Lenze g500-S User manual

Mains-operated geared motors
g500-S sha-mounted 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 18
Informaon on project planning 21
Safety instrucons 21
Basic safety instrucons 21
Applicaon as directed 21
Residual hazards 22
Drive dimensioning 24
Final conguraon 26
Surface and corrosion protecon 27
Lubricants 28
Venlaon 29
Informaon on mechanical installaon 35
Important notes 35
Transport 35
Installaon 35
Informaon on electrical installaon 36
Important notes 36
Connecon according to EN 37
Connecon according to cULus 40
Technical data 44
Notes regarding the given data 44
Standards and operang condions 45
Conformies and approvals 45
Protecon of persons and device protecon 46
EMC data 46
Environmental condions 47
Electrical supply condions 47
Radial forces and axial forces 48
Selecon tables 50
Dimensions 59
Basic dimensions 60
Gearbox with pre-stage 93
Addional lengths 93
Weights 94
Basic weights 94
Addional weights 94
Contents
3

Product extensions 95
Torque plates 95
Sha covers 96
Motor connecon 97
Connecon via terminal box 97
Connecon via QUICKON V2 connector 97
Connecon via M15 connector 97
Connecon via M12 connector 98
Brakes 99
Spring-applied holding brake 100
Brake resistors 102
Accessories 103
NFC adapter 103
QUICKON connector 104
UMCLN_SGG_100181 105
Product codes 106
Motor data 108
Rated data 108
Ecodesign Direcve 108
Environmental notes and recycling 109
Appendix 110
Good to know 110
Operang modes of the motor 110
Enclosures 111
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.
In combinaon with three-phase AC motors, our sha-mounted helical gearbox forms a
compact, powerful drive unit. Numerous opons at the input and output end allow the drive
to be precisely adapted to your applicaon.
The slim, sha-mounted helical gearboxes feature high permissible radial forces, closely
stepped raos and a low backlash. They are available in a 2-stage, 3-stage and 4-stage design
with a torque of up to 4500 Nm and a rao of up to i= 5849.
Types
•Slimline design saves installaon space of the machine
•Sha dimensions in accordance with market standards and standardized anges for easy
machine integraon
•High accuracy with axial output provide for the highest 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: MSEMAXX080-32 Smart Motor - g500-S660 sha-mounted helical gearbox
Product informaon
Product descripon
7

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.
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.
Product informaon
Product descripon
8

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.
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 Product
Sha-mounted helical
gearbox g500 - S
130 g500-S130
220 g500-S220
400 g500-S400
660 g500-S660
950 g500-S950
2100 g500-S2100
3100 g500-S3100
4500 g500-S4500
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.
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
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
Torque support
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 660 Nm
Gearbox g500-S130 g500-S220 g500-S400 g500-S660
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 130 220 400 660
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 M1/5/6 (AEF)
Color Unpainted
Primed
Painted in RAL colors
Surface and corrosion protecon OKS-G
Dierent types of surface and corrosion protecon
Output sha
Solid sha with featherkey (V) mm 25 x 50 25 x 50 30 x 60 35 x 70
40 x 80
Hollow sha with keyway (H) mm 25 25/30 30/35 40/45
Hollow sha with shrink disc (S) mm 25 25/30 35 40
Sha material Steel
Stainless steel
Sha sealing ring material NBR
FKM (Viton)
Output sha bearing Standard
Gearbox design With foot (HBR/VBR)
Without foot and centring (HCR)/(VCR/SCR)
With centring (HCR/VCR/SCR)
With output ange (HCK/VCK/SCK)
Output ange (K) mm 160 160 200 200/250
Lubricant Mineral oil
Synthec oil
Food-compable oil
Cooling Self-venlated
Torque plate Rubber buers
Sha cover Shrink disc cover
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 from 950 Nm to 4500 Nm
Gearbox g500-S950 g500-S2100 g500-S3100 g500-S4500
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 950 2100 3100 4500
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 surface and corrosion protecon
Output sha
Solid sha with featherkey (V) mm 40 x 80 50 x 100 60 x 120 70 x 140
80 x 160
Hollow sha with keyway (H) mm 40 50/55 60/70 70/80
Hollow sha with shrink disc (S) mm 40 50 65 75/80
Sha material Steel
Stainless steel
Sha sealing ring material NBR
FKM (Viton)
Output sha bearing Standard
Gearbox design With foot (HBR)/(VBR/SBR)
With foot and centering (HAR/VAR(SAR)
With foot and output ange (HAK/VAK/SAK)
Output ange (K) mm 250 250/300 350 400/450
Lubricant Mineral oil
Synthec oil
Food-compable oil
Cooling Self-venlated
Torque plate Rubber buers
Sha cover Shrink disc cover
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
g500-S130 ... S660
Hollow sha, with foot
Without centring (HBR)
Hollow sha, without foot
Without centring (HDR) With centering (HCR) Flange with through holes (HCK)
Product informaon
The modular system
Designs
15

Shrink disc, without foot
Without centring (SDR) With centring (SCR) Flange with through holes (SCK)
Solid sha, with foot
Without centring (VBR)
Solid sha, without foot
Without centring (VDR) With centering (VCR) Flange with through holes (VCK)
Product informaon
The modular system
Designs
16

g500-S950 ... S4500
Hollow sha, with foot
Without centring (HBR) With centring (HAR) Flange with through holes (HAK)
Shrink disc, with foot
Without centring (SBR) With centring (SAR) Flange with through holes (SAK)
Solid sha, with foot
Without centring (VBR) With centring (VAR) Flange with through holes (VAK)
Product informaon
The modular system
Designs
17

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-S130 ... S660 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
18

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
19

Posion of the hollow sha with shrink disc
The output ange is only available in posion "F".
Output ange and shrink disc are not possible in the same posion.
E
F
Product informaon
The modular system
Mounng posions
20