Lenze g500-H45 Technical manual

Geared servo motors
g500-H / m850 helical geared servo motor
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 8
Features 9
The modular system 10
Designs 12
Mounng posions 14
Informaon on project planning 16
Safety instrucons 16
Basic safety instrucons 17
Applicaon as directed 18
Foreseeable misuse 18
Residual hazards 19
General informaon 21
Drive dimensioning 22
Final conguraon 28
Surface and corrosion protecon 29
Lubricants 30
Venlaon 31
Informaon on mechanical installaon 37
Important notes 37
Transport 37
Installaon 37
Informaon on electrical installaon 38
Important notes 38
Preparaon 38
Contents
3

Technical data 39
Notes regarding the given data 39
Standards and operang condions 40
Conformies and approvals 40
Protecon of persons and device protecon 40
EMC data 40
Environmental condions 40
Data overview 41
Radial forces and axial forces 59
Selecon tables 64
Inverter mains connecon 400 V, Self-venlated motors 65
Dimensions 91
Basic dimensions 93
Gearbox with pre-stage 125
Addional lengths 125
Weights 126
Basic weights 126
Addional weights 126
Product extensions 127
Motor connecon 127
Connecon via ICN connector 127
Brakes 135
Spring-applied brakes 137
Feedback 138
Resolver 139
Absolute value encoder 140
Temperature monitoring 141
Thermal detectors PT1000 141
Product codes 142
Motor data 144
Rated data 144
Inverter mains connecon 400 V, Self-venlated motors 144
Torque characteriscs 146
Environmental notes and recycling 151
Appendix 152
Good to know 152
Approvals and direcves 152
Operang modes of the motor 153
Enclosures 154
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.
NOTICE
Please observe the notes in the following chapters!
▶Safety instrucons ^ 16
▶Informaon on mechanical installaon ^ 37
▶Informaon on electrical installaon ^ 38
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
When used in combinaon with servo motors, our helical gearboxes form a compact,
powerful and dynamic 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.
Designs
•Fine-scaling of size/torque provides for an opmum machine adaptaon
•Standardised sha and ange dimensions for an easy machine integraon
•High eciency
Synchronous servo motor m850 as basis for geared motor
In a power range of 2.0 to 9.2 kW, Lenze oers servo motors with an easily scalable modular
design.
The drives are designed for the open-loop or closed-loop controlled servo inverter operaon.
Medium dynamics and easy controllability via a favourable mass inera rao of the load to the
motor characterise these motors.
Customer benet
•Easy controllability by an advantageous rao of the mass inera of the load and that of the
motor
•High overload capacity of the motors
•Easy assembly and easy servicing thanks to connectors with bayonet catch and rotatable
connector boxes
•Reduced cabling thanks to one-cable technology in connecon with digital absolute value
encoders
•High eciency
•Space-saving thanks to compact direct aachment to Lenze gearboxes
•Can be used universally for a wide range of machine tasks due to the market-oriented
modular system
m850-S120/L3960 synchronous servo motor - g500-H450 helical gearbox m850-S120/L3960 synchronous servo motor- g500-H450 helical gearbox
with One Cable Technology (OCT) in connecon with a digital absolute
value encoder
Product informaon
Product descripon
7

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: m850 synchronous servo motor
Product range Version Flange height Overall length Rated speed Motor
mm rpm
m850 - S (synchronous)
120
su
ppl
y
S (short) 3960 m850-S120/S3960
M (medium) 3960 m850-S120/M3960
L (long) 3960 m850-S120/L3960
140
S (short) 3240 m850-S140/S3240
M (medium) 3240 m850-S140/M3240
L (long) 3240 m850-S140/L3240
190
S (short) 3000 m850-S190/S3000
M (medium) 3000 m850-S190/M3000
L (long) 2520 m850-S190/L2520
Product informaon
Idencaon of the products
8

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)
Remove oil control plug
(depending on
the mounting position)
Oil drain plug
(depending on the
mounting position)
Oil filler plug
(depending on the
mounting position)
Ventilation
Housing type
Output flange
Output shaft
Temperature monitoring
Spring-applied brake
Feedback
Motor connection
Cooling
Product informaon
Features
9

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.
Geared motors up to 450 Nm
Gearbox g500-H100 g500-H140 g500-H210 g500-H320 g500-H450
Min. motor assignment m850-S120 m850-S120 m850-S120 m850-S120 m850-S120
Max. motor assignment m850-S120 m850-S120 m850-S140 m850-S140 m850-S190
Technical data
Max. output torque Nm 100 140 210 320 450
Min. drive torque Nm 4.8 4.8 4.8 4.8 4.8
Max. drive torque Nm 7.4 9.0 14.0 17.4 35.0
Mounng posion
Standard M1, M2, M3, M4, M5, M6 (ABCDEF)
Combined M1/5/6 (AEF)
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 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 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 Normal
Reinforced
Gearbox version 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
160/200
160/200 160/200/250
Lubricant Synthec oil
Food-compable oil
Venlaon Without Vent valve
Cooling Self-venlated
Motor connecon Connector
ICN hybrid connector for One Cable Technology (OCT)
Spring-applied holding brake Without
With
Feedback
Without funconal safety Resolver
Absolute value encoder
Digital absolute value encoder for One Cable Technology (OCT)
With funconal safety Resolver
Absolute value encoder
Digital absolute value encoder for One Cable Technology (OCT)
Temperature monitoring PT1000 temperature sensor
Product informaon
The modular system
10

Geared motors 600 Nm to 3000 Nm
Gearbox g500-H600 g500-H850 g500-H1500 g500-H3000
Min. motor assignment m850-S120 m850-S120 m850-S120 m850-S120
Max. motor assignment m850-S190 m850-S190 m850-S190 m850-S190
Technical data
Max. output torque Nm 600 850 1500 3000
Min. drive torque Nm 4.8 4.8 4.8 4.8
Max. drive torque Nm 35.0 35.0 35.0 35.0
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 Normal
Reinforced
Gearbox version 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 Synthec oil
Food-compable oil
Venlaon Vent valve
Oil compensaon reservoir
Cooling Self-venlated
Motor connecon Connector
ICN hybrid connector for One Cable Technology (OCT)
Spring-applied holding brake Without
With
Feedback
Without funconal safety Resolver
Absolute value encoder
Digital absolute value encoder for One Cable Technology (OCT)
With funconal safety Resolver
Absolute value encoder
Digital absolute value encoder for One Cable Technology (OCT)
Temperature monitoring PT1000 temperature sensor
Product informaon
The modular system
11

Designs
Gearbox designs
Observe the available gearbox designs!
4The modular system ^ 10
The VCP design (reinforced ange) is suitable for absorbing high radial and axial
forces^ 59 .
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
12

Models at the output
Motor connecon
ICN connector ICN hybrid connector for One Cable
Technology (OCT)
Cooling: Self-venlated
Feedback Feedback and brake
Product informaon
The modular system
Designs
13

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 gearboxes can also be ordered with combined
mounng posions:
•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
14

Posion of the ICN connectors
R
L
B
T
Product informaon
The modular system
Mounng posions
15

Informaon on project planning
Safety instrucons
Disregarding the following basic safety measures and safety informaon may lead to severe
personal injury and damage to property!
Observe all specicaons of the corresponding documentaon supplied. This is the
precondion for safe and trouble-free operaon and for obtaining the product features
specied.
Please observe the specic safety informaon in the other secons!
Informaon on project planning
Safety instrucons
16

Basic safety instrucons
DANGER!
Dangerous electrical voltage
Possible consequences: Death or severe injuries from electric shock
▶Any work on the device must only be carried out in a deenergized state.
▶Aer switching o the mains voltage, observe the signs on the product.
Product
•The product must only be used as directed.
•Never commission the product in the event of visible damage.
•The product must never be technically modied.
•Never commission the product before assembly has been completed.
•The product must never be operated without required covers.
•Connect/disconnect all pluggable terminals only in de-energized condion.
•Only remove the product from the installaon in the de-energized state.
Personnel
Only qualied and skilled personnel are allowed to work with the product. IEC 60364 and/or
CENELEC HD 384 dene the qualicaons of these persons as follows:
•They are familiar with the installaon, mounng, commissioning, and operaon of the
product.
•They possess the appropriate qualicaons for their tasks.
•They are familiar with all regulaons for the prevenon of accidents, direcves, and laws
applicable at the locaon and are able to apply them.
Electrical connecon
When working on energized products, comply with the applicable naonal accident
prevenon regulaons.
The electrical installaon work must be carried out according to the appropriate regulaons
(e.g. cable cross-secons, fusing, PE conductor connecon). Addional informaon can be
obtained from this documentaon.
This documentaon contains notes about installaon according to EMC regulaons. Also
observe these notes for CE-marked products. The manufacturer of the system or machine is
responsible for adherence to the limits required in connecon with EMC legislaon.
Operaon
Where appropriate, you must equip the system with addional monitoring and protecve
devices. Comply with the safety regulaons and other regulaons applicable at the place of
operaon.
Aer disconnecng the product from the supply voltage, do not touch live device parts and
power terminals immediately because capacitors may be charged. Observe the corresponding
informaon labels on the product.
Dirt or dust deposits impede the heat dissipaon and cooling. Remove any such deposits
where appropriate at regular intervals.
Process engineering
The procedural notes and circuit details described are only proposals. It is up to the user to
check whether they can be adapted to the parcular applicaons. Lenze does not take any
responsibility for the suitability of the procedures and circuit proposals described.
Disposal
The products and accessories must be properly disposed of in accordance with the applicable
regulaons. The products contain raw materials that can be recycled such as metals, plascs
and electronic components.
Informaon on project planning
Safety instrucons
Basic safety instrucons
17

Applicaon as directed
•The product must only be actuated under the operang condions and power limits
specied in this documentaon.
•The product meets the protecon requirements of 2014/35/EU: Low-Voltage Direcve.
•The product is not classed as a machine under 2006/42/EC: Machinery Direcve.
•No machine is to be commissioned or put into operaon as intended in conjuncon with
the product unl it has been determined that the machine meets the regulaons of EC
Direcve 2006/42/EC: Machinery Direcve; observe EN 60204−1.
•Commissioning or pung into operaon as intended is only permied in compliance with
the EMC Direcve 2014/30/EU.
•The product is not a household appliance. Instead, it is a component that is intended
exclusively for further use in the context of commercial or professional use as dened by
EN 61000−3−2.
•The product can be used according to the technical data if the drive systems have to
comply with categories in accordance with EN 61800−3.
•Do not use the built-in brakes as fail-safe brakes. Disrupve factors that cannot be
inuenced may cause the braking torque to be reduced.
•The product is only to be operated together with an inverter.
•The harmonized standards of the series IEC/EN60034 are used.
Foreseeable misuse
•Operate directly on the mains voltage
•Use in potenally explosive atmospheres
•Operate in aggressive environments (acids, gases, vapors, dusts, oils)
•Operate under water
•Operate under radiaon
•Operate in generator mode
Informaon on project planning
Safety instrucons
Applicaon as directed
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!
High leakage current:
Carry out xed installaon and PE connecon in compliance with:
EN 61800−5−1 / EN 60204−1
Hot surface:
Use personal protecve equipment or wait unl the device has cooled down!
Protecon of persons
•The product does not provide any safety-related funcons.
-A higher-level safety system must be implemented.
-Provide addional monitoring and protecve equipment complying with the safety
regulaons applicable in each case.
•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 must be carried out at the marked posions of the components.
•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.
•Risk of injury from rotang parts.
-Before working on the drive system, ensure that the motor is at a standsll.
•There is a danger of unintenonal start-up or electric shocks!
•Installed brakes are no fail-safe brakes.
- torque may be reduced by disrupve factors that cannot be inuenced such as
ingressing oil.
Informaon on project planning
Safety instrucons
Residual hazards
19

Motor protecon
•Version with plug:
-Never disconnect the plug when energized. The plug could be destroyed.
-Switch o the voltage supply or disable the inverter prior to disconnecng the plug.
•Installed thermal detectors are no full protecon for the machine.
-Limit the maximum current if necessary. Parameterize the inverter so that it will be
switched o aer several seconds of operaon with I > Irated especially if there is a
danger of blocking.
-The 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 thermal detectors.
•Excessively high torques cause a fracture of the motor sha.
-Do not exceed the maximum torques according to the technical data on the
nameplate.
Gearbox protecon
•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