SCHABMULLER TSA 200-100-220, Operating And Maintenance Instructions Manual

Page 1: ...Version 1 0 Operating and maintenance instructions translation of original instructions Motor pump unit motor unit servo unit...

Page 2: ...habm ller GmbH 2019 Distribution as well as duplication of the instructions use and communication of the contents are forbidden Violation will result in claims for damages All rights reserved in the e...

Page 3: ...3 Storage 15 4 Installing the motor 17 4 1 Tightening torques for fastening elements 17 4 2 Mounting the shaft sealing rings 18 4 3 Installing O rings 21 4 4 Installing shafts with gearing 21 4 5 Ins...

Page 4: ...ntents Version 1 0 Page 4 of 56 9 Troubleshooting 50 10 Customer Service and Support 52 11 Disposal 53 11 1 Cleaning agents auxiliary materials and operating materials 53 11 2 Scrapping 53 11 3 Electr...

Page 5: ...e requested If you have any questions please contact Schabm ller GmbH 1 2 Further product documentation These operating instructions refer only to standard motors More detailed instructions can be fou...

Page 6: ...n the rating plate see page 7and page 8 The motor type is indicated by the following code Item Designation Comment 1 Motor type TSA asynchronous motor TSL DC motor TSS synchronous motor TSR synchronou...

Page 7: ...s permanent magnet motors and synchronous reluctance motors contain the following information customer specific rating plates may differ Item Designation 1 Serial number 2 Material number 3 Type desig...

Page 8: ...rating plate for DC motors contains the following information customer specific rating plates may differ Item Designation 1 Serial number 2 Material number 3 Type designation 4 Voltage 5 Output 6 Prod...

Page 9: ...aring IP6k9k IP64 67 IP43 54 IP00 20 Carbon Collector Drive motor TSL x x x x x x x x x x x TSA x x x x x x x x x x x TSS x x x x x x x x x x x x TSR x x x x x x x x x x x x Pump unit TSL x x x x x x...

Page 10: ...irection encoder and temperature sensor Optional brake attachment Mounting and shaft ends according to customer specification DC motor Battery voltage 24 V 80 V Stator diameter 112 125 140 150 160 178...

Page 11: ...on Pump units Asynchronous PM synchronous Terminal voltage 16 V 480 V 3 Stator diameter 150 170 200 mm Output 5 15 kW RPM range 2 000 4 000 rpm Air cooled Integrated speed direction encoder and temper...

Page 12: ...of their training experience and instruction as well as their knowledge of relevant standards accident prevention regulations and corresponding operating conditions are authorised to carry out the ne...

Page 13: ...ngs may result in death serious injury or property damage due to falling loads Electricity Failure to observe the warnings may result in death or serious injury from dangerous voltage 2 2 3 Signal wor...

Page 14: ...AUTION Danger of injury from falling objects Only lift packaging or our products at the lifting points provided for this purpose Take into account the weight indicated on the packaging or on our produ...

Page 15: ...re than two months The following points must be taken into account when selecting the storage location The room must be closed and covered The room must be protected against moisture vapours rodents a...

Page 16: ...to the water in the cooling circuit Separately supplied components If components are supplied separately terminal boxes bearing plates etc these parts must also be packed and protected If the manufac...

Page 17: ...th across flats 4 8 8 8 10 9 12 9 Tightening torques Nm M 3 0 6 1 4 1 9 2 2 5 5 M 4 1 3 1 5 3 3 6 4 3 5 3 5 1 6 1 7 M 5 2 6 3 1 6 7 1 8 5 10 10 2 12 8 M 6 4 5 5 2 10 3 12 14 7 18 17 6 21 10 M 8 10 8 1...

Page 18: ...ng it in 4 2 1 Removal and replacement The removal of sealing rings is generally not difficult Usually a screwdriver or similar is sufficient for disassembly However this will damage the sealing ring...

Page 19: ...2 For rubber seals Grease or oil shafts and seals 3 For shaft seals that cannot be lubricated by external media Fill the shaft seal with grease PETAMO GY193 4 Cover sharp edged transitions e g at ind...

Page 20: ...Operating and maintenance instructions Installing the motor Version 1 0 Page 20 of 56 Examples of the assembly of shaft seals Item Designation 1 Press in tool 2 Shaft seal...

Page 21: ...s dirt and foreign particles 4 Cover threads and feather key grooves or hub grooves with adhesive tape a sleeve or similar 5 Grease or oil the O ring and components with a suitable lubricant 6 Install...

Page 22: ...gearing up to half with grease e g Kl berplex BEM 34 132 and spread the grease up to the upper edge with a wooden or plastic rod 4b For external gearing Coat the gearing evenly with grease 5 Carefull...

Page 23: ...e the rotor armature against falling out of the motor 2 Treat the gearing see page 21 3 Grease or oil the O ring or shaft seal see page 21 4 Clean the flange surfaces bearing sleeves or shaft of forei...

Page 24: ...voltage of 50 V AC or 120 V DC or higher provide separate protection against accidental contact Note the tightening torques on the drawing these have priority Connection examples are shown below Depe...

Page 25: ...00 IP54 5 2 1 1 3 pin connection with size M6 M8 or M10 screws Example Item Designation 1 Possible customer connection 2 Counter nuts against each other tightening torques M6 max 3 5 Nm M8 max 11 Nm M...

Page 26: ...ection example to comply with protection class range IP64 IP67 5 2 2 1 Connection via terminal box Example view without cover Item Designation 1 Customer connection 2 Counter nuts against each other t...

Page 27: ...e sealing surfaces item 4 3 Do not twist damage or bend the silicone seal or the O ring item 5 when mounting the cover 5 2 3 Connection example to comply with protection class IP6K9K The connections a...

Page 28: ...ersion 1 0 Page 28 of 56 5 3 DC motor 5 3 1 Connection examples to comply with protection class range IP00 IP54 Examples Item Designation 1 Possible customer connection 2 Counter nuts against each oth...

Page 29: ...l connection Version 1 0 Page 29 of 56 5 3 2 Wiring diagrams Figure Connection Rotation 1 Permanent Right left rotation 2 Series split field Right left rotation 3 Series Right left rotation 4 Shunt Ri...

Page 30: ...e the instructions supplied by our suppliers for the attachments Observe the maximum screw in depth of the fastening screws see installation drawing screws that protrude too far into the motor damage...

Page 31: ...Maintain an air gap of min 0 9 mm and max 1 0 mm between the incremental encoder and counterpart 4 Mount the fastening elements with the screw item 3 with screw lock medium tight e g Three Bond 1344...

Page 32: ...2 Push the incremental encoder item 1 onto the shaft 3 Insert the cylinder pin item 2 correctly into the rubber part maintain an air gap of min 0 9 mm and max 1 0 mm between the incremental encoder an...

Page 33: ...lement 3 Remove the tachometer housing without the armature 4 Loosen and remove the fixing screw item 4 5 Remove the armature from the shaft 6 Check for abrasion of the carbon brushes interval like mo...

Page 34: ...e the hub against axial displacement with the circlip 4 Push the rotor onto the hub 5 Check that the rotor can be moved by hand 6 Push the magnetic part onto the hub 7 Screw the magnetic part complete...

Page 35: ...e torque adjustment factory set to nominal torque as standard 06 0 3 0 6 4 Braking torque adjustable on the central adjustment ring 08 8 10 16 12 32 14 0 4 0 8 60 16 60 The friction lining is dimensio...

Page 36: ...t 3 Push the hub onto the shaft and secure with the circlip 4 Check the nominal rotor thickness according to the table below and slide it onto the hub 5 Tighten the magnetic part with three screws for...

Page 37: ...ow and slide it onto the hub 5 Tighten the magnetic part with three screws for tightening torques see page 17 The air gap of the brake cannot be adjusted due to the design of the magnetic part If wear...

Page 38: ...turning motor for example requires a right turning pump Do not tilt the pump shaft and the motor shaft Do not assemble the coupling parts by hammering or pressing Observe the permissible tightening t...

Page 39: ...Page 39 of 56 6 5 Gearing 6 5 1 Gear manufacturer IMS SPN Danger of property damage Do not disassemble the gear unit Prevent dirt particles from entering the gear unit during installation Example Item...

Page 40: ...r damage 2 Clean the flange and sealing surfaces 3 Grease the gearing see page 21 4 Carefully assemble the motor item 1 and gear unit item 2 Do not tilt the motor pinion item 5 or toothed shafts Inser...

Page 41: ...Do not disassemble the gear unit Prevent dirt particles from entering the gear unit during installation Keep the motor shaft and the clamping ring bore free of oil and grease Example Item Designation...

Page 42: ...ing After mounting with clamping ring the slots of the clamping ring and shaft must lie on top of each other 5 Fasten the motor item 5 to the gear unit item 1 with screws item 6 6 Tighten the fixing s...

Page 43: ...ersion 1 0 Page 43 of 56 6 6 1 3 Tightening torque SPN E2X Fixing screws DIN 912 10 9 Tightening torque Nm M4 2 4 M5 4 9 M6 8 M8 20 M10 40 M12 69 Clamping screws Motor shaft DIN 912 10 9 SW Nm 5 8 M4...

Page 44: ...the correspondingly designed control and speed monitoring no higher speeds are used than specified in the technical documentation 3 The machine is properly assembled and aligned 4 The output elements...

Page 45: ...r of property damage Non compliance with the above measures see checklist may affect the performance of the motor and result in burning of the motor winding and voiding of the warranty If the motor is...

Page 46: ...al shutdown of the motor Carry out a general inspection of the engine at regular intervals see maintenance schedule page 46 The inspection must include the activities listed below The inspection dista...

Page 47: ...lting minimum residual height of the expired carbon brushes must not be undercut If the remaining height of the carbon brushes is undercut they must be replaced by original Schabm ller carbon brushes...

Page 48: ...hing screw X Measure the insulation resistance of the winding according to IEC 60034 X Not in the vehicle only in dismantled condition Check for noises and vibrations X Bearings Check the bearings for...

Page 49: ...still Check all the specified points Step Procedure 1 The alignment of the machine must lie within the permissible tolerances 2 All screws for mechanical and electrical connections must be firmly tigh...

Page 50: ...e are any foreign bodies in the motor Rotor defective Check for broken shaft loose rotor core or broken fan blades Remove any foreign bodies in the motor that block the rotor Motor overloaded Reduce t...

Page 51: ...e cooling ducts A connector may not be properly attached Check that all lines are correctly connected Shorted winding Stator must be rewound Ambient temperature too high adjacent vehicle parts become...

Page 52: ...chabm ller GmbH Industriestra e 8 92334 Berching Germany Telephone 49 8462 204 0 E mail service schabmueller de Internet http www schabmueller de When requested by Customer Service have the informatio...

Page 53: ...ants are a great danger potential for the environment This waste must be stored in suitable containers The disposal of this waste must be carried out by a specialist company in accordance with the int...

Page 54: ...Part 8 IEC standard voltages 60038 60038 0175 Noise limits 60034 9 60034 9 0530 Part 9 Degrees of protection due to the overall design of rotating electrical machines IP code classification 60034 5 6...

Page 55: ...Operating and maintenance instructions Standards Version 1 0 Page 55 of 56...

Page 56: ...SCHABM LLER DRIVE SOLUTIONS MADE IN GERMANY Schabm ller GmbH Industriestr 8 D 92334 Berching Germany Tel 49 8462 204 0 Fax 49 8462 1841 info schabmueller de www schabmueller de...