Lenze IE2 g500-H Guide

Geared motors
IE2 g500-H / m550-H helical geared motor generaon B
IE3 g500-H / m550-P helical geared motor generaon B
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 8
Applicaon as directed 9
Foreseeable misuse 9
Residual hazards 10
Product informaon 12
Idencaon of the products 12
Nameplates 12
Product codes 14
Equipment 17
Transport 18
Storage 20
Mechanical installaon 21
Important notes 21
Preparaon 21
Installaon 22
Mounng posions 22
Venlaon 23
Dimensions 27
Mounng 28
Product extensions 29
Electrical installaon 31
Important notes 31
Preparaon 31
Motor connecon 32
Connecon via terminal box 33
Connecon via ICN connector 37
Connecon via M12 connector 40
Connecon via HAN connector 41
Commissioning 43
Important notes 43
Before inial switch-on 44
Funconal test 44
Maintenance 45
Maintenance intervals 46
Maintenance work 48
Repair 57
Diagnoscs and fault eliminaon 58
Malfuncons 58
Contents
3

Technical data 60
Standards and operang condions 60
Conformity and approvals 60
Protecon of persons and device protecon 60
EMC data 60
Environmental condions 61
Motor data 62
Rated data 62
Ecodesign regulaon 68
Environmental notes and recycling 71
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
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!
Safety instrucons
7

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.
Safety instrucons
Basic safety instrucons
8

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 may be operated with or without an inverter.
•The harmonized standards of the series IEC/EN60034 are used.
Foreseeable misuse
•Use in potenally explosive areas
•Use in agressive environments
•Use under water
•Use under radiaon
•Use in generator mode
Safety instrucons
Applicaon as directed
9

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.
Safety instrucons
Residual hazards
10

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
•Excessively high torques cause damage to the gearbox.
-Do not exceed the output torque specied on the nameplate.
•Excessively high input speeds lead to higher temperatures.
-Do not exceed the input speed specied on the nameplate.
•Lateral forces on the gearbox sha are possible.
-Align the shas of gearboxes and driven machine exactly to each other.
•Toothed parts may be damaged by a lack of lubricant.
-Only use the gearbox in the mounng posion indicated on the nameplate.
-Use the lubricant type and amount specied on the nameplate when changing the
lubricant.
Safety instrucons
Residual hazards
11

Product informaon
Idencaon of the products
Nameplates
The nameplate is aached to the motor.
Product informaon
Idencaon of the products
Nameplates
12

11.1 11.2 11.3 11.511.4 11.6 11.7 11.8 11.9 12 13.1 13.2 13.3
4
1
L
23
22
20
19
23
Hz kW r/min C86 M2 n2 c
89
7.1 7.3
7.8
Brake
ACH
Fan
15
5
16.416.216.1
6.4 6.5 6.6 6.7
6.3
7.57.4
6.2
7.2
6.1 14
16.3
17.1 17.2 17.3
18
7.6 7.7SF
10
A
V
A
V
2
3
21
Posion Contents Posion Contents
1 Manufacturer 12 Motor code for Lenze frequency inverter
2 Country of producon 13 Gearbox output data
3 Approvals 13.1 Output torque
4 Standards 13.2 Output speed
5 Motor type 13.3 Load capacity
6 Gearbox data 14 Temperature monitoring
6.1 Product name 15 Feedback
6.2 Product code 16 Brake
6.3 Gearbox rao 16.1 Size
6.4 Posion: Sha, ange, terminal box/motec 16.2 Supply voltage
6.5 Mounng posion 16.3 Power
6.6 Lubricant 16.4 Braking torque
6.7 Lubricant quanty 17 Blower
7 Motor data 17.1 Rated voltage
7.1 Product name 17.2 Rated frequency
7.2 Product key 17.3 Rated power
7.3 Degree of protecon 18 An-condensaon heater
7.4 Eciency class 19 Customer data
7.5 Operang mode 20 Year of manufacture / week of manufacture
7.6 Rated frequency 21 Country of producon, code
7.7 Service factor 22 Material number
7.8 Class of insulaon 23 Serial number
8 Ambient temperature 24 Bar code
9 Weight
10 UL product category
11 Motor data at rated frequency
11.1 Rated frequency
11.2 Rated power
11.3 Rated voltage
11.4 Rated current
11.5 Rated voltage
11.6 Rated current
11.7 Rated speed
11.8 Power factor
11.9 Eciency
Product informaon
Idencaon of the products
Nameplates
13

Product codes
Gearbox product code
Example G 50 A H 045 M V C R 2 C 1A
Product type Gearboxes G
Product family 50
Generaon A
B
Gearbox type Helical gearbox H
Output torque 45 Nm 045
100 Nm 110
140 Nm 114
210 Nm 121
320 Nm 132
450 Nm 145
600 Nm 160
850 Nm 185
1500 Nm 215
3000 Nm 230
5000 Nm 250
8000 Nm 280
14000 Nm 314
Type of construcon Geared motor M
Gearboxes N
Sha type Solid sha with featherkey V
Solid sha without featherkey G
Housing type Foot mounng + centering A
Foot mounng B
With centering C
Flange mounng Without ange R
Flange with through holes K
Reinforced ange with through
holes P
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
Servomotor adapter with plug-in
hollow sha
S
Servomotor adapter with jaw
coupling
E
D
G
Drive size 1A
...
□H
08
...
82
Product informaon
Idencaon of the products
Product codes
14

Motor product code
Example M 55 B H 063 S 04 5 E 0 0 C C
Product type Motor M
Product family 55
Version B
Eciency class IE2 H
IE3 P
Size 063
071
080
090
100
112
132
160
180
Overall length Short S
Medium M
Long L
Number of poles 4-pole 04
Degree of protecon IP54/IP55 5
IP65/IP66 6
Cooling Self-venlaon E
Forced venlaon F
Brake Without 0
Spring-applied brakes F
Feedback Without 0
Absolute value encoder A
Incremental encoder E
Resolver R
Approvals None N
CE C
CE, CCC 3
CE, cULus L
CE, cULus, CCC 5
CE, cURus U
CE, cURus, CCC W
Design type Internal key C
Product informaon
Idencaon of the products
Product codes
15

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 steps / 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
16

Equipment
The following gure provides an overview of the elements and connecons on the product.
Their posion, size and appearance may vary.
Motor connection
(depending on
the mounting position)
Oil filler plug
(depending on the
mounting position)
Ventilation
(depending on
the mounting position)
Oil control plug
Housing type
Output flange
Output shaft
Brake
Cooling
Feedback
Temperature monitoring
(depending on the
mounting position)
Oil drain plug
Product informaon
Equipment
17

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!
The thread in the output sha can be used with smaller drives. Larger gearboxes have a
transport thread for eye bolts in accordance with DIN 580 in the gearbox housing as standard.
The eye bolt is not included in the scope of supply!
The posion of the transport thread can be seen in the following representaons.
Posion of the eye bolt
G50AH045 ... G50BH114 G50BH121 ... G50BH230
1. 2.
Transport
18

Thread M6 M8 M10 M12 M16 M20 M24
Load carrying
capacity
kg 80 140 230 340 700 1200 1800
Transport
19

Storage
Storage up to one year:
•Observe the climac condions according to the technical data
-4Environmental condions ^ 61
•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 ^ 12
-4Venlaon ^ 23
Storage
20