Lenze g500-H Mounting Instruction

Geared motors

IE2 g500-H / m550-H helical geared motor generaon B

IE3 g500-H / m550-P helical geared motor generaon B

Mounng and switch-on instrucons EN

Contents

About this document 5

Document descripon 5

Further documents 5

Notaons and convenons 6

Safety instrucons 7

Basic safety instrucons 7

Applicaon as directed 7

Residual hazards 8

Product informaon 10

Idencaon of the products 10

Nameplates 10

Product codes 12

Equipment 15

Transport 16

Storage 18

Mechanical installaon 19

Important notes 19

Preparaon 19

Installaon 20

Mounng posions 20

Venlaon 21

Dimensions 25

Mounng 26

Product extensions 27

Electrical installaon 29

Important notes 29

Preparaon 29

Motor connecon 30

Connecon via terminal box 31

Connecon via ICN connector 36

Connecon via M12 connector 39

Connecon via HAN connector 40

Commissioning 42

Important notes 42

Before inial switch-on 43

Funconal test 43

Maintenance 44

Maintenance intervals 45

Maintenance work 47

Repair 56

Diagnoscs and fault eliminaon 57

Malfuncons 57

Contents

3

Technical data 59

Standards and operang condions 59

Conformies and approvals 59

Protecon of persons and device protecon 59

EMC data 59

Environmental condions 60

Motor data 61

Rated data 61

Ecodesign Direcve 67

Environmental notes and recycling 72

Contents

4

About this document

WARNING!

Read this documentaon carefully before starng any work.

▶Please observe the safety instrucons!

Document descripon

This document is intended for skilled personnel who work with the products described.

The data and informaon compiled in this document serve to support you in the electrical and

mechanical installaon and commissioning.

•The document is only valid together with the complete documentaon of the product!

•For safety-rated aachments observe the enclosed operang instrucons of the

manufacturer!

•The document includes safety instrucons which must be observed.

•All persons working on and with the drives must have the documentaon at hand during

work and observe the informaon and notes relevant for it.

•The documentaon must always be complete and in a perfectly readable state.

Further documents

Informaon and tools with regard to the Lenze products can be found on the

Internet:

www.Lenze.com à Downloads

About this document

Document descripon

5

Notaons and convenons

Convenons are used in this document to disnguish between dierent types of informaon.

Numeric notaon

Decimal separator Point Generally shown as a decimal point.

Example: 1 234.56

Warnings

UL Warnings UL Are used in English and French.

UR warnings UR

Text

Engineering Tools " " Soware

Example: "Engineer", "EASY Starter"

Icons

Page reference ¶Reference to another page with addional informaon.

Example: ¶ 16 = see page 16

Documentaon reference ,Reference to other documentaon with addional informaon.

Example: , EDKxxx = see documentaon EDKxxx

Layout of the safety instrucons

DANGER!

Indicates an extremely hazardous situaon. Failure to comply with this instrucon will result

in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situaon. Failure to comply with this instrucon may result

in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situaon. Failure to comply with this instrucon may result in slight to

medium injury.

NOTICE

Indicates a material hazard. Failure to comply with this instrucon may result in material

damage.

About this document

Notaons and convenons

6

Safety instrucons

Basic safety instrucons

Disregarding the following basic safety instrucons and safety informaon may lead to severe

personal injury and damage to property!

•Only use the product as directed.

•Never commission the product in the event of visible damage.

•Never modify the product technically.

•Never commission the product before assembly has been completed.

•Never operate the product without the required covers.

•Connect/disconnect all pluggable connecons only in deenergized condion!

•Only remove the product from the installaon in the deenergized state.

•The product can – depending on their degree of protecon – have live, movable or

rotang parts during or aer operaon. Surfaces can be hot.

•Observe all specicaons of the corresponding documentaon supplied. This is the

condion for safe and trouble-free operaon and the achievement of the specied

product features.

•The procedural notes and circuit details given in the associated documentaon are

suggesons and their transferability to the respecve applicaon has to be checked. The

manufacturer of the product does not take responsibility for the suitability of the process

and circuit proposals.

•All work with and on the product may only be carried out by qualied personnel.

IEC 60364 and CENELEC HD 384 dene the qualicaons of these persons:

-They are familiar with installing, mounng, commissioning, and operang the product.

-They have the corresponding qualicaons for their work.

-They know and can apply all regulaons for the prevenon of accidents, direcves, and

laws applicable at the place of use.

Applicaon as directed

•The product is a professional equipment intended for use by trades, specic professions or

industry and not for sale to the general public. IEC 60050 [IEV 161‑05‑05]

•To prevent personal injury and damage to property, higher-level safety and protecon

systems must be used!

•All transport locks must be removed.

•Mounted eye bolts on the motor are not suitable for transporng geared motors.

•The product may only be operated under the specied operang condions and in the

specied mounng posions.

•The product may be operated on the mains or on the inverter.

•Only cered applicaon brakes may be used as safety brakes for funconal safety.

•The product must not be operated in private areas, in potenally explosive atmospheres

and in areas with harmful gases, oils, acids and radiaon.

Safety instrucons

Basic safety instrucons

7

Residual hazards

Even if notes given are taken into consideraon and protecve measures are implemented,

the occurrence of residual risks cannot be fully prevented.

The user must take the residual hazards menoned into consideraon in the risk assessment

for his/her machine/system.

If the above is disregarded, this can lead to severe injuries to persons and damage to

property!

Product

Observe the warning labels on the product!

Dangerous electrical voltage:

Before working on the product, make sure there is no voltage applied to the power terminals!

Aer mains disconnecon, the power terminals will sll carry the hazardous electrical voltage for the me given next to the

symbol!

High leakage current:

Carry out xed installaon and PE connecon in compliance with:

EN 61800‑5‑1 / EN 60204‑1

Hot surface:

Use personal protecve equipment or wait unl the device has cooled down!

Protecon of persons

•The power terminals may carry voltage in the switched-o state or when the motor is

stopped.

-Before working, check whether all power terminals are deenergized.

•Voltages may occur on the drive components (e.g. capacive, caused by inverter supply).

-Careful earthing in the marked posions of the components must be carried out.

•There is a risk of burns from hot surfaces.

-Provide protecon against accidental contact.

-Use personal protecve equipment or wait unl the device has cooled down.

-Prevent contact with ammable substances.

•There is a risk of injury due to rotang parts.

-Before working on the drive system, ensure that the motor is at a standsll.

•There is a risk of accidental start-up or electric shock.

Motor protecon

•Installed thermal detectors are no full protecon for the machine.

-If necessary, limit the maximum current. Parameterize the inverter so that it will be

switched o aer some seconds of operaon with I > Irated , especially if there is a risk

of blocking.

-Integrated overload protecon does not prevent overloading under all condions.

•The fuses are no motor protecon.

-Use a current-dependent motor protecon switch.

-Use the built-in temperature sensors.

•Too high torques cause a fracon of the motor sha.

-Do not exceed the maximum torques according to the technical data on the

nameplate.

Safety instrucons

Residual hazards

8

Gearbox protecon

•Excessive vibraon acceleraons and resonances will damage the gearbox.

-Do not operate the gearbox at vibraon acceleraons > 2 g (20 m/s2) of the machine.

-Do not operate the gearbox in the resonance range of the machine.

•Excessive torques will damage the gearboxes.

-Do not exceed the output torques specied on the nameplate.

•Excessive input speeds lead to increased temperatures.

-Do not exceed the input speeds specied on the nameplate.

•Avoid excessive lateral forces on the gearbox sha.

-Align the shas of the gearbox and driven machine exactly with each other.

•Machine elements can be damaged by a lack of lubricant.

-Mount the gearbox only in the mounng posion indicated on the nameplate.

-When changing the lubricant, use the lubricant type and quanty specied on the

nameplate.

Safety instrucons

Residual hazards

9

Product informaon

Idencaon of the products

Nameplates

The nameplate is aached to the motor.

Product informaon

Idencaon of the products

Nameplates

10

11.1 11.2 11.3 11.511.4 11.6 11.7 11.8 11.9 12 13.1 13.2 13.3

4

1

L

23

22

20

19

23

Hz kW r/min C86 M2 n2 c

89

7.1 7.3

7.8

Brake

ACH

Fan

15

5

16.416.216.1

6.4 6.5 6.6 6.7

6.3

7.57.4

6.2

7.2

6.1 14

16.3

17.1 17.2 17.3

18

7.6 7.7SF

10

A

V

A

V

2

3

21

Posion Contents Posion Contents

1 Manufacturer 12 Motor code for Lenze frequency inverter

2 Country of producon 13 Gearbox output data

3 Approvals 13.1 Output torque

4 Standards 13.2 Output speed

5 Motor type 13.3 Load capacity

6 Gearbox data 14 Temperature monitoring

6.1 Product name 15 Feedback

6.2 Product code 16 Brake

6.3 Gearbox rao 16.1 Size

6.4 Posion: Sha, ange, terminal box/motec 16.2 Supply voltage

6.5 Mounng posion 16.3 Power

6.6 Lubricant 16.4 Braking torque

6.7 Lubricant quanty 17 Blower

7 Motor data 17.1 Rated voltage

7.1 Product name 17.2 Rated frequency

7.2 Product key 17.3 Rated power

7.3 Degree of protecon 18 An-condensaon heater

7.4 Eciency class 19 Customer data

7.5 Operang mode 20 Year of manufacture / week of manufacture

7.6 Rated frequency 21 Country of producon, code

7.7 Service factor 22 Material number

7.8 Class of insulaon 23 Serial number

8 Ambient temperature 24 Bar code

9 Weight

10 UL product category

11 Motor data at rated frequency

11.1 Rated frequency

11.2 Rated power

11.3 Rated voltage

11.4 Rated current

11.5 Rated voltage

11.6 Rated current

11.7 Rated speed

11.8 Power factor

11.9 Eciency

Product informaon

Idencaon of the products

Nameplates

11

Product codes

Gearbox product code

Example G 50 A H 045 M V C R 2 C 1A

Product type Gearboxes G

Product family 50

Generaon A

B

Gearbox type Helical gearbox H

Output torque 45 Nm 045

100 Nm 110

140 Nm 114

210 Nm 121

320 Nm 132

450 Nm 145

600 Nm 160

850 Nm 185

1500 Nm 215

3000 Nm 230

5000 Nm 250

8000 Nm 280

14000 Nm 314

Type of construcon Geared motor M

Gearboxes N

Sha type Solid sha with featherkey V

Solid sha without featherkey G

Housing type Foot mounng + centering A

Foot mounng B

With centering C

Flange mounng Without ange R

Flange with through holes K

Reinforced ange with through

holes P

Number of stages 2-stage 2

3-stage 3

4-stage 4

Motor mounng Integrated motor C

IEC adapter with jaw coupling N

T

IEC adapter with plug-in hollow

sha

H

NEMA adapter with jaw coupling A

NEMA adapter with plug-in

hollow sha

B

Servomotor adapter with plug-in

hollow sha

S

Servomotor adapter with jaw

coupling

E

D

G

Drive size

1A

...

□H

08

...

82

Product informaon

Idencaon of the products

Product codes

12

Motor product code

Example M 55 B H 063 S 04 5 E 0 0 C C

Product type Motor M

Product family 55

Version B

Eciency class IE2 H

IE3 P

Size 063

071

080

090

100

112

132

160

180

Overall length Short S

Medium M

Long L

Number of poles 4-pole 04

Degree of protecon IP54/IP55 5

IP65/IP66 6

Cooling Self-venlaon E

Forced venlaon F

Brake Without 0

Spring-applied brakes F

Feedback Without 0

Absolute value encoder A

Incremental encoder E

Resolver R

Approvals None N

CE C

CE, CCC 3

CE, cULus L

CE, cULus, CCC 5

CE, cURus U

CE, cURus, CCC W

Design type Internal key C

Product informaon

Idencaon of the products

Product codes

13

Product code feedbacks

Example AS 1024 - 8 V - K 2

Meaning Variant Product code

Product family Resolver RS

Resolver for safety funcon RV

Incremental encoder IG

Incremental encoder with commutaon

signal

IK

Absolute value encoder, singleturn AS

Absolute value encoder, multurn AM

Number 2-pole Resolver for servo motors 0

2-pole Resolver for three-phase AC

motors

1

Number of pole pairs for resolvers 2

3

4

...

Number of bits, steps or increments per

revoluon

20

32

128

512

1024

2048

...

Supply voltage 5 V

8 V

15 V

24 V

...

Interface or signal level Standard

TTL T

HTL (for incremental encoders) H

Hiperface (for absolute value encoders) H

EnDat E

SinCos 1 Vss S

Digital D

For safety funcon

TTL U

HTL (for incremental encoders) K

Hiperface (for absolute value encoders) K

EnDat F

SinCos 1 Vss V

Digital D

Safety Integrity Level (SIL) 1

2

3

4

Product informaon

Idencaon of the products

Product codes

14

Equipment

The following gure provides an overview of the elements and connecons on the product.

Their posion, size and appearance may vary.

Motor connection

(depending on

the mounting position)

Oil filler plug

(depending on the

mounting position)

Ventilation

(depending on

the mounting position)

Oil control plug

Housing type

Output flange

Output shaft

Brake

Cooling

Feedback

Temperature monitoring

(depending on the

mounting position)

Oil drain plug

Product informaon

Equipment

15

Transport

•Ensure appropriate handling.

•Make sure that all component parts are securely mounted. Secure or remove loose

component parts.

•Only use safely xed transport aids (e.g., eye bolts or support plates).

•Do not damage any components during transport.

•Avoid electrostac discharges on electronic components and contacts.

•Avoid impacts.

•Check the carrying capacity of the hoists and load handling devices. The weights can be

found in the shipping documents.

•Secure the load against pping and falling down.

•Standing beneath suspended loads is prohibited.

The transport weights can be found in the shipping documents!

The motors mounted on the gearbox are somemes equipped with ears. These

are exclusively intended for mounng the motor on/removing the motor from

the gearbox and must not be used for the complete geared motor!

CAUTION!

Danger from pping or falling loads!

Standing beneath suspended loads is prohibited!

▶Use addional appropriate liing aids, if required, to achieve a direcon of loading which is

as vercal as possible (highest load carrying capacity). Secure liing aids against shiing!

▶Screw in the transport aids completely. They must have even and full-surface contact!

▶Transport aids must be loaded vercally in the direcon of the screw axis! Diagonal or

lateral tension reduces the load carrying capacity! Observe data in standard DIN 580!

The thread in the output sha can be used with smaller drives. Larger gearboxes have a

transport thread for eye bolts in accordance with DIN 580 in the gearbox housing as standard.

The eye bolt is not included in the scope of supply!

The posion of the transport thread can be seen in the following representaons.

Posion of the eye bolt

G50AH045 ... G50BH114 G50BH121 ... G50BH230

1. 2.

Transport

16

Thread M6 M8 M10 M12 M16 M20 M24

Load carrying

capacity

kg 80 140 230 340 700 1200 1800

Transport

17

Storage

Storage up to one year:

•Observe the climac condions according to the technical data

-4Environmental condions ^ 60

•Store in a dry, low-vibraon environment (Ve < 0.2 mm/s) without aggressive atmosphere

in the interior

•Protect from dust, shocks and sunlight

•Avoid temperature changes with condensate formaon.

•Store gearboxes with a venlaon unit with the venlaon element on top.

•Do not acvate venlaon unit, in order to prevent air exchange with the ambient air.

•Treat damaged corrosion protecon on shas and bare surfaces subsequently

Storage for more than one year, up to two years:

•Apply a long−term corrosion prevenve (e.g. Ancorit BW 366 from the Fuchs company) to

the shas and uncoated surfaces before storing the motor away.

•Do not acvate venlaon element

•Install gearbox in mounng posion M1 (A)

•Fill gearbox with the lubricant type lled in (see nameplate) up to the lling/venng bore

for mounng posion M1 (A)

-4Nameplates ^ 10

-4Venlaon ^ 21

Storage

18

Mechanical installaon

Important notes

•Install the product according to the informaon in the chapter "Standards and operang

condions".

4Standards and operang condions ^ 59

•The technical data and the data regarding the supply condions can be found on the

nameplate and in this documentaon.

•Ambient media − especially chemically aggressive ones − may damage sha sealing rings,

lacquers and plascs.

•Lenze oers special surface and corrosion protecon in this case.

•Only install the gearbox in the mounng posion shown.

4Mounng posions ^ 20

Preparaon

•Protect sha sealing rings from contact with solvents.

•Remove protecon covers from shas.

•Thoroughly remove ancorrosion agents from the sha and from ange faces.

•Draw the transmission elements onto the output sha only by using the centering thread.

•Align the output sha and transmission elements exactly to avoid tensions.

•Mount belt pulleys, sprockets, or gear wheels as close as possible to the sha shoulder in

order to keep the bending load of the sha and the bearing forces at a minimum level.

•Tighten all screw connecons with the specied torques and secure them with standard

screw locking adhesive.

•Check paint for damage and repair professionally.

Mechanical installaon

Important notes

19

Installaon

•The mounng surfaces must be plane, torsionally rigid and free from vibraons.

•The mounng areas must be suited to absorb the forces and torques generated during

operaon.

•Ensure an unhindered venlaon.

•For versions with a fan, keep a minimum distance of 10 % from the outside diameter of the

fan cover in intake direcon.

Mounng posions

The lubricant amount and gearbox venlaon are adapted to the mounng

posion. The mounng posion indicated on the nameplate must be observed

to avoid damages to the gearbox.

M1 [ A ]

M2 [ D ]

M5 [ F ]

M3 [ B ]

M4 [ C ]

M6 [ E ]

Mechanical installaon

Installaon

Mounng posions

20

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Lenze g500-H Mounting Instruction

Lenze g500-H Mounting Instruction

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