Vascat MAC R Series Instructions for use

INSTRUCTIONS AND MAINTENANCE MANUAL
MAC R MOTORS

INSTRUCTIONS AND MAINTENANCE MANUAL
MAC R MOTORS
PAGE: 2
CODE: CTT12 EDITION: 01 DATE: MAY 2013
Subject to technical changes without prior notice
CONTENTS
1. LEGAL NOTES AND SAFETY INSTRUCTIONS _______________________________________ 5
1.1 Justification _______________________________________________________________ 5
1.2 Users and purpose _________________________________________________________ 5
1.3 Hazards and warning signs ___________________________________________________ 6
1.4 Intended use ______________________________________________________________ 7
1.5 Qualified personnel _________________________________________________________ 7
1.6 Disclaimer ________________________________________________________________ 8
1.7 Scope of the documentation and external references _______________________________ 8
2. DECLARATIONS OF CONFORMITY ________________________________________________ 9
3. PRODUCT DESCRIPTION _______________________________________________________ 10
3.1 General information ________________________________________________________ 10
3.2 Reference standards _______________________________________________________ 11
3.3 Definitions _______________________________________________________________ 12
3.3.1 Duty ________________________________________________________________ 12
3.3.2 Mounting ____________________________________________________________ 13
3.3.3 IP protection rating ____________________________________________________ 14
3.3.4 IC Cooling Method_____________________________________________________ 15
3.3.5 Balancing and vibration level _____________________________________________ 16
3.3.6 Insulation class _______________________________________________________ 17
3.3.7 Heating limits _________________________________________________________ 17
3.4 Nameplate _______________________________________________________________ 18
3.5 General specifications ______________________________________________________ 19
3.5.1 Motor code __________________________________________________________ 19
3.5.2 Ambient conditions ____________________________________________________ 19
3.5.3 Duty ________________________________________________________________ 19
3.6 Mechanical specifications ___________________________________________________ 21
3.6.1 Mounting ____________________________________________________________ 21
3.6.2 IP protection rating ____________________________________________________ 22
3.6.3 Cooling Method _______________________________________________________ 22
3.6.4 Balancing and vibration level _____________________________________________ 22

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3.6.5 Bearings ____________________________________________________________ 23
3.7 Electrical specifications _____________________________________________________ 25
3.7.1 Windings and insulation ________________________________________________ 25
3.7.2 Connections _________________________________________________________ 25
3.7.3 Power-supply conditions ________________________________________________ 26
3.7.4 Standard thermal protection _____________________________________________ 27
3.7.5 Fan ________________________________________________________________ 28
3.8 Accessories ______________________________________________________________ 29
3.8.1 Feedback sensors _____________________________________________________ 29
3.8.2 Parking brake ________________________________________________________ 30
3.8.3 Noise level ___________________________________________________________ 31
4. SHIPMENT, RECEPTION, TRANSPORT AND STORAGE ______________________________ 32
4.1 Shipment ________________________________________________________________ 32
4.2 Reception _______________________________________________________________ 32
4.3 Transport ________________________________________________________________ 33
4.4 Storage _________________________________________________________________ 34
5. INSTALLATION AND START-UP __________________________________________________ 35
5.1 Motor installation __________________________________________________________ 35
5.1.1 Site ________________________________________________________________ 35
5.1.2 Mounting ____________________________________________________________ 36
5.1.3 Machine coupling _____________________________________________________ 37
5.2 Electrical connections ______________________________________________________ 39
5.2.1 Connection strips and terminals __________________________________________ 40
5.2.2 Connection diagrams __________________________________________________ 41
5.2.3 Power cables _________________________________________________________ 42
5.2.4 Connections for the fan, thermal sensors and accessories ______________________ 44
5.2.5 Final checks _________________________________________________________ 44
5.3 Start-up _________________________________________________________________ 45
5.3.1 Preliminary checks ____________________________________________________ 45
5.3.2 Start-up _____________________________________________________________ 46
6. MAINTENANCE________________________________________________________________ 47

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6.1 Safety instructions _________________________________________________________ 47
6.2 Maintenance operations and frequency ________________________________________ 47
6.2.1 Basic inspection ______________________________________________________ 48
6.2.2 Replacement of bearings _______________________________________________ 48
6.3 Replacing the encoder _____________________________________________________ 51
6.4 Replacing the brake and/or lining _____________________________________________ 52
6.5 Original spares ___________________________________________________________ 53
6.6 Operating faults ___________________________________________________________ 55
6.6.1 Electrical faults _______________________________________________________ 55
6.6.2 Mechanical faults______________________________________________________ 57
6.7 Technical support and service ________________________________________________ 58

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MAC R MOTORS
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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 the work related to the transport, connection, start-up and maintenance must be performed by responsible,
qualified personnel (in accordance with the EN 50110-1 (VDE 0105-100) and IEC 60364 standards). Incorrect
procedures may cause serious personal injury and material damages.
VASCAT motors may only be used for the purposes specified in section 0.
Furthermore, the conditions in the place where they are used must meet all the requirements given on the
specifications plate and in this document.
1.2 Users and purpose
The purpose of this instructions manual is to provide all the information required for the correct assembly, start-up
and maintenance of the MAC R motors and avoid hazards that may cause serious injury. This manual is for any
person or individual working with the motors to which it refers or who assume responsibility for their operation.
All the individuals working with three-phase MAC R motors must have this manual at their disposal and they must
follow the relevant instructions and indications.
The service instructions must be read carefully before using the machine. This will guarantee correct operation
free from hazards and complications and will extend the service life of the machine.
These service instructions give a description of the machine and information on its correct 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
This manual contains the information required for personal safety and the prevention of material damages. All the
information that refers to personal safety is highlighted in general with a warning triangle; however, the
informative notes (to avoid only material damages) are not. Depending on the hazard level, the signs indicate
hazards from major to minor as follows:
WARNING
This means that if the appropriate preventive measures are not adopted, the result will be death or serious
injury.
PRECAUTION
This means that if the appropriate preventive measures are not adopted, the result may be serious injury.
PRECAUTION
This means that if the appropriate preventive measures are not adopted, the result may be material damages.
NB
This means that the result may be an unwanted status or situation if the corresponding safety instruction is not
observed.
In the case of various hazard levels at the same time, the strictest security instruction will prevail in all
circumstances. If a safety instruction with a warning triangle warns of personal injury, the same instruction may
also contain a warning of possible material damages.
The signs that indicate the type of hazard (warning or precaution in this manual), which may be used in
conjunction with the above pictograms, are as follows:
VOLTAGE
Indicates the existence 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 properties caused by contact with shafts and other rotating parts.
DANGER
This means that if the appropriate preventive measures are not adopted, the result will be death or serious injury.

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1.4 Intended use
WARNING
VASCAT motors are to be used in industrial installations. They comply with the requirements of the harmonised
standards of the EN 60034 series.
Said units are parts designed to be mounted on machines in accordance with the current machines directive.
Start-up 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).
MAC R motors by VASCAT must be used only for the applications provided in the catalogues and the
associated technical documentation.
If third-party products and parts are used, they must be previously approved by VASCAT.
The correct and safe operation of the products requires their correct transport, storage, installation, assembly,
operation and maintenance.
The allowed ambient conditions must be observed. The use of MAC R motors in potentially explosive
atmospheres is strictly prohibited unless they have been designed specifically for said circumstance, in which
case the indications and warnings given in the associated documentation must be observed.
1.5 Qualified personnel
WARNING
VASCAT motors must be installed and operated in accordance with the specifications given in this document.
Only qualified personnel are authorised to intervene when, in accordance with the manual, they have all the
technical know-how and skills required to handle, start up and connect the motors in accordance with safety
standards.
Qualified personnel refers to the individuals who are capable of recognising the risks associated with their field
of activity and avoid associated hazards.

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1.6 Disclaimer
The indications given in this manual describe the product specifications but do not guarantee them.
VASCAT declines all liability for damages and operating faults caused by the following:
- Failure to follow the operating instructions.
- Damages caused by incorrect operation of the motor.
- 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 included in this 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
This manual contains all the information required for the correct handling, assembly (electrical and mechanical),
start-up and subsequent maintenance of MAC R series motors, together with the accessories that are necessary
for correct 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 involves any type of special work (considered as non-standard), additional documentation may be
necessary. In said case, 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 R models or their characteristic power and torque curves.
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
The VASCAT motors of the MAC R series are asynchronous electrical AC machines with a squirrel-cage rotor,
circular housing and forced ventilation. They have been specially designed to work in high-dynamics applications
that require speed variation. They can be powered by frequency converters or directly from the mains.
3.1 General information
The following table shows the standard technical specifications of the MAC R series:
Technical specifications Description
Motor type Three-phase asynchronous motor with squirrel-cage rotor
Frame sizes (Shaft heights) 80, 90, 100, 112, 132 and 160 mm
No. of poles 4 poles
Protection rating
(According to the IEC/EN 60034-5
standard)
IP54
Cooling Method
(According to the IEC/EN 60034-6
standard)
IC416
Power-supply voltage Up to 500 VAC
Insulation class
(According to the IEC/EN 60034-1
standard)
Materials Class F - Operating temperature Class F
Assembly type
(According to the IEC/EN 60034-7
standard)
IM B3, IM B5
Thermal protection
(According to the IEC/EN 60034-11
standard)
PTC140ºC sensor on stator winding
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 A
Shaft and flange types
(According to the IEC/EN 60072-1
standard)
Solid shaft with keyway and B5 flange
Bearings Rigid ball bearings (other types optional)
Paint Synthetic enamel RAL 7043 colour (other types optional)
Feedback sensors
(optional)
Incremental optical TTL or HTL 1024 or 2084 ppr encoder
Incremental optical Sin/Cos 1 Vpp 1024 or 2084 ppr encoder
(Other types of sensors available on request)
Brake (optional) Electromagnetic parking brake for absence of 24 VDC supply
(Other types of brake available on request)
Table 1: General specifications of MAC R motors
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 R motors are designed and manufactured according to the Low Voltage Directive 2006/95/CE and they
are to be used in industrial installations as incomplete machinery or machinery component, as provided in the
Machines Directive 2006/46/CE.
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 Dimensioning and behaviour in operation
IEC/EN 60034-2 Method for determining losses
IEC/EN 60034-5 Protection rating
IEC/EN 60034-6 Cooling
IEC/EN 60034-7 Mounting
IEC/EN 60034-8 Marking on terminals and direction of rotation
IEC/EN 60034-9 Noise emissions
IEC/EN 60034-11 Thermal protection
IEC/EN 60034-14 Mechanical vibration levels
IEC/EN 60034-18 Insulation evaluation
TS 60034-17 Technical specifications for the use of asynchronous motors
with frequency converters
IEC/EN 60072-1 Power series and dimensions of rotating electrical machines
Table 2: Reference standards
In accordance with the current Machines Directive, the start-up of these motors is prohibited in the European
Union until the conformity of the installation has been confirmed on the machine that 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 sector-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 Maximum
torque Inertia Noise level
-15% (1-η) -1/6 (1-cos
 ) +/-20% -10% +/-10% +3 dB
Table 3: Tolerances
3.3 Definitions
3.3.1 Duty
Three-phase induction motors are usually designed to develop their rated power in continuous service with no
overheating problems. However, most motors operate under a non-continuous type of service. Some motors
connect only for a few moments, 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 following table apply to MAC R motors:
Duty Description Definition
S1 Continuous service Operation in constant charging status with sufficient duration to reach
thermal balance.
S2 Temporary service
Operation in constant charging status during a shorter period than
necessary to reach thermal balance, followed by a standby period that is
sufficient to cool down to ambient temperature.
S3 Intermittent regular service Chain of identical services made up of a constant charging period
followed by a standby period.
S5 Intermittent regular service
with electrical braking
Chain of identical services made up of a start-up period, a constant
charging period and an electrical braking period followed by a standby
period.
S6
Regular uninterrupted
service with intermittent
charging
Chain of identical services made up of a constant charging period
followed by a period of load-free operation.
S7
Regular uninterrupted
service with intermittent
charging and electrical
braking.
Chain of identical services made up of a start-up period, a period of
constant charging, a period of load-free operation and a period of
electrical braking.
Table 4: Duty

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3.3.2 Mounting
The following are some of the mounting types applicable to the MAC R 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: Mounting

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3.3.3 IP protection rating
The protection rating of electrical machines is defined in accordance with IEC/EN 60034-5. Said standard
specifies the protection rating of each machine using an ‘IP’ code, which comprises two digits:
- First digit: Indicates the protection rating for contact and solid bodies.
- Second digit: Indicates the protection rating for water.
The following table 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 12 mm.
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 2.5 mm.
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 1 mm.
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 full protection against contacts and water sprayed in any
direction.

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3.3.4 IC Cooling Method
The type of cooling used in electrical machines is regulated by the IEC/EN 60034-6 standard. In order to identify
the type of cooling used in each motor, it is also given a code similar to the IP protection rating. There are two
types of code: full indication (e.g. IC9A7W7) and simplified indication (e.g. IC97W). Both begin with the initials IC
(International Cooling).
The following table shows the types of cooling most commonly used in MAC R motors:
SIMPLIFIED
INDICATION
FULL
INDICATION EN60034-6 DESCRIPTION
IC410 IC4A1A0
Cooling of the housing surface, using the surrounding medium, by
means of free convection
IC411 IC4A1A1
Cooling of the housing surface, using the surrounding medium, by
means of own circulation
IC416 IC4A1A6
Cooling of the housing surface, using the surrounding medium, by
means of an independent part fitted on the machine
Table 7: Cooling types

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3.3.5 Balancing and vibration level
The EN 60034-14 standard specifies the test procedures for the acceptance of vibration at factory and the
vibration limits for certain electrical machines in specific conditions when they are disconnected from a power
machine or charge
The standard defines two possible vibration levels for the shaft: type ‘A’ (machines with no special vibration
requirements); and type ‘B’ (machines with special vibration requirements).
The following table shows the maximum admissible limits for displacement, speed and acceleration (in effective
value) for a specific shaft height (H):
Vibration
level
Shaft
height
(mm)
56 ≤ H ≤ 132 132 ˂ H ≤ 280
Assembly Displacement
µm
Speed
mm/s
Accel.
m/s2
Displacement
µm
Speed
mm/s
Accel.
m/s2
A
Free
suspension 25 1.6 2.5 35 2.2 3.5
Rigid mount 21 1.3 2 29 1.8 2.8
B
Free
suspension 11 0.7 1.1 18 1.1 1.7
Rigid mount 14 0.9 1.4
Table 8: Vibration levels
If the machine does not specify the type to which it belongs, it must be considered as type ‘A’.

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3.3.6 Insulation class
The insulation rating of an electrical machine is identified on the motor specifications plate by means of a letter in
accordance with the IEC/EN 60034-18 standard.
The following table summarises the maximum allowed temperature in the installation of a winding in accordance
with its insulation rating:
Class Maximum temperature
A 105ºC
E 120ºC
B 130ºC
F 155ºC
H 180ºC
Table 9: Insulation classes
3.3.7 Heating limits
The IEC60034-1 standard defines the maximum admissible heating (increase in temperature) for the windings as
specified in the following table:
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 10: Heating limits
Accordingly, 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 the part 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.
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.

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3.4 Nameplate
All MAC R motors carry the following specifications plates:
Figure 1: Specifications plate for MAC R motors with shaft heights 80, 90, 100, 112 and 132
Figure 2: Specifications plate for MAC R motors with shaft height 160.
The following table contains a description of the different fields of the plates:
Pos. Description Pos. Description
1 Motor type 2 Serial No.
3 Year of manufacture 4 Construction type Code IM (EN60034-7)
5 / 6 Voltage (V) and Current (A) of the axial fan 7 / 8 Voltage (V) and Current (A) of the brake (*)
9, 10, 11 Efficiency of the motor with specified load % 12 / 17 Nominal current (A) connected in star/triangle
13 Rated power (kW) in star at 230 V / 29 Hz 14 Rated power (kW) in star at 400 V / 50-29 Hz
15 Rated speed (rpm) in star at 230 V / 29 Hz 16 Rated speed (rpm) in star at 400 V / 50-29 Hz
18 Rated power (kW) in triangle at 230 V / 50 Hz 19 Rated power (kW) in triangle at 400 V / 87-50 Hz
20 Rated speed (rpm) in triangle at 230 V / 50 Hz 21 Rated speed (rpm) in triangle at 400 V / 87-50 Hz
Table 11
(*) Positions 7 / 8are checked only if there is a parking brake.

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3.5 General specifications
3.5.1 Motor code
MAC R series motors are coded as follows:
MAC R 100 120 Y
Motor type Series Size Length Connections
MAC
Asynchronous Motor
for frequency
converter or mains
connection
IP54 – IC416
Axial fan
80
90
100
112
132
160
Shaft height
(mm)
70
100
120
125
140
160
170
215
Y (star)
D (triangle)
Defines default
configuration
Table 12: MAC R motor codes
3.5.2 Ambient conditions
In their standard version, MAC R motors are not suitable for working in saline or corrosive atmospheres or for
installation outdoors.
3.5.3 Duty
In all the series, unless specified otherwise, the powers assigned for continuous service (S1) apply, with an
ambient temperature of between -20º and +40ºC and at a maximum height of 1000 m above sea level.
If the working conditions differ from those above, a declassing factor must be applied to the torque and power,
called K1, with regard to the values given on the specifications plate, as shown in the following table:
Altitude Temperature
30ºC 40ºC 50ºC 55ºC
1000 [m] 1 1 0.92 0.86
2000 [m] 1 0.93 0.85 0.77
3000 [m] 0.93 0.85 0.76 0.69
4000 [m] 0.86 0.78 0.67 0.6
Table 13: Declassing factors
If the motor does not work in continuous service (S1), but rather in an S2-type temporary service, a multiplication
factor must be applied (K2) to the torque and power specified on the plate (S1 Service) to determine the torque
available for the service. The K2 factor is determined by the duration of the service according to the following
graph.

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Figure 3: Derating factor for an S2-type service