CAT Siemens 1TB 3026−0GA03 1TB 3026−1GA03 1TB 3030−0GA03 1TB 3030−1GA03 3030−0GB03 Operating Manual

BI619397

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI619397

Three-phase Motor Mining Motor Operating Instructions

1TB 3026 − 0GA03 1TB 3026 − 1GA03 1TB 3030 − 0GA03 1TB 3030 − 1GA03 1TB 3030 − 0GB03

Order No.: A5E00338220A

Edition 02.2008

BI619397

Documentation list Register Document No. 1

Operating instructions for motor (with parts list and cross-section)

2

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3

"Motor" drawings: Dimension drawings: 1TB 3026 – 0GA03 1TB 3026 – 1GA03 1TB 3030 – 0GA03 1TB 3030 – 1GA03 1TB 3030 – 0GB03

Order No. A5E00338220A

A5E00240616A A5E00429867A A5E00240616A A5E00429867A A5E00901331A

Rotor, complete (balancing unit): 1TB 3026 – 0GA03 / 1TB 3026 – 1GA03 1TB 3030 – 0GA03 / 1TB 3030 – 1GA03 1TB 3030 – 0GB03

A5E00338659A A5E00278478A A5E00278478A

Accessories packs

A5E00337211A

Transportation lock

A5E00700412A

Final assembly: 1TB 3026 – 0GA03 1TB 3026 – 1GA03 1TB 3030 – 0GA03 1TB 3030 – 1GA03 1TB 3030 – 0GB03

A5E00278060A “ “ “ “

4

Speed sensor installation

5

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A5E00218658A

Note: Refer to A5E00338220A Appendix Z1 "Revision table"

NOTE Please be careful always to use the latest version of the documentation!

Exclusion of liability We have checked that the content of this document corresponds to the hardware and software described. Nonetheless, differences cannot be ruled out and we cannot, therefore, guarantee that they are completely identical. However, the information in this document is regularly checked and the necessary corrections included in subsequent editions. Suggestions for improvement are welcome.

© Siemens AG, 2006. All rights reserved Order no.: A5E00338220A Order to A&D LD T Printed in the Federal Republic of Germany

We reserve the right to make technical changes

BI619397

Edition 02.2008

Safety information

Safety information These Operating Instructions contain information which you should observe to ensure your own personal safety as well as to protect the product and connected equipment.

Notices referring to your personal safety are highlighted in the manual by a safety alert symbol; notices referring to property damage only have no safety alert symbol. The information is marked according to the level of danger: DANGER indicates that death or serious injury will result if proper precautions are not taken.

WARNING indicates that death or serious injury could result if proper precautions are not taken.

CAUTION with a safety alert symbol indicates that minor personal injury could result if proper precautions are not taken.

CAUTION without a safety alert symbol indicates that property damage could result if proper precautions are not taken.

NOTICE indicates that an undesirable result or state could occur if the corresponding instruction is not followed.

If more than one level of danger is simultaneously applicable, the warning notice for the highest level is printed. If a warning notice is used with the safety alert symbol to warn against injury, this same notice may also include a warning regarding property damage.

Qualified personnel The associated equipment / system may only be set up and operated in conjunction with this documentation. The equipment / system may only be commissioned and operated by qualified personnel. For the purpose of the safety information in these Operating Instructions, a "qualified person" is someone who is authorized to energize, ground, and tag equipment, systems, and circuits in accordance with established safety procedures.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

3

BI619397

Edition 02.2008

Safety information

For proper handling Note the following:

WARNING This equipment is only allowed to be used for the applications described in the catalog and in the technical description, and only in conjunction with non-Siemens equipment and components recommended by Siemens. The successful and safe operation of this equipment is dependent on proper transport, storage, installation, assembly, operation, and maintenance.

Locally applicable safety information and regulations must be carefully observed.

Regulations which prohibit the deployment of unqualified personnel, e.g. VGB 4, DIN VDE 0105, and IEC 364, exist for work on electrical power installations.

Trademarks All names identified by ® are registered trademarks of Siemens AG. Other designations used in this document may be registered trademarks; the owner’s rights may be violated if they are used by third parties for their own purposes.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Contents

Contents 1

General .......................................................................................................................................8 1.1

2

3

4

5

6

General safety information............................................................................................8

Transport, storage, disposal...................................................................................................10 2.1 2.1.1

Suspending the motor ................................................................................................10 Motor ..........................................................................................................................10

2.2

Transport ....................................................................................................................13

2.3 2.3.1 2.3.2

Storage.......................................................................................................................13 Storage of new motors................................................................................................14 Storage of used motors ..............................................................................................15

2.4 2.4.1

Notes on environmental protection, recycling, and disposal .......................................15 Environment-related properties of the three-phase AC drive motors ..........................15

Motor ........................................................................................................................................16 3.1

General.......................................................................................................................16

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5

Motor types.................................................................................................................17 1TB3026 – 0GA03......................................................................................................17 1TB3026 – 1GA03......................................................................................................17 1TB3030 – 0GA03......................................................................................................18 1TB3030 – 1GA03......................................................................................................18 1TB3030–0GB03........................................................................................................19

3.3

Stator design ..............................................................................................................19

3.4

Rotor design ...............................................................................................................19

3.5

Built-on parts ..............................................................................................................20

3.6

Technical data ............................................................................................................21

3.7

Special accessories....................................................................................................22

Installation................................................................................................................................23 4.1

Safety information.......................................................................................................23

4.2 4.2.1 4.2.2 4.2.3

Motor installation ........................................................................................................23 Transportation lock .....................................................................................................23 Tests...........................................................................................................................24 Assembly conditions and instructions .........................................................................24

4.3

Commissioning ...........................................................................................................25

Operation..................................................................................................................................26 5.1

Safety information.......................................................................................................26

5.2

Monitoring of operation ...............................................................................................26

Maintenance.............................................................................................................................27 6.1

Safety information.......................................................................................................27

6.2

Maintenance intervals.................................................................................................28

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

5

BI619397

Edition 02.2008

6.3 6.3.1 6.3.2 6.3.3 6.3.4

Maintenance work on the installed motor....................................................................29 Checking for external damage ....................................................................................29 Checking the connections...........................................................................................29 Regreasing the bearings.............................................................................................30 Checking the interior of the motor for water ................................................................31

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.12

Dismantling the motor.................................................................................................32 Pressing off the D-end coupling..................................................................................34 Pressing the brake hub / gear wheel (N–end) off the shaft .........................................35 Pulling the speed sensor gear (N-end) off the shaft....................................................36 Withdrawing the complete rotor from the stator frame at the D-end............................38 Removing the labyrinth ring (D-end) ...........................................................................40 Pulling the bearing shield (D-end) and the bearing off the shaft .................................41 Pulling the inner labyrinth ring (D-end) off the shaft ....................................................42 Pressing the bearing (D-end) out of the bearing shield ...............................................43 Forcing off the bearing shield (N-end) and removing the bearing parts ......................43 Pulling the bearing inner ring or spacer ring off the shaft (N-end) ...............................45 Pulling the inner labyrinth ring (N-end) off the shaft ....................................................46 Removing the rubber seals and the air deflectors.......................................................47

6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5

Maintenance work on the dismantled motor ...............................................................48 Cleaning agents and cleaning work ............................................................................48 Work on the stator ......................................................................................................49 Work on the rotor ........................................................................................................50 Testing the insulation..................................................................................................50 Work on the bearings..................................................................................................52

6.6 6.6.1 6.6.2 6.6.3 6.6.4

Assembling the motor .................................................................................................53 Assembling the air deflectors and the rubber seals ....................................................55 Shrinking the labyrintrings (D-end and N-end) onto the shaft .....................................56 Assembly after special maintenance work ..................................................................57 Pressing the bearing (D-end) into the bearing shield and installing the bearing parts ...........................................................................................................................58 Pressing the bearing outer ring with the set of rolling elements into the bearing shield (N-end) and assembling the bearing parts........................................................61 Motor type 1TB 3026 − xGA03 / 1TB 3030 − xGA03 only...........................................61 Motor type 1TB3030-0GB03 only ...............................................................................64 Assembling the bearing shield (N-end) on the stator frame ........................................66 Shrinking the bearing parts onto the shaft ..................................................................67 Pressing the bearing shield (D-end) and the bearing onto the shaft ...........................67 Inserting the rotor into the stator frame and mounting the bearing shield (D-end) ......68 Shrinking the labyrinth ring (outer, D-end) onto the shaft............................................72 Assembling the bearing unit cover (D-end).................................................................73 Mounting the speed sensor gear (N-end) ...................................................................73 Assembling the labyrinth cover (N-end) ......................................................................74 Assembling the built-on parts (D-end and N-end) .......................................................75 Running in the bearings..............................................................................................77 Pressing on the coupling, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only.............................................................................................................................77 Pressing on the brake hub / gear wheel, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only .....................................................................................................79

6.6.5 6.6.5.1 6.6.5.2 6.6.6 6.6.7 6.6.8 6.6.9 6.6.10 6.6.11 6.6.12 6.6.13 6.6.14 6.6.15 6.6.16 6.6.17

6

Contents

6.7 6.7.1 6.7.2

Repair work ................................................................................................................81 Replacing defective connection leads.........................................................................81 Repairing the stator winding insulation .......................................................................82

6.8

Spare parts .................................................................................................................83

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

7

Contents

Appendix ..................................................................................................................................84 7.1

Parts list......................................................................................................................84

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8

List of consumables....................................................................................................92 H1 Chemical cleaning agents ....................................................................................92 H2 Chemical cleaning agents for windings ................................................................93 H3 Rolling-contact bearing grease.............................................................................94 H4 Mounting / dismounting fluids for bearing seats ...................................................94 H5 Sealants for joining parts or gaps.........................................................................94 H6 Locking agents for connecting elements ..............................................................95 H10 Anti-corrosion agent ...........................................................................................96 H11 Mounting fluid for temperature sensors ..............................................................96

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

List of tools .................................................................................................................97 W1 Assembly devices for inserting and withdrawing the rotor horizontally ................97 W2 Pressure unit for enlarging the coupling ..............................................................97 W3 Compression units for pressing on or for support while pressing off....................98 W4 Draw gear with crossbar or plate.........................................................................99 W6 Aids ...................................................................................................................100 W8 Devices for pulling off components (separator pulling tool, complete set) .........100

7.4 7.4.1

Repair parts list.........................................................................................................101 R1 Paints for renewing the paintwork or touching up damaged parts ......................101

7.5

Appendix B1a, Exploded view, motor types 1TB3026 – xGA03 / 1TB3030 – xGA03 only...............................................................................................................104

7.6

Appendix B1b, Exploded view, motor type 1TB3030 – 0GB03 only..........................108

7.7

Appendix B2a, Dismantling diagrams .......................................................................112

7.8

Appendix B2b, Assembly diagrams ..........................................................................116

7.9

Appendix X1, Fault table...........................................................................................119

7.10

Appendix Z1, Revision table .....................................................................................124

NOTE For clarity, these Operating Instructions do not contain every item of information in detail and, therefore, cannot consider every conceivable application.

Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, please contact your local SIEMENS office.

Furthermore, the contents of these Operating Instructions shall not become a part of or modify any prior or existing agreement, commitment, or legal relationship. The Purchase Agreement contains the complete and exclusive obligations of Siemens. All statements contained herein neither create new warranties nor modify the existing warranty.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

7

BI619397

Edition 02.2008

1

General

General DANGER Parts of electrical machines rotate during operation and certain exposed parts of these machines conduct dangerous voltages. Unauthorized removal of the cover plates, improper handling of these machines, incorrect operation, or inadequate maintenance can result in serious injury or property damage.

The persons responsible for safety must therefore guarantee that: •

Only appropriately qualified personnel may work on this equipment.

•

This personnel always have at their disposal, among other things, these Operating Instructions and all other product documentation supplied which is relevant to the task they are carrying out; they must also be obliged to observe the measures specified in these documents consistently.

•

All work by unqualified personnel on this equipment or in its vicinity is prohibited.

WARNING However, observance of other notes on transport, assembly, operation, and maintenance, as well as the technical data (in these Operating Instructions, in the product documentation, and on the unit itself) is equally indispensable to avoid malfunctions which could cause serious injury or substantial property damage directly or indirectly.

NOTE Regulations which prohibit the deployment of unqualified personnel, e.g. BGV A2, DIN VDE 0105, and IEC 364, exist for work on electrical power installations.

1.1

General safety information The machines described here are components of vehicles for industrial applications.

They are designed in accordance with the generally accepted rules of sound engineering practice.

DANGER Due to their functional characteristics and their field of application, these machines can cause serious injury or substantial property damage if incorrectly operated, inadequately maintained, or tampered with by unauthorized or unqualified personnel.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

General

WARNING It is mandatory that all tasks relating to transport, assembly, dismantling, maintenance, and repairs be carried out by qualified personnel or supervised by responsible skilled technicians.

Close attention must be paid to the following: •

The technical data and information regarding permitted use (assembly, connection, environmental, and operating conditions) which can be found in a number of places, including the catalog, the order documents, these Operating Instructions, the nameplate, and the other product documentation,

•

The general installation and safety specifications applicable to work on electrical power installations (e.g. DIN VDE),

•

Local, plant-specific regulations and requirements,

•

Correct use of tools and lifting and handling equipment,

•

Use of personal protective gear (e.g. safety boots, goggles etc.).

•

The obligation imposed in VBG 4, Articles 7 and 8, of the German accident prevention regulations as well as in Article 14 of the German law on hazardous substances (GefStoffV) (or equivalent national regulations) on the persons responsible for instructing employees in safety matters with regard to the safe use of substances that could pose a hazard to health or the environment (e.g. in the case of cleaning agents, lubricants, adhesives, paints etc.).

Details of specific products can be found in the respective "material safety data sheet" issued by the manufacturer of the product.

The information in these Operating Instructions does not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. The instructions therefore basically contain only the information required by qualified personnel (see above) who are using the equipment for its intended purpose as a traction motor.

Any confusion in these matters, especially if due to a lack of detailed product-specific information, must be clarified by your regional SIEMENS distributor. In this case, please always specify the motor type and serial number.

WE RECOMMEND TAKING ADVANTAGE OF THE ASSISTANCE AND SERVICES PROVIDED BY REGIONAL SIEMENS SERVICE CENTERS FOR TASKS INVOLVING PLANNING, ASSEMBLY, COMMISSIONING, AND SERVICE.

NOTE For additional detailed information regarding general work, such as inspecting incoming deliveries (for shipping damage), long-term storage and conservation of motors, etc., refer to the Siemens Work Guidelines, available from distributors.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

9

BI619397

Edition 02.2008

Transport,storage,disposal

2

Transport, storage, disposal

2.1

Suspending the motor DANGER Never stand underneath suspended loads!

DANGER Incorrect suspension will result in serious injury or property damage if proper precautions are not taken.

2.1.1

Motor Individual motors must be suspended using the three load rings (M30x50) (1TB3030 – 0GB03 upright only: four load rings) provided for this purpose. Refer from Fig. 2.1 to Fig. 2.6 and the dimension drawings for the mounting positions of the eyebolts.

A5E00240616A = 1TB 3026 – 0GA03 A5E00429867A = 1TB 3026 – 1GA03 A5E00240616A = 1TB 3030 – 0GA03 A5E00429867A = 1TB 3030 – 1GA03 A5E00901331A = 1TB 3030 – 0GB03 The lifting gear must be designed to support the weight of the motor.

Use suitable lifting gear (for weight, refer to the technical data in chapter 3.6 and the dimension drawings).

The weight is unevenly distributed between the suspension points.

All three suspension points must be used (1TB3030 – 0GB03 upright only: all four suspension points must be used).

WARNING Each of the three load rings and strands (1TB3030 – 0GB03 upright only: four load rings and strands) (e.g. three-strand lifting gear / 1TB3030 – 0GB03 upright only: four-strand lifting gear) must be capable of supporting the complete motor weight!

Any auxiliary eyebolts available, e.g. on bearing shields or elsewhere, are not designed to support the full weight of the motor. They are only suitable for lifting the various component parts during dismantling and assembly.

CAUTION Assembled drive units (motor with gear etc.) must not be suspended solely by the motor's load rings!

The motor's load rings are only designed to support the weight of the motor, and no extra load is allowed to be placed on them by the weight of the gear or heavy built-on parts.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Transport, storage,disposal

NOTICE When suspending the gear, the information provided in the gear manufacturer's operating instructions must be heeded.

Fig. 2.1

Mounting positions of the load rings, 1TB3026-0GA03

Fig. 2.2

Mounting positions of the load rings, 1TB3026-1GA03

Fig. 2.3

Mounting positions of the load rings, 1TB3030-0GA03

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

12

Transport,storage,disposal

Fig. 2.4

Mounting positions of the load rings, 1TB3030-1GA03

Fig. 2.5

Mounting positions of the load rings, 1TB3030-0GB03 horizontal

Fig. 2.6

Mounting positions of the load rings, 1TB3030-0GB03 upright

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

2.2

Transport, storage,disposal

Transport When dispatched from the works, the motors are normally transported on pallets and in frames or crates to which lifting gear can be attached.

CAUTION Transport without the brake system (N-end): The motors have a transportation lock [13.00] on the N-end to protect the bearings against damage during transport.

This transportation lock [13.00] must not be removed until immediately before the motor is started up (refer to chapter 4.2)!

The motor is not allowed to be transported without the transportation lock because this can cause incipient damage to the rolling-contact bearings.

The information provided in the assembly instructions for the transportation lock (A5E00700412A) must be heeded.

Transport with the brake system mounted (N-end): If the brake system is already mounted, the brake (N-end) must be securely locked (parking brake). The rotor must be immovably fastened.

The brake (N-end) is not allowed to be released until immediately before the motor is started up!

The motor must not be transported if the brake (N-end) is not locked because this can cause incipient damage to the rolling-contact bearings.

NOTE If the motor needs to be transported again in the future, it must be locked in accordance with the above instructions either using the original transportation lock or with the brake (N-end) mounted!

CAUTION When transporting the motor with the gear, the information provided in the gear manufacturer's operating instructions must be heeded.

2.3

Storage The motors must be stored in a dry room which is not susceptible to vibration. The ambient temperature should not exceed 77°F (25°C) or fall below 14°F (-10°C). If these storage temperatures are adhered to, the bearings must be regreased after a storage time ≥ 2 years before the motor is started up (refer to chapter 6.3.3).

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

13

BI619397

Edition 02.2008

Transport,storage,disposal

NOTE If the storage temperature deviates within the permissible range from 77°F (25°C) to 176°F (80°C) or 14°F (-10°C) to -40°F (-40°C), the bearings must be regreased after a storage time ≥ 6 months before the motor is started up (refer to chapter 6.3.3)!

The ambient temperature must not exceed 176°F (80°C) or fall below -40°F (-40°C)!

CAUTION The transportation lock must be mounted if vibrations cannot be ruled out.

Under no circumstances must the drive be allowed to turn, even a negligible amount, while the transportation lock is mounted, as this could damage both the transportation lock and parts of the motor.

2.3.1

14

Storage of new motors •

The motors should remain on the pallet in the condition in which they were delivered.

•

If the transport packaging is used to store the motors for a period of up to six months, its condition must be checked (e.g. with regard to damage in transit or during customs handling etc.).

•

If the motors are to be stored for longer than six months, long-term packaging must be provided.

•

Long-term packaging can be used for up to two years. The motors must be packed by appropriately qualified personnel in accordance with recognized guidelines, e.g.

HPE (Bundesverband Holzpackmittel-Paletten-Exportverpackung e.V.), as well as local conditions.

•

The corrosion protection on bright mounting surfaces must be inspected and if necessary renewed.

•

Please consult the manufacturer if the motors are to be stored for longer than two years.

•

The rotor of the stored motor must be turned by hand once every two years.

The packaging and the transportation locks must be removed for this purpose.

After turning the rotor shaft a few turns, remount the transportation lock with the rotor in a different position.

Then pack the motor again in the proper way.

•

During commissioning, the information provided in chapter 4.3 must be heeded.

•

Check the motor for water. The information provided in chapter 6.3.4 must be heeded.

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

2.3.2

2.4

Transport, storage,disposal

Storage of used motors •

Used motors should be stored on a pallet or another wooden base.

•

In case of protracted idle periods, suitable corrosion prevention, conservation, packaging, and drying measures must be taken, e.g. drying out the motor, sealing it in plastic film, and adding silica gel. Details can be found in the general Siemens Instructions for Work.

•

Motor servicing and cleaning are recommended prior to protracted idle periods or extended periods in storage.

•

The motors can then be stored in the same way as new motors.

Notes on environmental protection, recycling, and disposal Environmental compatibility is a quality characteristic which is systematically applied in the development, manufacture, and disposal of our products.

Our products serve their intended purpose and satisfy the most exacting ecological and economic requirements.

2.4.1

Environment-related properties of the three-phase AC drive motors Low-wear, three-phase AC drive motors guarantee low-maintenance operation.

Their high driving efficiency and lightweight construction help save energy.

Highly developed, contactless sealing systems guarantee oil tightness, thereby protecting the environment.

Notes on recycling: The three-phase motor is an environmentally compatible product.

98% of the product is recyclable.

All non-metallic materials are an exception; they require separate disposal as prescribed by the relevant national rules and regulations.

Notes on disposal: Oils, greases, and coolant must as far as possible be completely removed and disposed of separately.

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A5E00338220A Operating Instructions

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Edition 02.2008

3

Motor

3.1

General

Motor

The underscored numbers given in square brackets in the following text refer to the item numbers in the parts list (chapter 1) and in the drawings (fold-out sheets in the Appendix).

The four-pole three-phase motor has a "frame" design and is intended for (transverse) installation in mining vehicles. A special version with a ball bearing at the N-end can also be installed upright, in which case the motor can alternatively be used for excavators.

This quasi-enclosed motor is forced-ventilated with open air circulation. Air enters radially, or axially if additional air covers are used, and exits at both ends (D-end and N-end).

Fig. 3.1

16

Cross section of the motor 1TB3030-xGA03, 1TB3026-xGA03

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Motor

3.2

Motor types

3.2.1

1TB3026 – 0GA03

Fig 3.2

Installation position (left / right) 1TB3026 – 0GA03

3.2.2

1TB3026 – 1GA03

Fig 3.3

Installation position (left / right) 1TB3026 – 1GA03

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

3.2.3

1TB3030 – 0GA03

Fig 3.4

Installation position (left / right) 1TB3030 – 0GA03

3.2.4

1TB3030 – 1GA03

Fig 3.5

Installation position (left / right) 1TB3030 – 1GA03

18

Motor

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Motor

3.2.5

1TB3030–0GB03

Fig. 3.6

Installation position (upright / horizontal) – motor type 1TB3030–0GB03 only

3.3

Stator design The stator core, comprising insulated, electric sheet steel laminations, is shrink-fitted into the frame together with the stator thrust rings arranged on either side of it.

The core has axial air ducts for cooling.

The stator winding [1.31] is inserted into the slots of the core. The slots are sealed by means of slot caps.

The winding ends of the coils, the stator coil connectors [1.30], and the connection bars [1.12] to [1.13] are brazed together.

The terminal box [6.00], which is integrated in the stator frame, is fitted with a cover [6.10].

The motor is designed with two terminal boxes (pitched at 180°), whereby either one or both boxes are provided with winding connections, depending on the version.

The stator core with winding is vacuum impregnated and meets the requirements of thermal class 200.

The stator is designed to allow the cooling ducts and the air ducting spaces to be easily cleaned after dismantling the motor.

3.4

Rotor design A core [2.21], comprising insulated, electric sheet steel laminations, is shrink-fitted onto the rotor shaft [2.20] made of high-strength, heat-treated steel together with the rotor thrust rings [2.23 / 2.24] arranged on either side of it.

The rotor has axial air ducts for cooling.

The copper rotor bars are inserted into the slots of the core [2.21]. Together with the short-circuit rings brazed onto the D-end and N-end, they form the cage winding [2.30].

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A5E00338220A Operating Instructions

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Motor

The rotor is supported at the D-end in a deep-groove ball bearing [3.15] and at the N-end in a cylindrical-roller bearing [4.16]. The bearings are grease-lubricated and have a regreasing mechanism, which is accessible at the N-end via a tapered grease nipple [8.14] for each bearing. The used grease is stored in appropriate chambers. The bearing units [3.00 / 4.00] are sealed by means of contactless labyrinth rings.

A special version of the motor has a deep-groove ball bearing with a preloaded compression spring at the N-end instead of the cylindrical-roller bearing, to enable the motor to be operated upright as well as horizontally without requiring any internal modifications.

3.5

Built-on parts The rotor has a tapered shaft extension at the D-end, which is used to fasten a coupling.

A coupling can be supplied as an option. It is hydraulically assembled and dismantled.

The rotor also has a tapered shaft extension at the N-end, which is used to fasten a coupling for a brake disk.

This brake disk (brake hub / gear wheel) coupling is hydraulically assembled and dismantled.

The motor is designed to generate and absorb torques and to transfer torques generated by the N-end braking system. It is not designed to withstand any external lateral forces acting at the rotor shaft.

The motor is additionally equipped with temperature and speed measurement devices.

Three PT100s for the D-end bearing, the N-end bearing, and the stator core are combined for this purpose in a cable harness together with a speed sensor. They are connected by means of a central plug on the motor N-end. A special version with a builton terminal box instead of the plug can also be supplied.

Optional air covers are available for the air inlets and outlets provided on the motor frame. They can be adapted to the individual application and the specific vehicle connection.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

3.6

Motor

Technical data

General motor data Six-pole, three-phase asynchronous motor for installation in mining vehicles or equipment Mechanical motor data Separately ventilated, -22°F to 131°F (-30°C to +55°C)

1TB3026-xGA03 3

1,5 m /s

1TB3030-xGA03

1TB3030-0GB03

3

3

2.0 m /s

2.0 m /s

Option High Power: 2.5 m3/s Rotor diameter

545 mm

545 mm

545 mm

Stator bore diameter

550 mm

550 mm

550 mm

Length of core

450 mm

550 mm

550 mm

Air gap

2.5 mm

2.5 mm

2.5 mm

Electrical motor data Continuous operation point Rated voltage

1010 V

927 V

1375 V

Rated current

750 A

2 * 500 A

2 * 315 A

Rated power

910 kW

1120 kW

1120 kW

Rated speed

594 rpm

593 rpm

592 rpm

Displacement factor cos phi

0.71

0.79

0.79

Rated frequency

30 Hz

30 Hz

30 Hz

Thermal class

200

Rated insulation voltage

2300 V

Maximum voltage

1560 V

1560 V

1375 V

Maximum current

1300 A

2 * 960 A

2 * 540 A

Maximum speed

3550 rpm

3450 rpm

1500 rpm

Y

Double - Y

Double - Y

1 x 185 mm2

2 x 185 mm2

2 x 185 mm2

Circuit Connection leads per phase

(1 terminal box) Standards and regulations

(2 terminal boxes) IEC 60349-2 08/2002

Motor weights Motor, complete

3980 kg

4300 kg

Rotor, complete (balancing unit)

1160 kg

1300 kg

Stator, complete

2290 kg

2500 kg

Bearings Bearing (D-end) Bearing (N-end)

Rolling-contact bearing grease

Siemens AG Three-phase Motor

Deep-groove ball bearing DIN 625-6236 M (electrically insulated) Cylindrical-roller bearing DIN 43283 - NU 232ECM / C4HVA3091 (electrically insulated)

Deep-groove ball bearing DIN 625-6232 (electrically insulated)

Shell Retinax LX2 (corresponds to "H3.5", Appendix A1)

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Motor

Initial grease quantity, regrease quantity Bearing (D-end)

56 oz. (1600 g)

56 oz. (1600 g)

Bearing (N-end)

35 oz. (1000 g)

35 oz. (1000 g)

Bearing (D-end)

13 oz. (360 g) / year

6.5 oz. (180 g) / 6 months

Bearing (N-end)

13 oz. (360 g) / year

13 oz. (360 g) / 6 months

Regrease quantity

NOTE

3.7

•

Type 1TB3026 – xGA03 motors cannot be operated with the converters for type 1TB3030 – xGA03 motors.

•

Type 1TB3030 – xGA03 motors cannot be operated with the converters for type 1TB3026 – xGA03 motors.

•

Type 1TB3030–0GB03 only motors cannot be operated with the converters for type 1TB3026 – xGA03 motors.

Special accessories The motor is supplied already equipped with various special accessories: •

- Speed sensor [7.13] - D-end and N-end bearing temperature sensors [7.12] - Stator core temperature sensor [7.11] in a single cable harness

•

Motor type 1TB3030–0GB03 only: – Deep-groove ball bearing on the N-end – Terminal box for the bearing / stator temperature sensors and the speed sensor

NOTE The stator core temperature sensor [7.11], bearing temperature sensors [7.12], and speed sensor [7.13] are combined in a single cable harness.

The speed sensor [7.13] can be supplied separately if it needs to be exchanged in the cable harness (e.g. if it fails when the motor is installed).

The motor can be additionally equipped with the following components at the customer's request:

22

•

Motor – gear – coupling, D-end

•

Brake disk hub, N-end

•

Special air cover, depending on the application

•

Speed sensor – extension cable for mounting the speed sensor, pitched at 180° in a second sensor hole

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Installation

4

Installation

4.1

Safety information DANGER Please adhere strictly to the general safety procedures and requirements in chapter 1.1 of these Operating Instructions and the notes on permissible use and special knowledge required for work on electrical power installations.

Before any installation work is started on the motor, make sure that the intended measures cannot cause any faults in the plant or any danger to persons.

4.2

Motor installation This manual provides only general instructions for assembling and starting up the motor.

4.2.1

Transportation lock The transportation lock [13.00] must be removed from the N-end as shown in Fig. 4.1 prior to starting up the motor: •

Undo the ratchet lashing belts [13.13] and remove.

•

Loosen all external nuts [13.17], then remove them together with the hollow section [13.11] and the felt [13.19].

•

Unscrew the threaded rods [13.12] from the bearing shield.

•

Keep all transportation lock elements in a safe place for later reuse and protect them from corrosion.

NOTE The same transportation lock elements must be remounted on the motor for transport in the dismantled state, long-term storage etc.

The information provided in chapter 2.3 and the assembly instructions for the transportation lock (A5E00700412A) must be heeded.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

Operation

Fig. 4.1

4.2.2

Tests •

4.2.3

Transportation lock for the N-end

Test the insulation resistance of the windings after extended periods in storage or protracted idle periods (refer to chapter 6.5.4).

Assembly conditions and instructions The following checks must be carried out: •

Visual inspection of the complete motor (if accessible) for abnormalities prior to starting any assembly work on the machine, e.g.: – Has any (shipping) damage been suffered?

– Are any parts loose?

– Are any screws or bolts missing? etc.

24

•

The connection leads must not be damaged.

•

Leads must always be laid so that they can neither be pinched nor come into contact with rotating parts (risk of short-circuits). The maximum permissible temperature of the connection leads is 356°F (180°C).

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

4.3

Installation

•

Some parts of the frame of electrical machines can reach temperatures in excess of 212°F (100°C). Temperature-sensitive parts, such as ordinary cables or electronic components, must therefore neither rest on these frame parts nor be attached to them.

•

The cooling air must flow in and out without restriction. Hot exhaust air must not be inducted again. Adequate clearances must be provided in front of the air inlets and outlets.

The specified airflow must be constantly available.

For the required flow of cooling air, refer to chapter 3.6.

•

An appropriately designed controller and speed monitoring system must be used to ensure that the maximum speed is not exceeded (refer to chapter 3.6).

Commissioning During and after installation, verify that: •

All bolts, connecting elements, and electrical connections of all connections made are tightened to the specified torques and locked in the required way.

•

The equipotential bonding connections have been properly made.

•

The flow of cooling air is not restricted.

•

The drainage hole has been opened at the bottom (refer to note in A5E00337211A).

•

If the motor is started up after a storage period of two years or more, the bearings are regreased (refer to chapter 6.3.3).

•

The drainage hole for the bearing seal at the D-end permits free discharge on the underside of the frame.

NOTE If the storage temperature deviates within the permissible range from 77°F (25°C) to 176°F (80°C) or 14°F (-10°C) to -40°F (-40°C), the bearings must be regreased after a storage time ≥ 6 months before the motor is started up (refer to chapter 6.3.3)!

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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5

Operation

5.1

Safety information

Operation

DANGER Please adhere strictly to the general safety procedures in chapter 1.1 of these Operating Instructions and the notes on permissible use and special knowledge required.

Covers which prevent access to live or moving parts must not be opened during operation. Refer also to chapter 6.1 "Safety information".

5.2

Monitoring of operation WARNING An appropriately designed controller and speed monitoring system must be used to ensure that the maximum values specified in the technical data are not exceeded.

Deviations from normal operation (increased power consumption, temperatures, or vibrations, unusual noises or odors, tripping of monitoring devices etc.) indicate that the motor is not functioning properly. To avoid malfunctions that could, either directly or indirectly, cause serious injury or substantial property damage, notify the responsible maintenance personnel immediately (refer to Appendix X1 "Fault Table").

IF IN DOUBT, TURN OFF THE RELEVANT COMPONENT IMMEDIATELY!

In the case of malfunctioning or unusual operating conditions that could indicate electrical or mechanical overloading of the machine, the appropriate maintenance work and tests should be carried out without delay.

In the case of extended idle periods, start up the motor regularly (about once a month) or at least turn the rotor.

In the case of protracted periods when the vehicle is removed from service, suitable corrosion prevention, conservation, packaging, and drying measures must be taken; refer to the information provided in chapter 2.3. Details can be found, for instance, in the general Siemens Instructions for Work.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6

Maintenance

Maintenance

General note: All maintenance work on the motor must be carried out with the utmost care.

In particular, care should be taken to ensure that: •

All essential safety precautions are heeded

•

No impurities get into the motor

•

No parts are forgotten inside the motor

•

No tools are left inside the motor

•

All technical specifications (threadlocker, tightening torques etc.) are complied with

If these warnings are ignored, danger to persons or machine faults cannot be ruled out.

6.1

Safety information DANGER Please adhere strictly to the general safety procedures and requirements in chapter 1.1 of these Operating Instructions and the notes on permissible use and special knowledge required for work on electrical power installations.

Improper handling of the motor and tools may result in death or serious injury and/or substantial property damage.

•

All assembly, dismantling, and maintenance work and repairs must be performed by appropriately qualified personnel.

•

Before beginning any work on the motors, make sure that the vehicle cannot move and that the motor is resting securely on its base.

•

Before opening live parts of the motor, take special care to ensure that it is isolated in accordance with regulations. This applies especially to dismantling and installing the motor in the vehicle and after carrying out tests on the motor.

The standard "5 safety rules" (e.g. in accordance with DIN VDE 0105) are: •

isolate,

•

secure against switching on again,

•

verify that the equipment is not live,

•

ground and short-circuit (for voltages above 1000 V),

•

erect barriers around or cover adjacent live parts.

•

The specified maintenance intervals and the instructions for repair and part replacement must always be observed.

•

Only spare parts approved by the manufacturer may be used.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

27

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Edition 02.2008

Maintenance

CAUTION If tightening torques are specified for nuts and screws in the text of this manual or the parts list, use a torque wrench to tighten them finally!

Never use a pneumatic or impact screwdriver!

6.2

Maintenance intervals Careful and regular maintenance is necessary to detect and eliminate possible malfunctioning before serious damage can occur.

The maintenance intervals given in this manual are valid for typical working conditions.

Special working conditions and/or legal and official regulations may necessitate more frequent maintenance.

In the case of malfunctioning or unusual operating conditions that could indicate electrical or mechanical overloading of the drive, the appropriate maintenance work and tests should be carried out without delay.

Maintenance interval motor type 1TB303-0GB03 only Maintenance intervals After every 3000 hours or once every half year for bearing regreasing

Maintenance work •

See chapter 6.3.3

Regrease the bearings

Maintenance intervals all motor types (motor type 1TB303-0GB03 also) Maintenance intervals After every 6000 hours or once every year for minor service

After every 30,000 hours or once every 5 years for general service

Maintenance work

See chapter

•

Inspect for external damage

6.3.1

•

Check the connections

6.3.2

•

Clean the drainage holes

6.3.4/6.5.1

•

Regrease the bearings

6.3.3

On the removed, dismantled, and cleaned motor:

6.5

•

Replace the bearing (D-end)

6.4.6/6.6.8

•

Replace the bearing (N-end)

6.4.9/6.6.6

•

Check the insulation of the stator winding, insulation resistance > 2 MΩ

6.5.4

•

After cleaning: Insulation resistance 10 MΩ

•

Test the winding resistances

6.5.2

NOTICE The motor should be visually inspected in the course of all maintenance work. Refer to chapters 6.3.1 and 6.3.2, which specify that damaged or missing parts must be replaced or renewed in accordance with chapter 6.6.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

NOTICE If the motor has been removed and completely or partially dismantled due to the need to carry out repairs, all maintenance work described in chapter 6.4 that is likewise possible in this state of dismantling should then be performed.

6.3

Maintenance work on the installed motor The special consumables (H ...), tools (W ...), and repair parts (R ...) are listed in detail in the Appendix (refer to chapters 7.2 / 7.3 / 7.4).

The underscored numbers given in square brackets refer to the item numbers in the parts list (chapter 1) and in the drawings (fold-out sheets in Appendix B1 / B2).

In the case of fixing elements, the associated consumables and tightening torques are also given in brackets in the parts list.

If screw connections can be tightened:

6.3.1

6.3.2

•

Open the screw connection and clean the thread.

•

Renew the threadlocker and assemble the screw connection again.

Checking for external damage •

Inspect the motor for external damage of mechanical origin (visual inspection of all accessible parts).

•

Dismantle damaged parts and either repair the damage or replace with new parts.

•

Touch up damaged parts of the paintwork as described in chapter 6.5.2.

•

Remove coarse impurities (leaves, paper etc.) from the air outlet area.

Checking the connections •

Check that all cable glands for the connection leads are securely attached and retighten them where necessary.

•

Check the connection leads for damage and, where necessary, replace them.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

6.3.3

Maintenance

Regreasing the bearings WARNING It is generally known that the task of pressing in grease can pose serious risks, especially at storage temperatures below 50°F (10°C). Partial or total filling with grease which is still stiff impedes the movement of the rolling elements or balls, which are under no pressure when the system starts up. If these rolling elements accelerate rapidly in the gear area, this can cause damage, especially to the raceways, as the film of lubrication can partially break up.

The rolling-contact bearing manufacturers therefore strongly recommend the following: •

Use only approved, clean rolling-contact bearing grease (H3.5) from original containers.

•

Do not "overlubricate" the bearings.

•

Avoid regreasing the bearings when they are very cold (i.e. the units should preferably be regreased when still warm).

•

Heed and comply with the specified regrease quantities for the D-end and N-end (refer to chapter 3.6).

•

Under all circumstances, even if the grease has been stored at more than 50°F (10°C), run the vehicle at appropriately low speeds for a few kilometers after regreasing (e.g. drive it around the maintenance depot).

This ensures that the grease is evenly distributed without force and that the damage to the rolling elements or the raceways described above cannot occur.

NOTE The used grease chambers are sufficiently large to hold the regrease quantities until the general service.

Regreasing the bearings: WARNING The bearings run at high circumferential speeds in a wide temperature range. Extreme cleanliness is essential, especially when the bearings are regreased, to ensure that they function correctly!

30

•

The grease, grease gun, and grease nipple must be clean; wipe them with a lint-free cloth if necessary.

•

Regrease the bearing (D-end) [3.15] with rolling-contact bearing grease (H3.5); refer to chapter 3.6 for the required regrease quantity.

•

Regrease the bearing (N-end) [4.16] with rolling-contact bearing grease (H3.5); refer to chapter 3.6 for the required regrease quantity.

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.3.4

Maintenance

Checking the interior of the motor for water •

To check whether there is water inside the motor (motor types 1TB3030-0GA03 and 1TB3026-0GA03 only): – Inspect the drainage hole in the bearing shield [4.10] (N-end); refer to note in A5E00337211A, – Remove the plug [5.14].

– Clean the drainage hole.

•

To check the bottom of the terminal box for water: – Remove the screw [1.35].

– Clean the drainage hole and allow any water to drain out.

– Apply activator (H6.1) to the thread of the screw [1.35] and leave it to dry. Coat the thread with adhesive (H6.2), insert it, and tighten to a torque of 40 Nm.

•

Siemens AG Three-phase Motor

Motor type 1TB303-0GB03 only: 2 drain holes are provided on the end face for vertical use on the D-end bearing shield; they may not be clogged.

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6.4

Maintenance

Dismantling the motor The special consumables (H ...), tools (W ...), and repair parts (R ...) are listed in detail in the Appendix (refer to chapters 7.2 / 7.3 / 7.4).

This manual only describes dismantling and assembly of the motor. Refer to the information provided in the gear manufacturer’s operating instructions for all other work (e.g. removing from or mounting on the gear etc.).

Horizontal removal (and installation) of the rotor with the bearing shield (D-end) is the most practical method. To do this, fit two bushes onto the shaft extension (D-end) and hold the rotor horizontal using a special lifting eye. The rotor can be inserted and withdrawn in this position; refer to chapter 6.4.4.

CAUTION When suspending shafts vertically: The center holes in the shaft extensions (DIN 332) are provided with a set-back thread, i.e. eyebolts conforming to DIN 580 are unsuitable because only a few turns of the thread would be engaged. Other suitable elements with a length of engagement > 0.8 of the thread diameter must therefore be used.

NOTICE Before forcing a part out of the center holes, it is advisable to replace the fixing bolts with very long bolts or threaded pins capable of supporting the part after it has been removed.

When dismantling individual parts, take special care to ensure that sensitive built-on parts (grease nipples etc.) are protected from damage.

NOTE In order to ensure that the dismantling and assembly tools can be used efficiently, all threaded holes required for this purpose on the drive must be recut and cleaned after removing locked screws.

32

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Fig. 6.1

Maintenance

Cross-section of the motor 1TB3030-xGA03, 1TB3026-xGA03

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

33

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6.4.1

Maintenance

Pressing off the D-end coupling •

Mount the device (W2 / W3) for pressing off the coupling as shown in Fig. 6.2.

•

Connect the oil injection kit (W2.1) radially to the threaded G1/4 hole in the coupling.

NOTICE Use oil for pressing off (see W2.1 / Appendix A2).

•

Mount the device for the compression unit (W3) so that it holds the coupling [15.00] when it jumps out in the axial direction.

•

Gradually enlarge the coupling using the oil injection kit (W2.1) until it jumps out!

NOTICE Starting at 8700 psi (600 bar), gradually increase the pressure in steps of approximately 2900 psi (200 bar), leaving a pause of at least two minutes between each step. These pauses serve to allow the liquid to flow into the interface. Maximum gap oil pressure: 25,200 psi (1740 bar).

CAUTION Building up the pressure too quickly or exceeding the maximum gap oil pressure can result in permanent deformation (bulging) of the hub hole or the shaft seat, rendering the motor coupling and/or the rotor useless.

CAUTION The device (W3) should not be subjected to pressure. Ensure an adequate clearance (at least equivalent to the lateral displacement of the coupling). The coupling must be secured by extending the piston of the pressure cylinder to the maximum lateral displacement and locking it with the nut. This prevents the coupling from jumping out.

When the axial pressure (pressure gage) rises, the coupling has been released.

•

Release the hydraulic cylinder and remove the coupling.

WARNING Owing to the 1:50 gradient, the coupling has an axial force component, which means that the high oil pressure would force it to jump out in the axial direction if the shrink fit is loosened. Risk of injury!

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Fig. 6.2

6.4.2

Pressing off the coupling

Pressing the brake hub / gear wheel (N–end) off the shaft •

Motor / component assignment: – 1TB3030 – 0GA03 = gear wheel – 1TB3030 – 1GA03 = brake hub

•

To press off the brake hub / gear wheel [14.10]: – Mount the device (W2 / W3) for pressing off the brake hub / gear wheel as shown in Fig. 6.3.

– Connect the oil injection kit (W2.1) to the G1/4" threaded hole in the brake hub / gear wheel on both sides.

NOTICE Use oil for pressing off (see W2.1 / Appendix A2).

– Mount the device for the compression unit (W3) so that it holds the brake hub / gear wheel [14.10] when they jump out in the axial direction.

– Gradually enlarge the brake hub / gear wheel using the oil injection kit (W2.1) until they jump out.

NOTICE Starting at 8700 psi (600 bar), gradually increase the pressure in steps of approximately 2900 psi (200 bar), leaving a pause of at least two minutes between each step. These pauses serve to allow the liquid to flow into the interface. Maximum gap oil pressure: 26,800 psi (1850 bar).

CAUTION Building up the pressure too quickly or exceeding the maximum gap oil pressure can result in permanent deformation (bulging) of the hub hole or the shaft seat, rendering the brake hub / gear wheel and/or the rotor useless.

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

35

BI619397

Edition 02.2008

Maintenance

CAUTION The device (W3) should not be subjected to pressure. Ensure an adequate clearance (at least equivalent to the lateral displacement of the brake hub / gear wheel). The brake hub / gear wheel must be secured by extending the piston of the pressure cylinder to the maximum lateral displacement and locking it with the nut. This prevents the brake hub / gear wheel from jumping out. When the axial pressure (pressure gage) rises, the brake hub / gear wheel have been released.

– Release the hydraulic cylinder and remove the gear wheel / brake disk.

WARNING Owing to the 1:50 gradient, the brake hub / gear wheel have an axial force component, which means that the high oil pressure would force them to jump out in the axial direction if the shrink fit is loosened. Risk of injury!

Brake hub Motor type: 1TB3026 – 1GA03 1TB3030 – 1GA03

Gear wheel Motor type: 1TB3030 – 0GA03

Fig. 6.3

6.4.3

Pressing off the brake hub / gear wheel

Pulling the speed sensor gear (N-end) off the shaft •

Motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only: To remove the cover [5.10] (N-end), – Loosen the screws [5.15 / 5.16] and remove them together with the washers [5.12], then remove the cover [5.10].

•

To remove the lubrication hose [8.12] (N-end): – Disconnect the lubrication hose [8.12] from the bearing shield [4.10] (N-end) at the screwed joint [8.18].

36

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

NOTE The screwed joint [8.18] in the bearing shield [4.10] (N-end) must not be disconnected!

NOTE Protect the ends of the regreasing hose and the openings in the bearing shield from fouling.

•

To remove the speed sensor [7.13] (N-end): – Loosen and remove the screws [7.34], then remove the speed sensor [7.13].

•

To remove the bearing temperature sensor [7.12] (N-end): – Loosen the screws [7.33], then remove the temperature sensor [7.12].

•

Motor type 1TB3030–0GB03 only: Loosen screws [7.43] and remove the auxiliary terminal box [7.40] with holder [7.42].

•

Remove the labyrinth cover (N-end) [4.13]; to do this, loosen the screws [4.18] and remove the cover [4.13].

•

Motor type 1TB3030–0GB03 only: Remove the additional spacer plate [4.22].

•

Mount the device (W3 / W4) as shown in Fig. 6.4 and pull off the speed sensor gear [4.11], then remove the device (W3 / W4) again.

NOTE All the threaded holes provided in the labyrinth cover must be occupied by threaded rods when the device is mounted or the speed sensor gear pulled off.

Fig. 6.4

Siemens AG Three-phase Motor

Pulling the speed sensor gear off the shaft, in principle also motor type 1TB30300GB03

A5E00338220A Operating Instructions

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•

Maintenance

Motor type 1TB3030–0GB03 only: – Loosen the screws [4.17].

– Force the cover [4.12] off the bearing shield [4.10] using two jack screws (W6.2).

– Drive the parallel pin [4.25] out of the cover (only if this is actually necessary).

6.4.4

Withdrawing the complete rotor from the stator frame at the D-end •

Motor type 1TB3030-0GB03 only: Mount an additional device (W3 / W4 / W6) at the N–end as shown in Fig. 6.5 in order to press the shaft of the rotor [2.00] out of the inner ring of the deep-groove ball bearing.

Fig. 6.5

•

Additional device for withdrawing the rotor, for motor type 1TB3030–0GB03 only

To remove the bearing temperature sensor [7.12] from the bearing shield (N-end) [3.10]: – Remove the screws [7.20] and the clips [7.19].

– Disconnect the lubrication hose [8.13] from the bearing shield [3.10] (D-end) at the screwed joint [8.18].

NOTE The screwed joint [8.18] in the bearing shield [3.10] (D-end) must not be disconnected!

NOTE Protect the ends of the regreasing hose and the openings in the bearing shield from fouling.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

– Loosen and remove the screws [7.33] and washers [7.29] on the bearing shield [3.10] (D-end).

– Carefully pull the temperature sensor [7.12] out of the bearing shield (D-end) [3.10].

– Remove any thermo-lubricant (H11.1) from the temperature sensor.

•

To remove the bearing shield (D-end) [3.10] from the stator frame: – Make suitable provision for setting down the rotor.

– Mount the devices (W1) as shown in Fig. 6.6.

– Remove the screws [1.02].

– Force the bearing shield (D-end) [3.10] off the stator frame [1.30] using three forcing-off screws (W6.1).

NOTE Motor type 1TB3030-0GB03 only: Simultaneously press out the shaft of the rotor [2.00] with device (W3 / W4) from the inner ring of the groove ball bearing!

– Remove the devices (W3 / W4).

– Withdraw the complete rotor [2.00] and bearing shield (D-end) [3.10] at the D-end axially from the bearing (N-end) [4.16] or the stator frame [1.30] using the device (W1).

CAUTION If the correct attachment point (taking into account the centers of gravity of the rotor, bearing shield, bearing, and lifting eye) has not yet been determined when dismantling for the first time, the rotor must be specially supported and guided to avoid damage – in particular to the winding – as it is withdrawn.

NOTICE After withdrawing the rotor, determine the correct attachment point and mark it on the device.

– Carefully set down the rotor so that it rests securely on the core.

NOTE Be careful not to bend the dynamo sheets.

Consult the manufacturer if dynamo sheets are bent!

– Remove the devices (W1).

Siemens AG Three-phase Motor

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Maintenance

Fig. 6.6

6.4.5

Withdrawing the rotor from the stator frame at the D-end

Removing the labyrinth ring (D-end) •

Removing the labyrinth ring (outer) [3.12] from the shaft: – Remove the screws [3.18] and the bearing unit cover [3.14] on the D-end.

– Mount the device (W3 / W4 / W6) as shown in Fig. 6.7.

NOTE All the threaded holes provided in the cover must be occupied by threaded rods when the device is mounted or the sealing ring pulled off.

– Pull the labyrinth ring (outer) [3.12] off the shaft using the device (W3 / W4 / W6).

– Remove the devices.

•

Removing the cover of the used grease chamber [3.11]: – Loosen the screws [3.17].

– Mount the device (W6.4A) – Force the cover of the used grease chamber [3.11] off the bearing shield [3.10] using two forcing-off screws (W6.2).

– Remove the device.

•

40

Remove the O-rings [3.17 / 3.19].

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Fig. 6.7

6.4.6

Pulling the outer labyrinth ring (D-end) off the shaft

Pulling the bearing shield (D-end) and the bearing off the shaft •

Mount the device (W3 / W4) as shown in Fig. 6.8, then use it to withdraw the bearing shield (D-end) [3.10] and the deep-groove ball bearing [3.15 from the shaft [2.20].

•

Remove the device (W3 / W4).

Fig. 6.8

Siemens AG Three-phase Motor

Pulling the bearing shield (D-end) and the bearing off the shaft

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6.4.7

Maintenance

Pulling the inner labyrinth ring (D-end) off the shaft NOTE Only dismantle the labyrinth ring if it is damaged:

The position of the (inner) labyrinth ring [2.10] on the circumference in relation to the shaft and the drive end on the labyrinth ring to which it belongs (D-end or N-end) must be marked on the labyrinth ring and the shaft on the motor side prior to pulling off the labyrinth ring.

NOTE If the position and the drive end are not marked, or if the labyrinth rings [2.10] are inverted, the rotor must be balanced after the (inner) labyrinth rings have been reassembled!

•

Mount the device (W3 / W4) as shown in Fig. 6.9, then use it to pull the inner labyrinth ring [2.10] off the shaft.

NOTE All the threaded holes provided in the labyrinth ring must be occupied by threaded rods when the device is mounted or the labyrinth ring pulled off.

•

Remove the device (W3 / W4).

Fig. 6.9

42

Pulling the inner labyrinth ring (D-end) off the shaft

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.4.8

Maintenance

Pressing the bearing (D-end) out of the bearing shield •

Mount the device (W3 / W4) as shown in Fig. 6.10.

•

Using the device, press the bearing (D-end) [3.15] out of the bearing shield [3.10].

•

Remove the device (W3 / W4).

•

Remove the grease chamber separator ring (D-end) [3.13] using snap ring pliers.

NOTE Inspect the grease chamber separator ring for damage. Replace it with a new ring if any damage is discovered.

•

Remove the O-ring [3.16].

Fig. 6.10

6.4.9

Pressing the bearing (D-end) out of the bearing shield

Forcing off the bearing shield (N-end) and removing the bearing parts •

Remove two screws [1.01] and replace them with threaded guides (W6.4B).

•

Remove the plug [5.13] and screw in a suitable load ring.

Suspend the bearing shield (N-end) [4.10] from the crane.

•

Remove the remaining screws [1.01].

•

Remove the plug [5.14], insert forcing-off screws (W6.1), and press the bearing shield out of the center hole in the stator frame.

Siemens AG Three-phase Motor

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Maintenance

•

Remove the bearing shield by means of threaded guides, then remove the threaded guides, and reinsert the plug [5.13].

•

Not Motortype 1TB3030-0GB03: Pull off the cover (N-end) [4.12]; to do this, loosen the screws [4.17] and remove the cover.

•

Motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only: Remove the O-rings [4.15],.

•

Remove the O-ring [4.19].

•

Pressing the bearing [4.16] out of the bearing shield: – Not motor type 1TB3030–0GB03: Mount the device (W3 / W4) as shown in Fig. 6.11.

Using the device (W3 / W4), press the bearing outer ring with the cage and the rolling element (N-end) [4.16] out of the bearing shield (N-end).

Remove the device (W3 / W4) again.

Remove the O-rings [4.15].

– Motor type 1TB3030–0GB03 only (in principle as shown in Fig. 6.11): Remove device (W6.20).

If necessary press the deep-groove ball bearing [4.16] out of the bearing shield using the device (W3 / W4).

Remove the device (W3 / W4) again.

Fig. 6.11

44

Pressing the bearing outer ring with the cage and the rolling element (N-end) out of the bearing shield, in principle also motor type 1TB3030-0GB03

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

•

Maintenance

Remove the grease chamber separator ring (N-end) [4.14] using snap ring pliers.

NOTE Inspect the grease chamber separator ring for damage. Replace it with a new ring if any damage is discovered.

•

Motor type 1TB3030–0GB03 only: – Remove the compression springs [4.23].

NOTE Only remove the grease supply plate [4.26] if the grease bore is blocked downstream of the regreasing port.

To remove the grease supply plate [4.26], loosen the screws [4.27].

NOTE If the grease supply plate [4.26] is damaged in the course of dismantling, it must be replaced with a new plate when the unit is reassembled.

6.4.10

Pulling the bearing inner ring or spacer ring off the shaft (N-end) •

Motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only: Mount the device (W3 / W8) as shown in Fig. 6.12, then use it to pull the bearing inner ring (N-end) [4.16] off the shaft.

•

Motor type 1TB3030–0GB03 only (If necessary): Mount the device (W3 / W8) in principle as shown in Fig. 6.12, then use it to pull the spacer ring [4.24] off the shaft.

Fig. 6.12

Siemens AG Three-phase Motor

Pulling the bearing inner ring (N-end) off the shaft, in principle also motor type 1TB3030-0GB03

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6.4.11

Maintenance

Pulling the inner labyrinth ring (N-end) off the shaft NOTE Only dismantle the labyrinth ring if it is damaged!

The position of the (inner) labyrinth ring [2.10] on the circumference in relation to the shaft and the drive end on the labyrinth ring to which it belongs (D-end or N-end) must be marked on the labyrinth ring and the shaft on the motor side prior to pulling off the labyrinth ring.

NOTE If the position and the drive end are not marked, or if the labyrinth rings [2.10] are inverted, the rotor must be balanced after the (inner) labyrinth ring has been reassembled!

•

To pull the inner labyrinth ring [2.10] off the shaft [2.20]:

•

Mount the devices (W3 / W4) as shown in Fig. 6.13, then use it to pull off the inner labyrinth ring [2.10].

NOTE All the threaded holes provided in the labyrinth ring must be occupied by threaded rods when the device is mounted or the labyrinth ring pulled off.

•

Remove the device (W3 / W4).

Fig. 6.13

46

Pulling the inner labyrinth ring (N-end) off the shaft

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.4.12

Maintenance

Removing the rubber seals and the air deflectors The rubber seals must be removed for essential cleaning or repair work on the cooling air pipes or prior to dismantling the air deflectors.

•

Remove the rubber seals [1.15] from the cooling air pipes at the D-end and N-end.

NOTE All silicone residues on the cooling air pipes must be completely removed!

Always fit new rubber seals [1.15] when the unit is reassembled.

•

If the air deflectors need to be dismantled, the position of each deflector [1.16 / 1.17] (N-end / D-end) must be marked to facilitate subsequent reassembly.

•

Dismantle the air deflectors [1.16 / 1.17] individually; to do this, carefully loosen the screws [1.21] and remove the deflectors.

WARNING Before loosening the screws [1.21], take steps to prevent the air deflectors [1.16 / 1.17] from falling off!

Siemens AG Three-phase Motor

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6.5

Maintenance

Maintenance work on the dismantled motor The special consumables (H ...), tools (W ...), and repair parts (R ...) are listed in detail in the Appendix (refer to chapters 7.2 / 7.3 / 7.4).

6.5.1

Cleaning agents and cleaning work

Cleaning agents The following agents are recommended, depending on the type of fouling: •

Mechanical means: brushes or wooden sticks.

•

Compressed air at a maximum pressure of 72.5 psi (5 bar).

CAUTION When cleaning with compressed air, ensure that suitable exhaust devices and personal protective gear are employed (goggles, respiratory filter, or similar)!

•

For chemical cleaning agents (H1) and a warning notice, refer to the list of consumables in Appendix A1.

WARNING When using such agents, strict attention must be paid to the characteristic values stated in the material safety data sheet applicable to the cleaning agent concerned.

Cleaning work

48

•

If severely fouled, the stator and rotor cooling ducts must be cleaned using a suitable flexible shaft and a brush, and then blown out with compressed air. Blowing out suffices if they are only slightly dirty.

•

Use one of the above-mentioned chemical agents to remove greasy layers from the surfaces of parts. Then leave them to dry.

•

For cleaning dirty windings with (H2), refer to the list of consumables in Appendix A1.

•

For cleaning the drainage holes, refer to the information provided in chapter 6.3.4.

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.5.2

Maintenance

Work on the stator •

Inspect the motor for external damage of mechanical origin.

•

Refer to chapter 6.5.1 for details of cleaning.

•

Touch up damaged parts of the paintwork. Refer to the repair parts list in Appendix A3 for detailed information on (R1.1 / R1.3).

Carry out the following checks: •

Check that the mating and seat surfaces of all parts are in perfect condition.

•

Check the connection leads [6.17] for damage and replace them if necessary.

•

Check the stator winding [1.31], including the coil connector, for mechanical and electrical damage (if necessary, repair as described in chapter 6.7.2).

Testing the winding resistances (only in the event of a fault) Using 10 A DC, measure the winding resistance values between pairs of terminals.

•

Apply test voltage between the following terminals: – Motor type 1TB3026 – xGA03: U–V/U–W/V–W – Motor types 1TB3030 – xGA03, 1TB3030-0GB03: U – V / U – W / V – W und U1 – V1 / U1 – W1 / V1 – W1

•

Siemens AG Three-phase Motor

The following resistances must be measured at 68°F (20°C): – Motor type 1TB3026 – xGA03:

25.06 milliohms ± 5%

– Motor type 1TB3030 – xGA03:

35.32 milliohms ± 5%

– Motor type 1TB3030 – xGA03:

40.19 milliohms ± 5%

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6.5.3

Maintenance

Work on the rotor Carry out the following checks:

6.5.4

•

Inspect the shaft, core, and cage winding for mechanical damage.

•

Be careful not to bend the dynamo sheets; consult the manufacturer if dynamo sheets are bent.

•

Check all soldered connections, particularly for discoloration that could be an indication of thermal overloading (short-circuit).

Testing the insulation WARNING During the measurement and immediately afterwards, some of the terminals are at hazardous voltage levels and must not be touched. Such work must be carried out by qualified personnel. The safety regulations must be strictly observed. Ground the machine frame. Do not touch the winding and terminals unless they are grounded.

Testing the insulation resistance of the stator windings when the motor is cold •

Measure the insulation resistance with 500 V DC applied between each of the terminals U / V / W and the stator frame.

– Motor type 1TB3026 – xGA03: U / V / W terminals and stator frame – Motor types 1TB3030 – xGA03, 1TB3030 – 0GB03: U / V / W / U1 / V1 / W1 terminals and stator frame

NOTE The insulation resistance of clean windings is extremely sensitive to temperature; it drops to half its previous value for every 10 K rise in temperature, in other words if the temperature rises 50 K (e.g. from 77°F (25°C) to 167°F (75°C), the resistance drops to about 1/30th of its initial value.

50

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

High-voltage test CAUTION The insulation resistances must be tested before every high-voltage test!

Apply a power-frequency test voltage step by step between the winding and the machine frame.

Required values, Motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only The required insulation resistance when dry, the power-frequency test voltage to be applied, and the duration of the test depend on the condition of the stator to be tested.

Winding in actual condition: i.e. uncleaned or following minor repairs that did not affect the main insulation.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 2 MΩ

2500 V / 1 min.

Winding with partial reinsulation (refer to chapter 6.7.2): i.e. a combination of old and new insulation, but at least after cleaning the old insulation.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 10 MΩ

3750 V / 1 min.

New condition: i.e. winding replaced.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 10 MΩ

5000 V / 1 min.

Commissioning: Allowed once on initial startup.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

Siemens AG Three-phase Motor

> 10 MΩ

4000 V / 5 s

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Maintenance

Required values, Motor types 1TB3030-0GB03 only The required insulation resistance when dry, the power-frequency test voltage to be applied, and the duration of the test depend on the condition of the stator to be tested.

Winding in actual condition: i.e. uncleaned or following minor repairs that did not affect the main insulation.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 2 MΩ

2100 V / 1 min

Winding with partial reinsulation (refer to chapter 6.7.2): i.e. a combination of old and new insulation, but at least after cleaning the old insulation.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 10 MΩ

3450 V / 1 min

New condition: i.e. winding replaced.

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 10 MΩ

4600 V / 1 min

Commissioning: Allowed once on initial startup.

6.5.5

Insulation resistance test

High-voltage test

Resistance measurement with 500 V DC

Power-frequency test voltage 50 / 60 Hz

Resistance:

Test voltage / duration:

> 10 MΩ

3700 V / 5 s

Work on the bearings Replace the bearings in the course of a general service after 30,000 hours or 5 years, whichever is sooner. It is also recommended that the bearings be replaced whenever the rotor is removed, even after a short operating distance of only a few thousand kilometers, respectively a few hundred operating hours.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6

Maintenance

Assembling the motor The special consumables (H ...), tools (W ...), and repair parts (R ...) are listed in detail in the Appendix (refer to chapters 7.2 / 7.3 / 7.4).

In the case of fixing elements, the associated consumables and tightening torques are also given in brackets in the parts list.

Important general instructions: •

Replace all locking and sealing elements.

•

Screws secured with Loctite must never be reused.

They must always be replaced with new screws.

•

All mating, contact, and bearing seat surfaces must be cleaned thoroughly and undamaged. Unless otherwise specified in this manual, these surfaces must be dry.

•

All threadlocker residues must be completely removed from threaded holes prior to assembling the motor.

The threads must be recut if necessary. Any chips that are produced as a result of cutting and any threadlocker residues must be thoroughly and completely removed.

•

Particularly in the case of bearings, utmost care and cleanliness are vital; protect greased, exposed bearings and labyrinth rings etc. against fouling, if necessary by covering them.

•

When tightening screws, use a torque wrench that has been calibrated with ±10% accuracy.

•

The rotor must be rebalanced if parts of it have been replaced or modified (refer to chapter 6.6.1).

•

Use suitable heating devices with temperature control, for example induction equipment or an oil bath, to heat shrink-on components. This guarantees uniform heating and prevents the components from overheating.

NOTICE All shrunk-on parts must be secured in their end position until they are firmly seated (i.e. until they have cooled down)!

•

To reassemble the motor, simply reverse the dismantling procedure. If the motor has merely been partially dismantled for maintenance purposes, only the steps explained in this chapter that are actually necessary need to be carried out (in their logical order).

•

Inspect the rotor for burrs on the short-circuit rings.

•

Horizontal installation of the rotor is the most practical method. To do this, hold the rotor horizontal on the shaft extension (D-end) using a special lifting eye in the same way as for dismantling. The rotor can be inserted in this position; refer to chapter 6.6.9.

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Maintenance

NOTE Care should be taken to ensure that no contact occurs between the rotor and the stator winding when the rotor is inserted.

•

Lubricant quantity: When installing new rolling-contact bearings, the accessible spaces in these bearings should be completely filled with rolling-contact bearing grease (H3.5); refer to chapters 6.6.4 / 6.6.5.

CAUTION After installing new rolling-contact bearings, these bearings must first be run in on the completely assembled motor (refer to chapter 6.6.15 for the appropriate procedure)!

If the bearings are not run in, they could overheat the first time the motor accelerates to high speeds, possibly leading to bearing failure and other consequential damage.

Fig. 6.14

54

Cross section of the 1TB3030-xGA03 and 1TB3026-xGA03 motors

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6.1

Maintenance

Assembling the air deflectors and the rubber seals NOTE Assembly sequence:

•

1.

2.

Air deflectors [1.16 / 1.17] (N-end / D-end) Rubber seals [1.15] (N-end / D-end)

To assemble the air deflectors: – Remove all sealant residues from the contact surfaces of the stator frame and the air deflectors.

Rough up adhesive faces of the air deflectors and stator frame with abrasive cloth (graining 100 to 120).

Then clean with cleaning agent (H1.2).

NOTE The drying time must be observed!

– Apply a zigzag bead of sealant (H5.3) to the contact surfaces of the air deflectors [1.16 / 1.17] (N-end / D-end).

Use a sufficient quantity to completely coat all surfaces, so that sealant (H5.3) is evenly pressed out at the edges when the air deflectors are assembled.

– Apply activator (H6.12) to the threads of the screws [1.21], then coat with adhesive (H6.2).

– Arrange the individual air deflectors [1.16 / 1.17] (N-end / D-end) in the correct positions as marked at the time of dismantling.

Insert the screws [1.21] and tighten to a torque of 20 Nm. •

To assemble the rubber seals:

NOTE All dismantled rubber seals must be replaced with new seals!

– Remove all sealant residues from the pipe ends.

Clean the ends of the air outlet pipes (on the stator core) with a cloth soaked in alcohol (H1.1) (min. cleaning depth from the pipe end: 25 mm).

– Coat the outer surface (min. depth 15 mm), the ends of the pipes, and the inside of the rubber seals [1.15] evenly with sealant (H5.7).

NOTE The sealant (H5.7) also serves as adhesive!

Siemens AG Three-phase Motor

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Maintenance

– Push the rubber seals [1.15] with device (W6.40A) (D-end) or device (W6.40B) (N-end) onto the pipe ends.

They should be fitted with the following gap between the outer edge of the sealing lips and the contact surface of the bearing shield on the stator frame: D-end = min. 23 mm / max. 24 mm, N-end = min. 108 mm / max. 109 mm.

NOTE This installation gap for the rubber seals [1.15] is essential to ensure proper ventilation of the motor!

CAUTION The required vulcanizing time of the sealant (H5.7) must be observed before assembling the bearing shields.

Failure to do so could cause the rubber seals [1.15] to become displaced!

6.6.2

Shrinking the labyrintrings (D-end and N-end) onto the shaft •

Heat the labyrinth ring (D-end) [2.10] to approximately 430°F (220°C), push it onto the shaft [2.20] to the stop, and hold it in position until they are firmly seated (i.e. until they have cooled down) for a short time.

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

•

Mount the device (W3.7) on the labyrinth ring (N-end) [2.10]. Heat the unit to approximately 430°F (220°C), push it onto the shaft [2.20] to the stop, and hold it in position with the device (W3), until they are firmly seated (i.e. until they have cooled down).

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

NOTICE All shrunk-on parts must be secured in their end position until they are firmly seated (i.e. until they have cooled down)!

•

Dismantle the devices.

For dimension specifications, refer to the drawings.

– A5E00278478A for motor type 1TB3030 – xGA03, 1TB3030 – 0GB03 – A5E00338659A for motor type 1TB3026 – xGA03

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

NOTE The inner labyrinth rings [2.10] at the D-end / N-end must be assembled in the correct positions as marked at the time of dismantling. They must also be assembled with the correct orientation.

The assignment of the (inner) labyrinth rings must correspond to the D-end / N-end markings!

CAUTION The rotor balance must be checked if parts of the rotor have been replaced or modified.

Refer also to chapter 6.6.1.

6.6.3

Assembly after special maintenance work NOTE The inner labyrinth rings [2.10] at the D-end / N-end must be assembled in the correct positions as marked at the time of dismantling. They must also be assembled with the correct orientation (refer to the description in chapter 6.6.2).

The assignment of the (inner) labyrinth rings must correspond to the D-end / N-end markings!

If parts of the rotor have been replaced or modified: •

Dynamically balance the rotor [2.00] with all its parts [2.10 ... 2.40].

Balance quality Q = 1.5 according to VDI 2060; refer also to the following drawings: – A5E00338659A for motor type 1TB3026 – xGA03 – A5E00278478A for motor types 1TB3030 – xGA03 and 1TB3030 – 0GB03

NOTE Remove any balancing weights prior to balancing the rotor.

Remove any burrs and clean the slots.

•

The slots for the balancing weights [2.25] are located in the labyrinth rings (D-end and N-end) [2.10].

– Apply activator (H6.12) to the threads of the screws [2.26], then coat with adhesive (H6.11).

– Insert new weights [2.25] into the slots and brace them with screws [2.26].

– Tighten the screws [2.26] to a torque of 7 Nm. – The weights should be caulked on the sides with a chisel.

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6.6.4

Maintenance

Pressing the bearing (D-end) into the bearing shield and installing the bearing parts Preparatory steps for assembling the bearing [3.15] (important: refer to Fig. 6.15): •

Prior to assembling the bearing [3.15], press rolling-contact bearing grease (H3.5) through the regreasing hole in the bearing shield [3.10] until 2" (5 cm) of fresh grease (H3.5) emerges on the bearing seat. Then remove the excess grease.

•

Fill the grease chambers in the bearing shield [3.10] with rolling-contact bearing grease (H3.5).

•

Assemble the grease chamber separator ring [3.13] using snap ring pliers.

NOTE Be careful to assemble the grease chamber separator ring [3.13] in exactly the right position!

The opening of the grease chamber separator ring [3.13] must be facing the underside of the motor.

The motor underside varies according to the motor type.

NOTE Inspect the grease chamber separator ring for damage. Replace it with a new ring if any damage is discovered.

NOTE The complete grease supply line (regreasing duct) must be filled with rolling-contact bearing grease (H3.5).

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Legend: a) Complete grease supply line filled with grease b) Bearing completely filled with grease c) Grease chamber filled with grease as shown in the detail drawing, then pulled off with former d) Grease chamber 70% full of grease

f) Used grease chamber g) Flood chamber h) Coat evenly with sealant (H5.5); refer to chapter 6.6.11 i) Apply a 4 mm thick bead of sealant (H5.5); refer to chapter 6.6.4

e) Labyrinth surfaces Fig. 6.15

•

Preparatory steps for assembling the bearing (D-end)

To assemble the bearing [3.15]: – Prior to assembling the bearing [3.15], insert the O-ring [3.16] into the bearing shield [3.10]. Coat O-ring [3.16] and O-ring slot evenly with a thin layer of rollingcontact bearing grease (H3.5). Apply drops of sealand (H5.2) to the O-ring [3.16] if is necessary.

– Coat the cleaned bearing seat with mounting fluid (H4.1).

– Completely fill the bearing [3.15] with rolling-contact bearing grease (H3.5).

– Mount the devices (W3) as shown in Fig. 6.16.

– Insert the bearing [3.15] into the bearing hole in the bearing shield [3.10] and press it in as shown in Fig. 6.16; max. pressure 1450 psi (100 bar).

– Remove the devices (W3).

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•

Maintenance

Test the bearing insulation (bearing shield / bearing outer ring) with an insulation resistance tester: – Insulation resistance R > 10 MΩ.

– Test voltage U = 250 V DC.

Fig. 6.16

•

Pressing the bearing (D-end) into the bearing shield

To install the cover of the used grease chamber [3.11]: – Coat the sealing surface of the used grease chamber cover [3.11] evenly with a thin layer of sealant (H5.5) to ensure total sealing.

NOTICE There must be no sealant residues in the holes or on the threads.

– To install the used grease chamber cover [3.11] and the O-rings [3.16 / 3.19], coat the following parts evenly with a thin layer of rolling-contact bearing grease (H3.5): On the used grease chamber cover [3.11]: O-ring slot and center holes, O-rings [3.16 / 3.19], Labyrinth surfaces 0.5 to 1.0 mm thick,

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Fill the grease chamber 70% full of rolling-contact bearing grease; refer to Fig. 6.15.

– Insert the used grease chamber cover [3.11] into the bearing shield [3.10] together with the O-rings [3.16 / 3.19]; apply activator (H6.1) to the threads of the screws [3.17] and leave them to dry. Coat the threads with adhesive (H6.2), insert them, and tighten to a torque of 40 Nm.

6.6.5

Pressing the bearing outer ring with the set of rolling elements into the bearing shield (N-end) and assembling the bearing parts

6.6.5.1

Motor type 1TB 3026 − xGA03 / 1TB 3030 − xGA03 only Preparatory steps for assembling the bearing [4.16] (important: refer to Fig. 6.17): •

Prior to assembling the bearing [4.16], press rolling-contact bearing grease (H3.5) through the regreasing hole in the bearing shield [4.10] until 2" (5 cm) of fresh grease emerges on the bearing seat.

Then remove the excess grease.

•

Fill the grease chambers in the bearing shield [4.10] with rolling-contact bearing grease (H3.5).

•

Assemble the grease chamber separator ring [4.14] using snap ring pliers.

NOTE Be careful to assemble the grease chamber separator ring [4.14] in exactly the right position!

The opening of the grease chamber separator ring [4.14] must be facing the underside of the motor.

The motor underside varies according to the motor type.

NOTE Inspect the grease chamber separator ring for damage. Replace it with a new ring if any damage is discovered.

NOTE The complete grease supply line (regreasing duct) must be filled with rolling-contact bearing grease (H3.5).

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A5E00338220A Operating Instructions

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Maintenance

Legend: a) Complete grease supply line filled with grease

d) Grease chamber 70% full of grease

b) Bearing: Rolling elements and cage pockets between elements coated with a 1 mm thick layer of grease

e) Labyrinth surfaces

c) Grease chamber filled with grease as shown in the detail drawing, then pulled off with former Fig. 6.17

•

f) Area between cage and outer ring (clearances) filled with grease g) Coat evenly with sealant (H5.2); refer to chapter 6.6.13

Preparatory steps for assembling the bearing (N-end), motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only

To assemble the bearing [4.16].

– Prior to assembling the bearing outer ring with the set of rolling elements [4.16], insert the O-ring [4.15] into the bearing shield [4.10]; refer also to the instructions provided below. Coat the O-ring [4.15] and the O-ring slot evenly with a thin layer of rolling-contact bearing grease (H3.5). Apply drops of sealant (H5.2) to the Oring [4.15] if is necessary.

– Coat the cleaned bearing seat with mounting fluid (H4.1).

– Coat the rolling elements of the bearing [4.16] and the cage pocket between the elements with a 1 mm thick layer of rolling-contact bearing grease (H3.5). Fill the gap between the cage and the outer ring with rolling-contact bearing grease (H3.5).

– Mount the device (W3) as shown in Fig. 6.18.

– Carefully insert the outer ring and the set of rolling elements of the bearing [4.16] into the bearing hole in the bearing shield [4.10] and press them in; max. force 15 kN (1.5 t) (1.7 short tons).

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

– Remove the device (W3).

•

Test the bearing insulation (bearing shield / bearing outer ring) with an insulation resistance tester.

– Insulation resistance R > 10 MΩ.

– Test voltage U = 250 V DC.

Fig. 6.18

•

Pressing the bearing outer ring and cage (N-end) into the bearing shield, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only

To install the cover (N-end) [4.12]: – Fit the O-rings [4.15 / 4.19] onto the N-end cover [4.12], – To install the N-end cover [4.12] and the O-rings [4.15 / 4.19], coat the following parts equably with an layer of rolling-contact bearing grease (H3.5): O-rings [4.15], On the N-end cover [4.12]: corresponding seats of the O-rings, Fill the grease chamber 70% full of rolling-contact bearing grease; refer to Fig. 6.19.

– Insert the (outer) cover [4.12] into the bearing shield [4.10] together with the Orings [4.15 / 4.19]; apply activator (H6.1) to the threads of the screws [4.17] and leave them to dry. Coat the threads with adhesive (H6.2), insert them, and tighten to a torque of 40 Nm.

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6.6.5.2

Maintenance

Motor type 1TB3030-0GB03 only Preparatory steps for assembling the bearing [4.16] (important: refer to Fig. 6.19): •

If the grease supply plate [4.26] was removed: Clean the contact area for the grease supply plate on the bearing shield with cleaning agent (H1.2); apply a sufficient quantity of sealant (H5.7) to the contact area; assemble the grease supply plate [4.26] with screws [4.27]; to do this, apply activator (H6.1) to the threads of the screws [4.27] and leave them to dry; coat the threads with adhesive (H.6.2), insert them, and tighten to a torque of 5 Nm.

CAUTION The required vulcanizing time of the sealant (H5.7) must be observed before lubricating with grease!

•

Prior to assembling the bearing [4.16], press rolling-contact bearing grease (H3.5) through the regreasing hole in the bearing shield [4.10] until 2" (5 cm) of fresh grease emerges on the bearing seat.

2" (5 cm) of grease must emerge at each of the six grease bores.

Then remove the excess grease.

•

Even if the grease supply plate [4.26] was not dismantled, grease must still flow out of the six grease bores and into the grease chamber without restriction. Press rolling-contact bearing grease (H3.5) through the regreasing hole in the bearing shield [4.10] until 2" (5 cm) fresh grease emerges. Then remove the excess grease.

•

Fill the grease chambers in the bearing shield [4.10] with rolling-contact bearing grease (H3.5).

•

Assemble the grease chamber separator ring [4.14] using snap ring pliers.

NOTE Be careful to assemble the grease chamber separator ring [4.14] in exactly the right position!

The opening of the grease chamber separator ring [4.14] must be facing the underside of the motor.

The motor underside varies according to the motor type.

NOTE Inspect the grease chamber separator ring for damage. Replace it with a new ring if any damage is discovered.

NOTE The complete grease supply line (regreasing duct) must be filled with rolling-contact bearing grease (H3.5).

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Legend: a) Complete grease supply line filled with grease

d) Grease chamber in N-end cover completely filled with grease

b) Bearing: Completely filled with grease

e) Labyrinth surfaces

c) Grease chamber filled with grease as shown in the detail drawing, then pulled off with former

f) Labyrinth sure face to the Shaft, filled to 100% with grease.

Fig. 6.19

•

g) Coat evenly with sealant (H5.2); refer to chapter 6.6.13

Preparatory steps for assembling the bearing (N-end), motor type 1TB3030-0GB03 only

To assemble the bearing [4.16]: – Prior to assembling the bearing [4.16], insert the compression springs [4.23] into the bearing shield [4.10], fill up with rolling-contact bearing grease (H3.5) and remove with grease former (W6.10).

– Coat the cleaned bearing seat with mounting fluid (H4.1).

– Completely fill the bearing [4.16] with rolling-contact bearing grease (H3.5).

– Fill labyrinth surface facing rotor shaft with rolling-contact bearing grease (H3.5).

– Carefully insert the bearing [4.16] into the bearing hole in the bearing shield [4.10]; the bearing can be pressed against the compression springs by hand.

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Maintenance

•

Press the parallel pin [4.25] into the outer cover [4.12] (if necessary); to do this, coat the parallel pin with adhesive (H6.20) and press it in using the device (W6.5).

•

To install the cover (N-end) [4.12]: – Fit the O-ring [4.19] onto the N-end cover [4.12].

– To install the N-end cover [4.12] and the O-ring [4.19], coat the following parts equably with an layer of rolling-contact bearing grease (H3.5): O-ring [4.19], On the N-end cover [4.12]: corresponding seat of the O-ring, Completely fill the grease chamber in the N-end [4.12] cover with rolling-contact bearing grease; refer to Fig. 6.19.

– Insert the N-end cover [4.12] into the bearing shield [4.10] together with the Oring [4.19]; apply activator (H6.1) to the threads of the screws [4.17] and leave them to dry. Coat the threads with adhesive (H6.2), insert them, and tighten to a torque of 40 Nm.

•

6.6.6

Fit the spacer ring [4.24] onto the shaft.

Assembling the bearing shield (N-end) on the stator frame •

Roughen the flange surfaces and the centering surfaces on the bearing shield [4.10] and the stator frame [1.30] with emery cloth (grain 100 to 120).

•

Clean the flange surfaces and the centering surfaces on the stator frame [1.30] and the bearing shield [4.10] with cleaning agent (H1.2) (using a clean cloth in each case); observe the required drying time.

•

Coat the labyrinth surfaces on the bearing shield (N-end) [4.10] with a 0.2 to 0.5 mm thick layer of rolling-contact bearing grease (H3.5).

•

Apply a zigzag circular bead of sealant (H5.3) to the flange surface on the bearing shield [4.10]. Use a sufficient quantity of sealant (H5.3), so that the joint is completely filled after assembly and sealant (H5.3) is evenly pressed out.

NOTE Be careful not to exceed the permissible assembly time of 15 minutes between starting to apply sealant (H5.3) and tightening the screws.

66

•

Insert two threaded guides (W6.4C) into the stator frame.

•

Hang bearing shield [4.10] onto crane and mount onto stator frame over threaded guides.

•

Apply activator (H6.1) to the threads of the screws [1.01] and leave them to dry. Coat the threads with adhesive (H6.2) and insert them.

•

Remove threaded guids (W6.4C) and substitute with screws [1.01].

•

Tighten Screws [1.01] step by step in the order shown in Fig. 6.20, with a torque of 360 Nm.

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Fig. 6.20

6.6.7

Tightening sequence for the bearing shield (N-end)

Shrinking the bearing parts onto the shaft •

Motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only: Mounting the bearing inner ring (N-end): – Coat the cleaned bearing seat on the shaft with mounting fluid (H4.1).

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

– Heat the bearing inner ring (N-end) [4.16] to a maximum of 257°F (125°C) (Temperature difference between shaft and bearing inner ring ≥ 90 K), then push it onto the shaft [2.20] as far as it will go, and hold it in position while applying constant axial pressure.

NOTICE All shrunk-on parts must be secured in their end position until they are firmly seated (i.e. until they have cooled down)!

•

6.6.8

Coat the labyrinth surfaces on the two labyrinth rings [2.10] with a 0.2 to 0.5 mm thick layer of rolling-contact bearing grease (H3.5).

Pressing the bearing shield (D-end) and the bearing onto the shaft •

Coat the labyrinth surfaces on the bearing shield [3.10] with a 0.2 to 0.5 mm thick layer of rolling-contact bearing grease (H3.5).

•

Coat the cleaned bearing seat on the shaft with mounting fluid (H4.1).

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Edition 02.2008

Maintenance

•

Mount the device (W3) as shown in Fig. 6.21.

•

Using the device (W3), press the bearing shield (D-end) [3.10] onto the shaft.

•

Remove the device (W3).

Fig. 6.21

6.6.9

Pressing the bearing shield (D-end) onto the shaft

Inserting the rotor into the stator frame and mounting the bearing shield (D-end) NOTE Inspect the rotor for damage prior to installing it. The dynamo sheets of the rotor must not be bent!

Consult the manufacturer if dynamo sheets are bent!

•

To insert the rotor: – Mount the device (W1) as shown in Fig. 6.22.

– Push the lifting eye (W1.1A) and the insertion bush (W1.3A) onto the shaft extension (D-end), then fasten the extension to the shaft with the clamping screw (W1.5A) and the conical spring washer (W1.4). Position the lifting gear above the marked center of gravity so that the rotor remains horizontal as it is inserted.

– Roughen the flange surfaces and the centering surfaces on the bearing shield [3.10] and the stator frame [1.30] with emery cloth (grain 100 to 120).

– Clean the flange surfaces and the centering surfaces on the stator frame [1.30] and the bearing shield [3.10] with cleaning agent (H1.2) (using a clean cloth in each case); observe the required drying time.

– Apply a zigzag circular bead of sealant (H5.3) to the flange surface on the bearing shield [3.10]. Use a sufficient quantity of sealant (H5.3), so that the joint is completely filled after assembly and sealant (H5.3) is evenly pressed out.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

•

Maintenance

Motor types 1TB 3026 − xGA03 / 1TB 3030 − xGA03 only: – Insert two threaded guides (W6.4B) into the stator frame.

– Insert the rotor carefully so as not to damage the windings, cores, or bearing (Nend).

– Apply activator (H6.1) to the threads of the screws [1.02] and leave them to dry.

Then coat the threads with adhesive (H6.2) and insert them.

– Remove the threaded guides (W6.4B) and substitute with screws [1.02] also.

•

To mount the bearing shield (D-end) on the stator frame: – The tightening sequence shown in Fig. 6.24 must be adhered to.

Tightening torque = 180 Nm. – Remove the devices (W1).

NOTE Be careful not to exceed the permissible assembly time of 15 minutes between starting to apply sealant (H5.3) and tightening the screws.

•

Motor type TB 3030 − 0GB03 only: – Coat the cleaned N-end bearing seat on the shaft with mounting fluid (H4.1).

– Insert two threaded guides (W6.4B) into the stator frame.

– Insert the rotor carefully so as not to damage the windings, cores, or bearing (Nend).

NOTICE Take measures suitable for the protection of the rotor shaft grading (N-end).

– Mount the device (W3) as shown in Fig. 6.23: Mount the device (W3) in order to insert the shaft seat of the deep-groove ball bearing; pull the shaft into the bearing inner ring with the device (W3) – Apply activator (H6.1) to the threads of the screws [1.02] and leave them to dry.

Then coat the threads with adhesive (H6.2) and insert them.

– Remove the threaded guides (W6.4B) and substitute with screws [1.02] also..

– When tightening the screws [1.02] of the D-end bearing shield (until they are firmly seated) simultaneously move the complete shaft into the bearing inner ring using the attachment (W3) (N-end).

– Dismount the device (W3).

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

Maintenance

– To mount the bearing shield (D-end) on the stator frame: The tightening sequence shown in Fig. 6.24 must be adhered to.

Tightening torque = 180 Nm. Remove the devices (W1).

NOTE Be careful not to exceed the permissible assembly time of 15 minutes between starting to apply sealant (H5.3) and tightening the screws.

– Test the bearing insulation (bearing inner ring / shaft) with an insulation resistance tester: Insulation resistance R > 10 MΩ.

Test voltage U = 250 V DC.

Fig. 6.22

70

Inserting the rotor into the stator frame at the D-end

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Maintenance

Fig. 6.23

Additional device for inserting the rotor, motor type 1TB3030–0GB03 only

Fig. 6.24

Tightening sequence for the bearing shield (D-end) [3.10]

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6.6.10

Maintenance

Shrinking the labyrinth ring (outer, D-end) onto the shaft •

Coat the cleaned labyrinth ring seat on the shaft with mounting fluid (H4.1).

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

•

Heat the labyrinth ring (outer) [3.12] to approximately 390°F (200°C) and push it onto the shaft [2.20] as far as it will go; using the device (W3), press it in as shown in Fig. 6.25 and hold it in position.

NOTICE All shrunk-on parts must be secured in their end position until they are firmly seated (i.e. until they have cooled down)!

•

Maintain an axial press force of 314 kN (32 t) (35 short tons) for cooling.

NOTE There must be no gap between the labyrinth ring (outer) and the bearing!

Fig. 6.25

72

Shrinking the (outer) labyrinth ring onto the shaft (D-end)

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6.11

Maintenance

Assembling the bearing unit cover (D-end) To mount the bearing unit cover (D-end) [3.14] on the used grease chamber cover [3.11]: •

Coat the sealing surface of the used grease chamber cover (D-end) [3.11] evenly with a thin layer of sealant (H5.5) to ensure total sealing.

NOTICE There must be no sealant residues in the holes or on the threads.

•

6.6.12

Insert the bearing unit cover (D-end) [3.14]; apply activator (H6.1) to the threads of the screws [3.18] and leave them to dry. Then coat the threads with adhesive (H6.2), insert them, and tighten to a torque of 20 Nm.

Mounting the speed sensor gear (N-end) •

Clean the seat of the speed sensor gear on the shaft with cleaning agent (H1.2).

•

Mount the devices (W3) as shown in Fig. 6.26.

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

•

Shrink the speed sensor gear [4.11] onto the shaft (N-end) [2.20].

Heat the speed sensor gear [4.11] to approximately 390°F (200°C) and push it onto the shaft [2.20] as far as it will go; press it in using the device (W3) and hold it in position. Pressing-in force: 220 kN (22.4t) (24.7 short tons).

•

Motor type 1TB3030-0GB03 only: The inner ring of the bearing may be forced off the shaft shoulder because the bearing is preloaded with compression springs; the speed sensor gear [4.11] must therefore always be pressed in to the stop using the device (W3) and held in position until it has cooled down. Pressing-in force: 220 kN (22.4t) (24.7 short tons).

NOTICE All shrunk-on parts must be secured in their end position until they are firmly seated (i.e. until they have cooled down)!

•

Siemens AG Three-phase Motor

After they have cooled down, coat the labyrinth surfaces on the speed sensor gear [4.11] with a 0.2 to 0.5 mm thick layer of rolling-contact bearing grease (H3.5).

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Maintenance

Fig. 6.26

6.6.13

Shrinking the speed sensor gear onto the shaft (N-end)

Assembling the labyrinth cover (N-end) To mount the labyrinth cover (N-end) [4.13] on the bearing shield [4.10]: •

Coat the labyrinth slots in the cover (N-end) [4.13] with a 0.2 to 0.5 mm thick layer of rolling-contact bearing grease (H3.5).

•

Coat the sealing surface of the cover (N-end) [4.13] evenly with a thin layer of sealant (H5.2) to ensure total sealing.

NOTICE There must be no sealant residues in the holes or on the threads.

•

Motor type 1TB3030-0GB03 only: Coat the sealing surface of the spacer plate [4.22] evenly with sealant (H5.2) to ensure total sealing; position the side of the spacer plate [4.22] that is coated with sealant on the sealing surface of the bearing shield.

NOTE If necessary, threaded rods can be used guiding and temporarily fastening to facilitate the assembly process.

•

74

Insert the labyrinth cover (N-end) [4.13]; apply activator (H6.1) to the threads of the screws [4.18] and leave them to dry. Then coat the threads with adhesive (H6.2), insert them, and tighten to a torque of 20 Nm.

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6.14

Maintenance

Assembling the built-on parts (D-end and N-end) •

To connect the lubrication hoses [8.12 / 8.13]: – Lay the lubrication hoses [8.12 / 8.13] as shown in the "Additional parts" drawing (A5E00337211A), then fasten them with fixing accessories [7.19 / 7.20 / 7.28], and connect them to the screwed joints [8.18]. Apply activator (H6.1) to the threads of the fixing elements [7.20] and leave them to dry. Then coat with adhesive (H6.2), insert them, and tighten. The lubrication hoses [8.12 / 8.13] must be completely filled with rolling-contact bearing grease (H3.5).

– Apply activator (H6.1) to the threads of the screwed joints [8.18] and leave them to dry. Then coat with adhesive (H6.2), insert them into the hydraulic block [8.10], and tighten to a torque of 38 Nm. – Screw the tapered grease nipple [8.14] into the hydraulic block [8.10]. Tightening torque = 11 Nm. – Screw the two grease nipple caps [8.15] into the thread between the tapered grease nipples using the screw [8.17]; apply activator (H6.1) to the thread of the screw [8.17] and leave it to dry. Then coat with adhesive (H6.2), insert it into the hydraulic block [8.10], and tighten hand-tight.

– Glue the plate [12.20] to the hydraulic block [H8.10] with sealant (H5.7).

– Screw the hydraulic block [8.10] to the holding plates [8.11] on the motor frame [1.00]. To do this, apply activator (H6.1) to the threads of the screws [8.16], and leave them to dry. Then coat with adhesive (H6.2), insert them and tighten to a torque of 20 Nm.

•

To install the bearing temperature sensors [7.12] in the bearing shields [3.10 / 4.10]: – Fill the locating hole of the temperature sensors [7.12] with thermo-lubricant (H11.1), so that lubricant is pressed out of the hole when the sensor is inserted.

– Insert the temperature sensors [7.12] into the bearing shields [3.10 / 4.10] with thermo-lubricant (H11.1).

– Apply activator (H6.1) to the threads of the screws [7.33] and leave them to dry.

Then coat with adhesive (H6.2), insert them with washers [7.29], and tighten to a torque of 8 Nm.

•

To install the stator temperature sensor [7.11] in the stator frame [1.30]: – Fill the locating hole with thermo-lubricant (H11.1), so that when the temperature sensor [7.11] is inserted, the hole is completely filled up to the O-ring seal.

– Insert the temperature sensor [7.11] into the stator frame [1.30] with thermolubricant (H11.1).

– Apply activator (H6.1) to the threads of the screws [7.32] and leave them to dry.

Then coat with adhesive (H6.2), insert them with washers [7.29], and tighten to a torque of 8 Nm.

•

To install the speed sensor [7.13]: – Refer to the handling instructions (A5E00218658A) for a description of the installation procedure.

– Install the connector [7.24] on the holding plate [8.11].

Siemens AG Three-phase Motor

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Maintenance

•

To install the connection leads [6.17]: Insert the new lead through the corresponding penetration in the terminal box (refer to Fig. 6.29).

•

Screw the cable lug onto the terminal post insulator [1.11]. Apply activator (H6.1) to the threads of the screws [1.25] and leave them to dry. Then coat with adhesive (H6.2), insert them with spring washers [7.36] and washers [7.30], and tighten to a torque of 92 Nm.

NOTICE Dose the adhesive (H6.2) carefully so that it does not spread between the connection bars [1.12 / 1.13] and the cable lugs of the connection leads [6.17]!

•

Screw the cable gland [6.19] into the terminal box: Refer to capter 6.7.1.

•

Motor types 1TB 3026 – 0GA03 / 1TB 3030 – 0GA03 only To mount the cover [5.10] (N-end): – Apply activator (H6.1) to the threads of the screws [5. 15 / 5.16] and leave them to dry. Then coat with adhesive (H6.2). Mount the cover [5.10] (N-end), insert the screws [5. 15 / 5.16] with washers [5.12], and tighten to a torque of 8 Nm.

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Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6.15

Maintenance

Running in the bearings CAUTION The temperatures must be continuously monitored while running in the bearings.

A rapid temperature rise represents a serious threat to the motor bearings and the motor itself.

In this case, the motor must be switched off immediately!

The procedure for running in the bearings is as follows: The motor must be operated at no load for 30 minutes at a speed of 1500 rpm (either externally driven or connected to the converter). The speed must then be increased in steps of 500 rpm and the motor operated for a period of 30 minutes at each speed until the maximum speed is reached. Maintain the maximum speed until the temperature of the two bearings no longer rises or until it falls by 2 K. The bearings have now been run in and are allowed to be operated at maximum speed.

Only motor types 1TB3030 – xGA03, 1TB3026 – xGA03

6.6.16

Only motor type 1TB3030 – 0GB03

Speed [rpm]

Time [min]

Speed [rpm]

Time [min]

1500

30

1500

30

2000

30

1800

Until temperature of both bearings stabilize or falls by 2 K

2500

30

--

--

3000

30

--

--

3550

Until temperature of both bearings is stabilized or falls by 2 K

--

--

Pressing on the coupling, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only •

Cleaning and inspection steps: – Clean the shaft seat, joint, and hub hole thoroughly and inspect them for damage.

– Push the motor coupling [15.10] onto the shaft [2.20].

•

Check and document the lateral displacement of the coupling on the shaft during the assembly process: – Measure the lateral displacement (measuring accuracy 0.1 mm; minimum lateral displacement = 12.6 mm, maximum lateral displacement = 14.7 mm.

•

To press on the motor coupling [15.10]: – Mount the device (W2 / W3) as shown in Fig. 6.27.

Siemens AG Three-phase Motor

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Maintenance

– Connect the oil injection kit (W2.1) to the G1/4" threaded hole in the coupling (Dend).

NOTICE Use glycerin for pressing on; take account of the ambient conditions.

Refer to W2.1 / Appendix A2.

NOTE A dial gage can be used to indicate when the coupling is floating and the axial force can be increased. The coupling is floating if the pointer moves very slightly in both directions.

– Apply axial force using the compression unit (W3.1) while at the same time gently enlarging the coupling hub with (W2.1). Gradually increase the axial and radial force until the coupling hub is flush against the shaft end face. Note the maximum axial pressure: 160 kN (16.3 t) (17.8 short tons). Start by increasing the pressure in (W2.1) to 8700 psi (600 bar), then gradually increase it by around 2900 psi (200 bar) at a time, leaving a pause of at least two minutes between each step.

Maximum gap oil pressure: 25,000 psi (1740 bar). Maximum pressure in (W3.1): 10,000 psi (700 bar).

CAUTION Building up the pressure too quickly or exceeding the maximum gap oil pressure can result in permanent deformation (bulging) of the hub hole or the shaft seat, rendering the motor coupling and/or the rotor useless.

– Maintain the axial force in (W3.1) and gradually reduce the pressure in (W2.1) to zero; after approximately 10 minutes, reduce the axial force in (W3.1) to zero as well.

– Remove the devices (W2 / W3) and allow glycerin to drain from the shaft.

– Seal the threads of the coupling with plugs [15.20].

If the motor is not to be operated straight away, make sure that the coupling and the rotor of the motor are locked again with the transportation lock elements as described in chapter 2.3.

Fig. 6.27

78

Pressing on the coupling

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.6.17

Maintenance

Pressing on the brake hub / gear wheel, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only Motor / component assignment: – 1TB3030 – 0GA03 = gear wheel – 1TB3030 – 1GA03 = brake hub •

Cleaning and inspection steps: – Clean the shaft seat, joint, and hub hole thoroughly and inspect them for damage.

•

Check and document the lateral displacement of the brake hub / gear wheel on the shaft during the assembly process.

Measure the lateral displacement;, refer to the final assembly drawings for specifications: – 1TB3030 – 0GA03 = gear wheel, final assembly drawing A5E00278060A – 1TB3030 – 1GA03 = brake hub, final assembly drawing A5E00496181A

•

To press on the brake hub / gear wheel [14.10]: – Push the brake hub / gear wheel [14.10] onto the shaft [2.20].

– Mount the device (W2 / W3) as shown in Fig. 6.28.

– Connect the oil injection kit (W2.1) to the G1/4" threaded hole in the brake hub / gear wheel [14.10] (N-end).

NOTICE Use glycerin for pressing on; take account of the ambient conditions.

Refer to W2.1 / Appendix A2.

NOTE A dial gage can be used to indicate when the brake hub / gear wheel is floating and the axial force can be increased. The brake hub / gear wheel is floating if the pointer moves very slightly in both directions.

– Apply axial force using the compression unit (W3.1) while at the same time gently enlarging the brake hub / gear wheel with (W2.1). Gradually increase the axial and radial force until the brake disk hub is flush against the shaft end face. Note the maximum axial pressure: 175 kN (16.3 t) (17.8 short tons). Start by increasing the pressure in (W2.1) to 8700 psi (600 bar), then gradually increase it by around 2900 psi (200 bar) at a time, leaving a pause of at least two minutes between each step. Maximum gap oil pressure: 27,500 psi (1900 bar). Maximum pressure in (W3.1): 27,000 psi (1850 bar).

CAUTION Building up the pressure too quickly or exceeding the maximum gap oil pressure can result in permanent deformation (bulging) of the hub hole or the shaft seat, rendering the brake hub / gear wheel and/or the rotor useless.

Siemens AG Three-phase Motor

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Maintenance

– Maintain the axial force in (W3.1) and gradually reduce the pressure in (W2.1) to zero; after approximately 10 minutes, reduce the axial force in (W3.1) to zero as well.

– Remove the devices (W2 / W3) and allow glycerin to drain from the shaft.

– Seal the threads of the brake hub / gear wheel with plugs [14.20].

If the motor is not to be operated straight away, make sure that the brake disk hub and the rotor of the motor are locked again with the transportation lock elements as described in chapter 2.3.

Motor type: 1TB3026 – 1GA03 1TB3030 – 1GA03

Motor type: 1TB3030 – 0GA03

Fig. 6.28

80

Pressing on the brake hub / gear wheel

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

6.7

Maintenance

Repair work The special consumables (H ...), tools (W ...), and repair parts (R ...) are listed in detail in the Appendix (refer to chapters 7.2 / 7.3 / 7.4).

In the case of fixing elements, the associated consumables and tightening torques are also given in brackets in the parts list.

6.7.1

Replacing defective connection leads •

Unscrew the terminal box cover [6.10]; to do this, loosen the fixing element [6.18].

•

Unscrew the damaged lead; to do this, loosen the fixing elements [1.25 / 7.36 / 7.30] and pull the lead out of the cable gland.

•

Clean the terminal box using one of the agents indicated under (H1), then blow it out with compressed air.

WARNING When working with compressed air, ensure that suitable personal protective gear is worn (protective clothing, goggles, gloves etc.).

Locally applicable safety information and regulations must be carefully observed.

•

Insert the new lead through the corresponding penetration in the terminal box (refer to Fig. 6.29).

•

Screw the cable lug onto the terminal post insulator [1.11]. Apply activator (H6.1) to the threads of the screws [1.25] and leave them to dry. Then coat with adhesive (H6.2), insert them with spring washers [7.36] and washers [7.30], and tighten to a torque of 92 Nm.

NOTICE Dose the adhesive (H6.2) carefully so that it does not spread between the connection bars [1.12 / 1.13] and the cable lugs of the connection leads [6.17]!

•

Screw the cable gland [6.19] into the terminal box. Assembly sequence (refer to Fig. 6.29): – 1. Tighten part a) to a torque of 20 Nm – 2. Tighten part b) to a torque of 20 Nm

•

Siemens AG Three-phase Motor

Inspect the sealing faces on the terminal box cover [6.10] and the terminal box in the stator frame for damage, then clean them using one of the agents indicated under (H1), and coat the joint on the terminal box evenly with a thin layer of sealant (H5.5).

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•

Maintenance

Screw on the terminal box cover [6.10]; apply activator (H6.1) to the threads of the screws [6.18] and leave them to dry. Then coat with adhesive (H6.2), insert them with conical spring washers [7.22], and tighten to a torque of 20 Nm.

NOTE We recommend that you ask your local Siemens Service Center to repair terminal post insulators.

Fig. 6.29

6.7.2

Fastening the connection leads

Repairing the stator winding insulation The vacuum impregnation means that the windings form a single unit with the coil connectors.

We recommend that you ask your local Siemens Service Center to carry out winding repairs.

If a winding or a coil connector is seriously damaged, the winding must be completely replaced. Partial repair of a winding is not possible.

82

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

7.2

Appendix

List of consumables Consumables recommended for dismantling and assembling the motor which are not included in the parts lists: WARNING As specified in Article 14 of the German law on hazardous substances (GefStoffV) (or similar national regulations), the "responsible person" is obliged to instruct his or her employees in safety matters if ever they use substances involving a hazard to health or the environment (e.g. cleaning agents or lubricants, adhesives, paint coatings etc.).

7.2.1

H1 Chemical cleaning agents (commercial name / manufacturer) Generally approved cleaning agents: •

White spirit 155 / 185 / Shell AG

•

Kerosene / Shell AG

•

Methylated spirit (ethanol)

•

Loctite 7063 cleaner

WARNING The information given in the material safety data sheet pertaining to the chemical cleaning agent concerned must be adhered to at all times when this agent is used. The material safety data sheet must be requested when the cleaning agent is purchased.

H1.1 Chemical cleaning agents for outdoor use and for cleaning mechanical parts Solvent based cleaners: •

Alcohols (methylated spirit, propanol, butanol)

•

Acetone

•

White spirit 155 / 185 / Shell AG

•

Aral 4005 / Aral AG

•

Rivolta S.L.X / Bremer u. Leguil GmbH, D-47051 Duisburg

Water based cleaners for outdoor use with ionic and anionic surfactants: •

92

Low surface-tension water (e.g. 1 to 2% washing-up liquid)

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Appendix

Alkaline cleaners for outdoor use, not suitable for cleaning motors with unprotected surfaces: •

Flamil 4 / Flore Chemie, D-56075 Koblenz

NOTICE When applied to the insulation system, the pH must not be higher than 9 and the application time must not exceed 30 minutes. Subsequent rinsing with clean water is necessary.

Hydrochloric acid cleaners for outdoor use, not suitable for cleaning motors with unprotected surfaces: NOTICE When applied to the insulation system, the pH must not be lower than 2 and the application time must not exceed 30 minutes. Subsequent rinsing with clean water is necessary.

H1.2 Chemical cleaning agents for joints •

Loctite 7063 cleaner / Loctite Deutschland GmbH, D-81905 Munich

NOTE A drying time of ≥ 1 minute at an ambient temperature of > 68°F (20°C) must always be observed!

7.2.2

H2 Chemical cleaning agents for windings (commercial name / manufacturer) H2.1 Chemical cleaning agents for windings High-boiling petroleum fractions: •

White spirit 155 / 185 / Shell AG

•

Kerosene / Shell AG

•

Ascal UM / Brenntag, D-45403 Mühlheim/Ruhr

Aliphatic hydrocarbon mixtures (free of aromatics): •

Aral 4005 / Aral AG

Isoaliphatic hydrocarbon mixtures (free of aromatics): •

Rivolta S.L.X TOP / Bremer u. Leguil GmbH, D-47051 Duisburg

•

Haku 1025 / 920 / Kluthe GmbH, D-69008 Heidelberg

•

WBC 16 / Biesterfeld, D-90453 Nuremberg

Alcohol based cleaner: •

Siemens AG Three-phase Motor

Methylated spirit

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Appendix

H2.2 Chemical cleaning agents for severely fouled or oily windings Water based, alkaline cleaner: •

Flamil 4 / Flore Chemie, D-56075 Koblenz

NOTICE When applied to the insulation system, the pH must not be higher than 9 and the application time must not exceed 30 minutes (oily windings) or 2 to 3 hours (severely fouled windings). Subsequent rinsing with clean water is necessary.

The windings should then be dried in an oven for 12 hours at 230 to 248°F (110 to 120°C).

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

7.2.3

H3 Rolling-contact bearing grease (commercial name / manufacturer) H3.5 •

7.2.4

Shell RETINAX LX2 rolling-contact bearing grease / Shell AG

H4 Mounting / dismounting fluids for bearing seats (commercial name / manufacturer) H4.1

7.2.5

•

SKF LH MF 300 mounting fluid (for installing rolling-contact bearings and joining interference fits / SKF GmbH, D-97424 Schweinfurt)

•

SKF LH MF 900 demounting fluid (for removing bearings and detaching interference fits / SKF GmbH, D-97424 Schweinfurt)

H5 Sealants for joining parts or gaps (commercial name / manufacturer) H5.2 •

94

Hylomar SQ 32M sealant / Marston Ölchemie GmbH, D-53909 Zülpich

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Appendix

H5.3 •

Loctite 518 sealant / Loctite Deutschland GmbH, D-81905 Munich

H5.5 •

Atmosit Compact sealant, Art. No. 112 / Henkel Teroson GmbH, D-69112 Heidelberg

H5.7 •

Elastosil N199 sealant / Wacker Chemie GmbH, D-81737 Munich

NOTE A vulcanizing time of ≥ 24 hours at an ambient temperature of ≥ 68°F (20°C) must always be observed for H5.7 sealant!

7.2.6

H6 Locking agents for connecting elements (commercial name / manufacturer) H6.1 •

Loctite 7471 activator / Loctite Deutschland GmbH, D-81905 Munich

NOTE A drying time of ≥ 2 minutes at an ambient temperature of > 68°F (20°C) must always be observed for 7471 activator (H6.1)!

H6.2 •

Loctite 243 adhesive / Loctite Deutschland GmbH, D-81905 Munich

H6.11 •

Loctite 272 adhesive / Loctite Deutschland GmbH, D-81905 Munich

H6.12 •

Loctite 7091 activator / Loctite Deutschland GmbH, D-81905 Munich

NOTE 7091 activator (H6.12) does not require any drying time!

H6.15 •

Sicomed 99 / Sichel Werke GmbH, D-30453 Hanover

H6.20 •

Siemens AG Three-phase Motor

Loctite 641 adhesive / Loctite Deutschland GmbH, D-81905 Munich

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7.2.7

Appendix

H10 Anti-corrosion agent (commercial name / manufacturer) H10.4 •

7.2.8

Tectyl 506 brown / Valvoline GmbH, D-22238 Hamburg

H11 Mounting fluid for temperature sensors (commercial name / manufacturer) H11.1 •

96

TEGO Z thermo-lubricant, Semco cartridge

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

7.3

Appendix

List of tools Devices and special tools recommended for dismantling and assembling the motor:

7.3.1

7.3.2

W1 Assembly devices for inserting and withdrawing the rotor horizontally e.g. Siemens Tool No.

Device

Qty.

Description

W1.1A

1

Lifting eye, complete, for loads up to 1600 kg, with variable suspension point overhang up to 890 mm, for Ø = 200 mm

756084310

W1.3A

1

Insertion bush

756085510

W1.4A

1

Conical spring washer

756085810

W1.5A

1

Clamping screw

946104923

W2 Pressure unit for enlarging the coupling e.g. Siemens Tool No.

Device

Qty.

Description

W2.1

2

940780403 Oil injection kit up to 40,600 psi (2800 bar) (1x for pressing off, 1x for pressing on), for connection to G1/4" threaded hole in the coupling (e.g. PML 162-1-2800 oil injection kit from E.P.P HY-POWER GmbH, D-90427 Nuremberg)

NOTICE Note on pressure medium: Use oil for pressing off, viscosity approx. 900 mm2/s, e.g.

LH DF 900 dismounting fluid / SKF, D-97419 Schweinfurt.

Use glycerin for pressing on. Water-free and ultra-pure glycerin is highly hygroscopic and must therefore be protected against the ingress of air. Vessels and containers of the pressure pump that are used for glycerin must always be kept tightly sealed. The usability of the glycerin must be checked regularly with the help of reaction paper. Where necessary, the contents of the pressure pump must be renewed.

Environmental requirements for using glycerin: Minimum ambient temperature: 64.4°F (18°C).

Risk of crystallization at temperatures lower than 64.4°F (18°C)!

Siemens AG Three-phase Motor

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Edition 02.2008

7.3.3

98

Appendix

W3 Compression units for pressing on or for support while pressing off e.g. Siemens Tool No.

Device

Qty.

Description

W3.1.1C

1

Hollow piston cylinder , cylinder type CMF 30N100 from E.P.P. HY-POWER GmbH, D-90427 Nuremberg (outside Ø = 115 mm / inside Ø = 34 mm (through-type) / length = 233 mm / stroke = 100 mm, force = 334 kN)

990078358

W3.1.1D

1

Hollow piston cylinder, cylinder typ RCH-603, from Enerpac GmbH, D 40401 Düsseldorf (outside Ø = 159 mm / inside Ø = 54 mm / lenght = 247 mm / stroke = 76 mm / force = 576 kN)

990078371

W3.1.2C

1

Pump, type PML 142 from E.P.P. HY-POWER, D-90427 Nuremberg

940780367

W3.2A

1

Threaded spindle M20x600; thread lengths: 40 / 200 mm

940780257

W3.2B

1

Threaded spindle M30x600; thread lengths: 50 / 250 mm

940780284

W3.2C

1

Mounting spindle, length = 550 mm, UNC 1 1/4" -7-2B / 70 mm, M30 / 240 mm

207228001

W3.3

1

Flanged nut M30 to DIN 6331

--

W3.3A

1

Flanged nut M20 to DIN 6331

--

W3.4C

1

Pressure pot (D-end, form A), Outside Ø = 200 mm, length = 350 mm / inside Ø = 182 mm, length = 325 mm / center hole Ø = 31 mm

940780171

W3.4D

1

Pressure pot (sensor wheel, N-end) Outside Ø = 190 mm, length = 335 mm / inside Ø = 172 mm, length = 310 mm / center hole Ø = 34 mm

990078172

W3.4F

1

Pressure pot (hub for brake disk, N-end) Outside Ø = 180 mm, length = 90 mm / inside Ø = 160 mm, length = 75 mm / center hole Ø = 34 mm

990078171

W3.4H

1

Pressure pot (for inserting the rotor, N-end) Motor type 1TB3030 – 0GB03 only Outside Ø = 180 mm, length = 375 mm / inside Ø = 162 mm, length = 350 mm / center hole Ø = 33 mm

990078179

W3.5E

1

Pressure plate (form A), outside Ø = 196 mm / threaded center hole M20 / thickness = 30 mm

207305001

W3.5F

1

Tube (form D)

940780182

W3.5G

1

Dismantling tool (for outer ring of N-end bearing),

970077300

W3.5H

1

Pressure plate, outside Ø = 310 mm (D-end: 310 mm, N-end: 280 mm) center hole 21 mm

970115100

W3.5K

1

Pressure plate, outside Ø = 200 mm / center hole Ø = 31 mm / thickness 20 mm

940780139

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

7.3.4

Appendix

e.g. Siemens Tool No.

Device

Qty.

Description

W3.6

1

Holding plate (form A), outside Ø = 500 mm / threaded center hole M20 / thickness = 20 mm

940780750

W3.7

1

Ring for assembling labyrinth ring

204114000

W4 Draw gear with crossbar or plate (For screwed-in, threaded drawbars, axial force optionally from W3 or from separate, central threaded spindle, suitable for shaft center hole DIN 332-DS M30) e.g. Siemens Tool No.

Device

Qty.

Description

W4.1A

1

Universal extraction plate, motor type 1TB3030 – 0GB03 only, Outside Ø = 425 mm / innside Ø = 33 mm / thickness = 30 mm

206194000

W4.1B

1

Universal extraction plate, Outside Ø = 425 mm / inside Ø = 31 mm / thickness = 30 mm

940780327

W4.1C

1

Extraction plate (speed sensor disc), Outside Ø = 220 mm / inside Ø = 30.5 mm / thickness = 30 mm

940780210

W4.1D

1

Extraction plate (labyrinth ring), Outside Ø = 250 mm /inside Ø = 31 mm / thickness = 37 mm

940780209

W4.2C

10

Drawbars M8 x 470 (DIN 668, min. tensile strength = 10.9) (speed sensor disc))

207209000

W4.2H

6

Drawbars M12x650 (DIN 668, min. tensile strength = 10.9) / thread lengths 40 / 200 mm

940780325

W4.2J

8

Drawbars M10x 600

940780317

W4.2K

6

Drawbars M12x515

207209001

W4.3A

6

Flanged nuts M8 to DIN 6331

--

W4.3B

8

Flanged nuts M10 to DIN 6331

--

W4.3C

6

Flanged nuts M12 to DIN 6331

--

W4.4A

6

Washer innside Ø = 17 mm DIN6340 (for W4.2H)

--

W4.4B

8

Washer innside Ø = 10.5 mm DIN6340 (for W4.2J)

--

W4.6C

1

Crossbar (form A), outside Ø= 368 mm, width = 80 mm, thickness = 110 mm / inside Ø = 328 mm, depth = 60 mm / center hole = 21 mm

940780030

W4.7A

1

Distance plate 160x80x30 mm

207313000

Siemens AG Three-phase Motor

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7.3.5

Appendix

W6 Aids Description

e.g. Siemens Tool No.

4

Jack screws M16x120

980350203

W6.2

2

Jack screws M10x100

980350201

W6.4A

2

Threaded guids M10x200

206119003

W6.4B

2

Threaded guids M16x150

206119006

W6.4C

2

Threaded guids M20x200

206119007

W6.5

1

Assembly device for inclined parallel pin, motor type 1TB3030 – 0GB03 only

201134100

W6.10

1

Grease former, motor type 1TB3030 – 0GB03 only

207153000

W6.20

2

Bearing lock washer

207307000

W6.30

1

Centering tube (for W3.1.1D)

990078180

Device

Qty.

W6.1

outside Ø = 31 mm, innside Ø = 53 mm, lenght = 240 mm

7.3.6

100

W6.40A

1

Assembly device (for rubber seal D-end)

207229000

W6.40B

1

Assembly device (for rubber seal N-end)

207229050

W8 Devices for pulling off components (separator pulling tool, complete set) Device

Qty.

Description

W8.35

1

Separator pulling tool, Kukko pullers and separator set

e.g. Siemens Tool No. 940780633

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Appendix

7.4

Repair parts list

7.4.1

R1 Paints for renewing the paintwork or touching up damaged parts (Refer to chapter 6.5.2) NOTICE Remove any loose, damaged, or old paint before touching up paintwork. The surface to be primed or painted must be free from dirt, dust, and grease, and roughened with emery paper (grain 80).

CAUTION Hot parts – burn hazard!

When working with hot parts, ensure that suitable personal protective gear is worn (protective clothing, gloves etc.).

Repair agent R1.1

Description

Supplier

Primer coat (coat thickness: 60 µm): Epoxy resin two-component primer, RAL 3012 beige-red Epoxy resin two-component hardener; mixing ratio 5:1% by weight

e.g.

Brillux König + Flügger GmbH & Co. KG, D-59423 Unna

Processing information: Suitable for overcoating after oven drying at 140°F (60°C) / 30 minutes after cooling.

Drying time at room temperature: 24 hours R1.3

Top coat (coat thickness: 60 µm): Two-component PUR-AC thixotropic paint, RAL 9011 graphite black Two-component PUR hardener; mixing ratio 9:1 % by weight

e.g.

Brillux König + Flügger GmbH & Co. KG, D-59423 Unna

Processing information: Requires approx. 15 minutes drying time.

Suitable for overcoating after oven drying at 176°F (80°C) / 30 minutes after cooling.

Drying time at room temperature: 24 hours

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7.5

Appendix

Appendix B1a, Exploded view, motor types 1TB3026 – xGA03 / 1TB3030 – xGA03 only

Footnotes: a) PT100 [7.12], D-end bearing temperature measurement b) D-end [8.13 / 8.18] / N-end [8.12 / 8.18] bearing lubrication c) PT100 [7.12], N-end bearing temperature measurement d) Speed sensor [7.13] e) Central bearing lubrication [8.10] (D-end bearing) f) Central bearing lubrication [8.10] (N-end bearing) g) Assembly direction for air deflectors [1.17] (N-end), only motor types: - 1TB3026 – 0GA03 - 1TB3026 – 1GA03 h) Spacer tube [1.34] (N-end), only motor types: - 1TB3026 – 0GA03 - 1TB3026 – 1GA03 i) Gear wheel [14.10] (N-end), only motor types: - 1TB3026 – 1GA03 - 1TB3030 – 1GA03 j) Brake hub [14.10] (N-end), only motor types: - 1TB3030 – 0GA03 k) Motor coupling [15.10] (D-end), only motor types: - 1TB3026 – 0GA03 - 1TB3030 – 0GA03 l) Motor coupling [15.10] (D-end), only motor types: - 1TB3026 – 1GA03 - 1TB3030 – 1GA03 m) Blanking plug [6.20], only motor types: - 1TB3026 – 0GA03 - 1TB3026 – 1GA03 n) Socket cap screws [1.03], only motor types: - 1TB3026 – xGA03 = M8x35 - 1TB3030 – xGA03 = M8x12

104

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A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Siemens AG Three-phase Motor

A5E00338220A Operating Instructions

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Edition 02.2008

7.6

Appendix

Appendix B1b, Exploded view, motor type 1TB3030 – 0GB03 only

Footnotes: a) PT100 [7.12], D-end bearing temperature measurement b) D-end [8.13 / 8.18] / N-end [8.12 / 8.18] bearing lubrication c) PT100 [7.12], N-end bearing temperature measurement d) Speed sensor [7.13] e) Central bearing lubrication [8.10] (D-end bearing) f) Central bearing lubrication [8.10] (N-end bearing)

108

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Siemens AG Three-phase Motor

Appendix

A5E00338220A Operating Instructions

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7.7

Appendix

Appendix B2a, Dismantling diagrams

Figure captions for Appendix B2a

Diagramm

112

Fig no. / caption Fig. 6.2

Pressing off the coupling

Fig. 6.3

Pressing off the brake hub / gear wheel

Fig. 6.4

Pulling the speed sensor gear off the shaft, in principle also motor type 1TB3030-0GB03

Fig. 6.5

Additional device for withdrawing the rotor, for motor type 1TB3030–0GB03 only

Fig. 6.6

Withdrawing the rotor from the stator frame at the D-end

Fig. 6.7

Pulling the outer labyrinth ring (D-end) off the shaft

Fig. 6.8

Pulling the bearing shield (D-end) and the bearing off the shaft

Fig. 6.9

Pulling the inner labyrinth ring (D-end) off the shaft

Fig. 6.10

Pressing the bearing (D-end) out of the bearing shield

Fig. 6.11

Pressing the bearing outer ring with the cage and the rolling element (Nend) out of the bearing shield, in principle also motor type 1TB3030-0GB03

Fig. 6.12

Pulling the bearing inner ring (N-end) off the shaft, in principle also motor type 1TB3030-0GB03

Fig. 6.13

Pulling the inner labyrinth ring (N-end) off the shaft

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Siemens AG Three-phase Motor

Appendix

A5E00338220A Operating Instructions

113

BI619397

Edition 02.2008

7.8

Appendix

Appendix B2b, Assembly diagrams

Figure captions for Appendix B2b

Diagramm

116

Fig no. / caption Fig. 6.16

Pressing the bearing (D-end) into the bearing shield

Fig. 6.18

Pressing the bearing outer ring and cage (N-end) into the bearing shield, motor types 1TB 3026 – xGA03 / 1TB 3030 – xGA03 only

Fig. 6.21

Pressing the bearing shield (D-end) onto the shaft

Fig. 6.22

Inserting the rotor into the stator frame at the D-end

Fig. 6.23

Additional device for inserting the rotor, motor type 1TB3030–0GB03 only

Fig. 6.25

Shrinking the (outer) labyrinth ring onto the shaft (D-end)

Fig. 6.26

Shrinking the speed sensor gear onto the shaft (N-end)

Fig. 6.27

Pressing on the coupling

Fig. 6.28

Pressing on the brake hub / gear wheel

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Siemens AG Three-phase Motor

Appendix

A5E00338220A Operating Instructions

117

BI619397

Edition 02.2008

7.9

Appendix

Appendix X1, Fault table Symptom

Possible fault

How to check

How to remedy

Remarks

Grounding socket

No contact with frame

Rust under contact area

Dismantle and clean socket

Ground fault signal

Connection lead damaged with ground contact

Check the connection lead

Replace the connection lead

Check route of lead for sharp edges and chafing

Winding insulation damaged

Check the insulation resistances

Repair after consulting manufacturer

Determine the causes of the damage: impurities in the motor, rotor parts in the motor

Water in the "Nend" area of the frame

Withdraw the rotor with the bearing shield (N-end)

Dry out the frame

Impermissible winding temperature

Temperature indication is unrealistic or defective

Overloading

Reduce the load, localize any blockages, and clear them

Cooling ducts blocked in motor

Clean the ducts

Temperature sensor lead interrupted

Check the connection lead, check the plug connections

Resistance thermometer defective Local overheating

Siemens AG Three-phase Motor

Replace the connection lead, clean or replace contacts on the plug connections

Check route of lead for sharp edges and chafing

If more than one thermometer is used, rearrange the connections

Temperature sensor lead interrupted

Check the connection lead

Replace the connection lead

Soldered connection between cable lug and coil connector is loose

Withdraw the rotor with the bearing shield (N-end) and check the soldered connection

If necessary, replace the cable lug and remake the soldered connection between the cable lug and the coil connector

Winding insulation damaged

Test the winding resistances, test the insulation resistances, measure the impedance

Repair after consulting manufacturer

Determine the causes of the damage: impurities in the motor, rotor parts in the motor

Bearing dirty

Remove the bearing cap

Replace the bearing, regrease

Check the bearing seal and replace if necessary

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Edition 02.2008

Symptom Local overheating

Smoke development

Appendix

Possible fault

How to check

120

Remarks

Incorrect bearing clearance

Lift the shaft and measure the clearance with a dial gage

Install a bearing with the correct clearance, check the seat

Determine the causes of the change in the bearing clearance

Bearing damage

Remove the bearing cap

Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core touches the stator core

Bearing seized

Remove the bearing cap, bearing discolored or deformed, bearing cap discolored

Consult the manufacturer

Determine causes of seizing:failure of lubrication, excessive loading

Bearing overlubricated or underlubricated

Lubricate the bearing correctly

Bearing service life is reduced

Cooling ducts blocked in motor

Clean the ducts

Insufficient air supply

Check the ventilation system

Air inlet blocked

Clean the air inlet

Winding insulation damaged

Test the winding resistances, test the insulation resistances, measure the impedance

Repair after consulting manufacturer

Determine the causes of the damage: impurities in the motor, rotor parts in the motor, excess current

Bearing seized

Bearing cap discolored, bearing discolored or deformed, bearing damage can only be determined after dismantling

Remove the bearing, consult the manufacturer

Determine causes of seizing:failure of lubrication, excessive loading

Consult the manufacturer

Determine the cause, localize consequential damage: stator / rotor core, stator winding, built-on shaft parts

Shaft bent

Scorching smell

How to remedy

Connection lead damaged or interrupted

Check the connection lead

Replace the connection lead

Check route of lead for sharp edges and chafing

Winding insulation damaged

Test the winding resistances, test the insulation resistances, measure the impedance

Repair after consulting manufacturer

Determine the causes of the damage: impurities in the motor, rotor parts in the motor, excess current

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Symptom Humming noise

Rubbing noise

Knocking noise

Siemens AG Three-phase Motor

Appendix

Possible fault

How to check

How to remedy

Remarks

Connection lead interrupted

Check the connection lead

Replace the connection lead

Check route of lead for sharp edges and chafing

Terminal loose

Open the terminal box and check the terminals

Fasten the terminal, replace the cable lug if necessary

Incorrect bearing clearance

Lift the shaft and measure the clearance with a dial gage

Install a bearing with the correct clearance, check the seat

Determine the causes of the change in the bearing clearance

Shaft bent

Can be determined only after dismantling

Consult the manufacturer

Determine the cause, localize consequential damage: stator / rotor core, stator winding, built-on shaft parts

Current flow at bearing

Visible only after dismantling the bearing

Consult the manufacturer

Determine the cause of current flow and take suitable steps

Bearing damage

Remove the bearing cap

Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core touches the stator core

Motor suspension broken

Check the suspension

Consult the manufacturer

Localize consequential damage: shaft bearing, gear coupling to motor

Motor suspension loose

Check the screwed joint, check the bearing, check the dampers

Tighten the screws to the specified torque, replace the dampers

Motor coupling loose or broken

Check the screwed joint, perform a visual inspection of particularly critical locations for cracks

Tighten the screws to the specified torque, replace broken screws

Check the seal for damage and replace if necessary

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Symptom Whistling noise

Radial vibrations

Appendix

Possible fault

How to check

122

Remarks

Incorrect bearing clearance

Lift the shaft and measure the clearance with a dial gage

Install a bearing with the correct clearance, check the seat

Determine the causes of the change in the bearing clearance

Bearing damage

Remove the bearing cap

Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core touches the stator core

Excessive bearing clearance

Lift the shaft and measure the clearance with a dial gage

Install a bearing with the correct clearance, check the seat

Determine the causes

Bearing damage

Remove the bearing cap

Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core touches the stator core

Consult the manufacturer

Determine consequential damage: small parts (screws, weights etc.) inside motor Localize consequential damage: shaft bearing, gear coupling to motor

Balancing weights loose or lost

Axial vibrations

How to remedy

Motor suspension broken

Check the suspension

Consult the manufacturer

Motor suspension loose

Check the screwed joint, check the bearing

Tighten the screws to the specified torque

Rotor out of balance

Visual inspection, balance

Clean the rotor, refer to chapter 6.5.1; rebalance the rotor, refer to chapter 6.6

Incorrect bearing clearance

Lift the shaft and measure the clearance with a dial gage

Install a bearing with the correct clearance, check the seat

Determine the causes of the change in the bearing clearance

Bearing damage

Remove the bearing cap

Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core touches the stator core

Motor suspension broken

Check the suspension

Consult the manufacturer

Localize consequential damage

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

Edition 02.2008

Appendix

Symptom

Possible fault

How to check

How to remedy

Axial vibrations

Motor suspension loose

Check the screwed joint, check the bearing

Tighten the screws to the specified torque

Machine loses torque

Connection lead interrupted

Check the connection lead

Replace the connection lead

Soldered connection between cable lug and coil connector is loose

Withdraw the rotor with the bearing shield (N-end) and check the soldered connection

If necessary, replace the cable lug and remake the soldered connection between the cable lug and the coil connector

Motor running unevenly

Soldered connection between cable lug and coil connector is loose

Withdraw the rotor with the bearing shield (N-end) and check the soldered connection

If necessary, replace the cable lug and remake the soldered connection between the cable lug and the coil connector

Oil / grease leakage

Bearing overgreased

Remove the used grease cover

Remove the excess grease, clean the used grease duct, fasten the used grease cover

Contaminated or prematurely aged grease

Current flow at bearing

Visible only after dismantling the bearing

Consult the manufacturer

Determine the cause of current flow and take suitable steps

Shocks or vibrations

Regrease the bearings and drain grease from the used grease duct

Press in plenty of fresh grease while turning the motor

Determine the cause of shocks and vibrations

Siemens AG Three-phase Motor

Remarks

Check route of lead for sharp edges and chafing

A5E00338220A Operating Instructions

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Edition 02.2008

7.10

Appendix

Appendix Z1, Revision table Description of changes

Page

Dept.

Name

Date

Edition 06.2006 / Version AA changed to Edition 02.2008 / Version AB

--

OM7

Mr. Pfannschmidt

12.03.08

Title Mining Truck changed to Mining Motor

--

Additional motor version 1TB 3030 -- 0GB03 incorporated, all details adapted.

1-120

124

Siemens AG

A5E00338220A

Three-phase Motor

Operating Instructions

BI619397

FREIGABE Autor (produktverantwortliche Abteilung)

...........................

...........

Name

Abteilung

.............. ........................

Datum

Unterschrift

Geprüft:

Übersetzer

Redakteur

Möltner A&D LD T TP6 ............................ ............ ............................ ............

Name

Abteilung

..............

Datum

........................

Unterschrift

Name

Abteilung

3/17/2008 .............. .........................

Datum

Unterschrift

........................

Unterschrift

Bemerkungen Inhalt überprüft, Gefahrenhinweise ausreichend

Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung ihres Inhalts nicht gestattet, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen verpflichten zu Schadensersatz. Alle Rechte vorbehalten, insbesondere für den Fall der Patenterteilung oder GM-Eintragung.

Daten der Unterlage: System:

Three-phase Motor

Titel:

Mining Motor

MLFB:

−

Monat und Jahr der Erstellung:

03.08

Format:

DIN A4

Gesamtblattzahl:

126

Sprache nach SN 01014:

76

(englisch)

Änderungen: Revisionsstand wurde für MTU nicht realisiert Archivdaten: Film-Nr. / lfd. Nr.: Datum der Archivierung:

*

die Prüfung der MTU ist auf dem Freigabevermerk dokumentiert Datum

3/17/2008

Bearb.

Möltner

Gepr.

*

Norm

n. ng.

Abt.

A&D LD T

Referenzblatt für mitzuliefernde technische Unterlagen (MTU) Typ:

A5E00338220A AB

9999996

3/17/2008

Bey

Zust.

Mitteilung

Datum

Name

Ersatz für / ersetzt durch:

AB

Blatt

1 1 Bl.