ATB CD Series Operating Manual

Explosion-proof f&g three-phase-motors

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Operating Manual

Explosion-Proof

F&G Three-Phase-Motors

II2G EEx d(e) IIC(B) T3-6

II2D T80–120°C IP 65(66)

BA01.05-E

under license of

MOTORENTECHNIK GMBH

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Page 1 Operating Manual Explosion-Proof F&G Three-Phase-Motors II2G EEx d(e) IIC(B) T3-6 II2D T80–120°C IP 65(66) BA01.05-E under license of MOTORENTECHNIK GMBH...
Page 2 All rights on this manual and its translation reserved. No part of this manual can be reproduced in any form whatsoever (print, photocopy, microfilm or any other means) or processed electronically without the prior written permission of the ATB Motorentechnik GmbH Company, Nordenham All changes reserved.
Page 3 Warning! Hazardous electrical current! Ensure protection against explosions! Before installing Switch off the power to the device. Make sure that device cannot be The personnel must be duly instructed switched on again by accident. to proceed with caution and according Make sure that the device is de- to regulations during shipping, hoisting, energized.
Page 4: Table Of Contents
Table of Contents About this Manual Target audience Abbreviations and symbols Explosion-protected Motors Intended use Liability and Warranty Guarantee Servicing Spare Parts Delivery, Storage, Transport Delivery Storage Transport Installation Mechanical checks Site Mounting Mains supply and connections Mains connection of explosion-protected motors Motors with direct line lead-in Terminal box Cable and line lead-ins...
Page 5 Operation and Repairs Duty types and thermal protection Special operating conditions Motors with backstop Heat input through the driven machine Start-up Maintenance Inspection Lubrication Explosion protection Instructions for ensuring explosion protection during operation Repairs Additional dust protection requirements (application in zone 21 and 22) Intended use Installation and Operation -Cable and line lead-ins...
Page 6: About This Manual
About this Manual These operating instructions apply to AC motors of the following series: CD...; dCD...; CEIGL...; BD... and dBD..Besides the general assembly instructions, these guidelines are to be followed for the installation, start-up and maintenance of explosion-protected AC motors with a degree of protection of "pressure-resistant encapsulation" marked: (II..), EEx de II.
Page 7 Warning! warns against major damages to property and major injuries or death. All of the dimensions are in mm unless otherwise specified. In order to ensure clarity, at the top of every page you will find the name of the chapter on the left hand and the current section on the right hand; the only exceptions are the first page of each chapter and the blank pages at the end of the chapter.
Page 8: Explosion-Protected Motors
Explosion-protected Motors Intended use The motors are to be operated only according to the data specified on the rating plate. According to the relevant marking on the rating plate, the motors are fit for use in areas subject to explosion hazards. The motors are fit to be built into another machine.
Page 9: Servicing
Servicing For any technical information on F&G motors ATB’s customer service is always at your disposal. Should any difficulties with our motors be encountered, please contact our factory or local branch office. Log on to our website to find at the address of our local branch office nearest your.
Page 10: Storage
Storage Storage up to a maximum of 36 months is possible in the following conditions: • In order to prevent a drop in the insulation resistance, the surrounding environment must be dry and dust-free. • The room temperatures should not drop below +5 °C or exceed +30 °C with an air humidity of <...
Page 11 Figure 1: Eyebolt dimensions Table 1: Minimum dimensions for lifting eyebolts and crossbeams Frame size Ø horizontal vertical...
Page 12: Installation
Installation Mechanical checks After removing the shipping braces and shaft blocks (see also the marking on the motor), the motor shaft must be rotated by hand. In the case of brakemotors the brake must be vented at standstill (maximum of 10 min). This must be performed after applying voltage as per the circuit diagram from page 39.
Page 13 Table 2: Minimum distance (LE) of an obstacle from the air opening, see Fig. 2. Shaft height LE [mm] up to 160 180 to 225 over 250 Figure 2: Minimum distance of obstacles from the air opening The motors are intended for use in areas subject to explosion hazards. The following data on the rating plate distinguish the motor as explosion- protected equipment: •...
Page 14: Mounting
Mounting The motors are mounted either on the motor feet or on the flange at the installation site. All motors with shaft heights of up to 355 mm can be mounted either horizontally or vertically thanks to their bearing layout. This applies also for motors to be mounted with the feet on roofs and side walls.
Page 15 Figure 3: Motor Fastening Large-surface Washer In order to achieve an adequately large contact surface, apply a large- surface washer under each nut or screw head (Fig. 3). Alternatively use flange nuts or bolts. If the motors shaft end points up or down (vertical mounting arrangement), it is necessary to fit an appropriate cover to prevent any foreign bodies from dropping in the driven machine through the air inlet and outlet openings in the ventilator hood.
Page 16 Please note! If balancing with half key (H), work on the vertical (visible) key components on the shaft diameter or cover these with washers with keyway along the relevant length. If the coupling is longer than the key, it is necessary to fill the keyway in the remaining part of the coupling.
Page 17: Mains Supply And Connections
Use the utmost care in mounting dynamically balanced pulleys or couplings on the shaft end. Machines to be connected to the motor by means of couplings are to be aligned according to the specifications of the coupling's manufacturer. Only use flexible couplings! Mains and other electrical connections The motors work as per VDE 0530 with mains voltage oscillations of up to ±10 % or frequency oscillations of up to –5 % to +3 %.
Page 18: Mains Connection Of Explosion-Protected Motors
Mains connection of explosion-protected motors Besides any general installation regulations, follow carefully EN 60079-14 and EN 50281-1-2. Afterwards suitable overload protection is to be provided either with a motor circuit breaker or similar protective devices. These may include also PTC thermistors with tripping devices ( Section "Motors with temperature monitoring“, page 25).
Page 19 Figure 5: Terminal box with fastening screw Figure 6: Terminal box with grub screw > Then tighten the fastening components to the relevant torque, see the following table. Table 4: Torque values for 8.8-type screws Thread size Torque 6 Nm 10 Nm 25 Nm 49 Nm...
Page 20 Please note! Terminal boxes fastened as per Fig. 6 are to be turned counter-clockwise by a maximum of one turn away from the thread end stop. Screwed-on covers must be duly secured. Anti-corrosion protection can be achieved with non-hardening sealing materials or sealing grease in particular on the processed sealing surfaces of the covers of terminal boxes having the following degree of protection: "pressure-resistant encapsulation, EEx d IIC(B) marking".
Page 21: Cable And Line Lead-Ins
Cable and line lead-ins Connect the motors with cable and line lead-ins or by means of a duct system as per EN 60079-14. These must meet the following requirements: • EN 50019 for wiring spaces with a degree of protection of "increased safety", (EEx e II marking on the component) •...
Page 22: Motors With Terminal Boxes Whose Mains Lead Is Located In
Motors with terminal boxes whose mains lead is located in the layer separating the upper and lower parts Use only the supplied original gaskets to ensure compliance with the “Ex e II” degree of protection. Depending on the type (see marking on the plug), the plugs are fit for the following diameters ( Table 5).
Page 23: Mains And Guard Circuit Connection
Figure 7: Cable lead-in Maximum two line lead-ins, Roxtec, RS Type plugs Mains and guard circuit connection The mains can be connected either with or without cable lug both in models with terminal board ( Fig. 8) and in those with single-conductor bushings Fig.
Page 24 Figure 8: Line connection Connection without cable lug Clamp Connection with cable lug Single-wire conductor without cable lug > When connecting a single-wire conductor without cable lug to terminals with just one screw, bend the conductor end as illustrated Figure 9: Conductor bushing Connection without cable lug Connection with two cable lugs...
Page 25 Take note of the maximum connectable conductor cross-section for the terminals. If no other data is available on the terminals, refer to the following table. Table 6: Rated cross-sections Shaft height Rated cross-section [mm 63 to 112 132 to 160 10 (r) 180 to 225 250 to 280...
Page 26 Table 8: Torques and current intensities for live pins Thread size Torque [Nm] Permissible continuous current [A] Brass Copper 15.5 Depending on the model, additional terminals for instance for temperature monitoring or space heater are located either in the main terminal box or in additional terminal boxes;...
Page 27: Motors With Unidirectional Fan
Motors with unidirectional fan Make sure that the fan's direction of rotation matches that of the motor. Motors with separate cooling via separately powered external fans Make sure by means of the electric control that the main motor can be operated with the motor switched-on for separate cooling.
Page 28: Motors With Space Heater
Motors with space heater Terminals HE1-HE2 or U1-V1 The rating data for the space heater are specified either on the rating plate or on a separate plate. Depending on the model, there are two heating variants: • by means of heater bands powered via terminals HE1-HE2 or •...
Page 29 periodically occurring commutation voltage peaks (threshold value for terminals and winding insulation): 1. Terminals have effective clearance and creepage distances to withstand a voltage of 750V based on DIN EN50019 - increased safety type "e". The maximum transient over voltage from the frequency inverter to the motor is 2.15 kV (phase to phase and phase to earth).
Page 30 Torque curves on frequency operation 2p=2 Diagram 1: frame size 63 - 160 f [Hz] Diagram 2: frame size 180 - 225 f [Hz] Diagram 3: frame size 250 - 400 f [Hz] A: Field weakening range above 50 Hz B: Field weakening range above 87 Hz...
Page 31 Torque curves on frequency operation 2p=4 to 2p=8 Diagram 4: frame size 63 - 160 f [Hz] Diagram 5: frame size 180 - 225 f [Hz] Diagram 6: frame size 250 - 400 f [Hz] A: Field weakening range above 50 Hz B: Field weakening range above 87 Hz...
Page 32: Motors With Built-In Frequency Converter (Compact Drive)
Motors with built-in frequency converter (compact drive) Please note! Wait at least 3 min. after disconnecting the drive from the mains before connecting it again; otherwise there is the risk of damaging the input current limitation. Warning! After disconnecting the drive from the mains, the conductive parts of the frequency converter and the connected conductor may still be live for up to 180 sec.
Page 33 The parameters can be changed with the keypad according to the instructions provided in the converter manual. Insert the keypad plug in the test socket of terminals 5-6-15-16. The keypad is not approved for use in the area subject to explosion risk. Operating on unearthed network (IT) Motors with an incorporated CEIGL ...
Page 34 Figure 10: PTC tripping device Rated control supply voltage (A1-A2) Normally closed auxiliary contacts (21-22) Test/Reset Manual/automatic reset Thermistor (T1-T2) Mains LED (green) Remote reset (Y1-Y2) Trip LED (red) Normally open auxiliary contact (13-14)
Page 35 In case of a device with shared power and control voltage supply ( Fig. 12) no automatic restarting of the drive takes place after a power failure or the tripping of the protective device. Caution! In case of a device with a separate control voltage supply Fig.
Page 36 G1: Frequency converter R: approx. 0Ω in TN and TT network version R = 10M Ω in IT network version L1, L2, L3: Power supply input K11, K12, K14: Converter relay outputs Br 1, Br 2: Brake rheostat 2TP1, 2TP2: PTC connection 5, 6, 15, 16: Keypad connection (parameter...
Page 37 G1: Frequency converter G2: Relay G3: PTC tripping device L1, L2, L3, N: Power supply input: converter, relay, PTC tripping device 14, 13/32, 31: I/O keys Y1, Y2: PTC tripping device reset 21, 2N: "Failure" message 14, 2N: "On" message K11, K12, K14: Converter relay outputs Br 1, Br 2: Brake rheostat...
Page 38 G1: Frequency converter R: approx. 0 Ω for the TN and TT network versions R = 10M Ω for IT-network version G2: Relay G3: PTC tripping device L1, L2, L3: Power supply input: power and control N/-, L/+: control voltage 220 - 240V~ or 24V=, fuse maximum 16A 14, 13/32, 31: I/O keys...
Page 39: Motors With Brake
Motors with brake The mains line in the version with incorporated brake is connected in the motor terminal box and in the version with the built-on brake in the separate brake terminal box. Observe the supplied connection diagram and the rated voltage visible on the rating plate.
Page 40: Motors With Water Cooling
Motors with water cooling Before connecting, check the cleanness of the cooling water (max. permissible content of deposits: 30 mg/l). The water connections are to be connected according to the signs on the motor. The quantity of cooling water necessary for cooling the motor is to be complied with (see the sign on the water inlet).
Page 41: Connection Diagrams
Connection diagrams The circuit diagram on the motor is to be followed. Single-speed – one pole ∆ Y circuit circuit Pole changing Low rpm High rpm Dahlander connection Low rpm High rpm Dahlander connection Low rpm High rpm 1TP1- Pre-alarm PTC U>2.5V not allowed Use tripping device with PTB 1TP2...
Page 42: Brakemotors With Incorporated Brake
Brakemotors with incorporated brake Brake connection via motor winding Y circuit Terminals BA1-BA2 can be connected directly to the motor terminals to supply the brake. Compare the motor/brake voltages to determine whether the connection is to be made on U1-U2 or U1-V1.
Page 43 TB1-TB2 Temperature monitoring: Microtherm T 10 Brake connection via external power supply ∆ Y circuit Brake connection circuit Brake power supply via terminals BA1- BA2. Observe Pole changing the voltage data Low rpm High rpm on the rating Y circuit Y circuit plate.
Page 44: Operation And Repairs
Operation and Repairs Duty types and thermal protection • In S1 duty class motors a temperature sensor (TS) can be used in addition to the motor circuit breaker as required by DIN EN 60079-14, VDE 0165. • If in S1 duty cycle motors protection is to be provided against overheating only by means of the TS, a proven combination of TS and tripping device is to be used for said purpose.
Page 45: Motors With Backstop
Motors with backstop Motors with built-in backstop must be operated at a minimum rpm higher –1 than the value specified on the rating plate – e.g. FXM 850 min – to prevent excessively high temperatures. Heat input through the driven machine It must be ensured that no quantities of heat greater than the maximum heating values specified in table are conveyed from a mounted machine to the interface with the motor (e.g.
Page 46 • Check the direction of rotation and operation during idle running. In case of unidirectional external fans (axial fans) observe the sign for the direction of rotation on the motor. If the direction of rotation needs to be changed, invert the two power lines and the fan. •...
Page 47: Maintenance
Maintenance Inspection • The motors are to be constantly monitored depending on the operating conditions. • Keep the motors clean and the venting openings free Section "Site", page 10) Any national regulations valid for the maintenance/repair of electrical equipment in areas subject to explosion hazards - e.g. in Germany the Operational Safety Order, etc - are to be complied with.
Page 48 The drip space in the bearing cap for outflowing old grease is large enough to collect the outflowing grease during the nominal bearing service life with state-of-the art regreasing. See the plate on the motor for the specified lubricating intervals and the type and quantity of grease to be used.
Page 49: Explosion Protection
Explosion protection The marking (II2G), EEx de IIC T4, for instance, indicates where the motor is to be used and that it has been designed, built and approved according to the relevant European standards required for operation in areas subject to explosion hazards.
Page 50: Repairs
on the motor or by issuing a test report. • The surfaces of ignition-protected gaps must not be reworked. Keep these surfaces metallically clean. Corrosion protection can be achieved by means of non-hardening sealing materials or sealing grease. The approved sealing materials include besides the corrosion protection greases available on the market: Hylomar, by Marston-Domsel or Admosit and Fluid-D, by Teroson (follow the manufacturer's usage...
Page 51: Additional Dust Protection Requirements
Additional dust protection requirements (application in zones 21 and 22) Intended use A marking of at least IP 65 and II 2D T …° C must be found on the motor's rating plate. Installation and Operation Cable and line lead-ins Separately approved lead-ins belonging to category 2G with at least IP 65 or category 2D are to be used.
Page 52 ATB Motorentechnik GmbH Helgoländer Damm 75 D-26954 Nordenham info@atb-nordenham.de www.atb-nordenham.de © 2005 by ATB Motorentechnik GmbH rights of modification reserved BA 01.05 Printed in the Federal Republic of Germany (02/05) under license of MOTORENTECHNIK GMBH...

This manual is also suitable for:

Dcd series Ceigl series Bd series Dbd series