SIMODRIVE. AC Induction Motors for Main Spindle Drives 1PH2, 1PH4, 1PH7. Manufacturer/Service Documentation

Transcription

1 SIMODRIVE Planning Guide Edition AC Induction Motors for Main Spindle Drives 1PH2, 1PH4, 1PH7 Manufacturer/Service Documentation

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3 Foreword SIMODRIVE AC Induction Motors for Main Spindle Drives 1PH2, 1PH4, 1PH7 Planning Guide General Information on AC Induction Motors AC Built in Motors AC Main Spindle Motors AC Main Spindle Motors Encoders References Index AL 1PH2 1PH4 1PH7 GE LV SV Valid for Equipment series 6SN Edition

4 3ls SIMODRIVE documentation Printing history Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the Remarks column. Status code in the Remarks column: A.... New documentation. B.... Unrevised reprint with new Order No. C.... Revised edition with new status. If factual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on that page. Edition Order No. Remarks SN1060 0AC00 0BP0 A SN1197 0AA20 0BP0 C SN1197 0AA20 0BP1 C SN1197 0AA20 0BP2 C SN1197 0AA20 0BP3 C SN1197 0AA20 0BP4 C SN1197 0AA20 0BP5 C SN1197 0AC60 0BP0 C This Manual is part of the documentation on CD ROM (DOCONCD) Edition Order No. Remark FC5298 6CA00 0BG2 C Trademarks SIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK and SIMODRIVE are trademarks of Siemens AG. All other product and system names are registered trademarks of their respective companies and must be treated accordingly. Additional information is available in the Internet under: This publication was produced with Interleaf V 7 The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement. Subject to change without prior notice. Order No. 6SN1197 0AC60 0BP0 Printed in the Federal Republic of Germany Siemens Aktiengesellschaft

5 Foreword Information on SIMODRIVE documentation This document is part of the technical customer documentation developed for SIMODRIVE. All documents are available individually. The documentation list, which includes all Advertising Brochures, Catalogs, Overviews, Short Descriptions, User Manuals and Technical Descriptions with Order No., location and price, can be obtained from your local Siemens office. This Manual 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. Furthermore, we would like to point out that the contents of this document shall neither become part of nor modify any prior or existing agreement, commitment or relationship. The sales contract contains the entire obligation of Siemens. Any statements contained herein neither create new warranties nor modify the existing warranty. Hotline If you have any questions please contact the following Hotline: A&D Technical Supports Tel.: +49 (180) FAX: +49 (180) Definition of qualified personnel For the purpose of this documentation and the product labels, a qualified person is someone who is familiar with the installation, mounting, start up and operation of the equipment and the hazards involved. He or she must have the following qualifications: Trained and authorized to energize, de energize, clear, ground and tag circuits and equipment in accordance with established safety procedures. Trained in the proper care and use of protective equipment in accordance with established safety procedures. Trained in rendering first aid. v

6 Foreword 1.2 Überschrift Explanation of the symbols The following danger and warning concept is used in this document:! Danger This symbol indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken.! Warning This symbol indicates that death, severe personal injury or property damage can result if proper precautions are not taken.! Caution This symbol indicates that minor personal injury or material damage can result if proper precautions are not taken. Caution This warning (without warning triangle) indicates that material damage can result if proper precautions are not taken. Notice This warning indicates that an undesirable situation or condition can occur if the appropriate instructions/information are not observed. Note For this document, this represents a possible advantage if the Note text is observed. vi

7 Foreword Danger and warning information! Danger Start up and commissioning is prohibited until it has been clearly identified that the machine, in which the components described here should be installed, is in full compliance to the specifications of Directive 98/37/EG. Only appropriately qualified personnel may commission the SIMODRIVE units and the AC motors. This personnel must carefully observe the technical customer documentation belonging to this product and be knowledgeable about and observe the danger and warning information. Operational electrical units and motors have parts and components which are at hazardous voltage levels. Hazardous axis motion can occur when working with the equipment. All work must be undertaken with the system in a no voltage condition (powered down). SIMODRIVE drive units are designed for operation on low ohmic, grounded line supplies (TN line supplies). SIMODRIVE units with AC motors may only be connected to the line supply through residual current operated circuit breakers, if corresponding to EN 50178, Section , it has been proven that the SIMODRIVE drive unit is compatible with the residual current operated circuit breaker.! Warning Perfect and safe operation of these units and motors assumes professional transport, storage, mounting and installation as well as careful operator control and servicing. The information provided in catalogs and quotations additionally applies to special versions of units and motors. In addition to the danger and warning information/instructions in the technical customer documentation supplied, the applicable domestic, local and plant specific regulations and requirements must be carefully taken into account. vii

8 Foreword ! Caution The motors can have surface temperatures of over +80 C. This is the reason that no temperature sensitive components, e.g. cables or electronic components may be in contact or be attached to the motor. When handling cables, please observe the following They must not be damaged They must not be stressed They must not come into contact with rotating components. Caution SIMODRIVE drive units with AC motors are subject, as part of the routine test, to a voltage test in accordance with EN While the electrical equipment of industrial machines is being subject to a voltage test in accordance with EN , Section 19.4, all SIMODRIVE drive unit connections must be disconnected/withdrawn in order to avoid damaging the SIMODRIVE drive units. Motors should be connected up according to the circuit diagram provided. It is not permissible to directly connect the motors to the three phase line supply as this will destroy the motors. Note SIMODRIVE units with AC motors fulfill, when operational and in dry operating rooms, the Low Voltage Directive 73/23/EWG. SIMODRIVE units with AC motors fulfill, in the configuration specified in the associated EC Declaration of Conformance, the EMC Directive 89/336/EWG. viii

9 Foreword ESDS Instructions! Caution ElectroStatic DischargeSensitive devices (ESDS) are individual components, integrated circuits or boards which could be destroyed by electrostatic fields or electrostatic discharge. Handling ESDS boards: When handling components which can be destroyed by electrostatic discharge, it must be ensured that personnel, the workstation and packaging are well grounded! Electronic boards may only be touched by personnel in ESDS areas with conductive flooring if they are grounded through an ESDS bracelet they are wearing ESDS shoes or ESDS shoe grounding strips. Electronic boards should only be touched when absolutely necessary. Electronic boards should not be brought into contact with plastics and articles of clothing manufactured from man made fibers. Electronic boards may only be placed on conductive surfaces (desk with ESDS surface, conductive ESDS foam rubber, ESDS packing bag, ESDS transport containers) Electronic boards may not be brought close to data terminals, monitors, or television sets. Minimum clearance > 10 cm). Measuring work may only be carried out on the electronic boards, if the measuring unit is grounded (e.g. via a protective conductor), or for floating measuring equipment, the probe is briefly discharged before making measurements (e.g. a bare metal control housing is touched). Note Refer to the following Guides for technical information regarding SIMODRIVE 611: SIMODRIVE 611, Planning Guide Drive Converters Order No.: 6SN1197 0AA00 SIMODRIVE 611 Analog System, Start up Guide Transistor PWM Inverters for AC Feed Drives and AC Main Spindle Drives Order No.: 6SN1197 0AA60 Commissioning software (IBS) with documentation is available to commission the main spindle motor module. Order No. for the commissioning software: 6SN1153 2AX10 AB5 Order No. for the commissioning documentation: 6SN1197 0AA30 0B ix

10 Foreword Space for your notes x

11 General Information on AC Induction Motors 1 Electrical Data AL/ Definitions AL/ Motor rating plate data AL/ Mechanical Data for 1PH4 and 1PH AL/ Definitions AL/ Termination system AL/ Engineering AL/3-33 AL AL-11

12 12.01 Space for your notes AL AL -12

13 12.01 General Information on AC Induction Motors 1.1 Definitions Electrical Data 1.1 Definitions 1 AL Mechanical limiting speed n max The maximum permissible speed n max is defined by the mechanical system (bearings, short circuit ring of the squirrel cage rotor etc.). It is not permissible that this speed is exceeded! The motor may not be continuously operated at this speed. After max. 3 minutes, the speed must be reduced corresponding to the following load duty cycle: 30 % n max 60 % 2/3 n max 10 % Standstill Max. continuous speed n S1cont Thermal time constant T th The maximum permissible speed, which is permanently permitted without speed duty cycles. The thermal time constant defines the temperature rise of the motor winding when the motor load is suddenly increased (step increase) to its permissible S1 torque. After T th, the motor has reached 63 % of its S1 final temperature. S1 duty (continuous operation) S6 duty (intermittent load) Operation with constant load, the duration of which is long enough so that the motor goes into a thermal steady state condition. This is operation which comprises a sequence of similar load duty cycles, of which each one comprises a time with constant motor load and a no load time. If not otherwise specified, the power on time refers to a load duty cycle of 10 min. S6 40 %: 4 min load 6 min no load AL/1-13

14 General Information on AC Induction Motors 1.1 Definitions AL Mode of operation 1PH Constant torque M rated is available from standstill up to the rated operating point. The constant power range starts from the rated operating point (refer to the P/n diagrams). At higher speeds, e.g. in the constant power range, the maximum available torque M max is calculated for a specific speed n in a first approximation according to the following formula: M max [Nm] 9.6 P max [W] n The AC motors have a high overload capability in the constant power range. For some AC motors, the overload capability is reduced for the highest speed range. The precise data can be taken from the motor characteristics in the appropriate motor sections. The motor field remains constant in the base speed range up to the rated operating point. This is then followed by a wide constant power range. P, M P max S6 M rated P rated S1 n rated n max n Fig. 1-1 Principle characteristic of power P and torque M as a function of speed n (operating modes acc. to VDE 0530 Part 1) Power characteristics The constant power range for main spindle drives with typical machining and constant cutting power can be advantageously used and reduces the required drive converter output. The following limits and characteristics are essentially valid for all main spindle motor PWM converter combinations. AL/1-14

15 12.01 General Information on AC Induction Motors 1.1 Definitions P P rated 2 S6 25 % Stall limit AL 1.5 S6 40 % S6 60 % 1 S1 output speed Speed limit n max n Fig. 1-2 Power characteristics, limiting and characteristics Motor limits The speed and performance data of induction motors are limited for thermal and mechanical reasons 1). The maximum current is only limited by the thermal properties of the motor winding. Thermal limit Heat losses are stored in the motor and dissipated to the cooling medium. The motor temperature which is obtained is, among other things, dependent on the load duty cycle however, under no circumstances may the critical motor temperature be exceeded. The characteristics for continuous duty S1 and intermittent operation S6 60 %, S6 40 % and S6 25 % describe the permissible power values for an ambient temperature of up to 40 C. A winding temperature rise of approx. 105 K can occur. Mechanical limiting It is not permissible that the mechanical limiting speed is exceeded. If this speed is exceeded, this can result in damage to the bearings, short circuit rings, press fits etc. A monitoring function in the PWM converter prevents the limit speed from being exceeded. Maximum torque M max Torque which is briefly available for dynamic operations (e.g. accelerating). M max = 2 M rated 1) Stressing of the shaft end, bearings AL/1-15

16 General Information on AC Induction Motors 1.1 Definitions AL Drive converter limits Voltage limiting characteristic (stall limit) In the upper speed range, the drive converter provides the motor with the maximum output voltage in order to impress the controlled motor current. In order to guarantee a specific current impressed in the motor up to the maximum speed, the current and therefore the maximum available motor output must be reduced for increasing speed. Above this characteristic (stall limit) if more output is demanded, then the speed will decrease. There is no danger that the motor or drive converter could be damaged. Thermal limiting The drive converter output is thermally limited. When the power on duration decreases, the short time output increases. The short time output is defined by the short time current. S6 25 % 25 % t 10 min duty cycle The power on duration is standardized according to VDE 0530 for 15 %, 25 %, 40 %, 60 %. If a load duty cycle is not specified, it is 10 min. Fig. 1-3 Power on duration in intermittent operation Motor power module assignment If the drive converter rated current exceeds the rated motor current, then the thermal characteristic (S1) of the motor defines the continuous output of the combination. This means that the drive converter is not fully utilized. In the opposite case, the rated drive converter current determines the available continuous output. This means that the motor is not fully thermally utilized. If load duty cycles apply, the motor must be selected so that the RMS current does not exceed the permissible S1 value of the motor. Generally, the following applies: If a range is defined by two limit values or characteristics, then the lower limit defines the range which can be utilized. AL/1-16

17 12.01 General Information on AC Induction Motors 1.1 Definitions Operation with an uncontrolled (non regulated) infeed. The drive modules can be used with uncontrolled (non regulated) and controlled (regulated) infeed modules of the SIMODRIVE 611 drive converter system. The engineering and performance data in the Catalog refer to operation with the controlled (regulated) infeed/regenerative feedback modules. This data may have to be corrected with operation with uncontrolled (non regulated) infeed modules. When operating main spindle and induction drive modules with an uncontrolled (non regulated) infeed (UI module), then a lower maximum motor output is available in the upper speed range than when using the infeed/regenerative feedback module (refer to the diagram). As a result of the lower DC link voltage of 490 V for the UI module, the available continuous output is obtained as follows: If V DC link < 1.5 U N motor, then as continuous output, only AL U P cont P DC link N 1.5 U N motor is possible at rated speed. V DC link V DC link 490 V for UI module 600 V for I/R module Output P S6 S1 P n = P n ( V DC link 600 ) 2 x Motor output limit with I/R module with UI module Speed n Fig. 1-4 Power speed diagram, general Furthermore, for the UI module, it must be ensured that the braking energy fed back does not exceed the pulsed resistor power rating: 5 kw infeed module 200 W continuous power (regenerative feedback power) 10 kw short time power for 120 ms once per 10 s duty cycle without pre load condition 10 kw infeed module 300 W continuous power (regenerative feedback power) 25 kw short time power for 120 ms once per 10 s duty cycle without pre load condition AL/1-17

18 General Information on AC Induction Motors 1.1 Definitions AL 28 kw infeed module max. 2 x 300 W continuous power max. 2 x 25 kw short time power for 120 ms once per 10 s duty cycle without pre load condition or max. 2 x 1.5 kw continuous output max. 2 x 25 kw short time power for 12 ms once per 10 s duty cycle without pre load condition For higher regenerative feedback powers, a separate pulsed resistor module must be provided or the regenerative feedback power must be reduced by using longer braking times. Power speed diagram Powers for duty types S1 and S6 The duty types are defined in IEC 60034, Part 1. For duty types S1 and S6, acc. to IEC 60034, Part 1, a maximum load duty cycle of 10 min is defined as long as no special information exists. All of the AC motor performance data (output etc.) refer to continuous operation and the appropriate duty type S1. However, for many applications, duty type S1 does not exist, if e.g. the load varies as a function of time. For this particular case, an equivalent sequence can be specified which represents, as a minimum, the same stressing for the motor. Duty type S6... can be considered as close to normal applications. (S6 = continuous operation with intermittent load). For shorter accelerating times and to handle torque surges, a peak current is available for 10 seconds in a 60 second cycle. The power module currents (S1/S6 40%/peak current) are specified in the diagrams. Core types Core types are a subset of the overall motor range. Core types have shorter delivery times and are in some cases available ex stock. The range of options is restricted. They have a different order designation. AL/1-18

19 12.01 General Information on AC Induction Motors 1.2 Motor rating plate data 1.2 Motor rating plate data Rating plate for shaft heights 100 to 225 Example: Shaft height 132 AL 3 mot. 1PH7137 2NG00 0BA00 No. L IM B3 IP 55/54 Th.Cl.FYF V A kw cosϕ Hz RPM F 350 Y S1 398 Y S1 450 Y S1 EN max RPM TEMP SENSOR KTY ENCODER D S/R CODE No.: 412 Made in Germany Temperature sensor, encoder, Code No. Operation Type of construction, degree of protection, temperature rise class Motor Order No., Serial No. AL/1-19

20 General Information on AC Induction Motors 1.2 Motor rating plate data Space for your notes AL AL/1-20

21 12.01 General Information on AC Induction Motors 2.1 Definitions Mechanical Data for 1PH4 and 1PH7 2.1 Definitions 2 AL Types of construction Type of Designation Type of Designation construction construction Ï IM B3 IM B5 Type of construction Ó Ó Ï Designation IM B35 Ó Ó Ó Ó Ó IM V5 ÓÓÓÓ IM V1 Ó Ó ÓÓÓÓ IM V15 Ó Ó Ó Ó IM V6 ÓÓÓÓ IM V3 ÓÓ Ó Ó Ó IM V36 Fig. 2-1 Types of construction Vibration severity limit values It is generally valid that a high cantilever force load capability cannot be simultaneously realized for high speeds and high vibration quality as the different tasks require different bearings. AL/2-21

22 General Information on AC Induction Motors 2.1 Definitions AL 3 Permissible vibration velocity V rms [mm/s] 2.8 Level R Level S Level SR n Fig. 2-2 Vibration severity limit values, AC motors, shaft heights 100 mm to 132 mm Permissible vibration velocity V rms [mm/s] Level R Level S Level SR n Fig. 2-3 Vibration severity limit values, AC motors, shaft heights 160 mm to 225 mm AL/2-22

23 General Information on AC Induction Motors 2.1 Definitions Requirements placed on the balancing process of mounted components and parts, especially pulley wheels In addition to the balance quality of the motor, the vibration quality of motors with mounted belt pulleys is essentially determined by the balance quality of the mounted component. If the motor and mounted component are separately balanced before assembly, then the balancing process for the belt pulley must be adapted to the motor balancing type. For 1PH4 and 1PH7 main spindle motors, a differentiation should be made between the following balancing types: Half key balancing Full key balancing Smooth shaft end (no keyway) For 1PH7 motors, the balancing type is coded in the Order designation. Half and full key balanced motors can be identified by the letter H (half key) or F (full key) on the shaft face. The following table describes the requirements placed on the balancing process as a function of the motor balancing type. For the highest demands placed on the system balance quality, we recommend that motors with smooth shaft (without keyway) are used. For full key balanced motors, belt pulleys are recommended with two keyways which are located opposite to one another, however, only one keyway in the shaft end. AL Table 2-1 Balancing process Balancing equipment/ process step Auxiliary shaft to balance the mounted component The component is mounted on the auxiliary shaft for balancing Position the mounted component on the auxiliary shaft Balance the mounted component Motor half key balanced Auxiliary shaft with keyway Keyway with the same dimensions as in the motor shaft end Auxiliary shaft half key balanced Motor full key balanced Auxiliary shaft with keyway Groove design, with the exception of the groove width (the same as the motor) can be freely selected Auxiliary shaft full key balanced Motor with smooth (no keyway) shaft end Auxiliary shaft without keyway Auxiliary shaft, if required, tapered Balance quality of the auxiliary shaft 10% of the required balance quality of the mounted component Mounting with key Key design, dimensions and materials the same as in the motor shaft end Select the position between the mounted component and key of the auxiliary shaft as for the mounting on the motor Mounting with key Key design, dimensions and materials the same as for full key balancing of the auxiliary shaft No specific requirements The component should be mounted with the lowest possible play, e.g. a light press fit on the tapered auxiliary shaft We recommend two plane balancing, i.e. balancing in two planes at both sides of the mounted component at the right angle to the axis of rotation Cantilever force Specific cantilever forces may not be exceeded in order to guarantee perfect operation. For various shaft heights, a minimum force may not be fallen below. This can be taken from the cantilever force diagrams. AL/2-23

24 General Information on AC Induction Motors Definitions AL The cantilever force diagrams in the motor sections show cantilever force F Q for various operating speeds as a function of the bearing lifetime The force diagrams and tables only apply for standard drive shaft ends; for non standard drive shaft end dimensions, every application is specifically designed corresponding to the permissible force load levels. For force levels which go beyond this, please inquire.! Caution For coupling and belt outdrives: If you use mechanical transmission elements which subject the shaft end to a cantilever force, then you must ensure that the maximum limit values, specified in the cantilever force diagrams, are not exceeded. Only for belt outdrives (shaft heights 180 and 225): For applications with extremely low cantilever forces, it must be ensured that the motor shaft is subject to a minimum cantilever force which is specified in the diagrams. Low cantilever forces can cause the bearings to roll in an undefined fashion which results in increased bearing wear. For applications with cantilever loads, which are less than the specified minimum cantilever forces (e.g. coupling outdrive), then the bearings may not be used for belt outdrives. For applications such as these, the induction motor must be ordered with bearings for coupling outdrive. Note The cantilever forces at the shaft end must be precisely dimensioned according to the guidelines of the belt manufacturer. only shaft height 132 (1PH7) F 1QAS F QAS F 2QAS L h h F 1QAS F QAS F 2QAS F 3QAS x x 1.5x x55 mm F 1QAS max N F 2QAS 1.1 F QAS F 3QAS max N x55 mm F 1QAS 0.9 F QAS F 2QAS 1.1 F QAS Fig. 2-4 Point of application of cantilever forces at the shaft ends of motors AL/2-24

25 12.01 General Information on AC Induction Motors 2.1 Definitions Dimension x: Dimension l: Distance between the points of application of force F Q and the shaft shoulder in mm. Shaft stump length in mm. Total cantilever force: F Q = cf U The pre tensioning factor C is a value gained by experience from the belt manufacturer. It can be assumed as follows: for v belts c = 1.5 to 2.5 for special plastic belts (flat belts), depending on the type of load and belt type c = 2.0 to 2.5 The circumferential force F U is calculated from the following equation: F U = P/(nD) in [N] F U [N] Circumferential force D [mm] Belt pulley diameter P [kw] Motor output n Motor speed AL Lifetime (L h ) Estimated bearing lifetime under fluctuating operating conditions (F QAS ; n) L h tot q1 L h1 100 q2 L h2 q3 L h3 L h from the diagram q Time [%] under constant conditions Axial force stressing The axial force, acting on the locating bearing, comprises the external axial force (e.g. gearbox with helical teeth, machining forces through the tool), a bearing alignment force and possibly the force due to the weight of the rotor when the motor is vertically mounted. This is the reason that there is a maximum axial force which depends on the direction. When using, for example, helical gears as drive element, in addition to the radial force, there is also an axial force on the motor bearings. For axial forces in the direction of the motor, the bearing alignment force can be overcome, so that the rotor moves corresponding to the existing bearing axial play (up to 0.2 mm). The permissible axial force F AZ in operation is calculated, depending on the motor mounting position. AL/2-25

26 General Information on AC Induction Motors 2.1 Definitions Calculating the permissible axial force depending on the mounting position, refer to Fig AL Horizontal mounting F AZ 1PH4 F AZ F AZ = F A F C F AZ = F A F AZ 1PH7 F AZ F AZ = F A F C F AZ = F C Shaft end facing downwards F AZ F AZ F AZ = F A F L F C F AZ = F L +F C Shaft end facing upwards F AZ F AZ F AZ = F A +F L F C F AZ = F C F L Fig. 2-5 Permissible axial force for 1PH7 motors F AZ F A F C F L Operational axial force Permissible axial force as a function of the average speed Bearing alignment force, for 1PH4 > refer to Table 3-11 in Section 1PH4 for 1PH7 > refer to Table 3-60 in Section 1PH7 Force due to the rotor weight, for 1PH4 > refer to Table 3-11 in Section 1PH4 for 1PH7 > refer to Table 3-60 in Section 1PH7 AL/2-26

27 12.01 General Information on AC Induction Motors 2.2 Termination system 2.2 Termination system Connecting AC motors The following tables show the type of the terminal box used, number of terminals, cross sections which can be connected, number of auxiliary terminals and cross section for PE connection. AL Table 2-2 Motor Shaft height 100 Shaft height 132 Shaft height 160 Overview, connection system for 1PH4 motors No. of main terminals Max. cross section which can be connected Terminal strip for temperature sensor PE connection size/ cable lug width 3xM5 16 mm 2 3 terminals M4/9 mm 3xM5 3xM10 35 mm 2 with cable lug connection 70 mm 2 with cable lug connection 3 terminals M5/15 mm 3 terminals M6/15 mm Table 2-3 Motor Shaft height 100 Shaft height 132 Shaft height 160 Shaft height 180 Shaft height 225 Overview, termination system for 1PH7 motors No. of main terminals Max. cross section which can be connected Terminal strip for temperature sensor PE connection, size/ cable lug width 6xM5 25 mm 2 3 terminals M5/9 mm 6xM6 6xM6 3xM12 3xM12 35 mm 2 with cable lug connection 50 mm 2 with cable lug connection 2 x 50 mm 2 with cable lug connection 2 x 50 mm 2 with cable lug connection 3 terminals M6/15 mm 3 terminals M6/15 mm 4 terminals Without cable lug using a terminal clamp 1) 4 terminals Without cable lug using a terminal clamp 1)! Caution Observe the motor current requirement for your application! Adequately dimension the connecting cables corresponding to IEC ) Cable cross section, corresponding to the line conductor cross section AL/2-27

28 General Information on AC Induction Motors 2.2 Termination system AL Power cable Motor 1/U 2/V SIMODRIVE connector sleeves acc. to DIN U V 6/W W Note The cables are available in a UL version or for higher mechanical requirements. Technical data is listed in Catalog NC Z. Connection information Note The system compatibility is only guaranteed when using shielded power cables. Shields and the shielding system must be incorporated in the overall grounding concept. Open or unused cores/electrical cables/conductors which can be touched must be connected to protective ground. If the brake feeder cables in the SIEMENS cable accessories are not used, then the brake conductor cores and shields must be connected to the cabinet ground. (open circuit cables result in capacitive charging effects!)! Warning Before carrying out any work on the AC motor, ensure that it is powered down and is locked out so that it cannot be powered up again! Carefully observe the rating plate data and circuit diagram in the terminal box. Adequately dimension the connecting cables. The motor cables should either be twisted or three core cables with additional ground cable should be used. The insulation from the ends of the cables should be removed so that the remaining insulation extends up to the cable lug or the terminal. The connecting cables must be freely arranged in the terminal box so that the protective conductive is somewhat longer than is absolutely necessary and the cable core insulation cannot be damaged. It should be ensured that the connecting cables are strain relieved. Please ensure that the following minimum air clearances are maintained: Supply voltages up to 500 V: Minimum air clearance 4.5 mm AL/2-28

29 12.01 General Information on AC Induction Motors 2.2 Termination system After connecting up, it should be checked that the inside of the terminal box is clean and there are no bits of cables in it, all of the terminal screws are screwed tightly, the minimum air clearances are maintained, the cable entries are reliably sealed, unused cable entries are closed and the caps are tightly screwed in and all of the sealing surfaces are in a good condition. For air cooled motors, the cooling ducts, through which the ambient air flows, should be regularly cleaned depending on the degree of pollution at the mounting location. These air ducts can be cleaned, e.g. using dry, oil free compressed air. For totally enclosed fan cooled machines, the inside of the motor can be cleaned during standard service/maintenance intervals. For water cooled motors, the cooling conditions (intake temperature, liquid quantity, cooling power) must be maintained. If required, the cooling medium should be cleaned using filters before it is fed into the motor cooling circuit. AL Press drive Note For press drives with acceleration rates > 2 g, special measures are required. You can obtain these from your local Siemens office. AL/2-29

30 General Information on AC Induction Motors Termination system AL Cross sections When connecting cables/conductors at the terminal board, the connecting cables should be dimensioned corresponding to the rated current and the cable lug sizes should be selected to match the terminal stud dimensions. Table 2-4 specifies the current load capability acc. to EN for PVC insulated cables with copper conductors for an ambient temperature of 40C and routing type C (cables and conductors routed along walls/panels and in cable ducts). Table 2-4 I rms at +40 C [A] Current load capability Cross section required[mm 2 ] Comments Correction factors with reference to ambient temperature and routing type are specified in EN Order No., power cable Table 2-5 Power cables for 1PH motors (available by the meter) No. of cores x cross section [mm 2 ] Power cable (available by the meter) Order No. 4 x 1.5 6FX A0 4 x 2.5 6FX A0 4 x 4 6FX A0 4 x 6 6FX A0 4 x 10 6FX A0 4 x 16 6FX A0 4 x x 1.5 6FX008-1BA25 - A0 4 x x 1.5 6FX008-1BA35 - A0 4 x x 1.5 6FX008-1BA50 - A0 Draggable 8 Not draggable 5 (only with overall shield) without brake cable: with overall shield B B with brake cable: with overall shield B A (2 x 1.5) Available lengths for 25 mm 2 to 50 mm 2 10 m 1 B for 1.5 mm 2 to 50 mm 2 50 m 1 F 100 m 2 A for 1.5 mm 2 to 6 mm m 3 A (on request) 500 m 6 A The power cables for 1PH motors are selected according to the magnitude of the rated motor current I rated at +40 C acc. to Table 2-4. AL/2-30

31 12.01 General Information on AC Induction Motors 2.2 Termination system Signal cables The signal cable used is described in Section Encoders (GE). Pre assembled cables offer many advantages with respect to cables which are assembled by customers. In addition to having the security that they function perfectly and the high quality, there are also cost advantages. In order to avoid disturbing effects (e.g. as a result of EMC), the signal cables must be routed separately away from power cables. AL Note Please use power and signal cables from the MOTION-CONNECT family (refer to Catalog NC Z). Please observe the maximum cable length specified in the connection overviews. Technical data is provided in Catalog NC Z. AL/2-31

32 General Information on AC Induction Motors 2.2 Termination system Space for your notes AL AL/2-32

33 12.01 General Information on AC Induction Motors 3 Engineering Engineering 3 AL Selection When selecting a suitable 1PH motor, a differentiation must be made between the following three cases: Case 1: The motor essentially operates in continuous duty. Case 2: A periodic load duty cycle defines how the drive is dimensioned. Case 3: A wide field weakening range is required. Case 1 A motor should be selected whose S1 output is the same or greater than the required drive output. Using the P/n diagrams, a check should be made as to whether the power is available over the required speed range. It may be necessary to select a larger motor. Case 2 The load duty cycle determines how the drive is dimensioned. It is assumed that the speeds during the load duty cycle lie below the rated speed. If the torques during the load duty cycle are not known, but only the power, then the power can be converted into a torque using the following equation: M = P 9550/n, M in Nm, P in kw, n in RPM The torque to be generated by the motor comprises the frictional torque M friction, the load torque of the driven machine M load and the accelerating torque M B : M = M friction + M load + M B AL/3-33

34 General Information on AC Induction Motors 3 Engineering The accelerating torque M B is calculated as follows: M B = π 30 J motor+load n t B = J Motor+load n 9.55t AL M B J motor+load n t B Accelerating torque in Nm referred to the motor shaft (on the motor side) Total motor moment of inertia in kgm 2 (on the motor side) Speed range in RPM Accelerating time in s M M 2 = M max (cycle) M 1 M 1 M 4 M 3 t t 1 t 2 t 3 t 4 t 5 T Fig. 3-1 Load duty cycle with 1PH7 motor The RMS torque M rms must be calculated from the load cycle: M rms = 2 2 M 1 t 1 + M 2 t 2... T Motor selection A differentiation should be made depending on the period T and the thermal time constant T th, which is dependent on the shaft height: T/T th 0.1 (for a period duration of 2 to 4 min) A motor with rated torque M n should be selected: M n > M rms and M max (cycle) < 2M n 0.1 T/T th 0.5 (for a period duration of between approx. 3 min and 20 min) A motor with rated torque M n should be selected: M n > M rms and M max (cycle) < 2M n T Tth T/T th > 0.5 (for a period duration of approx. 15 min) If, during the load duty cycles, torques above M n occur for longer than 0.5 T th, then a motor with a rated torque M n > M max (cycle) should be selected. AL/3-34

35 12.01 General Information on AC Induction Motors 3 Engineering Drive converter selection The required currents for overload are specified in the power speed diagrams (powers for S6 25 %, S6 40 %, S6 60 %). Intermediate values can be interpolated. Example: Moment of inertia of the motor + load: J = 0.2 kgm 2, friction can be neglected. AL n Traversing diagram, speed 1. Cycle 2. Cycle 1 s 120 s 60 s 1 s 60 s 2.5 s T on = s T = s 230 s T off = 230 s t [s] M L [Nm] Nm 30 Nm 36 Nm 20 M [Nm] 48 Load cycle diagram t [s] Nm 36 Nm Nm Nm t [s] Nm 12.6 Nm Motor torque curve Fig. 3-2 Load duty cycle for the example AL/3-35

36 General Information on AC Induction Motors 3 Engineering Calculating the accelerating torques: M B = J n 9.55t a AL Acceleration for 1 s from 0 to 2000 RPM: M B = Nm = 41.8 Nm 42 Nm Braking for 1 s from 2000 to 1500 RPM: M B = 0.2( 500) = 10.5 Nm Braking for 2.5 s from 1500 to 0 RPM: M B = 0.2( 1500) = 12.6 Nm Max. torque M max : 42 Nm for 1 s Calculating the RMS motor torque in the operating cycle M rms = M 1 t 1 + M 2 t M n t n T M rms = ( 10.5) ( 12.6) M rms = 24.7 Nm 25 Nm Motor selection: With the data: Speed 2000 RPM Max. motor torque M max 42 Nm RMS motor torque: 25 Nm a motor with n n = 2000 RPM, M n 25 Nm is selected. Drive converter selection From the power speed diagram: The power at rated speed and 42 Nm maximum torque should be entered. The current demand can be calculated from the characteristics. AL/3-36

37 12.01 General Information on AC Induction Motors 3 Engineering Case 3 A higher field weakening range is required For applications requiring a field weakening range greater than that for standard 1PH motors, as is listed in the motor Sections, proceed as follows: Starting from the max. speed n max and the power P max specified there, a motor should be selected which provides the required power P max at this operating point (n max, P max ). Finally, a check should be made as to whether the motor can generate the torque or the power at the transition speed required by the application (n n, P n ). Example: A power P max = 8 kw is required at n max = 5250 RPM. The field weakening range should be 1 : 3.5. The transition speed, required by the application, would then be 5250/3.5 RPM = 1500 RPM. The power speed diagram indicates, as solution, a motor with e.g. P n = 9 kw, n n = 1500 RPM, M n = 57 Nm. AL AL/3-37

38 General Information on AC Induction Motors 3 Engineering Space for your notes AL AL/3-38

39 1PH2 AC Built-in Motor 1 Motor Description PH2/ Features and technical data PH2/ Cooling PH2/ Machine safety PH2/ Mounting PH2/ Rotor PH2/ Stator PH2/ Electrical connection PH2/ Order Designations PH2/ Technical Data and Characteristics PH2/ Power speed diagrams PH2/ Built in motors with sleeve PH2/ Built in motors without sleeve PH2/ Dimension Drawings PH2/4-85 1PH2 1PH2-39

40 12.01 Space for your notes 1PH2 1PH2-40

41 PH2 AC Built-in Motor 1.1 Features and technical data Motor Description Features and technical data Applications The 1PH2 series was developed for the closed loop speed controlled operation of main spindles for turning, milling, grinding and for machining centers. The built in motor is a compact drive solution where the mechanical motor output is directly transferred to the spindle without any mechanical transition elements. Features 1PH2 motors are liquid cooled induction motors which are supplied in the form of components. A complete motor spindle unit is obtained after the motor components have been mounted on the spindle. This motor series has been adapted to the requirements of lathes, milling machines and machining centers. They differ as far as the following points are concerned: 1PH2 with sleeve: The rotor with sleeve is completely machined. Additional machining/working after mounting is not required. Max. speed: up to RPM. torque: up to 750 Nm (S1 duty). The torque is transferred to the spindle without any play, force locked through a cylindrical stage press fit. The rotor with sleeve is pre balanced and can be disassembled. 1PH2 without sleeve: The rotor is completely machined. Additional machining/working after assembly is not required. This version does not have a sleeve which results in a lower moment of inertia and minimized accelerating times. Max. speed up to: RPM. torque: up to 250 Nm (S1 duty). The torque is transferred to the spindle without any play, force locked through a cylindrical stage press fit. For motors without sleeve, it is not possible to disassemble the rotors without causing some damage. The rotor without sleeve is not balanced. It is possible to mount the rotor onto conventional spindles It is possible to route through tool clamping systems, compressed air and cooling medium lines/pipes. 1PH2 1PH2/1-41

42 1PH2 AC Built-in Motor 1.1 Features and technical data Technical features Note The motors (exception, 1PH218. and 1PH225.) can be supplied from a DC link voltage up to DC=700 V. Table 1-1 Motors 1PH2 1PH2 Technical feature Machine type Type of construction (similar to ISO) Degree of protection (acc. to EN ; IEC ) Cooling Thermal motor protection (acc. to IEC ) Winding insulation (acc. to IEC 60034) Motor voltage Version Induction motor with squirrel cage rotor Individual components: Stator, rotor, motor encoder IP 00 Water cooling with T H2O = 25 C and Q = 8 l/min 2 PTC thermistor (1 sensor as reserve) Temperature rise class F for a cooling medium temperature of +25 C Max.: 3 ph. 430 V AC Speed control range > 1: Connection type Motor: Free cable ends with l = 1.5 m, preferably l = 0.5 m Motor encoder: Plug connection (flange mounted socket is supplied with the encoder system) PTC thermistor: via the motor encoder plug connector Encoder system 1) Toothed wheel encoder 1) SIZAG2 (not included) Balancing quality Rotors with sleeve are pre balanced; Rotors without sleeve are not balanced Fig PH2 rotor and stator 1) The motor is only conditionally capable of C axis operation due to the lower actual value resolution when using SIZAG 2 (256/512 increments per revolution). Refer to the Section, Encoder Systems (GE), Chapter Toothed Wheel Encoders SIZAG. 1PH2/1-42

43 PH2 AC Built-in Motor 1.1 Features and technical data Design Typical mounting Incremental encoder for position and speed sensing Stator Rotor with sleeve Cooling medium outlet Cooling medium intake 1PH2 Free cable ends + 2 PTC thermistors for temperature monitoring Pressurized oil bore to release the rotor Cooling jacket with groove O rings Fig. 1-2 Typical installation by directly mounting the rotor onto the main spindle Scope of supply Completely machined rotor Stator with winding, cooling jacket with groove and O rings 1PH2/1-43

44 1PH2 AC Built-in Motor 1.1 Features and technical data Technical data Table 1-2 1) current for the operating mode acc. to IEC [A] I rated Engineering data Ordering and engineering data for standard motors S1 S6 60 % S6 40 % motor output for the operating mode acc. to DIN VDE ) P rated [kw] S1 T = 70 K S1 T = 105 K S6 60 % S6 40 % PH2 voltage No load current torque Max. speed speed AC Main spindle motor [V] V N [A] 0 I M [Nm] n max n rated T = 105 K T = 70 K Order No. Built in motors with sleeve, rated speed 1500 RPM PH WF4 1PH WF PH WF4 1PH WF4 1PH WF4 1PH WF4 Built in motors with sleeve, rated speeds 750 RPM, 600 RPM, 500 RPM PH WC PH WP PH WB PH WB PH WB41 1PH WB Built in motors without sleeve, rated speed 2000 RPM or 1500 RPM PH WG42 1PH WG PH WF42 1PH WF42 1PH WF PH WF42 1PH WF42 1) Data for T = 70 K and rated speed, if not specified differently Winding temperature rise T = 105 K: 1PH2 built in motors can also be utilized with T = 70 K instead of a winding temperature rise of T = 105 K. This means that a higher torque is available from the same motor envelop dimensions (refer to Table 1-2). In this case, the user must observe that increased temperatures will be present at the spindle bearings. Furthermore, larger main spindle modules must be selected than for T = 70 K (on request). In order to achieve the operational values, it is important to maintain the specific cooling and mounting conditions. 1PH2/1-44

45 PH2 AC Built-in Motor 1.1 Features and technical data Dimensions Table 1-3 Dimensions, 1PH2 motor Main spindle motor Type Built in motors with sleeve 1PH2093 6WF4 1PH2095 6WF4 1PH2113 6WF4 1PH2115 6WF4 1PH2117 6WF4 1PH2118 6WF4 1PH2182 6WC41 1PH2184 6WP41 1PH2186 6WB41 1PH2188 6WB41 1PH2254 6WB41 1PH2256 6WB41 Built in motors without sleeve 1PH2092 4WG42 1PH2096 4WG42 1PH2123 4WF42 1PH2127 4WF42 1PH2128 4WF42 1PH2143 4WF42 1PH2147 4WF42 Standard spindle diameter d [mm] Inner rotor diameter d i [mm] Outer stator diameter D A [mm] Overall outer diameter D [mm] Total length L [mm] PH2 Rotor with sleeve L Rotor without sleeve L D D A d i d D D A d i Hollow shaft Rotor Sleeve Air gap Stator Hollow shaft Rotor Air gap Stator Fig. 1-3 Dimensions 1PH2/1-45

46 1PH2 AC Built-in Motor 1.1 Features and technical data Assignment Motor drive converter The following current data refer to the SIMODRIVE 611 analog and digital drive converter system. Table 1-4 Assignment, motor drive converter 1PH2 Motor type Built in motors with sleeve 1PH2093 1PH2095 1PH2113 1PH2115 1PH2117 1PH2118 1PH2182 1PH2184 1PH2186 1PH2188 1PH2254 1PH2256 Built in motors without sleeve 1PH2092 1PH2096 1PH2123 1PH2127 1PH2128 1PH2143 1PH2147 Power module 24/32/32 A 30/40/51 A 60/80/102 A 60/80/102 A 60/80/102 A 85/110/127 A 45/60/76 A 60/80/102 A 85/110/127 A 85/110/127 A 120/150/193 A 120/150/193 A 24/32/32 A 45/60/76 A 60/80/102 A 85/110/127 A 120/150/193 A 120/150/193 A 120/150/193 A 1PH2/1-46

47 PH2 AC Built-in Motor 1.2 Cooling 1.2 Cooling The stators of built in motors are liquid cooled. The user connects the cooling ducts to the cooling circuit. The following conditions must be maintained: Cooling medium and cooling quantity An anti corrosion agent (e.g Tyfocor) should be added to the water. For Tyfocor, the following ratio should be maintained: Water: 75 % Anti corrosion agent: 25 % A sufficient thermal transition can be achieved with a flow rate of: 8 l/min When using another cooling medium (e.g. oil, cooling lubricating medium), it may be necessary to de rate the motor in order to limit the thermal loading of the spindle bearings. The following properties of the cooling medium must be available in order to calculate the de rating: Specific gravity ρ [kg/m 3 ] Specific thermal capacitance c p [J/(kgK)] Note The motor output does not have to be reduced (de rated) for oil water mixtures with less than 10% oil. The cooling medium must pre cleaned or filtered in order to avoid cooling circuit blockages. 1PH2 The maximum permissible particle size after filtering: 100 µm The cooling duct geometry is designed so that the stator power loss and some of the rotor losses are dissipated. The geometry is identical for all built in motors. Cooling medium pressure Maximum pressure drop at the motor: Maximum pressure at the intake: 0.3 bar 7.0 bar Cooling medium intake temperature Recommendation: 25 C In order to avoid moisture condensation, the cooling medium intake temperature can be up to 40 C, depending on the ambient temperature. The motors are designed for operation up to a cooling medium temperature of 40 C, but still maintaining all of the specified motor data. In this case, often, additional thermal de coupling must be provided between the motor components and the spindle bearings in order to avoid critical bearing temperatures. 1PH2/1-47

48 1PH2 AC Built-in Motor 1.2 Cooling Cooling powers For a cooling medium temperature of 25 C, the following cooling powers to dissipate the heat must be provided in continuous operation: Table 1-5 Cooling powers Built in motors with sleeve Motor type Cooling power [W] 1PH2093 1PH2095 1PH2113 1PH2115 1PH2117 1PH2118 1PH2182 1PH2184 1PH2186 1PH2188 1PH2254 1PH Built in motors without sleeve Motor type 1PH2092 1PH2096 1PH2123 1PH2127 1PH2128 1PH2143 1PH2147 Cooling power [W] Cooling units In order to guarantee the cooling medium intake temperature of 20 C, a cooling unit should be used (i.e. heat exchanger). 1PH2 Cooling unit 2 1 1PH2 3 Motor spindle 4 1 Filter 1) 2 Flow quantity display 1) 3 Setting valve Flow quantity 1) Pump Cooling medium reservoir Compressor/heat exchanger 6 Temperature sensing, cooling medium 1 ) Components are not absolutely required Fig. 1-4 Example of a cooling circuit It is possible to operate several motors from one cooling unit. The cooling units are not part of the scope of supply of 1PH2 motors. 1PH2/1-48

49 PH2 AC Built-in Motor 1.2 Cooling Table 1-6 Helmut Schimke Industriekühlanlagen Ginsterweg Haan Tel.: 02129/ Fax: 02129/ Manufacturers of cooling systems for water cooled motors Hyfra Industriekühlanlagen Industriestr Krunkel Tel.: 02687/8980 Fax: 02687/89825 Riedel Kältetechnik Äuß. Bayreuther Str Nürnberg Tel.: 0911/ Fax: 0911/ KKT Kraus Industriekühlung Industriestr Lauf Tel.: 09123/ Fax: 09123/ PH2 1PH2/1-49

50 1PH2 AC Built-in Motor 1.3 Machine safety Machine safety! Caution Electrical systems should be designed and constructed so that they do not represent potential sources of danger. Information and instructions are specified in VDE 0113 (EN ). Degree of protection The motor components have degree of protection IP 00. The spindle manufacturer defines the final degree of protection as a result of the spindle housing. Protection against contact, foreign bodies and water for electrical equipment is specified acc. to DIN IEC 34 Part 5. Recommended: IP 44 (Minimum degree of protection) 1PH2 Shock hazard protection! Caution In order to prevent accidents caused by coming into contact with active parts, protective measures are required, both against direct as well as against indirect contact. Information is provided in DIN VDE 0100, Part 410 and DIN VDE 0106, Part 100. Note When grounding, it should be observed that there is conductive transition between the protective conductor and spindle box and is protected against corrosion (e.g. connecting surfaces are bare and have a coating of Vaseline). Protection against indirect contact The stator assembly is connected to the cooling jacket so that there is an electrical connection. In order to guarantee an adequate electrical connection to the spindle box, the cooling jacket must be connected to the spindle box so that there is a good electrical connection. The cross section is the effective contact surface. The spindle manufacturer is responsible for grounding/earthing the complete motor spindle in compliance with the relevant regulations 1PH2/1-50

51 PH2 AC Built-in Motor 1.3 Machine safety Recommended grounding Protection against hazardous currents flowing through the human body (example for protective conductor connection) Connecting surfaces for grounding and protective conductors acc. to DIN Grounding and protective conductor Spindle box Cooling jacket Fig. 1-5 Recommended grounding, motor spindle High voltage test! Before the stators of built in motors are shipped, they are subject to a high voltage test in accordance with VDE However, the Standards Commission recommends, when installing electrical components (such as, e.g. built in motors), that after the components have been finally mounted, the system is subject to a high voltage test in compliance with VDE Warning If the user carries out an additional high voltage test, then the cable ends of the temperature sensors must be short circuited before this test! If the test voltage is connected to a temperature sensor, then this sensor will be destroyed. 1PH2 Thermal motor protection A PTC thermistor is integrated in the stator winding to sense the motor temperature. Technical data, refer to the Section, Transmitters (GE). The signal is sensed and evaluated in the drive converter, whose closed loop control takes into account the temperature characteristics of the motor resistances. An external tripping unit is not required. The PTC thermistor function is monitored. An appropriate signal is output to the drive converter when a fault condition develops. When the motor temperature increases, an alarm, motor overtemperature, signal is output, which must be externally evaluated. If this signal is not observed, the drive converter trips when the motor limiting temperature is exceeded, and an appropriate fault signal is output. Note When connecting up, observe the polarity! The PTC thermistor characteristic depends on the polarity. Polarity: 1PH2092 to 1PH2147 Brown conductor = +Temp White conductor = Temp 1PH2182 to 1PH2256 Yellow conductor = +Temp Green conductor= Temp 1PH2/1-51

52 1PH2 AC Built-in Motor 1.4 Mounting Mounting Rotor Design The squirrel cage rotor has an inner bore which is machined to the final dimensions. Note Built in motors with sleeve: The rotor is located on an inner sleeve with stage press fit. The fit between the rotor and spindle can be released using pressurized oil without changing the joint surfaces. Built in motors without sleeve: The forces transferred without any play and without using a sleeve which results in lower moments of inertia. The rotor bore allows hollow spindles to be used through which tool clamping systems, compressed air and cooling medium lines can be routed. 1PH2 The spindle manufacturer mounts the rotor on the spindle using a thermal operation. In order to guarantee play free and force locked torque transfer, the spindle, in the area of the press fit, must be machined with the specified dimensions and tolerances. Dimensions The dimensions can be taken from the dimension drawings in Section 4. A minimum spindle wall thickness is required in the area of the press fit: Table 1-7 Spindle wall thickness Motor types Built in motors with sleeve 1PH PH PH PH Built in motors without sleeve 1PH PH PH Spindle wall thickness [mm] Pressurized oil connection (only for 1PH2 motors with sleeve) The pressurized oil connections to disassemble the rotor are located in the rotor. If an outer spindle diameter is required which exceeds the standard value, then the bores for the oil pressure disassembly must be located in the spindle. The spindle must have a larger inner diameter at the introduction zone in order to allow centered mounting without damaging the inner rotor bore. 1PH2/1-52

53 PH2 AC Built-in Motor 1.4 Mounting Mounting! Warning Safe working procedures must be ensured and guaranteed when assembling and disassembling the rotor/spindle assembly and when re using parts and components which have been disassembled. The information and instructions in DIN should be carefully observed. Preparation The rotor is thermally mounted onto the spindle. The following preparatory measures must be first carried out: The operation should take place in a dry, dust free environment. Suitable tools and equipment must be used. The jointing surfaces must be free of any accumulated dirt, machining grooves and damage which could diminish the build up of a pressurized oil film when disassembling the rotor/spindle assembly 1). The anti corrosion agent on the jointing surfaces of the rotor sleeve must be removed. Clean the oil connection bores 1). The plugs should be unscrewed from the oil connection bores. Preparing the mounting equipment and set up: A recommended mounting procedure is shown in Fig In this case, a set up for vertical mounting is prepared so that the hot rotor is supported in the vertical position where it can accept the spindle. 1PH2 1) only for built in motors with sleeve 1PH2/1-53

54 1PH2 AC Built-in Motor 1.4 Mounting PH2 Fig. 1-6 Mounting the rotor onto the spindle Introducing the rotor into the spindle Heat up the rotor in an oven to T = 180 C up to max. 200 C. Note Observe the hazards due to components and parts at high temperatures. Maximum spindle temperature before mounting: 30 C Quickly introduce the spindle to the correct position. Allow the rotor and spindle to cool down to room temperature. Re close the oil connection bore with the threaded plugs supplied and secure them using Loctite 243 1). After the rotor/spindle assembly has been mounted for the first time, we recommend that the rotor position with respect to the spindle is marked on the face side 1). This means that if the rotor is subsequently mounted, it is not necessary to fine balance the complete spindle. Check the concentricity. The maximum radial eccentricity of the outer rotor diameter referred to the spindle axis is 0.05 mm. 1) only for built in motors for lathe applications 1PH2/1-54

55 PH2 AC Built-in Motor 1.4 Mounting If, after room temperature has been reached, the parts are not in the required position with respect to one another, then they can be re aligned using pressurized oil 1). In so doing, the information and instructions in the Section, Disassembly, must be carefully observed. Recommended viscosity of the disassembly fluid: 300 mm 2 /s at 20 C After the procedure has been completed, the oil must flow out between the joint surfaces. Full load can be applied to the rotor spindle assembly after approx. 24 hours. Disassembly Built in motors with sleeve When servicing the spindle (e.g. changing the bearings), it may be necessary to disassemble the spindle. The rotor can be released from the spindle axis using pressurized oil. The following procedure should be followed:! Warning Observe all of the relevant safe working procedures when releasing the rotor from the spindle! Provide a protective barrier, e.g. Perspex panel. Release the two studs on the face of the rotor and check that the areas around the oil connection bores are free of any accumulated dirt. Mount the spindle in a vertical position so that the oil connection bores are located horizontally above one another and provide an endstop. The rotor can suddenly release when the oil pressure is being established! Arrange a set up which holds the rotor (refer to Fig. 1-7). Connect a suitable manually operated oil pump to one of the two oil connection bores. The manual oil pump must have a manometer to be able to measure the oil pressure. Pump oil into the joint between the rotor spindle through the lower bore until the oil is discharged through the upper oil connection bore. Close the oil connection bores with the studs provided. For disassembly, a disassembly fluid with a viscosity of 900 mm 2 /s at 20 C (e.g. LH DF 900 from SFK) is recommended. 1PH2 Table 1-8 Max. oil pressure Motor type 1PH PH PH PH Max. oil pressure p max 800 bar 800 bar 600 bar 770 bar If the pressure increases above the values specified above, the operation must be immediately stopped. 1) only for built in motors with sleeve 1PH2/1-55

56 1PH2 AC Built-in Motor 1.4 Mounting Slowly increase the pressure in the rotor spindle assembly up to approximately 2/3 p max and maintain it at this level for approx. 15 min so that the oil can be distributed and can penetrate the complete joint. Please ensure that the oil pressure does not decrease during this time. Then release the rotor from the spindle by increasing the pressure step by step, closely monitoring the oil pressure.! Warning Carefully observe the maximum oil pressure! After a separating oil film has been established between the jointing surfaces, the axial force, obtained from the various, graduated diameters, allows the rotor to slide away without having to apply external force. Removing the rotor from the spindle. The release pressure causes radial and tangential stressing in the various components. When selecting a suitable spindle material, the stressing, which occurs in the spindle when releasing the rotor, should be observed. Equations for ring shaped cross sections are defined, e.g. in DIN PH2 Connection for a manually operated hydraulic pump Connecting nipple (e.g. SKF type ) Extension pipe (e.g. SKF type ) Type Dim. Fig. 1-7 Disassembling built in motors with sleeve 1PH2/1-56

57 PH2 AC Built-in Motor 1.4 Mounting Built in motors without sleeve Generally, it is not possible to remove the rotor from the spindle without causing some damage. This should be taken into account in the mechanical design (e.g. when service is required, when changing bearings), so that the bearings on the drive and non drive ends can be disassembled. The rotor can be removed from the spindle, e.g. by cutting the rotor or by thermally releasing it. Balancing (acc. to VDI 2060, DIN ISO 1940) The rotors with sleeve are supplied in the following balance qualities: (reference speed, 3600 RPM) Table 1-9 Balance quality Motor types Built in motors with sleeve 1PH PH PH PH Balance quality G 2.5 G 2.5 G 2.5 G 2.5 Rotors without sleeve are not balanced. 1PH2 D B U 1) 1PH gmm 1PH PH gmm 1500 gmm Balancing disk (not included in the scope of supply) material: steel Fig. 1-8 Recommended, balancing disk for built in motors without sleeve After the rotor has been mounted onto the spindle, it may be necessary to finely balance the complete rotor spindle system. The balancing planes required should be provided on the spindle system. It is not permissible to remove material from the short circuit ring. 1) Necessary adjustment for each balancing disk 1PH2/1-57

58 1PH2 AC Built-in Motor 1.4 Mounting Stator Design The stators of built in motors comprise a wound stator core, which is pressed into a cooling housing. An open, spiral cooling duct is machined into the outer side of the cooling housing. The spindle manufacturer must mount the stator into a spindle housing. Dimensions The dimensions should be taken from the dimension drawings in Section 4. 1PH2 Spindle housing The spindle housing seals off the open stator cooling duct tothe outside. In this case, the inner contour of the spindle housing must fit, in the stator area, the outer cooling jacket contour. The spindle housing must fulfill the following functions: Seal the open cooling duct towards the outside. Center the stator with respect to the spindle. Accept the spindle with bearings. Cooling medium intake and outlet Accept the torque of the stator. Retain the spindle in the machine tool. Degree of protection of the motor spindle acc. to IEC 34, Part 5/VDE 0530, Part 5. A water drain hole is provided at the lowest point on the drive and non drive ends to allow condensation water to drain (acc. to DIN IEC 34, S10; Code 5b). The following minimum insulating clearances (minimum air distances) should be observed: Table 1-10 Minimum insulating clearances Supply voltage in [V] to 660 Minimum air clearance in [mm] PH2/1-58

59 PH2 AC Built-in Motor 1.4 Mounting Hoisting harness/assembly Ring nut Distance sleeve Stator with cooling jacket Spindle box Fig. 1-9 Transport and installation of the built in stator 1PH2 Mounting The spindle manufacturer mounts and bolts the stator into the spindle housing. The following procedure should be observed: The stator should be mounted in a dry, dust free environment. Only suitable tools and equipment should be used. The joint surfaces and O ring grooves must be free of any accumulated dirt, machining scores, swarf and damage. Any sharp edges in the spindle housing should be carefully removed. In order to guarantee a tight seal and for disassembly, a suitable anti corrosion agent should be applied between the spindle housing and the cooling jacket, which does not come into contact with the cooling liquid. Install and lightly grease the 4 O rings. Allow the stator to slide, centered into the spindle housing (refer to Fig. 1-9). Suitable transport lugs should be used to hoist the built in stators, e.g. ring bolts acc. to DIN 580. Bolt the face side of the stator to the spindle housing. The bolts must be evenly tightened, carefully measuring the torque. In order to check that the O ring seals are tight, the motor spindle cooling duct should be filled with a fluid and the pressure of this fluid continuously increased up to 7 bar. If there are any leaks, the sealing joints/surfaces and the O rings should be checked, and if required, replaced. 1PH2/1-59

60 1PH2 AC Built-in Motor 1.4 Mounting Electrical connection The connecting cables are brought out as free cable ends and as standard have the following conductor cross sections (Cu) or outer diameter: Connecting cables Table 1-11 Conductor cross section of the connecting cable Motor type Cable cross section [mm 2 ] Outer cable diameter [mm] Built in motors with sleeve 1PH2093 1PH2095 1PH2113 1PH2115 1PH2117 1PH2118 1PH2182 1PH2184 1PH2186 1PH2188 1PH2254 1PH max. 5.6 max. 7.2 max. 7.2 max. 9.2 max. 11 max. 11 1PH2 Built in motors without sleeve 1PH2092 1PH2096 1PH2123 1PH2127 1PH2128 1PH2143 1PH Information and instructions for using cables is provided in VDE 0298, Part 3. We recommend that the free cable ends are brought out of the spindle box in a suitable protective tubing with cable gland. It should be ensured that the cables are effectively strain relieved. 1PH2/1-60

61 PH2 AC Built-in Motor 2 Order Designations Order Designations 2 Order designation The order designation comprises a combination of digits and letters. It is subdivided into three hyphenated blocks. The first block is made up of seven positions and designates the motor type. Additional features are coded in the second block. The third block is provided for additional data. 1 P H Z Built in induction motors Frame size 09: D A = 180 mm 11: D A = 220 mm 12: D A = 235 mm 14: D A = 280 mm 18: D A = 280 mm 25: D A = 390 mm 1PH2 Length Pole number Cooling type W = Liquid cooling speed B = 500 RPM P = 600 RPM C = 750 RPM F = 500 RPM G = 2000 RPM Winding version 4 = normal version Built in motor 4 pole: 6 pole: 1 = with sleeve 1 = 1.5 m cable length 2 = without sleeve 2 = 0.5 m cable length Specify supplementary data in plain text 1PH2/2-61

62 1PH2 AC Built-in Motor 2 Order Designations Selection help In addition to the main electrical data (rated torque M rated, rated speed n rated, max. speed n max ), the required mounting dimensions must also be taken into account. A check should be made as to whether the overall diameter D as well as the total length L of the motor fit into the available mounting space. A check should also be made as to whether the inner bore d of the rotor can accept the spindle. In order to make it as simple as possible to select the most suitable built in motor, the following checklist should help you in determining the motor from Table 1-2. User: Machine: Date: Type: Checklist: torque M rated [Nm] speed n rated Max. speed n max Transition speed n 1 output P rated [kw] 1PH2 Mounting space: Outer motor diameter D [mm] Motor length L [mm] Spindle geometry: Outer spindle diameter in the motor area d [mm] Outer spindle diameter in the encoder area d Encoder [mm] Inner spindle diameter d s [mm] 1PH2/2-62

63 PH2 AC Built-in Motor 2 Order Designations P [kw] Power speed diagram P rated n rated n 1 n max n M rated P rated * 9.55 n rated (M rated in Nm) * d s 1PH2 *d Encoder Fig. 2-1 Explanation of the terminology in the checklist 1PH2/2-63

64 1PH2 AC Built-in Motor 2 Order Designations Space for your notes 1PH2 1PH2/2-64

65 PH2 AC Built-in Motor 3.1 Power speed diagrams Technical Data and Characteristics Power speed diagrams The built in motors must be continually cooled in operation, independent of the operating mode. Note Depending on the design of the motor spindle, varying levels of frictional losses occur (e.g. bearing losses, losses at rotating glands). The manufacturer of the built in motors does not know the magnitude of these losses. This means that the motor outputs and torques, specified in this documentation, refer to values which the built in motor rotor transfers to the spindle. In order to determine the net shaft output, all of the frictional losses must be subtracted from the specified values. The dotted lines in the diagrams indicate the output limit of the particular SIMODRIVE 611 for the specified built in motor. The power module is specified. 1PH2 1PH2/3-65

66 1PH2 AC Built-in Motor 3.1 Power speed diagrams Built in motors with sleeve Table 3-1 AC built in motor 1PH2093 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 24/32/32 A (S1) Power module 24/32/32 A (S6 40 %) PH S6 25 % S6 40 % (28 A) S6 60 % (28 A) S1 (24 A) n Fig. 3-1 Power speed diagram 1PH2093 6WF4 1PH2/3-66

67 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-2 AC built in motor 1PH2095 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 Power module 24/32/32 A (S6 40 %) P [kw] Power module 30/40/51 A (S1) Power module 30/40/51 A (S6 40 %) S6 25 % S6 40 % (34 A) S6 60 % (32 A) S1 (30 A) 1PH n Fig. 3-2 Power speed diagram 1PH2095 6WF4 1PH2/3-67

68 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-3 AC built in motor 1PH2113 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) PH S6 25 % S6 40 % (67 A) S6 60 % (61 A) S1 (56 A) n Fig. 3-3 Power speed diagram 1PH2113 6WF4 1PH2/3-68

69 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-4 AC built in motor 1PH2115 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) P [kw] S6 25 % S6 40 % (66 A) S6 60 % (60 A) S1 (55 A) 1PH n Fig. 3-4 Power speed diagram 1PH2115 6WF4 1PH2/3-69

70 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-5 AC built in motor 1PH2117 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) S6 25 % 1PH S6 40 % (74 A) S6 60 % (67 A) S1 (60 A) n Fig. 3-5 Power speed diagram 1PH2117 6WF4 1PH2/3-70

71 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-6 AC built in motor 1PH2118 6WF4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 85/110/127 A Power module 120/150/193 A (S1) S6 25 % S6 40 % (100 A) S6 60 % (90 A) S1 (82 A) 1PH n Fig. 3-6 Power speed diagram 1PH2118 6WF41 1PH2/3-71

72 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-7 AC built in motor 1PH2182 6WC4 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 Power module 45/60/76 A (S1) Power module 45/60/76 A (S6 40 %) P [kw] PH S6 40 % (52 A) S6 60 % (44 A) S1 (37 A) n Fig. 3-7 Power speed diagram 1PH2182 6WC4 1PH2/3-72

73 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-8 AC built in motor 1PH2184 6WP41 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) S6 40 % (80 A) S6 60 % (68 A) 1PH2 15 S1 (56 A) n Fig. 3-8 Power speed diagram 1PH2184 6WP41 1PH2/3-73

74 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-9 AC built in motor 1PH2186 6WB41 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) S6 40 % (87 A) 1PH S6 60 % (77 A) S1 (65 A) n Fig. 3-9 Power speed diagram 1PH2186 6WB41 1PH2/3-74

75 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-10 AC built in motor 1PH2188 6WB41 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 85/110/127 A Power module 120/150/193 A (S1) S6 40 % (103 A) 1PH2 30 S6 60 % (92 A) 25 S1 (78 A) n Fig Power speed diagram 1PH2188 6WB41 1PH2/3-75

76 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-11 AC built in motor 1PH2254 6WB41 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 120/150/193 A (S1) Power module 120/150/193 A (S6 40 %) 50 1PH S6 40 % (161 A) S6 60 % (141 A) 30 S1 (117 A) n Fig Power speed diagram 1PH2254 6WB41 1PH2/3-76

77 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-12 AC built in motor 1PH2256 6WB41 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] P [kw] Observe the cooling conditions! SIMODRIVE S6 40 % (158 A) Power module 120/150/193 A (S1) Power module 120/150/193 A (S6 40 %) 50 S6 60 % (143 A) S1 (119 A) 1PH n Fig Power speed diagram 1PH2256 6WB41 1PH2/3-77

78 1PH2 AC Built-in Motor 3.1 Power speed diagrams Built in motors without sleeve Table 3-13 AC built in motor 1PH2092 4WG42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 Power module 24/32/32 A (S1) P [kw] Power module 24/32/32 A (S6 40 %) 10 1PH S6 25 % 6 5 S6 40 % (25 A) S6 60 % (23 A) S1 (22 A) n Fig Power speed diagram 1PH2092 4WG42 1PH2/3-78

79 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-14 AC built in motor 1PH2096 4WG42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! SIMODRIVE 611 P [kw] Power module 45/60/76 A (S1) Power module 45/60/76 A (S6 40 %) S6 25 % S6 40 % (50 A) S6 60 % (46 A) S1 (43 A) 1PH n Fig Power speed diagram 1PH2096 4WG42 1PH2/3-79

80 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-15 AC built in motor 1PH2123 4WF42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 60/80/102 A (S1) Power module 60/80/102 A (S6 40 %) 20 S6 25 % 18 1PH S6 40 % (74 A) S6 60 % (64 A) 12 S1 (57 A) n Fig Power speed diagram 1PH2123 4WF42 1PH2/3-80

81 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-16 AC built in motor 1PH2127 4WF42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 85/110/127 A Power module 120/150/193 A (S1) S6 25 % S6 40 % (108 A) 1PH S6 60 % (97 A) S1 (85 A) n Fig Power speed diagram 1PH2127 4WF42 1PH2/3-81

82 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-17 AC built in motor 1PH2128 4WF42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 120/150/193 A (S1) Power module 120/150/193 A (S6 40 %) 50 1PH S6 25 % S6 40 % (132 A) 30 S6 60 % (116 A) 25 S1 (101 A) n Fig Power speed diagram 1PH2128 4WF42 1PH2/3-82

83 PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-18 AC built in motor 1PH2143 4WF42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 120/150/193 A (S1) Power module 120/150/193 A (S6 40 %) S6 25 % S6 40 % (132 A) 1PH2 36 S6 60 % (116 A) 30 S1 (101 A) n Fig Power speed diagram 1PH2143 4WF42 1PH2/3-83

84 1PH2 AC Built-in Motor 3.1 Power speed diagrams Table 3-19 AC built in motor 1PH2147 4WF42 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] Observe the cooling conditions! P [kw] SIMODRIVE 611 Power module 120/150/193 A (S1) Power module 120/150/193 A (S6 40 %) S6 25 % 1PH2 56 S6 40 % (153 A) 48 S6 60 % (136 A) 40 S1 (116 A) n Fig Power speed diagram 1PH2147 4WF42 1PH2/3-84

85 PH2 AC Built-in Motor 4 Dimension Drawings Dimension Drawings 4 Note Siemens AG reserves the right to change motor dimensions within the scope of mechanical design improvements without prior notice. Dimension drawings can become out of date. Updated dimension drawings can be requested at no charge. Version with sleeve 1PH209 6W motor dimensions PH209 6W rotor companion dimensions PH209 6W stator companion dimensions PH211 6W motor dimensions PH211 6W rotor companion dimensions PH211 6W stator companion dimensions PH218 6W motor dimensions (dimension drawing) PH218 6W rotor companion dimensions (spindle) PH218 6W stator companion dimensions (housing) PH225 6W motor dimensions (dimension drawing) PH225 6W rotor companion dimensions (spindle) PH225 6W stator companion dimensions (housing) PH2/4-86 1PH2/4-87 1PH2/4-88 1PH2/4-89 1PH2/4-90 1PH2/4-91 1PH2/4-92 1PH2/4-93 1PH2/4-94 1PH2/4-95 1PH2/4-96 1PH2/4-97 1PH2 Version without sleeve 1PH209V 4W motor dimensions PH209V 4W rotor companion dimensions PH209V 4W stator companion dimensions PH212V 4W motor dimensions PH212V 4W rotor companion dimensions PH212V 4W stator companion dimensions PH214V 4W motor dimensions PH214V 4W rotor companion dimensions PH214V 4W stator companion dimensions PH2/4-98 1PH2/4-99 1PH2/ PH2/ PH2/ PH2/ PH2/ PH2/ PH2/ PH2/4-85

86 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH209 6W motor dimensions 1PH2/4-86

87 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH209 6W rotor companion dimensions 1PH2/4-87

88 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH209 6W stator companion dimensions 1PH2/4-88

89 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH211 6W motor dimensions 1PH2/4-89

90 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH211 6W rotor companion dimensions 1PH2/4-90

91 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH211 6W stator companion dimensions 1PH2/4-91

92 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH218 6W motor dimensions (dimension drawing) 1PH2/4-92

93 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH218 6W rotor companion dimensions (spindle) 1PH2/4-93

94 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH218 6W stator companion dimensions (housing) 1PH2/4-94

95 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH225 6W motor dimensions (dimension drawing) 1PH2/4-95

96 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH225 6W rotor companion dimensions (spindle) 1PH2/4-96

97 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH225 6W stator companion dimensions (housing) 1PH2/4-97

98 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH209 4W motor dimensions 1PH2/4-98

99 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH209 4W rotor companion dimensions 1PH2/4-99

100 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH209 4W stator companion dimensions 1PH2/4-100

101 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH212 4W motor dimensions 1PH2/4-101

102 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH212 4W rotor companion dimensions 1PH2/4-102

103 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH212 4W stator companion dimensions 1PH2/4-103

104 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH214 4W motor dimensions 1PH2/4-104

105 PH2 AC Built-in Motor 4 Dimension Drawings 1PH2 Fig PH214 4W rotor companion dimensions 1PH2/4-105

106 1PH2 AC Built-in Motor 4 Dimension Drawings PH2 Fig PH214 4W stator companion dimensions 1PH2/4-106

107 1PH4 AC Main Spindle Motor 1 Motor Description PH4/ Features and technical data PH4/ Cooling PH4/ Degree of protection, thermal motor protection PH4/ Bearing concept PH4/ Vibration severity limit values PH4/ Options/accessories PH4/ Holding brake PH4/ Selector gearbox PH4/ Encoders PH4/ Mounting PH4/ Order Designations PH4/ Technical Data and Characteristics PH4/ Power speed diagrams PH4/ Cantilever force/axial force diagrams PH4/ Dimension Drawings PH4/ PH4 1PH4-107

108 12.01 Space for your notes 1PH4 1PH4-108

109 PH4 AC Main Spindle Motor 1.1 Features and technical data Motor Description Features and technical data Applications Features Technical features The 1PH4 series is suitable for the closed loop speed controlled operation of main spindles on machine tools, transfer lines and special purpose machines. For compact machine tool designs, the power loss from the electrical drives can have a negative impact on the machining precision. The resulting requirement for cold running motors resulted in the development of the water cooled 1PH4 AC main spindle motors. 1PH4 motors are water cooled squirrel cage induction motors. As a result of the compact design, high maximum speeds can be attained (up to (RPM)). Dependent on the shaft height, the 1PH4 series has rated outputs from 7.5 to 52 kw at rated speeds of 1500 RPM. The output of water cooled 1PH4 motors can be increased by up to 40 % over air cooled motors. The 1PH4 series is flange and shaft compatible to the air cooled 1PH7 AC motors. Note The motors can be fed from a DC link voltage of up to 700 V DC. 1PH4 Table 1-1 Standard motors Technical features Machine type Type of construction (acc. to IEC ) Degree of protection (acc. to IEC ) Cooling Thermal motor protection (acc. to IEC ) Winding insulation (acc. to IEC 60034) Motor voltage Motor noise (acc. to DIN 45635) Tolerance +3 db Version Induction motor with squirrel cage rotor IM B35, IM V15, IM V36 IP 65 (shaft gland cooling IP 55) Water cooling ( 25 C, otherwise de rating) PTC thermistor Temperature rise class F for a cooling medium temperature of +25 C Max.: 3 ph. 430 V AC Speed control range > 1: Terminal box arrangement to shaft height 132: max. 69 db (A) shaft height 160: max. 71 db (A) Top 1PH4/1-109

110 1PH4 AC Main Spindle Motor 1.1 Features and technical data Table 1-1 Standard motors Technical features Connection type Encoder system Balancing Shaft end Bearing version (A side) Flange version, concentricity (smooth running properties) Vibration severity (acc. to IEC ) Paint finish Version Motor: via terminal box Encoder: via signal connector Integrated optical encoder Speed sensing Indirect position sensing (incremental) Standard: Full key balancing (dynamic) (acc. to DIN ISO 8821) Cylindrical (acc. to DIN 748, Part 3); with keyway and key (acc. to DIN 6885); solid shaft (no keyway) to shaft height 132: Tolerance zone k6 shaft height 160: Tolerance zone m6 Double bearing design 1) (deep groove ball bearings and roller bearings) Tolerance N (acc. to DIN ) Level R Anthracite Options Table 1-2 Options 1PH4 Technical feature Version Terminal box arrangement Terminal box, mounted on the left or right Balancing Half key balancing (dynamic) (acc. to DIN ISO 8821) Code: H at the shaft face Shaft end Bearing version (A side) Flange version, concentricity (smooth running properties) Vibration severity (acc. to IEC ) Mounted/integrated components Rating plate Cylindrical; without keyway and without key (acc. to DIN 748, Part 3); solid shaft Tolerance zone k6 (up to shaft height 132) Tolerance zone m6 (up to shaft height 160) Single bearing design for coupling outdrive or planetary gear mounting; bearing design for increased speeds Tolerance R (acc. to DIN ) Level S (single/double bearing design) Level SR for shaft heights 100 to 160 (single bearing design) Selector gearbox Holding brake 2nd rating plate, supplied loose 1) Not suitable for coupling operation; min. cantilever force required. 1PH4/1-110

111 Motor type 1PH4... nrated Shaft height 100 mm nmax 2) Mrated I 0 (A) motor output for operating mode (acc. to EN ) Prated[kW] S1 S6 60 % S6 40 % motor current for operating mode (acc. to EN ) I rated[a] S1 S6 60 % 103 4NF NF NF Shaft height 132 mm S6 40 % Drive converter module for motor operating mode (acc. to EN ) [A] S1 1) 24/32 45/60 45/60 1) 133 4NF / NF / NF / NF /150 Shaft height 160 mm nmax with L37 2) (RPM) (RPM) (Nm) (RPM) 163 4NF NF NF U N (V) 120/ / /250 S6 60 % 24/32 45/60 45/60 S6 40 % 24/32 45/60 45/60 60/80 60/80 85/110 85/110 85/110 85/110 1) 120/ / / / / / /150 1) 200/250 Table 1-3 Technical data drive converter assignment, 1PH4 Technical data PH4/ ) possibly use a larger module; refer to the diagram 2) Max. speed for S1 and S6 duty, refer to power speed diagram; max. continuous operating speed, refer to Table 1 8 1PH4 AC Main Spindle Motor 1.1 Features and technical data 1PH4

112 1PH4 AC Main Spindle Motor Cooling 1.2 Cooling 1PH4 main spindle motors are water cooled in order to attain a high power density. Liquid cooling with a cooling unit is required for operation. Cooling medium An anti corrosion agent (e.g. Tyfocor, from the Tyfo company) should be added to the water. Please observe the ratio specified by the manufacturer. If Tyfocor is used, 75% water and 25% anti corrosion agent should be used. An adequate thermal transfer is achieved with a flow quantity of: 8l/min When using another cooling medium (e.g. oil, cooling lubricating medium) deep rating may be required in order that the thermal motor limit is not exceeded. The following cooling medium properties must be available when calculating the de rating: Specific gravity ρ [kg/m 3 ] Specific thermal capacity c p [J/(kgK)] Note The motor output does not have to be reduced (de rated) for oil water mixtures with less than 10% oil. The cooling medium must pre cleaned or filtered in order to avoid cooling circuit blockages. 1PH4 Maximum permissible pollution after filtering: 100 µm The cooling duct geometry is designed so that the power losses of the stator and part of the rotor losses are dissipated. The geometry is identical for all built in motors. Cooling medium inlet temperature Recommended: up to 25 C In order to avoid moisture condensation, depending on the ambient temperature, the cooling medium intake temperature can be up to 40 C. If the cooling medium temperature is increased, the rated output P N is reduced as follows: Table 1-4 output reduction Cooling medium temperature [ C] output reduction [%] PH4/1-112

113 PH4 AC Main Spindle Motor 1.2 Cooling Cooling powers and cooling quantity Table 1-5 Type Cooling power and cooling quantity Cold water flow [l/min] 0.75 Cooling power [W] Connection Max. permissible pressure [bar] 1PH4103 1PH4105 1PH G 1/4 1PH4133 1PH4135 1PH4137 1PH G 3/8 7 1PH4163 1PH4167 1PH G 1/2 Cooling units refer to Section 1.2 1PH2 AC Main Spindle Motor 1PH4 1PH4/1-113

114 1PH4 AC Main Spindle Motor 1.3 Degree of protection, thermal motor protection Degree of protection, thermal motor protection Degree of protection (acc. to IEC 34 5) The motor components have, as standard, degree of protection IP 65. The motors have degree of protection IP 55 at the shaft gland. Thermal motor protection A PTC thermistor is integrated in the stator winding to sense the motor temperature. Technical data, refer to Section, Encoder Systems (GE). The signal is sensed and evaluated in the drive converter, whose closed loop control takes into account the temperature characteristic of the motor resistors. An external tripping unit is not required. The PTC thermistor function is monitored. When a fault develops, an appropriate signal is output to the drive converter. If the motor temperature increases, a relay signal Pre alarm, motor overtemperature is initiated. This signal must be externally evaluated. If this signal is ignored, the drive converter trips when the motor limiting temperature is exceeded. An appropriate fault message is output. 1PH4 1PH4/1-114

115 PH4 AC Main Spindle Motor 1.4 Bearing concept 1.4 Bearing concept Standard: Double bearing design on the A side (deep groove ball bearings and roller bearings). The double bearing design is not suitable for a coupling outdrive. Bearing versions Table 1-6 Bearing versions Applications Bearing/option Bearing/option A side Belt drive Minimum cantilever force required For high cantilever forces Coupling outdrive or planetary gear Reduced cantilever forces permissible Increased max. speed Outdrive without cantilever force required, e.g. coupling outdrive Standard Double bearing design K00, (K02, K03) single bearing design L37 Single bearing design spindle bearings B side Bearing change interval (t LW ) For single and double bearings, for a cooling medium temperature of +25 C, bearing temperature +85 C and horizontal mounting. 1PH4 Table 1-7 Bearing change intervals for shaft heights 100, 132 and 160 Double bearing design (standard) Single bearing design (K00) Bearing for increased speed (L37) Shaft heights [mm] Average operating speed n m Average operating speed n m Average operating speed n m Average operating speed n m Average operating speed n m Average operating speed n m 100 n m < < n m < 6000 n m < < n m < 7000 n m < n m < n m < < n m < 5500 n m < < n m < 6500 n m < n m < n m < < n m < 4500 n m < < n m < 5000 n m < n m <8000 t LW [h] Grease change intervals 0.8 t LW (t LW = bearing change interval) 1PH4/1-115

116 1PH4 AC Main Spindle Motor 1.4 Bearing concept Continuous operating speed The max. permissible continuous operating speed n S1cont depends on the bearings and the shaft height. Table 1-8 Assignment, max. speed/continuous operating speed to shaft height and bearings Shaft height [mm] Double bearing design Single bearing design Bearing design for high speeds n 1) max n s1cont n 1) max n s1cont n 1) max n s1cont ! Important If the motor is operated at speeds between n s1cont and n max, a speed duty cycle with low speeds and standstill intervals is required in order to reliably guarantee that the grease is well distributed in the bearings. 1PH4 1) Mechanical limiting speed (perm. for 10 min cycle with: 3 min n max, 6 min 2/3 n max, 1 min standstill) 1PH4/1-116

117 PH4 AC Main Spindle Motor 1.6 Options/accessories 1.5 Vibration severity limit values Within the 1PH series, the vibration severity limit values are identical! The diagrams are in Section AL. 1.6 Options/accessories Holding brake Application A single disk brake can be mounted on the A side to hold the motor shaft, without any play, at standstill. Design The drive end bearing endshield is supplied with a special output bearing cover as retaining element for the solenoid assembly (brake assembly). Customers can bolt on the solenoid assembly. The armature disk of the brake should be bolted to the drive out element (pulley or similar). The brakes do not have any slip rings and are maintenance free. Both of the friction surfaces are metallic. Retrofitting: Not possible Degree of protection Supply voltage Mode of operation IP V DC 10 % The brake operates according to the working principle, i.e. the brake is opened when it is in a no current condition. Only switch in the brake when the motor is at a standstill. The holding brake must be released (no current) when the gearbox is being changed over and when the motor is running. There is no residual torque after the brake has been released. After the motor has been mounted, the brake must be checked to ensure that it is functioning perfectly. 1PH4 1PH4/1-117

118 1PH4 AC Main Spindle Motor 1.6 Options/accessories 12.01! Caution The holding brake is only designed for a limited number of emergency braking operations. It is not permissible to use it as working brake. Before withdrawing the solenoid assembly, the actuation voltage must be connected to the holding brake so that the membrane spring is not over extended. Selection data The holding brakes described here cannot be used together with the two stage selecltor gearbox. Table 1-9 Selecting the holding brake Holding brake For motors, shaft heights The motor is prepared for mounting a holding brake; Customers mount the holding brake Motor with mounted ZF holding brake Code G95 G46 Technical data Table 1-10 Technical data, holding brake 1PH4 1PH4 Shaft height [mm] Holding brake ZF type Order No. Holding torque [Nm] 100 EB 3M Power consumption 1) [W] Closing time [ms] EB 8M 2LX EB 8M 2LX ) Coil temperature 20 C 1PH4/1-118

119 PH4 AC Main Spindle Motor 1.6 Options/accessories Dimensions Single disk holding brakes for motors, shaft heights 100 to Electromagnetic single disk brake 2 Armature disk of the brake 3 Three Allen screws acc. to DIN 7984 or External special drive end bearing endshield 5 Adjustment screw or ring to adjust the air gap or as endstop for the tensioning elements (variable to compensate for tolerances) 6 Space for the tensioning element 7 Four Allen screws M 5x15 or M 6x20 acc. to DIN Electr. connection: Flat connector DIN A6, Air gap s = 0.5 mm between the braking assembly and armature disk 10 Disassembly dimensions for the flat connector sleeve, Size 6.3 1PH4 Fig. 1-1 Mounting a holding brake on the A side of 1PH4 10 to 1PH4 16 AC motors as example: Mounting the armature disk to a pulley disk with key (upper halves) or to a pulley disk for tensioning elements (lower halves) 1PH4/1-119

120 1PH4 AC Main Spindle Motor 1.6 Options/accessories Table 1-11 Motor Dimensions for mounting the single disk holding brake [mm] Drive shaft end 1PH4 d D I h y d 1 d 2 d 3 d 4 H8 3x offset by max. +/ Shaft height 100 1PH Shaft height 132 1PH Shaft height 160 1PH M M M Selector gearbox 1PH4 Selector gearbox The fact that 1PH4 motors are shaft and flange compatible with the air cooled 1PH7 motors means that the same gearboxes can be used (refer to Section 1PH7, Section 1.8). The seal between the motor flange and gearbox flange for shaft heights 132 and 160 must be established using a sealing compound due to the discontinuous centering edge (e.g. Terostat 93, from the Teroson company). 1PH4/1-120

121 PH4 AC Main Spindle Motor 1.8 Mounting 1.7 Encoders Refer to Section Encoder Systems (GE). 1.8 Mounting Refer to Section 1PH7. 1PH4 1PH4/1-121

122 1PH4 AC Main Spindle Motor 1.8 Mounting Space for your notes 1PH4 1PH4/1-122

123 PH4 AC Main Spindle Motor 2 Order Designations Order Designations 2 Order designation The order designation comprises a combination of digits and letters. It is sub divided into three hyphenated blocks. The first block is made up of seven positions and designates the motor type. Additional features are coded in the second block. The third block is provided for additional data. Please note that not every theoretically possible combination is available. Please refer to the ordering tables for possible combinations. 1 P H N. 2 6 Z AC induction motor for main spindle drives Frame size Pole number N = with optical sin/cos encoder speed F = 1500 / min 1PH4 Winding version 2 = 1PH4 Type of construction 6 = IM B35, IM V15; IM V36 Supplementary data in plain text or coded with short code(s), refer to the next page When ordering special AC motor versions, in addition, a code is required for each required version. 1PH4/2-123

124 1PH4 AC Main Spindle Motor 2 Order Designations Supplementary data for options 1PH4 Option Terminal box arrangement (when viewing the A side) Mounted on the righthand side Mounted on the lefthand side The small terminal box and signal connector connections rotated through 90 (cable entry from the A side) The small terminal box and signal connector connections rotated through 90(cable entry from B side) The small terminal box and signal connector connections rotated through 180 Bearing design on the DE Single bearing design for coupling, planetary gear or for low up to average cantilever forces Single bearing design for increased speeds Radial shaft sealing ring; oil tight Vibration severity (acc. to IEC 34 14, DIN VDE 0530, Part 14) Level S for double bearing designs Level S for single bearing designs Level SR for single bearing designs Brief designation K09 K10 K83 K84 K85 K00 L37 K18 K05 1) 4) K02 1) 4) K03 1) 4) Shaft and flange accuracy (acc. to DIN 42955) Tolerance R K04 2) Shaft end DE Shaft end B (without keyway) K42 Balancing Half key balancing L69 Gearbox 5) The motor is prepared for mounting a 2LG43 ZF selector gearbox K00 3) Holding brake Motor with mounted holding brake (A side) G46 4) Others 2nd rating plate, supplied loose Without encoder system K31 H30 1) Automatically includes version K04 2) Increased shaft accuracy 3) Use G97+K00 for gearbox 2LG42 gearbox (old version); G97=non standard cylindrical shaft end for shaft height 100, WE 28x60mm 4) Cannot be combined with mounted gearbox 5) A sealing compound (e.g. Terostat 93, from the Teroson company) must be used to establish the seal between the motor flange and gearbox flange for shaft heights 132 and PH4/2-124

125 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Technical Data and Characteristics Power speed diagrams Independent of the operating mode, the main spindle AC motors must be continuously cooled in operation. The dotted lines in the diagrams indicate the power limit of the particular drive converter for the specified AC motor. The power module is specified. The output values for a relative power on duration of 25 %, 40 % and 60 % are specified. 1PH4 1PH4/3-125

126 1PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-1 AC main spindle motor 1PH4103 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (32A) 9.0 S6 60% (29A) 1PH4 Output [kw] S1 (26A) only with option L Speed Fig. 3-1 Power speed diagram 1PH4103 4NF2 1PH4/3-126

127 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-2 AC main spindle motor 1PH4105 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% 16.0 S6 40% (47A) 14.0 S6 60% (42A) Output [kw] S1 (38A) 1PH only with option L Speed Fig. 3-2 Power speed diagram 1PH4105 4NF2 1PH4/3-127

128 1PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-3 AC main spindle motor 1PH4107 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] 24.0 S6 25% PH4 Output [kw] S6 40% S6 60% S1 (58A) (52A) (46A) only with option L Speed Fig. 3-3 Power speed diagram 1PH4107 4NF2 1PH4/3-128

129 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-4 AC main spindle motor 1PH4133 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (74A) S6 60% (65A) Output [kw] S1 (55A) 1PH only with option L Speed Fig. 3-4 Power speed diagram 1PH4133 4NF2 1PH4/3-129

130 1PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-5 AC main spindle motor 1PH4135 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] 40.0 S6 25% 35.0 S6 40% (99A) 30.0 S6 60% (86A) PH4 Output [kw] S1 (73A) only with option L Speed Fig. 3-5 Power speed diagram 1PH4135 4NF2 1PH4/3-130

131 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-6 AC main spindle motor 1PH4137 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% 40.0 S6 40% (114A) 35.0 S6 60% (100A) 30.0 Output [kw] 25.0 S1 (85A) PH only with option L Speed Fig. 3-6 Power speed diagram 1PH4137 4NF2 1PH4/3-131

132 1PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-7 AC main spindle motor 1PH4138 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (136A) 40.0 S6 60% (119A) PH4 Output [kw] S1 (102A) only with option L Speed Fig. 3-7 Power speed diagram 1PH4138 4NF2 1PH4/3-132

133 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-8 AC main spindle motor 1PH4163 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (142A) S6 60% (125A) Output [kw] S1 (107A) 1PH only with option L Speed Fig. 3-8 Power speed diagram 1PH4163 4NF2 1PH4/3-133

134 1PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-9 AC main spindle motor 1PH4167 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (158A) 1PH4 Output [kw] S6 60% (138A) S1 (120A) only with option L Speed Fig. 3-9 Power speed diagram 1PH4167 4NF2 1PH4/3-134

135 PH4 AC Main Spindle Motor 3.1 Power speed diagrams Table 3-10 AC main spindle motor 1PH4168 4NF2 output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Time constant (therm.) T th [min] Max. speed n max Moment of inertia J [kgm 2 ] Weight m [kg] S6 25% S6 40% (197A) S6 60% (173A) 60.0 Output [kw] S1 (148A) 1PH only with option L Speed Fig Power speed diagram 1PH4168 4NF2 1PH4/3-135

136 1PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force/axial force diagrams 1PH4 main spindle motors are provided with double bearings on the A side in order to accept high cantilever forces due to belt tension. For a definition, refer to Section, General AL. Cantilever force! Caution When using mechanical transmission elements, which subject the shaft end to a cantilever force, it should be ensured that the maximum limit values, specified in the cantilever force diagrams, are not exceeded. Note For applications with an extremely low cantilever force load, it should be observed, that the motor shaft is subject to a minimum cantilever force load as specified in the diagrams. Low cantilever forces can result in the fact that the cylindrical roller bearings roll in an undefined fashion which results in increased bearing wear. For these particular applications, single bearing designs should be used. 1PH4 The maximum permissible and the minimum required cantilever forces are shown in the following diagrams. Axial force The maximum permissible axial forces F AAS for horizontal motor mounting are specified in the following force diagrams for shaft heights 100 to 160. The force diagrams and tables only apply for standard drive shaft ends; for non standard drive shaft end dimensions, every application is specifically designed corresponding to the permissible force load levels. For force levels which go beyond this, please inquire. Note When using option L37 (increased speed), for motors, shaft heights 100 to 160, it should be ensured that the motors are only suitable for operation without cantilever force! 1PH4/3-136

137 PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Forces due to the rotor weight For an explanation, refer to Section AL, Section 2.1. Table 3-11 Bearing alignment force F C and force due to weight F L of the rotor Motor type F L in [N] F C in [N] 1PH4103 1PH4105 1PH4107 1PH4133 1PH4135 1PH4137 1PH4138 1PH4163 1PH4167 1PH Table 3-12 Axial forces F A for double bearing designs (standard) as a function of the speed 1PH410 4 Speed n in Axial force FA in [N] PH413 4 Speed n in Axial force FA in [N] PH416 4 Speed n in Axial force FA in [N] Cantilever force 1PH410 Permissible cantilever forces for double bearing designs (standard). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. Max. continuous operating speed n s1max = 5600 RPM Mechanical limiting speed n max = 9000 RPM 1PH4 F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4000 RPM n=5500 RPM n=6000 RPM 1) n=7500 RPM 1) Minimum cantilever force x [mm] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-137

138 1PH4 AC Main Spindle Motor Cantilever force/axial force diagrams Cantilever force 1PH413 Permissible cantilever forces for double bearing designs (standard). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. Max. continuous operating speed n s1max = 5200 RPM Mechanical limiting speed n max = 8000 RPM F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4000 RPM n=5000 RPM n=6700 RPM Minimum cantilever force x [mm] 1PH4 Cantilever force 1PH416 Permissible cantilever forces for double bearing designs (standard). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. Max. continuous operating speed n s1max = 4000 RPM Mechanical limiting speed n max = 6500 RPM F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4000 RPM n=5300 RPM 1) Minimum cantilever force x [mm] 1PH4/3-138

139 PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force 1PH410 Permissible cantilever forces for 1PH410 for single bearing designs (option K00) Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = 6500 RPM n max = 9000 RPM F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4000 RPM n=5000 RPM n=6300 RPM n=7000 RPM n=8000 RPM 1) x [mm] Cantilever force 1PH410 Permissible cantilever forces for 1PH410 for single bearing designs (option K00) as a function of the axial forces Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h. 1PH4 F Q [N] RPM 4000 RPM 5000 RPM 6300 RPM 2000 RPM 1500 RPM RPM 1) F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-139

140 1PH4 AC Main Spindle Motor Cantilever force/axial force diagrams Cantilever force 1PH413 Permissible cantilever forces for 1PH413 for single bearing designs (option K00). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = 6000 RPM n max = 8000 RPM F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4000 RPM n=5000 RPM n=6700 RPM n=7500 RPM 1) x [mm] 1PH4 Cantilever force 1PH413 Permissible cantilever forces for 1PH413 for single bearing designs (option K00) as a function of the axial forces Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h. F Q [N] RPM 5000 RPM 6000 RPM 8000 RPM 1) 3000 RPM 1500 RPM 2000 RPM F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-140

141 PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force 1PH416 Permissible cantilever forces for 1PH416 for single bearing designs (option K00). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = 4500 RPM n max = 6500 RPM F Q [N] n=1500 RPM n=2000 RPM n=3000 RPM n=4500 RPM n=6000 RPM 1) x [mm] Cantilever force 1PH416 Permissible cantilever forces for 1PH416 for single bearing designs (option K00) as a function of the axial forces. Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h F Q [N] 2000 RPM 1500 RPM 1PH RPM 4500 RPM RPM 1) F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-141

142 1PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force 1PH410 Permissible cantilever forces for 1PH410 for single bearing designs (option K00 with L37) Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = RPM n max = RPM F Q [N] RPM 6000 RPM 7000 RPM 8500 RPM RPM RPM x [mm] 1PH4 Cantilever force 1PH410 Permissible cantilever forces for 1PH410 for single bearing designs (option K00 with L37) as a function of the axial forces Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h. F Q [N] RPM 6000 RPM 7000 RPM 8500 RPM RPM RPM F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-142

143 PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force 1PH413 Permissible cantilever forces for 1PH413 for single bearing designs (option K00 with L37). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = 9250 RPM n max = RPM F Q [N] RPM RPM 6000 RPM 7500 RPM 5000 RPM 4500 RPM x [mm] Cantilever force 1PH413 Permissible cantilever forces for 1PH413 for single bearing designs (option K00 with L37) as a function of the axial forces Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h. 1PH4 F Q [N] RPM 7500 RPM 9000 RPM RPM 4500 RPM 5000 RPM F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-143

144 1PH4 AC Main Spindle Motor 3.2 Cantilever force/axial force diagrams Cantilever force 1PH416 Permissible cantilever forces for 1PH416 for single bearing designs (option K00 with L37). Permissible cantilever force F Q at a distance x from the shaft shoulder for a nominal bearing lifetime of h. 1) Max. continuous operating speed Mechanical limiting speed n s1max = 7000 RPM n max = 8000 RPM F Q [N] RPM RPM 5000 RPM 6000 RPM 7000 RPM 8000 RPM x [mm] 1PH4 Cantilever force 1PH416 Permissible cantilever forces for 1PH416 for single bearing designs (option K00 with L37) as a function of the axial forces. Permissible cantilever force F Q as a function of the axial force F A for a nominal bearing lifetime of h RPM 8000 RPM 1200 F Q [N] 4000 RPM 5000 RPM 6000 RPM 3000 RPM F A [N] 1) Permissible for continuous operation, however with a reduced bearing lifetime 1PH4/3-144

145 PH4 AC Main Spindle Motor 4 Dimension Drawings Dimension Drawings 4 Note Siemens AG reserves the right to change the motor dimensions within the scope of mechanical design improvements without prior notice. Dimension drawings can become out of date. Updated dimension drawings can be requested at no charge. 1PH type of construction IMB 35 1PH type of construction IMB 35 1PH type of construction IMB PH4/ PH4/ PH4/ PH4 1PH4/4-145

146 1PH4 1PH4/4-146 Fig PH type of construction IMB 35 A B C D E F Cooling medium outlet G 1/ PH PH PH Type k q a e Cooling medium intake G 1/ j6 38k q Pg k a + 1 e Signal connection 60 Terminal box, which can be rotated through 4 x Tolerances of the keyway and key acc. to DIN 6885 T1 Flange size A250 acc. to DIN Shaft centering DR M12 acc. to DIN 332 Mounting flange and shaft end acc. to DIN N Type of construction IMB 35 Date: Cont.pers.: Kümmeth Chk.: Heerlein ASI1 A PE D T4 Index Memo Date Contact/Chk. Siemens AG Replacement for: Dim. w/out tol mm Sigraph DESIGN N9 11 Type of construction IMB gk Scale 1:4 (f.1ph ) Material Semi finished product/oi.no. Model/Item No. 259 Dimension drawing 1PH A B C D E Sheet No. 1 No. of sheets 1 1PH4 AC Main Spindle Motor 4 Dimension Drawings 12.01

147 1PH4/4-147 Fig PH type of construction IMB 35 A B C D E F a 1 Cooling medium outlet G 3/ PH PH PH PH Type k q a e Cooling medium intake G 3/ PH h6 42 k q Pg k a + 1 e a Signal connection Flange size A350 acc. to DIN Shaft centering DR M16 acc. to DIN 332 Mounting flange and shaft end acc. to DIN N Type of construction IMB 35 ERN mm 1PH added Küm/He Index Memo Date Contact/Chk. Replacement for: Terminal box, which can be rotated through 4 x Sigraph DESIGN Date: Cont.pers.: Kümmeth Chk.: Heerlein ASI1 PE D T4 Siemens AG N9 gk 433 Tolerances of the keyway and key acc. to DIN 6885 T1 Dim. w/out tol. Scale PH Type of construction IMB :5 (f.1ph ) Material Semi finished product/oi.no. Model/Item No. Dimension drawing a A B C D E Sheet No. 1 No. of sheets PH4 AC Main Spindle Motor 4 Dimension Drawings 1PH4

148 1PH4 1PH4/4-148 Fig PH type of construction IMB 35 A B C D E F Cooling medium outlet G 1/ Cooling medium intake G 1/ PH PH PH Type k q a e h6 55 m q k a e Pg 36 Pg 36 Pg 9 Signal connection gk Tolerances of the keyway and key acc. to DIN 6885 T1 Flange size A400 acc. to DIN Shaft centering DR M20 acc. to DIN 332 Mounting flange and shaft end acc. to DIN N Type of construction IMB 35 ERN / HTL Dim. w/out tol mm Index Memo Date Contact/Chk. Replacement for: Terminal box, which can be rotated through 4 x Sigraph DESIGN Date: Cont.pers.: Buhl D. Chk.: Heerlein ASI1 A PE D AC Scale N :5 (f.1ph ) Material Semi finished product/oi.no. Model/Item No Dimension drawing 1PH Sheet Siemens AG Type of construction IMB 35 No A B C D E No. of sheets 1 1PH4 AC Main Spindle Motor 4 Dimension Drawings 12.01

149 1PH7 AC Main Spindle Motor 1 Motor Description PH7/ Features and technical data PH7/ Cooling PH7/ Thermal motor protection PH7/ Bearing concept PH7/ Encoders PH7/ Vibration severity - limit values PH7/ Mounting 1PH4 and 1PH7 motors PH7/ Options PH7/ Gearbox mounting PH7/ Gearboxes PH7/ Order Designations PH7/ Technical Data and Characteristics PH7/ Power speed diagrams PH7/ Cantilever force/axial force diagrams PH7/ Dimension Drawings PH7/ PH7 1PH7-149

150 12.01 Space for your notes 1PH7-150

151 PH7 AC Main Spindle Motor 1.1 Features and technical data Motor Description Features and technical data Applications Features Technical features The 1PH7 series is suitable for the closed loop speed controlled operation of main spindles on machine tools, transfer lines and special purpose machines. 1PH7 motors are air cooled four pole squirrel cage induction motors. Depending on the shaft height, 1PH7 motors have rated outputs of 3.7 to 100 kw at rated speeds from 500 to 2500 RPM. Wide constant power range Short length Full rated torque is continuously available even at standstill High overload capability Minimized disturbing envelop dimensions as a result of the integrated terminal box (for shaft heights ) Note The motors can be fed from a DC link voltage of up to 700 V DC. For shaft heights 180 and 225, the appropriate version must be selected. Table 1-1 Technical features Technical feature Version Shaft height Type of construction (acc. to IEC ) Degree of protection (acc. to IEC ) Cooling Winding insulation (acc. to IEC ) Thermal motor protection (acc. to IEC ) IM B3 1) ; IM B5; IM B35; IP 55; fan IP 54 2) IM B3; IM B35 Air cooling/separately driven fan on the B side Air flow direction: from DE to NDE Temperature rise class F for a cooling medium temperature of 40 C. PTC thermistor (acc. to IEC 34-6) in the stator winding 1PH7 1) IM B3 not for core types 2) Not for combustible, explosive, chemically aggressive or electrically conductive dusts 1PH7/1-151

152 1PH7 AC Main Spindle Motor 1.1 Features and technical data Table 1-1 Technical features, continued 1PH7 Technical feature Version Shaft height Motor voltage Max.: 3 ph. 430 V AC Motor noise (acc. to DIN 45635/Part 10) Tolerance +3 db Vibration stressing (acc. to IEC ) Terminal box arrangement Cable entry (when viewing the DE) Power cable: Signal cable 70 db (A) 75 db (A) 2) right right 0.4 g for 63 Hz Top mounted 78 db (A) 3) right left 81 db (A) 1) 3) Connection type Motor: via terminal box Encoder: through connector (17-pin; mating connected is not included in the scope of supply) Fan: via terminal box Encoder system Balancing Shaft end Bearing version (A side; Standard) Flange version, concentricity (smooth running properties) Vibration severity (acc. to IEC ) Paint finish Installation altitude Rating plates Documentation Integrated optical encoder, refer to Section Encoder Systems (GE) Speed sensing Indirect position sensing (incremental) Standard: Half key balancing (dynamic) (acc. to IEC and EN ) Code: H on the shaft face Cylindrical; without keyway and without key (acc. to DIN 748; Part 3) Suitable for belt and coupling outdrives. Observe the particular version in the Order No.[MLFB]. Tolerance R (acc. to DIN ) Suitable for belt outdrive Tolerance N (acc. to DIN ) Level R Level S for core types (refer to the Order code) without paint finish 1000 m above sea level, otherwise de rating (acc. to IEC and EN ): 2000 m Factor m Factor rating plates, one on the motor, one supplied loose in the terminal box Operating Instructions are supplied with the motor 1) refer to P n diagrams 2) For 60Hz operation from the line supply, a panel (on request) is available to reduce the sound pressure level 3) For shaft heights 180 and 225, noise dampening (on request) is available to reduce the sound pressure level. 1PH7/1-152

153 PH7 AC Main Spindle Motor 1.1 Features and technical data Options Table 1-2 Options Technical features Version Shaft height Type of construction 1) all mounting positions are possible (refer to Section AL) Cooling 3) Airflow direction: from NDE to DE Cable entry 2) 3) Power cable: Shaft end Signal cable: left NDE or left NDE left DE NDE or right NDE DE Cylindrical (acc. to DIN 748; Part 3) with keyway and key (acc. to DIN 6885) Tolerance zone: k6 Tolerance zone: m6 Bearing design Standard Bearing design for coupling outdrive Bearing design for coupling outdrive and increased speed (only shaft height 180) Bearing design for Flange version, concentricity (smooth running characteristics) Vibration severity (acc. to IEC ) Mounted/integrated components Balancing 3) Sealing Standard Level S 4) Level SR (=S/1.6) increased cantilever force Tolerance R (acc. to DIN ) Level S and SR, only for coupling outdrive The motors can be supplied complete with mounted gearbox. Full key balancing (dynamic) (acc. to IEC and EN ) DE flange with shaft sealing if drops of oil or oil mist occasionally lubricate the sealing ring) 1PH7 1) For shaft heights 180 and 225, it must be ensured that the correct hoisting concept is applied 2) Only in the specified combination 3) Not for core types 4) For core types, included in the basic version 1PH7/1-153

154 1PH7 AC Main Spindle Motor 1.1 Features and technical data Technical data Table 1-3 Technical data, 1PH7 AC motors 1PH7 AC motor Order No. Shaft height 100 mm 1PH7101-NF 1PH7103-ND 1PH7103-NF output P rated [kw] speed n rated torque M rated [Nm] current I rated [A] Moment of inertia J [kgm 2 ] Max. 2) speed n max Increased max. speed PH7101-NG PH7105-NF PH7107-ND PH7107-NF PH7107-NG Shaft height 132 mm 1PH7131-NF PH7133-ND PH7133-NF PH7133-NG PH7135-NF PH7137-ND PH7137-NF PH7137-NG Shaft height 160 mm 1PH7163-NB 1PH7163-ND 1PH7163-NF 1PH7163-NG PH7167-NB 1PH7167-ND PH7167-NF PH7167-NG Shaft height 180 mm 1PH7184-NT 1PH7184-ND 1PH7184-NE 1PH7184-NF 1PH7184-NL 1PH7186-NT 1PH7186-ND 1PH7186-NE Shaft height 225 mm 3) 1PH7224-NC 1PH7224-ND 1PH7224-NF I 0 [A] U N [V] Complete order designation, refer to Chapter 2 or Catalog NC ) Motors with a gray background are core types 2) For continuous operation (with 30% n max, 60% n max, 10 % standstill) for a load duty cycle of 10 min., max. continuous speed and bearing change intervals, refer to Section 1.4 3) For bearings for increased cantilever force n max =4500 RPM 1PH7/1-154

155 1PH7/ ) Max. speed for S1 and S6 duty, refer to P n diagram 2) for S6 16% Motor type 1PH7... nrated nmax 1) Mrated motor output for oper. mode acc. to EN Prated[kW] S1 S6 60 % S6 40 % S6 25 % motor current for Drive converter module for oper. mode acc. to EN operating mode acc. to EN I rated[a] [A] S1 S6 60 % S6 40 % S6 25 % S6 60 % S6 40 % S6 25 % 101 _NF_ /32/32 24/32/32 24/32/32 24/32/ _ND_ /32/32 24/32/32 24/32/ _NF_ /32/32 24/32/32 24/32/32 24/32/ _NG_ /32/32 24/32/32 24/32/32 24/32/ _NF_ /32/32 24/32/32 24/32/32 24/32/ _ND_ /32/32 24/32/32 24/32/32 24/32/ _NF_ /32/32 30/40/51 30/40/51 30/40/ _NG_ /40/51 30/40/51 30/40/51 30/40/ _NF_ /32/32 30/40/51 30/40/51 30/40/ _ND_ /40/51 45/60/76 45/60/76 45/60/ _NF_ /60/76 45/60/76 45/60/76 45/60/ _NG_ /60/76 60/80/102 60/80/102 60/80/ _NF_ /60/76 45/60/76 45/60/76 60/80/ _ND_ /60/76 45/60/76 45/60/76 60/80/ _NF_ /80/102 60/80/102 60/80/102 85/110/ _NG_ /80/102 85/110/127 85/110/127 85/110/ _NB_ /40/51 45/60/76 45/60/ _ND_ /80/102 60/80/102 60/80/102 85/110/ _NF_ /110/127 85/110/127 85/110/ /150/ _NG_ /110/127 85/110/ /150/ /150/ _NB_ /60/76 45/60/76 45/60/ _ND_ /110/127 85/110/127 85/110/ /150/ _NF_ /110/127 85/110/ /150/ /150/ _NG_ /150/ /150/ /150/ /150/ _NT_ /110/127 85/110/127 85/110/127 85/110/ _ND_ /150/ /150/ /150/ _NE_ ) ) 85/110/127 85/110/127 85/110/ _NF_ /150/ /250/ /250/ _NL_ /250/ /250/ /250/ _NT_ ) ) 120/150/ /150/ /150/ _ND_ /150/ /250/ /250/ _NE_ ) ) 120/150/ /150/ /150/ _NC_ ) ) 120/150/ /150/ /150/ _ND_ /250/ /250/ /250/ _NF_ ) ) 200/250/ /250/ /250/257 S1 Table 1-4 Technical data - drive converter assignment 1PH PH7 AC Main Spindle Motor 1.1 Features and technical data 1PH7

156 1PH7 AC Main Spindle Motor 1.2 Cooling Cooling Note 1PH7 main spindle motors are force ventilated. When mounting the motors, it must be ensured that the motor can be well ventilated. This is especially true for encapsulated mounting. It is not permissible that the hot discharged air is drawn in again. Temperatures of over 100 C can occur at the surface of the motor. Mounting The fan is axially mounted at the B end. The minimum clearance to the customer s mounted parts and components and the air discharge opening as well as the minimum clearance S between the air intake and air discharge openings and adjacent components must be observed and maintained (refer to Table 1-5 ). Fig. 1-1 Minimum clearance to air intake and discharge openings Table 1-5 Minimum clearances 1PH7 Shaft height [mm] Clearance to the customer s mounted parts and components [mm] Clearance S [mm] Airflow direction Standard: Option: from DE to NDE from NDE to DE. For shaft heights 180 and 225, the length changes (refer to dimension drawings) not for core types Air discharge Shaft heights 100 to 160: Shaft heights 180 and 225: axial radial, clockwise (when viewing the DE); the fan can be rotated through 4 x 90 1PH7/1-156

157 PH7 AC Main Spindle Motor 1.2 Cooling Ambient/cooling medium temperature Operation: T = 15 C to +40 C (without restrictions) Bearing design: T = 20 C to +70 C The rated output P N is reduced as follows when the temperature increases: Table 1-6 Reduced rated output Temperature Shaft height [mm] Reduction > 40 C to 50 C 100 to 225 to 92 % P N Airflow Table 1-7 Airflow for 1PH7 Shaft height [mm] Airflow [l/sec] Supply values, separately driven fan Table 1-8 Supply values, separately driven fan Shaft height [mm] 100 to to to to 225 Voltage[V] 3 ph. 400 V AC 50 Hz (10 %) 3 ph. 400 V AC 60 Hz (10 %) 3 ph. 400 V AC 60 Hz (+10 %) 3 ph. 480 V AC 60 Hz (+5 %/ 10 %) 1PH7 Table 1-9 Current drain Motor type I rated A, at 400V, 50 Hz 1PH710 1PH713 1PH716 1PH718 1PH A 0.26 A 0.24 A 1.1 A 1.8 A I max A, at 480V, 60 Hz 0.13 A 0.26 A 0.30 A 1.3 A 2.3 A I rated A, at 400V, 60 Hz 0.08 A 0.19 A 0.31 A 1PH7/1-157

158 1PH7 AC Main Spindle Motor 1.2 Cooling Recommended connection The fan is connected through a terminal box. The fan is operated through a motor protection circuit breaker. L1 L2 L3 PE Additional fan NE SIMODRIVE > U1 V1 W1 Motor protection circuit breaker is not included in the motor scope M Fan Fig. 1-2 Recommended connection Fan control In order to minimize the motor noise at standstill, the fan can be shut down at n < n min and when the controller enable is withdrawn (alternatively, pulse enable is withdrawn). An example of the fan control is shown in Fig PH7 PLC 3 ph. 480 V AC, 60 Hz 3 ph. 400 V AC, 50 Hz (tolerances, refer to Table 1-8) In act I<n min Controller enable *) > K1 Fan motor K1 *) alt. pulse enable (this depends on the particular application) M 3 Fig. 1-3 Example: Fan control 1PH7/1-158

159 PH7 AC Main Spindle Motor 1.3 Thermal motor protection 1.3 Thermal motor protection Thermal motor protection A PTC thermistor is integrated in the stator winding to sense the motor temperature. For the technical data, refer to Section Encoder Systems (GE). The signal is sensed and evaluated in the associated SIMODRIVE/SINUMERIK unit, whose control takes into account the temperature characteristics of the motor resistors. An external tripping unit is not required. The PTC thermistor function is monitored. An appropriate signal is output to the drive converter when a fault situation develops. Connection: via signal cable! Warning If the user carries out an additional high voltage test, then the cable ends of the temperature sensors should be short circuited before this test! If the test voltage is connected to a temperature sensor, then the sensor will be destroyed. 1PH7 1PH7/1-159

160 1PH7 AC Main Spindle Motor 1.4 Bearing concept Bearing concept Bearing concept 1PH7 AC main spindle motors are suitable for the following drive types: Coupling drive Belt drive Shaft heights 100 to 160: Shaft heights 180 and 225: Shaft heights 180 and 225: Deep groove ball bearings on the A and B sides > suitable for coupling and belt outdrive Deep groove ball bearings on the A and B sides > suitable for coupling outdrive Cylindrical roller and deep groove ball bearings on the A side and deep groove ball bearings on the B side > suitable for belt outdrive Bearing versions The bearing versions and their applications are summarized in the following table. Table 1-10 Bearing versions Application Coupling drive Planetary gear Bearing arrangement Shaft heights 100 to 160 Shaft heights 180 and 225 1PH7 Low cantilever forces Belt drive with normal cantilever force Pinion outdrive with straight teeth Deep groove ball bearings Deep groove ball bearings Cylindrical roller bearings Deep groove ball bearings Minimum cantilever force required! Belt drive with increased cantilever force Cylindrical roller bearings Deep groove ball bearings Minimum cantilever force required! 1PH7/1-160

161 PH7 AC Main Spindle Motor 1.4 Bearing concept Bearing change interval, shaft heights 100 to 225 (t LW ) The values specified in Tables1-11 and 1-12 are valid for the following conditions: Coupling and belt outdrive Cooling medium temperature +30 C Bearing temperature +85 C Horizontal mounting Table 1-11 Recommended bearing change intervals Type Average operating speed 1) n m Continuous speed n s1 1PH710 n m < n m < 6000 n s PH713 n m < n m < 5500 n s PH716 n m < n m < 4500 n s PH718 n m < n m < 4000 n s ) 1PH7224 n m < n m < 3500 n s ) t LW [h] Table 1-12 Recommended bearing change intervals for increased maximum speeds Type Average operating speed n m Continuous speed n s1 1PH n m n s PH n m n s PH n m 8000 n s PH n m 7000 n s PH n m 5500 n s t LW [h] PH7 1) A speed duty cycle with low speeds and standstill periods is assumed. 2) For increased cantilever force: Shaft height 180: ns13000 RPM Shaft height 225: ns12700 RPM 1PH7/1-161

162 1PH7 AC Main Spindle Motor 1.4 Bearing concept Continuous speed The max. permissible continuous operating speed n S1cont depends on the bearings and the shaft height (refer to Table 1-13). Table 1-13 Shaft height [mm] Assignment, max. speed to shaft height and bearing design Coupling outdrive, belt outdrive Belt outdrive with increased cantilever force Increased max. speed n max 1) n s1cont 2) n max 1) n s1cont 2) n max 1) n s1cont 2) ) ) ) )! Important If the motor is operated with speeds between n s1cont and n max, a speed duty cycle with low speeds and standstills is assumed in order to reliably guarantee that the grease is distributed in the bearings. 1PH7 1) Mechanical limiting speed (perm. for 10 min cycle with: 3 min n max, 6 min 2/3 n max, 1 min standstill) 2) Max. continuous operating speed 3) only coupling outdrive permissible 1PH7/1-162

163 PH7 AC Main Spindle Motor 1.5 Encoders 1.5 Encoders An incremental rotary encoder is integrated in the B side bearing endshield to sense speed and rotor position. Application Main spindle C axis operation Connection The actual value cable is fed to the drive converter. The actual value cables must be routed separately away from the power cables in order to avoid disturbances. Pre assembled cables should be used (refer to Catalog NC Z). Technical data Technical data and signal characteristics, refer to Section Encoder Systems (GE). 1PH7 1PH7/1-163

164 1PH7 AC Main Spindle Motor 1.6 Vibration severity - limit values Vibration severity - limit values The vibration severity limit values are identical within the 1PH series! In order to maintain the vibration severity limit values for shaft heights 160, 180 and 225, for type of construction IM B35, the motor foot must be supported. It can be generally stated that a high cantilever force load capability cannot be combined with high speed and high vibration quality, as the different tasks require different bearing concepts. The diagrams are provided in Section 2.1 General information on AC induction motors (AL A). Permissible vibrations In order to ensure perfect functioning and a long lifetime, the vibration values, specified in the following table should not be exceeded at the motor. Please inquire if higher values are present. Table 1-14 Vibration values Vibration frequency Vibration values for shaft height Shaft heights 100 to 160 Shaft heights 180 and 225 < 6.3 Hz Vibration travel s [mm] Hz Vibration velocity v am [mm/s] > 63 Hz Vibration acceleration a [m/s 2 ] PH7 1PH7/1-164

165 PH7 AC Main Spindle Motor 1.7 Mounting 1PH4 and 1PH7 motors 1.7 Mounting 1PH4 and 1PH7 motors Mounting instructions! Warning These motors are electrically operated. When electrical equipment is operated, certain parts of these motors are at hazardous voltage levels. If this motor is not correctly handled/operated, this can result in death or severe bodily injury as well as significant material damage. Please carefully observe the warning information in this section an on the product itself. Only qualified personnel may carry out service or repair work on this motor. Before starting any work, the motor must be disconnected from the line supply and grounded. Only spare parts, certified by the manufacturer, may be used. The specified service/maintenance intervals and measures as well as the procedures for repair and replacement must be carefully maintained and observed.! Warning When transporting the motors, use all of the hoisting lugs provided! Any work carried out on the drive system must be carried out with the drive system in a no voltage condition! The motor should be connected up according to the circuit diagram provided. In the terminal box, it must be ensured that the connecting cables are connected so that there is electrical isolation between the cables and the terminal board cover. After the motor has been installed, the brake (if one is used) must be checked to ensure that it is functioning perfectly! 1PH7 Note Flange mounting is only possible using studs and nuts. Clearance M1 for threading the nut between the motor flange and motor frame acc. to DIN Shaft height Shaft height 100 Shaft height 132 Shaft height 160 Shaft height 180 Shaft height 225 M1 44 mm 50 mm 65 mm 70 mm 90 mm M1 1PH7 1PH7/1-165

166 1PH7 AC Main Spindle Motor 1.7 Mounting 1PH4 and 1PH7 motors Cable outlet NDE Shaft height 100: Signal connector Terminal box Power connection (angular element is included in the scope of supply) Shaft height 132, 160: Signal connector Terminal box Power connection 1PH7 Shaft height 180, 225: via terminal box, depending on the version ordered Fig. 1-4 Cable outlet 1PH7/1-166

167 PH7 AC Main Spindle Motor 1.7 Mounting 1PH4 and 1PH7 motors Mounting instructions The following mounting instructions must be carefully observed: For high speed machines, we recommend that the complete unit is dynamically balanced after couplings or belt pulleys have been mounted. Use suitable equipment when mounting drive elements. Use the thread at the shaft end Do not apply any blows or axial pressure to the shaft end Especially for high speed motors with flange mounting, it is important that the mounting is stiff in order to locate any resonant frequency as high as possible so that it remains above the maximum rotational frequency. When motors are flange mounted, if the mounting is too soft, then this can have a negative impact on the vibration quality of the drive unit. For type of construction IM B35, to maintain the vibration severity limit values, foot mounting is required on the B side Note 1PH7 main spindle motors are separately ventilated. When mounting the motors, it must be ensured that the motors can be well ventilated. This is especially true for encapsulated mounting. It is not permissible that hot discharged air is drawn in again. Mount air cooled motors so that the cooling air can enter and be discharged without any restrictions (also refer to Section 1.2 Cooling ). The caps of the screw holes to foot mount the 1PH7 motor must be re located after the motor has been mounted.! Caution Liquid must be prevented from collecting in the flange, both in the vertical as well as horizontal mounting position. This would have a negative impact on the bearing and bearing grease. 1PH7 Natural frequency when mounted The motor is a system which is capable of vibration at its natural frequency. For all 1PH motors, this resonant frequency lies above the specified maximum speed. When the motor is mounted onto a machine tool, a new system, which is capable of vibration, is created with modified natural frequencies. These can lie within the motor speed range. This can result in undesirable vibrations in the mechanical drive transmission. Note Motors must be carefully mounted on adequately stiff foundations or bedplates. Additional elasticities of the foundation/bedplates can result in resonance effects of the natural frequency at the operating speed and therefore result in inadmissibly high vibration values. 1PH7/1-167

168 1PH7 AC Main Spindle Motor 1.7 Mounting 1PH4 and 1PH7 motors The magnitude of the natural frequency when the motor is mounted depends on various factors and can be influenced by the following points: Mechanical transmission elements (gearboxes, belts, couplings, pinions, etc.) Stiffness of the machine design to which the motor is mounted Stiffness of the motor in the area around the foot or customer flange Motor weight Machine weight and the weight of the mechanical system in the vicinity of the motor Damping properties of the motor and the machine tool Mounting type, mounting position (IM B5; IM B3; IM B35; IM V1; etc.) Motor weight distribution, i.e. length, shaft height 1PH7 1PH7/1-168

169 PH7 AC Main Spindle Motor 1.8 Options 1.8 Options Gearbox mounting The following prerequisites must be fulfilled in order to mount a ZF selector gearbox to the motors: Shaft heights 100 to 160: Type of construction IM B5, IM B35 or IM V15 Shaft with key and full key balancing Shaft heights 180 and 225: Type of construction IM B35 Bearing design for coupling outdrive Vibration severity level R Flange and shaft accuracy R Shaft with key and full key balancing Degree of protection IP 55, prepared for mounting a ZF gearbox For questions regarding gearboxes, please directly contact the following: ZF Friedrichshafen AG Antriebstechnik Maschinenbau D Friedrichshafen Telephone: ( ) 77-0 Telefax: ( ) Internet: Group.de 1PH7 1PH7/1-169

170 1PH7 AC Main Spindle Motor 1.8 Options Gearboxes Application If the drive torque is not sufficient at low speeds.. If the constant power range is not sufficient in order to utilize the cutting power over the complete speed range. The following advantages are obtained by locating the gearbox outside the spindle box: Gearbox vibration/oscillations are not transferred. Separate lubricating systems for the main spindle (grease) and selector gearbox (oil). No noise and no temperature fluctuations caused by the gearbox pinion wheels in the spindle box. Instead of using belts, the drive power can also be transferred from the gearbox out drive using pinion (on request) or co axially through a compensating coupling. Features Version as planetary gear Gearbox efficiency: above 95 % Gearboxes are available for motors, shaft heights 100 to 225 Selector gearboxes are available up to a drive output of 100 kw Types of construction: IM B35 (IM V15) and IM B5 (IM V1) are possible Note 1PH7 The 1PH7 and 1PH4 motors are only designed for stressing in accordance with the specifications (refer to the cantilever force diagram and maximum torque). When using force/torque increasing elements, for example, a gearbox, the increased mechanical stressing (e.g. as a result of high belt pre tensioning forces) must be able to be handled by the appropriate mechanical element. The system designer must taken this into account. For a gearbox, this means that the gearbox must be able to handle, e.g. increased belt pre tension forces and transfer them to the machine. For drive units, which for example, are mounted at the gearbox flange or gearbox housing, motors with type of construction IM B35 must be supported at the non drive end. The support must be implemented so that it does not subject the motor to any stressing. 1PH7/1-170

171 PH7 AC Main Spindle Motor 1.8 Options P [kw] P = constant with gearbox P rated P = constant without gearbox 1 2 n rated n rated n max n M = constant 1 n rated n rated n max P rated M M = constant 2 Logarithmic scale speed speed with two stage selector gearbox max. permissible speed output and also constant power of the AC motor in the speed range from n rated to n max or n rated to n max Torque Fig. 1-5 Speed-power diagram when using a two stage selector gearbox to extend the speed range with constant power from AC motors for main spindle drive Example: AC motor without selector gearbox: For P = constant from n rated = 1500 RPM to n max = 6300 RPM a constant power control range greater than 1:4 is possible. The same AC motor with selector gearbox: For gearbox stage i 1 = 4 and i 2 = 1 a constant power control range of greater than 1:16 is possible (n rated = 375 RPM to n max = 6300 RPM). 1PH7 1PH7/1-171

172 1PH7 AC Main Spindle Motor 1.8 Options Design PH7 1 Drive hub 12 Drive shaft 2 Adapter plate 13 Radial shaft sealing ring 3 Radial shaft sealing ring 14 Planetary gear supply assembly 4 Hub bearings 15 Axial bearings with plate springs 5 Gearbox housing 16 Shift sliding sleeve 6 Sun gear 17 Shift fork 7 Annular gear 18 Brake disk 8 Annular gear bearing 19 Solenoid 9 Bearing housing 20 Selelctor shaft 10 Driveout bearings 21 Plate 11 Driveout bearings Fig. 1-6 Gearbox mounting (1PH7: Shaft height / 1PH4: Shaft height ) The following applies for the selector gearbox: Stage I: i 1 = 4 Stage II: i 2 = 1 Both gearbox ratios are electrically selected and the setting is monitored using limit switches. The gearbox out drive lies coaxially to the motor shaft. Torsional play (measured at the gearbox out drive): Standard: 30 angular minutes (for shaft heights ) 40 angular minutes (for shaft heights 180 / 225) For milling and machining with interrupted cutting, the following special versions are available on request for shaft heights : Lower play: max. 20 Lower play for increased requirements: max. 15 1PH7/1-172