Lenze g500-H User manual

Geared motors
g500-H / MF helical geared motor, inverter-opmized
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 13
Informaon on project planning 16
Safety instrucons 16
Basic safety instrucons 16
Applicaon as directed 16
Residual hazards 17
General informaon 19
Drive dimensioning 22
Final conguraon 26
Surface and corrosion protecon 27
Lubricants 28
Venlaon 29
Mechanical installaon 35
Important notes 35
Transport 35
Installaon 35
Electrical installaon 36
Important notes 36
Preparaon 36
Contents
3

Technical data 37
Notes regarding the given data 37
Standards and operang condions 38
Conformies and approvals 38
Protecon of persons and device protecon 38
EMC data 38
Environmental condions 39
Data overview 40
Radial forces and axial forces 50
Selecon tables 55
Motor – inverter assignment 80
Dimensions 81
Basic dimensions 82
Gearbox with pre-stage 117
Integrated inverters 118
Addional lengths 119
Weights 120
Basic weights 120
Addional weights 120
Product extensions 121
Motor connecon 121
Connecon opons 121
Assignment of the terminal boxes 122
Assignment of the connectors HAN 129
Connecon via terminal box 131
Connecon via ICN connector 134
Connecon via M12 connector 137
Connecon via HAN connector 138
Brakes 140
Spring-applied brakes 142
Feedback 157
Resolver 157
Incremental encoder 158
Absolute value encoder 159
Blower 160
Temperature monitoring 161
Thermal contacts TC0 161
PTC thermistor 161
Thermal detectors PT1000 162
Motor data 163
Rated data 163
Rated data 120 Hz 163
Environmental notes and recycling 165
Appendix 166
Good to know 166
Operang modes of the motor 166
Enclosures 167
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
This document uses the following convenons to disnguish dierent types of informaon:
Numbers
Decimal separator Point In general, the decimal point is used.
Example: 1 234.56
Warning
UL warning UL Are used in English and French.
UR warning UR
Text
Programs » « 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 another 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 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
Three-phase AC motor for inverter operaon
In a power range from 0.12 to 22 kW, Lenze oers inverter-compable three-phase AC motors
for more extensive tasks.
The energy-ecient, inverter-opmized MF three-phase AC motors are parcularly suitable
for tasks that demand large seng ranges with minimal sizes.
Customer benet
•Exceed eciency class IE2
•Four-pole motors in the designs B3, B5 and B14
•Seng range up to 1:24 with constant torque
•More dynamic than convenonal three-phase AC motors
•Opmized for use as geared motors with g500 gearboxes and i510 cabinet, i550 cabinet,
and i550 protec frequency inverters
g500-H600 gearbox with MFEMAXX090-32 motor
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
Three-phase AC motor product name
Meaning Variant Product name
Product family MF
Wildcard Cooling □
Internal code MA
Wildcard Brake
Feedback
□□
Size 063
080
090
100
112
132
Overall length 1
...
4
Number of pole pairs 4-pole 2
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.
Oil drain plug
(depending on the mounting position)
Temperature monitoring
Feedback
Cooling
Brake
Output shaft
Output flange
Housing type
Oil control plug
(depending on the mounting position)
Ventilation
(depending on the mounting position)
Oil filler plug
(depending on the mounting position)
Motor connection
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
Gearboxes g500-H45 g500-H100 g500-H140 g500-H210 g500-H320 g500-H450
Min. motor assignment MF□MA□□063 MF□MA□□063 MF□MA□□063 MF□MA□□063 MF□MA□□063 MF□MA□□063
Max. motor assignment MF□MA□□063 MF□MA□□090 MF□MA□□090 MF□MA□□100 MF□MA□□112 MF□MA□□132
Technical data
Max. output torque Nm 45 100 140 210 320 450
Min. drive power kW 0.55 0.55 0.55 0.55 0.55 0.55
Max. drive power kW 0.75 4.0 4.0 7.5 11 22
Mounng posion
Standard M1/M2/M3/M4/M5/M6 (ABCDEF)
Combined M1-M6 (A-F) M1/5/6 (AEF)
Color Unpainted
Primed/RAL colors
Surface and corrosion protecon Without OKS
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
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
Venlaon Without Vent valve
Cooling Integral fan
Blower
Product extensions
Connecon method Y/Δ
Connecon type Terminal box
ICN connector
HAN connector
M12 connector
Spring-applied brake Without
With
Feedback Without
Resolver
Incremental encoder
Absolute value encoder
Temperature monitoring TKO thermal contact
PT1000 temperature sensor
PTC thermistor
Product informaon
The modular system
10

Geared motors 600 Nm to 3000 Nm
Gearboxes g500-H600 g500-H850 g500-H1500 g500-H3000
Min. motor assignment MF□MA□□063 MF□MA□□063 MF□MA□□063 MF□MA□□063
Max. motor assignment MF□MA□□132 MF□MA□□132 MF□MA□□132 MF□MA□□132
Technical data
Max. output torque Nm 600 850 1500 3000
Min. drive power kW 0.55 0.55 0.55 0.55
Max. drive power kW 22 22 22 22
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-S
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
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
Venlaon Vent valve
- Oil compensaon reservoir
Cooling Integral fan
Blower
Product extensions
Connecon method Y/Δ
Connecon type Terminal box
ICN connector
HAN connector
M12 connector
Spring-applied brake Without
With
Feedback Without
Resolver
Incremental encoder
Absolute value encoder
Temperature monitoring TKO thermal contact
PT1000 temperature sensor
PTC thermistor
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^ 50 .
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

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
13

Posions of the terminal boxes/connectors
Power terminal box Blower terminal box HAN connector
with/without ICN connector with/without ICN connector
R
L
B
T
R
L
B
T
R
L
B
T
Posions of the connecons
Power terminal box Blower terminal box HAN connector
ICN cable glands/connectors ICN cable glands/connectors
R
LE
R
L
F
E
R
LE
Posions of the 8400 motec frequency inverters
8400 motec posions Posions of the connectors
I/O connecon
R
L
B
T
Product informaon
The modular system
Mounng posions
14

Posion of the manual release lever
Product informaon
The modular system
Mounng posions
15

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 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.
Informaon on project planning
Safety instrucons
Basic safety instrucons
16

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.
Informaon on project planning
Safety instrucons
Residual hazards
17

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
18

General informaon
Operaon on a frequency inverter
Large seng ranges and opmum operaon with rated torque. These are the strengths of the
MF motor on the frequency inverter. Compared to the 50-Hz operaon, the seng range
increases by 250 %. It is quite simply not possible for a drive to be operated any more
eciently in a machine.
120 Hz f
M, U
MN
UAC
Torque reducon at low motor frequencies
At low motor frequencies (usually < 20 Hz) and with an integral fan, the motor is not cooled
suciently at the rated torque. The motor can be operated from 5 Hz by reducing the torque
accordingly.
Constant cooling takes place over the enre speed range in motors with a blower. This means
that they can be used with their rated torque from 5 Hz.
Informaon on project planning
General informaon
19

The diagram shows the motor size-dependent torque reducon for self-venlated motors,
taking into account the thermal behavior during operaon on the inverter.
C
MFEMA 063 ... 071
080-32MFEMA
MFEMA 090 ... 100
MFEMA 112 ... 132
120 Hz
1.0
0.9
0.8
0.7
0.6
0.5
0.4
M/MN
0510 20 30 40 50 ... 100 110 130 140 150
14 120
A
B
f [Hz]
MFEMA 080-42
D
AOperaon with integral fan and brake
BOperaon with integral fan and "holding current reducon" brake control
COperaon with blower
DOperaon below 5 Hz is possible depending on the applicaon and the control mode. Vericaon of the applicaon by Lenze required.
Thermal power limit
The thermal power limit, dened by the heat balance, limits the permissible connuous
gearbox power. It is aected by
•the churning losses in the lubricant. These are determined by the mounng posion and
the circumferenal speed of the gears
•the load and the speed spectrum.
•the ambient condions: temperature, air circulaon, input or dissipaon of heat via shas
and the foundaons.
NOTICE
A thermal check with the Drive Soluon Designer (DSD) or contacng your Lenze
representave is required if
▶the input speed n1 > 1500 rpm is fallen below in case of the gearbox raos given in the
following.
▶the drive speeds menoned in the following will be exceeded as a funcon of the mounng
posion. For a short period of me up to 5 min, 30 % higher speeds are permissible.
▶the ambient temperature is predominantly above +30 °C.
Gearbox Rao i
g500-H850 ... H3000 ≤ 10
Motor Mounng posion M1 Mounng posion M3, M5, M6 Mounng posion M2, M4
MF☐MA☐☐063 ... 100 4000 rpm 3500 rpm 3000 rpm
MF☐MA☐☐112 ... 132 3000 rpm 2600 rpm 1500 rpm
Informaon on project planning
General informaon
20