Installation, Operation and Maintenance of

Large AC Motors
6800 Frame Horizontal Footless Mounting. Water Cooled Explosion Proof Mining Motor.

Instruction Manual B B-3741-1 January 2007

Table of Contents
SECTION 1: GENERAL DESCRIPTION ................................................................................................. 1 INTRODUCTION ................................................................................................................................ 1 RECEIVING AND ACCEPTING ......................................................................................................... 1 STORAGE .......................................................................................................................................... 2 SECTION 2: INSTALLATION .................................................................................................................. 3 INSTALLATION .................................................................................................................................. 3 HANDLING ......................................................................................................................................... 3 INSPECTION ...................................................................................................................................... 3 LOCATION ......................................................................................................................................... 4 MOUNTING ........................................................................................................................................ 4 PRE-INSTALLATION CHECKS ......................................................................................................... 4 COUPLING ......................................................................................................................................... 5 COUPLING ALIGNMENT ................................................................................................................... 5 COUPLING ALIGNMENT PROCEDURE .......................................................................................... 5 LUBRICATION ................................................................................................................................... 6 ANTI-FRICITON BEARINGS (Grease Lubricated) ............................................................................ 6 ELECTRICAL CONNECTION ............................................................................................................ 6 GROUNDING .................................................................................................................................... 6 SECTION 3: OPERATION ....................................................................................................................... 7 PRE-OPERATION CHECK ................................................................................................................ 7 VARIABLE FREQUENCY DRIVE APPLICATIONS ... 7 INITIAL START ................................................................................................................................... 7 TEMPERATURE LIMITS .7 VIBRATION LIMITS ........................................................................................................................... 8 STARTING DUTY ............................................................................................................................. 8 SECTION 4: ROUTINE MAINTENANCE ................................................................................................ 9 SCHEDULED MAINTENANCE .......................................................................................................... 9 PERIODIC INSPECTION ................................................................................................................... 9 BEARING LUBRICATION ................................................................................................................ 10 ANTI-FRICTION BEARING REMOVAL/REPLACEMENT................................................................ 14 ROTOR AND STATOR REMOVAL ................................................................................................. 14 WINDING MAINTENANCE .............................................................................................................. 14 RENEWAL PARTS ........................................................................................................................... 16

SECTION 1: GENERAL DESCRIPTION

INTRODUCTION
DANGER
HIGH VOLTAGE AND ROTATING PARTS CAN CAUSE SERIOUS OR FATAL INJURY. THE USE OF ELECTRIC MACHINERY, LIKE ALL OTHER UTILIZATION OF CONCENTRATED POWER AND ROTATING EQUIPMENT, CAN BE HAZARDOUS. INSTALLATION, OPERATION, AND MAINTENANCE OF ELECTRIC MACHINERY SHOULD BE PERFORMED BY QUALIFIED PERSONNEL. FAMILIARIZATION WITH NEMA MG2 SAFETY STANDARD FOR CONSTRUCTION AND GUIDE FOR SELECTION, INSTALLATION AND USE OF INTEGRAL HP MOTORS, NATIONAL ELECTRICAL CODE AND SOUND LOCAL PRACTICES IS RECOMMENDED.

tors, stators, enclosures and insulation systems, to the smallest component...carefully selected and mated for optimum performance. The result is a product that is indeed, more than a motor... more like a system. Reliance 6800 Frame Motors are designed for easy disassembly, re-assembly, and inspection. These common accessories are available:

Bearing temperature detectors Winding temperature detectors Vibration monitors Special conduit boxes

IMPORTANT
The motor shaft must be blocked to prevent axial movement whenever the motor is moved

This manual contains the information that you need to get the most out of your Reliance 680 Frame Motor. Please read it carefully and thoroughly before unpacking and installing motor.

RECEIVING AND ACCEPTING

Warning
EYEBOLTS OR LIFTING LUGS ARE INTENDED FOR LIFTING THE MOTOR ONLY WITH THE STANDARD ACCESSORIES SUCH AS TACHOMETER, ETC., MOUNTED BY RELIANCE ELECTRIC. THE LIFTING MEANS ON THE MOTOR MUST NOT BE USED TO LIFT THE MOTOR PLUS ADDITIONAL EQUIPMENT SUCH AS GEARS, PUMPS, COMPRESSORS, OR OTHER DRIVEN EQUIPMENT. THE LIFTNG MEANS ON THE MOTOR CANNOT BE USED TO LIFT ASSEMBLIES OF MOTOR AND OTHER EQUIPMENT MOUNTED ON A COMMON BASE.

THE PRODUCTS DESCRIBED IN THIS INSTRUCTION MANUAL ARE MANUFACTURED BY RELIANCE ELECTRIC COMPANY.

These instructions do not cover all details or variations in equipment nor provide every possible contingency or hazard to be met in connection with installation, operation and maintenance. Should further information be desired or should particular problems arise which are not covered within this manual, the matter should be referred to Reliance Electric Industrial Company. Reliance 6800 Frame Motors are designed and built to provide you with a drive power system composed of matched components. Such a system is capable of delivering the horsepower, torque, speed and power efficiency characteristics that are needed for reliable production machinery. This systems approach was used not only in the design of the motor, but also in the state-ofthe-art manufacturing used to produce and test these rugged and dependable machines. It extends from the major assemblies such as ro1

In all cases, care should be taken to assure lifting in the direction intended in the design of the lifting means. Lift using all lugs provided. Likewise, precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or shock forces. Angle of lift with rope or chain should never be less than 45 degrees from the horizontal.

Upon receipt, thoroughly inspect the wrapping and crate for any sign of damage. If any damage is evident, do not accept the motor until the freight or express agent makes an ap-

propriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight or express agent at once and request him to make an inspection.

STORAGE
Do not unpack until ready for use. If the motor is to be stored for a period of any time prior to installation, it should be placed in an area which is clean, dry and warm.

Motors subject to extended storage must be handled and treated per the requirements of Reliance Service Bulletin B-8018-2 available from your Reliance District Sales Office.

Caution
Sleeve bearing motors are shipped without oil. Fill bearing reservoirs to the proper level before rotating the shaft. Failure to observe this precaution could result in damage to or destruction of the equipment.

The motor should be inspected periodically and the insulation resistance checked and recorded monthly. If there is a significant change in insulation resistance, it should be investigated and corrective action should be taken. Consult your local Reliance Sales Office for additional data. Reliance 6800 anti-friction bearing motors are shipped with the proper amount of grease in each bearing. At 30 day intervals of storage, remove only enough packing to expose the shaft and remove the shaft shipping brace, rotate the shaft (by hand) 10 to 15 revolutions. This distributes the grease, preventing bearing corrosion due to condensation, or to the presence of contaminating gases near the motor. After rotating the shaft replace protective packing and shaft shipping brace. If the motor is stored and directly exposed to weather conditions, it is important that the bearing grease be inspected for the presence of water at the grease drain. If the grease is contaminated with water, the motor must be disassembled, grease removed from the bearing(s) and housing(s) and bearing(s) inspected for corrosion. If corrosion is present, the bearing(s) must be replaced. If there is no corrosion, repack the bearing(s) / housing(s) with grease as instructed in Section 4 under Bearing Lubrication.
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SECTION 2: INSTALLATION
INSTALLATION
Warning
INSTALLATION SHOULD BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE AND CONSISTENT WITH ALL LOCAL CODES. COUPLING, BELT, AND CHAIN GUARDS SHOULD BE INSTALLED AS NEEDED TO PROTECT AGAINST ACCIDENTAL CONTACT WITH MOVING PARTS. MACHINES ACCESSIBLE TO THE PUBLIC SHOULD BE FURTHER GUARDED BY SCREENING, GUARD RAILS, ETC., TO PREVENT PERSONNEL FROM COMING IN CONTACT WITH THE EQUIPMENT. DIRECTION INTENDED IN THE DESIGN OF THE LIFTING MEANS. LIKEWISE, PRECAUTIONS SHOULD BE TAKEN TO PREVENT HAZARDOUS OVER LOADS DUE TO DECELERATION, ACCELERATION OR SHOCK FORCES.

Should additional handling or shipment of motors be required, be certain to block the shaft as it was blocked at the Reliance Factory. Blocking the shaft limits the rotor movement both axially and radially which prevents damage to the bearings.

INSPECTION
Before installing the motor, make the following checks: 1. Inspect for any damage resulting from shipment. Refer to paragraphs on receiving and storage. (Refer to Section 1 under Receiving and Accepting and Storage).

The assurance of successful startup depends upon the use of good handling, inspection, and installation practices. The motor should be mounted with adequate stiffness and mass to maintain system resonant frequencies removed from excitation frequencies by 15%. The need for closer alignment and heavier bases becomes more critical with higher speed operation and large motors.

HANDLING
Carefully remove the motor from packaging. Lifting provisions are provided as eyebolts on top of the motor. Place a lifting hook in each of the lifting means provided and carefully lift the motor from its packing. Use a hoist with adequate capacity.

2. If the motor has been in storage for an extended period or had been subjected to adverse moisture conditions, check the insulation resistance of the stator winding. (Refer to Section 4 under Checking Insulation Resistance). 3. Examine the motor nameplate data to make sure it agrees with the power circuit to which it will be connected. The motor is guaranteed to operate successfully at line frequency not more than 5%, and line voltage not more than 10%, above or below the nameplate ratings, or a combined variation of voltage and frequency of not more than 10% above or below nameplate ratings. Efficiency, power factor and current may vary from nameplate data.

Warning
LIFTING MEANS ARE PROVIDED FOR HANDLING THE MOTOR, AND SHOULD NOT BE USED TO LIFT THE MOTOR PLUS ADDITIONAL EQUIPMENT SUCH AS GEARS, PUMPS, COMPRESSORS, OR OTHER DRIVEN EQUIPMENT. IN THE CASE OF ASSEMBLIES ON A COMMON BASE, ANY LIFTING MEANS PROVIDED ON THE MOTOR OR GENERATOR SHOULD NOT BE USED TO LIFT THE ASSEMBLY AND BASE BUT, RATHER, THE ASSEMBLY SHOULD BE LIFTED BY A SLING AROUND THE BASE OR BY OTHER LIFTING MEANS PROVIDED ON THE BASE. IN ALL CASES CARE SHOULD BE TAKEN TO ASSURE LIFTING IN THE 3

4. Check to make sure that direction of motor rotation is correct for the intended application and motor requirement. 5. Remove shaft blocking before energizing motor.

LOCATION
The motor must be located in an environment that satisfies local codes and National Board of Fire and Underwriters regulations. The following additional considerations should also govern its location. Exposure to high ambient temperatures, humidity and atmospheric contamination should be avoided. Acids, alkalis and gases also have detrimental effects on electrical machinery. The location of installation should be accessible for routine maintenance and inspection.

COUPLING
1. In preparation for making the coupling alignment, wash off the rust-protective coating on the motor shaft with solvent. Any factory-installed couplings should also be cleaned with solvent prior to installation on the shaft. 2. Cylindrical bore couplings should be heated for proper mounting. Do not press or drive this type of coupling onto the shaft. Tapered bored couplings should be installed per the coupling manufacturers recommendations.

Permanent handling equipment to facilitate major service and repair without complete disassembly of the individual units should be considered.

COUPLING ALIGNMENT
There are a number of different procedures in alignment of the motor to the driven equipment. The end result depends upon the accuracy of the parts in roundness, flatness, runout of the reference surfaces, rigidity of the mounting platform, and the skill of the set-up-person. The motor mounting surface must be flat and perpendicular to the shaft axis.

MOUNTING
The dimensions for mounting are shown on the outline drawing supplied with the motor software and should be referred to.

PRE-INSTALLATION CHECKS COUPLING ALIGNMENT PROCEDURE

Before operating, the motor should be checked for any changes resulting from improper handling during shipment, storage, installation or by an unsatisfactory foundation. Failure to check or do the necessary work as mentioned above could cause misalignment resulting in vibration. Before shipment, every Reliance motor is given a running test to check operation. Although complete factory tests have been made, motors should be verified to prevent premature bearing failure.

Refer to accepted procedures for coupling alignment such as double-dial indicator or laser alignment. Coupling alignment shall be within the following limits: MAXIMUM PERMISSIBLE ANGULAR MISALIGNMENT = .001 inch per inch of coupling hub diameter. MAXIMUM PERMISSIBLE PARALLEL MISALIGNMENT = .002 inch TIR (Total Indicated Runout). The motor mounting bolts should be SAE Grade #8, 1.00 inch ( ISO Class 8.8, M24) torqued to 125 +25/-00 lb-ft (170 +34/-00 Nm). Caution
Do not use the coupling to compensate for poor alignment. This can result in vibration, noise, cou4

Before the motor is checked for alignment, remove all shipping blocks and supports installed at the factory. The shaft should turn over freely with minor resistance due to the contact lip seals used within this design. The degree of accuracy required in the alignment depends on the rated speed of the machine. The greater the speed, the greater the care and accuracy necessary for proper alignment.

pling wear, overloaded bearings and early failure.

Failure to properly ground the motor could cause severe bodily injury or loss of life.

LUBRICATION
NOTE: The lubrication system should be checked in preparation for rotating the shaft during the alignment operation

ANTI-FRICITON BEARINGS GREASE LUBRICATED

Bearing chambers are packed with grease during assembly, and do not normally need additional grease at the time of installation unless the unit has been in storage for 6 months or longer. If the motor has been kept in extended storage, lubricant must be added per Section 4, Table II.

All large motors should be grounded with the grounding conductor equipped with a brazed copper terminal, or with a suitable solderless terminal fastened to the motor. Soldered terminals should not be used. A washer should be used between bolt head and terminal lug. The other end should be fastened with suitable clamps or terminals to rigid metallic conduit or to the nearest available ground. Grounding conductor size should be in accordance with the following National Electrical Code.

ELECTRICAL CONNECTION
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH THE NATIONAL ELECTRIC CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING PRACTICES, GROUNDING DISCONNECTS AND OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

The motor is provided with a quick disconnect socket or other suitable means for connection to the power source. Typically the customer provides the mating plug or approved packing gland parts. The customer side power and ground cable should be sized in accordance with the given countries applicable electrical and mine authorities electric code.

A main terminal box may be provided for power lines to the stator. Other terminal boxes for all other electrical connections may be provided.

GROUNDING
Warning
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SECTION 3: OPERATION
8. Replace all panels and covers.

PRE-OPERATION CHECK
9. Check direction of rotation by momentarily applying power to the motor.

Caution
THIS EQUIPMENT IS AT LINE VOLTAGE WHEN A-C POWER IS CONNECTED. DISCONNECT AND LOCKOUT ALL UNGROUNDED CONDUCTORS OF THE AC POWER LINE BEFORE PROCEEDING. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

INITIAL START Caution

Read and fully understand each of the steps in the following procedure before attempting to start the motor.

Before starting the motor for the first time the following checks must be made: 1. Hold-down bolts must be tightened to 125 +25/-00 lb-ft (170 +34/-00 Nm). 2. If the motor has been idle for a long period of time after installation, check the insulation resistance. Refer to Section 4 under Checking Insulation Resistance 3. Check the incoming power to be sure that line voltage, frequency and phase are correct for the motor (refer to the motor nameplate). 4. Inspect all electrical connections for correct termination, clearance, mechanical strength, and electrical continuity. 5. Check to be sure that the shipping brace has been removed from the motor shaft. 7. Manually turn the shaft to make sure that it rotates freely.

1. When alignment is correct and motor is properly lubricated, prepare for no load uncoupled startup. The coupling should be uncoupled and a solo plate should be installed if required. 2. Inspect the motor carefully. Make the initial start by following the regular sequence of starting operations in the control instructions. 3. After starting, check that the motor is running smoothly and with the proper direction of rotation. If the motor shows excessive vibration, shut down immediately and investigate. Check for coupling and key unbalance, lack of lubrication, and structural resonance. 4. If bearing temperature detectors are provided, check the temperatures frequently during the initial hour of operation. At initial start, the bearing temperature rate of rise will be high. This rate of rise should decrease within 30 minutes. If this rate of rise does not decrease or the temperature exceeds 130C, stop the motor.

Caution
When the driven equipment is likely to be damaged by the wrong direction of rotation, it is best to uncouple the motor from its load during the check for rotation and/or during the initial start. Some motors are designed for a single direction of rotation as indicated by nameplates. Running those units in the wrong direction will reduce airflow causing overheating. Check to see that both the motor and driven equipment are operating in the correct direction of rotation. If it is necessary to change rotation, disconnect and lockout all input power and interchange any two input power phases. 6

5. Check to make sure that the protective controls are functioning properly before any prolonged operation. 6. Run the motor for at least two hours if no problems are encountered.
Warning

TO INSURE THAT THE MOTORS ARE NOT UNEXPECTEDLY STARTED, TURN OFF AND LOCK OUT OR TAG POWER SOURCE BEFORE PROCEEDING. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

Caution
Repeated starts and/or jogs can greatly reduce the life of an induction motor. If it is necessary to repeatedly start or jog a motor, check the application with your local Reliance Electric sales office.

After this initial start and no load run has been completed, assemble and lubricate the coupling the manufacturers recommended with lubricant. Check to see that the coupling is not binding. After the coupling has been assembled and lubricated, repeat steps 2 through 6 under the initial start section of this manual. Check to see that the driven equipment is not transmitting vibration back to the motor through the coupling or the base.

From ambient temperature, the motor is normally capable of making two starts in succession while coasting to rest between these starts. The motor is also normally capable of making one start from its rated load operation temperature. For cooling time required before additional starts can be made consult your local Reliance Electric Sales Office or the motor starting nameplate if one is provided.

VIBRATION LIMITS
Condition AMPLITUDE ON BRACKET In/sec .2 .3

If more starts or less time between starts than defined above are attempted, severe damage to the motor electrical windings and rotor may result. The starting conditions listed above apply only if the inertia of the connected load, the load torque during acceleration, the applied voltage, and the starting method are those for which the motor was designed. For starting situations not covered here, consult your local Reliance Electric Sales Office before proceeding. Refer also to the motor nameplate which may list starting conditions.

Warning Shutdown

The vibration levels listed above are only guidelines.

TEMPERATURE LIMITS
Condition Bearing RTD C 120 130 Winging RTD C 125 135

Warning Shutdown

The temperature levels listed above are only guidelines.

STARTING DUTY (Jogging and Repeated Starts)

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SECTION 4: ROUTINE MAINTENANCE

Warning

DO NOT USE SOLVENTS CONTAINING TRICHLOROETHANE TO CLEAN INTERIOR OR EXTERIOR OF MOTOR. DAMAGE MAY OCCUR TO PAINT AND INSULATION SYSTEMS.
Warning

PERIODIC INSPECTION
Warning
DISCONNECT AND LOCKOUT POWER BEFORE TOUCHING ANY INTERNAL PART. HIGH VOLTAGE MAY BE PRESENT EVEN WHEN THE MACHINE IS NOT ROTATING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

EXTERNAL SURFACES MAY BE HOT, CARE SHOULD BE TAKEN WHEN MAINTENANCING MOTORS THAT HAVE BEEN RUNNING TO AVOID BURNS.

Every 3 months or 500 operating hours, whichever comes first: 1. Listen for any abnormal noises and check cause immediately. 2. Check for excessive vibration. 3. Check to see that all covers are in place and secure. 4. Check for proper lubrication. 5. Check bearing temperature rise. 6. Check voltage and frequency variations. Unbalanced voltage or single-phase operation of polyphase motors will cause excessive heating and ultimately failure. Only a slight unbalance of voltage applied to a polyphase motor will cause large unbalance currents and result in overheating. Check power supply total harmonic distortion to avoid overheating. Periodic checks of phase, voltage, frequency, and power consumption of an operating motor are recommended. These checks can also provide an excellent indication of the load from the driven equipment. Comparisons of this data with previous no load and full load power demands will give an indication of the performance of the driven machine.

SCHEDULED MAINTENANCE
Inspections which are important to the proper operation and maintenance of a Reliance motor, should occur every 3 months or 500 operating hours, whichever comes first. In addition, the following should always be observed. Provide adequate ventilation Avoid sharp blows and excessive axial thrust loads on the output shaft. Maintain proper lubricant level (check weekly on oil-lubricated units).

Reliance Electric 6800 Frame motors, when properly applied, require minimal routine maintenance. Since clearances and fits are precisely machined, no periodic mechanical adjustments are required. Like any precision machine, periodic inspection and simple routine maintenance will prolong your motors life and help detect potentially damaging conditions. The minimal time spent performing the simple procedures below cannot begin to compare with the cost of lost productivity and time consuming major repairs incurred through neglect or routine inspection and maintenance.

BEARING LUBRICATION
The motor is equipped with anti-friction bearings. When properly cared for, (i.e. inspection and lubrication) bearings will provide Use the years of uninterrupted service. following lubrication procedure.
Standard Conditions Severe Conditions

SERVICE CONDITIONS
Eight hours per day, normal or light loading, clean ambient air at -18 c (-32 f) TO 40C (104F) Twenty four hours per day operation or shock loading, vibration, ambient air containing dirt or dust at 40-50C (100-120F). Heavy shock or vibration, ambient air containing dirt, dust or high humidity and temperatures in excess of 40 C (104 F)

Anti-Friction cated)

Bearing

(Grease

Lubri-

Extreme Conditions

6800 Frame motors are designed with the exclusive Reliance PLS Positive Lubrication System which routes new grease directly into the bearing. The re-lubrication periods shown in Table II are offered as a guide for varying service conditions, speeds, bearing types and operating hours using standard motor grease. Cleanliness is important in lubrication. Any grease used to lubricate anti-friction bearings should be fresh and free from contamination. Similarly, care should be taken to properly clean the grease inlet areas of the motor prior to lubricating to prevent grease contamination.

TABLE II RELUBRICATION INTERVALS

ANTI FRICTION BEARINGS EQUIPPED MOTORS Speed Standard Severe Extreme (RPM) Conditions CondiConditions tions 3000 & 6 months 3 months 2 months above Below 3000 6 months 3 months 3 months

ROLLER BEARING EQUIPPED MOTORS

Below 3000 4 months 2 months 1.5 months

IMPORTANT
Mixing of lubricants must not be done. Lubricants from different manufacturers and of different compositions may not be compatible, resulting in inadequate lubrication and bearing failure. Do not use automotive greases, greases with EP additives or greases other than those specifically listed on the motor lubrication nameplate and this instruction manual. Failure to follow these instructions may result in lubrication breakdown and bearing failure. If a lubricant other than that listed on the motor nameplate and/or this instruction manual is desired to be used, consult your local Reliance Sales Office for approval prior to its use.

RELUBRICATION VOLUME VOLUME IN CUBIC INCHES

DRIVE METHOD 3000 & 3600 RPM BELOW 3000 RPM

Coupled Duty 1.5 3.0 Belted Duty -----------4.0 Data contained on a lubrication nameplate on the motor takes precedent over this Table

Recommended Lubricant
Refer to the motor Lubrication Nameplate for the type of lubricant to be used. If there is no Lubrication Nameplate on the motor, use a polyurea base hydrocarbon oil lubricant. Note: The Lubrication Nameplate on the motor takes precedent over this data. Use only clean, fresh grease from clean containers.

Lubrication Instructions
1 Select Service Conditions from Table I 2. Select Lubrication Frequency and ommended volume fill from Table II. rec-

Grease Lubrication Procedure TABLE I

9

Reliance anti-friction bearings may be lubricated with the motor running or stationary, however, stationary with the motor warm is preferred.

ANTI-FRICTION BEARING REPLACEMENT

1. For anti-friction bearing motors the inner cap bolts must be removed before removing the motor bracket. 2. Remove all bolts that secure the bracket to the frame. 3. Using a hoist, support the bracket.

Warning
IF RE-LUBRICATION IS DONE WHILE THE MOTOR IS RUNNING, STAY CLEAR OF ROTATING PARTS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

1. Locate the grease inlet, remove all caked grease and dirt from the fitting. There is one grease inlet per bearing. There is one 1. Remove relief plug. grease relief plug per bearing. Remove all hardened grease from the relief plug area. Remove caked grease from the grease drain pipe with a screw driver, if possible. If severe caking appears in the grease drain pipe, run the motor until the bearing housing is warm, permitting free flow of grease through the housing.

4. Jacking holes have been provided in the bracket mounting lugs to facilitate the removal of the bracket from the frame rabbet fit. Tighten the jack bolts evenly to avoid mis-alignment of the bracket during removal. 5. At this stage, the bearing is still seated in the bracket bearing bore. Remove the bracket from the bearing by rocking the bracket from side-to-side while applying an axial force on the bracket. After the bracket has cleared the bearing, use the hoist to move the bracket off of the shaft and away from the motor. 6. The bearing can now be removed by using a conventional bearing puller. Locate the puller arms behind the bearing outer race for ball bearings and behind the bearing inner race for roller bearings. Protect the shaft center by using a spacer block of brass or some other soft material between the shaft and bearing puller. Remove the bearing by applying axial force with the bearing puller. 7. With roller bearings, the bearing rolling elements and outer race are contained within the bearing bracket bore. This bearing assembly can be removed from the bracket bearing bore by pulling on the rolling elements or by tapping on the outer race through the shaft bore in the bracket.

3. Add the recommended volume of the recommended lubricant per the motor Lubrication Nameplate or the above chart using a hand operated grease gun. 4. Start the motor and run with the relief plug open for several minutes. Some grease should be purged from the grease drain pipe. 5. Replace plugs and wipe off any excess grease.

TABLE V FASTENER TORQUE VALUES TORQUE VALUE

FASTENER LB-FT Nm

Flange Mounting Bracket Mounting Inner Bearing Cap Frame Covers

125 80 55 15

170 108 75 20

All torque values have a tolerance of plus 20% and minus zero.
10

8. Clean and inspect all parts. Remove all old grease from the inner caps, brackets, grease inlet and drain piping and shaft. Replace all shaft and cap seals.

9. All shaft bearing shoulders and journals should be free of nicks before replacing bearing. Dress shaft with emery cloth or stone as necessary. Assemble the bearing inner caps onto the shaft. 10. Heat bearing to 250F (120C) for at least 30 minutes. 11. Place bearing onto shaft. Make certain that the bearing is contacting the locating shoulder on shaft. DO NOT use impact force on bearing. 12. Let the bearing cool. Protect the bearing from contamination. Fill the outboard side cavity of the bearing, cage and rolling element area of the bearing, 100% with grease. Fill the bearing inner cap cavities and bracket bearing housing cavity with grease to 60% full. Fill the grease inlet pipe 100% with grease. 13. Assemble the brackets in reverse order of Steps 1 through 6. Torque bolts per table V.

portions of the windings will provide a good indication of their general condition. To thoroughly inspect and clean the windings it may be necessary to remove the rotor. There are numerous methods for cleanings windings. The following methods are most commonly used, in order of preference. NOTE: Before cleaning the windings check for loose blocking, evidence of damage to insulation, distortion or movement of coils, etc. If any of these conditions exist, contact your local Reliance Electric Service Engineer for recommendations. DRY WIPING This method is satisfactory when the surfaces to be cleaned are accessible and when only dry dirt is to be removed. Use a clean dry, lint-free cloth. The lint will adhere to the insulation and increase dirt collection. Lint is particularly objectionable on high voltage insulation systems as it tends to concentrate corona discharge. BRUSHING AND SUCTION CLEANING Remove the dry dust and dirt by brushing with a bristle brush, followed by a vacuum suction cleaning. DO NOT USE WIRE BRUSHES.

ROTOR AND STATOR REMOVAL

Consult Reliance Electric for proper removal procedures.

WINDING MAINTENANCE
BLOWING

Warning
SOLVENTS CAN BE TOXIC AND / OR FLAMMABLE. FOLLOW MANUFACTURERS SAFETY PROCEDURES AND DIRECTIONS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY.

Dry dirt and dust can be removed from inaccessible crevices by using a jet of low pressure, oil free compressed dry air.

Caution
To avoid damage to the windings do not use air pressures greater than 30 psi (200 kPa). Avoid directing the air in such a way that the dirt will be blown into inner crevices.

Caution
Do not use solvents containing trichloroethane to clean interior or exterior of motor. Damage may occur to paint and insulation system.

Warning
USE OF AN AIR JET MAY CAUSE FLYING DEBRIS AND GENERATE PARTICULATE MATTER. WEAR SUITABLE SKIN, EYE AND RESPIRATORY PROTECTION. FAILURE TO OBSERVE THIS PRECAUTION COULD
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De-energize motor by opening manual disconnect and locking out. To inspect the ends and outside surface of the windings, remove the brackets from the motor. Inspection of these

RESULT IN BODILY INJURY.

SOLVENT CLEANING Caution

Do not use solvents with trichloroethane. Damage may occur to paint and insulation system.

RM = Minimum insulation resistance in mega ohms at 40C of the entire machine winding. KV = Rating machine potential, in kilovolts. For machines in good condition, insulation and resistance readings of 10 to 100 times RM are common. If the insulation resistance is lower than that calculated from the formula, the windings should be dried out as follows:

CLEANING WITH WATER AND DETERGENT

Windings can be cleaned by hose washing or by pressure spray from a low pressure steam generator or shop steam line.

Caution
To avoid damage to the windings, jet pressure and temperature should not exceed 30 psi (200 Kpa) and 90C respectively. Oil, grease, tar and wax can be removed by adding a NON-CONDUCTIVE DETERGENT to the wash water. After washing, it is necessary to dry the windings in an oven. Bake in an oven (preferably a circulating air oven) at a temperature not over 90C until insulation resistance remains constant.

Bake in an oven (preferably a circulating air oven) at a temperature not over 90C until insulation resistance remains constant.

RENEWAL PARTS
The high productivity expected in industry today demands a well planned maintenance program. The success of which often can depend on the number and type of spare parts on hand. Serious consideration should be given to having all vital replacement components on hand to protect the units against costly down time.

RECONDITIONING WINDINGS
If after cleaning with solvent or water and detergent, the insulation shows signs of dryness, it may be necessary to re-impregnate the windings. Consult your local Reliance Electric Service Engineer for proper type and method of reinsulating the windings. A detailed parts list, which gives Reliance Electrics recommendations for spare parts that should be stocked for your motor, can be ordered from the following offices: 1. 2. 3. Nearest Reliance Electric Sales Office. Nearest Reliance Electric Distributor. Reliance Renewal Parts, Greenville, SC.

CHECKING INSULATION RESISTANCE

If the motor has been in storage for an extensive period or has been subjected to adverse moisture conditions, check the insulation resistance of the stator winding with megger or an insulation resistance meter. The minimum insulation resistance (RM) can be determined from the following formula: RM = KV + 1 Where

Be sure to include complete nameplate data, purchase order number, serial number, model number, rating, etc., for your motor when ordering the spare parts list. Parts can be obtained from your nearest distributor or directly from our factory. When ordering parts for which a part number is not available, give complete description of part and purchase order number, serial number, model
12

number, etc. of the equipment on which the part is used.

SECTION 5: APPLICATION SPECIFICS

ICDS SYSTEM SNAPSHOT
The ICDS motor is a 1250 HP, 1.15 SF, 4160 volt three phase induction motor with on board temperature monitoring and real time power measurement. The motor has sensors and electronics located in the main conduit box as well as four other small X/P boxes located on top of the motor. The main conduit box is located on the drive end of the motor and is One divided into three compartments. compartment for electronics, a center compartment for the main power leads and current transformer, and a third compartment for the potential transformers. Winding Temperatures (one per phase) 100 ohm RTDs (3 total) Bearing Temperatures (one per bearing) 100 ohm RTDs (2 total)

BASIC TROUBLESHOOTING

ACCESSIBLE MOTOR SENSORS

See assembly drawing for locations. Potential Transformers 35:1 ratio PT (2 total) Current Transformer 300:5 ratio CT Water In Temperature 100 ohm RTD Water Out Temperature 100 ohm RTD XP Enclosure Temperature 100 ohm RTD DE Vibration Probe 0-25mm/sec probe ODE Vibration Probe 0-25mm/sec probe

Note: The troubleshooting tips below require the explosion proof covers be removed to access devices inside the conduit boxes. Refer to proper mine site and MSHA regulations for proper servicing of devices inside an XP conduit box.
RTDs
1. If values displayed are exceptionally high (greater than 185 C winding or 145 C water and bearing temperatures) a loose wire could be the culprit. All RTDs terminate on one of two modules on the CompactLogix rack. Confirm placement and secure leads. No external surface temperature readings (water RTDs) should ever exceed 145 C or motor must be deenergized and allowed to cool. Confirm proper water flow is going through motor. 2. Numbers greater than 800 C indicate an RTD that has been disconnected, broken wires or the temperature element has failed. 3. Disconnect RTD from CompactLogix module and check resistance with an ohmmeter. Values of the RTD should be less than 250 ohms. If resistance values show infinity then the RTD has failed or the wires between the element and terminals are broken. Replace wires or RTD if possible. If resistance values show close to zero or less than 100 ohms then check the leads you are
13

ACCESSIBLE ELECTRONICS
See assembly drawing for location PowerMonitor 3000 CompactLogix Controller 1606 XLP Power supply 12 volt DC supply DBT UOI Isolator

INTERNAL MOTOR SENSORS

measuring. Measure between the red and white leads (or black and white leads on water RTDs). Check wiring harness on water RTDs for proper continuity and signs of any damage. If measurements with an ohmmeter are correct confirm proper color placement on terminal strip and tighten leads. Confirm that no external motor surface temperatures ever exceeds 145C.

POWER MONITOR
If problems exists with the readings on either voltage, current, real power output, or reactive power output then the PowerMonitor 3000 should be checked for problems 1. Check the configuration of the PowerMonitor with the external display unit. These values are: a. Confirm that configuration is set for Open Delta 3 CT. b. Confirm that the potential transformer ratio is set for 4160 primary and 120 secondary. c. Confirm the current transformer ratio is set for 300 primary and 5 secondary. d. Confirm that the neutral current I4 CT is set for 5 primary and 5 secondary. 2. Check for proper wiring from the CTs and PTs to the PowerMonitor. Review against wiring diagram.

VIBRATION MONITORS
If problems exist with the vibration probe readings the following should be checked.

1. Check +24 volts output from PLC terminal. 2. Check 1 amp fuses for continuity with an ohmmeter 3. Check wiring harness for continuity with an ohmmeter on each of the three leads. 4. Check remaining wiring between PLC, analog module, and probes. 5. If only one probe is not functioning, swap the working probe with the non working probe to eliminate the probe as the possible cause of problem. If probe still does not operate then replace probe.

COMPACTLOGIX PLC
If no data is being received from the PLC confirm the problems. 1. Confirm all the proper lights are on the PowerMonitor, each PLC module, and the PLC itself. The activity light of the Powermonitor and the PLC should be continuously blinking. 2. Confirm that the receive and transmit lights on the DBT UOI are blinking. 3. Confirm the DBT PMC-D and PMC-V are operating properly. 4. Reload the program from compact flash if no activity lights are blinking. Insert compact flash card in appropriate slot and cycle 120 volt power on the PLC.

www.baldor.com

www.ptplace.com

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www.reliance.com

Baldor Electric Company Headquarters P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.648.5792, Fax (1) 479.648.5792, International Fax (1) 479.648.5895 Baldor - DODGE/Reliance 6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, FAX: (1) 864.281.2433
5/07 Copyright 2007 Baldor Electric Company All Rights Reserved. Printed in USA. This material is not intended to provide operational instructions. Appropriate instruction manuals and precautions should be studied prior to installation, operation or maintenance of equipment. .

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