Lenze g500-S Guide

Geared servo motors
g500-S / MCS sha-mounted helical geared servo motor
Mounng and switch-on instrucons EN

Contents
About this document 5
Document descripon 5
Further documents 5
Notaons and convenons 6
Safety instrucons 7
Basic safety instrucons 7
Applicaon as directed 7
Residual hazards 8
Product informaon 10
Idencaon of the products 10
Nameplates 10
Product codes 11
Equipment 14
Transport 15
Storage 16
Mechanical installaon 17
Important notes 17
Preparaon 17
Installaon 18
Mounng posions 18
Venlaon 19
Dimensions 23
Mounng 24
Product extensions 28
Electrical installaon 30
Important notes 30
Preparaon 30
Motor connecon 31
Connecon via terminal box 31
Connecon via ICN connector 34
Commissioning 41
Important notes 41
Before inial switch-on 41
Funconal test 42
Maintenance 43
Maintenance intervals 44
Maintenance work 46
Repair 52
Diagnoscs and fault eliminaon 53
Malfuncons 53
Contents
3

Technical data 54
Standards and operang condions 54
Conformies and approvals 54
Protecon of persons and device protecon 54
EMC data 54
Environmental condions 55
Motor data 56
Rated data 56
Inverter power supply 400 V, self-venlated motors 56
Inverter power supply 400 V, forced venlated motors 62
Inverter power supply 230 V, self-venlated motors 66
Environmental notes and recycling 69
Contents
4

About this document
WARNING!
Read this documentaon carefully before starng any work.
▶Please observe the safety instrucons!
Document descripon
This document is intended for skilled personnel who work with the products described.
The data and informaon compiled in this document serve to support you in the electrical and
mechanical installaon and commissioning.
•The document is only valid together with the complete documentaon of the product!
•For safety-rated aachments observe the enclosed operang instrucons of the
manufacturer!
•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

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 may only be operated on the inverter.
•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.
Safety instrucons
Basic safety instrucons
7

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 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 temperature sensors 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.
Safety instrucons
Residual hazards
8

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.
Safety instrucons
Residual hazards
9

Product informaon
Idencaon of the products
Nameplates
The nameplate is aached to the motor.
l
DE
2
10.1
8.2
10.2
7.7
10.3
7.8
10.4 8.3
9
10
8.1
18
14
3 7.6
12.1
4
13
7.3
7.4 7.5
16
11.1
11
7.2
15
19
1
12.2
12.3
11.2 11.3
7.1
17
5.7
5.9 5.8 5.4
Pos. Contents Pos. Contents
1Manufacturer/producon locaon 9 Encoder type designaon
2 Motor type/standard 10 Brake data
3 Gearbox type 10.1 Brake type
4 Motor type 10.2 AC/DC brake voltage
5.4 Rao (gearbox) 10.3 Performance
5.7 Load capacity (gearbox) 10.4 Braking torque
5.8 Output speed (geared motor) 11 Fan specicaons
5.9 Output torque (geared motor)t 11.1 AC/DC fan voltage
7.1 Rated voltage/motor voltage 11.2 Rated frequency
7.2 Rated current/motor current 11.3 Electrical power input
7.3 Rated power/motor power 12.1 Material number
7.4 Output torque (motor) 12.2 Serial number
7.5 Motor speed [rpm] 12.3 Year of manufacture/week of manufacture
7.6 Motor code for controller parameterizaon (C86 Y 1.
Frequency)
13 Bar code
7.7 Rated frequency 14 Permissible ambient temperature
7.8 Cos phi 1. Frequency 15 Weight
8.1 Temperature class (motor) 16 UL le number
8.2 Degree of protecon (motor) 17 Conformity/approvals
8.3 Motor protecon 18 Connuous standsll torque M0 [Nm]
19 Addional customer data
Product informaon
Idencaon of the products
Nameplates
10

Product codes
Gearbox product code
Example G 50 B S 113 M H D R 2 C 1B
Product type Gearbox G
Product family 50
Version B
Gearbox type Sha-mounted helical gearbox S
Output torque 130 Nm 113
220 Nm 122
400 Nm 140
660 Nm 166
950 Nm 195
2100 Nm 221
3100 Nm 231
4500 Nm 245
8000 Nm 280
14000 Nm 314
19000 Nm 319
Type of construcon Geared motor M
Gearbox N
Sha design Solid sha with featherkey V
Hollow sha with keyway H
Hollow sha with shrink disc S
Housing type Foot mounng + centering A
Foot mounng B
With centering C
Threaded pitch circle D
Flange mounng Without ange R
Flange with through holes K
Number of stages 2-stage 2
3-stage 3
4-stage 4
Motor mounng Integrated motor C
IEC adapter with jaw coupling N
T
IEC adapter with plug-in hollow
sha
H
NEMA adapter with jaw coupling A
NEMA adapter with plug-in
hollow sha
B
Servo motor adapter with plug-in
hollow sha
S
Servo motor adapter with jaw
coupling
E
D
G
Drive size 1A
...
□H
08
...
82
Product informaon
Idencaon of the products
Product codes
11

Product code of MCS synchronous servo motor
Example M C S 06 C 41 - RS0 B0
Meaning Variant Product code
Product family Motor M
Type Compact servo motors C
Version Synchronous S
Motor frame size Square dimension 62 mm 06
Square dimension 89 mm 09
Square dimension 116 mm 12
Square dimension 142 mm 14
Square dimension 192 mm 19
Overall length C
...
P
Rated speed rpm x 100 11
...
60
Inverter mains connecon 3 x 230 V L
3 x 400 V -
Feedback SinCos absolute value encoder, single-turn, EnDat
AS2048-5V-E
ECN
Digital absolute value encoder, mul-turn,
Hiperface DSL®
AM20-8V-D
EKM
SinCos absolute value encoder, mul-turn, EnDat
AM32-5V-E
EQI
SinCos absolute value encoder, mul-turn, EnDat
AM2048-5V-E
EQN
Digital safety absolute value encoder, mul-turn,
Hiperface DSL®
AM20-8V-D2
EVM
Resolver p=1 RS0
Safety resolver, p=1
RV03
RV0
SinCos absolute value encoder, mul-turn,
Hiperface®
AM128-8V-H
SKM
SinCos absolute value encoder, mul-turn,
Hiperface®
AM1024-8V-H
SRM
SinCos absolute value encoder, single-turn,
Hiperface®
AS1024-8V-H
SRS
SinCos safety absolute value encoder, mul-turn,
Hiperface®
AM128-8V-K2
SVM
SinCos safety absolute value encoder, mul-turn,
Hiperface®
AM1024-8V-K2
SVM
SinCos safety absolute value encoder, single-turn,
Hiperface®
AS1024-8V-K2
SVS
Brake Without brake B0
Permanent magnet brake DC 24V P1
Permanent magnet brake DC 24V, reinforced P2
Product informaon
Idencaon of the products
Product codes
12

Product code feedbacks
Example AS 1024 - 8 V - K 2
Meaning Variant Product code
Product family Resolver RS
Resolver for safety funcon RV
Incremental encoder IG
Incremental encoder with commutaon
signal
IK
Absolute value encoder, singleturn AS
Absolute value encoder, multurn AM
Number 2-pole Resolver for servo motors 0
2-pole Resolver for three-phase AC
motors
1
Number of pole pairs for resolvers 2
3
4
...
Number of bits, steps or increments per
revoluon
20
32
128
512
1024
2048
...
Supply voltage 5 V
8 V
15 V
24 V
...
Interface or signal level Standard
TTL T
HTL (for incremental encoders) H
Hiperface (for absolute value encoders) H
EnDat E
SinCos 1 Vss S
Digital D
For safety funcon
TTL U
HTL (for incremental encoders) K
Hiperface (for absolute value encoders) K
EnDat F
SinCos 1 Vss V
Digital D
Safety Integrity Level (SIL) 1
2
3
4
Product informaon
Idencaon of the products
Product codes
13

Equipment
The following gure provides an overview of the elements and connecons on the product.
Their posion, size and appearance may vary.
Output flange
(depending on the mounting position)
Oil drain plug
(depending on the mounting position)
Oil filler plug
(depending on the mounting position)
Ventilation
(depending on the mounting position)
Remove oil control plug
Housing type
Output shaft
Temperature monitoring
Permanent magnet brake
Feedback
Motor connection
Cooling
Torque plate
Product informaon
Equipment
14

Transport
•Ensure appropriate handling.
•Make sure that all component parts are securely mounted. Secure or remove loose
component parts.
•Only use safely xed transport aids (e.g., eye bolts or support plates).
•Do not damage any components during transport.
•Avoid electrostac discharges on electronic components and contacts.
•Avoid impacts.
•Check the carrying capacity of the hoists and load handling devices. The weights can be
found in the shipping documents.
•Secure the load against pping and falling down.
•Standing beneath suspended loads is prohibited.
The transport weights can be found in the shipping documents!
The motors mounted on the gearbox are somemes equipped with ears. These
are exclusively intended for mounng the motor on/removing the motor from
the gearbox and must not be used for the complete geared motor!
CAUTION!
Danger from pping or falling loads!
Standing beneath suspended loads is prohibited!
▶Use addional appropriate liing aids, if required, to achieve a direcon of loading which is
as vercal as possible (highest load carrying capacity). Secure liing aids against shiing!
▶Screw in the transport aids completely. They must have even and full-surface contact!
▶Transport aids must be loaded vercally in the direcon of the screw axis! Diagonal or
lateral tension reduces the load carrying capacity! Observe data in standard DIN 580!
Posion of the ring bolts
Transport
15

Storage
Storage up to one year:
•Observe the climac condions according to the technical data
-4Environmental condions ^ 55
•Store in a dry, low-vibraon environment (Ve < 0.2 mm/s) without aggressive atmosphere
in the interior
•Protect from dust, shocks and sunlight
•Avoid temperature changes with condensate formaon.
•Store gearboxes with a venlaon unit with the venlaon element on top.
•Do not acvate venlaon unit, in order to prevent air exchange with the ambient air.
•Treat damaged corrosion protecon on shas and bare surfaces subsequently
Storage for more than one year, up to two years:
•Apply a long−term corrosion prevenve (e.g. Ancorit BW 366 from the Fuchs company) to
the shas and uncoated surfaces before storing the motor away.
•Do not acvate venlaon element
•Install gearbox in mounng posion M1 (A)
•Fill gearbox with the lubricant type lled in (see nameplate) up to the lling/venng bore
for mounng posion M1 (A)
-4Nameplates ^ 10
-4Venlaon ^ 19
Storage
16

Mechanical installaon
Important notes
•Install the product according to the informaon in the chapter "Standards and operang
condions".
4Standards and operang condions ^ 54
•The technical data and the data regarding the supply condions can be found on the
nameplate and in this documentaon.
•Ambient media − especially chemically aggressive ones − may damage sha sealing rings,
lacquers and plascs.
•Lenze oers special surface and corrosion protecon in this case.
•Only install the gearbox in the mounng posion shown.
4Mounng posions ^ 18
Preparaon
•Protect sha sealing rings from contact with solvents.
•Remove protecon covers from shas.
•Thoroughly remove ancorrosion agents from the sha and from ange faces.
•Draw the transmission elements onto the output sha only by using the centering thread.
•Align the output sha and transmission elements exactly to avoid tensions.
•Mount belt pulleys, sprockets, or gear wheels as close as possible to the sha shoulder in
order to keep the bending load of the sha and the bearing forces at a minimum level.
•Tighten all screw connecons with the specied torques and secure them with standard
screw locking adhesive.
•Check paint for damage and repair professionally.
Mechanical installaon
Important notes
17

Installaon
•The mounng surfaces must be plane, torsionally rigid and free from vibraons.
•The mounng areas must be suited to absorb the forces and torques generated during
operaon.
•Ensure an unhindered venlaon.
•For versions with a fan, keep a minimum distance of 10 % from the outside diameter of the
fan cover in intake direcon.
Mounng posions
M1 [ A ]
M2 [ D ]
M5 [ F ]
M3 [ B ]
M4 [ C ]
M6 [ E ]
Mechanical installaon
Installaon
Mounng posions
18

Venlaon
No venng measures are required for the G50BS113 … BS122 gearboxes.
The G50BS122 gearbox can oponally be equipped with a breather element.
From G50BS140 onwards, the gearboxes are supplied with breather elements as
standard.
Gearboxes that are delivered with a venlaon unit are provided with a label.
Remove the transport locking device on the vent valve before inial commissioning.
Loosely enclosed vent valves must be mounted in accordance with the mounng posion.
G50BS122 ... BS166
Mounng posion M1 (A) Mounng posion M2 (D) Mounng posion M3 (B)
Filling and venlaon
+
+
②
+
+
Check
③
Drain
②
②G50BS122
③G50BS140
Mechanical installaon
Installaon
Venlaon
19

Mounng posion M4 (C) Mounng posion M5 (F) Mounng posion M6 (E)
Filling and venlaon
+
+
+
②
③④
+
+
Check
②
Drain
②G50BS122
③G50BS140
④G50BS166
Mechanical installaon
Installaon
Venlaon
20