LAFERT ATE ZONE 2-22 User manual

BRUSHLESS SERVO MOTORS
ATE ZONE 2-22
SERVO MOTORS
OPERATING INSTRUCTIONS
3010/21 EN

BRUSHLESS SERVOMOTORS - ATEX - OPERATING INSTRUCTIONS – 3010/21 1
Read these Operating Instructions before performing any
transportation, installation, commissioning, maintenance or repair
activities on the industrial motors and generators.
The instructions contained in this manual cannot provide all the
detailed information on the possible construction variations, nor every
possible case regarding assembly, operation and maintenance.
The symbols provided below will draw attention to the safety
measures and supplementary instructions contained in these
Operating Instructions.
SPECIAL SAFETY AND WARRANTY
INSTRUCTIONS:
DANGER:
NOTE ON EXPLOSION PROTECTION
Strictly observe the safety measures and supplementary instructions
contained in these Operating Instructions, for the protection of
property and people.
Low-voltage electric machines contain dangerous rotating
and conductive parts. They may have very hot surfaces.
All the transportation, installation, commissioning,
maintenance and repair activities must be carried out by
qualified personnel and under the supervision of experts
in charge (in conformity with directives VDE 0105; IEC
364). Improper use of the mentioned machines can
cause serious damage to property and people
.
To receive further information, contact the manufacturer or an
authorised workshop immediately.
All motors and generators must be installed and used
exclusively by qualified personnel.
GENERAL INFORMATION
SCOPE
These instructions refer to three-phase servomotors powered by drives
generating alternate current, at low voltage and with external
ventilation, with protection degree up to IP65, in accordance with
standards EN 60034.
The motors comply with the requirement of industrial installations, in
accordance of DIN harmonising standards VDE0530/EN60034. It is
compulsory to follow any special instructions regarding their use.
Brushless servo motors, with external ventilation, are designed to
operate at a maximum altitude of ≤ 1000 m above sea level and at
ambient temperature between – 20°C and + 40°C. The motor shall
not be exposed to direct sun light.
Observe the information provided on the rating plate. The
operating conditions must line up with the data reported
on the rating plate.
Brushless servo motors are part of a machine, according to Directive
Machines 2006/42/EC. It is forbidden to commission the machine if
the final product does not fulfil this standard (EN 60204-1).
TRANSPORT
Any damage discovered on delivery must be immediately reported to
the delivery company. Do not commission the machine.
LIFTING EYEBOLTS
Lift the motors exclusively by the relative lifting eyebolts
provided for this purpose. Do not add loads to the motor.
The lifting eyebolts are designed to support only the
weight of the motor. Should it be necessary, use
appropriate jacks, slings and lifting beams?
INSTALLATION AND COMMISSIONING
NOTE ON EXPLOSION PROTECTION
The installation shall comply with standard 60079-14
for setting electrical machinery
MECHANICAL PARTS
TRANSMISSION ELEMENTS
Use elastic couplings only. Rigid couplings require a
special bearing design.
The use of transmission elements that cause radial or axial shaft loads
during operation (pulleys, gearwheels, etc.), requires checking
compatibility with admissible motor loads. Relevant data is contained
in the respective technical catalogue.
Rotors are dynamically balanced with half key, in conformity with
standard DIN ISO 8821.
When the motor is balanced with a half key (H), the coupling has also
to be balanced in the same way. Remove the overhanging visible part
of the key.
Remove anti-corrosion paint using specific solvent and grease the
shaft extension. Only use suitable tools to mount or pull off pulleys or
couplings, as illustrated in figure 1 (warm up if necessary) and use a
protective cover against any accidental contact. Avoid inadmissible
tension of the belts (technical catalogue). It is necessary to use the
intermediate disc to protect centring on the shaft end.
If necessary, completely balance the motor with the pinion according
to standard ISO1940.
Fig. 1 removing the pinion
The bearings must strictly not be subject to pressure or impact.
COUPLINGS
Transmission of the machine's rotating motion can be carried out
through direct coupling or through belts and gears.
Make sure the selected transmission gears can transmit
the maximum torque delivered by the motor and support
the pre-selected maximum operating speed. Sizing the
pinion must be done with an ample safety margin in mind.

BRUSHLESS SERVOMOTORS - ATEX - OPERATING INSTRUCTIONS – 3010/21 2
NOTE ON EXPLOSION PROTECTION
• When the installation is finished, IP test shall be
done. Closing the connector, use 1.8 Nm of
tightening torque.
• If there are threaded hole in the motor housing,
use M5 screw according to ISO965-1, 6g
tolerance to connect external devices and to
complete the IP protection.
• Cables or tubes connected to the motor must have
a thermal rating ≥ 90° C.
COUPLING WITH BELTS
Install the motor with the shaft perfectly parallel and aligned with the
pulley, to avoid axial thrusting on the supports.
The belt tension must be suitable to avoid sideways shifting during full
motor operation, while it must strictly not exceed the maximum
applicable load, stated in the technical catalogue. Excessive belt
tension can cause the bearings to wear quickly, and even break the
shaft.
Consult the belt supplier’s catalogue for peripheral belt speeds,
transmitted powers, ratios between pulley diameters etc. Always use
balanced pulleys.
NOTE ON EXPLOSION PROTECTION
If using belt pulleys/toothed belt pulleys use only belts
that cannot cause electrostatic charge.
PRESS-FITTING TRANSMISSION GEARS
Couplings, pinions etc. must always be pressed on according to
standard and using appropriate tools. It is strictly forbidden to use
hammers, to avoid damaging bearings and any accessories. Prior to
pressing on the transmission gear, use alcohol or specific solvent to
remove any rust-proof paint from the motor shaft and key (it is
important to avoid the solvent from leaking into the bearings).
Do not use emery cloth, scrapers or other to remove the paint. Grease
the end of the shaft and key before fitting the drive gear on and
performing assembly according to the manufacturer's instructions.
CLAMPING AND POSITIONING
Make sure the flange is attached correctly and that it adheres
correctly to the entire surface that it is fitted onto. Also check for
correct alignment in case of direct coupling.
Avoid resonance of the supporting base with rotation frequency. Turn
the rotor manually to ensure there are no anomalous noises. (see
"Vibrations during operation").
ALIGNMENT
If the motor is connected to the machine by a coupling, both axes
must be axially and radially aligned. Make sure the comparators are
securely fitted on. The measurements must be taken in four points, 90°
from each-other, turning both coupled parts simultaneously.
AXIAL OSCILLATION (FIG. 2)
The permanent margin for error must not exceed 0.03 mm, in relation
to a diameter of 200 mm.
RADIAL OSCILLATION (FIG. 3)
The remaining margin for error must not exceed 0.03 mm. The
adjustment of the axial distance between the two coupled halves («E»
dimension) must be carried out based on the manufacturer's
requirement for coupled drive gears.
Once again, make sure the machine is aligned with the
operating temperature.
COMBINED MEASUREMENT OF AXIAL AND RADIAL ALIGNMENT
(FIG. 4)
Figure 4 illustrates how to combine the two measurements in a
relatively easy way. The comparators are placed a flat iron seats,
screwed or locked in, eg. with captive screws.
Fig. 2 Fig. 3 Fig. 4
Fig. 2 Axial alignment
Fig. 3 Radial alignment
Fig. 4 Radial and axial alignment
The tolerances provided by the coupling manufacturer’s underlines
what the coupling can support, therefore, do not use these to assess
how accurate the alignment needs to be. When tolerance ranges are
too broad, this leads to vibration, causing damage to the bearing
and/or machine. It is therefore advisable to achieve the lowest
possible offsets.
The machine must be aligned with the utmost caution. Remember to
record all measurements, for future checks.
VIBRATIONS DURING OPERATION
Vibration levels Veff ≤ 2.3 mm/s is not problematic for coupled
machines. If there are any anomalies in relation to normal operation,
such as high temperatures, anomalous noises or vibrations, check the
cause and, if necessary, contact the manufacturer.
Do not disable the safety devices, not even to perform
tests. In case of doubt, switch the machine off.
ELECTRICAL PARTS
INSULATION RESISTANCE
(See "Check before commissioning")
CONNECTION DIAGRAMS: POWER AND SIGNAL
Below are the standard types of electrical power and signal
connections.
POWER CONNECTOR

BRUSHLESS SERVOMOTORS - ATEX - OPERATING INSTRUCTIONS – 3010/21 3
RESOLVER CONNECTOR
INCREMENTAL ENCODER CONNECTOR
HYPERFACE ENCODER CONNECTOR
Thermal protection can have different pinout in the
connector according to customer needs.
NOTE ON EXPLOSION PROTECTION
• Connector shall have a maximum temperature of
130°C. Wiring shall have a maximum
temperature of 90° C.
• The tolerance of the connectors thread is
according to DIN 13, class 6g – 6H.
• Do not unplug connectors while they carry
voltage, or the motor is running.
The drive shall be a sinusoidal three phases pulse with
modulation device with a bus voltage ≤ 750 VDC a
switching frequency 8 - 16 kHz, maximum rising
voltage/time in compliance with IEC60034-25 curve A
(cable length included). With different drive characteristics the motor
performances can vary.
NOTE ON EXPLOSION PROTECTION
Additional drive characteristics shall:
• correctly manage the thermal protector
• limit the common mode current
• limit the current ripple due to PWM
• limit electrical noise and vibrations by a fine
tuning of the parameters
THERMAL PROTECTION
NOTE ON EXPLOSION PROTECTION
• Motor protection is made through appropriate
thermal protection. The drive has to handle the
input sent by the thermal protection. The input can
vary depending the type of those protection.
Below a list of thermal protection used. Other
thermal protection can be used according to
customer needs.
• For full performances characteristic it's
recommended a transducer suitable for 120 °C
working temperature.
THERMAL PROTECTION DRIVE HAS TO OPEN WHEN
PTO (Normally Closed) the temperature is greater than 140°C
Normally Open the temperature is greater than 140°C
KTY83-110 (PTC) the resistance is greater than 2150 Ohm
KTY84-130 (PTC) the resistance is greater than 1216 Ohm
KTY84-150 (PTC) the resistance is greater than 1191 Ohm
SNM (PTC) the resistance is greater than 1330 Ohm
KD 335 YGM (PTC) the resistance is greater than 1330 Ohm
TF101/K (PT100) the resistance is greater than 153,58 Ohm
B57227 -K333 A1 (NTC)
the ratio between the measured resistance
value and the resistance@25°C is less than
0,17251 Ohm
AM-LPTC600 (PTC) the resistance is greater than 1262 Ohm
AM-LPTC1000 (PTC) the resistance is greater than 2124 Ohm
EQUIPOTENTIAL BONDING
NOTE ON EXPLOSION PROTECTION
• According to EN 60079-14 and 61241-0, it
shall be a connection to an equipotential
bonding system (see following figure).
• The ground must be fixed in the appropriate pin
with size of 4 mm2and greater or equal to
conductor size.

BRUSHLESS SERVOMOTORS - ATEX - OPERATING INSTRUCTIONS – 3010/21 4
MOTOR PERFORMANCES
NOTE ON EXPLOSION PROTECTION
• Motor performances comply with IEC60034-1
once the motor is coupled to a metal flange not
insulated and without additional external
heating.
• For complex performances cycle, RMS value of
the current shall be within the label data.
• The maximum speed shall be never exceed.
• For rotating speed close to 0 [rpm], the RMS
current value shall be halved than label data
MAINTENANCE
Before carrying out any work on the motor, disconnect it
and secure it against restarting.
Attention: danger of accidents! Avoid any contact with
moving parts!
CLEANING
The air passages must be cleaned on a regular basis, depending on
the ambient conditions.
NOTE ON EXPLOSION PROTECTION
• Clean servomotors in explosion-proof areas
regularly. Prevent dust deposits > 5mm.
• Explosion protection can only be ensured if
servomotors and brakes are serviced and
maintained correctly.
BEARING LUBRICATION
All motors have 2ZC3 or 2RSC3 bearings with grease suitable for
high and low temperatures and permanent lubrication.
REPAIR INSTRUCTIONS
Any repair work performed during the warranty period is
subject to manufacturer approval.
GENERAL WARNINGS
For motor repairs, it will be necessary to contact the supplier.
INSTRUCTIONS FOR STORAGE
Prolonged electric motor storage (ex. spare motors) must be carried
out the following precautions.
STORAGE LOCATION
Make sure the motor is stored in a dry and dust-free environment with
minimum vibrations (Veff ≤0.2 mm/s) (damage to the bearings).
Ambient temperature: between -10°C and +40°C, relative humidity <
50%.
ROTOR LOCKING DEVICE
On motors with roller bearings, fix the rotor in place by means of the
locking device, to protect the bearings against damage due to
vibration.
Motors shipped on vibration dampers should also be stored in this
condition.
Where pulleys, half couplings, etc. are already mounted on the shaft
extension, fit the locking device or place the motor on vibration
dampers, if possible.
Use dampers and locking device also for any future transport of the
motor.
CHECK BEFORE COMMISSIONING
BEARINGS
Before commissioning a motor that has been stored for more than 4
years, check the bearings.
For motors without regressing device, grease has to be renewed or
bearings have to be changed after 2 years at the latest.
Even minor corrosion can considerably shorten the
service life of the bearings.
The rotor has to be rotated every month by approx. 30 degrees, in
order to avoid compression spots on the bearings due to static load.
To turn the rotor on brake motors, turn the power on to
unblock its movement. When the rotor has been turned,
switch the power back off.
INSULATION RESISTANCE
Before commissioning check the insulation resistance.
With values ≤ 1kW per Volt rated voltage, dry the
winding.
Check the insulation resistance of each phase against earth by means
of a hand-driven generator (max. 630 VDC) until the measured value
is constant. The insulation resistance of new windings is above 10
MΩ. The resistance can be lowered considerably by moisture.
If, at room temperature, the resistance is below 0.5 MW, the winding
must be dried. In this case the winding temperature must not exceed
80° C.
For drying connect the space heater or another heating device or
apply an AC voltage of 5 or 6% (connect in delta) of the rated motor
voltage to terminals U1 and V1. Repeat the measurement. The motor
can be put into operation when the resistance is above 0.5 MΩ.
Insulation resistance is temperature-dependent, i.e. if the temperature
is increased/decreased by 10K, the resistance value is
halved/doubled, respectively.

BRUSHLESS SERVOMOTORS - ATEX - OPERATING INSTRUCTIONS – 3010/21 5
WARNING FOR THE CORRECT DISPOSAL OF THE MOTORS AT
THE END OF THEIR LIFE TIME
According to the art. 26 of the Italian law
2014, March 14th n. 49
" Implementation of the DIRECTIVE
2012/19/EU OF THE EUROPEAN
PARLIAMENT AND OF THE COUNCIL
of 4 July 2012, on waste electrical and
electronic equipment (WEEE)”
The above symbol, applied to the equipment or its packaging, means
that at the end of its lifetime the motors need to be disposed
separately from the other waste materials.
The users must dispose their unused motors on behalf of the national
authorized collection centers which have been approved for the
electrical and electronic waste.
The right collection for recycling, treatment and disposal will
contribute to avoid any potential negative environmental & healthy
effect and will help both the reuse and the recycling of the motor’
components/materials.
TABLE OF DISPOSAL CODES FOR ELECTRIC MOTORS
CODE OF THE MOTOR (WASTE)
DISPOSED IN ALL ITS PARTS
EWC
(European
Waste Code)
EWC DESCRIPTION
In the event of disposal of the full motor 16.02.14 Discarded equipment
In the event of disposal of a disassembled motor
Aluminium parts: flange, cover, terminal box and frame in
aluminium
Steel parts: rotor with shaft (both die-cast and with magnets),
stator pack with wire windings, cast iron flange and cover,
terminal box, brake with magnet, friction disc, springs, etc.
Plastic parts: fan, fan cover, terminal box, brake cover, shaft
protection
Electrical components: switches, capacitors, starters, terminal
board, etc.
12.01.03
12.01.01
12.01.05
16.02.16
Non-ferrous metal filings and turnings
Ferrous metal filings and turnings
Plastics shavings and turnings
Components removed from discarded equipment

Lafert Servo Motors S.p.A.
E. Majorana, 2/A
I-30020 Noventa di Piave (Venice), Italy
Tel. +39 / 0421 572 211
Fax +39 / 0421 225 858
[e-mail]
www.lafert.com