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Siemens SIMOTICS T-1FW4407-1KM81-1BC0-Z Operating Instructions Manual

Heavy duty low-voltage motor
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Edition
11/2018
Operating Instructions
Installation Instructions
Low-voltage motor
SIMOTICS T-1FW4 Heavy Duty
Type 1FW4407-1KM81-1BC0-Z
www.siemens.com/drives

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Summary of Contents for Siemens SIMOTICS T-1FW4407-1KM81-1BC0-Z

  • Page 1 Operating Instructions Installation Instructions Low-voltage motor SIMOTICS T-1FW4 Heavy Duty Type 1FW4407-1KM81-1BC0-Z Edition 11/2018 www.siemens.com/drives...
  • Page 2 13.11.2018 16:04 V5.00...
  • Page 3 Introduction Safety information Description Low-voltage motor Preparations for use SIMOTICS T-1FW4 Heavy Duty Type 1FW4407-1KM81-1BC0-Z Assembly Electrical connection Operating Instructions Installation Instructions Start-up Operation Maintenance Spare parts Disposal Service and Support Technical data Quality documents Edition 11/2018...

  • Page 4: Edition

    Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 5: Table Of Contents

    Table of contents Introduction..............................11 Compiling personal documents....................11 Safety information............................13 Information for those responsible for the plant or system............13 The 5 safety rules........................13 Qualified personnel........................14 Safe handling.........................14 Working on machines with permanent magnets..............15 Electrostatic sensitive devices....................17 Interference immunity......................18 Interference voltages when operating the converter..............18 Electromagnetic fields when operating electrical power engineering installations....18 Description..............................21 Preparations for use...........................25...
  • Page 6 Table of contents Assembly..............................37 Safety instructions when mounting..................37 5.1.1 Safety instructions for installation...................37 Preparations for installation....................38 5.2.1 Requirements for installation....................38 5.2.2 Insulation resistance and polarization index................38 5.2.3 Testing the insulation resistance and polarization index............39 5.2.4 Preparing the mating faces....................41 Lift the machine to where it will be installed, and position it...........42 5.3.1 Preconditions for correct alignment and secure attachment ..........42 5.3.2...
  • Page 7 Table of contents 6.5.4 Internal equipotential bonding in the auxiliary terminal box...........61 6.5.5 Terminating the connection work (auxiliary circuit)..............62 Converter operation.......................62 6.6.1 Connection to a converter......................62 6.6.2 Operation on a converter with a low pulse frequency............63 6.6.3 Converter operation on a grounded network................64 Start-up...............................65 Safety instructions for commissioning..................65 Checks to be carried out prior to commissioning ..............66...
  • Page 8 Table of contents 9.1.3 First service after installation or repair ..................85 9.1.4 General inspection.........................86 9.1.5 Measuring the insulation resistance during the course of maintenance work......86 9.1.6 Roller bearing.........................87 9.1.7 Regreasing intervals and types of grease for operating rolling bearings.......87 9.1.8 Touch up any damaged paintwork..................88 9.1.9 Maintaining terminal boxes....................89...
  • Page 9 Table of contents Table 7-1 Guidelines for setting the tripping temperature of bearing thermometers........71 Table 7-2 Alarm and shutdown temperatures of the temperature monitoring..........72 Table 8-1 Electrical faults .........................79 Table 8-2 Mechanical faults ........................79 Table 8-3 Roller bearing faults .......................80 Table 8-4 Cooling system faults ......................81...
  • Page 10 Table of contents SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 11: Introduction

    Compiling personal documents On the Internet pages in Industry Online Support you have the possibility of compiling personal documents using the function Documentation (https://support.industry.siemens.com/My/ww/ en/documentation) Using the "Documentation" function, from Product Support manuals, you can compile your own "Documentation". However, you can also include other Product Support content such as FAQs or characteristics in the documentation that you compile.
  • Page 12 Introduction 1.1 Compiling personal documents In the "Documentation" function, you have the option of creating your own compiled documents in your own structure and managing them. You can delete or shift individual chapters or topics. Further, using the note function you can import your own content. The compiled "documentation"...

  • Page 13: Safety Information

    Safety information Information for those responsible for the plant or system This electric machine has been designed and built in accordance with the specifications contained in Directive 2014/35/EU ("Low-Voltage Directive") and is intended for use in industrial plants. Please observe the country-specific regulations when using the electric machine outside the European Community.

  • Page 14: Qualified Personnel

    Safety information 2.3 Qualified personnel Qualified personnel All work at the machine must be carried out by qualified personnel only. For the purpose of this documentation, qualified personnel is taken to mean people who fulfill the following requirements: ● Through appropriate training and experience, they are able to recognize and avoid risks and potential dangers in their particular field of activity.

  • Page 15: Working On Machines With Permanent Magnets

    Safety information 2.5 Working on machines with permanent magnets Risk of burns due to hot surfaces Individual machine parts can become hot in operation. Burns can result when coming into contact with these parts. ● Never touch machine parts during operation. ●...
  • Page 16 Safety information 2.5 Working on machines with permanent magnets WARNING Strong magnetic field when the machine is open A strong magnetic field is always present inside the machine. If the housing is open, e.g. when maintenance openings are open or when working inside the machine, magnetic objects can be suddenly attracted by this magnetic field.

  • Page 17: Electrostatic Sensitive Devices

    Safety information 2.6 Electrostatic sensitive devices Danger due to induced voltages Electrical voltages are induced in the stator when rotating the rotor. Touching the stator connections can result in death or severe physical injury. ● Before starting any work at the machine, carefully ensure that the system is secured to prevent the rotor accidentally turning in compliance with the regulations.

  • Page 18: Interference Immunity

    Safety information 2.7 Interference immunity The necessary ESD protective measures for electrostatic sensitive devices are illustrated once again in the following drawings: a = conductive floor surfaceb = ESD table c = ESD shoes d = ESD overall e = ESD wristband f = cabinet ground connection Interference immunity By selecting suitable signal cables and evaluation units, ensure that the interference immunity...
  • Page 19 Safety information 2.9 Electromagnetic fields when operating electrical power engineering installations ● It is forbidden for people with pacemakers to be close to the machine. ● Do not carry any magnetic or electronic data media. SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...
  • Page 20 Safety information 2.9 Electromagnetic fields when operating electrical power engineering installations SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 21: Description

    Description Area of application The series 1FW4 motors are multi-pole, permanent-magnet synchronous motors with plug-on shaft. The motors are available as a water-cooled version. The operating behavior is comparable to that of electrically excited synchronous motors. Motors of the 1FW4 series are used together with converters as slow running direct drives. WARNING Risk of explosion This machine is not designed for use in hazardous areas.

  • Page 22: Figure 3-1 Rating Plate Diagram

    Description Rating plate The rating plate shows the identification data and the most important technical data. The data on the rating plate and the contractual agreements define the limits of proper usage. Rating plate ① ⑪ Motor type: Three-phase motor Maximum operating speed [rpm] ②...
  • Page 23 Description Ambient conditions The standard machines are not suitable for use in corrosive atmospheres, atmospheres with a high salt content, or outdoor applications. Water cooling The cooling system is designed as a closed, internal cooling circuit. The cooling water pipe system is integrated into the stator core and designed in stainless steel.
  • Page 24 Description SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 25: Preparations For Use

    Preparations for use Good planning and preparation of machine applications are essential in terms of keeping installation simple and avoiding errors, ensuring safe operation, and allowing access to the machine for servicing and corrective maintenance. This chapter outlines what you need to consider when configuring your plant in relation to this machine and the preparations you need to make before the machine is delivered.

  • Page 26: Cooling Water Inlet Temperature (Plug-On Shaft)

    Preparations for use 4.4 Cooling water inlet temperature (plug-on shaft) Constituent Value Sulfate ions < 50 ppm Nitrate ions < 50 ppm Dissolved solids < 340 ppm Max. grain size < 100 μm Operating pressure 6 bar max. Inlet temperature <...

  • Page 27: Rotational Speed Limit Values

    Preparations for use 4.6 Rotational speed limit values Rotational speed limit values Excessive rotational speed can lead to serious damage to the machine and the converter. This can result in death, serious injury or material damage. ● The converter control must ensure that operation at impermissible speeds is prevented. ●...

  • Page 28: Transport

    Preparations for use 4.9 Transport Transport 4.9.1 Safety instructions for transport Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ●...

  • Page 29: Transporting A Motor That Has Already Been In Operation

    Preparations for use 4.9 Transport 4.9.3 Transporting a motor that has already been in operation If you have already operated the motor and now want to transport it, proceed as follows: 1. Allow the motor to cool down. 2. Remove the connections provided by the customer. 3.

  • Page 30: Storage

    Preparations for use 4.10 Storage WARNING Center of gravity not centered If the center of gravity of a load is not located centrally between the attachment points, the machine can tip over or slip out of the lifting equipment and fall when it is being transported or lifted.
  • Page 31 Preparations for use 4.10 Storage General instructions for storage Wherever possible, store the machine in a storage room. The place of storage must satisfy the following general conditions: ● Select a sufficiently sized dry and horizontal place of storage that is above flood level and free of vibration (v ≤...
  • Page 32 Preparations for use 4.10 Storage Storage for longer than three months Lubricate the machine after every two years of storage. 1. Unpack the machine. 2. Remove the rotor shipping brace, if one is fitted. 3. When stored for longer than two years, lubricate with twice the grease quantity in accordance with the lubricant plate.

  • Page 33: Protecting The Cooling-Water System

    C (IVIC C = high stress). If voltage peaks higher than those specified according to IVIC C can occur, then please contact your Siemens partner: ● For a line supply voltage (converter input voltage) up to max. 480 V, and when controlled from a SINAMICS G/SINAMICS S converter with uncontrolled/controlled infeed: Comply with the guidelines for configuring motor and converter.

  • Page 34: Reducing Bearing Currents

    – Use a separate high-frequency equipotential bonding cable between the motor enclosure and the driven machine. ● Use the common-mode filter (damping cores) at the converter output. The Siemens sales representative is responsible for selection and dimensioning. ● Limit the rise in voltage by using output filters. Output filters dampen the harmonic content in the output voltage.

  • Page 35: Insulated Bearings When Operating The Converter

    Preparations for use 4.11 Converter operation ● Use the motor reactors. ● Preferably use an IT line supply with an insulated neutral point. Note Converter documentation The operating instructions for the converter are not part of this documentation. Refer also to the configuration/engineering information for the converter.
  • Page 36 Preparations for use 4.11 Converter operation SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 37: Assembly

    Assembly Safety instructions when mounting Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.

  • Page 38: Preparations For Installation

    Assembly 5.2 Preparations for installation Damage to mounted parts and components as a result of high temperatures The motor components get very hot during operation. High temperatures can damage parts mounted by customers, such as cables manufactured out of materials that are not heat resistant.

  • Page 39: Testing The Insulation Resistance And Polarization Index

    Assembly 5.2 Preparations for installation The following information is provided regarding the state of the winding insulation: ● Is the winding head insulation conductively contaminated? ● Has the winding insulation absorbed moisture? As such, you can determine whether the machine needs commissioning or any necessary measures such as cleaning and/or drying the winding: ●...

  • Page 40: Table 5-1 Stator Winding Insulation Resistance At 40° C

    Assembly 5.2 Preparations for installation Limit values for the stator winding insulation resistance The following table specifies the measuring voltage and limit values for the insulation resistance. These values correspond to IEEE 43‑2000 recommendations. Table 5-1 Stator winding insulation resistance at 40° C meas MΩ...

  • Page 41: Preparing The Mating Faces

    Assembly 5.2 Preparations for installation For a winding temperature of approx. 25° C, the minimum insulation resistances are 20 MΩ (U ≤ 1000 V) or 300 MΩ (U > 1000 V). The values apply for the complete winding to ground. Twice the minimum values apply to the measurement of individual assemblies.

  • Page 42: Lift The Machine To Where It Will Be Installed, And Position It

    Assembly 5.3 Lift the machine to where it will be installed, and position it Lift the machine to where it will be installed, and position it 5.3.1 Preconditions for correct alignment and secure attachment Detailed specialist knowledge of the following measures is required in order to correctly align and securely fit the equipment.

  • Page 43: Shock Load And Shaft Adaptation

    Assembly 5.3 Lift the machine to where it will be installed, and position it Bright surfaces on machine parts ● Remove the anti-corrosion coating from the machined surfaces of machine parts and from small components. To do this, use petroleum, petroleum ether - or a similar solvent or cleaning agent.

  • Page 44: Mounting The Output Elements

    Assembly 5.3 Lift the machine to where it will be installed, and position it WARNING Insufficient screw locking Vibration and shock loads can loosen the screws. The machine or components may fall down. This can result in death, serious injury or material damage. ●...
  • Page 45 Assembly 5.3 Lift the machine to where it will be installed, and position it ● When lifting the machine, use only approved and undamaged sling guides and spreaders of sufficient rated capacity. Check the lifting equipment prior to its use. The weight of the machine is shown on the rating plate.

  • Page 46: Putting The Machine Down

    Assembly 5.3 Lift the machine to where it will be installed, and position it 5.3.7 Putting the machine down Requirements The following preconditions must be satisfied before setting down the machine at the installation location: ● The mating faces must be clean. ●...

  • Page 47: Installing The Machine

    Note Service Center For any installation work that is required, contact the Service Center (Page 103) or commission service engineers trained by Siemens and authorized for this task. 5.4.1 Selecting fixing screws ● Unless specified otherwise, use mounting bolts with at least strength class 8.8 to ISO 898‑1.

  • Page 48: Aligning The Machine To The Driven Machine And Attaching It To It (Im B5)

    0.05 mm in diameter. 5.4.5 Axial and radial forces You can obtain the permissible values for axial and radial forces by contacting the Siemens Service Center (Page 103) or referring to the machine catalog. SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z...

  • Page 49: Connecting The Cooling Water Supply

    Assembly 5.5 Connecting the cooling water supply NOTICE Damage to bearings or the shaft Large output masses and their centers of gravity outside the shaft extensions can lead to resonance in operation. This can result in damage to the bearings and shaft. Ensure that the permissible loads for the forces on the shaft extension are adhered to in accordance with the catalog data or configuration data.

  • Page 50: Insulated Bearings

    Assembly 5.6 Insulated bearings Insulated bearings Both bearings are insulated for motors with a plug-on shaft. Insulation on the drive end side is bridged in the delivery state. Comply with the plates on the machine relating to bearing insulation and possible bridges. WARNING Bearing damage when opening the bridging If the bridging of the insulated DE bearing is opened, this leads to potential differences...

  • Page 51: Electrical Connection

    Electrical connection Safety instructions relating to the electrical connection Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.

  • Page 52: Preparation

    Electrical connection 6.3 Preparation ● Connect the machine in such a way that a permanent, safe electrical connection is maintained. Avoid protruding wire ends. ● Lay and secure external auxiliary cables separately from the main cable. Elements with cable ties may be present for this purpose. ●...

  • Page 53: Selecting Cables

    Electrical connection 6.3 Preparation 6.3.2 Selecting cables Take the following criteria into account when selecting the connecting cables: ● Rated current ● Rated voltage ● If required, service factor ● System-dependent conditions, such as ambient temperature, routing type, cable cross- section as defined by required length of cable, etc.

  • Page 54: Table 6-3 Tightening Torques Of Bolts (Cable Lug)

    Electrical connection 6.3 Preparation ● The maximum permissible clamping thickness of 10 mm for the cable lug or strap is not exceeded. ● The minimum required screw-in depth and the tightening torque for the clamping bolt as given in the table below are observed. Screw-in depth and tightening torque are different depending on whether cable lugs or ground terminals are used.

  • Page 55: Inserting And Routing The Cables

    Electrical connection 6.4 Inserting and routing the cables Inserting and routing the cables 6.4.1 Circuit diagram For the machine, the neutral point is formed internally. A separate neutral point circuit must not therefore be wired in the main terminal box by the servicing or commissioning personnel. Figure 6-2 Neutral point connection Data on the connection and connecting the motor winding can be found in the circuit diagram...

  • Page 56: Introducing The Cables Into The Terminal Box And Routing Them

    Electrical connection 6.4 Inserting and routing the cables See also Connecting cables with cable lugs (Page 56) 6.4.3 Introducing the cables into the terminal box and routing them The connection cables are inserted into the terminal box via an exchangeable cable entry plate or cable entry support .

  • Page 57: Use Of Aluminum Conductors

    Electrical connection 6.4 Inserting and routing the cables ① Customer connecting cable ② Connection bar See also Terminal box (Page 55) 6.4.5 Use of aluminum conductors If you are using aluminum conductors, then comply with the following: ● Use only cable lugs that are suitable for connecting aluminum conductors. ●...

  • Page 58: Using Single-Stranded Cables

    Electrical connection 6.4 Inserting and routing the cables 6.4.6 Using single-stranded cables NOTICE High temperatures from induced eddy currents With high currents and where several single-stranded cables are used instead of multiple- stranded cables, high temperatures can result in the cable entry area due to induced eddy currents.

  • Page 59: Finishing Connection Work

    Electrical connection 6.5 Connecting the auxiliary circuits 6.4.9 Finishing connection work 1. Before closing the terminal box, please check that: – The electrical connections in the terminal box have been made in accordance with the specifications above and tightened with the correct tightening torque. Remove the used bolts and fastening elements.

  • Page 60: Introducing Cables Into The Auxiliary Terminal Box And Routing Them

    Electrical connection 6.5 Connecting the auxiliary circuits 6.5.2 Introducing cables into the auxiliary terminal box and routing them The required data for connecting the auxiliary circuits is located on the terminal diagram on the inside of the respective auxiliary terminal or terminal box cover. ●...

  • Page 61: Internal Equipotential Bonding In The Auxiliary Terminal Box

    Electrical connection 6.5 Connecting the auxiliary circuits WARNING Risk of electric shock The insulation of the temperature sensors for the winding monitoring with respect to the winding is implemented according to the requirements for basic insulation. The temperature sensor connections are located in terminal boxes, safe to touch - and have no protective separation.

  • Page 62: Terminating The Connection Work (Auxiliary Circuit)

    Electrical connection 6.6 Converter operation 6.5.5 Terminating the connection work (auxiliary circuit) 1. Before closing the auxiliary terminal box, please check that: – The cables are connected in accordance with the terminal diagram. – The cables are freely arranged so that they cannot come into contact with the machine, and the cable insulation cannot be damaged.

  • Page 63: Operation On A Converter With A Low Pulse Frequency

    ● Use iron cores mounted above the motor connecting cable at the converter output. These help to reduce common-mode components. The Siemens sales representative is responsible for selection and dimensioning. ● Limit the voltage rate of rise by using an output filter to dampen harmonic components in...

  • Page 64: Converter Operation On A Grounded Network

    Electrical connection 6.6 Converter operation 6.6.3 Converter operation on a grounded network NOTICE Damage resulting from protective conductor currents When the machine is operated on a converter with current limiter, but without ground-fault monitoring, protective conductor currents of up to 1.7 times the external conductor current can arise if there is a ground fault on the output side.

  • Page 65: Start-Up

    Start-up Safety instructions for commissioning Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.

  • Page 66: Checks To Be Carried Out Prior To Commissioning

    Start-up 7.2 Checks to be carried out prior to commissioning Checks to be carried out prior to commissioning The following list of checks to be performed prior to commissioning does not claim to be complete. It may be necessary to perform further checks and tests in accordance with the specific situation on-site.

  • Page 67: Greasing The Roller Bearings Prior To Commissioning

    Start-up 7.3 Greasing the roller bearings prior to commissioning ● Check the correct functioning of the brakes or backstops. ● Set the values for "Alarm" and "Shutdown" at the monitoring devices. ● Carefully ensure that temperature-sensitive parts and components, e.g. cables are not in contact with the machine enclosure.

  • Page 68: Setting The Converter Pulse Frequency

    Start-up 7.4 Setting the converter pulse frequency General specifications ● Pay attention to the instructions on the lubricant plate. ● Regrease in portions. The shaft must rotate so that the new grease can be distributed in the bearings. Regreasing the roller bearings prior to commissioning ●...

  • Page 69: Preparing For Test Run

    Start-up 7.5 Preparing for test run Preparing for test run If you want to start the machine for a trial run, ensure that it is connected to the cooling water supply. WARNING Risk of burns from hot steam If the cooling water supply fails, the motor will overheat. If cooling water enters the hot machine, hot steam will suddenly be generated, which escapes under high pressure.

  • Page 70: Measure The Insulation Resistance And Polarization Index For The Commissioning

    Start-up 7.7 Measure the insulation resistance and polarization index for the commissioning 4. During the test run, check and document the following: – Check whether it is running smoothly. – Document the voltage, current and power values. As far as possible, document the corresponding values of the driven machine.

  • Page 71: Switching On The Machine

    Start-up 7.8 Switching on the machine As such, you can determine whether the machine needs commissioning or any necessary measures such as cleaning and/or drying the winding: ● Can the machine be put into operation? ● Must the windings be cleaned or dried? Detailed information on testing and the limit values can be found here: "Testing the insulation resistance and polarization index"...

  • Page 72: Set Values For Temperature Monitoring (Slot Thermometer)

    Start-up 7.10 Set values for temperature monitoring (slot thermometer) 7.10 Set values for temperature monitoring (slot thermometer) Before the machine runs for the first time, set the alarm and shutdown temperatures at the temperature monitoring. 1. Measure the normal operating temperature T at the installation location in °...

  • Page 73: Operation

    Operation Safety instructions for operation Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.
  • Page 74 Operation 8.1 Safety instructions for operation Faults in operation Any changes with respect to the normal condition can indicate that the machine is not functioning correctly. ● Higher power consumption, temperatures or vibration levels. ● Unusual noise or smells. ● Monitoring devices respond. This can cause faults which can result in eventual or immediate death, serious injury or material damage.

  • Page 75: Switching On The Machine

    Operation 8.2 Switching on the machine Damage caused by the short-circuit current When the permanent magnet rotor is a driven, a voltage ("rotor voltage") is induced in the stator winding, that can be measured at the motor terminals. If a cable or converter short-circuit simultaneously occurs, then a short-circuit current is driven by the induced rotor voltage.

  • Page 76: Stoppages

    Operation 8.3 Stoppages Stoppages The stoppage is a shutdown for a period of time, during which the machine is stopped but remains at the location of use. Under normal ambient conditions, e. g. the stopped machine is not exposed to any vibration, no increased level of corrosion, etc.

  • Page 77: Avoidance Of Damage To Roller Bearings During Stoppages

    Operation 8.4 Switching off the machine 8.3.3 Avoidance of damage to roller bearings during stoppages Extended stoppages at the identical or almost identical resting position of the roller bearings can lead to damage such as brinelling or corrosion, for example. ●...

  • Page 78: Switching On Again After An Emergency Switching-Off

    Operation 8.5 Switching on again after an emergency switching-off Switching on again after an emergency switching-off ● Check the machine before recommissioning the driven machine after an Emergency Off. ● Eliminate all the causes that have led to the emergency off Decommissioning the machine NOTICE Damage as a result of an extended period out of service...

  • Page 79: Electrical Faults Water-Cooled Machines

    Operation 8.8 Faults 8.8.2 Electrical faults water-cooled machines Note When operating the machine with a converter, also refer to the operating instructions of the frequency converter if electrical faults occur. Table 8-1 Electrical faults ↓ Motor fails to start ↓ Motor accelerates sluggishly ↓...

  • Page 80: Rolling-Contact Bearing Faults

    Operation 8.8 Faults ↓ Grinding noise ↓ Radial vibrations ↓ Axial vibrations Possible causes of faults Remedial measures Rotor out of true, shaft bent Contact the Service Center. Poor alignment Align the machine set and check the coupling. Coupled machine not balanced Rebalance the coupled machine.

  • Page 81: Water Cooling Faults

    Operation 8.8 Faults 8.8.5 Water cooling faults The following table shows the possible causes of and remedial measures for faults on water- cooled machines. Table 8-4 Cooling system faults ↓ Overheating ↓ Water leaking Possible causes of faults Remedial measures Reduced cooling ●...
  • Page 82 Operation 8.8 Faults SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 83: Maintenance

    Maintenance Observe the following when carrying out any work on the machine: ● Comply with the general safety instructions (Page 13) ● Comply with the applicable national and sector-specific regulations. ● When using the machine within the European Union, comply with the specifications laid down in EN 50110‑1 regarding safe operation of electrical equipment.

  • Page 84: Inspections In The Event Of Faults

    Maintenance 9.1 Inspection and maintenance Risk of burn injuries due to hot surfaces In operation, the temperature of individual machine parts can increase - and only decrease slowly after switching off. You can burn yourself if you touch hot surfaces. ●...

  • Page 85: First Service After Installation Or Repair

    Maintenance 9.1 Inspection and maintenance 9.1.3 First service after installation or repair ● Check after approx. 500 operating hours, but after not more than one year: Check When the At stand‐ motor is still running The electrical parameters are maintained. The permissible bearing temperatures are not exceeded (Page 71).

  • Page 86: General Inspection

    Maintenance 9.1 Inspection and maintenance 9.1.4 General inspection ● Check that the installation conditions are observed. Perform the following checks after approx. 16 000 operating hours or at the latest after two years: Checking When the At stand‐ motor is still running The electrical parameters are maintained...

  • Page 87: Roller Bearing

    Do not disassemble the bearing. Do not remove the rotor. If it becomes necessary to remove the rotor with permanent magnets or change a bearing at the machine site, please contact a Siemens Service Center (Page 103). NOTICE Different intervals for regreasing and inspection The required relubrication intervals for roller bearings are not the same as the servicing intervals.

  • Page 88: Touch Up Any Damaged Paintwork

    Maintenance 9.1 Inspection and maintenance These greases have lithium soap as the thickening agent and mineral oil as the base oil. They exceed the standard requirements of DIN 51825 in several important respects and are, therefore, compatible with the specified relubrication intervals. Note Damage due to mixing grease types Mixing greases and oils which are based on different types of soap or oil can degrade their...

  • Page 89: Maintaining Terminal Boxes

    Maintenance 9.2 Corrective Maintenance 9.1.9 Maintaining terminal boxes Requirement The machine is de-energized. Checking the terminal box ● Terminal boxes must be regularly checked for tightness, undamaged insulation, and tight terminal connections. ● If dust or humidity have infiltrated the terminal box, this should be cleaned and dried (particularly the insulators).

  • Page 90: Prepare Servicing Work

    Maintenance 9.2 Corrective Maintenance See also Service and Support (Page 103) If the motor has to be transported, please observe the information and instructions in the chapter "Transport (Page 28)". 9.2.1 Prepare servicing work ● The drawings and parts lists do not contain any detailed information about the type and dimensions of fixing elements and components.

  • Page 91: Replacing The Speed Encoder

    Maintenance 9.2 Corrective Maintenance 9.2.3 Replacing the speed encoder Preparation NOTICE Electrostatic discharge Electronic modules contain components that can be seriously damaged by electrostatic discharge. These modules can easily be destroyed unless they are handled properly. To protect your equipment against damage, follow the instructions given in the chapter headed "Electrostatic Sensitive Devices"...

  • Page 92: Connecting The Speed Encoder

    Maintenance 9.2 Corrective Maintenance Separating the speed encoder ① 1. Remove screw M5x50 ( 2. Screw in screw M5x10 and screw M6x70 one after the other. This releases the encoder ② cone in the motor shaft ( 3. Remove the speed encoder. Mounting the speed encoder 1.

  • Page 93: Figure 9-2 Electrical Connection Of The Speed Sensor

    Replacing or adjusting the speed encoder Replacing or adjusting the speed encoder in an incorrect manner can result in machine malfunctions. Arrange to have the speed encoder replaced or adjusted by Siemens service personnel. This will ensure problem-free functioning. SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z...
  • Page 94 Maintenance 9.2 Corrective Maintenance SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 95: Spare Parts

    See also Spares on Web (https://www.sow.siemens.com/) Guide for Spares on Web (http://support.automation.siemens.com/WW/news/en/25248626) You can use commercially available, standard components, but ensure that they have the same construction type, dimensions, strength class etc. SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z...
  • Page 96 Spare parts 10.2 Ordering spare parts via the Internet NOTICE Rotor removal or bearing change Improper handling can lead to irreparable damage to the motor. If it is necessary to remove the rotor or change the bearings, then under all circumstances please contact the Service Center (Page 103).

  • Page 97: Disposal

    Disposal 11.1 Introduction Protecting the environment and preserving its resources are corporate goals of the highest priority for us. Our worldwide environmental management system to ISO 14001 ensures compliance with legislation and sets high standards in this regard. Environmentally friendly design, technical safety and health protection are always firm goals even at the product development stage.

  • Page 98: Preparing For Disassembly

    Disposal 11.4 Preparing for disassembly 11.4 Preparing for disassembly Disassembly of the machine must be carried out and/or supervised by qualified personnel with appropriate expert knowledge. 1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in terms of the quality of dismantling the machine and provision of the components.

  • Page 99: Disposing Of Permanent Magnets

    Disposal 11.6 Disposing of permanent magnets Personal protective measures ● Ensure that you never wear or carry any of the following objects and that they are kept a safe distance from the machine: – All kinds of magnetic metal parts such as, keys, glasses, tools, knives, scissors, tape measures, etc.

  • Page 100: Disposal Of Components

    Note Authorized waste disposal companies Information regarding authorized waste disposal companies and workshops can be obtained from the Siemens Service Center (Page 103). 11.7 Disposal of components Components The machines consist mainly of steel and various proportions of copper and aluminum. Metals are generally considered to be unlimitedly recyclable.
  • Page 101 Disposal 11.7 Disposal of components ● Paint residues ● Anti-corrosion agent ● Coolant additives such as inhibitors, antifreeze or biocides Dispose of the separated components according to local regulations or via a specialist disposal company. The same applies for cloths and cleaning substances which have been used while working on the machine.
  • Page 102 Disposal 11.7 Disposal of components SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 103: Service And Support

    (https://support.industry.siemens.com/cs/ww/en/sc/ 2090) Siemens Support for on the move With the "Siemens Industry Online Support" App, you can access more than 300,000 documents for Siemens Industry products – any time and any‐ where. The App supports you in the following areas: ●...
  • Page 104 Service and Support SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 105: Technical Data

    Technical data Tightening torques for screw and bolt connections Bolt locking devices ● Refit nuts or bolts that are mounted together with locking, resilient, and/or force-distributing elements with identical, fully-functional elements when re-assembling. Always renew keyed elements. ● When screwing together threads secured with a liquid adhesive, use a suitable medium such as Loctite 243.
  • Page 106 Technical data B.1 Tightening torques for screw and bolt connections Applications The above-mentioned tightening torques apply for the following applications: ● Case A Applies to electrical connections in which the permissible torque is normally limited by the bolt materials and/or the current carrying capacity of the insulators, with the exception of the busbar connections in case B.

  • Page 107: Quality Documents

    Quality documents Quality documents can be found here: https://support.industry.siemens.com/cs/ww/en/ps/13323/cert (https:// support.industry.siemens.com/cs/ww/en/ps/13323/cert) SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...
  • Page 108 Quality documents SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...

  • Page 109: Index

    Index Connection Electrical, 55 " Temperature sensor, 60 Connection cables, 47 "Siemens Industry Online Support" App, 103 Connection data, 55 Converter, 67 Converter documentation, 35 Cooling capacity, 23 5 safety rules, 13 Cooling system Faults, 81 Cooling water Connection, 49...
  • Page 110 Index ESD guidelines, 17 Live parts, 14 Long-term storage, 32 Low-Voltage Directive, 13 Faults Cooling system, 81 Electrical, 79 Machine Inspection, 78, 84 Mounting, 47 Mechanical, 79 setting down, 46 Roller bearings, 80 Machine design, 21 Faults in operation, 74 IEC, 21 Fixing, 51 Machine type, 95...
  • Page 111 Serial number, 11, 22, 95 Water cooling Shaft adaptation, 43 Switching off, 72, 77 Shaft assembly, 27 Water drip loop, 52 Siemens Industry Online Support Water pressure, 22 App, 103 Spare parts, 103 Spare parts ordering, 95 SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z...
  • Page 112 Index SIMOTICS T-1FW4 Heavy Duty 1FW4407-1KM81-1BC0-Z Operating Instructions 11/2018...
  • Page 114 Further Information www.siemens.com/drives Siemens AG Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY...

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