect the motor according to the connection diagram inside of the terminal box!

Earthing shall be done with the earthing clip that can be found at the enclosure or at the end shield depend-ing on the type of construction. In addition all motors are equipped with a ground conductor clamp inside of the terminal box. Unused cable glands of the terminal box have to be closed for protection against dust and humidity. For electrical connection the standard security and starting instructions are valid. The cable glands or screwed sealing plugs must be admitted for use in Ex-applications. The installation torques, sealing areas and clamp ranges of the cable clamps given by the manufacturer have to be observed unconditionally. Supply cables have to be selected according to DIN VDE 0100 taking into account rated current and opera-tional conditions (i.e. ambient temperature, method of cable installation etc. complying with DIN VDE 0298 and IEC / EN 60204-1).

For room temperatures of more than 40°C cables have to be used, that are allowed for an operation of at least 90°C. This is also valid for motors that are marked with X on the supplemental sheet of the EC-type examination certificate which indicates special requirements for the cable design.

Take extra care when connecting the supply cables in the terminal box of the motor. The nuts of the connec-tion screws have to be fastened without force. For motors with a terminal board fitted with slotted bolts according to directive 94/9/EC only cable lugs com-plying with DIN 46295 shall be used. The cable lugs are fixed with pressure nuts with integrated spring washer. Alternatively a solid round wire can be used. The diameter of the wire must be suitable for the slot width of the slotted bolt. When inserting the feed line in the terminal box it has to be secured that no tensile loading acts on the cables. The inside of the terminal box must be kept clean. The seals must be undamaged and have to be fitting. The terminal box must always be closed when the motor is in operation. Attention, do not open terminal boxes in atmospheres with risk of dust explosions when they are still

hot from operation!

On order type AK 16/5 can be delivered as additional separate terminal box for motors (IE.-)KPR/KPER 56 - 132S..T. The installer must have the permission to install electric equipment in areas with risks of explosions and must implement the motor connection diagrams. The creepage distances and air gaps are kept by pre-assembly of the terminal board (connection plate) and the block for connecting PTC thermistors or anti con-densation heating. The type of protection IP55(66) is kept by using a closed base plate with 4 x M4 threads and dimensions 56 x 56, as well as the included seals and standard parts.



7

Terminal box overview Terminal

Terminal board I B max Q Bmin Q Bmax

Terminal type Connecting a

box type [A] [mm2] [mm

2] thread [mm]

KA 05-13 KB 5580 27,5 2,5 U-clamp terminal M4

25 A KB 3Ex (KS 10A) 53 6 10 slot terminal S10 x 1 4,3 ± 0,1

63 A KB 4Ex (KS 14A) 72 10 16 slot terminal S14 x1,25 6,3 ± 0,2

100 A KB 4Ex (KS 14A) 72 10 16 slot terminal S14 x1,25 6,3 ± 0,2

200 A KB 5Ex (KS 18A) 118 25 35 slot terminal S18 x 1,5 9,2 ± 0,2

25 AV KL 155 30 4 U-clamp terminal M5 -

25 AV KB 5590Ex/d 5,2 35 4 U-clamp terminal M5 -

63 AV KB 5121Ex-3 58,5 10 U-clamp terminal M5 -

100 AV KB 5121Ex-3 58,5 10 U-clamp terminal M5 -

100 AV KB 5130Ex 114 35 U-clamp terminal M6 -

200 AV KB 5130Ex 114 35 U-clamp terminal M6 -

100/63 AV KM 8/6, VEM 8/6 63 10 Stud/U-clamp terminal *)

M6/M5 -

200 A-SB KM 10/8, VEM 10/8 100 70 Stud/saddle terminal

M8/2xM6 -

200 A-SB KB 5130 Ex 118 35 U-clamp terminal M6 -

400 A KM 10/8, VEM 10/8 100

70 Stud/saddle

terminal M8/2xM6 -

KM 16/12, VEM 16/12 250 120 M12/ 2xM10

400 AV KM 10/8, VEM 10/8 100 70 Stud/saddle terminal

M8/ 2xM6 -

400 A-SB KM 10/8, VEM 10/8 100

70 Bolzen/

Laschenklemme

M8/ 2xM6

KM 16/12, VEM 16/12 250 120 M12/2xM10

630 A VEM KLP 630-16 455 35 300 Stud/screw ter-minal

M16/M12/M8

-

K1X 200 A KM 10/8, VEM 10/8 100 70 Stud/saddle terminal

M8/ 2xM6 -


M8/ 2xM6 -


M12/ 2xM10 -


M12/ 2xM10 -

1000 A VEM KLP 1000 1000 70 2x 240 current bar M10 -

I B max max. rated current Q B max max. rated cross-section a slot width of the slotted bolt (terminal board according to DIN 22412) M Anzug max. tightening torque for connecting thread *) for single-core connection of solid conductors 6…10 mm

2, connector formed as loop

Tightening torques for connections (DIN 46200)

Thread Ø S10x1 S14x1,25 S18x1,5 M4 M5 M6 M8 M10 M12 M16 M20

Terminal board

(Motor) - - - 1,5 2,5 4 7,5 12,5 - 15 -

Terminal stud 6 10 20 1,2 1,2 3 6 10 15,5 30 52

Screw terminal 7,5 20

U-clamp terminal/

saddle terminal - - - 1,2 1,2 3 - 10 - - -

Seal for terminal box

Seal Permitted coolant temperature

Surface seal, silicon red, 3mm thick

-40°C Silicone foam Ø 8 mm white EPDM E 9566, 3 mm thick *)

EPDM, black, 3mm thick -30°C

*) only terminal box KA 05-13



8


Series (IE.-)KPER/O 63 to 132T, (IE.-)KPR/O 56 to 100 Type Type of

construction End shield Fixed bearing cover Terminal box

(IE.-)KPER/O (IE.-)KPR/O DS NS DS NS or adapter

cover

bolts/tightening torque for bolts MA

63… 56…

all

M 4 2,0 Nm

M 4 2,0 Nm

M 4 1,5 Nm

(for (IE.-) KPER/O 100

L M 5

2,0 Nm)

M 4 1,5 Nm

M 4 2,5 Nm

M 5 1,0 Nm

71… 63… 80… 71… M 5

4,0 Nm M 5

4,0 Nm 90… 80… 100 L 90… M 6

7,0 Nm M 6

7,0 Nm

100 LX,112… 100… B3

M 8 10,0 Nm

M 8 10,0 Nm

M 5 2,0 Nm

M 5 2,0 Nm

B5, B14 M 8

15,0 Nm

132 S…T -

B3, B14-FT130

M 8 10,0 Nm M 4

2,0 Nm B5, B14

M 8 15,0 Nm


Series (IE.-)K1.R 112 up to 400, (IE.-)W.1R 112 up to 315, (IE.-)W.2R 400

Thread Ø M5 M6 M8 M10 M12 M16 M20

End shield - - 25 45 75 170 275

Bearing cover 5 8 15 20 20 - -

Terminal box - 4 7,5 12,5 - 20 -

Axial shaft gasket

Seal material Permitted minimum coolant temperature

FPM 80, FKM -25°C

Silicone -30°C

Motors with type of protection „increased safety“„e“ and with outgoing cable (including the design

version with flat terminal box with separate certificate according to directive 94/9/EC) The outgoing cable is led through with 4 or 7 conductors according to the demands of the customer. If the entire terminal box is delivered and the connection is done in an Exe-protected surrounding, than the following instructions have to be observed:

1. When mounting the terminal box at least the requirements for type of protection IP54 must be fulfilled.

2. For compliance with the required clearances the terminal socket has to be fastened according to the indicated drawing of holes.

3. The inner earth conductor from the motor (green/yellow) with crimped lug has to be placed under the clamping yoke of the earth connection.

4. The outgoing cables of the motor have to be soldered into the angled lugs of the terminal socket. The correct connection U1, V1, W1 (U2, V2, W2) has to be observed.

When mounting the aggregate please take note that the motor number on the name plate agrees completely with the number on the riveted plate inside of the terminal box cover. Protective measures against unacceptable warming If there is no other information on the test certificate or on the name plate concerning duty type and toleranc-es, electrical machines are designed for continuous duty and normal, not frequently recurring starts, at which no significant warming occur. The motors shall only be operated in the duty type indicated on the name plate. If no specification of duty type is done on the name plate, the motors must only be operated in continuous duty S1.

The range A of the voltage and frequency limits of IEC/EN 60034-1 (DIN VDE 0530, part 1) – voltage 5 %,

frequency 2 %, shape of curve, mains symmetry – has to be observed, so that the warming is kept within the permissible limits. Bigger deviations from design values can result in excess warming of the electrical



9

machine to unacceptable temperatures. These deviations have to be indicated on the name plate. The motor has to be protected against unacceptable warming at starting for example with a motor protection switch. That means a current-dependent delayed protection switch according to DIN VDE 0660 or a similar device for all phases has to be installed, so that unacceptable warming is prevented. The protective device must be adjusted to the rated current. Windings in delta-connection have to be protected by connecting the release or relay in series with the phase windings. Selection and adjustment of the releases must be based on the rated value of the phase current (x0.58 rated current of the motor). If such a connection is not possible, suitable protection switches must be used, for example with phase failure control. For pole-changing motors current-dependent delayed releases or relays have to be provided for each rotational speed level that can be locked against each other.

For type of protection „increased safety“„e“ the starting will be controlled as well. Therefore the pro-tection device must switch off within the time period tE that is given for the corresponding tempera-ture class when the rotor is blocked. The requirement is fulfilled if the release time (it can be taken from the release characteristics (starting temperature 20°C) for the ratio IA/IN) is not higher than the indicated tE time.

Electrical machines of type of protection „increased safety“„e“ for heavy starting (start-up time > 1,7 x tE time) must be protected by a starting control according to the information of the certificate of conformity. They have to be certified accordingly.

Thermal motor protection by means of direct temperature monitoring of the winding is permissible if this is certified and indicated on the name plate. The protection consists of thermo couples according to DIN 44081 / 44082 that ensures explosion protection together with a tripping device with type of

protection marking II (2) G. For pole-changing motors it is necessary to have separate protection devices for each rotation speed level, that can be locked against each other.

Auxiliary devices Explosion-protected motors can be equipped with different auxiliary devices as option: Additional thermal motor protection For monitoring the stator winding temperature it is possible to have thermo couples installed in the motor (PTC thermistors, KTY or PT100). For their connection suitable auxiliary clamps for auxiliary circuits are available in the main terminal box or in additional terminal boxes. The connection is done according to the attached connection diagram. Thermal motor protection as inherent protection The use of thermal winding protection as inherent motor protection is only permissible if the operation is test-ed separately and certified by a notified body. On the name plate instead of the tE time a tA time is marked. In addition the following text will be printed on the name plate: “operation only with tested PTC tripping device

and marking II (2) G”. Anti-condensation heating The heating tapes must comply with the directive 94/9/EC. The heating power and the input supply voltage are indicated on the name plate of the motor. For their connection either in the main terminal box or in the auxiliary terminal boxes suitable clamps for auxiliary circuits are provided. The connection is done according to the attached connection diagram. The anti-condensation heating has to be switched on only after discon-nection of the motor. It shall not be switched on while the motor is in operation. Forced ventilation unit The fans must comply with the directive 94/9/EC. The forced ventilation unit is dissipating the lost heat at operation of the main motor. During operation of the main motor the motor of the forced ventilation unit has to be switched on. After disconnection of the main motor the forced ventilation has to continue depending on the temperature. For motors with forced ventilation units that are dependent of the sense of rotation, the sense of rotation has to be observed unconditionally (see rotation mark). Only manufacturer approved forced ventilation units shall be used. The forced ventilation unit has to be connected according to the connection diagram that is supplied inside of the terminal box. Special design for terminal box on N-side The terminal box for this special design is located on N-side of the motor before the fan cover. To realise this design the stator housing was turned during production. Special marking for type designation: KNS… for sizes 56 to 132..T (VEM motors Thurm GmbH)



10

KN … for sizes 112 to 400 (VEM motors GmbH) For motors of category 2 a special approval is necessary. Fitting with RFID transponder (Memory motor) As option it is possible to equip the motor with an RFID transponder (TAG). This feature is called memory motor, marked with “MM” according to factory standard EW-N 1002, page 13. The transponder D14-TAGspecial ATEX (RFID System iID®2000, 13.56 MHz based on ISO 15693.is used.

Reading out the data must only be done by using a reader approved according to directive 94/9 EC.

External heat and cooling sources No extra measures will be necessary for existing external heat and cooling sources, if the temperatures at the installation site are not exceeded. If the temperatures are exceeded or impacts on operational tempera-tures or maximum surface temperatures can be expected provisions will have to be made to maintain and confirm explosion protection. If in doubt please contact the manufacturer. Maintenance and repair In Germany maintenance, repair and changes of explosion-protected machines have to be done taking the workplace safety ordinance (BetrSichV), the explosion protection ordinance (ExVO,11.GSGV), the security advices and the description of the general maintenance manual into account. Outside of Germany the required national standards must be applied. More information about testing and maintenance of electrical systems or repair and reconditioning of electric equipment can be found in IEC/EN 60079-17 and IEC/EN 60079-19. Activities that will influence the explo-sion protection such as: - repair of the stator winding and of the terminals, - repair of the ventilation system - repair of the bearings and of the sealing of dust explosion protected motors (Ex 2D, 3D) must only be done by VEM service personnel or by authorized workshops with trained personnel which is qualified for such tasks by industrial training, experience and special schooling. For dust explosion-protected motors the dust explosion protection is depending very much on the local envi-ronmental conditions. For that reason the motors have to be checked and maintained regularly.

Thick layers of dust will result in a temperature rise on the surface of the motor due to thermal insulation. Layers of dust on the motors or even the total coverage should be avoided as far as possible by suitable installation and constant maintenance.

The indicated surface temperature of the motor is only valid, if the dust layer on the motor is max. 5 mm. The securing of these conditions (dust type, maximum layer thickness and other) has to be assured. The motor shall not be opened before a suitable time has passed to reduce the inner temperatures to values that are not ignitable. If the motors have to be opened for maintenance or repair, the work has to be done in a dust-free room if possible. If this is not possible suitable measures have to be taken to prohibit that dust can col-lect inside of the enclosure. At disassembly take extra care that the sealing parts like sealing, end faces and other are not damaged. Careful and regular maintenance, inspections and revisions are necessary to detect and clear faults in time, before consequential damages will happen. As individual operating conditions can not be defined for all ap-plications the listed terms represent a general advice for undisturbed operation. Individual local conditions (degree of pollution, load, etc.) must be taken into account when adjusting these terms.

What to do? Time period Terms

First inspection After about 500 operating hours ½ year at the latest

Control of air circulation and surface of motor

Depending on local environmental pollution

Relubrication (as option) See name plate or relubrication sign

Main inspection After about 10,000 operating hours Once a year

Remove condensate water Depending on the local environmental conditions

The necessary relubrication intervals for anti-friction bearings are different to these inspection inter-vals. They have to be observed as well!



11

The motors up to size 315M are equipped as standard with anti-friction bearings with life-time lubrication. From size 315MX upwards they are equipped with relubrication devices which can be ordered for smaller motors as option. Information about bearings and relubrication can be found in the general installation, maintenance and operation manual or on the name plate or relubrication sign.

Maintenance works (without relubrication) has to be done at standstill of the motor. It has to be assured that the machine is secured against re-connection and labelled with an appro-priate sign.

In addition the security advices and accident prevention regulations of the manufacturers for the use of oils, lubricants and detergents has to be observed! Adjacent live parts have to be covered or secured! It has to be assured that the auxiliary circuits like anti-condensation heating are dead (zero potential). For design versions with condensate drain hole please observe that the drain plug screw has to be lubricated with a suitable sealant (for example Epple 28) before relocking. The work has to be marked with an additional repair sign including the following information: - date, - executive company, - if necessary type of repair, - if necessary marking of the person legally authorised in accordance with the BetrSichV.

If the operations are not done by the manufacturer, they must be approved by a person legally au-thorised in accordance with the BetrSichV. He has to issue a written confirmation or mark the ma-chine with his test mark. Outside of Germany the relevant state regulations have to be observed.

Painting and impregnation after repair or maintenance work After repainting of explosion-protected motors or after impregnation of a complete stator that has been rewinded, bigger layers of paint or resin can be found on the surface of the motors. (This can result in electrostatic charges with risk of explosion during discharge). Nearby charging processes can also result in electrostatic charge of complete surfaces or parts of the surface. There is the risk

of explosion due to discharge. Therefore the requirements according to IEC/EN 60079-0: Equipment - Gen-eral requirements, article 7.4 and TRBS 2153 must be observed under all circumstances: Limitation of the total thickness of paint or insulation layer depending on the individual explosion group:

IIA, IIB: Total layer thickness ≤ 2 mm IIC: Total layer thickness ≤ 0,2 mm

Limitation of the surface resistance of the used paint or resin to:

IIA, IIB, IIC, III surface resistance ≤ 1GΩ for motors of group II and III Breakdown voltage ≤ 4 kV for explosion group III (only dust, measured according to the method described in IEC 60243-1 for thickness of insulation material). In addition the specifications of E DIN EN 60079-32 Elec-trostatic risks, especially annex A: Basics of static electricity, annex B: Electrostatic discharges in special situations and annex C: Combustibility of materials should be observed.

Spare parts

Except for standard, commercially available and equivalent parts (like anti-friction bearings) only original spare parts (see spare parts list) shall be used; this applies especially for seals and connec-tion parts. For spare parts orders the following information is necessary:

Spare parts name Motor type Motor number

Storage For storage or use outside we recommend the use of a protection cover. A long term exposure with direct intensive solar radiation, rain, snow, ice or dust must be avoided.



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Long term storage (more than 12 months) Long term storage must be done indoors in vibration-free, dry rooms with temperatures not below -20°C and not above +40°C. The storage environment must not contain aggressive gas, vapours, dusts and salts. Pref-erably motors shall be moved and stored only in original packing. Storage and transport with motors standing on their fan covers is not allowed. Additionally unprotected metal surfaces like shaft ends and flanges must be protected with a medium for long-time corrosion protection in addition to the existing factory-provided temporary corrosion protection. If there is a risk of motors being covered by moisture from condensation, please provide precautionary measures against humidity. Than a special packing in airtight sealed plastic foil is necessary or as alternative packing in plastic foil with desiccants. Please put desiccant bags in the termi-nal box as well. For the transport please use the eye bolts/attachment eyes of the motors together with suitable lifting acces-sories. The eye bolts/attachment eyes must only be used for lifting the motors without additional mountings like foundation plates, gears and others. Motors with reinforced bearings are supplied with a transportation safety device. The transportation safety device at the shaft end must only be removed during installation of the motor and before switching on. Turn the shafts at least once a year so that false brinelling is avoided. During longer periods of storage the working life of the grease is reduced (ageing). When using open bearings it is recommended to check the condition of the grease once a year. If a pollution or oil drainage is visible, the grease must be exchanged. Closed bearings (ZZ 2RS) must be replaced after storage times > 48 months. Disposal When disposing of the motors please observe applicable national law. In addition please take care that all oil and grease is disposed according to the ordinance of waste oils (Altölverordnung). They must not be contaminated with solvents, cold cleaners and paint residues. Before recycling the individual materials must be separated. Most important components are grey cast iron (housing), steel (shaft, stator and rotor sheets, consumables), aluminium (rotor), copper (windings) and plas-tics (insulation materials like for example Polyamide, Polypropylene and others). Electronic components like printed circuit boards (inverter, encoder, etc.) must be recycled separately. Terminal board connections

In standard design surface cooled motors are adapted for both rotational directions. The types K12R 355/2-pole and low-noise motors marked with a „G“ after the pole number are an exception. They are equipped with a fan dependent on the direction of rotation. If such fans or return stops (zone 22) are used a sign for sense of rotation has to be fixed on the fan cover.

The connections U1, V1, W1 at phases L1, L2, L3 (in alphabetical or natural order) result always in clockwise rotation. The sense of rotation can be reversed at direct starting if two main connections at the terminal board are changed. For a machine with only one shaft end or with two shaft ends that have different diameters, the sense of rotation is that rotational direction which is seen, if a person looks at the front end of the only or thicker shaft end.

For each motor the correct connection diagram is attached. The connection must be done accordingly. For the connection of auxiliary circuits please see the additional connection dia-gram, which is also attached.

Hints for screwed cable glands that are admitted for explosion protection The terminal boxes are designed as standard with metric threaded holes according to EN 50262 or on re-quest with NPT-threaded holes according to ANSI B1.20.1-1983. At delivery the holes are closed with plugs or ATEX-certified cable glands. For connection of the motor only use cable entries and plugs that are designed according to directive 94/9/EC (ATEX) and have at least IP 55 type of protection. For motors in type of protection “flameproof enclosure” „tD“ (IP 6X necessary!) the cable entries and plugs must be designed according to directive 94/9/EC (ATEX) and have at least IP 65 type of protection.

All unused cable entry points must be closed with plugs according to the minimum type of protec-tion listed in directive 94/9/EC (ATEX). Existing plugs must be checked accordingly and if neces-sary they have to be changed.

The specification of thread type is given on the equipment (name plate or terminal box). Alternatively the instruction about cable entry thread, number and position of cable entries can be given in the dimensional



13

drawing of the motor. For explosion protected VEM-motors cable glands of the company Jacob are used, if not ordered otherwise. The following specifications must be observed for these special cable glands: Ex-brass screw connection, metric thread, EC declaration of conformity DMT 99 ATEX E 016

Thread Part-No. For cable diameter Width across flats Installation torque mm mm Nm

M 12,x1,5 50.612 M/EX 3...6 14 5

M 12x1,5 50.612 M1/EX 3...6,5 14 5

M 16x1,5 50.616 M/EX 5...9 17 5

M 20x1,5 50.620 M1/EX 6...12 22 7,5

M 20x1,5 50.620 M/EX 9...13 22 7,5

M 25x1,5 50.625 M/EX 11...16 27 10

M 32x1,5 50.632 M/EX 14...21 34 15

M 40x1,5 50.640 M/EX 19...27 43 20

M 50x1,5 50.650 M/EX 24...35 55 20

M 63x1,5 50.663 M/EX 32...42 65 20

M 63x1,5 50.663 M1/EX 40...48 65 20

M 75x1,5 *) HAWKE International 54,5...65,3 95 20

M 80x1,5 *) HAWKE International 67...73 106,4 20

M 90x1,5 *) HAWKE International 67 … 77,6 115 20

M 100x1,5 *) HAWKE International 75 … 91,6 127 20 *) Baseefa06ATEX0056X or IEC BAS 06.0013X.

Ex-EMC-brass screw connection, metric thread EC declaration of conformity DMT 99 ATEX E 016

Thread Part-No. For cable diameter Width across flats Installation torque mm mm Nm

M 12x1,5 50.612 M/EMV/EX 3...6 14 5

M 12x1,5 50.612 M1/EMV/EX 3...6,5 14 5

M 16x1,5 50.616 M/EMV/EX 5...9 17 5

M 20x1,5 50.620 M1/EMV/EX 6...12 22 7,5

M 20x1,5 50.620 M/EMVEX 9...13 22 7,5

M 25x1,5 50.625 M/EMV/EX 11...16 27 10

M 32x1,5 50.632 M/EMV/EX 14...21 34 15

M 40x1,5 50.640 M/EMV/EX 19...27 43 20

M 50x1,5 50.650 M/EMV/EX 24...35 55 20

M 63x1,5 50.663 M/EMV/EX 32...42 65 20

M 63x1,5 50.663 M1/EMV/EX 40...48 65 20

M 75x1,5 *) HAWKE International 54,5...65,3 95 20

M 80x1,5 *) HAWKE International 67...73 106,4 20

M 90x1,5 *) HAWKE International 67 … 77,6 115 20

M 100x1,5 *) HAWKE International 75 … 91,6 127 20 *) Baseefa06ATEX0056X or IEC BAS 06.0013X.

If screwed cable glands or plugs according to directive 94/9/EC (ATEX) from other manufacturers are used please observe the corresponding manufacturers information.



14



15



16

VEM motors GmbH

Carl-Friedrich-Gauß-Straße 1 D-38855 Wernigerode phone: +49-(0)39 43-68-0 fax: +49-(0)39 43-68-21 20

email: [email protected] internet: www.vem-group.com VEM motors Thurm GmbH

Äußere Dresdner Strasse 35 D-08066 Zwickau phone: +49-(0)375-427-0 fax: +49-(0)375-427-383

email: [email protected] internet: www.vem-group.com

Safety regulations for electrical equipments in low-voltage power installations (2014/35/EU)

1. General endangerings These safety regulations are valid in connection with the operating and maintenance instructions of the product and they are to be observed strictly. Electrical machines are equipped with hazardous live parts and rotating parts. Therefore, severest personal and physical damages can be caused through non-intended use, because of faulty operation, through imperfect maintenance and because of non-permissible disassembly of protective devices. It is to be guaranteed that only qualified persons (definition for skilled persons see EN 50110-1DIN VDE 0105 or IEC 60364) will be engaged to realize any work at the equipments (such as design, transport, assembly, installation, commissioning, maintenance, repair, disassembly), though it should be noted that the documents for the mounting, the commisioning, the operation, the maintenance and the repair of the equipment are available and that they are to be observed.

2. Intended use The machines are intended for industrial power installations. The conditions on the site have to coincide with all the data given on the rating plate. In particular the indicated degree of protection is to be realized by the driven machine. Corresponding details are part of the DIN EN 60034-1 / DIN VDE 0530 T.1.

3. Transport, storage

The ring bolts or shackles of the equipments are exclusively intended for transporting the equipments. Additional parts or loads must never be attached. Before the commissioning, existing transport lockings are to be removed. Electrical equipments with recognizable damages must never be put into operation.

4. Mounting of the equipment When mounting the electrical equipment there is to be observed that the informations about the technical data and operating conditions (such as determined in the documents being part of the equipment), the general safety and mounting regulations and the specific regulations of the installation and of the operation are followed. In case of types of construction with the shaft end upwards, there must be taken measures preventing that foreign matters can fall into the ventilation system. For ensuring the unhindered ventilation of the machine, there are to be followed the informations given by part of the manufacturer.

5. Electric connection The connection is to be realized only by qualified skilled persons and in released state being protected against re-starting. All the data being necessary for that are to be taken from the operating and maintenance instructions delivered with the equipment. Before re-starting the installation for the first time, there is to be checked if the electrical equipment is running in the required direction of rotation. When exceeding the tolerances according to DIN

VDE 0530 part 1 / DIN EN 60034-1 (for voltage 5 %, for frequency 2 %) and when deviating from the waveform and the symmetry, the temperature can possibly rise and the electromagnetic compatibility can be impaired.

6. Operation The maintenance measures specified in the operating and maintenance instructions are to be carried out by a qualified personnel in regular periods. The reasons for every variation in view of the normal operation, in particular the reasons for modified noise, for modified temperatures and for the reaction of protective devices are to be determined and eliminated by qualified personnel. If there's any doubt, the equipment is to be switched-off immediately.

7. Important information Because of the great variety of the operating conditions and for the clear understanding of the operating and maintenance instructions, it is only the general case of application which can be considered in this operating and maintenance manual. For special cases (such as exceptional enviromental conditions or special safety instructions) it is necessary to come to an agreement with the manufacturer or with the selling company.

8. Warranty The warranty requires the observance of the safety regulations and of the operating and maintenance instructions as well as the intended use. In case of further questions, requirements and instructions please contact us indicating the type of motor and the number of motor.

VEM motors GmbH, Carl-Friedrich-Gauss-Str. 1, D 38855 Wernigerode The Safety Regulations and the Operating Instruction must be kept in a safe place. ID-Nr. 59693 01/03.2016

BFP ATEX-3GD

12.4 RMA - Decontamination statement


RMA-Nr./ RMA-No.Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMAnumber from your sales or service representative.

Firma/ Company

Firma/ CompanyStraße/ StreetPLZ, Ort/ Zip, CityLand/ Country

Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor,dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen. Bitte füllen Sieauch diese im Sinne der Gesundheit unserer Mitarbeiter vollständig aus./ This return form includes a decontaminationstatement. The law requires you to submit this completed and signed decontamination statement to us. Please com-plete the entire form, also in the interest of our employee health.

Ansprechpartner/ Person in charge

Name/ Name Abt./ Dept. Tel./ Phone E-Mail

Gerät/ DeviceAnzahl/ QuantityAuftragsnr./ Order No.

Serien-Nr./ Serial No.Artikel-Nr./ Item No.

Grund der Rücksendung/ Reason for return

Kalibrierung/ Calibration Modifikation/ ModificationReklamation/ Claim Reparatur/ Repairandere/ other

bitte spezifizieren/ please specify

Ist das Gerät möglicherweise kontaminiert?/ Could the equipment be contaminated?

Nein, da das Gerät nicht mit gesundheitsgefährdenden Stoffen betrieben wurde./ No, because the device was not operated withhazardous substances.

Nein, da das Gerät ordnungsgemäß gereinigt und dekontaminiert wurde./ No, because the device has been properly cleaned anddecontaminated.

Ja, kontaminiert mit:/ Yes, contaminated with:

explosiv/ explosive

entzündlich/ flammable

brandfördernd/ oxidizing

komprimierteGase/

compressedgases

ätzend/ caustic

giftig,Lebensgefahr/poisonous, risk

of death

gesundheitsge-fährdend/ harmful to

health

gesund-heitsschädlich/ health hazard

umweltge-fährdend/

environmentalhazard

Bitte Sicherheitsdatenblatt beilegen!/ Please enclose safety data sheet!

Das Gerät wurde gespült mit:/ The equipment was purged with:

Diese Erklärung wurde korrekt und vollständig ausgefüllt und von einerdazu befugten Person unterschrieben. Der Versand der (dekontaminier-ten) Geräte und Komponenten erfolgt gemäß den gesetzlichen Bestim-mungen.

This declaration has been filled out correctly and completely, and signed byan authorized person. The dispatch of the (decontaminated) devices andcomponents takes place according to the legal regulations.

Datum/ Date

rechtsverbindliche Unterschrift/ Legally binding signature

Falls die Ware nicht gereinigt, also kontaminiert bei uns eintrifft, muss dieFirma Bühler sich vorbehalten, diese durch einen externen Dienstleisterreinigen zu lassen und Ihnen dies in Rechnung zu stellen.

Should the goods not arrive clean, but contaminated, Bühler reserves theright, to comission an external service provider to clean the goods and in-voice it to your account.

Firmenstempel/ Company Sign

DE00001101/2019

RMA-Formular und Erklärung über DekontaminierungRMA-Form and explanation for decontamination



Dekontaminierungserklärung

Die Analyse defekter Baugruppen ist ein wesentlicher Bestandteil der Qualitätssicherung der FirmaBühler Technologies.

Um eine aussagekräftige Analyse zu gewährleisten muss die Ware möglichst unverändert untersuchtwerden. Es dürfen keine Veränderungen oder weitere Beschädigungen auftreten, die Ursachen ver-decken oder eine Analyse unmöglich machen.

Bei elektronischen Baugruppen kann es sich um elektrostatisch sensible Baugruppen handeln. Es istdarauf zu achten, diese Baugruppen ESD-gerecht zu behandeln. Nach Möglichkeit sollten die Baugrup-pen an einem ESD-gerechten Arbeitsplatz getauscht werden. Ist dies nicht möglich sollten ESD-gerechte Maßnahmen beim Austausch getroffen werden. Der Transport darf nur in ESD-gerechten Be-hältnissen durchgeführt werden. Die Verpackung der Baugruppen muss ESD-konform sein. VerwendenSie nach Möglichkeit die Verpackung des Ersatzteils oder wählen Sie selber eine ESD-gerechte Ver-packung.

Beachten Sie beim Einbau des Ersatzteils die gleichen Vorgaben wie oben beschrieben. Achten Sie aufdie ordnungsgemäße Montage des Bauteils und aller Komponenten. Versetzen Sie vor der Inbetrieb-nahme die Verkabelung wieder in den ursprünglichen Zustand. Fragen Sie im Zweifel beim Herstellernach weiteren Informationen.

Analysing defective assemblies is an essential part of quality assurance at Bühler Technologies.

To ensure conclusive analysis the goods must be inspected unaltered, if possible. Modifications orother damages which may hide the cause or render it impossible to analyse are prohibited.

Electronic assemblies may be sensitive to static electricity. Be sure to handle these assemblies in anESD-safe manner. Where possible, the assembles should be replaced in an ESD-safe location. If un-able to do so, take ESD-safe precautions when replacing these. Must be transported in ESD-safe con-tainers. The packaging of the assemblies must be ESD-safe. If possible, use the packaging of the sparepart or use ESD-safe packaging.

Observe the above specifications when installing the spare part. Ensure the part and all componentsare properly installed. Return the cables to the original state before putting into service. When in doubt,contact the manufacturer for additional information.

DE00001101/2019



be370007 bfp atex-3gd - buehler technologies...fluidcontrol installation and operation instructions...

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