Lenze M55BH063S04 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document provides comprehensive mounting and switch-on instructions for Lenze IE2 and IE3 bevel geared motors, specifically models g500-B, m550-H Version B, and m550-P Version B. It is intended for skilled personnel involved in the electrical and mechanical installation and commissioning of these products.

Function Description

The Lenze geared motors are professional equipment designed for use in trades, specific professions, or industry. They are suitable for operation on the mains or with an inverter. The product consists of a motor and a gearbox, designed to provide specific output torque and speed for various applications. The document details the identification of products through nameplates and product codes, which specify gearbox type, output torque, type of construction, shaft type, housing type, flange mounting, number of stages, motor mounting, and drive size. Motor product codes further specify efficiency class (IE2 or IE3), size, overall length, number of poles, degree of protection (IP54/IP55, IP65/IP66), cooling type (self-ventilation or forced ventilation), brake type (without or spring-applied), feedback options (absolute value encoder, incremental encoder, resolver), and approvals (CE, CCC, cULus, CURus).

The geared motors can be equipped with various extensions, including different types of connectors for electrical installation (terminal box, ICN, M12, HAN), and optional components like oil compensation reservoirs for specific mounting positions.

Important Technical Specifications

Efficiency Classes:

IE2 (High Efficiency) and IE3 (Premium Efficiency) according to EN IEC 60034-30-1.

Degree of Protection:

IP54, IP55, IP65, IP66 according to EN IEC 60529, EN IEC 60034-5.

Temperature Class:

B (130 °C) and F (155 °C) for insulation system according to EN IEC 60034-1.

Permissible Voltage:

Up to 500 V according to IEC 60034-18-41.

Climate Conditions:

Storage: 1K3 (-25 ... +60 °C) according to EN 60721-3-1:1997.
Transport: 2K3 (-25 ... +70 °C) according to EN 60721-3-2:1997.
Operation: 3K3 (0 ... +40 °C) according to EN 60721-3-3:1995 + A2:1997.
Extended Operation: -30 ... +10 °C and -30 ... +40 °C depending on temperature package.

Site Altitude:

0 ... 1000 m amsl: Without current derating.
1000 ... 4000 m amsl: Reduce power by 5%/1000 m.

Air Humidity:

Average relative humidity 85% without condensation.

Motor Data (Examples for 50 Hz, 230V/400V):

Rated Power (P_rated): Ranges from 0.12 kW (063S04) to 22 kW (180L04).
Rated Speed (n_rated): Typically around 1400-1485 rpm.
Max. Speed (n_max): 4500 rpm.
Rated Torque (M_rated): Ranges from 0.810 Nm (063S04) to 142 Nm (180L04).
Efficiency (η): Varies with load, typically ranging from 54.9% to 93.7% depending on model and load.
Moment of Inertia (J): Ranges from 2.4 kgcm² to 2400 kgcm².
Weight (m): Ranges from 4.32 kg to 255.3 kg.

Electrical Connections:

Minimum PE conductor cross-section of 10 mm² (Cu) or 16 mm² (Al) if leakage current > 3.5 mA (AC) or > 10 mA (DC).
Max. pulse voltage amplitude of 1560 V at motor terminals (for inverter operation).

Usage Features

Mounting Positions: The geared motors support six mounting positions (M1 to M6), indicated on the nameplate. The lubricant amount and gearbox ventilation are adapted to the specific mounting position to prevent damage.

Ventilation: Gearboxes from G50BB145 onwards are supplied with breather elements. For smaller gearboxes (G50AB045 to BB124), no venting measures are required, though the G50BB124 can optionally be equipped with breather elements. Transport locking devices on vent valves must be removed before commissioning.

Hollow Shaft and Shrink Disc: For hollow shaft versions, specific instructions are provided for mounting the machine shaft, including cleaning, loosening clamping screws, pushing the gearbox onto the shaft, and tightening screws in multiple passes. A shrink disc cover is provided for protection against accidental contact.

Torque Plate Mounting: Instructions emphasize supporting the socket of the torque plate at both ends, checking axial clearance, and transferring force at right angles to the torque plate for knee lever designs.

Manual Release Lever: For brakes, a lockable manual release lever can be assembled for service work. It is crucial not to lock the manual release in the service position during operation to avoid brake damage.

Electrical Installation: Detailed connection diagrams are provided for power, brake, feedback, temperature monitoring, and blower connections via terminal box, ICN, M12, and HAN connectors. EMC-compliant wiring is essential and detailed in separate inverter documentation.

Maintenance Features

Maintenance Intervals:

After assembly and 3 hours: Check all fixing screws for tightness.
First day, then monthly: General check for unusual noises, vibrations, and high temperatures.
Every 6 months: Check tightness, clean geared motor/gearbox, check rubber buffer, relubricate roller bearings (for adapter with grease nipple).
Annually: Check vent valve.
According to diagram/lubricant table: Change lubricant.
When changing lubricant: Replace roller bearing grease filling.

Lubrication:

Gearboxes G50BB045, G50BB111, and G50BB124 are lubricated for life.
For other gearboxes, lubricant type and quantity are specified on the nameplate.
Change intervals depend on lubricant temperature, with shorter periods for difficult operating conditions.
Instructions for checking and changing lubricant are provided, including filling height specifications for different threaded holes.

Spring-Applied Brake Maintenance:

Holding Brake HBR (with emergency stop): At least every two years, or after 1 million cycles for standard brakes.
Application Brake ABR (with emergency stop): At least every two years, or after 1 million cycles for standard brakes, or 10 million cycles for LongLife design.
Operations: Remove contamination, check ventilation, check/adjust air gap, measure rotor thickness, check for thermal damage.
Air Gap: For IP65/66 brakes, the air gap cannot be adjusted; brakes must be replaced if the maximum air gap is reached. For IP54/55 brakes, the air gap can be adjusted by loosening cheese head screws and screwing sleeve bolts.

Safety: All maintenance work must be performed by qualified personnel on de-energized drives, after surfaces have cooled down, and with loads secured. Safety functions related to brakes and feedback systems require professional execution to avoid loss of safety functions.