Lenze g500-H User manual

Mains-operated geared motors
g500-H helical geared motor / Smart Motor m300-E
Project planning EN

Contents
About this document 5
Document descripon 5
Further documents 5
Notaons and convenons 6
Product informaon 7
Product descripon 7
Idencaon of the products 10
Features 11
The modular system 12
Designs 15
Mounng posions 16
Informaon on project planning 18
Safety instrucons 18
Basic safety instrucons 18
Applicaon as directed 18
Residual hazards 19
Drive dimensioning 21
Final conguraon 23
Surface and corrosion protecon 24
Lubricants 25
Venlaon 26
Informaon on mechanical installaon 32
Important notes 32
Transport 32
Installaon 32
Informaon on electrical installaon 33
Important notes 33
Connecon according to EN 34
Connecon according to cULus 37
Technical data 41
Notes regarding the given data 41
Standards and operang condions 42
Conformies and approvals 42
Protecon of persons and device protecon 43
EMC data 43
Environmental condions 44
Electrical supply condions 44
Radial forces and axial forces 45
Selecon tables 50
Dimensions 60
Basic dimensions 61
Gearbox with pre-stage 96
Addional lengths 96
Weights 97
Basic weights 97
Addional weights 97
Contents
3

Product extensions 98
Motor connecon 98
Connecon via terminal box 98
Connecon via QUICKON V2 connector 98
Connecon via M15 connector 99
Connecon via M12 connector 100
Brakes 101
Spring-applied holding brake 102
Brake resistors 104
Accessories 105
NFC adapter 105
QUICKON connector 106
UMCLN_SGG_100181 107
Product codes 108
Motor data 110
Rated data 110
Ecodesign Direcve 110
Environmental notes and recycling 111
Appendix 112
Good to know 112
Operang modes of the motor 112
Enclosures 113
Contents
4

About this document
Document descripon
This document addresses to all persons who want to carry out any conguraons with the
products described.
The data and informaon compiled in this document serve to support you in the dimensioning
and selecon processes and in carrying out the electrical and mechanical installaon. You will
receive informaon regarding product extensions and accessories.
•The document includes safety instrucons which must be observed.
•All persons working on and with the drives must have the documentaon at hand during
work and observe the informaon and notes relevant for it.
•The documentaon must always be complete and in a perfectly readable state.
Further documents
Informaon and tools with regard to the Lenze products can be found on the
Internet:
www.Lenze.com à Downloads
About this document
Document descripon
5

Notaons and convenons
Convenons are used in this document to disnguish between dierent types of informaon.
Numeric notaon
Decimal separator Point Generally shown as a decimal point.
Example: 1 234.56
Warnings
UL Warnings UL Are used in English and French.
UR warnings UR
Text
Engineering Tools " " Soware
Example: "Engineer", "EASY Starter"
Icons
Page reference ¶Reference to another page with addional informaon.
Example: ¶ 16 = see page 16
Documentaon reference ,Reference to other documentaon with addional informaon.
Example: , EDKxxx = see documentaon EDKxxx
Layout of the safety instrucons
DANGER!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon will result
in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon may result
in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situaon. Failure to comply with this instrucon may result in slight to
medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instrucon may result in material
damage.
About this document
Notaons and convenons
6

Product informaon
Product descripon
The new freedom in moon for engineers. Lenze Smart Products reduce the number of
dierent drives by up to 70 %. Without contactor and starter, with freely adjustable xed
speeds and many integrated funcons for technical material-handling applicaons. The Lenze
Smart motor also fulls the highest requirements regarding energy eciency and can be
conveniently operated by means of a smart phone.
When used in combinaon with three-phase AC motors, our helical gearboxes form a
compact, powerful drive unit. Numerous opons at the input and output end provide for the
drive to be exactly adapted to your applicaon.
The robust helical gearboxes are characterized by high permissible radial forces, closely
stepped raos and a low backlash. They are available in a 2-, 3- and 4-stage design with an
output torque of up to 3000 Nm and a rao of up to i= 3529.
Versions
•Fine-scaling of size/torque provides for an opmum machine adaptaon
•Market standard sha dimensions and standardized anges for easy machine integraon
•High eciency
Reducon in the number of variants made easy
Before now, dierent output speeds (e. g. for dierent conveying speeds) were enabled by
dierent gearbox raos or, in the case of very large dierences, by means of the number of
pole pairs of the motors. This led to a large number of dierent drive variants..
Things are dierent with the Lenze Smart Products: Due to the possibility of freely adjusng
the motor speed within a vefold adjustment range at a constant torque, very dierent
speeds can be enabled with one single drive variants. The cost and eort involved in design,
selecon, procurement and storage are thus reduced considerably.
Fig. 1: Smart Motor MSEMAXX080-32 - helical gearbox g500-H450
Easy adjustment
NFC technology (NFC = Near Field Communicaon) is used to adapt the Lenze Smart Products
to the applicaon as well as for diagnoscs). The drive can be adjusted very easily without
opening the terminal box. without voltage supply and without me-consuming addressing.
Only an NFC-capable Android smartphone or the Lenze NFC adapter for PCs is needed as a
tool. The data can therefore be read and wrien when the drive is in a de-energised state –
via password protecon, of course.
Product informaon
Product descripon
7

Data that can be set
•Name of data record (e. g. the designaon of the drive in your documentaon)
•Speed and rotang direcon 1 (also controllable without digital inputs)
•Speed and rotang direcon 2-5 (controllable by means of digital inputs)
•Acceleraon me
•Deceleraon me
•Energy-saving funcon
Readable data
•Idencaon data (Lenze material number and serial number, type designaon, soware
version)
•Error messages
•Operang and power-on hours
Adjustment by means of a smartphone
The Lenze Smart Products can be adjusted with an Android smartphone. The corresponding
app in German and English can be obtained from www.Lenze.com or the Google Store. For
convenience, the data records created can be archived on the smartphone and repeatedly
transferred to the Lenze Smart Products for dierent applicaons.
Seng with the PC
With the »EASY Starter« engineering tool (extended version, soware license »EASY
Advanced«“ or »Engineer HighLevel« required) can be used to set the Lenze Smart products.
The relevant version be easily downloaded from hp://www.lenze.com . As the sengs are
very simple and clear, there is an easy-to-use dialog box which can be opened directly via the
navigator The corresponding buon is directly accessible in the navigaon bar. Analogously to
other product sengs, the parameter values. can be archived.
Product informaon
Product descripon
8

Starng and stopping smoothly and gently
An acceleraon ramp and – in contrast to a convenonal starter – a deceleraon ramp can be
set for Lenze Smart Products. This ensures that the conveyed material is handled in a dened
and jerk-free manner..
Contactor and motor protecon funcons integrated
The Lenze Smart Products can be started and stopped by mean of digital inputs. It is also
possible to switch between dierent speeds and rotang direcons. Up to 5 dierent speed
modes (e. g. creep speed and normal speed in both direcons as well as stopping) can be used
for a motor. Reversing-contactor changes and pole changes are thus a thing of the past.
In addion, motor-protecons devices are not needed as monitoring of temperature, short
circuits, earth faults and phase failures has already been integrated.
Easy installaon
Connecon takes place completely from the outside by means of connectors.
The Lenze Smart Products come with an especially clever connecng technology – Phoenix
Contact QUICKON. Electrical installaon is therefore very easy without special tools and
requires less than one minute.
In addion to the QUICKON connector, the M15 connecon customary on the market is
available.
As a standard feature, the digital inputs and outputs are connected at M12 sockets of the type
currently available on the market.
Already exisng signal cables can oen be reused.
Worldwide and ecient
The drive can be used worldwide:
•In all 3-phase networks with 400 ... 480 V supply voltage an a mains frequency of
50 ... 60 Hz
•At ambient temperatures of -30 ... +40 °C
•Is suitable for many approvals
The Lenze Smart Motor fulls the requirements as described in the highest eciency
requirement for IES2.
If very lile torque is needed in the paral-load operaonal range, the integrated energy
saving funcon can be used to opmize the energy absorpon of the drive.
Product informaon
Product descripon
9

Applicaon examples
Roller conveyors with belt ejector Belt conveyors
Idencaon of the products
Gearbox product name
Gearbox type Product series Type Rated torque Nm Gearbox
Helical gearbox g500 - H
45 g500-H45
100 g500-H100
140 g500-H140
210 g500-H210
320 g500-H320
450 g500-H450
600 g500-H600
850 g500-H850
1500 g500-H1500
3000 g500-H3000
Product name of the motor
Product series Type Size Overall length Number of pole
pairs
Motor
MSEMA
XX
(without built-on
accessories)
063
-
4
2 (4-pole)
MSEMAXX063-42
080 3 MSEMAXX080-32
BR
(with brake)
063 4 MSEMABR063-42
080 3 MSEMABR080-32
Product informaon
Idencaon of the products
10

Features
The following gure provides an overview of the elements and connecons on the product.
Their posion, size and appearance may vary.
(depending on the mounting position)
Oil filler plug
(depending on the mounting position)
Ventilation
(depending on the mounting position)
Remove oil control plug
(depending on the
mounting position)
Oil drain plug
Housing type
Output flange
Output shaft
Connection of spring-applied brake
Mains connection
Control terminal
Brake resistor connection
(prewired upon delivery)
X5
External
X4
Internal brake resistor
PE
by means of Android smartphone
by means of PC via NFC adapter
Adjustment of speeds
M12 connector
X1, X2
In the terminal box
QUICKON V2 connector
M15 connector
X3
External brake resistor
Standard
LongLife
Manual release lever
Spring-applied brake
Integral fan
Cooling
Product informaon
Features
11

The modular system
Values printed in bold are standard designs. Values that are not printed in bold
are potenal extensions, some of them including a surcharge.
Product informaon
The modular system
12

Geared motors up to 450 Nm
Gearboxes g500-H45 g500-H100 g500-H140 g500-H210 g500-H320 g500-H450
Min. motor assignment MSEMA□□
063-42 063-42 063-42 063-42 063-42 063-42
Max. motor assignment MSEMA□□
063-42 080-32 080-32 080-32 080-32 080-32
Technical data
Max. output torque Nm 45 100 140 210 320 450
Min. drive torque Nm 1.75 1.75 1.75 1.75 1.75 1.75
Max. drive torque Nm 1.75 5.0 5.0 5.0 5.0 5.0
Mounng posion
Standard M1, M2, M3, M4, M5, M6 (ABCDEF)
Combined M1-M6 (A-F) M1/5/6 (AEF)
Color Unpainted
Primed
Painted in RAL colors
Surface and corrosion protecon OKS-G
Dierent types of OKS
Output sha
Solid sha with featherkey mm 14 x 28
20 x 40
20 x 40 25 x 50 25 x 50 30 x 60 30 x 60
35 x 70
Solid sha without keyway mm 20 x 40 20 x 40 25 x 50 25 x 50 30 x 60 35 x 70
Sha material Steel
Stainless steel
Sha sealing ring material NBR
FKM (Viton)
Output sha bearing Standard
Reinforced
Gearbox design With foot (VBR)
With foot and centering (VAR)
With foot and output ange (VAK)
With centering (VCR)
With output ange (VCK)
With output ange (VCP)
Output ange mm 120/140/160 120/140/160 120/140/160 120/140
160/200
160/200 160/200/250
Lubricant Mineral oil
Synthec oil
Food-compable oil
Cooling Self-venlated
Motor connecon
Power connecon Terminal box
QUICKON V2 connector
M15 connector
Control terminal M12 connector
Spring-applied brake
Version Without
Standard
LongLife
Without/with manual release lever
Brake resistor Without
Integrated
External
Feedback Without
Temperature monitoring Internal
Product informaon
The modular system
13

Geared motors 600 Nm to 3000 Nm
Gearboxes g500-H600 g500-H850 g500-H1500 g500-H3000
Min. motor assignment MSEMA□□
063-42 063-42 063-42 063-42
Max. motor assignment MSEMA□□
080-32 080-32 080-32 080-32
Technical data
Max. output torque Nm 600 850 1500 3000
Min. drive torque Nm 1.75 1.75 1.75 1.75
Max. drive torque Nm 5.0 5.0 5.0 5.0
Mounng posion
Standard M1, M2, M3, M4, M5, M6 (ABCDEF)
Combined -
Color Primed
Painted in RAL colors
Surface and corrosion protecon OKS-G
Dierent types of OKS
Output sha
Solid sha with featherkey mm 35 x 70
40 x 80
40 x 80 50 x 100 60 x 120
Solid sha without keyway mm 35 x 70 40 x 80 50 x 100 60 x 120
Sha material Steel
Stainless steel
Sha sealing ring material NBR
FKM (Viton)
Output sha bearing Standard
Reinforced
Gearbox design With foot (VBR)
With foot and centering (VAR)
With foot and output ange (VAK)
With centering (VCR)
With output ange (VCK)
Output ange mm 200/250 250/300 250/300/350 300/350/450
Lubricant Mineral oil
Synthec oil
Food-compable oil
Cooling Self-venlated
Motor connecon
Power connecon Terminal box
QUICKON V2 connector
M15 connector
Control terminal M12 connector
Spring-applied brake
Version Without
Standard
LongLife
Without/with manual release lever
Brake resistor Without
Integrated
External
Feedback Without
Temperature monitoring Internal
Product informaon
The modular system
14

Designs
Gearbox designs
Observe the available gearbox designs!
4The modular system ^ 12
The VCP design (reinforced ange) is suitable for absorbing high radial and axial
forces^ 45 .
Solid sha, with foot
Without centring (VBR) With centring (VAR) Flange with through holes (VAK)
Solid sha, without foot
With centering (VCR) Flange with through holes (VCK) Reinforced ange with through holes (VCP)
Product informaon
The modular system
Designs
15

Mounng posions
Details of the mounng posion are needed to ensure the corresponding lubricant amount,
posion of the venlaon, oil checks and oil drain plug on the gearbox.
To reduce the number of dierent versions, the following gearboxes can also be ordered with
combined mounng posions:
•g500-H45 in mounng posion M1-M6 (A-F)
•g500-H100 ... H450 in mounng posion M1/5/6 (AEF)
M1 [ A ]
M2 [ D ]
M5 [ F ]
M3 [ B ]
M4 [ C ]
M6 [ E ]
Dened posions on the geared motor
All of the dened posions refer to the areas on the geared motor in
mounng posion M1 (A) .
Posion of the built-on accessories with T, L, R, B, F, E (Top, Le,
Right, Boom, Front and End)
If the geared motor is rotated into a dierent mounng posion
M2 ... M6 (B...F), the dened posions on the geared motor are
retained.
T [ 2 ]
E [ 1 ]
R [ 5 ]
B [ 4 ]
F [ 6 ]
L [ 3 ]
Example: Mounng posion M5 (F)
E [ 1 ]
T [ 2 ]
R [ 5 ]
F [ 6 ]
B [ 4 ]
L [ 3 ]
Product informaon
The modular system
Mounng posions
16

Posion of the terminal boxes
R
L
B
T
Posions of the connecons
Mains connecon Control terminal
Cable gland for terminal box
QUICKON V2 connector
M15 connector
M12 connector
E
E
Posion of the manual release lever
Product informaon
The modular system
Mounng posions
17

Informaon on project planning
Safety instrucons
Basic safety instrucons
Disregarding the following basic safety instrucons and safety informaon may lead to severe
personal injury and damage to property!
•Only use the product as directed.
•Never commission the product in the event of visible damage.
•Never modify the product technically.
•Never commission the product before assembly has been completed.
•Never operate the product without the required covers.
•Connect/disconnect all pluggable connecons only in deenergized condion!
•Only remove the product from the installaon in the deenergized state.
•The product can – depending on their degree of protecon – have live, movable or
rotang parts during or aer operaon. Surfaces can be hot.
•Observe all specicaons of the corresponding documentaon supplied. This is the
condion for safe and trouble-free operaon and the achievement of the specied
product features.
•The procedural notes and circuit details given in the associated documentaon are
suggesons and their transferability to the respecve applicaon has to be checked. The
manufacturer of the product does not take responsibility for the suitability of the process
and circuit proposals.
•All work with and on the product may only be carried out by qualied personnel.
IEC 60364 and CENELEC HD 384 dene the qualicaons of these persons:
-They are familiar with installing, mounng, commissioning, and operang the product.
-They have the corresponding qualicaons for their work.
-They know and can apply all regulaons for the prevenon of accidents, direcves, and
laws applicable at the place of use.
Applicaon as directed
•The product is a professional equipment intended for use by trades, specic professions or
industry and not for sale to the general public. IEC 60050 [IEV 161-05-05]
•To prevent personal injury and damage to property, higher-level safety and protecon
systems must be used!
•All transport locks must be removed.
•Mounted eye bolts on the motor are not suitable for transporng geared motors.
•The product may only be operated under the specied operang condions and in the
specied mounng posions.
•The product is suitable for horizontal conveying only.
•The product may only be operated from the mains.
•Built-in brakes must not be used as safety brakes.
•The product must not be operated in private areas, in potenally explosive atmospheres
and in areas with harmful gases, oils, acids and radiaon.
Informaon on project planning
Safety instrucons
Basic safety instrucons
18

Residual hazards
Even if notes given are taken into consideraon and protecve measures are implemented,
the occurrence of residual risks cannot be fully prevented.
The user must take the residual hazards menoned into consideraon in the risk assessment
for his/her machine/system.
If the above is disregarded, this can lead to severe injuries to persons and damage to
property!
Product
Observe the warning labels on the product!
Dangerous electrical voltage:
Before working on the product, make sure there is no voltage applied to the power terminals!
Aer mains disconnecon, the power terminals will sll carry the hazardous electrical voltage for the me given next to the
symbol!
Electrostac sensive devices:
Before working on the product, the sta must ensure to be free of electrostac charge!
High leakage current:
Carry out xed installaon and PE connecon in compliance with:
EN IEC 61800−5−1 / EN IEC 60204−1
Hot surface:
Use personal protecve equipment or wait unl the device has cooled down!
Protecon of persons
•The power terminals may carry voltage in the switched-o state or when the motor is
stopped.
-Before working, check whether all power terminals are deenergized.
•Voltages may occur on the drive components (e.g. capacive, caused by inverter supply).
-Careful earthing in the marked posions of the components must be carried out.
•There is a risk of burns from hot surfaces.
-Provide protecon against accidental contact.
-Use personal protecve equipment or wait unl the device has cooled down.
-Prevent contact with ammable substances.
•There is a risk of injury due to rotang parts.
-Before working on the drive system, ensure that the motor is at a standsll.
•There is a risk of accidental start-up or electric shock.
Motor protecon
•Installed thermal detectors are no full protecon for the machine.
-If necessary, limit the maximum current. Parameterize the inverter so that it will be
switched o aer some seconds of operaon with I > Irated , especially if there is a risk
of blocking.
-Integrated overload protecon does not prevent overloading under all condions.
•The fuses are no motor protecon.
-Use a current-dependent motor protecon switch.
-Use the built-in temperature sensors.
•Too high torques cause a fracon of the motor sha.
-Do not exceed the maximum torques according to the technical data on the
nameplate.
Informaon on project planning
Safety instrucons
Residual hazards
19

Gearbox protecon
•Excessive vibraon acceleraons and resonances will damage the gearbox.
-Do not operate the gearbox at vibraon acceleraons > 2 g (20 m/s2) of the machine.
-Do not operate the gearbox in the resonance range of the machine.
•Excessive torques will damage the gearboxes.
-Do not exceed the output torques specied on the nameplate.
•Excessive input speeds lead to increased temperatures.
-Do not exceed the input speeds specied on the nameplate.
•Avoid excessive lateral forces on the gearbox sha.
-Align the shas of the gearbox and driven machine exactly with each other.
•Machine elements can be damaged by a lack of lubricant.
-Mount the gearbox only in the mounng posion indicated on the nameplate.
-When changing the lubricant, use the lubricant type and quanty specied on the
nameplate.
Informaon on project planning
Safety instrucons
Residual hazards
20