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Documentation for

DC-Motor

Type : G5L160M34-2
Order- No : 723589 (051132)
Mach.- No : 06-042429
Subject : MD Gottwald

Contents:

Part 1: Safety Information LDW 12.300/0499 DE/EN

Part 2: Operating Instruction LDW 12.184/1100 EN

Part 3: Test Report

Part 4: Drawing Annex

Revision 0 2006-11-01 Lloyd Dynamowerke GmbH & Co. KG


Hastedter Osterdeich 250
D-28207 Bremen
Elektrische Maschinen, Antriebssysteme und Anlagen

LDW 12.300/0499 DE/EN


Printed in Germany Lloyd Dynamowerke GmbH
Änderungen vorbehalten Hastedter Osterdeich 250
D–28207 Bremen
 Lloyd Dynamowerke GmbH 1999

Weitergabe sowie Vervielfältigung dieser Betriebsanleitung,


Verwertung und Mitteilung ihres Inhalts verboten soweit nicht
ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu
Schadensersatz. Alle Rechte vorbehalten,
insbesondere das Recht, Patent–, Gebrauchsmuster–
oder Geschmacksmusteranmeldungen durchzuführen.
Sicherheitsinformationen / Safety Informations Inhaltsverzeichnis / Contents

1 Symbol- und Hinweiserklärung 1


1.1 Arbeitssicherheitssymbol 1
1.2 Achtungs-Hinweis 1

2 Arbeitssicherheitshinweise 1

3 Umweltschutz und Entsorgung 2

4 Zitierte Normen und andere Unterlagen 3

1 Explanation of symbols and notes 4


1.1 Safety symbol 4
1.2 Warnings 4

2 Notes on work safety 4

3 Environmental Protection and Disposal 5

4 Standards and other documents quoted 6

Seite / page I
LDW 12.300/0499 DE/EN
Sicherheitsinformationen

1 Symbol- und Hinweiserklärung

1.1 Arbeitssicherheitssymbol

Dieses Symbol finden Sie bei allen Arbeissicherheitshinweisen, bei denen


Gefahr für Leib und Leben von Personen besteht. Beachten Sie diese
Hinweise und verhalten Sie sich in diesen Fällen besonders vorsichtig.
Geben Sie alle Arbeitssicherheits-Hinweise auch an andere Benutzer weiter.
Es müssen die allgemeingültigen Sicherheits- und Unfallverhütungsvor-
schriften beachtet werden.

1.2 Achtungs-Hinweis

A C H T U N G ! Dieses Achtung! steht an den Stellen, die besonders zu beachten sind,


damit die Richtlinien, Vorschriften, Hinweise und der richtige Ablauf der
Arbeiten eingehalten, sowie eine Beschädigung und Zerstörung der
Maschine und/oder anderen Anlagenteilen verhindert wird.

2 Arbeitssicherheitshinweise
Dieses Informationsblatt mit den Warnhinweisen gilt als Zusatz zur produktspezifischen
Betriebsanleitung und muß aus Sicherheitsgründen besonders beachtet werden.
Die elektrischen Maschinen sind Betriebsmittel zum Einsatz in industriellen Anlagen.
Während des Betriebes haben diese Betriebsmittel gefährliche, spannungsführende blanke
Teile, ggf. auch bewegte bzw. rotierende Teile. Sie könnten deshalb, z. B. bei
unzulässigem Entfernen der erforderlichen Abdeckungen, bei unsachgemäßem Einsatz,
falscher Bedienung oder unzureichender Wartung, schwerste gesundheitliche oder
materielle Schäden verursachen.
Die für die Sicherheit der Anlage Verantwortlichen müssen deshalb gewährleisten, daß
• nur qualifizierte Personen mit Arbeiten an den Maschinen bzw. Geräten
beauftragt werden.
• diese Personen u. a. die mitgelieferten Betriebsanleitungen und übrigen
Unterlagen der Produktdokumentation bei allen entsprechenden Arbeiten stets
verfügbar haben und verpflichtet werden, diese Unterlagen konsequent zu
beachten.
• Arbeiten an den Maschinen bzw. Geräten oder in deren Nähe für
nichtqualifizierte Personen untersagt werden.
Qualifiziertes Personal sind Personen, die aufgrund ihrer Ausbildung, Erfahrung und
Unterweisung sowie ihrer Kenntnisse über einschlägige Normen, Bestimmungen,
Unfallverhütungsvorschriften und Betriebsverhältnisse, von dem für die Sicherheit der
Anlage Verantwortlichen berechtigt worden sind, die jeweils erforderlichen Tätigkeiten

Seite 1
LDW 12.300/0499 DE
Sicherheitsinformationen
auszuführen und dabei mögliche Gefahren erkennen und vermeiden können (Definition für
Fachkräfte siehe auch DIN VDE 0105 oder IEC 364). Unter anderem sind auch Kenntnisse
über Erste-Hilfe-Maßnahmen und die örtlichen Rettungseinrichtungen erforderlich.
Für Arbeiten z. B. an Starkstromanlagen ist das Verbot des Einsatzes nichtqualifizierter
Personen geregelt.
Es wird vorausgesetzt, daß die grundsätzlichen Planungsarbeiten der Anlage sowie alle
Arbeiten zu Transport, Montage, Installation, Inbetriebsetzung, Wartung und Reparaturen
von qualifiziertem Personal ausgeführt werden.
Hierbei sind insbesondere zu beachten:
• Technische Daten und Angaben über die zulässige Verwendung (Montage-,
Anschluß-, Umgebungs- und Betriebsbedingungen) die u. a. im Katalog, den
Auftragsunterlagen, der Betriebsanleitung, den Schildangaben und der übrigen
Erzeugnisdokumentation enthalten sind.
• die allgemeinen Einrichtungs-und Sicherheitsvorschriften, die örtlichen
anlagenspezifischen Bestimmungen und Erfordernisse.
• der fachgerechte Einsatz von Werkzeugen, Hebe- und Transporteinrichtungen.
• die Benutzung persönlicher Schutzausrüstungen.
• Im Betrieb muß der erforderliche Berührungsschutz vorhanden bzw. eine
gefährliche Annäherung verhindert sein. Dies gilt nicht nur bezüglich der
Gefährdung durch bewegte Maschinenteile oder elektrische Spannung führende
Teile, sondern auch durch erhöhte Oberflächentemperaturen der Maschinen.
Falls im Sonderfall bei beabsichtigtem Einsatz der Maschinen in nicht industriellen
Bereichen eventuell erhöhte Anforderungen gestellt werden, müssen diese Bedingungen
bei der Montage durch zusätzliche Schutzmaßnahmen anlagenseitig gewährleistet werden.

3 Umweltschutz und Entsorgung


Umweltschutz
• Durch aufgespürte und beseitigte Leckstellen, z. B. am Getriebe,
Hydraulikleitungen und Lagerstellen, wird unter anderem auch verhindert, daß Öl
und andere Schmierstoffe unkontrolliert ins Erdreich eindringen können.
• Schlecht befestigte Maschinenteile, vorzugsweise Blechhauben, Sicherheitsgitter,
Schutzabseckungen, Luftkanäle usw. erzeugen häufig eine erhebliche, unnötige
Geräuschkulisse und stellen somit eine durchaus vermeidbare Lärmbelästigung
am Arbeitsplatz dar.
• Undichte Leitungen usw. belasten durch die austretenden Medien nicht nur die
Luft, sondern sie sind auch eine Ursache für unnötige Energieverluste und
manchmal sogar Quellen für Explosions- und Gesundheitsrisiken.
Entsorgung
Bei Öl- und Fettwechsel ist die sachgerechte Entsorgung der Rückstände nach geltendem
Landesrecht vorzunehmen.

A C H T U N G ! Kontamination von Erdreich, Kanalisation und Gewässern


vermeiden!

Seite 2
LDW 12.300/0499 DE
Sicherheitsinformationen
Die Entsorgung von verbrauchten Reinigungsmitteln ist problematisch. Sie enthalten oft als
Bestandteile eine wassergefährdenden Chlorkohlenwasserstoffe. Sie müssen deshalb
unbedingt getrennt gesammelt und entsogt werden.
Ähnliches gilt auch für die Entsorgung verbrauchter Kühl- und Schmierstoffe. Sie dürfen auf
keinen Fall in den Boden oder in die Kanalisation gelangen.
Ausgelaufener Schmierstoff ist sofort mit einem geeigneten Bindemittel zu beseitigen.
Verschlissene Keilriemen, Brems- und Kupplungsbeläge, Kunststoffteile, ausgewechselte
Teile aus Schichtwerkstoffen usw. gehören nicht in den Hausmüll. Sie müssen gesondert
abgeführt werden.

4 Zitierte Normen und andere Unterlagen


• VBG 4
Elektrische Anlagen und Betriebsmittel
• DIN VDE 0100 -....
Errichten von Starkstromanlagen mit Nennspannungen bis 1000V
• DIN VDE 0101
Errichten von Starkstromanlagen mit Nennspannungen über 1KV
• DIN VDE 0141
Erdungen für Starkstromanlagen mit Nennspannungen über 1KV
• DIN VDE 0105
Betrieb von Starkstromanlagen
• IEC 364
Elektrische Anlagen von Gebäuden
• DIN EN 292-1 und 2
Sicherheit von Maschinen
• ZH 1/11
Sicherheit bei Arbeiten an elektrischen Anlagen
• ZH 1/95
Sicherheitslehrbrief für Elektrofachkräfte

Seite 3
LDW 12.300/0499 DE
Safety Information

1 Explanation of symbols and notes

1.1 Safety symbol

This symbol marks all those safety instructions where life and limb are at
risk. Please read and follow these instructions with special care. Always
pass on instructions on safety to other users. The general notes on safety
and accident prevention must be observed.

1.2 Warnings

CAUTION! This word ”WARNING” marks those parts of the text which must be
followed in order to ensure that instructions, regulations, notes and
correct sequences are adhered to, and to avoid damage to, or
destruction of, the machine and/or other parts of the system.

2 Notes on work safety


This information sheet containing details of the warning symbols used, is an addendum to
the Operating Instructions supplied with each unit and, in the interest of safety, must be
carefully observed.
The electrical machines are working units for use in industrial machinery. During operation,
these machines have dangerously exposed, electrically live parts and/or moving or rotating
parts. Therefore, if essential protective covers are improperly removed for example, or if
the machinery is improperly used, incorrectly operated or inadequately serviced, the most
serious damage to health or to machinery can result.
For this reason, persons responsible for the safety of the machine must ensure that:
• qualified persons only are delegated to work on the machines or apparatus,
• these persons must keep the Operating Instructions provided, and other relevant
documents, available when carrying out the operations to which they refer and to
follow that documentation without fail,
• unauthorised persons are prohibited from working on, or approaching, the
machinery or apparatus.
Qualified persons are persons who, as a result of their training, experience and the
instruction they have received, and of their knowledge of the relevant Standards, directives,
accident prevention regulations and operating conditions, have been authorised by those
responsible for the safety of the machine to carry out the particular task required and who
are able to recognise and avoid the potential hazards (for a full definition of specialist
personnel see DIN VDE 0105 or IEC 364). A knowledge of first-aid and local rescue

page 1
LDW 12.300/0499 EN
Safety Information
equipment is also essential. According to regulations, unqualified personnel are forbidden
to work for example on power installations.
It is a pre-condition that the basic planning work for the machine as well as all operations
involving transportation, assembly, installation, commissioning, maintenance and repair is
carried out by qualified personnel.
In this connection, the following must be especially complied with:
• he technical data and details on the permitted use (assembly, connection, site
and operating conditions) which are also contained in the catalogue, the order
documentation, the Operating Instructions, the machine labels and other product
documents,
• the general regulations on setting up and safety, the local regulations and
requirements specific to the system,
• the proper use of tools, lifting gear and transportation equipment,
• the presence of the necessary contact prevention guards or prevention of
potentially dangerous approach. This applies not only to dangers associated with
moving or electrically live machine parts, but also with parts of the machine with
raised surface temperatures.
If, in special cases where it is intended to use the machine in non-industrial situations, more
stringent requirements are called for, these must be reliably provided by supplementary
safety measures provided at the installation stage.

3 Environmental Protection and Disposal


Environmental Protection
• Oil and lubrication substances are prevented from getting onto the ground in an
uncontrolled manner by locating and repairing leakage points, e.g. in the gears,
hydraulic lines and bearings.
• Poorly fixed machine parts, mainly metal covers, protection grids, protective
covers, air channels, etc. are often the cause of unnecessary noise and are thus
a source of noise pollution at the workplace which is preventable.
• Substances escaping through leaking lines etc. not only put a burden on the air
but are also a source of unnecessary energy loss and sometimes even the cause
of explosions or health risks.
Disposal
Following oil and lubricating material changes, residues must be disposed of according to
national laws and regulations.

CAUTION!
Avoid pollution of the ground, sewage systems and bodies of water.
The disposal of used cleaning agents may be a problem. They often contain chlorinated
hydrocarbons which represent a pollution threat to water. They must, therefore, be
collected and disposed of separately.
This is also valid for the disposal of used coolants and greasing substances. They must
never enter into the ground or sewage systems.
page 2
LDW 12.300/0499 EN
Safety Information
Any lubricating material which has escaped must be cleared by means of a fixing agent
immediately.
Worn fan belts, brake and coupling linings, plastic parts, replaced parts made of stratified
composites do not belong in household waste. They must be disposed of specially.

4 Standards and other documents quoted


• VBG 4
Electrical Installations and Machines
• DIN VDE 0100 -...
Installation of Electrical Power Systems with Nominal Voltages of up to 1000 V
• DIN VDE 0101
Erection of power installations with rated voltages exceeding 1 KV.
• DIN VDE 0141
Earthing system for power installations with rated voltages above 1 KV.
• DIN VDE 0105
Operation of Electrical Power Systems
• IEC 364
Electrical Systems in Buildings
• DIN EN 292-1 and 2
The Safety of Machines
• ZH 1/11
Safety when Working on Electrical Installations
• ZH 1/95
Safety Lesson for Electricians

page 3
LDW 12.300/0499 EN
DC Machines
System Series 5
Models G5.090M.. to G5.160M..

LDW 12.184/1100 EN
Printed in Germany Lloyd Dynamowerke GmbH
Subject to revision Hastedter Osterdeich 250
D–28207 Bremen
 Lloyd Dynamowerke GmbH

The copying, distribution and utilization of this document


as well as the communication of its contents to others
without expressed authorization is prohibited. Offenders
will be held liable for the payment of damages. All rights
reserved in the event of the grant of a patent, utility
model or ornamental design registration.
Elektrische Maschinen,
Antriebssysteme und Anlagen
Contents
1 General 1
1.1 Scope 1
1.2 Specifications and Standards 1
1.2.1 Other standards 2
1.3 General design 3
1.4 Machine designation 3
1.5 Electrical design 3
1.5.1 Rating 3
1.5.1.1 Different duties 4
1.5.1.1.1 Model G5L... 4
1.5.1.1.2 Model G5K... 4
1.5.1.2 Utilisation in accordance with insulation class F 4
1.5.1.2.1 Different cooling air temperature and/or installation altitude 4
1.5.1.2.2 Model G5L... 4
1.5.1.2.3 Model G5K... 4
1.6 Overload capacity 5
1.6.1 Operational shock load 5
1.6.2 Dynamic shock load 5
1.6.3 Zero speed load 5
1.6.4 Voltage 5
1.6.5 Speed 6
1.6.6 Field weakening range 6
1.6.7 Excitation 6
1.6.8 Auxiliary series winding 6
1.6.9 Efficiency 6
1.6.10 Radio interference suppression 6
1.6.11 Thermal protection of motor 6
1.6.12 Smoothing reactors 7
1.7 Mechanical design 7
1.7.1 General standard design 7
1.7.2 Types 7
1.8 Protection systems 7
1.9 Types of cooling 8
1.10 Cooling 9
1.10.1 Self-cooling model G5E... 9
1.10.2 Separate cooling model G5L...(G5F...) 9
1.10.3 Natural cooling model G5K... 9
1.10.4 Fan connection data 9
1.10.5 Data for the cooling air required 9
1.10.6 Connection data of the LLK air/air heat exchanger 10
1.11 Additional radial forces without axial external force 10
1.12 Flanges 11
1.13 Shaft extensions 11
1.14 Drive 11
1.15 Noises 11
1.16 Vibration 11
1.17 Insulation 12
1.18 Paint finish 12
1.19 Accessories 12

2 Installation 13
2.1 Delivery and storage 13
2.2 Commutator Protection for Transport and Storage 13
2.2.1 How to insert the protective tape 14
2.3 Installation 14
2.4 Pulling on the coupling or pulley 15
2.5 Alignment 15
2.6 Connection 16
2.7 Terminal box 16

LDW 12.184/1100 EN Page I


Contents
2.7.1 Standard components 17

3 Commissioning 18
3.1 Mechanical inspection 18
3.2 Insulation resistance 18
3.3 Drying 18

4 Maintenance 19
4.1 Bearings 19
4.1.1 Minimum service life of the grease for long-term lubricated bearings 20
4.2 Commutator 21
4.3 Brushes 21
4.3.1 General 21
4.3.2 Overload 22
4.3.3 Brush pressure 22
4.3.4 Service life 22
4.3.5 Striation 22
4.3.6 Maintenance instructions and spare brushes 22
4.4 Brush assembly 23
4.5 Brush monitoring system 24
4.6 Filter unit 25
4.7 Pressure switch unit (for monitoring the air flow) 26
4.8 Differential pressure switch unit (for monitoring filter contamination) 27
4.9 Tachometer unit 28
4.10 Brake unit 30
4.11 air/air heat exchanger unit 32
4.12 Dismantling and reassembly 33

5 Mounting modifications 35
5.1 Alternative ways of fitting terminal box 35
5.2 Alternative ways of fitting separate fan 36
5.3 Alternative ways of fitting separate fan 37
5.4 Alternative ways of fitting pipe connection 38
5.5 Alternative ways of fitting pipe connection 39
5.6 Alternative ways of fitting pipe connection 40
5.7 Alternative ways of fitting air/air heat exchanger 41

6 Circuit diagrams 42
6.1 Main circuit diagrams (examples) 42
6.2 Additional circuit diagrams (examples) 43
6.3 Connection diagrams for fan motors 43

7 After-sales service 44

8 Instructions and training 44

9 Standards 45
9.1 European standards 45
9.2 International standards 45
9.2.1 IEC standards: 45
9.3 National standards 45
9.3.1 DIN standards: 45
9.3.2 DIN VDE guidelines: 45
9.3.3 DIN ISO standards: 46
9.3.4 Lloyd Dynamowerke (LDW) company standards: 46
9.3.5 VDI specifications: 46

LDW 12.184/1100 EN Page II


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1 General

1.1 Scope
These operating instructions apply to DC machines with the following model designations :

G5L090M.. to G5L160M.. Forced ventilation with radially mounted fan, with air/water heat exchanger mounted
on machine orusing pipe connection, type of cooling IC 06, IC 86 W, IC 17

G5F090M.. to G5F160M.. Forced ventilation with axially mounted fan, type of cooling IC 06

G5K090M.. to G5K160M.. Natural cooling (totally-enclosed machine), type of cooling: IC 410

G5L132M..+LLK to G5L160M..+LLK Separate cooling with air/air heat exchanger mounted on machine, type of cooling:
IC 666

G5E090M.. to G5E160M.. Self-cooling, type: IC 01

1.2 Specifications and Standards


The motor (generator) complies with the DIN VDE specifications, particularly the ”Provisions for rotating electrical machinery”
EN 60034-1, the relevant DIN, IEC and EN (European) standards, and the specifications prescribed by the customer.

The motor (generator) is designed according to the scope of the confirmed order.

The company ordering the unit must ensure that the protection system of the machine complies with the provisions of the
machinery protection legislation for the particular application.

The electrical machines are equipment for use in industrial power plants. During operation this equipment has dangerous, live
bare parts, which may also be moving or rotating. It can therefore cause extremely serious injuries or damage, for instance if
the covers required are removed in contravention of the regulations, the equipment is used improperly, operated incorrectly or
not maintained adequately.

Those responsible for the safety of the plant must therefore ensure that
• only qualified personnel are to be entrusted with working on the machines or equipment.
• these persons amongst others are to have the operating instructions and other product documentation supplied
available at all times when carrying out such work, and agree to follow this documentation consistently.
• Unqualified personnel are prohibited from working on the machines in their vicinity.
Qualified personnel are persons who on account of their training, experience and instruction as well as their knowledge of
relevant standards, requirements, accident prevention regulations and operating conditions, have been authorised by those
responsible for the safety of the plant to carry out the various jobs required, being able to recognise and avoid possible
dangers involved (see also DIN VDE 0105 or IEC 364 for definition of qualified employees). A knowledge of first-aid measures
and the local rescue services etc is also required.

Unqualified personnel are prohibited from working on power plants, eg in DIN VDE 0105 or IEC 60364.

It is assumed that the basic planning of the plant and all transport, installation, commissioning, maintenance and repair work
will be carried out by qualified personnel.

LDW 12.184/1100 EN Page 1


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

The following points are to be noted in this connection:


• Technical data and details of the permissible use (installation, connection, environmental and operating
conditions) which are contained in the catalogue, the order documentation, the operating instructions, the name
plate and the other product documentation etc.
• The general installation and safety regulations, the local regulations and requirements governing the particular
plant.
• Proper use of tools, lifting gear and handling equipment.
• The use of personal protective equipment.
• During operation the protection against electric shock hazard required must be present or people prevented
from coming dangerously close.
• This applies in relation to danger not only from moving machine parts or live parts, but also from hot surfaces of
the machines.
In the interest of clarity the operating instructions cannot contain all of the detailed information on possible design variants,
and in particular cannot take into account every conceivable case of installation, operation or maintenance. The operating
instructions therefore essentially only cover the points required by qualified personnel when the machinery is used as
intended in industrial applications.

For planning, installation, commissioning and servicing it is advisable to take advantage of the support and services of the
LDW Service Centre responsible.

If there are any deviations from normal operation (higher power consumption, temperatures, vibration, noises etc or operation
of the monitoring equipment) it may be presumed that operation is impaired. To avoid faults that could give rise directly or
indirectly to severe injuries or damage, the maintenance personnel responsible must then be notified immediately.

WARNING!
In case of doubt switch the equipment concerned off immediately!

It is stressed that the contents of the operating instructions and product documentation do not form part of or serve to modify
any former or current agreement, undertaking or legal relationship.

All of LDW’s obligations arise from the particular contract of purchase, which also contains the complete warranty conditions,
which alone have legal force. These contractual warranty conditions are neither extended nor limited by the contents of these
instructions and documentation.

The provisions of the machinery protection legislation are satisfied by protection systems IP 23 and IP 44. Any second shaft
extensions ordered shall have protective caps fitted by the manufacturer if they are not being used. The same applies to the
couplings, pinion or belt drives mounted. The dimensions of the machinery comply with IEC 60072, those of the shaft
extensions to DIN 748-3.

1.2.1 Other standards

According to the following standards the motors can be operated at the ratings listed; in some cases this means utilisation
exceeding insulation class F:

NBN C 51-101 Belgium


CSA C 22.2-54 Canada
NF C 51-111 France
BS 4999 UK
CEI 2-3 Italy
NEN 3173 The Netherlands
SEN 260 101 Sweden
SEV 3009 Switzerland
NEMA gen. industrial drives USA

Values for other standards available on request.

LDW 12.184/1100 EN Page 2


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.3 General design


The angular shape of the machines makes them very compact.

Taking account of the static converter supply the machines are designed with laminated cores. This allows them to withstand
current harmonics during stationary operation, and makes them suitable for rapid changes in current or load during dynamic
operation (see subsection entitled ”Dynamic shock loads”).

The main and commutating pole cores and the stator yoke are a one-piece design. The main pole coils are wound into the
finished frame by machine. The commutating pole coils are wound separately. The entire frame is impregnated with a high-
quality class H resin.

Over the entire area at shaft height the connection between the coils and the pole system guarantees low resistance to heat
transmission, and uses special insulation elements to prevent vibration. The accurate pitch of the pole system benefits
commutation. The winding is impregnated and consolidated with resin using a special technique. The rotor is also
impregnated with class H resin.

All of the connecting dimensions, including the axial spacing of the mounting holes (IEC dimension B), comply with the IEC
standards.

1.4 Machine designation


The machine’s designation consists of several letters and digits. The letters K and L are used as supplementary designation.

Key:

G5 - series 5 DC machine
K - natural cooling, totally-enclosed
L - forced ventilation - radial with fan, cooler or pipe connection
1st digit - shaft height in mm
M - separating character
2nd digit - length code

Key to fan and cooler units:

D... - separate fan model D...


L... - separate fan model L...
LLK - air/air heat exchanger with separate fan
LWK - air/air heat exchanger with separate fan

Example: G5L132M26+LLK

G= DC machine
Series 5
separate ventilation
Shaft height 132 mm
Machine length code = 26
LLK = air/air heat exchanger

1.5 Electrical design

1.5.1 Rating

The ratings specified in the tables apply under the following conditions :
• Continuous duty S1
• Utilisation without filter according to insulation class F, utilisation with filter exceeding insulation class F
• Maximum cooling air temperature of 40°C
• Maximum installation height of 1000 m ASL
• Specification : EN 60034-1
• Rotor supply as specified
Under different conditions the following tables can be used to roughly determine the model. The conditions must always be
specified when ordering, so that the motors can be designed and tested accordingly.

LDW 12.184/1100 EN Page 3


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.5.1.1 Different duties

S2 - short-time duty

S3 - intermittent duty, maximum duration 10 min

Binding values and other operating data available on request.

1.5.1.1.1 Model G5L...

Table 1

Duty Perm. output about :


S2 - 30 min 107% of the listed rating
S2 - 60 min 100% of the listed rating
S3 - 40% 120% of the listed rating
S3 - 60% 110% of the listed rating

1.5.1.1.2 Model G5K...

Table 2

Duty Perm. output about :


S2 - 30 min 180% of the listed rating
S2 - 60 min 150% of the listed rating
S3 - 40% 150% of the listed rating
S3 - 60% 125% of the listed rating

1.5.1.2 Utilisation in accordance with insulation class F

The permissible output is about 80% of the listed rating in the case of the G5L and about 70% in the case of the G5K model.

1.5.1.2.1 Different cooling air temperature and/or installation altitude

1.5.1.2.2 Model G5L...

Table 3 Permissible output as a percentage of the listed rating about :

Installation Cooling air temperature in °C


alt. ASL 25 30 35 40 45 50 55 60
1000 m 110 106 103 100 95 90 85 80
1500 m 106 103 100 95 90 85 80 77
2000 m 103 100 95 90 85 80 77 74

1.5.1.2.3 Model G5K...

Table 4 Permissible output as a percentage of the listed rating about :

Installation Cooling air temperature in °C


alt. ASL 25 30 35 40 45 50 55 60
1000 m 115 110 105 100 92 85 77 70
1500 m 110 105 100 92 85 77 70 63
2000 m 105 100 92 85 77 70 63 55

LDW 12.184/1100 EN Page 4


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.6 Overload capacity

1.6.1 Operational shock load

According to EN 60034-1 the motors must generally have an overload capacity of up to 1.6 times the rated torque at the rated
speed for 15 s. About 1.8 times the rated current is required to produce this.

The agreed shock load, for the field weakening range as well, can be taken from the test certificate.

1.6.2 Dynamic shock load

The laminated core design of the commutating field circuit allows any rate of increase in current encountered in practice to be
achieved. In order to optimise the machine the value required is to be specified when ordering. This rate (di/dt) is specified in
A/s, the associated current surge as a multiple of the rated current (IN). The values agreed can be taken from the test
certificate.

1.6.3 Zero speed load

Guide values for the permissible duration of the load at zero speed can be taken from the following table:

Table 5

Rotor current load duration


[% of IN] [s]

200 10
100 30
50 90
20 600
15 continuous

1.6.4 Voltage

The voltages specified in the tables are taken from DIN 40030 and DIN IEC 38. Intermediate values are possible. The rated
speeds and outputs resulting for these can be converted linearly with the rotor voltage with sufficient accuracy, using the next
higher voltage in the table as the starting point. If the voltage required lies above the highest value in the table, or below 80%
of the smallest value in the table, it is necessary to consult the manufacturer about the machine.

Table 6

Rated voltage
3ph mains Static converter single- four-
(50 Hz) circuit quadrant operation
220 V B2H 170 V -
380 V B2H 300 V -
400 V B2H 310 V -

220 V B2 - 150 V
380 V B2 - 260 V
400 V B2 - 300 V

380 V B6 460 V 400 V


400 V B6 470 V 420 V
500 V B6 600 V 520 V

LDW 12.184/1100 EN Page 5


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.6.5 Speed

The speeds specified in the tables are met with a tolerance to EN 60034-1. At intermediate speeds the data of the rotor circuit
with the next lower speed is to be used. The slight increase in speed can be achieved by using a matching exciting voltage.

A speed adjustment range of up to about 20 rpm at constant torque is permissible with all of the machines on this list.

Lower speeds are generally not possible. Please enquire in such cases.

1.6.6 Field weakening range

An increase in the speed through field weakening is permissible at constant rotor voltage up to the speeds and shock loads
specified in the tables. The output remains constant with this increase.

To enable optimal design and testing of the machines, field weakening range and shock load must be specified in the order.

1.6.7 Excitation

The machines are designed for 200 V separate excitation. Other exciting voltages, between 110 V and 340 V for example, are
generally possible. The excitation outputs specified in the tables are maximums used to design the supply unit. Exact values
and data for different operating conditions (see subsection entitled ”Rating”) are available on request or will be communicated
in the event of an order being placed.

In order to protect them against self-induced voltages, machines whose exciter circuit is opened are to be equipped with
protective resistors of the following size connected in parallel:

Table 7

Exciting voltage Protective resistor


110 V 10 Exciter
220 V 7 x resistance
340 V 5 (cold)

1.6.8 Auxiliary series winding

The motors on this list can be fitted with an auxiliary series winding if required (at additional cost).

It is used to increase the torque in the event of an overload (twice the current then also corresponds to twice the torque) and
to achieve a stable speed characteristic even in the case of unregulated drives. The rated speed may turn out to be slightly
higher.

1.6.9 Efficiency

The efficiencies specified in the tables apply at the rated output, speed and voltage. They are determined according to EN
60034-2 and include the excitation losses. The power consumption of the motors of separate fans is not taken into account.

1.6.10 Radio interference suppression

If degree G (basic) radio interference suppression is specified in the order, the commutating poles are normally connected
symmetrically in relation to the rotor.

Capacitors are also connected if necessary.

Please consult the manufacturer about machines that are to be provided with degree N or K radio interference suppression.

1.6.11 Thermal protection of motor

The machines are designed so that the thermal time constants of the rotor and commutating pole windings are about the
same. The machine can therefore be protected effectively by fitting thermal sensors (eg thermistor protection) or resistance
thermometers (eg PT 100) in the commutating and main pole windings (except in exceptional circumstances, such as in the
event of the rotor jamming).

LDW 12.184/1100 EN Page 6


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.6.12 Smoothing reactors

The requisite inductance of any smoothing reactor needed is specified in the output table.

More detailed information on reactors that can be supplied with machines are to be found under ”Accessories” in the other
part of the list.

1.7 Mechanical design

1.7.1 General standard design

The two end plates have 3 identical square air vents at the top and on the right and left of the feet. An identical additional vent
at the bottom (between the feet) is possible at additional cost. The covers, fans or heat exchangers appropriate to the type of
cooling and protection system are fitted on these vents. The identical square vents allow the machines to be installed in the
horizontal or vertical attitude with the same components. If the installation is changed subsequently, ventilation covers must
be turned or re-fitted to suit the protection system.
The separate fan and terminal box are arranged on top. With this arrangement the separate fan only projects slightly beyond
the width of the machine and the terminal box is fully accessible. It is also possible to fit this fan on the side (see subsection
entitled ”Alternative ways of fitting separate fan”). All of the separate fans can be provided with a filter at additional cost.
The air/air heat exchanger is arranged on top and the terminal box on the right. It is possible at additional cost to mount the
air/air heat exchanger on the side with the additional spacer plates required (see subsection entitled ”Alternative ways of
fitting air/air heat exchanger”). The terminal box is then fitted on top (or opposite - depending on what is specified in the
order).
The top air vents are provided for the connection when pipe ventilation is used. Side connection is also possible, even when
retrofitting is involved (see subsection entitled ”Alternative ways of fitting pipe connection”).
The brush assembly can be turned ±90°, allowing the brushes to be changed through the servicing openings without any
problems. Accurate marking ensures that the brush assembly can be moved back into the neutral zone.
Monitoring devices such as pressure switches for monitoring the air flow, differential pressure switches for the filter,
microswitches for brush wear are available at additional cost.

1.7.2 Types

The most commonly used types are shown in the following figures. The designation complies with IEN 60034-7, but code I
(top line) is preferably to be used. The flange-type machines are also supplied with feet. Machines with air/air heat
exchangers fitted can also be produced in flanged form without foot mounting. It is generally necessary to consult the
manufacturer about the maximum speeds of flange-type machines.

Code I IM B3 IM B35 IM V15 IM V36 IM B5 IM V1 IM V3


Code II IM 1001 IM 2001 IM 2011 IM 2031 IM 3001 IM 3011 IM 3031
Figure 1

1.8 Protection systems


The protection systems possible with the different types of cooling can be seen from the following figures. The designation
complies with EN 60034-5.
Unless specified otherwise in the order, the air inlet is on top with protection system IP23 and cooling type IC06 or IC17, and
the air outlets are on the side of the machine. These openings can be in a different position to this, but such a change must
be specified when ordering, since it is not always possible subsequently (see also subsections entitled ”Alternative ways of
fitting ...”).

Please consult the manufacturer about special designs.

LDW 12.184/1100 EN Page 7


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.9 Types of cooling


The following figures show the types of cooling listed. The designation IC.. here complies with EN 60034-6 edition. Any
differences from EN 60034-6 edition are added in brackets (IC..).

The air must enter at the non-drive end (commutator end). For a pipe connection, separately installed fan and separately
supplied heat exchanger the end plate is to be provided with a plate marked ”Air inlet”.

Cooling provided by connecting the machines to a ventilation system via pipe connections fitted

Model G5L

IP23 - IC17 IP23 - IC17 IP44 - IC37 IP44 - IC37


Figure 2

Cooling provided by radially mounted


fan

Model G5L

IP23 - IC06 Figure 3 IP23 - IC06

Cooling provided by axially mounted fan

Model G5F

IP23 - IC06
Figure 4
Cooling provided by an air/water heat exchanger.
Air flow generated by separate fan.

Water inlet temperature 25°C. Water heated about 5 K. Cooling air temperature about
40°C. Different water temperatures have a linear
effect on the temperature of the cooling air (see Section
entitled ’Rating’, different cooling air temperature)

Please consult the manufacturer about these machines Model IP44 - IC86W (ICW37A86) G5L + LWK
Figure 5
Natural cooling. Losses dissipated via the surface

Model G5K

Cooling provided by an air/air heat exchanger. Internal IP44 - IC410 (IC 0041)
and external air flow provided by separately driven fans Figure 6
Model G5L + LLK

IP44 - IC666 (IC0666)


Figure 7

LDW 12.184/1100 EN Page 8


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.10 Cooling

1.10.1 Self-cooling model G5E...

The fan is mounted at the drive end of the self-cooled machines. The cooling air enters the non-drive end radially and is
drawn through the machine. It leaves the machine radially as well. Connection of air supply and exhaust lines to self-cooled
machines is not permitted.

1.10.2 Separate cooling model G5L...(G5F...)

Depending on the type of machine, separate cooling can be provided by radially or axially mounted fans, the plant’s own
cooling air system, or an LLK air/air heat exchanger mounted on the machine (only in the case of machine models G5L 132...
and G5L 160...)
Power consumptions and flow rates of the fans and air/air heat exchangers and the cooling air flow rates required with the
static back pressure of the DC machines are assembled in the following tables.
The exact data for the particular machine is to be found on the name plates of the fan motors and the DC machine.

WARNING!
The direction of ventilation is from the non-drive end to the drive end. The air inlet
end is provided with a corresponding plate.
A subsequent change in the air direction, which is possible in mechanical terms
using the identical openings in the two end plates, may only be made after
obtaining the agreement of the manufacturer of the motor.

1.10.3 Natural cooling model G5K...

The losses of this enclosed machine are radiated from its surface as heat.

WARNING!
Dangerously hot surface temperature!

1.10.4 Fan connection data

Table 8 Fans with multivoltage range, can be used at 50 and 60 Hz

Machine model Fan Power Current Voltage Frequency Weight


kW A V Hz kg
G5L, G5F 090 D-04/S515 0.09 0.7 220- 300 50/60 4.6
0.13 0.4 380- 520
G5L, G5F 100 D-04/S515 0.09 0.7 220- 300 50/60 4.6
0.13 0.4 380- 520
G5L, G5F 112 D-05/S515 0.13 0.73 220- 300 50/60 5.3
0.14 0.42 380- 520
G5L, G5F 132 D-052/S515 0.28 1.8 220- 300 50/60 7.0
0.30 0.9 380- 520
G5L, G5F 160 D-066/S515 1.1 5.2 220- 300 50/60 18.5
1.4 3.0 380- 520

1.10.5 Data for the cooling air required

Table 9

Machine model Cooling air flow rate [m3/s] Static back pressure [hPa)

G5L 090 0.09 4.5


G5L 100 0.10 4.0
G5L 112 0.10 5.5
G5L 132 0.12 6.0
G5L 160 0.35 8.5

LDW 12.184/1100 EN Page 9


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.10.6 Connection data of the LLK air/air heat exchanger

Table 10 Fan motors 380 V - 50 Hz

Internal circuit External circuit


Machine model Power Current Power Current
kW A kW A
G5L 132 ... +LLK 0.25 0.73 0.06 0.24
G5L 160 ... +LLK 0.55 1.40 0.12 0.50

1.11 Additional radial forces without axial external force

Figure 8

LDW 12.184/1100 EN Page 10


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

The drive-end shaft extensions of the normal model are designed for the fully rated torque to DIN 748-3.

In the adjacent diagrams the permissible additional forces Fr are specified for normal drive-end shaft extensions and bearings
with a calculated bearing service life of 20,000 operating hours. To avoid compromising the fatigue strength of the shaft
extension these limits must on no account be exceeded.

The additional forces specified do not mean that masses (couplings, flywheels etc) of this magnitude may be mounted on the
shafts.

The normal non-drive end shaft extension is designed for the full torque with coupling operation. Only small additional forces
are permitted; please ask the manufacturer of the motor about these.

1.12 Flanges
The dimensions of the flanges of type IMB35, IMV15, IMV36 and IMB5, IMV1, IMV3 machines comply with IEC 60072-1. The
outside diameters of the flanges are only squared off to an extent that still leaves an adequate sealing surface for mounting
on oil-lubricated gearboxes for instance. All flanges are oil-tight.

To seal the bearing the flange end is provided with a shaft seal which runs on a hardened bush.

1.13 Shaft extensions


The shaft extensions are supplied with rounded end keys to DIN 6885-1. Second free shaft extensions (not for G5F), smaller
diameters and different lengths, and the model with tapered shaft extensions, are available as special models. The machines
are always balanced dynamically with full keys and marked with an ”F” on the shaft extension. The standard of balancing
corresponds to Q 2.5 to DIN ISO 1940 as standard. The tolerance on the concentricity of the shaft extensions, coaxiality and
axial trueness of the connecting flanges lies between ”N” and ”R” to DIN 42955.

1.14 Drive
With direct coupling an elastic or flexible coupling is the only possibility for the model with antifriction bearings. The machines
must be aligned carefully. Converter machines mounted on base frames are to be realigned carefully at the installation
location in relation to the foundations of the base frame and only then bolted up if necessary.

Shear loads (eg with belt or pinion drive) must not exceed the permissible additional radial forces (diagrams entitled
”Additional radial forces without axial external force”, Subsection 1.11).

1.15 Noises
The levels of noise produced by the machines lie within the permissible limits to EN 60034-9. Special noise reduction
measures are possible if more stringent requirements are imposed.

The sound pressure and acoustic power levels are to be found in the table.

1.16 Vibration
The machines are designed with vibration severity levels between ”N” and ”R” to DIN ISO 2373 as standard. Based on VDI
2056, the following externally excited vibration up to 63 Hz measured in the vicinity of the bearing is permissible:
- standard machines v eff = 4.5 mm/s, but vibration amplitude not exceeding 100 µm

- vibration-resistant machines (at additional cost) v eff = 11 mm/s, but vibration amplitude not exceeding 250 µm.

LDW 12.184/1100 EN Page 11


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

1.17 Insulation
The machines on this list are designed to thermal insulation H. This ensures a long service life. High-quality insulating
materials and appropriate impregnation are used to protect all of the windings to a certain degree against the effectives of
moisture, non-conductive dust and chemically active gases and vapours in the cooling air. The resins, varnishes and
impregnating techniques used ensure adequate protection when the machine is installed in a humid climate. If there are acid
fumes in the cooling air the type of acid and its concentration are to be specified. Only with these details can suitably resistant
insulation giving protection against acid be selected at additional cost. In cases in which the environmental conditions are
particularly difficult, the type of cooling is to be selected in a similar manner at the planning stage (eg central ventilation
system).

1.18 Paint finish


The machines are provided with a protective coat of paint - colour RAL 7031.

Other colours are available on request.

1.19 Accessories
Unless mounted on a base frame or support structure, belt-drive machines are to be secured on the foundation with the aid of
clamping rails, and direct-coupled machines with foundation blocks. Bottom-ventilated machines installed on a concrete
foundation require a special foundation plate (at additional cost) for each end plate. Special foundation work is required for
this when installing on a concrete foundation. Direct installation on a concrete or masonry foundation is not permitted.

The fixings are to be ordered separately.

LDW 12.184/1100 EN Page 12


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

2 Installation

2.1 Delivery and storage


After it has been unpacked each machine is to be checked to see that it is mechanically sound and no damage has arisen in
transit. The machine may only be lifted by the eyes provided for this purpose.

If the machine is not being commissioned immediately it must be stored in a dry, dust-free room that is as free from vibration
as possible. Avoid letting the temperature fall below the dew-point. Building dust can lead to striation on the commutator.

When storing for over 6 months it is advisable to seal the entire machine in sheet polyethylene. A dessicant such as silica gel
is to be placed in this envelope and replaced according to the manufacturer’s instructions when its moisture absorption
capacity is exhausted.

For lengthy storage (over about 3 months) the carbon brushes are to be raised to prevent corrosion underneath while the
machine is idle.

Every 8 to 12 weeks the rotor is to be turned about 15 to 20° to prevent pressure points in the rings of the antifriction bearings
as a result of the static loads from the rotor. If the machine is packed in a case a hatch is to be provided in one the end of the
case, through which the rotor can be turned using the coupling or shaft extension at the drive end.

The case must be mar0ked as follows:

WARNING!
Do not subject to vibration while idle!
After opening the hatch turn the rotor about 15 to 20° clockwise every 8 to
12 weeks
The case must also be marked to indicate that the hatch must remain accessible during storage.

The temperature range over which the bearing grease can be used to provide lubrication is about -20 to +140°C, but the
grease can be stored at temperatures down to -40 °C.

Impairment of the lubricating capacity is not to be expected if the machine is stored under dry conditions free from dust and
vibration for up to 2 years. Before commissioning, the machines with hydraulic-type tapered grease nipples are to be re-
greased with twice the amount of grease indicated on the lubrication plates.

In machines with long-term lubrication (including fan motors) the service life of the grease is about 4 years. It is advisable to
replace or clean and re-grease the bearings after this period.

2.2 Commutator Protection for Transport and Storage

For the protection of the commutator slipring surface during transport and storage, parts of the machines are equipped with a
protective tape wound around the commutator (see figure 9). Please observe that this tape is removed before taking the
machine into service.

Figure 9

LDW 12.184/1100 EN Page 13


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

WARNING!
Remove protective tape between the commutator and the coal brushes
before taking the machine into service.
After having taken the machine into service, standstill periods may frequently occur. Before the temperature falls below the
thaw point, the protective tape must be inserted between the coal brushes and the commutator, or the coal brushes have tobe
lifted.

2.2.1 How to insert the protective tape


1. Attach the protection tape using

adhesive tape
protective tape

wire tie
protective tape

direction of rotation

Figure 10
ashesive tape (see fig. 10) Figure 11
2. Turn the rotor so that the protective tape is drawn between the brush and the commutator. After a full rotation, or
as soon as all brushes are separated from the commutator, the adhesive tape has to be detaches and
withdrawn from the machine.
3. The ends of the protective tape are put together and connected by means of wire ties (see figure 11)

2.3 Installation
The installation area must allow the amount of cooling air required to flow to and from the machine unhindered. The
installation must ensure that the heated exhaust air is not drawn directly into the intake. To avoid compromising the protection
system the slits of the ventilation grilles must face downwards. Any transportation covers for the air supply and exhaust
openings are to be removed.

If the machine has not been supplied with base frame or clamping rails, it is to be installed mounted on a torsionally stiff steel
foundation or a concrete plinth into which foundation blocks have been cast. Levelling of the machine with foundation blocks
must be carried out with the blocks firmly screwed to the feet of the machine. Shims with a total thickness of about 2 mm are
to be inserted between the foundation blocks and the feet of the machine. Packing during initial levelling of the machine must
only take place under the foundation blocks if possible. Re-levelling of the machine is always necessary after the foundation
block mix has set completely. Check that the feet surfaces rest evenly without distorting the frame before tightening the
holding-down bolts.

It is advisable to remove the electrical machines, gearboxes etc mounted on the machine base frame to enable it to be
levelled. The machine base frame is levelled on the prepared surfaces with a spirit level and secured firmly to prevent it
shifting subsequently. After this the machines can be mounted. Note that the first machine mounted is provided with shims
with a total thickness of about 2 mm between the feet of the machine and the base frame bearing surfaces as a levelling aid.
In the case of machine base frames on which machines are mounted that cannot be removed when the base frame is
anchored, the levelling is to be checked and corrected as necessary before commissioning the machines.

LDW 12.184/1100 EN Page 14


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

2.4 Pulling on the coupling or pulley


Only elastic or flexible couplings may be used for DC machines directly coupled to the engine or machine.

Couplings, pulleys etc may only pulled on and off with suitable equipment. A tapped hole is provided in the end of the shaft for
this equipment. Make sure when using it that no impact loads are transferred into the shaft and the centring hole is not
damaged.

The rust protection coating on the shaft extension is to be peeled or washed off beforehand with Siwapur 99 or diesel oil. The
stub shaft is then to be greased or oiled. Any shaft seals present are to be lubricated with a few drops of oil.

The diameters of the shaft extensions of model G5.090... have a j6 and those of other models a k6 tolerance zone, unless a
different zone has been specified in the order. The hub hole of the parts to be pulled on is to have an H7 tolerance zone and
be balanced without keys inserted. The machine is balanced in the factory with full keys and the shaft extension marked with
an ”F”, unless balancing with half keys has been expressly specified in the order; in which case the shaft extension is marked
with an ”H”.

2.5 Alignment
Even when elastic or flexible couplings are being used the machines must be carefully aligned, otherwise operation may be
noisy and the bearings could be overloaded. The shafts of the coupled machines must not be angled or offset parallel to one
another.

The shafts are brought to the same height by inserting or removing shims
under the feet of the frame. The two shafts are aligned accurately axially
(Fig. 12) and radially (Fig. 13) with dial gauges, deviations being measured
as the shaft is rotated through a full 360°. Both measurements are to be
carried out simultaneously, so that correction according to one dial gauge
does not upset the alignment according to the other one. The biggest
difference between the values measured at two opposite positions is not to
exceed 0.05 mm. If personnel have sufficient experience in carrying out
alignment and the coupling is suitable, the alignment can also be carried out
with a straight-edge. The straight-edge is to be placed on a common line
scribed on the two halves of the coupling and the light gap under it used to
check the alignment. The axial gap between the halves of the coupling is Figure 12
measured with feeler gauges (see Fig. 14).

To prevent any axial forces that could damage the bearings arising, the axial
gaps between the halves of the coupling specified by the coupling
manufacturer are to be observed carefully.

In the case of belt drives the motor pulley and the driven pulley must always
have parallel axes and be concentric. To avoid damage to the bearings and
shaft the belt must never be stronger than needed to transmit the forces. Figure 13
See the diagrams in Subsection 1.11 for the maximum permissible radial
forces.

Figure 14

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General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

2.6 Connection
The machines must always be connected as shown on the circuit diagrams provided, observing the direction of rotation and
the DIN VDE safety regulations.

The circuit diagrams show the terminals in their actual position. The connections are always made according to the terminal
markings. To allow connection of the machine the terminals are exposed by removing the cover of the terminal box. The leads
are to be provided with terminals and, after removing the hexagonal nuts, laid on the corresponding stud terminals, directly on
the terminals of the cables leading into the machine.

The contact nuts are then to be retightened firmly. Torque values to DIN 46200: M6 -> 3 Nm, M8 -> 6 Nm, M12 -> 15.5 Nm. It
must be ensured that the terminals of the leads are connected as far away as possible from the neighbouring terminals.
Leads for the monitoring system (for excitation as well from model G5.112 onwards) are to be introduced into the terminal
strip immediately after stripping and clamped in place. Terminal points for connecting an earth wire and marked with the earth
symbol are provided in the terminal box (see view of the inside of the terminal box). The leads are to be connected with strain
relief for the terminals using plastic Pg fittings (see table for standard components).

Should the terminal box have to be turned through 90° subsequently, the machine cables are to be marked before being
disconnected from the terminals. The bottom part of the terminal box can then be removed from the stator, turned 90° and the
machine cables re-introduced through the next opening in the bottom part. Depending on the routing of the mains cables it
may be necessary to also release the additional terminal and turn through 90°.

When re-fitting the bottom part of the terminal box, washers are to be inserted in the same position under the bolts. The
torque values to which the bolts are to be tightened are: M6 -> 6 Nm, M8 -> 10 Nm.

In the case of machines with a radially or axially mounted separate fan unit or LLK heat exchanger fitted it must be checked
that the direction of rotation of the fan’s impeller is correct as shown by the arrow on its housing. If necessary the direction of
rotation of the fan motor is to be changed by swopping the U1 and W1 leads of the mains supply on the terminal board. The
fan’s motor is to be wired according to the mains voltage available. Its power consumption is to be checked with the servicing
openings of the DC machine closed and the fan motor at operating temperature. The measurement is to be carried out with
the DC machine running and stopped.

2.7 Terminal box


All machines are provided with a square terminal box made of an plastic resistant to impacts, high temperature, oil, petrol and
sea water and complying with protection system IP55. It is fitted on top of the machine (exception: machines fitted with an
air/air heat exchanger), and has Pg fittings on two opposite side, which are sealed with plugs as standard.

Cable glands are available at additional cost.

Due to the symmetrical arrangement of the terminals the mains cables can be connected from the right or left. Turning the
terminal box through 90 degrees allows the cables to be routed axially from the drive or non-drive end as well.

As a special design the terminal box can be fitted on the side (right or left). In the case of sizes 90 and 100 this requires a
special stator frame (see subsection entitled ”Alternative ways of fitting terminal box).

With a side terminal box it must be ensured that the cable entries screwed on the bottom do not project below the feet!

PTC resistor, Pt 100 or microswitch connections are made to additional terminals (see subsection entitled ”Alternative ways of
fitting terminal box” and Assignment of terminal boxes).

Marked terminals are provided in the terminal box on the stator for connecting the earth and neutral wires.

LDW 12.184/1100 EN Page 16


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

2.7.1 Standard components


Table 11

Machine model Pg thread* each end Main terminals Excitation/ additional Earth wire
terminal connection
G5.090 2 x Pg21 4 x M6 4 x 4 mm2 U terminal
G5.100 1 x Pg16
G5.112 2 x Pg29 4 x M10 6 x 4 mm2 Terminal plate
2 x Pg16
G5.132 2 x Pg36 4 x M12 6 x 4 mm2 Terminal plate
G5.160 2 x Pg16

* All Pg threads are sealed with plugs if Pg fittings are not specified in the order.
View of the inside of the terminal box (example: Circuit diagram for separate excitation)

Model G5.090 2-pole


Model G5.100 2-pole
Model G5.112 4-pole
Model G5.132 4-pole
Model G5.160 4-pole
clockwise rotation

two-pole machine four-pole machine

Figure 15

LDW 12.184/1100 EN Page 17


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

3 Commissioning

3.1 Mechanical inspection


Once installation, connection and checking of the machines according to these instructions have been completed, all of the
bolts and screws and screw connections of the mechanical and electrical parts are to be rechecked to see that they have
been firmly tightened. It must also be possible to turn the rotor easily, since distortion of the machine would jeopardise quiet
running and endanger the bearings. Check that the brushes rest perfectly on the commutator and their stranded leads are
guided freely. Dust and foreign bodies that have got into the machine are to be removed.

3.2 Insulation resistance


Although the strength of the insulation of every machine is tested in the test bay for compliance with the specifications
stipulated in the order, before commissioning it is necessary to recheck that the insulation resistance has not been impaired
by moisture or mechanical damage in transit or during prolonged storage or installation. For this purpose the insulation
resistance of the winding relative to the iron core is to be measured with a magneto. The minimum value of the insulation
resistance must not fall below 1 MΩ at room temperature.

3.3 Drying
If the insulation resistance of the winding is less than 1 MΩ and the machine has been stored in a very moist environment, the
machine must be dried to avoid damage. The simplest way of carrying this out is in a closed room or area that has been
partitioned off, which is heated with heating resistors or incandescent lamps with the air being changed at an appropriate rate.
The windings should not generally be heated to more than 75°C - measured at the winding overhangs, this temperature
should not be reached in less than six hours, and no part of the machine get hotter than 90°C.

Drying can also be carried out with direct current, the machine being driven mechanically, its shunt winding excited
separately, its series winding disconnected and its rotor winding short-circuited at the terminals via protective switches. During
this process it is necessary to check the current, which must not lie above the rated value!

This short-circuit drying technique is only to be carried out by a suitably qualified electrician. Current must not be passed
through the stationary rotor from outside under any circumstances. Once the prescribed insulation value has been achieved
the machine is to be allowed to run without any load for a period of time.

LDW 12.184/1100 EN Page 18


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4 Maintenance
Dust, oil and dirt are to be cleaned off the machines thoroughly from time to time. In the case of the enclosed model G5 K
machine, dust and dirt deposits are to be removed from the surface as well to ensure it radiates sufficient heat. Any cleaning
may only be carried out with the machine disconnected from the power. The inside of the machine is not to be cleaned with
trichloroethylene, but with a steam jet for instance.

The maintenance of the machines primarily relates to inspection of the bearings, the commutator, the brush-holders and the
brushes. It is particularly important to ensure that the commutator has a smooth and clean ground surface and the brushes
rest on it properly. A dark brown patina on the commutator is normal and should not be removed. Any brush discharge
occurring is often attributable to mechanical causes. Other points to look for include the commutator becoming out- of-round,
the mica protruding between the commutator segments, the brushes jamming in the holders and the entire machine running
noisily as a result of having become unbalanced or installed incorrectly. In all these cases suitable remedial measures must
be taken.

4.1 Bearings
All of the machines of this series are fitted with antifriction bearings.

The service life of these bearings also depends on that of the lubricating grease. The bearings are long-term lubricated and
protected against dirt. The bearing at the drive end is a fixed design. To protect the bearings against external vibration and
make them runner quieter a ball bearing shim is fitted at the non-drive end (moveable bearing end) of the machine. The
springiness of this shim pushes the outer ring of the ball bearing at the non-drive end and the inner ring of the ball bearing at
the drive end axially, far enough to take up the play in the bearings.

As a guide, the number of operating hours are tabulated below as a function of the speed for ”Klüber STABURAGS NBU 8EP”
grease. Re-greasing is to be carried out with the same grade of grease.

If the machine is continually being operated over a range of speeds, the value used in the table must correspond to their root
mean square taking into account the times.

The values specified for the number of operating hours relate to operation at a room temperature of 40°C. The service life can
be expected to double at a room temperature of 25°C.

Machines with a lubricator have lubrication plates with the following data:

- grade of grease

- greasing interval and quantity

- after how many greasings is the spent grease to be removed from the collection
cavity in the end plates

Re-greasing must be carried out with the same grade of grease. Since they do now allow the old grease to escape, the end
plates of these machines must be removed after the interval specified on the lubrication plate, and the grease removed from
their collection cavity.

It is possible to fit measuring nipples for monitoring using the intermittent pulse method.

The normal bearing system is generally adequate even for the vertical types, unless unusually heavy couplings or high
speeds necessitate special measures that make it necessary to consult the manufacturer.

LDW 12.184/1100 EN Page 19


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.1.1 Minimum service life of the grease for long-term lubricated bearings

Table 12 Machine horizontal corresponding to types IM B3, IM B35

Machine model Operating hours


Speed rpm
500 750 1200 1800 3000
G5E, G5L, G5F 090 35,000 35,000 35,000 35,000 20,000
G5K 090 35,000 34,000 21,000 13,000 7,500
G5E, G5L, G5F 100 35,000 35,000 35,000 34,000 19,000
G5K 100 35,000 33,000 20,000 13,000 7,000
G5E, G5L, G5F 112 35,000 35,000 35,000 30,000 16,000
G5K 112 35,000 30,000 18,000 11,000 6,000
G5E, G5L, G5F 132 35,000 35,000 35,000 29,000 15,000
G5L 132 + LK 35,000 35,000 28,000 18,000 9,000
G5K 132 35,000 30,000 18,000 11,000 5,500
G5E, G5L, G5F 160 35,000 35,000 35,000 22,000 10,000
G5L 160 + LK 35,000 35,000 22,000 13,000 6,000
G5K 160 35,000 24,000 14,000 8,500 4,000

Table 13 Machine vertical corresponding to types IM V15, IM V36

Machine model Operating hours


Speed rpm
500 750 1200 1800 3000
G5E, G5L, G5F 090 35,000 35,000 35,000 23,000 13,000
G5K 090 33,000 22,000 13,000 8,500 5,000
G5E, G5L, G5F 100 35,000 35,000 35,000 22,000 12,000
G5K 100 33,000 22,000 13,000 8,500 5,000
G5E, G5L, G5F 112 35,000 35,000 31,000 20,000 10,000
G5K 112 30,000 20,000 12,000 7,500 4,000
G5E, G5L, G5F 132 35,000 35,000 31,000 19,000 9,500
G5L 132 + LK 35,000 31,000 18,000 11,000 6,000
G5K 132 29,000 19,000 11,000 7,000 3,500
G5E, G5L, G5F 160 35,000 35,000 24,000 14,000 6,500
G5L 160 + LK 35,000 25,000 14,000 8,500 4,000
G5K 160 24,000 16,000 9,000 5,500 2,500

LDW 12.184/1100 EN Page 20


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.2 Commutator
The commutator is supplied by the factory precision ground, the running surface does not have to be re-finished when the
machine is commissioned provided no damage has been suffered in transit. The commutator is only to be re-finished if it has
been attacked over time by aggressive elements in the circulating air. The running surface of the commutator is particularly
liable to attack if the circulating air is dry and the machine is continually operated under a fractional load.

If possible, re-finishing is to be carried out with the brushes raised and with the aid of carborundum cloth, using a wooden
block hollowed out to conform to the curvature of the commutator, or with the aid of a rubber polisher for the commutator.
Under no circumstances may emery cloth be used for this purpose. The commutator may only be re-finished with the machine
cold.

Commutators that have become out-of-round are to be turned on a lathe with a very sharp cutting tool or a diamond. Ensure
accurate concentricity (≤ 0.02 mm). The smallest commutator diameters permissible after re-finishing are specified in the
following table.

Table 14

Model Commutator diameter


new worn
G5.090 82 78
G5.100 90 86
G5.112 102 98
G5.132 132 128
G5.160 175 171

After the outside diameter has been turned the mica must be scratched out over the full width with a suitable metal saw blade
or milling cutter, to a depth of about 1 to 1.5 mm, and the burr produced removed completely. Any mica particles left behind in
the slits scratched out can lead to commutation faults. After this work the commutator is to be re-finished in the manner
described above. The machine is to be cleaned thoroughly before re-commissioning.

4.3 Brushes

4.3.1 General

Carbon brushes from well-known specialist manufacturers are fitted to the DC machines we manufacture.

As a result of many years’ experience, test bay trials, regular contact with our carbon brush suppliers and feedback from
service engineers, we are in a position to specify a grade of brushes suitable for normal conditions for the wide range of
application of the DC machines.

A compromise often has to be made between good commutation and good running characteristics.

We use block brushes for the machines.

Depending on the way they are manufactured the brushes break down into three groups, each of which is reserved for a
certain application.
1. Special graphite brushes
2. Electrographitised brushes
3. Metallised brushes
Thanks to their high series and shunt resistances special graphite brushes are preferred for particularly difficult commutation
conditions with moderate current densities (up to about 9 A/cm2). They are also used for static converter supplies with high
levels of current ripple. They also have good running characteristics.

Electrographitised brushes are the most important group, and come in grades covering the wide field of DC machines. Their
permissible continuous load lies between 10 and 13 A/cm2. The current densities can be exceeded by about 100% in
intermittent operation, and by up to 400% in the case of some grades.

Metallised brushes are used for low-voltage machines (10 to 100 V), where brush current densities from 14 to 25 A/cm2 are
permissible and particularly low brush losses are required for heating reasons. The current densities can be exceeded by
about 100 % in intermittent operation.

LDW 12.184/1100 EN Page 21


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.3.2 Overload

Lengthy overloading accelerates brush wear, impairs the commutation capacity of the brushes and increases the tendency to
distribute the current unevenly.

4.3.3 Brush pressure

The correct brush pressure for normal stationary-type DC machines is 2.5 N/cm2.

4.3.4 Service life

The service life of the brushes essentially depends on the load and the condition of the circulating air. At a humidity of 6 to 12
g of water per m3 of air, normal wear can be assumed to be 5 mm at 1000 operating hours. Since the humidity and
contamination of the circulating air have a very marked effect on the ”carbon brush/commutator” unit, this value can fluctuate
by about 100% even under normal loading conditions.

4.3.5 Striation

The brush cross section of each DC machine is determined by the design data. A brush that is too lightly loaded, ie when the
machine is operated under a fractional load for a long period, can be the cause of striation. In these circumstances reducing
the number of brushes per bolt is a way of increasing the current density and hence preventing the striation. If this measure
cannot be applied or does not lead to success, a carbon brush manufacturer must be consulted who can determine the most
suitable grade of brush on site - possibly by means of brush trials - taking into account the actual operating and circulating air
conditions.

Example of the designations used to dimension a carbon


brush. These dimensions are specified in the order t, a, r.
4.3.6 Maintenance instructions and spare brushes

The machines are supplied with the brushes bedded in to avoid the
need for this during commissioning. All that needs to be checked is
that the brushes move freely in the holders and that the spring
tension of the teeth is sufficient to ensure that all brush-holders
achieve a brush pressure of eg 2.5 N/cm2 (depending on the grade
of brush and purpose of the machine).

In the course of operation it is necessary to keep the progress of


the wear under observation and prevent the rivetting or the
stamped contacts of the stranded leads touching the surface of the
commutator. The carbon brushes must be replaced once they are
worn down to about a third to a half of the original radius ”r”. Some 10 x 25 x 32
of the brushes already have a minimum mark (in the form of a t (tangential)
groove on the tangential side or a marking to the bottom of the a (axial)
trade mark).
r (radial)
If after many hours of operation spare brushes are necessary, the Figure 16
same or an equivalent make are to be used to avoid jeopardising
the commutation or the commutator.

Spare brushes with insulated stranded leads are to be used. If brushes with uninsulated stranded leads are used it must be
ensured that the lead cannot come into contact with the bearing plate or the service plates. The minimum air gap is ≥ 4.5 mm.

To ensure the entire running surface of these brushes rests on the commutator, they are bedded in with the aid of a strip of
sandpaper held taut around the commutator, with the abrasive side facing outwards, which is pulled to and fro until the
running surfaces of the brushes have adopted the curvature of the commutator. Finally the bedding in is to be carried out
several times in the direction of rotation only. The process is to be started with coarser and finished with fine sandpaper. Then
the carbon dust removed carefully. The brushes will be fully bedded in after several hours of operation.

LDW 12.184/1100 EN Page 22


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.4 Brush assembly


The brush assembly with flanged brush-holders is secured axially with 2 bolts with washers lying in the side service openings.
It has been set in the factory in the optimum position for operation. This position (neutral zone) is identified with a mark in the
service opening of the end plate and a corresponding mark on the brush assembly. It must be ensured that this position is
maintained under all circumstances after dismantling, otherwise the commutation will be impaired and brush discharge
induced.

If the brush-rocker has been pushed out of the neutral zone in the factory to achieve a particular motor speed characteristic or
generator voltage characteristic, this brush position must always be reset. When a rotor is replaced it should be noted that the
neutral zone may shift, making it necessary to reset the assembly.

This resetting and checking of the neutral zone can only be carried out with the brushes well bedded in and resting fully on
the commutator. It is to be carried out as follows:

A mV meter with a FSD of about 600 mV is connected to the stranded lead of each plus and minus brush. The exciting
current is limited to about 20 to 30% of the design value by drop resistance with field resistance connected. This current is
then switched on and off with the rotor stationary. The position producing the lowest pointer deflection on the meter is to be
sought by pushing the brush-rocker. In the course of this the rotor is to be turned several times in the direction of rotation in
which the brushes have been bedded in. The rotor must not spring back (flipping the brushes). This setting of the neutral zone
is adequate for machines with only one direction of rotation.

For reversing motors it is better to determine the neutral zone by running clockwise and anticlockwise at the same speed, with
the same rotor voltage and the same rotor and exciting current, and with brushes bedded in perfectly for the direction of
rotation concerned.

Maintenance of the complete brush assembly mainly involves keeping the insulating elements clean.

The machines can also be supplied with a brush monitoring system.

LDW 12.184/1100 EN Page 23


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.5 Brush monitoring system


The brush monitoring system operates independently of the potential of the rotor circuit and employs microswitches fitted to
the brush-holders. Depending on the design, one microswitch can monitor one or more holder pockets.

The microswitches are designed as ”normally closed contacts” and connected in series (see following wiring diagram).

Microswitch (representated with contact operate


for both carrying devices)

Brush holder (representated as double brush holder)

connection in the terminal box

connection at the
brush yoke

Figure 17

The carbon brush that wears down to its minimum permissible length first opens the circuit with its microswitch as a result.
This type of switching ensures that the circuit monitors itself for any break in a cable.

An evaluation unit or an isolating transformer (not supplied with the machine) can be connected via terminals 901 and 902 in
the terminal box.

Electrical data of the microswitch

Switching capacity: Ohmic load DC 7A 28 V


AC 3A 220 V

Inductive load DC 4A 28 V
AC 2A 220 V

The minimum voltage required is 24 V; the minimum current 100 mA. To ensure reliable switching, particularly after the
machine has been idle for a long time, the current should not fall below the minimum, and when there are several
microswitches connected in series the minimum current should be increased.

LDW 12.184/1100 EN Page 24


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.6 Filter unit


If machines are fitted with a filter unit because the cooling air available at the installation location is not sufficiently clean,
these filters are to be cleaned thoroughly or replaced at regular intervals depending on the dust level.

Excessively dirty filters impair the cooling of the machines and lead to heat damage.

The fine filters we use (fibre layer filters) can be cleaned by washing in water (up to about 40°C), knocking, suction or blowing
out with compressed air. Dusts containing grease may have to be washed out in warm water (maximum of 40°C, possibly
adding commercial detergents). Avoid wringing the fine filter material out and spraying it clean. It is however generally
advisable to replace dirty filter materials.

Coarse (metal) filters an be cleaned by blowing them out with compressed air or washing in solvents.

All filters are always to be dried again after cleaning.

Diagram of ”Radial fan unit”

Pos. Description

48 Fan without filter


49 screw for fan
50 spring ring for fan
51 Adapter
52 screw for adapter
53 spring ring for adapter
54 filter with filter cartridge
55 filter cartridge

Figure 18

Diagram of ”Axial fan unit”

Pos. Description

48 fan (without filter)


49 srew for fan Figure 19
50 spring ring for fan
54 filter with filter cartridge
55 filtercartridge
56 adapter GF
57 screw for adapter GF
58 spring for adapter GF

LDW 12.184/1100 EN Page 25


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.7 Pressure switch unit (for monitoring the air flow)


Pressure switches fitted give a signal if the impeller is not turning. The pressure switches on machines with fans (and filters)
are set in the factory in machines ordered with this facility.

Setting the 625 pressure switch

- Align pipe bend tangentially in relation to the impeller and screw pressure switch tight with lock-nut.

- Transfer the dot marking of the pressure switch to the wall of the frame.

- Fit fan to check contact signal given to machine.

- The contact can be adjusted with the fan running, by turning the plastic main adjusting screw and the secondary
(cheese-head) adjustment screw if necessary. The cover must be removed to gain access.

- Contact 3 must open reliably with fan switched off.

- Maximum load on the switching contacts 1.0 A at 250 V AC; range of adjustment 2 to 8 mbar.

Pressure switch unit


outside diameter position of the high bend
fan impeller marked with a red point

pressure switch 625 schema of connection


(without box) 1 lead

2 normally closed contact


adjusting screw 3 offnormal contact
Pos. Description
main adjusting screw
103 pressure switch 625 with box

Figure 20

LDW 12.184/1100 EN Page 26


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.8 Differential pressure switch unit (for monitoring filter contamination)


Differential pressure switches fitted give a signal when the filter is dirty. The differential pressure switches on machines with
fans and filters ordered with this facility are set in the factory.

Setting the 602 differential pressure switch

- Suction tube (hose end fitting) fitted in front of air inlet in the middle of the filter directed towards the fan.

- Switch fan on, set for reliable contact when connected to 2 (normally closed contact).

- Cover 50% of filter. Contact must open. Maximum load on the switching contacts 1.0 A at 250 V AC

Differential pressure switch unit

Pos. Description
104 differential pressure switch, complete
105 flexible tube
106 clip schema of connection
107 screw for clip 1 lead
108 spring ring for clip 2 normally closed contact
109 hose stem 3 offnormal contact
110 fixed link
111 screw dor hose stem
112 nut for fixed link
113 spring ring for hose link
114 screw for fixed link
115 spring washer for fixed link

Figure 21

LDW 12.184/1100 EN Page 27


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.9 Tachometer unit


If the machine has a A4 commutator tachometer (see 5.4) at the non-drive end, after removing the outer cover the tachometer
housing is to be unscrewed from the intermediate plate. The tachometer rotor is to be removed by releasing the thrust bush.
The intermediate plate can now be unscrewed, for further dismantling for changing a bearing for instance.

If it is necessary to remove the complete rotor, in order to turn the outside diameter of the machine’s commutator for instance,
to allow the rotor to be held between the lathe’s centres the tachometer driver screwed on is to be removed to expose the
shaft’s centring hole.

If the machine has a flange driver it is to be removed by undoing 3 M5 bolts.

If the machine has a driver screwed into the thread of the shaft centring hole (evident from the hexagonal head for a 19 mm
spanner), this is to be heated to a maximum of 100°C to release the Loctite compound so that it can be unscrewed.

Reassembly is carried out in the reverse order, the driver being secured again with ”Loctite 75” or a equivalent compound.
The concentricity of both types of driver is to be checked about 5 mm from the end of the shaft with the machine installed
without the tachometer fitted. The maximum permissible deviation is 0.05 mm, and the driver is to be corrected to achieve this
if necessary. Only then is the tachometer to be fitted, and the rotor is to be pushed onto the shaft first. After fitting the
tachometer housing the thrust bush is to be tightened to be secure the rotor. It must be ensured with a visual inspection
through the brush-holders that the centre of the commutator is in the middle of the brush-holders. The concentricity, measured
on the surface on the commutator, is to be re-checked through the brush-holders, with the maximum permissible deviation
again being 0.05 mm. It can be corrected by for instance turning the tachometer rotor 90o on the driver.

In the case of a tachometer unit with coupling (see 5.5), after undoing the bolts securing the tachometer, the tachometer
including coupling half is to be pulled off. Lantern wheel, second half of coupling and driver can then be removed. When the
tachometer is reassembled the concentricity of the driver is to be checked (maximum deviation 0.05 mm). The gap between
driver and tachometer shaft (> 4 mm), and the gap between the coupling hubs (3-part curved tooth coupling = 4 mm, 2-part
curved tooth coupling = 2 mm), are also to be checked.

Sectional diagram of ”A4 tachometer unit”

Pos. Description

59 driver A (cone)
60 driver B (flange)
61 screw for driver B
62 spring ring for driver B
63 adapter ring
64 screw for adapter ring
65 spring ring for adapter ring
66 tacho
67 screw for tacho

Figure 22

LDW 12.184/1100 EN Page 28


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

Sectional diagram of ”Tachometer unit with coupling”

Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 tacho
77 screw for tacho
78 spring ring for tacho
79 coupling
80 adapter ring for brake
81 screw for adapter ring
82 spring ring for adapter ring
83 brake
84 adapter ring for tacho
85 Threaded rod for brake and adapter ring
86 Nut for brake and adapter ring
87 spring ring for brake and adapter ring
88 straight dowl
89 spring ring

Figure 23

LDW 12.184/1100 EN Page 29


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.10 Brake unit


If the brake is also provided with a tachometer, the section entitled ”Tachometer unit (with coupling)” is applicable to fitting and
removal. Before dismantling, marks are to be made from end plate to intermediate plate for the brake, from here to the brake
and on to the intermediate plate for the tachometer. Brake and intermediate plate for the tachometer are secured with
common bolts or studs. Once these have been undone the brake can be removed. After removing the circlip the pinion can be
pulled off the shaft.

If the brake is mounted on the end plate at the non-drive end with an intermediate plate, this is also to be removed if the end
plate is to be removed (otherwise the bearing cap bolts will not be accessible).

When fitting, the concentricity of the intermediate plate for the tachometer unit is to be checked and the plate realigned if
necessary (maximum deviation 0.05 mm) and bolted up. Pay attention to the previous marks.

Sectional diagram of ”Brake unit with intermediate plate”

Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 tacho
77 screw for tacho
78 spring ring for tacho
79 coupling
80 adapter ring for brake
81 screw for adapter ring
82 spring ring for adapter ring
83 brake
84 adapter ring for tacho
85 Threaded rod for brake and adapter ring
86 Nut for brake and adapter ring
87 spring ring for brake and adapter ring
88 straight dowl
89 spring ring

Figure 24

LDW 12.184/1100 EN Page 30


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

Sectional diagram of ”Brake unit without intermediate plate”

Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 Tacho
77 screw for Tacho
78 spring ring for Tacho
79 coupling
83 brake
88 straight dowl
89 spring ring
90 adapter ring for tacho
91 screw for brake and adapter ring
92 spring ring for brake and adapter ring

Figure 25

LDW 12.184/1100 EN Page 31


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.11 air/air heat exchanger unit


LLK air/air heat exchangers are connected to the DC motor elastically with 4 bolts through a rubber pad. After undoing the 4
nuts and the earth cable the air/air heat exchanger can be lifted off. The mounting plates do not have to be removed in the
process. If they are however removed, they are to be reseated with Hylomar sealing compound. When fitted on the side of the
DC machine, the cooler has to be removed to make the holes in the feet of the machine accessible. After mounting the DC
machine on a frame or foundation the cooler is to be refitted. Ensure that the 4 nuts of the cooler unit are tightened so that the
gasket is in contact all the way round between mounting plate and cooler (compress gasket about 1 to 2 mm).

air/air heat exchanger unit

Pos. Description

93 air/air heat exchanger (LLK)


94 ring buffer
95 nut for LLK
96 spring ring for LLK
97 entry fitting drive end
98 entry fitting non-drive end
99 screw for entry fitting
100 protective conductor
101 sealing drive end
102 sealing non-drive end

Figure 26

LDW 12.184/1100 EN Page 32


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

4.12 Dismantling and reassembly


Depending on the purpose of the work it is necessary to consider before dismounting the machine whether it has to be
dismantled completely or only partially.

Removing the rotor necessitates removing the end plates for example. To replace a bearing it is only necessary to remove the
end plate concerned. Replacing a commutating pole coil necessitates dismantling the machine into its main parts and
disconnecting the circuit connections involved. However even for partial dismantling it is better not to dismantle the machine
further than is absolutely necessary in order to clean it thoroughly or investigate whether all of its parts are in good operating
order.

Marks are to be made from the stator to the end plates before dismantling.

Before starting work it is necessary to make absolutely certain that the machine is disconnected from the mains. One half of
the coupling, the pulley or the like is then to be pulled off the stub shaft. After exposing the commutator service openings all of
the carbon brushes are to be lifted off the commutator and clamped firmly in the holder guide boxes with the aid of the
pressure lever, in order to prevent the remaining work causing any damage to the surface of the commutator. For the same
reason it is advisable to wrap the commutator in a protective envelope of cardboard.

To prevent the rotor falling onto the bottom pole, the air gap between rotor and pole is to be filled with cardboard before
continuing dismantling.

After removing the bearing head bolts from the drive and non-drive ends, the end plates are to be separated from the frame
after undoing the retaining bolts. The plates are separated with the aid of two large screwdrivers driven into the outer ring gap.
The plates are levered out of the frame’s centring aperture axially with the screwdrivers. It must be noted that with ball
bearings the bearing head (bearing seat in the plate) has to slide over the outer ring of the bearing. The end plates are
therefore not to be tilted, and are to be driven out over the outer rings of the bearings as evenly as possible, possibly by
tapping their flanges lightly.

However when removing the end plate from the non-drive end, the leads on the brush assembly are to be marked and
disconnected beforehand. Moreover any tachometers are to be removed before removing the end plate.

It is possible to remove the rotor of the small machines by hand. Any lifting cables or other aids that have to be used must not
be slung around unprotected shaft extensions and on no account around the commutator or fans. The rotor must not be
deposited on the bandages.

Refitting and reassembly are to be carried out similarly in the reverse order.

Reassembly is to be carried out on a aligning plate. The marks from the stator to the end plates are to be brought into
coincidence. This ensures that the feet are in one plane and the neutral zone marks remain valid.

Replacing a bearing requires pulling it off the shaft of the machine with a puller. The legs of the puller grip the outer ring of the
bearing, leading to deformation of the races or balls or rollers. It is always advisable not to reuse a bearing pulled off in this
way, even if it still appears to be suitable.

New bearings may be pulled onto the shaft cold, but it is advisable to heat them to about 100°C.

2/3 of the free space inside bearings with long-term lubrication must be filled with grease. After they have been cleaned and
dried carefully the outside grease collection cavities in the end plates are to be filled to 3/4 of their capacity with the same
grade of grease.

In machines with a lubricator for the bearings the new bearing is also to be filled to 2/3 of its capacity with grease, but the
collection cavities of the cap left empty!

Any shaft seals present are to be renewed at the same time when a bearing is replaced. Fill the lip cavity facing outwards with
the bearing grease.

In order to retain the machine’s original thermal characteristic (defined air throughput), renewing of the insulation system and
rewinding of the main pole coils are only to be carried out in the factory.

To allow mounting of the inner bearing cap an auxiliary stud or threaded rod is to be screwed into one of the tapped holes in
the cap before refitting the end plate. The stud is then to be guided though a bearing head hole in the end plate. The exposed
length of the stud must be about the width of the bearing +30 mm.

LDW 12.184/1100 EN Page 33


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

The ball bearing shim at the non-drive end is to be reinserted in the same position when the machine is reassembled.

Further dismantling of the machine and reassembly requires the measures described in the Subsections concerned. Marking
in advance individual parts where it is not absolutely clear how they belong together is strongly recommended. It is particularly
important during reassembly to pay attention to good insulation, sufficient spacing between live parts, good contacts, secure
connection of all screw joints and ensure that the bearings are in perfect condition. It is advisable to carry out insulation and
operating tests after completing the work.

Table for exploded drawing of ”Basic design”


1 stator with winding 25 ground strap
2 rotor with winding 26 lifting eye
3 brush yoke, complete (without carbon brush) 27 key
4 end plate drive end 28 grease nipple
5 end plate non-drive end 29 carbon brush
6 bearing drive end 30 screw for bearing cap drive end
7 bearing non-drive end 31 gasket for pos. 30 and 36
8 bearing cap drive end 32 screw for end housing without lifting eye
9 bearing cap non-drive end 33 spring ring for pos. 32 and 34
10 end-float washer for bearing 34 screw for end housing with lifting eye
11 end guard non-drive bearing 35 screw for cover sheet
12 inner raceway drive end 36 srew for bearing cap non-drive end
13 sealing for shaft, drive end 37 screw for end guard non-drive end
14 cover sheet (outlet) 38 screw for brush yoke
15 cover sheet (closed) 39 spring washer for pos. 38
16 terminal box 40 screw for terminal box
17 cover of terminal box 41 screw for cover of terminal box
18 sealing terminal box 42 spring ring for pos. 41
19 sealing 43 screw for ground strap
20 auxiliary terminals 44 spring ring for pos. 43
21 compression gland for connection 45 screw for auxiliary terminals
22 compression gland for connection 46 screw plug
23 blind hole for compression gland 47 fan impeller (only with self-cooling)
24 blind hole for compression gland

LDW 12.184/1100 EN Page 34


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5 Mounting modifications

5.1 Alternative ways of fitting terminal box


mounting modifications: Terminal box
1. character: position of terminal box
O = above
R = right
L = left
2. character: position of cable glands
R = right U = below
L = left A = axial to D
O = above N = axial to ND
RU, RO, LU, LO spezial mounting,
RA, RN, LA, LN at frame size 90 and 100 = additional price

Figure 28

LDW 12.184/1100 EN Page 35


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.2 Alternative ways of fitting separate fan


mounting modifications: fan

1. character: position of fan


O = above
R = right
L = left
2. character: direction of rotation of fan rotor
R = clockwise
L = anticlockwise
following characters:
A = fan is mounted at drive end on inquiry only !
Q = fan is mounted cross to the motor axle
- - - = subsequent change is possible, but remark A

Figure 29

LDW 12.184/1100 EN Page 36


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.3 Alternative ways of fitting separate fan


mounting modifications: fan

Figure 30

LDW 12.184/1100 EN Page 37


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.4 Alternative ways of fitting pipe connection


mounting modifications: pipe connection

NO= Standard : 1 pipe connection, air inlet on non-drive end, on inquiryonly !


A : 1 special bearing plate end housing (additional price !)
NU, AU = special bearing plate end housing (additional price !)
--- = subsequent change is possible, but remark A.-. !

Figure 31

LDW 12.184/1100 EN Page 38


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.5 Alternative ways of fitting pipe connection


mounting modifications: pipe connection
1. character : position of air inlet
N = non-drive end A = drive end
2. character : position of air inlet opening
3. character : position of air outlet opening
O = above U = below
R = right L = left
NO-O = Standard : 2 pipe connections, air inlet on non-drive end
A.-. = air inlet on drive end, on inquiry only !

NO-U, AO-U, NR-U, AR-U, NL-U, AL-U, NU-U,


AU-U, NU-O, AU-O, NU-R, AU-R, NU-L, AU-L } special bearing plate end housing (additional price)

- - - = subsequent change is possible, but remark A.-.

Figure 32

LDW 12.184/1100 EN Page 39


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.6 Alternative ways of fitting pipe connection


mounting modifications: pipe connection

Figure 33

LDW 12.184/1100 EN Page 40


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

5.7 Alternative ways of fitting air/air heat exchanger


mounting modifications: air-air heat exchanger

O = Standard
L, R = Special mounting (additional price)

Figure 34

LDW 12.184/1100 EN Page 41


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

6 Circuit diagrams

6.1 Main circuit diagrams (examples)


Sense of rotation
DIN VDE 0530-8
seperate excitation with series
seperate excitation series excitatation connection component

Motor

clockwise rotation

anti-clockwise rotation

seperate excitation seperate excitation with series


series excitatation connection component

Generator

clockwise rotation

anti-clockwise rotation

Figure 35

LDW 12.184/1100 EN Page 42


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

6.2 Additional circuit diagrams (examples)


EGZ-001
Additional terminals 101-102 thermal sensor

EGZ-003
Additional terminals 101-102 thermal sensor (advance warning)
103-104 thermal sensor (cut-out)

EGZ-004
Additional terminals 201-202 heating

EGZ-007
Additional terminals 101-102 thermal sensor
201-202 heating

EGZ-020
Additional terminals 701-702 tachometer

EGZ-021
Additional terminals 101-102 thermal sensor
701-702 tachometer

EGZ-094
Additional terminals 301-302 thermometer (PT 100) laminated paper
303-304 thermometer (PT 100) non-laminated paper
305-306 thermometer (PT 100) non-laminated paper

EGZ-300
Additional terminals 901-902 Brush monitoring system (microswitch, normally closed contact)

6.3 Connection diagrams for fan motors

L1 L2 L3 L1 L2 L3

U1 V1 W1 U1 V1 W1

U2 V2 W2 U2 V2 W2

Figure 36

LDW 12.184/1100 EN Page 43


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

7 After-sales service
Please consult our After-Sales Service Department if you have a problem.
Experienced experts will help you. Please give your statement if possible via telefax, telex
or by phone.

Lloyd Dynamowerke GmbH


Electrical Machines and Systems

: Hastedter Osterdeich 250


D-28207 Bremen

: +49(0)421 4589-247

: +49(0)421 4589-305
@ : service@ldw.is-bremen.de

: http://www.ldw.de

In case of emergency you can call at any time:

+49(0)170 8568251

8 Instructions and training


When you are interested at instructions and/or training, please call our service.

LDW 12.184/1100 EN Page 44


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

9 Standards
The following list makes no claim to completeness; it simply lists the main standards and guidelines relating to rotating
electrical machinery. This list of standards will be amended continuously with view to the conformity between national
standards (DIN) and European standards (EN/CEN/CENELEC).

9.1 European standards


• EN 60034-1 Rotating electrical machines
Rating and perfotmance
• EN 60034-5 Rotating electrical machines
Classification of degrees of protection provided
by enclosures for rotating machinery
• EN 60034-6 Rotating electrical machines
Methods of cooling
• EN 60034-7 Rotating electrical machines
Classification of types of constructions and
mounting arrangements (IM Code)
• EN 60034-9 Rotating electrical machines
Noise limits
• EN 60204-1 Rotating electrical machines
Electrical equipment of machines
General requirements

9.2 International standards

9.2.1 IEC standards:


• IEC 60034-ff Rotating electrical machines
• IEC 60034-5 = BS 4999-105 Classification of degree of protection provided
by enclosures of rotating electrical machinery
(IP code)
• IEC 60317 Winding wires

9.3 National standards

9.3.1 DIN standards:


• DIN 625 Ball bearings
• DIN 3404 Lubricating nipples; button head
• DIN 6796 Conical spring washers for bolted connections
• DIN 40430 Steel conduit thread
• DIN 46234 Cable lugs
• DIN 46235 Cable lugs
• DIN 46255 Fittings with armoured conduit threads
• DIN 51807-2 Testing the properties of lubricating greases in
relation to water
• DIN 51825 Greases K
• DIN 71412 Grease nipples

9.3.2 DIN VDE guidelines:


• DIN VDE 0100 Erection of power installations with nominal
voltages up to 1000V
• DIN VDE 0101 Erection of power installations with rated
voltages exceeding 1kV
• DIN VDE 0105 Operating power plants
• DIN VDE 0141 Earthing system for power installations with
rated voltages above 1kV
• DIN VDE 0530-14 Rotating electrical machines; mechanical
vibrations of certain machines with shaftheighs
56mm and higher

LDW 12.184/1100 EN Page 45


General Technical Notes and Operating Instructions
DC Machines System Series 5 G5.090M.. to G5.160M..

• DIN VDE 0875 Suppression of Radio disturbances caused by


electrival appliances and systems

9.3.3 DIN ISO standards:


• DIN ISO 1940 Mechanical vibration
Balance quality requirements of rigid rotors
• DIN ISO 8821 Mechanical vibration

9.3.4 Lloyd Dynamowerke (LDW) company standards:


• LDW 12 Model designations
• LDW 1294 Marking the end of the shaft
• LDW 1299 Paint finishes

9.3.5 VDI specifications:


• VDI 2056 Standards of evaluation for mechanical
vibrations of machines.
If you would like to purchase any of the above-mentioned standards (some only available in German), please contact the
supplier directly:

c/o Lloyd Dynamowerke GmbH


Hastedter Osterdeich 250
D-28207 Bremen
Telefon +49 (0) 421 4589 - 286
Telefax +49 (0) 421 4589 - 241
or
BEUTH VERLAG GmbH
Burggrafenstraße 6
D-10787 Berlin

LDW 12.184/1100 EN Page 46


Part 4: Drawing Annex
Contents

Description Number

Dimension drawing 65819300

Connection diagram 614500

Revision 0 2006-11-01 Lloyd Dynamowerke GmbH & Co. KG


Hastedter Osterdeich 250
D-28207 Bremen