Vascat MAC-HS Series User manual

OPERATION AND MAINTENANCE MANUAL
MAC-HS MOTORS

OPERATION AND MAINTENANCE MANUAL
MAC-HS MOTORS PAGE: 2
CODE: CTT32 EDITION: 04 RELEASE: SEPTEMBER 2020
Subject to technical changes without prior notice
CONTENTS
1. LEGAL NOTES AND SAFETY INSTRUCTIONS 5
1.1 Justification ____________________________________________________________________________________ 5
1.2 Target readership and purpose_____________________________________________________________________ 5
1.3 Hazards and warning signs________________________________________________________________________ 6
1.4 Intended use ___________________________________________________________________________________ 7
1.5 Skilled personnel________________________________________________________________________________ 7
1.6 Disclaimer _____________________________________________________________________________________ 8
1.7 Scope of the documentation and external references____________________________________________________ 8
2. DECLARATIONS OF CONFORMITY 9
3. PRODUCT DESCRIPTION 12
3.1 General information_____________________________________________________________________________ 12
3.2 Reference standards____________________________________________________________________________ 13
3.3 Definitions ____________________________________________________________________________________ 14
3.3.1 Duty ____________________________________________________________________________________ 14
3.3.2 Types of construction _______________________________________________________________________ 15
3.3.3 Degree of protection IP______________________________________________________________________ 16
3.3.4 Cooling Methods___________________________________________________________________________ 17
3.3.5 Vibration grade ____________________________________________________________________________ 18
3.3.6 Insulation class____________________________________________________________________________ 19
3.3.7 Stress category severity _____________________________________________________________________ 19
3.3.8 Heating limits _____________________________________________________________________________ 19
3.4 Nameplate____________________________________________________________________________________ 21
3.5 General specifications___________________________________________________________________________ 22
3.5.1 Motor code _______________________________________________________________________________ 22
3.5.2 Ambient conditions _________________________________________________________________________ 22
3.5.3 Duty ____________________________________________________________________________________ 22
3.6 Mechanical specifications ________________________________________________________________________ 24
3.6.1 Mounting_________________________________________________________________________________ 24
3.6.2 IP protection rating _________________________________________________________________________ 24
3.6.3 Cooling Method ___________________________________________________________________________ 25
3.6.4 Balancing and vibration grade ________________________________________________________________ 25
3.6.5 Bearings _________________________________________________________________________________ 26
3.7 Electrical specifications __________________________________________________________________________ 27

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3.7.1 Windings and insulation _____________________________________________________________________ 27
3.7.2 Connections ______________________________________________________________________________ 27
3.7.3 Power-supply conditions_____________________________________________________________________ 28
3.7.4 Standard thermal protection __________________________________________________________________ 29
3.7.5 Thermal sensors___________________________________________________________________________ 30
3.7.6 Anti-condensation heaters ___________________________________________________________________ 31
3.7.7 Fan and pressure gauge ____________________________________________________________________ 31
3.8 Accessories___________________________________________________________________________________ 32
3.8.1 Feedback sensors _________________________________________________________________________ 32
3.8.2 Provision for torque flange assembly ___________________________________________________________ 33
3.8.3 Blocking device____________________________________________________________________________ 33
3.8.4 Provision for accelerometer assembly __________________________________________________________ 34
3.8.5 Noise level _______________________________________________________________________________ 34
4. SHIPMENT, RECEPTION, TRANSPORT AND STORAGE 35
4.1 Shipment_____________________________________________________________________________________ 35
4.2 Reception ____________________________________________________________________________________ 35
4.3 Transport_____________________________________________________________________________________ 36
4.4 Storage ______________________________________________________________________________________ 37
5. INSTALLATION AND START-UP 38
5.1 Motor installation _______________________________________________________________________________ 38
5.1.1 Site _____________________________________________________________________________________ 38
5.1.2 Mounting_________________________________________________________________________________ 39
5.1.3 Machine coupling __________________________________________________________________________ 40
5.2 Electrical connections ___________________________________________________________________________ 42
5.2.1 Connection strips and terminals _______________________________________________________________ 43
5.2.2 Connection diagrams _______________________________________________________________________ 44
5.2.3 Power cables _____________________________________________________________________________ 46
5.2.4 Connections for the fan, thermal sensors and accessories __________________________________________ 48
5.2.5 Final checks ______________________________________________________________________________ 48
5.3 Start-up ______________________________________________________________________________________ 49
5.3.1 Preliminary checks _________________________________________________________________________ 49
5.3.2 Start-up__________________________________________________________________________________ 50

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6. MAINTENANCE 52
6.1 Safety instructions______________________________________________________________________________ 52
6.2 Maintenance operations and frequency _____________________________________________________________ 52
6.2.1 Basic inspection ___________________________________________________________________________ 53
6.2.2 Cleaning of the fan and air filter _______________________________________________________________ 53
6.2.3 Replacement of bearings ____________________________________________________________________ 54
6.3 Replacing the encoder __________________________________________________________________________ 57
6.3.1 Solid shaft encoder_________________________________________________________________________ 57
6.4 Original spares ________________________________________________________________________________ 58
6.5 Operating faults________________________________________________________________________________ 60
6.5.1 Electrical faults ____________________________________________________________________________ 60
6.5.2 Mechanical faults __________________________________________________________________________ 62
6.6 Technical support and service_____________________________________________________________________ 63

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1. LEGAL NOTES AND SAFETY INSTRUCTIONS
1.1 Justification
VASCAT motors contain low-voltage parts and rotating elements that make them hazardous; they also contain hot surfaces.
Users must take notice of all the hazard warning signs described in this manual (see section 1.3).
All tasks related to the transport, connection, commissioning and maintenance must be performed by responsible, skilled
personnel (in accordance with the EN 50110-1 (VDE 0105-100) and IEC 60364 standards). Inappropriate procedures may cause
serious personal injury and material damages.
VASCAT motors may only be used for the purposes specified in Section 1.4.
Furthermore, the site conditions must meet all the requirements given on the motor nameplate and in this document.
1.2 Target readership and purpose
The purpose of the operation manual is to provide all the information required for the appropriate mounting, commissioning and
maintenance of the MAC HS motors and avoid hazards that may cause serious injury. The manual is targeted for any person or
individual who handles or is responsible for operation of the motors dealt with in the manual.
All the individuals working with MAC HS three-phase motors must have this manual at their disposal and they must follow the
relevant instructions and indications.
The operation and maintenance instructions must be read carefully before operating the machine. This will guarantee proper
operation free from hazards and complications and will extend the service life of the machine.
These service instructions provide a description of the machine and information for its proper handling and operation from
delivery to the end of its service life.
This manual must always be complete and perfectly legible.

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1.3 Hazards and warning signs
The manual contains the information required for personnel safety and the prevention of material damages. All information related
to personnel safety is highlighted in general with a warning triangle; however, the hints (to avoid only material damages) are not.
Depending on the hazard level, the signs indicate hazards from major to minor as follows:
WARNING
If no preventive measures are adopted, the result may be death or serious injury.
CAUTION
If no appropriate measures are taken, the result may be serious injury.
PRECAUTION
If no appropriate measures are taken, the result may be material damages.
NB
The result may be an unwanted condition or situation if the corresponding safety instruction is not observed.
If several hazard levels are present at the same time, the most stringent instruction for each case will apply. If a safety instruction
with a warning triangle warns of personal injury, the same instruction may also contain a warning of possible material damages.
Signs indicating the type of danger Warning or Caution in the manual that may be used together with the pictograms above are
as follows:
VOLTAGE
Indicates the presence of voltage on connection terminals or live parts.
HOT SURFACE
Indicates the possibility of the contact surface having a very high temperature with the consequent risk of burns.
MOVING ROTATING PARTS
Indicates the possibility of injury and trauma caused by contact with shafts and other rotating parts.
DANGER
If no appropriate measures are taken, the result will be death or serious injury.

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1.4 Intended use
WARNING
VASCAT motors have been designed for industry plants. They comply with the requirements of the harmonised standards of the
EN 60034 series.
Such pieces of equipment are devices designed to be mounted in machines in accordance with the current Machinery Directive.
Commissioning is not allowed until the end product is checked and found to be compliant with said Directive (please see, among
others, the EN 60204-1 standard).
VASCAT MAC HS motors must be used only for the applications provided in the catalogues and the related technical
documentation.
If third-party products and parts are used, they must be previously approved by VASCAT.
Proper and safe operation of the products requires their proper transportation, storage, installation, mounting, assembly, operation
and maintenance.
Allowed ambient conditions must be observed. The use of MAC HS motors in hazardous areas is strictly prohibited unless they
have been designed specifically for said circumstance, in which case the indications and warnings given in the related
documentation must be observed.
1.5 Skilled personnel
WARNING
VASCAT motors must be installed and operated in accordance with the specifications given in this document. Only skilled
personnel in the context of the manual, i. e. individuals who have the required technical know-how and skills for handling,
commissioning and starting the motors according to safety standards, shall be allowed to operate the motors.
Skilled personnel refers to those individuals who are capable of recognising the risks related to their field of activity and avoiding
the related hazards.

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1.6 Disclaimer
The indications given in the manual describe the product features, but no warranty is implied.
VASCAT declines all liability for damages and operating faults caused by the following:
- Failure to follow the operating instructions.
- Damages caused by inappropriate motor handling.
- Changes made to motors without prior authorisation.
- Operating errors.
- Carrying out inappropriate work on and with the motors.
The indications that refer to procedures and the connection details provided in the manual must be considered only as proposals
and whether or not they are applicable must be studied for each case in particular. VASCAT does not guarantee their
appropriateness in any case.
The data given in this manual is reviewed regularly and subsequent editions are published when corrections are necessary.
1.7 Scope of the documentation and external references
The manual contains all the information required for the correct handling, installation (electrical and mechanical), commissioning
and subsequent maintenance of MAC HS series motors, together with the accessories required for proper operation.
It also describes the safety instructions to guarantee that no personal injuries or material damages will be caused during the
entire process.
If the motor design includes any special features (considered as non-standard), additional documentation may be necessary. In
those cases, the customer must check with VASCAT to make sure that he has all the relevant information.
This document provides no information about the technical data sheets or the specific technical data of the various MAC HS
models or their characteristic curve.
To obtain said information, please log on to the VASCAT website at http://www.vascat.com.

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2. DECLARATIONS OF CONFORMITY

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3. PRODUCT DESCRIPTION
VASCAT MAC HS motors are asynchronous AC electrical machines with a squirrel-cage rotor, square laminated steel frame and
forced cooling. They have been specially designed to operate in high-dynamics applications that require speed variation. They
must be powered exclusively by frequency converters.
3.1 General information
The following table shows the standard technical specifications of the MAC-HS series:
Technical specifications
Description
Motor type
Three-phase asynchronous motor with squirrel-cage rotor
Frame sizes (Shaft heights)
100, 132, 160, 200, 225 and 250 mm
No. of poles
MAC-HS4 series: 4 poles
MAC-HS2 series: 2 poles
Protection rating
(According to the IEC/EN 60034-5 standard)
MAC-HS series: IP23
Type of cooling
(According to the IEC/EN 60034-6 standard)
MAC-HS series: IC06
Power-supply voltage
Up to 500 VAC (other voltages on request)
Insulation class
(According to the IEC/EN 60034-1 standard)
Materials Class H
Mounting type
(According to the IEC/EN 60034-7 standard)
IM B3 or B35 (other types of assembly optional)
Thermal protection
(According to the IEC/EN 60034-11 standard)
PTC140 and Pt100 probes on stator winding and
Pt100 on the bearings (other sensors optional)
Installation altitude
(According to the IEC/EN 60034-1 standard)
<1000 m above sea level
Operating temperature
(According to the IEC/EN 60034-1 standard)
0 to +40ºC
Vibration level
(According to the IEC/EN 60034-14 standard)
Class B
Shaft and flange types
(According to the IEC/EN 60072-1 standard)
Solid shaft without keyway and B5 flange (other setups
optional)
Bearings
High speed hybrid ceramic spindle bearings
Paint
Epoxy resin RAL 7035 colour (other types optional)
Feedback sensors
(optional)
Incremental optical TTL, HTL and Sin/Cos 1 Vpp 1024 or 2084
ppr encoder (Other types of sensors available on request)
Provision for torque flange assembly
(optional)
Assembly according to customer’s requirements
Blocking device
(optional)
Available with torque flange provision only
Provision for accelerometers
(optional)
Assembly according to customer’s requirements
Table 1: General specifications of MAC-HS motors
On many occasions, VASCAT, S.A. adapts its motors to the specific requirements of each customer/application. Therefore, the
above table must be understood as a general reference only. The exact specifications of each motor can be found on the
corresponding technical data sheet and the additional documentation provided to the customer (where applicable).

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3.2 Reference standards
The MAC-HS motors are designed and manufactured according to the Low Voltage Directive 2014/35/CE and they have been
designed for their use in industrial applications as an incomplete machine or as a machine component as provided for in the
2006/42/CE Machinery Directive.
The following table summarises the main reference technical standards that have been taken into account for the design of these
motors:
Standard
Description
IEC/EN 60034-1
Rating and performance
IEC/EN 60034-2
Standard methods for determining losses
IEC/EN 60034-5
Degrees of protection
IEC/EN 60034-6
Cooling
IEC/EN 60034-7
Classification of construction types
IEC/EN 60034-8
Terminal markings and direction of rotation
IEC/EN 60034-9
Noise limits
IEC/EN 60034-11
Thermal protection
IEC/EN 60034-14
Mechanical vibration levels
IEC/EN 60034-18
Functional evaluation of insulation systems
TS 60034-25
Guidance for the design and performance of a.c. motors
specifically designed for converter supply
IEC/EN 60072-1
Power series and dimensions of rotating electrical machines
Table 2: Reference standards
In accordance with the current Machinery Directive, the commissioning of these motors is prohibited in the European Union until
conformity of the installation has been confirmed in which the machine is to be installed (see EN 60204-1). If the electrical
machine is to be used outside the European Union, the specific laws of the country in which it is located will apply. Furthermore,
safety standards, local installation and industry-specific standards must be applied.

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The data given in all the documentation provided by VASCAT includes tolerances in accordance with the IEC/EN 60034-1
standard and they are based on test procedures as provided in the IEC 60034-2 standard. The table shows the tolerances for
some of the most relevant parameters:
Efficiency
Power factor
Slip
Inertia
Noise level
Torque
Speed
Power
-15% (1-η)
-1/6 (1-cos  )
+/-20%
+/-10%
+3 dB
-7%
+/-2%
-5%
Table 3: Tolerances
3.3 Definitions
3.3.1 Duty
Three-phase induction motors are usually designed to deliver their rated power in continuous service with no overheating
problems. However, most motors operate under a non-continuous type of service. Some motors are switched on for a few
moments only, others work all day, but they only charge up briefly, etc. The EN 60034-1 standard defines 10 main service types
and those summarised in the table below apply to MAC HS motors:
Duty
Description
Definition
S1
Continuous duty
Operation under constant load, for a time duration enough to reach
thermal balance.
S2
Short-time duty
Operation under constant load, for a time period shorter than required to
reach thermal balance, followed by a standby period that is sufficient to
cool down to ambient temperature.
S3
Intermittent periodic duty
A series of identical duty cycles consisting of a constant-load period
followed by a stillstand period.
S5
Temporary intermittent duty
with starting and electric
braking
A series of identical duty cycles consisting of a start period, a constant-
load period and an electric braking period, followed by a stillstand
period.
S6
Continuous operation
periodic duty under
intermittent load
A series of identical duty cycles consisting of a constant-load period
followed by a no-load operation period.
S7
Continuous operation
periodic duty under
intermittent load with
electric braking
A series of identical duty cycles consisting of a start period, a constant-
load period, a no-load period and an electric braking period.
Table 4: Duty types

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3.3.2 Types of construction
The following are some of the mounting types applicable to the MAC HS motors, labelled in accordance with the IEC/EN 60034/7
standard.
Mounting
Diagram
Assembly
Mounting
Diagram
Assembly
IM B3
IM1001
Foot-mounting on
lower horizontal plane
IM V1
IM3011
With flange shaft
down (through-holes)
IM B5
IM3001
With horizontal flange
(through-holes)
IM V3
IM3031
With flange shaft up
(through-holes)
IM B6
IM1051
Foot-mounting on
vertical plane shaft
left
IM V5
IM1011
Foot-mounting on
vertical plane shaft
down
IM B7
IM1061
Foot-mounting on
vertical plane (shaft
right)
IM V6
IM1031
Foot-mounting on
vertical plane shaft up
IM B8
IM1071
Foot-mounting on
upper horizontal
plane
IM V18
IM3611
With flange shaft
down (threaded
holes)
IM B14
IM3601
With flange (threaded
holes)
IM V19
IM3631
With flange shaft up
(threaded holes)
IM B35
IM2001
Flange-mounting
(through-holes) and
feet
IM V15
IM2011
Flange-mounting
(through-holes), shaft
down and feet
IM V36
IM2031
Flange-mounting
(through-holes), shaft
up and feet
Table 5: Types of construction

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3.3.3 Degree of protection IP
The degree of protection of electrical machines is defined in accordance with IEC/EN 60034-5. Said standard specifies the
degree of protection of each machine using an ‘IP’ code, which comprises two digits:
- First digit: Indicates the degree of protection for contact and solid bodies.
- Second digit: Indicates the degree of protection for water.
The table below shows the meaning of each digit:
First digit
Protection offered
Second
digit
Protection offered
0
No special protection against contacts. No
protection against the penetration of solid foreign
bodies.
0
No special protection against water.
1
Protection against casual contacts of large surfaces,
e.g. a hand. Protection against the penetration of
solid foreign bodies with a diameter of more than 50
mm.
1
Protection against drops of water that fall vertically.
2
Protection against contact with fingers. Protection
against the penetration of solid foreign bodies with a
diameter of more than 12mm.
2
Protection against drops of water falling at an angle of
up to 15º from the vertical axis.
3
Protection against contacts with tools, wires, etc.
with a diameter of more than 2.5 mm. Protection
against the penetration of solid foreign bodies with a
diameter of more than 2.5mm.
3
Protection against water sprayed at an angle of more
than 60° from the vertical axis.
4
Protection against contacts with tools, wires, etc.
with a diameter of more than mm. Protection against
the penetration of solid foreign bodies with a
diameter of more than 1mm.
4
Protection against water sprayed in any direction
5
Full protection against contacts. Protection against
damaging dust deposits.
5
Protection against jets of water in any direction.
6
Full protection against contacts. Full protection
against the penetration of dust.
6
Protection against the beating of the sea.
7
Protection against temporary immersion under a
specified pressure and for a specified time.
8
Protection against prolonged immersion.
Table 6: IP code
For example, a machine defined as IP54 indicates complete protection against contact and water spraying from any direction.

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3.3.4 Cooling Methods
The cooling methods used in electrical machines are regulated by the IEC/EN 60034-6 standard. In order to identify the cooling
method used in each motor, it is also given a code similar to the IP protection rating. There are two types of code: complete code
(e.g. IC9A7W7) and short code (e.g. IC97W). Both begin with the initials IC (International Cooling).
The table below shows the most common cooling methods for MAC HS motors:
SHORT
CODE
COMPLETE
CODE
EN60034-6
DESCRIPTION
IC00
IC0A0
Free circulation using the surrounding medium by means of free
convection
IC01
IC0A1
Self-ventilated with integral fan cooling,
Cooling air is blown through the motor by a fan mounted on the shaft
IC06
IC0A6
Separate ventilation with radial fitted fan unit,
Cooling air is blown through the motor by a separately excited fan
motor. The inlet side may be equipped with an air filter.
IC16
IC1A6
Circulation via pipe or duct,
Cooling medium is supplied by external part
IC17
IC1A7
Single pipe ventilated,
Cooling air is blown across the motor through the pipe connection with
a separate customer provided external blower fan and discharges on
the other side to open space.
IC37
IC3A7
Double pipe ventilated,
Cooling air is blown across the motor through a pipe connecting by
means of a separate customer provided external blower fan and
discharges on the other side’s pipe connecting.
IC410
IC4A1A0
Totally-enclosed nonventilated,
Cooling without using a fan, only by natural ventilation and radiation on
the totally enclosed motor surface.
IC411
IC4A1A1
Totally-enclosed fan-cooled,
Cooling air is blown over the totally enclosed motor surface by a fan
mounted on the shaft.
IC416
IC4A1A6
External surface cooling,
Cooling air is blown over the totally enclosed motor surface by an
separately excited fan motor.
IC97W
IC9A7W7
Cooling using an independent heat exchanger by means of liquid
coolant or remote fluid
Table 7: Cooling methods

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3.3.5 Vibration grade
The EN 60034-14 international standard specifies the factory acceptance vibration test procedures and vibration limits for certain
electrical machines under specified conditions, when uncoupled from any load or prime mover.
The standard defines two vibration grades: Grade ‘A’ (machines with no special vibration requirements); and Grade ‘B’ (machines
with special vibration requirements).
The table below shows the limits of maximum vibration magnitude in displacement, velocity and acceleration (RMS) for shaft
height (H):
Vibration
grade
Shaft
height
(mm)
56 ≤ H ≤ 132
132 ˂H ≤ 280
H ˃280
Mounting
Displacement
µm
Vel.
mm/s
Accel.
m/s2
Displacement
µm
Vel.
mm/s
Accel.
m/s2
Displacement
µm
Vel.
mm/s
Accel.
m/s2
A
Free
suspension
25
1.6
2.5
35
2.2
3.5
45
2.8
4.4
Rigid mount
21
1.3
2
29
1.8
2.8
37
2.3
3.6
B
Free
suspension
11
0.7
1.1
18
1.1
1.7
29
1.8
2.8
Rigid mount
14
0.9
1.4
24
1.5
2.4
Table 8: Limits of maximum vibration magnitude
When no grade is specified, machines complying with this standard shall be grade “A”.

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3.3.6 Insulation class
The insulation thermal class rating of an electrical machine is identified on the motor nameplate by means of a letter in
accordance with the IEC/EN 60034-18 international standard.
The table below summarises the maximum allowed temperature in the insulation system of a winding in accordance with its
insulation thermal class rating:
Thermal
class rating
Thermal class
A
105ºC
E
120ºC
B
130ºC
F
155ºC
H
180ºC
Table 9: Thermal classes
3.3.7 Stress category severity
The table below describes the four stress categories defined in the IEC 6034-18-41 international standard:
Stress category
Overshoot Factor (OF)
Up/Ua
Impulse Risetime
A –Benign
OF ≤ 1,1
0,3 μs
B –Moderate
1,1 < OF ≤ 1,5
C –Severe
1,5 < OF ≤ 2,0
D –Extreme
2,0 < OF ≤ 2,5
Table 10: Phase-to-ground stress categories
3.3.8 Heating limits
The IEC60034-1 international standard defines the maximum admissible heating (temperature rise) for the windings as specified
in the table below:
Thermal Class
Coolant
temperature
Heating
(per element)
Operating
temperature
B (130ºC)
< 40ºC
< 80ºC
< 120ºC
F (155ºC)
< 40ºC
< 105ºC
< 145ºC
H (180ºC)
< 40ºC
< 125ºC
< 165ºC
Table 11: Heating limits
In this regard the rated working conditions of the motor must be such that the operating temperature on the windings is always
below the temperature specified by the insulation class of its composing materials. Therefore, the working thermal class of a
motor can correspond to the following:
a) The same thermal insulation class. This would be the case of a motor built with Class F insulation (155°C) with a
maximum working temperature of 140°C, corresponding to a Class F.

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b) A thermal class lower than the insulation class. This would be the case of a motor built with Class H insulation
(180°C) with a maximum working temperature of 140°C, corresponding to a Class F.