Vemco K21B Series User manual

Edition 07.2010 VEM-Ident-No. 73753 01en
Additional
Installation, Operating and
Maintenance Instructions
Water Cooled Three-Phase Asynchronous Motors
with squirrel-cage rotor for low voltage applications
Translation
Type series
K21B/K23B
WE1B//W21B/W41B
Motors that comply with the Regulation 2005/32/EC
and the order No. 640/2009 receive the marking IEx
before the type designation, whereas x= 1,2,3 (acc. to
EN 60034-30). (Example IE1-K21R 132 S4)

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
2
General
Attention! Read installation, operation and maintenance instructions, connection diagram,
additional connection diagram and safety regulations before transportation, installation,
start-up, maintenance and repair. Mind the information!
The existing additional operation and maintenance manual is valid together with the already mentioned doc-
uments and the operation and maintenance manual for standard motors, where the basic specifications for
connection, installation, operation and maintenance as well as the spare parts lists are included.
This manual shall help the user to ease the secure and proper transportation, installation, start-up and
maintenance of the explosion-protected electric machine.
Observance of this manual and the conditions and methods used for installation, operation, use and mainte-
nance of the electric motor can not be monitored by the manufacturer. An improper installation can result in
property damage and thus result in personal injuries. We therefore do not accept responsibility and liability
for losses, damages or costs resulting from improper installation, improper or wrong use and maintenance or
connected with this in any kind.
Technical drawings and pictures are simplified illustrations. Due to improvements and changes it might hap-
pen that they do not correspond in detail with the supplied electric machine. We strive to improve our prod-
ucts continuously. Consequently technical data and illustrations remain subject to change without prior no-
tice. Specifications may only be considered binding after written confirmation by the supplier.
Symbols
In this manual two symbols will be used, that indicate important passages:
Security and warranty advices,
possible damage to persons included.
Warning against electric voltage, danger of life.
Advice that damages to the electrical machine and/or
the auxiliary devices can happen.
Security regulations
The security regulations, accident prevention regulations, standards and approved rules of technique must
be observed unconditionally!
The non-observance of the security advices can result in endangering people and/or damaging of the ma-
chine.
Efficiency classes
Listed are the IE-classes and the rated efficiency. The motor efficiency is determined according to EN
60034-2-1. For motors < 1kW the direct measurement method is used. For motors ≥ 1kW the individual loss
method is used. The additional losses of this method are determined from the residual losses. The type des-
ignation is extended with the efficiency class as prefix (example IE1-K11R 132 M2…).
Installation and electrical connection
At installation and start of operation the security advices that are enclosed with the motor have to be ob-
served. Installation work shall only be done by qualified personnel who is skilled because of a technical edu-
cation, expertise and schooling of knowledge about
security regulations,
accident prevention regulations,
standards and approved rules of technique
(for example VDE-regulations, standards).
The qualified personnel must have the ability to assess the assigned job, identify possible dangers and avoid
them. The qualified personnel must be authorized by the person in charge for security of the plant to carry
out the necessary work and tasks.
A careful installation of the motors on an exactly level support has to be ensured to avoid strain when tight-
ening the machine. Machines that shall be coupled must be adjusted exactly. If possible elastic couplings
shall be used.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
3
Motor connection
The connection has to be done by qualified personnel according to the valid security regulations.
Outside of Germany the required national standards must be applied.
Name plate designations have to be observed under all circumstances!
Compare current type, mains voltage and frequency!
Mind connection type!
Mind rated current for motor protection switch setting!
For motors with type of protection „increased safety“ “e” the tE- time has to be observed!
Connect the motor according to the connection diagram inside of the terminal box!
Earthing shall be done with the earthing clip that can be found at the enclosure or at the end shield depend-
ing on the type of construction. In addition all motors are equipped with a ground conductor clamp inside of
the terminal box. Unused cable glands of the terminal box have to be closed for protection against dust and
humidity. For electrical connection the standard security and starting instructions are valid. The cable glands
or screwed sealing plugs must be admitted for use in Ex-applications. The installation torques, sealing areas
and clamp ranges of the cable clamps given by the manufacturer have to be observed unconditionally.
Supply cables have to be selected according to DIN VDE 0100 taking into account rated current and opera-
tional conditions (i.e. ambient temperature, method of cable installation etc. complying with DIN VDE 0298
and IEC / EN 60204-1)
Take extra care when connecting the supply cables in the terminal box of the motor. The nuts of the connec-
tion screws have to be fastened without force.
Tightening torques for bolts (terminal box, end shield, bearing cover)
Thread Ø
M5
M6
M8
M10
M12
M16
M20
End shield
-
-
25
45
75
170
275
Bearing cover
5
8
15
20
20
-
-
Terminal box
-
4
7,5
12,5
-
20
-
Engineering design
Up to size 280 the housing of the motor is manufactured as grey cast iron housing with cast-in cooling pipes.
Starting from size 315 the housing is manufactured as double-walled, welded steel construction. Terminal
boxes, end shields, insulation of the winding, type of protection and colouring are the same as for standard
motors. The advantage of water cooling can be found in a noise reduction compared to surface cooled three-
phase motors of the same size and output. The lost heat is dissipated without influence on the environment
and the cooling principle allows for a compact design of the motors with increased output and optimised vi-
bration damping at the same time.
Shaft
height
Material for
Foot mounting
Housing
End shield
Feet
225 –280
Grey cast iron with cast-in
cooling pipes
Grey cast
iron
Grey cast
iron
bolted on
315
Steel-welded construction
Grey cast
iron
Grey cast
iron
cast on
355
Type of protection
The standard version of the motors has a degree of protection in IP 55; according to the order, the degree of
protection can be increased to IP 56. Protection types of IP 65 and higher are available on request.
For all motors in types of mounting with shaft end upwards (IM V3 / IM V36), the user must prevent the in-
gress of water along the shaft.
The operator must prevent that water can ingress in the motor from the shaft for motors with flange end-
shields in types of mounting IM V3 / IM V36. Flange motors in type of constructions IM V3 / IM V36 are fitted
with a drain hole as standard so that condensate water can be drained.
For applications in the open, normally no specific protection measures against weather influences are re-
quired. If it is possible, that the motors are stored or operated below freezing point, freezing of the cooling
water inside the motor must be prevented. Additionally, the motors must be protected against intensive sun
radiation, e.g. by a protective roof.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
4
Classification of shaft size to output
Size
Rated output [kW]
GR
EHL
GR
EHL
GR
EHL
GR
EHL
2-pole
4-pole
6-pole
8-pole
225 S
37
45
37
45
-
-
18,5
22
225 M
45
55
45
55
30
37
22
30
250 M
55
75
55
75
37
45
30
37
280 S
75
90
75
90
45
55
37
45
280 M
90
110
90
110
55
75
45
55
315 S
110
132
110
132
75
90
55
75
315 M
132
160
132
160
90
110
75
90
315 MX
160
200
160
200
110
132
90
110
315 MY
200
250
200
250
132
160
110
132
315 L
250
315
250
290
160
200
132
160
315 LX
315
355
315
355
200
240
160
200
355 M
355
400
355
400
250
315
200
250
355MX
400
500
400
500
315
400
250
315
355 L
500
560
500
560
400
450
315
355
GR… basic series, EHL… increased output
Water cooling
For water cooled motors the waste heat arising from the motor operation is dissipated by the cooling water.
The inlet and outlet for the cooling water is implemented at the non-driving end (N-end). The cooling water
must always contain a rust preventive agent, if the frost line could be crossed, also an anti-freeze or a com-
bined agent must be added.
The motors are intended for operation in closed cycle systems.
From size 315 upwards the operation in open cycle systems is available as a special version. If an open
cycle system shall be used, it is necessary to contact the manufacturer VEM motors GmbH.
Motor handling
If there is a possibility that the motors are stored or operated below the frost line, the freezing of the cooling
water inside the motor must be prevented. For that purpose the cooling water can be drained off or an anti-
freeze must be added to the cooling water, respectively before storage. The following different steps must be
observed:
Version 1 - continuous operation with anti-freeze
If the motor is operated continuously with an anti-freeze and anti-corrosion medium, e.g. HAERTOL Frostox
PSF 12/DI or a similar additive, then a continuous protection against corrosion and freezing is given.
Version 2 –interrupted duty and water as cooling medium
For interrupted motor operation, it is recommended to drain the cooling water off. Before the cooling water is
drained off, an anti-freeze, e.g. HAERTOL Frostox PSF 12/DI or similar products must be added for protec-
tion of the cooling system. By this procedure, the cooling jacket is protected against corrosion for about three
months.
Version 3 –after long-term standstill (with or without anti-freeze in the cooling system)
After long-term standstill and before putting into operation, it must be checked that there are no obstacles to
the free flow of cooling water. Possible traces of rust must be pickled off by a 10 % oxalic acid by the follow-
ing procedure:
Empty the cooling system, if there are any remains of water inside
Fill the cooling system by 10 % oxalic acid (about 100 g per litre) and leave it inside for about 15 min.
Empty the cooling system, rinse it with fresh water –repeat this, if necessary
If the motor was in standstill for a long period, and if the water cooling system was empty during this time it
must be checked that the cooling water is able to circulate without any restrictions before putting into opera-
tion again.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
5
Water feeding, technical requirements for the cooling water
The cooling water must have the quality of drinking water. The maximum water pressure is 3.5 bar, and the
maximum temperature of the entering water must not exceed 35 °C. The following minimum requirements for
the cooling system have to be observed.
Size
Flow rate of
cooling water
Min. water
pressure
Temperature rise
of cooling water
[l/min]
[bar]
[°C]
225
10
0,5
6
250
16
0,7
7
280
18
1,0
9
315
18
1,5
8
355
20
2,0
10
The water inlet and outlet are situated on N-side of the housing. Use suitable sealants for the joints.
Size 225 to 280 Size 315/355
The water supply must be secured during operation of the motor.
Operation without cooling water is not admissible.
In addition there is an air relief plug with 3/8 ” thread on N-end of the motor and a water drain plug with 3/8 “
thread at the lowest point for motors of size 225 to 280. When the cooling system is filled, the air relief plug
must be opened. The motor must be filled with cooling water, until the water exits from the air relief hole. The
filling procedure must be done carefully to make sure that no air remains inside the cooling circuit. Then the
air relief hole must be closed. Again an appropriate sealant must be used. Check that the joints are water-
proof.
To empty the motor, take off the plugs for air relief and water drain. After complete drainage the plugs must
be tightened again. If the cooling system is filled again, check that all plugs are water-proof.
Auxiliary devices
Additional thermal motor protection
For monitoring the stator winding temperature it is possible to have thermo couples installed in the motor
(PTC thermistors, KTY or PT100). For their connection suitable auxiliary clamps for auxiliary circuits are
available in the main terminal box or in additional terminal boxes. The connection is done according to the
attached connection diagram.
Anti-condensation heating
The heating power and the input supply voltage are indicated on the name plate of the motor. For their con-
nection either in the main terminal box or in the auxiliary terminal boxes suitable clamps for auxiliary circuits
are provided. The connection is done according to the attached connection diagram. The anti-condensation
heating has to be switched on only after disconnection of the motor. It shall not be switched on while the
motor is in operation.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
6
Maintenance and repair
Careful and regular maintenance, inspections and revisions are necessary to detect and clear faults in time,
before consequential damages will happen. As individual operating conditions can not be defined for all ap-
plications the listed terms represent a general advice for undisturbed operation. Individual local conditions
(degree of pollution, load, etc.) must be taken into account when adjusting these terms.
What to do?
Time period
Terms
First inspection
After about 500 operating hours
½ year at the latest
Control of air circulation
and surface of motor
Depending on local environmental pollu-
tion
Relubrication (as option)
See name plate or relubrication sign
Main inspection
After about 10,000 operating hours
Once a year
Remove condensate water
Depending on the local environmental
conditions
The necessary relubrication intervals for anti-friction bearings are different to these inspection inter-
vals. They have to be observed as well!
The motors up to size 315M are equipped as standard with anti-friction bearings with life-time lubrication.
From size 315MX upwards they are equipped with relubrication devices which can be ordered for smaller
motors as option. Information about bearings and relubrication can be found in the general installation,
maintenance and operation manual or on the name plate or relubrication sign.
Maintenance works (without relubrication) has to be done at standstill of the motor.
It has to be assured that the machine is secured against re-connection and labelled with an appro-
priate sign.
In addition the security advices and accident prevention regulations of the manufacturers for the use of oils,
lubricants and detergents has to be observed!
Adjacent live parts have to be covered or secured! It has to be assured that the auxiliary circuits like anti-
condensation heating are dead (zero potential).
For design versions with condensate drain hole please observe that the drain plug screw has to be lubricated
with a suitable sealant (for example Epple 28) before relocking.
Spare parts
Except for standard, commercially available and equivalent parts (like anti-friction bearings) only
original spare parts (see spare parts list) shall be used; this applies especially for seals and connec-
tion parts. For spare parts orders the following information is necessary:
Spare parts name
Motor type
Motor number
Long term storage (more than 12 months)
Long term storage must be done indoors in vibration-free, dry rooms with temperatures not below -20°C and
not above +40°C. The storage environment must not contain aggressive gas, vapours, dusts and salts. Pref-
erably motors shall be moved and stored only in original packing. Storage and transport with motors standing
on their fan covers is not allowed. Additionally unprotected metal surfaces like shaft ends and flanges must
be protected with a medium for long-time corrosion protection in addition to the exisiting factory-provided
temporary corrosion protection. If there is a risk of motors being covered by moisture from condensation,
please provide precautionary measures against humidity. Than a special packing in airtight sealed plastic foil
is necessary or as alternative packing in plastic foil with desiccants. Please put desiccant bags in the termi-
nal box as well.
For the transport please use the eye bolts/attachment eyes of the motors together with suitable lifting acces-
sories. The eye bolts/attachment eyes must only be used for lifting the motors without additional mountings
like foundation plates, gears and others.
Motors with reinforced bearings are supplied with a transportation safety device. The transportation safety
device at the shaft end must only be removed during installation of the motor and before switching on.
Disposal
When disposing of the motors please observe applicable national law.
In addition please take care that all oil and grease is disposed according to the ordinance of waste oils
(Altölverordnung). They must not be contaminated with solvents, cold cleaners and paint residues.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
7
Before recycling the individual materials must be separated. Most important components are grey cast iron
(housing), steel (shaft, stator and rotor sheets, consumables), aluminium (rotor), copper (windings) and plas-
tics (insulation materials like for example Polyamide, Polypropylene and others). Electronic components like
printed circuit boards (inverter, encoder, etc.) must be recycled separately.
Terminal board connections
In standard design surface cooled motors are adapted for both rotational directions.
The connections U1, V1, W1 at phases L1, L2, L3 (in alphabetical or natural order) result always in clock-
wise rotation. The sense of rotation can be reversed at direct starting if two main connections at the terminal
board are changed.
For a machine with only one shaft end or with two shaft ends that have different diameters, the sense of
rotation is that rotational direction which is seen, if a person looks at the front end of the only or thicker shaft
end.
For each motor the correct connection diagram is attached. The connection must be done
accordingly. For the connection of auxiliary circuits please see the additional connection dia-
gram, which is also attached.

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
8

Additional Installation, Operating and Maintenance Instructions (Translation) English
Edition 07.2010 VEM-Ident-No. 73753 01en
9
VEM motors GmbH
Carl-Friedrich-Gauß-Straße 1
D-38855 Wernigerode
phone: +49-(0)39 43-68-0
fax: +49-(0)39 43-68-21 20
email: motors@vem-group.com
internet: www.vem-group.com
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