» Operating and maintenance guidelines

» Operating and maintenance guidelines

EMK-motors

Operating and maintenance guidelines EMK motors

Operating and maintenance guidelines EMK motors 3

Spare Parts 5

Lubrication periods 6

Measures 7

Operating and maintenance guidelines spring-operated brake 9

Table of contents

EMK Operating and maintenance guidelines 3

Important for installations in wet internal conditions

or outdoors.

Please note that trouble free operation can only be en-

sured if all the measures set out below are carried out.

The motor terminal box is to be fitted so that the cable

entries are directed downwards.

Use suitable conduit screw fittings for the cable being

used and if necessary use reducing nipples.

Conduit screw fittings and plugs are to be coated with

sealing compound, tightened up securely and recoated.

Cable intakes are also to be made completely water-

tight.

The sealing surfaces of terminal boxes and termi¬nal

box covers are to be properly cleaned before reassem-

bly.

Gaskets are to be glued down on one face. Brittle gas-

kets are to be replaced!

When reassembling after maintenance work, etc. the

end shield centring spigots are also to be coated with

sealing compound.

The corrosion protection consists of a number of paint

coatings. Depending on environmental conditions the

paint coating must be renewed on a regular basis or

wherever necessary.

The electrical connection and maintenance of an elec-

tric drive may only be carried out by qualified electrical

personnel, who are conversant with the relevant regu-

lations. Similarly, the applicable accident prevention

regulations are to be adhered to.

Every EMZ motor is dispatched only after the specifi-

cations on the order have been checked, and a trial run

had been carried out. Until installed, the motor is to be

stored dry and in the same way as the mounting positi-

on. For longer stocked motors the insulated resistance

of every phase has to be measured to ground. It has to

be greater than 0,5 MΩ. For trouble free functioning,

proper installation and operation is essential.

Installation

The motor is to be installed according to its mounting

position and on an even and vibration-free base. The

shaft extensions up to 50 mm 0 have tolerances con-

forming to ISO k6 and above to ISO m6. Before fitting,

the rust inhibitor must be removed from the shaft end,

however, care must be exercised to ensure that no sol-

vent penetrates into the bearing. The motor shaft end

has been provided with a centre and a tapped hole, ac-

cording to the DIN specification 332 type D, which can

be used to pull on the transmission elements without

exerting harmful forces on the motor bearings.

Hammer blows and jolts are to be avoided at all times!

So as not to load the motor shaft excessively, the motor

and the driven machine are to be carefully aligned.

Operating and maintenance guidelines EMK motors » EMK motors distinguish themselves...

SizeTorques (Nm)

Plastic Metal

M12 x 1,5 1,5 8

M16 x 1,5 3,0 10

M20 x 1,5 6,0 12

M25 x 1,5 8,0 12

M32 x 1,5 10,0 18

M40 x 1,5 13,0 18

M50 x 1,5 15,0 20

M63 x 1,5 16,0 20

M72 x 1,5 - 28

M80 x 1,5 - 40

4 Technical amendments reserved, errors excepted

The stated rated motor power applies for a maximum

40 °C ambient temperature and installation altitude up

to 1000 m (3330 feet) above sea level. For higher am-

bient temperatures or installation at greater heights

the power rating is reduced accordingly. (Refer to DIN

57530).

The unimpeded access of ventilating cooling air must

be ensured.

Condensate water drain holes (only on customer‘s re-

quest) are plugged with plastic plugs that can be ope-

ned as required. Open condensate water drain holes are

not permitted because then the IP44 resp. IP55 is lost!

Electrical connection

The motor is connected in accordance with the data

shown on the nameplate and per the accompanying

circuit diagram. Ensure that the terminal links are cor-

rectly placed and all connections, including the protec-

tive earth conductor, are screwed tightly.

To protect the motor from being overloaded, appropri-

ate protective devices must be provided. Fuses do not

give this protection. For motors with high starting fre-

quencies the conventional motor protection is insuffici-

ent; and it is advisable to purchase these motors with

thermistors imbedded in the windings and to monitor

them with an external tripping relay. In this manner the

motors are fully protected against practical all possible

overloads.

Maintenance

For motors up to and including size 132 it is sufficient

to keep the cooling passages cleaned and to check the

bearings. These motors have bearings with service life

lubrication. If the motor is being overhauled the bea-

rings are to be replaced. Motors larger than size 160 are

provided with a lubricator. In addition to keeping the

cooling passages clean the bearing should be checked

regularly and relubricated with a grease pump accor-

ding to the schedule below.

Relevant for greasing interval and grease quantity are

the grease labels fitted on the motor.

Please pay attention that the regreasing device may

not be filled for the first greasing interval.

For this, the double grease quantity has to be used.

As soon as the maximum number of relubrications is

exceeded, the old grease must be removed from the

grease chambers and bearings, after which these must

be cleaned thoroughly. Next the inner chambers and

the bearings must be provided with new grease. The

outer chambers may not be filled with grease.

The type of grease to be used for lubricating the be-

arings can be found on the relubrication plate of the

motor.

WARNING:

When motor is exploited in extremely conditions, i.e.:

» dustiness > 800mg/m3

» relative humidity > 80%

» aggressive in air

it is necessary to decrease minimum two times period

between consecutive inspections.

Drain-hole

EMK-motors are equipped with a drain-hole (originally

closed) which has to be opened during service regularly.


Faults Cause Remedy

Motor overheated (can only be determined by measure-ment)

Motor connected in delta instead of in star as intended. Correct the wiring connection.

Mains voltage deviates from the rated motor voltage by more than 5 %. Too high voltage is particularly detrimental for multi-pole motors, since such

motors have a ,,no-load” current approximately equal to the full load current even when operating on normal current.

Arrange for the correct mains voltage to be applied.

Volume of cooling air inadequate, air ducts clogged up. Ensure the unimpeded access and discharge of cooling air.

Cooling air is preheated. Arrange for cool air supply.

Overload at normal mains voltage. Current excessive. Speed too low. Install larger motor (determine the frame size by measuring the power).

Motor capability exceeded (S1 to S8, DIN 57 530). The motor e.g. becomes overheated due to excessive starting frequency. Here it is not sufficient simply

to use a larger motor since in all probability the same conditions would still arise.

Adapt to the duty-cycle rating necessary for the operating con-ditions. It is preferable under these circumstances to consult a qualified electrical engineer to determine the correct size of motor required in order that the motor may be adapted to suit

the actual mode of operation.

Supply cable has loose contact (temporary single phasing!) Fuse burnt out. Correctly secure the loose contact. Replace the fuse.

Motor does not start Fuse burnt out. Replace the fuse.

Motor protection switch has tripped. Check protection switch for correct setting and adjust.

Motor contactor inoperative. Control fault. Check contactor operation and control and rectify.

Motor does not start or starts with difficulty Designed for delta connection but connected in star. Connect motor correctly.

Voltage or frequency of electrical supply deviates considerably from required rated value during starting conditions. Improve mains supply conditions.

Motor does not start when connected in star, however, starts in delta

Torque insufficient from the connection in star.If delta current is not excessive then reconnect for DIRECT-ON-LINE starting, otherwise a larger size of motor or motor having

special windings will be required.

Contact fault on the star/delta starter. Rectify starter fault.

Motor hums and takes exces-sive current Fault in windings. Motor must be examined and repaired by an electrical service

centre.

Rotor grazing. Motor must be examined and repaired by an electrical service centre.

Fuses blow or motor protec-tion switch trips immediately

Short circuit on the line or motor. Remove short circuit.

Short circuit to motor frame of between the windings turns. Fault to be remedied by a qualified electrical engineer.

Motor incorrectly wired up. Correct the connections.

Wrong direction of rotation Motor incorrectly connected. Interchange any two of the incoming mains phases.

For winding faults The motor MUST be repaired at an electrical service centre.

Spare Parts » When requiring spares please quote the serial number and data shown on the

nameplate together with part numbers and description.

Motor malfunctions


bearing h/3000 rpm h/1500 rpm h/1000 rpm h/750 rpm quantity (g)

6309 5200 9500 11700 12800 20

6311 3500 7400 9400 10700 25

6312 2600 5900 7800 8800 25

6313 2500 5700 7700 8900 30

6314 1800 4800 6600 7600 30

6315 1400 3900 5400 6400 30

6316 1600 4500 6300 7500 40

6317 1200 3700 5400 6500 40

6319 1000 3300 5100 6200 50

6320 820 3300 5100 6400 60

6322 580 2800 4600 5800 70

6324 440 2300 4000 5200 80

NU309 2800 7000 9500 11000 20

NU311 1600 5100 7400 8800 25

NU312 1300 4000 5900 7300 25

NU313 1000 3800 5700 7200 30

NU314 810 3000 4800 6000 30

NU315 500 2400 3900 5000 30

NU316 480 2700 4500 4800 40

NU317 430 2200 3700 4900 40

NU319 330 1800 3300 4600 50

NU320 240 1600 3300 4600 60

NU322 120 1300 2800 4100 70

NU324 110 1100 2300 3600 80

Motortype : KAE

BG AS BS BG AS BS

56 6201-2RZ 6201-2RZ 160 6309/NU309 6309

63 6201-2RZ 6201-2RZ 180 6311/NU311 6311

71 6202-2RZ 6202-2RZ 200 6312/NU312 6312

80 6204-2RZ 6204-2RZ 225 (2) 6312/NU312 6312

90 6205-2RZ 6205-2RZ 225 (4-8) 6313/NU313 6312

100 6206-2RZ 6206-2RZ 250 (2) 6313/NU313 6313

112 6306-2RZ 6306-2RZ 250 (4-8) 6314/NU314 6313

132 6308-2RZ 6308-2RZ 280 (2) 6314/NU314 6314

280 (2-4) 6317/NU317 6314

Motortype: KOI Motortype: KZI

BG AS BS BG AS BS

315 (2) 6317/NU317 6317 315 (2) 6317/NU317 6317

315 (4-8) 6319/NU319 6319 315 (4-8) 6319/NU319 6319

355 (2) 6317/NU317 6317 355 (2) 6319/NU319 6319

355 (4-8) 6322/NU322 6320 355 (4-8) 6322/NU322 6322

Lubrication periods

4-all bearings: C3 bearing play


Motive

In many cases, low-voltage motors are stored for lon-

ger periods of time before assembly and commissio-

ning, sometimes for several years.

In order to prevent premature damage, our customers

must be informed about this topic and, if necessary,

also about the following measures:

» Storage

When storing the motors, the supplied operating inst-

ructions must always be followed:

» Storage room

The motors must be stored in a dry, ventilated, dust-

free, and vibration-free room. Further, the storage

temperature should not be below -15°C (according to

EN60034-1) and the relative humidity should be below

60%.

If this is guaranteed, no special protective packaging

is required.

In all other cases, special packaging with plastic bags

and humidity indicators and a regular inspection will

be necessary.

» Anti-rust

All exposed, outer components (e.g. shaft end, flanges,

feet) have a protective coating for 6 months storage

under dry conditions.

In order to secure a longer storage period, all accessib-

le bare parts must be provided with a long-term corro-

sion protection coating (e.g. Tectyl 506), provided this

has not already been applied by the factory.

Measures » For prolonged storage and before commissioning of low-voltage motors

EA regular inspection of the corrosion coating and, if

necessary, a renewal is necessary.

» Rotor holding device

The rotor holding device serves as a protection of the

bearings during transport and / or in the case of non-

vibration-free mounting (danger of brinelling). If a

rotor retaining device has been mounted on the drive

end of the shaft (DE shaft end) by the factory (e.g. for

designs with roller bearings), this must not be remo-

ved.

If the disassembly of the rotor retaining device is un-

avoidable (e.g. during inspections, tests, etc.), it must

be reattached before dispatch or during further sto-

rage. This also applies in particular to motors in which

a coupling half must be mounted on the DE shaft end.

The coupling half must be removed again after the ad-

justment, the rotor holding device must be reassem-

bled and the coupling half must be supplied or stored

separately.

» Condensation water

If condensation drain holes are present on the motor,

any condensation water must be drained off by remo-

ving the plugs.

Commissioning

The operating instructions of the EMK motor as well

as the safety information „Warnings“ which are sup-

plied with each motor or can be downloaded from the

Internet must be observed entirely.

» Bearings / Lubrication

The rolling bearings must be relubricated if the time

between delivery and commissioning is more than 2

years.


a) Shaft height 56 to 132 (closed bearings)

If the time from delivery to commissioning of the en-

gines is

» under proper conditions (storage in dry, dust-free

and vibration-free rooms) more than 4 years

» more than 2 years under unfavourable conditions

the bearings must be replaced.

b) Shaft height 160 to 355

If the time from delivery to commissioning of the en-

gines is

» under proper conditions (storage in dry, dust-free

and vibration-free rooms) more than 4 years

» more than 2 years under unfavourable conditions

the bearings must be relubricated.

Only identical or compatible greases may be used for

relubrication!

» Insulation resistance

The insulation resistance of the windings to ground

must be measured before commissioning of the mo-

tors. If the minimum values specified by the manufac-

turer are not observed, the motor windings must be

dried.

The following conditions apply to the measurement:

The insulation resistance of the winding is measured

with a DC voltage of 500V to ground. Here, the measu-

ring voltage is applied until the reading values main-

tain stable. The specified minimum values must be

reached during the measurement:

Minimum insulation resistance for new, cleaned or

repaired windings (at 25°C) 10 MOhm

Critical specific insulation resistance after long opera-

tion time at 25ºC winding temperature 0,5 MOhm/kV

The critical value of the insulation resistance is calcu-

lated by multiplying the nominal voltage (in kV) by the

given specific critical insulation resistance (0.5 MOhm

/ kV).

Example:

critical insulation resistance for =690V:

0,69 kV x 0,5 MOhm/kV = 0,345 MOhm


Instruction manual » Spring-operated brake EMK-KHF 3-Phase-Induction-motors

General Description

» Application

DThe spring-operated DC-energized disc brakes are

used for the EMK three-phase AC motors of the KHF

series in frame sizes 80 - 132. The brake must not be

operated in potentially explosive or aggressive atmos-

pheres. Ambient temperature: -20°C to + 40°C

» Design and mode of operation

The brake is a single-disc brake with two friction

surfaces. In the de-energized state, more preloading

springs are used to generate the braking torque due to frictional locking. The brake is released electromagneti-

cally.

During the braking process, the brake disc is pressed against the counter friction surface by the compression

springs. In the braked state, there is an air gap between the magnetic part and the armature plate. By activating

the coil of the magnet part, the armature plate is pressed against the spring force to the magnet part and the

brake is released. In addition, the brake can be released mechanically by pulling the release lever in the direction

of the fan cover.

» Operation

» Electrical wiring

The connection of the brake motor must in accordance with the circuit in the motor terminal box. The AC voltage

for the excitation winding of the brake must be connected to the two free terminals (~) of the rectifier.

Fig: Brake assembly

Fig. Brake circuit

10

Instruction manual » Spring-operated brake EMK-KHF 3-Phase-Induction-motors

Operating conditions

The EMK-KHF series motors can be used under the fol-

lowing conditions:

Frequency / voltage:

3AC50Hz, 230VD/400VY, 3AC60Hz, 460VY

Ambient temperature: -20 - + 40°C

-20 - + 40°C

Installation altitude:

<= 1.000 m above sea level

Relative humidity

<= 85%

The environment should be free of acidic and alkaline

gases, which may interfere with the insulation could

damage the wiring.

The friction surface of the brake must be free of oil

and grease.

Maintenance

The motor should be checked and cleaned regularly.

The intake port of the fan cover should be cleaned of

dirt to ensure proper cooling. The motors have perma-

nently lubricated, maintenance-free bearings.

The brake disc should have a minimum thickness of

1mm. If the minimum thickness is not reached, the

brake disc should be replaced.

The electromagnetic brake should be cleaned regular-

ly and made dust-free.

Adjustment of the brake should only be carried out by

qualified personnel.

To adjust the air gap, tighten the three adjustment

screws evenly.


Technical Data

» Operating values of the brake

» Dimensions of the brake

IEC frame size air gap (mm)) stat. brake torque (Nm) max. air gap (mm)brake release time (s) %

fast slow

80 0.3-0.8 7 1.0 <0.20 <0.50

90 0.3-0.8 15 1.0 <0.20 <0.50

100 0.3-0.8 30 1.0 <0.20 <0.50

112 0.3-0.8 40 1.0 <0.25 <0.60

132 0.4-0.9 80 1.2 <0.25 <0.60

IEC frame size Brake type d1 d2 d3 d4 d5 d6 d L1 L2 L3 L h1 h2 h b

80 DLTZ3-08 117 105 92 65 3xM5 10 20 54,3 31 3 20 124 71 21,6 6 0,3

90 DLTZ3-15 127 114 97 65 3xM6 10 24,8 60 36 3 25 126 73 28,1 8 0,4

100 DLTZ3-30 147 133 116 80 3xM6 10 29,5 60 36 3 30 134 83 32,8 8 0,4

112 DLTZ3-40 166 150 130 90 3xM8 12 29,5 62 39 3 30 162 96 32,8 8 0,5

132 DLTZ3-80 187 170 150 104 3xM8 12 39,5 75,2 48 3 30 175 105 42,8 12 0,5

Figure: KHF 80-132

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