ATB CD Series User manual

IBA01.05-E
Explosion-Proof
F&G Three-Phase-Motors
II2G EEx d(e) IIC(B) T3-6
II2D T80–120°C IP 65(66)
MOTORENTECHNIK GMB
H
under license of
Operating Manual

I
Any and all brands and product names herein are trademarks or registered
trademarks of the relevant holders.
1. 2001 Edition, Date of Publication 02/ 01
2. 2002 Edition, Date of Publication 03/ 02
3. 2003 Edition, Date of Publication 06/ 03
4. 2004 Edition, Date of Publication 04/ 04
5. 2005 Edition, Date of Publication 02/ 05
© ATB Motorentechnik GmbH, Nordenham
Author: Wolfgang Sobel
All rights on this manual and its translation reserved.
No part of this manual can be reproduced in any form whatsoever (print,
photocopy, microfilm or any other means) or processed electronically without
the prior written permission of the ATB Motorentechnik GmbH Company,
Nordenham
All changes reserved.
Printed on paper chlorine-free and acid-free bleached cellulose.

I
Warning!
Hazardous electrical current!
Ensure protection against
explosions!
Before installing
Switch off the power to the device.
Make sure that device cannot be
switched on again by accident.
Make sure that the device is de-
energized.
Connect to earth and short out.
Cover or close off any neighboring live
parts with a barrier.
Follow carefully the assembly
instructions provided for the device.
Only qualified personnel as per EN
50110-1/-2 (VDE 0105, part 100) can
perform any work on this
device/system.
The electrical connections are to be
made as per the relevant specifications
(e.g. cross-section of the supply line,
fuses, protective connection).
Opening the motor - save for the
terminal box - during the warranty
period without the manufacturer's
permission shall lead to the termination
of the warranty.
Original spare parts are to be used for
the approved repairs or repairs not
falling under the warranty.
Live and rotating parts of electrical
motors can cause major or deadly
injuries.
Any shipping, installation, start-up and
maintenance works are to be carried
out only by qualified personnel (follow
carefully any regulations on explosion
protection such as EN 60079-14 and
SeitenEN 50821-1-2 as well as any
other national accident prevention
regulations).
As regards any equipment subject to
these guidelines, it is important to adopt
the necessary safety precautions to
protect the personnel against possible
injuries.
The personnel must be duly instructed
to proceed with caution and according
to regulations during shipping, hoisting,
and positioning and while repairing the
motor.
Do not lift the motor together with the
drive equipment by the motor lifting
eyebolts.
Do not use the supplied lifting eye bolts
at ambient temperatures below –20°C,
in accordance with DIN 580. Lower
temperatures could lead to the ring
screws breaking and consequent
breaking and consequent injury to
personnel and/ or damage to the
installation.
Do not load the eyebolts as per DIN
580 no more than 45° compared to the
screwing direction. The use of
crossbeams is recommended. See the
operating instructions for the layout
dimensions of the lifting eyebolts and
the minimum dimensions of the loading
crossbeams and chain lengths.
In the case of motors with built-in brake
appropriate safety measures are to be
adopted against the possible failure of
the brake especially in applications
involving the pulling of loads.
Operating the motor with the supplied
shaft protection cover alone is
forbidden.
Contact with the capacitor for the start-
up and running of single-phase motors
is to be avoided until the unloading
procedure is carried out securely.
If a high-voltage test is necessary, the
procedures and precautionary
measures set forth in accident
prevention regulations are to be
followed.

2
Table of Contents
About this Manual
Target audience
Abbreviations and symbols
4
4
4
1 Explosion-protected Motors 6
Intended use 6
Liability and Warranty Guarantee 6
Servicing
- Spare Parts
7
7
Delivery, Storage, Transport
- Delivery
- Storage
- Transport
7
7
8
8
2 Installation 10
Mechanical checks 10
Site 10
Mounting 12
Mains supply and connections
- Mains connection of explosion-protected motors
- Motors with direct line lead-in
- Terminal box
- Cable and line lead-ins
- Motors with terminal boxes whose mains lead is located in
the layer separating the upper and lower parts
- Mains and guard circuit connection
- Motors with unidirectional fan
- Motors with separate cooling via separately powered
external fans
- Motors with temperature monitoring
- Motors with space heater
- Motors for operating on frequency converters
- Motors with built-in frequency converter (compact drive)
- Motors with brake
- Motors with brake or tachometer mounted under the
ventilator hood
- Motors with water cooling
Connection diagrams
- Brake motors with incorporated brake
15
16
16
16
19
20
21
25
25
25
26
26
29
37
37
38
39
40

3
3 Operation and Repairs 39
Duty types and thermal protection
Special operating conditions
Motors with backstop
Heat input through the driven machine
Start-up
Maintenance
- Inspection
- Lubrication
Explosion protection
- Instructions for ensuring explosion protection during
operation
Repairs
42
42
43
43
43
43
45
45
47
47
48
4 Additional dust protection requirements
(application in zone 21 and 22)
49
Intended use
Installation and Operation
-Cable and line lead-ins
-Operation and Repairs
49
49
49
49

4
About this Manual
These operating instructions apply to AC motors of the following series:
CD...; dCD...; CEIGL...; BD... and dBD....
Besides the general assembly instructions, these guidelines are to be
followed for the installation, start-up and maintenance of explosion-protected
AC motors with a degree of protection of "pressure-resistant encapsulation"
marked: (II..), EEx de II. T or EEx d II. T.
Any independent manufacturing equipment mounted on or built into the
motors like brakes, rotary encoders or frequency converters, etc. have their
own operating instructions which are to be duly followed.
Target audience
This manual is addressed to the specialists in charge of installing, operating
and servicing the motors. Besides conventional technical training they must
possess knowledge in the field of explosion protection.
Abbreviations and symbols
This manual uses abbreviations and symbols having the following meanings:
>indicates handling instructions
Îdraws your attention to interesting tips and
additional information
Please note!
warns against minor damages to property.
Caution!
warns against major damages to property and
minor injuries.

5
Warning!
warns against major damages to property and
major injuries or death.
All of the dimensions are in mm unless otherwise specified.
In order to ensure clarity, at the top of every page you will find the name of
the chapter on the left hand and the current section on the right hand; the
only exceptions are the first page of each chapter and the blank pages at the
end of the chapter.

6
1 Explosion-protected Motors
Intended use
The motors are to be operated only according to the data specified on the
rating plate. According to the relevant marking on the rating plate, the motors
are fit for use in areas subject to explosion hazards.
The motors are fit to be built into another machine. Start-up is forbidden until
the conformity of the final product with Directive 89/392/EEC as amended by
98/37/EC is determined.
Liability and Warranty Guarantee
We cannot be held liable for any damage or malfunctions resulting from
assembly errors, the failure to follow these operating instructions or improper
repairs.
Original spare parts are manufactured and tested specifically for these
motors.
We recommend that you obtain any spare parts and accessories only from
the manufacturer.
We hereby specify that any spare parts and accessories not supplied by the
manufacturer require our approval.
Under any circumstances the mounting and use of third-party products can
negatively affect the motor's original structural properties and impair the
safety for persons, the motor or other real values (explosion protection).
The manufacturer shall not be liable for any damages resulting from the use
of spare parts or accessories not authorized by the manufacturer.
Any unauthorized conversions and alterations to the motor shall not be
approved for safety reasons and the manufacturer cannot be held liable for
any resulting damages.

7
Servicing
For any technical information on F&G motors ATB’s customer service is
always at your disposal.
Should any difficulties with our motors be encountered, please contact our
factory or local branch office. Log on to our website to find at the address of
our local branch office nearest your.
ATB Motorentechnik
Helgoländer Damm 75
D-26954 Nordenham
Tel.: [phone]
Fax.: [phone]
E-Mail: [e-mail]
Internet: www.atb-nordenham.de
Spare parts
When ordering spare parts, besides the name of the required part, specify
also the motor type and serial number.
Delivery, Storage, Transport
Delivery
>Check the motor for damages during transportation.
In case of damage during transportation an investigation of fault is to be
performed by the forwarding agent.
>Report any covert damages to the forwarding agent or manufacturer no
later than seven days from the transfer of the motor.
The entire packaging material can be recycled by means of the Dual
System.

8
Storage
Storage up to a maximum of 36 months is possible in the following
conditions:
• In order to prevent a drop in the insulation resistance, the surrounding
environment must be dry and dust-free.
• The room temperatures should not drop below +5 °C or exceed +30 °C
with an air humidity of < 70 % and register changes in temperature greater
than 10 °C/day.
• In order to prevent damage during storage any occurring oscillations must
amount to Veff < 0.2 mm/s.
• For motors with regreasing systems repress an amount of grease double
that specified on the motor at standstill before storage.
Please note!
In case of storage conditions deviating from those specified
above the measures set forth in the separate AR9 storage
instructions must be adopted.
Transport
Do not lift the motor together with mounted driven machines such as, for
instance, pumps, gearing, etc. by the motor lifting eyebolts.
Do not use eyebolts as per DIN 580 at ambient temperatures lower than –
20 °C.
At these temperatures the eyebolts may break and hence injure the
personnel and/or damage the machinery. Do not load the eyebolts as per
DIN 580 no more than 45° compared to the screwing direction. The use of
crossbeams is recommended. Layout dimensions of the lifting eyebolts and
the minimum dimensions of the loading crossbeams and chain lengths.
(ÎFig. 1).
Please note!
When mounting vertical motors from the horizontal position,
the shaft must not touch the floor to avoid damaging the
bearings.

9
Figure 1: Eyebolt dimensions
Table 1: Minimum dimensions for lifting eyebolts and crossbeams
Frame size
Øt
horizontal vertical
eheh
90 20 167 100 220 187
100 20 185 112 242 201
112 20 202 103 262 236
132 25 243 170 307 247
160 30 262 206 314 293
180 30 294 223 402 372
200 35 390 219 451 399
225 40 366 230 510 490
250 40 435 282 546 548
280 40 498 301 600 574
315 50 640 337 700 595
355 60 629 397 816 893
400 60 790 312 890 771
450 60 833 317 980 660

10
2 Installation
Mechanical checks
After removing the shipping braces and shaft blocks (see also the marking
on the motor), the motor shaft must be rotated by hand. In the case of
brakemotors the brake must be vented at standstill (maximum of 10 min).
This must be performed after applying voltage as per the circuit diagram
from page 39.
Please note!
Save the shipping braces and shaft blocks for subsequent
transportation, as the bearings risk being damaged during
transportation.
Site
The completely closed motors are intended for operating sites in which they
are exposed to soiling, humidity and other open air conditions as per the
relevant degree of protection.
The motors must be installed in a place with ambient temperatures of –20 °C
to a maximum of +40 °C and a max. of 1000m above sea level. Any
permissible ambient temperatures (Ta) and heights (MSL) other than those
indicated above must be specified on the rating plate. Lower temperatures
and values not found on the rating plate require the use of space heaters.
ÎSection 3 “Operation and Repairs”
Please note!
The ventilator hood air inlet and outlet must not be obstructed,
as there is the risk of heating beyond the permissible
temperature class and of reducing the life of the winding
insulation ÎFig. 2 and ÎTable 2.
This applies in particular to the use of soundproof covers. The
air ducts must checked and cleaned regularly in factories with
heavy soiling.

11
Table 2:
Minimum distance (LE) of an obstacle from the air opening, see Fig. 2.
Shaft height LE [mm]
up to 160 35
180 to 225 85
over 250 125
Figure 2: Minimum distance of obstacles from the air opening
The motors are intended for use in areas subject to explosion hazards. The
following data on the rating plate distinguish the motor as explosion-
protected equipment:
• Degree of protection
• Explosion group
• Temperature class
Depending on the appliance category the motor is assigned to the relevant
zone of the operating site.

12
Mounting
The motors are mounted either on the motor feet or on the flange at the
installation site. All motors with shaft heights of up to 355 mm can be
mounted either horizontally or vertically thanks to their bearing layout. This
applies also for motors to be mounted with the feet on roofs and side walls.
Motors with reinforced bearings are to be operated at a minimum load to
ensure the smooth operating of the anti-friction bearings (ÎTable 3).
Table 3: Minimum load on the shaft collar for motors with reinforced bearing
Shaft
height
Minimum
load
Shaft
height
Minimum
load
Shaft
height
Minimum
load
112
1100N 200 3400N 315 8000N
132
1600N 225 3800N 355 2000N
160
1900N 250 4900N 400 2000N
180
2700N 280 5500N 450 2300N
The bearings may be damaged if the minimum load is exceeded. Trial runs
with no-load should last only a few minutes.
You can find the max. permissible loads in our catalogue "Explosion-
Protected High and Low Voltage AC Motors" or contact the manufacturer.
Align the motors according to the requirements of the coupling or pulley
manufacturer. The feet are to be positioned evenly and, if necessary, lined.
Please note!
Make sure that the fastening screws are duly dimensioned.
Data on the foundation loading generated by the motor can be requested
from the manufacturer by specifying the motor number. The fastening
screws must be duly tightened according to their layout and secured to
prevent loosening during operation and hence the damaging of the drive.
(ÎTable 4, page 17).

13
Figure 3: Motor Fastening
cLarge-surface Washer
In order to achieve an adequately large contact surface, apply a large-
surface washer under each nut or screw head
(Fig. 3).
ÎAlternatively use flange nuts or bolts.
If the motors shaft end points up or down (vertical mounting arrangement), it
is necessary to fit an appropriate cover to prevent any foreign bodies from
dropping in the driven machine through the air inlet and outlet openings in
the ventilator hood.
Please note!
The flow of cooling air through the motor must not be limited
by said cover (ÎSection "Site", page 10).
The balance of the motors is specified on the shaft end plate and/or on the
rating plate (H = half key, F = full key, N = no key).
The design of the coupling or pulley must match the motor's balance.

14
Please note!
If balancing with half key (H), work on the vertical (visible) key
components on the shaft diameter or cover these with washers
with keyway along the relevant length.
If the coupling is longer than the key, it is necessary to fill the
keyway in the remaining part of the coupling.
In case of failure to comply with the foregoing, out-of-balances
liable of causing excessive vibrations may occur.
Please note!
Mount the pulleys or couplings only through the threaded bores in
the shaft end to avoid damaging the anti-friction bearings
(ÎFig. 4).
Fig. 4: Fastening of the pulley or coupling
>Screw the threaded bolts in the threaded bore.
>Then mount the pulley or coupling on the shaft end: make sure to screw
a nut with a washer having at least the same diameter of the pulley hub
or coupling on the threaded bolt.

15
Use the utmost care in mounting dynamically balanced pulleys or couplings
on the shaft end. Machines to be connected to the motor by means of
couplings are to be aligned according to the specifications of the coupling's
manufacturer.
ÎOnly use flexible couplings!
Mains and other electrical connections
The motors work as per VDE 0530 with mains voltage oscillations of up to
±10 % or frequency oscillations of up to –5 % to +3 %. The mains ratings
must match the voltage and frequency data specified on the ratings plate.
Connect the motors according to the connection diagrams attached to the
terminal box (ÎFigure 11 page 34). Use only the supplied original
connection components, (ÎSection " Mains and guard circuit connection",
page 21).
Please note!
Carry out the motor, controller, overload protection and
earthing connection operations in compliance with local
installation requirements.
Please note!
If the accidental starting of the system may expose the
personnel to danger, do not use any automatically restarting
motor protective equipment.

16
Mains connection of explosion-protected motors
Besides any general installation regulations, follow carefully EN 60079-14
and EN 50281-1-2. Afterwards suitable overload protection is to be provided
either with a motor circuit breaker or similar protective devices. These may
include also PTC thermistors with tripping devices (ÎSection "Motors with
temperature monitoring“, page 25). These must be specified on the rating
plate together with a tripping time tA.
In addition, any "Special Requirements" specified in the test certificate are to
be complied with. These are marked with an "X" after the test certificate
number on the rating plate.
Motors with direct line lead-in
The free end of the cable inserted in the motor must be connected according
to the regulations in force concerning the connection area. If the line lead-in
used on the motor is provided with pull relief, the cable can be laid freely;
otherwise the cable must be secured with a pull relief device in the near
vicinity.
The maximum operating temperature at the line lead-in must not
exceed 90° C.
Terminal box
Open the box by loosening the screws on the cover (Fig. 5) or, in the case of
models with grub screw (Fig. 6), by turning the grub screw counter-clockwise
and then loosening the tapped cover.
Close the terminal box again after connecting the mains by following the
same instructions in the opposite order.
In order to change the position of the cable and line lead-ins, you can turn
the terminal box by 4 x90°.
>Loosen either
– the four fastening screws (ÎFig. 5 ) or
– the anti-rotation pins by means of the grub screw (ÎFig. 6 ).
>Turn the terminal box to the desired position.

17
Figure 5: Terminal box with fastening screw c
Figure 6: Terminal box with grub screw c
>Then tighten the fastening components to the relevant torque, see the
following table.
Table 4: Torque values for 8.8-type screws
Thread size
Torque
M5
6 Nm
M6 10 Nm
M8 25 Nm
M10 49 Nm
M12 85 Nm
M16 210 Nm
M20 425 Nm

18
Please note!
Terminal boxes fastened as per Fig. 6 are to be turned
counter-clockwise by a maximum of one turn away from the
thread end stop. Screwed-on covers must be duly secured.
Anti-corrosion protection can be achieved with non-hardening sealing
materials or sealing grease in particular on the processed sealing surfaces of
the covers of terminal boxes having the following degree of protection:
"pressure-resistant encapsulation, EEx d IIC(B) marking".
The approved sealing materials are:
• For threads and surfaces:
Hylomar, by Marston-Domsel or
• for surfaces:
Admosit and Fluid-D, by Teroson.
Please note!
In the case of "increased safety" terminal boxes the gaskets
used are included in the approval. Only original gaskets are
to be used.
Please note!
"Pressure-resistant encapsulation“ terminal boxes must be
sealed by means of approved cable or line lead-ins.