and Maintenance of
Large AC Motors
6800 Frame
Horizontal Footless
Mounting. Water Cooled
Explosion Proof Mining Motor.
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
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.
IMPORTANT
The motor shaft must be blocked to prevent axial
movement whenever the motor is moved
THE
PRODUCTS
DESCRIBED
IN
THIS
INSTRUCTION MANUAL ARE MANUFACTURED
BY RELIANCE ELECTRIC COMPANY.
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.
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.
SECTION 2: INSTALLATION
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.
INSTALLATION
Warning
INSTALLATION SHOULD BE IN ACCORDANCE
WITH THE NATIONAL ELECTRIC CODE AND
CONSISTENT WITH ALL LOCAL CODES.
INSPECTION
Before installing the motor, make the following
checks:
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.
3.
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
LOCATION
COUPLING
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.
LUBRICATION
NOTE:
The lubrication system should be
checked in preparation for rotating the shaft
during the alignment operation
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.
GROUNDING
Warning
5
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.
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.
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.
VIBRATION LIMITS
Condition
AMPLITUDE
ON BRACKET
In/sec
.2
.3
Warning
Shutdown
TEMPERATURE LIMITS
Condition
Warning
Shutdown
Bearing
RTD
Winging
RTD
C
120
130
C
125
135
STARTING DUTY
(Jogging and Repeated Starts)
7
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.
Warning
SCHEDULED MAINTENANCE
SERVICE CONDITIONS
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.
Anti-Friction
cated)
Bearing
(Grease
Standard
Conditions
Severe
Conditions
Lubri-
Extreme
Conditions
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
4 months
2 months
1.5 months
RELUBRICATION VOLUME
VOLUME IN CUBIC INCHES
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.
DRIVE
METHOD
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.
Lubrication Instructions
1 Select Service Conditions from Table I
2. Select Lubrication Frequency and
ommended volume fill from Table II.
rec-
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.
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.
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.
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
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.
DRY WIPING
WINDING MAINTENANCE
BLOWING
Warning
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
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
11
SOLVENT CLEANING
Caution
Do not use solvents with trichloroethane. Damage
may occur to paint and insulation system.
Caution
To avoid damage to the windings, jet pressure
and temperature should not exceed 30 psi (200
Kpa) and 90C respectively.
RENEWAL PARTS
RECONDITIONING 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:
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.
1.
2.
3.
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
RM = KV + 1
Where
12
BASIC TROUBLESHOOTING
RTDs
ACCESSIBLE ELECTRONICS
13
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.
VIBRATION MONITORS
If problems exist with the vibration probe
readings the following should be checked.
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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.
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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.
.
B-3741-1