weg dc motor 10061218 manual english

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l 10061218 DC Motors D Series

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Installation, Operation and Maintenance Manual

Document Number: 10061218

Models: DNF, DND, DNS, DNE, DNX, DNA, DNX, DCF, DCD, DCS,

DCE, DCX, DCA and DCW

Language: English

Review 6

September 2012

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Dear Customer,

Thank you for purchasing the WEG DC motor. It is a product developed with quality and efficiency

levels which ensure an outstanding performance.

Since the electric motor plays an important role in the comfort and well being of mankind, it must be

identified and treated as a driving machine whose characteristics involve certain care, such as proper

storage, installation and maintenance.

All efforts have been made to ensure that the information contained in this manual is faithful to the

configurations and operation of the motor.

Therefore, read carefully this manual before proceeding with the installation, operation or maintenance

of the motor in order to ensure the safe and continuous operation of the motor and also the safety of

your installations. If you need further information, please, contact WEG.

Keep this manual close to the motor, so it can be referred to when needed.

ATTENTION

1. It is imperative to observe the procedures contained in this manual for the warranty to be valid;

2. The motor installation, operation and maintenance procedures must be performed by qualified personnel.

NOTES

1. Reproduction of the information contained in this manual, in whole or in part, is allowed since the source is mentioned;

2. In case this manual is lost, the electronic file in PDF format is available at www.weg.net or another printed copy may be requested.

WEG EQUIPAMENTOS ELTRICOS S.A.

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INDEX

1 INTRODUCTION .................................................................................................11 1.1 TERMINOLOGY ..............................................................................................................................11 1.2 SAFETY WARNINGS IN THIS MANUAL ..........................................................................................11

2 GENERAL INSTRUCTIONS .................................................................................12 2.1 QUALIFIED PERSONNEL ................................................................................................................12 2.2 SAFETY INSTRUCTIONS ................................................................................................................12 2.3 STANDARDS...................................................................................................................................12 2.4 CHARACTERISTICS OF THE ENVIRONMENT ................................................................................12 2.5 OPERATING CONDITIONS .............................................................................................................12

3 RECEIVING, STORAGE AND HANDLING .............................................................13 3.1 RECEIVING .....................................................................................................................................13 3.2 STORAGE .......................................................................................................................................13

3.2.1 Indoor storage ....................................................................................................................................13 3.2.2 Outdoor storage .................................................................................................................................13 3.2.3 Further care during storage.................................................................................................................13 3.2.4 Extended storage ...............................................................................................................................13

3.2.4.1 Storage location ..................................................................................................................14 3.2.4.1.1 Indoor storage ................................................................................................14 3.2.4.1.2 Outdoor storage .............................................................................................14

3.2.4.2 Separate parts ....................................................................................................................14 3.2.4.3 Space heater.......................................................................................................................14 3.2.4.4 Insulation resistance ............................................................................................................14 3.2.4.5 Exposed machined surfaces................................................................................................14 3.2.4.6 Bearings..............................................................................................................................15

3.2.4.6.1 Grease-lubricated rolling bearing.....................................................................15 3.2.4.6.2 Oil-lubricated rolling bearing............................................................................15 3.2.4.6.3 Sleeve bearing ................................................................................................15

3.2.4.7 Brushes ..............................................................................................................................15 3.2.4.8 Terminal box .......................................................................................................................15 3.2.4.9 Preparation for commissioning ............................................................................................16

3.2.4.9.1 Cleaning .........................................................................................................16 3.2.4.9.2 Bearing lubrication ..........................................................................................16 3.2.4.9.3 Checking the insulation resistance ..................................................................16 3.2.4.9.4 Brushes..........................................................................................................16 3.2.4.9.5 Others ............................................................................................................16

3.2.4.10 Inspections and records during storage...............................................................................16 3.2.4.11 Maintenance plan during storage.........................................................................................17

3.3 HANDLING......................................................................................................................................18 3.3.1 Handling of horizontal motors..............................................................................................................18 3.3.2 Handling of vertical motors..................................................................................................................18

3.3.2.1 Positioning of vertical motors...............................................................................................18

4 INSTALLATION...................................................................................................19 4.1 LOCAL OF INSTALLATION .............................................................................................................19 4.2 DIRECTION OF ROTATION .............................................................................................................19 4.3 INSULATION RESISTANCE.............................................................................................................19

4.3.1 Safety Instructions ..............................................................................................................................19 4.3.2 General considerations .......................................................................................................................19 4.3.3 Measurement on the windings ............................................................................................................19 4.3.4 Minimum insulation resistance.............................................................................................................20 4.3.5 Conversion of measured values ..........................................................................................................20

4.4 PROTECTIONS ...............................................................................................................................20 4.4.1 Thermal protections ............................................................................................................................20

4.4.1.1 Temperature sensors ..........................................................................................................20 4.4.1.2 Temperature limits for the windings .....................................................................................20 4.4.1.3 Alarm and tripping temperatures..........................................................................................21 4.4.1.4 Temperature and ohm resistance of the thermoresistors PT100 ..........................................21 4.4.1.5 Space heater.......................................................................................................................22

4.4.2 Water leak sensor ...............................................................................................................................22

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4.5 COOLING....................................................................................................................................... 22 4.5.1 Water heat exchangers ...................................................................................................................... 22

4.5.1.1 Heat exchangers for application with seawater ................................................................... 22 4.5.2 Independent fans ............................................................................................................................... 22

4.6 ELECTRICAL CHARACTERISTICS ................................................................................................. 23 4.6.1 Electric connections ........................................................................................................................... 23

4.6.1.1 Main connection ................................................................................................................. 23 4.6.1.2 Grounding .......................................................................................................................... 23

4.6.2 Wiring Diagram .................................................................................................................................. 24 4.6.2.1 Main terminal box ............................................................................................................... 24 4.6.2.2 Accessory terminal box....................................................................................................... 25 4.6.2.3 General identification of the accessories and instrument ..................................................... 25

4.6.2.3.1 Thermostat wiring diagram............................................................................. 26 4.6.2.3.2 Thermistor (PTC) wiring diagram .................................................................... 27 4.6.2.3.3 Thermosensor (Pt-100) wiring diagram........................................................... 29 4.6.2.3.4 Space heater wiring diagram.......................................................................... 30

4.7 MECHANICAL CHARACTERISTICS ............................................................................................... 31 4.7.1 Foundations....................................................................................................................................... 31 4.7.2 Forces on the foundations.................................................................................................................. 31 4.7.3 Base types......................................................................................................................................... 31

4.7.3.1 Concrete base.................................................................................................................... 31 4.7.3.2 Sliding base........................................................................................................................ 31 4.7.3.3 Metal base.......................................................................................................................... 31 4.7.3.4 Anchors.............................................................................................................................. 31

4.7.4 Alignment and leveling........................................................................................................................ 32 4.7.5 Couplings........................................................................................................................................... 33

4.7.5.1 Direct coupling ................................................................................................................... 33 4.7.5.2 Coupling by gears .............................................................................................................. 33 4.7.5.3 Coupling by means of pulleys and belts .............................................................................. 33 4.7.5.4 Coupling of motors equipped with sleeve bearings ............................................................. 34

5 START ...............................................................................................................35 5.1 POWER SUPPLIES......................................................................................................................... 35

6 COMMISSIONING ..............................................................................................36 6.1 PRELIMINARY INSPECTION .......................................................................................................... 36 6.2 INITIAL START-UP.......................................................................................................................... 36 6.3 OPERATION ................................................................................................................................... 37

6.3.1 General .............................................................................................................................................. 37 6.3.2 Data record........................................................................................................................................ 37 6.3.3 Temperatures..................................................................................................................................... 37 6.3.4 Bearings ............................................................................................................................................ 37 6.3.5 Heat exchangers................................................................................................................................ 37 6.3.6 Vibration ............................................................................................................................................ 38 6.3.7 Tripping ............................................................................................................................................. 38

7 MAINTENANCE ..................................................................................................39 7.1 General........................................................................................................................................... 39 7.2 GENERAL CLEANING .................................................................................................................... 39 7.3 INSPECTIONS IN THE WINDINGS ................................................................................................. 39 7.4 WINDING CLEANING ..................................................................................................................... 39 7.5 CLEAN BRUSH COMPARTMENT .................................................................................................. 40 7.6 MAINTENANCE OF THE COOLING SYSTEM................................................................................. 40

7.6.1 Maintenance of heat exchangers........................................................................................................ 40 7.7 Commutator ................................................................................................................................... 40

7.7.1 Checking the commutation ................................................................................................................ 41 7.8 BRUSH HOLDER............................................................................................................................ 42

7.8.1 Adjustment of the neutral zone ........................................................................................................... 42 7.9 BRUSHES ...................................................................................................................................... 42

7.9.1 Adequacy of brushes to load conditions............................................................................................. 43 7.10 MOTOR OUT OF OPERATION ....................................................................................................... 43 7.11 SHAFT GROUNDING DEVICE ........................................................................................................ 44 7.12 BEARING MAINTENANCE.............................................................................................................. 44

7.12.1 Grease rolling bearings....................................................................................................................... 44

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7.12.1.1 Lubrication instruction .........................................................................................................44 7.12.1.2 Procedure to lubricate the rolling bearings ...........................................................................44 7.12.1.3 Bearing lubrication with spring device to remove the grease ................................................45 7.12.1.4 Grease type and quantity ....................................................................................................45 7.12.1.5 Optional greases .................................................................................................................45 7.12.1.6 Procedure for changing the grease......................................................................................45 7.12.1.7 Low-temperature greases ...................................................................................................45 7.12.1.8 Grease compatibility ............................................................................................................46 7.12.1.9 Horizontal bearing assembly and disassembly .....................................................................47 7.12.1.10 Vertical bearing assembly and disassembly .........................................................................48

7.12.2 Oil rolling bearings...............................................................................................................................49 7.12.2.1 Lubrication instruction .........................................................................................................49 7.12.2.2 Oil types.....................................................................................................49 7.12.2.3 Oil Change.....................................................................................................49 7.12.2.4 Bearing operation................................................................................................................50 7.12.2.5 Bearing operation................................................................................................................50

7.12.3 Sleeve bearings ..................................................................................................................................50 7.12.3.1 Bearing data...............................................................................................50 7.12.3.2 Oil change..................................................................................................50 7.12.3.3 Seals...................................................................................................50 7.12.3.4 Bearing operation................................................................................................................51 7.12.3.5 Bearing maintenance...........................................................................................................51 7.12.3.6 Assembly and disassembly of the bearings..........................................................................51

7.12.4 Bearing protection ..............................................................................................................................51 7.12.4.1 Protection adjustments........................................................................................................51 7.12.4.2 Disassembly/assembly of the bearing temperature sensors .................................................51

8 MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................52 8.1 DISASSEMBLY ...............................................................................................................................52

8.1.1 Tacogenerator Disassembly ................................................................................................................52 8.2 ASSEMBLY .....................................................................................................................................52 8.3 MEASUREMENT OF THE AIR-GAP.................................................................................................53 8.4 GENERAL RECOMMENDATIONS...................................................................................................53 8.5 SPARE PARTS................................................................................................................................53 8.6 LIST OF PARTS...............................................................................................................................53

9 MAINTENANCE PLAN.........................................................................................55

10 ANOMALIES, CAUSES AND SOLUTIONS ............................................................57 10.1 MOTORS.........................................................................................................................................57

11 WARRANTY .......................................................................................................59

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1 INTRODUCTION This manual is intended to provide information on the DC motors. Special motors can be supplied with specific documents (drawings, connection diagram, characteristic curves, etc.). Those documents together with this manual must be thoroughly studied before proceeding with installation, operation or maintenance of the motor. All procedures and standards contained in this manual must be observed in order to ensure the proper operation of the motor and safety of the personnel involved in the operation. Following these procedures is also important to ensure the validity of the motor warranty. Thus, we recommend the careful reading of this manual before installing and operating the motor. If any additional explanations are necessary, please, contact WEG.

1.1 TERMINOLOGY

D N F 160 . 190 S

SPECIFIES A DIRECT CURRENT MACHINE

COMPENSATION

N Non compensated motors C Compensated motors COOLING TYPES

F Independent forced ventilation D Forced ventilation by means of ducts S Self-ventilated E Non-ventilated X Axial independent forced ventilation A Ventilation by means of air-air heat exchanger W Ventilation by means of air-water heat exchanger IEC FRAME

CORE LENGTH IN mm

CODE OF THE ND-ENDSHIELD AND COMMUTATOR TRACKS Frames 90 to 132 S Short endshield (one size fits all) Frames 160 to 500 S Short endshield M Long endshield Frame 560 and higher (single endshield) A, B, C,... (code for the number of tracks on the commutator)

1.2 SAFETY WARNINGS IN THIS MANUAL In this manual, the following safety warnings are used:

DANGER

The not following of the procedures recommended in this warning can lead to death, serious injuries and considerable material damages.

ATTENTION

The not following of the procedures recommended in this warning can lead to material damages.

NOTE

The text aims at providing important information for the complete understanding and proper operation of the product.

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2 GENERAL INSTRUCTIONS All personnel working in the assembly, operation or maintenance of electrical installations must be permanently informed and updated on the safety standards and instructions and are advised to strictly comply with them. Before beginning any job, the person in charge must make sure that all points have been duly observed and warn the respective personnel about the danger inherent to the task to be performed. Motors of this type, when inappropriately applied or lacking adequate maintenance, or also when handled by people lacking qualification may cause serious personal injuries and/or material damages. Therefore, it is highly recommended that services be always performed by qualified personnel.

2.1 QUALIFIED PERSONNEL The term qualified personnel represents those who, due to their training, experience, education level, knowledge of applicable standards, safety standards, accident prevention and knowledge of operating conditions, have been authorized by those in charge to execute all necessary tasks, and are able to recognize and avoid any possible danger. Such qualified personnel must also know first aid procedures and must be able to provide them, if necessary. All operation, maintenance, and repair tasks are to be exclusively performed by qualified personnel.

2.2 SAFETY INSTRUCTIONS

DANGER

During operation, this equipment features exposed energized or spinning parts which may present high voltages or high temperatures. Thus, the operation with open terminal boxes, unguarded couplings, or improper handling, failing to comply with the operating standards, may cause severe personal injuries and material damages.

The personnel in charge of the safety at installation must ensure that: Only qualified personnel perform the installation and

operation of the equipment; Such personnel must have immediate access to this

manual and other documents provided with the motor as well as perform tasks in strict compliance with the service instructions, relevant standards, and specific product documentation.

ATTENTION

Failure to comply with the installation and safety standards will void the product warranty. Firefighting equipment and first aid notices must be available in visible and easily-accessible locations within the work site.

All qualified personnel must also observe: All technical data regarding allowed applications

(operating conditions, connections and installation environment) provided in the catalog, purchase order documents, operating instructions, manuals, and other documentation;

The specific determinations and conditions for local installation;

The use of appropriate tools and equipment for handling and transportation;

That the protection devices of the individual component parts are removed just before the installation.

Individual parts must be stored in vibration-free environments, avoiding falls and ensuring their protection against aggressive agents and/or that they do not present risks to the safety of personnel.

2.3 STANDARDS The motors are specified, designed, manufactured and tested according to the following standards: Table 2.1: Applicable standards for DC motors

IEC NBR NEMA

Specification 60034-1 5116 MG1-1,10,20 Dimensions 60072 5432 MG1-4,11

Tests 60034-2 5165 MG1-12 Degrees of protection 60034-5 6146 MG1-5

Cooling 60034-6 5110 MG1-6

Mounting 60034-7 5031 MG1-4

Noise 60034-9 7565 MG1-9

Mechanical vibration 60034-14 5165 MG1-7

2.4 CHARACTERISTICS OF THE ENVIRONMENT

The motors were developed for the following operating conditions: Ambient temperature: -15C to +40C; Altitude up to 1,000 m.a.s.l.; Environment according to the motor degree of

protection.

ATTENTION

For motors with water cooling, the ambient temperature should not be lower than +5C. At temperatures below +5C, antifreeze additives must be added to the water.

Special operating conditions can be met on request, which must be specified on the purchase order and are described on the nameplate and specific data sheet for each motor.

2.5 OPERATING CONDITIONS For the product warranty to remain valid, the motor must operate according to the rated data indicated on the nameplate, and all applicable standards and codes, as well as the information provided in this manual, must be observed.

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3 RECEIVING, STORAGE AND HANDLING

3.1 RECEIVING All the motors supplied are tested and are in perfect operating conditions. All machined surfaces are protected against corrosion. The package must be checked upon receipt for occasional damages during transportation.

ATTENTION

All damages must be immediately photographed, documented, and reported to the transportation company, to the insurance company and to WEG. Failure to comply with such procedures will void the product warranty.

ATTENTION

Parts supplied in additional packages must be checked upon receipt.

When lifting a package (or container), the correct

hoisting points, the weight indicated in the package or on the nameplate, and the operating capacity of the hoisting devices must be observed.

Motors packed in wooden crates must always be lifted by their own eyebolts or by a proper forklift, and must never be lifted by its wooden parts;

The package must never be tumbled. Carefully place it on the floor (without impact) to avoid bearing damage;

Do not remove the grease-based corrosion protection from the shaft end, nor the closing plugs in terminal box holes;

These protections must remain in place until the final assembly. A complete visual inspection of the motor must be performed after removing the package;

The shaft locking device must only be removed shortly before installing the motor and stored in a safe location for future transportation.

3.2 STORAGE Any damage to the painting or corrosion protection of the machined parts must be corrected.

ATTENTION

Space heaters must remain active during storage in order to avoid water condensation inside the motor.

3.2.1 Indoor storage If the motor is not installed immediately after reception, it must remain inside the package and stored in a location protected against humidity, vapors, fast heat variations, rodents, and insects. The motor must be stored in vibration-free locations in order to avoid bearing damage.

3.2.2 Outdoor storage The motor must be stored in a dry location, free of flooding and vibrations. Repair all damages to the package before storing the motor, which is necessary to ensure proper storage conditions. Place the motor on platforms or foundations to protect it against land humidity and keep it from sinking into the soil. Free air circulation underneath the motor must be assured. The cover or canvas used to protect the motor against the weather must not be in contact with its surfaces. In order to ensure free air circulation between the motor and such covers, place wooden blocks as spacers. 3.2.3 Further care during storage When the motor will be stored for over two months, the brushes must be lifted and removed from their holder in order to prevent oxidation caused by the contact with the commutator.

ATTENTION

Before putting the motor into operation, the brushes must be placed in their holders again and their proper setting must be checked.

3.2.4 Extended storage When the motor is stored for a long period of time before being operated, it is exposed to external agents, such as temperature fluctuations, moisture, aggressive agents, etc. Empty spaces inside the motor, such as bearing, terminal boxes, and windings, are exposed to air humidity, which can cause condensation and, depending on the degree of air contamination, aggressive substances may also penetrate these empty spaces. Consequently, after long storage periods, the winding insulation resistance may drop below acceptable values. Internal components, such as rolling bearings, may oxidize, and the lubricant power of the lubricant agent in the bearings may be adversely affected. All of these influences increase the risk of damage before starting up the motor.

ATTENTION

All preventive measures described in this manual, such as constructive aspects, maintenance, packaging, storage, and periodical inspections, must be followed and recorded in order to maintain the product warranty.

The following instructions are valid for motors stored for long periods of time and/or idle for two or more months before being operated.

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3.2.4.1 Storage location In order to ensure the best storage conditions for the motor during long periods of time, the chosen location must strictly meet the criteria described below. 3.2.4.1.1 Indoor storage The storage room must be closed and covered; The location must be protected against moisture,

vapors, aggressive agents, rodents, and insects; The location must be free of corrosive gases, such as

chlorine, sulphur dioxide, or acids; The environment must be free of continuous or

intermittent vibrations; The environment must present an air-filtered ventilation

system; Ambient temperature between 5C and 60C, and must

not be subject to sudden temperature variations; Relative humidity 50%.

3.2.4.4 Insulation resistance During the storage period, the motor windings insulation resistance must be measured and recorded quarterly before the motor installation. Any eventual insulation resistance reduction must be investigated. 3.2.4.5 Exposed machined surfaces All exposed machined surfaces (e.g. shaft end and flanges) are factory-protected with a temporary rust inhibitor. This protection film must be reapplied at least twice a year or when removed and/or damaged. Recommended Products: Name: Dasco Guard 400 TX AZ, Manufacturer: D.A. Stuart Ltda Name: TARP, Manufacturer: Castrol.

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3.2.4.6 Bearings 3.2.4.6.1 Grease-lubricated rolling bearing The rolling bearings are lubricated at the factory to

perform the tests in the motor.

ATTENTION

During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the grease circulate inside the rolling bearing and keep the bearing in good operating conditions.

After 6 months of storage and before starting the

operation of the motor, the rolling bearings must be relubricated.

If the motor remains stored for a period over two years, the rolling bearings must be disassembled, washed, inspected and relubricated.

3.2.4.6.2 Oil-lubricated rolling bearing Depending on the assembly position, the motor can be

transported with or without oil in the bearings; The motor must be stored in its original operation

position and with oil in the bearings, except when specific documentation of the machine determines another transportation and/or storage method;

The oil level must be observed, remaining in the middle of the sight glass;

ATTENTION

During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the oil circulate and keep the bearing in good operating conditions.

After 6 months of storage and before starting the

operation of the motor, the rolling bearings must be relubricated.

If the motor remains stored for a period over two years, the rolling bearings must be disassembled, washed, inspected and relubricated.

3.2.4.6.3 Sleeve bearing Depending on the mounting position and lubrication

type, the motor can be transported with or without oil in the bearings and must be stored in the original operation position with oil in the bearings when specified;

The oil level must be observed, remaining in the middle of the sight glass.

ATTENTION

During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the oil circulate and keep the bearing in good operating conditions.

If not possible to turn the motor shaft, the following procedure must be carried out in order to protect the bearing inside and the contact surfaces against corrosion. Drain all the oil from the bearing; Disassemble the bearing; Clean the bearing; Apply an anticorrosive product (e.g.: TECTIL 511,

Valvoline or Dasco Guard 400TXAZ) on the upper and lower halves of the bearing sleeve and on the contact surface on the motor shaft;

Assemble the bearing; Close all the threaded holes with plugs; Seal the interstices between the shaft and the bearing

seal on the shaft by applying water-proof adhesive tape;

All the flanges (e.g.: oil inlet and outlet) must be protected with blind covers;

Remove the upper sight glass from the bearing and apply the anticorrosive spray inside the bearing;

Put some dehumidifier bags (silica gel) inside the bearing. The dehumidifier absorbs the humidity and prevents condensation inside the bearing;

Close the bearing with the upper sight glass. If the storage period exceeds 6 months. Repeat the procedure described above; Put new dehumidifier bags (silica gel) inside the bearing. If the storage period exceeds 2 years. Disassemble the bearing; Preserve and store the bearing component parts. 3.2.4.7 Brushes The brushes must be lifted on the brush holders, since their contact with the collector rings during the storage period may cause oxidation of the commutator. 3.2.4.8 Terminal box When the insulation resistance in the motor windings is measured, the main junction box and the other terminal boxes must also be inspected, especially considering the following aspects: The inner part must be dry, clean, and free of any dust

accumulation; The contact elements cannot be corroded; The sealing must remain under appropriate conditions; The cable inlets must be correctly sealed. If any of these items is not correct, the parts must be cleaned or replaced.

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3.2.4.9 Preparation for commissioning 3.2.4.9.1 Cleaning The motor inner and outer parts must be free of oil,

water, dust and dirt. The motor inner part must be cleaned with compressed air at reduced pressure;

Remove the rust inhibitor from the exposed surfaces with a cloth damped in a petroleum-based solvent;

Make sure the bearings and cavities used for lubrication are free of dirt and the cavity plugs are correctly sealed and tightened. Oxidation and marks on bearing seats and on the shaft must be carefully removed.

3.2.4.9.2 Bearing lubrication Only use the specified lubricant to lubricate the bearings. Information on bearings and lubricants are indicated on the bearing nameplate, and lubrication must be performed as described in the item Bearing maintenance of this manual, always considering the relevant type of bearing.

NOTE

Sleeve bearings containing anticorrosive products and dehumidifier bags must be disassembled and washed, and the dehumidifier bags removed. Assemble the bearings again and lubricate.

3.2.4.9.3 Checking the insulation resistance Before operating the motor, the insulation resistance must be measured according to the item Insulation resistance of this manual. 3.2.4.9.4 Brushes Before installing and operating the motor, the brushes should be lowered back to their original position. 3.2.4.9.5 Others Follow the remaining procedures described in item Commissioning of this manual before operating the motor.

3.2.4.10 Inspections and records during storage

Stored motors must be periodically inspected and inspection records must be filed. The following points must be inspected: 1. Physical damages; 2. Cleanliness; 3. Signs of water condensation; 4. Protective coating conditions; 5. Paint conditions; 6. Signs of vermin or insect activity; 7. Satisfactory operation of space heaters. It is

recommended that a signaling system or alarm be installed in the location in order to detect power interruption in the space heaters;

8. Record ambient temperature and air relative humidity around the machine, winding temperature (using RTDs), insulation resistance and index;

9. The storage location must also be inspected to assert its compliance with the criteria described in the item Storage Plan.

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3.2.4.11 Maintenance plan during storage During the storage period, the motor maintenance must be performed and recorded in accordance with the plan described in Tabela 3.1. .1: Storage plan

Monthly Every 2 months Every 6 months

Every 2 years

Before starting

operation Note

Storage location

Inspect cleanliness conditions X X

Inspect humidity and temperature conditions X

Check signs of insects X

Measure vibration level X

Package

Inspect physical damages X

Inspect relative humidity inside X

Replace the dehumidifier in the package (if applicable) X When necessary

Space heater

Check operating conditions X

WHOLE MOTOR

Clean external part X X

Check paint conditions X

Check oxidation inhibitor in the exposed machined parts

X

Reapply oxidation inhibitor X

Windings

Measure insulation resistance X X

Measure polarization index X X

Terminal box and grounding terminals

Clean the inner part of the boxes X X

Inspect the seals

Grease or oil rolling bearing

Spin the shaft X

Relubricate the bearing X X

Disassemble and clean the bearing X

Sleeve bearings

Spin the shaft X

Apply anticorrosive and dehumidifier X

Clean the bearings and relubricate them X

Disassemble and store the parts If the storage period

exceeds 2 years

Brushes

Lift brushes During storage

Lower brushes and check contact with the commutator

X

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3.3 HANDLING In order to lift the motor, use the eyes provided for that

purpose only. If necessary, use a device to space the lifting cables and thus protect parts of the motor;

The frame eyebolts are designed to lift the motor only. Do not use them to lift the driven motor-machine unit;

Observe the weight informed; Do not lift the motor with jolts or place it abruptly on

the floor, which can cause damages to the bearings; The eyes on the covers, bearings, terminal box, etc.,

are designed to handle these components only; Never use the shaft to lift the motor.

ATTENTION

In order to move or transport the motor, the shaft must be locked with the lock device supplied with the motor.

The lifting equipment and devices must be capable of supporting the weight of the motor.

3.3.1 Handling of horizontal motors

Figure 3.1: Handling of horizontal motors Handling of horizontal motors must be performed as shown in Figure 3.1. The lifting chains or cables must have a maximum

angle of 30 to the vertical. In order to lift the motor, use the eyes provided for that

purpose only. 3.3.2 Handling of vertical motors

Figure 3.2: Handling of vertical motors

Handling of vertical motors must be performed as shown in Figure 3.2. Always use the upper eyes of the motor for moving in the vertical position, ensuring that the lifting chains or cables also remain in the vertical position, thus avoiding too much effort in the eyes. 3.3.2.1 Positioning of vertical motors The vertical motors are supplied with eyes for lifting on the front and rear. Some motors are transported in the horizontal position and need to be moved to their original position. The following procedure shows the movement of the motors from the horizontal to the vertical position and vice-versa.

Figure 3.3: Positioning of vertical motors 1. Lift the motor by means of the side eyes using 2

hoists; 2. Lower the front part of the engine and at the same

time lift the rear part until it reaches balance; 3. Remove the cables from the front of the motor and

turn it 180 to allow the fixture of these cables to the other eyes of the rear part of the motor;

4. Fix the loose cables to the eyes of the rear part of the motor and lift it until it is in a vertical position.

ATTENTION

Noncompliance with these recommendations may cause damage to equipment and/or injury to people.

Mximo 30

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4 INSTALLATION

4.1 LOCAL OF INSTALLATION Electric motors must be installed in easily accessible places, allowing periodic inspections, local maintenance and, if necessary, removal for external services. The following environment characteristics must be ensured: Clean and well-ventilated location; The installation of other equipment or walls must not

block or hinder the motor ventilation; The area around and above the motor must be

sufficient for its maintenance or handling; Fan cooled motors must be at least 50mm above the

floor to allow air inlet; The environment must be in accordance with the motor

protection degree.

4.2 DIRECTION OF ROTATION The motor rotation direction is indicated on a plate fixed to the frame on the drive end.

ATTENTION

Motors supplied with a single direction of rotation must not operate in the opposite direction. In order to operate the motor in the opposite direction, please contact WEG.

4.3 INSULATION RESISTANCE 4.3.1 Safety Instructions

DANGER

In order to measure the insulation resistance, the motor must be shutdown and still. The winding being tested must be connected to the frame and grounded until all residual electrostatic charges are removed. Noncompliance with these procedures may result in personnel injuries.

4.3.2 General considerations When motor is not immediately operated, it must be protected against moisture, high temperatures, and dirt, avoiding impacts to the insulation resistance. Winding insulation resistance must be measured before operating the motor. If the environment is too humid, the insulation resistance must be measured periodically during storage. It is difficult to establish fixed rules for the actual value of a motor insulation resistance, as it varies according to environmental conditions (temperature, humidity), machine cleanliness conditions (dust, oil, grease, dirt), and quality and condition of the insulating material used. Evaluating periodical follow-up records is useful to conclude whether the motor is able to operate.

4.3.3 Measurement on the windings

The insulation resistance must be measured with a megohmmeter. The test voltage for motor windings must be in accordance with the IEEE43 standard. Table 4.1: Voltage for the insulation resistance test of the windings

Winding rated voltage (V)

Insulation resistance test - continuous voltage (V)

< 1000 500

1000 - 2500 500 - 1000

2501 - 5000 1000 - 2500

5001 - 12000 2500 - 5000

> 12000 5000 - 10000

Before measuring the winding insulation resistance, check that: The brushes are lifted; All power cables are disconnected; The motor frame is grounded; The winding temperature was measured; All temperature sensors are grounded. Measure the winding insulation resistance as follows: Commutation/compensation winding:

Terminal B2 and frame; Excitation winding:

Terminals F1 / F2 and frame; Armature winding: Wrap the commutator with a bare flexible wire (or flexible braid) and measure the commutator insulation resistance to the ground (frame).

ATTENTION

Much higher values may be frequently obtained in motors being operated for a long period of time. Comparison with values obtained in previous tests in the same motor, under similar load, temperature, and humidity conditions, may be an excellent parameter to evaluate the winding insulation conditions, instead of exclusively using the value obtained in a single test as the basis. Significant or abrupt reductions in the insulation resistance are considered suspicious.

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20

Table 4.2: Insulation resistance referential limits in electric machines

Insulation resistance value Insulation evaluation

2M or less Bad < 50M Dangerous

50...100M Regular 100...500M Good

500...1000M Very Good > 1000M Excellent

4.3.4 Minimum insulation resistance If the measured insulation resistance is below 100M at 40C, before putting the motor into operation, contact WEG. 4.3.5 Conversion of measured values The insulation resistance must be kept at 40C. If the measurement is performed at a different temperature, it will be necessary to correct the reading to 40C by using an insulation resistance variation curve according to the temperature obtained from the motor itself. If this curve is not available, the approximate correction provided by the curve in Figure 4.1, according to the NBR 5383 / IEEE43 standard, may be employed.

4.4 PROTECTIONS 4.4.1 Thermal protections The protection devices against overheating are installed on the poles, bearings and other component parts that require temperature monitoring and thermal protection. Those devices must be connected to an external temperature monitoring and protection system. 4.4.1.1 Temperature sensors

Thermostat (bimetallic) - Bimetallic thermal detectors with normally closed silver contacts. They open at a certain temperature. The thermostats are connected in series or independently according to the wiring diagram. Thermistors (PTC or NTC) - Thermal detectors composed of semiconductors that vary their resistance sharply when they reach a certain temperature. Thermistors are connected in series or independently according to the wiring diagram.

NOTE

The thermostats and thermistors must be connected to a control unit which will interrupt the supply of the motor or will activate a signaling device.

Thermoresistance Pt100 - Calibrated resistance element. Its operation is based on the principle that the electric resistance of a metallic conductor varies linearly with the temperature. The detector terminals must be connected to a control panel, which includes a thermometer.

Figure 4.1: Insulation resistance variation coefficient according to the temperature

NOTE

The RTD thermoresistors provide monitoring by means of the absolute temperature informed by its instant resistance value. With this information, the relay can perform the reading of the temperature, as well as the parameterization for alarm and tripping according to the preset temperatures.

4.4.1.2 Temperature limits for the windings The temperature of the winding hottest spot must be kept below the insulation thermal class limit. The total temperature is composed by the ambient temperature plus temperature elevation (T), plus the difference between the average winding temperature and the winding hottest spot temperature.

Temperatura do enrolamento C R40C = Rt x Kt40C

To convert the measured insulation resistance (Rt) for 40C, multiply it by the temperature

coefficient (Kt)

Coe

ffici

ent o

f ins

ulat

ion

resi

stan

ce v

aria

tion

Kt 4

0C

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The ambient temperature is normally, at most, 40C. Above this value, the working conditions are considered special. The numeric values and the composition of the acceptable temperature at the winding hottest spot are indicated in Table 4.3. Table 4.3: Insulation class

Insulation class F H

Ambient temperature C 40 40 T = temperature rise (temperature measurement method by resistance variation) C 105 125

Difference between the hottest spot and the average temperature

C 10 15

Total: hottest spot temperature C 155 180

ATTENTION

In case the motor operates with temperatures in the windings above the limit values of the insulation thermal class, the useful life of the insulation and, consequently, of the motor, will be significantly reduced or it may even cause the burnout of the motor.

4.4.1.3 Alarm and tripping temperatures The temperature level for alarm and tripping must be set as low as possible. This temperature level can be determined based on test results or through the motor operating temperature. The alarm temperature can be set for 10C above the machine operating temperature at full load, always considering the highest local ambient temperature. The temperature values set for tripping must not exceed the maximum acceptable temperatures for the

stator winding insulation class and for the bearings (according to the lubrication system). Table 4.4: Stator maximum temperature

Maximum temperature set for protections (C)

Class of Temperature - UL508

Alarm Tripping F 130 155 H 155 180

Table 4.5: Maximum temperature of the bearings

Maximum temperature set for protections (C) Alarm Tripping

110 120

ATTENTION

The alarm and tripping values may be determined as a result of experience, but cannot exceed the values indicated in Table 4.4 and Table 4.5.

ATTENTION

The motor protection devices are listed in the WEG design - Specific wiring diagram of each motor. The decision of not using those devices is full responsibility of the user; and in case of damages, it can void the warranty.

4.4.1.4 Temperature and ohm resistance of the thermoresistors PT100 Table 4.6 shows the temperature values as a function of the ohm resistance measured for thermoresistances PT100 type. Table 4.6: Temperature X Resistance (Pt100)

C 0 1 2 3 4 5 6 7 8 9 0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51

10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40 20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28 30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15 40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01 50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86 60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69 70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51 80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32 90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12

100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91 110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68 120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45 130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20 140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94 150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67

Formula: - 100 = C 0.386

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4.4.1.5 Space heater When the motor is equipped with space heaters to prevent water from condensing inside during long periods out of operation, you must ensure they are powered on right after the motor is shut down and that they are powered down before the motor goes into operation. The motor wiring diagram and a specific nameplate fixed to the motor specify the power supply and power rating of the space heaters. 4.4.2 Water leak sensor Motors with air-water heat exchanger feature a water leak sensor intended to detect any water leak from the heat exchanger into the motor. This sensor must be connected to the control panel, according to the wiring diagram of the motor. The signal of this sensor must be used for alarm. When this protection goes off, the heat exchanger must be inspected and, if any water leak is detected, the motor must be shut down and the problem corrected.

4.5 COOLING Only the proper installation of the motor and of the cooling system can ensure its continuous operation without overheating. 4.5.1 Water heat exchangers The water heat exchanger (when used) is a surface heat transmitter designed to dissipate heat of electrical equipment or others in an indirect way, that is, air in closed circuit is cooled by the heat exchanger after removing the heat generated by the equipment that must be cooled. The heat transmission occurs from the equipment to the air and from the air to the water.

NOTE

The protection devices of the cooling system must be monitored periodically;

NOTE

The water inlets and outlets must not be blocked, since that could cause overheating and even the burnout of the motor.

Clean water, with the characteristics below, must be used as coolant: PH: 6 to 9; Chlorides: maximum 25.0 mg/l; Sulfates: maximum 3.0 mg/l; Manganese: maximum 0.5 mg/l; Suspended solids: maximum 30.0 mg/l; Ammonia: no traces

ATTENTION

The data of the heat exchangers that compose the air-water heat exchanger are described on the nameplate and dimension drawing of the motor. This data must be observed for the proper operation of the motor cooling system and thus prevent overheating.

4.5.1.1 Heat exchangers for application with

seawater

ATTENTION

In case of heat exchangers to work with seawater, in order to avoid corrosion, the materials in contact with water (pipes and flush plates) must be resistant to corrosion. Besides, the heat exchangers may feature sacrificial anodes (for instance: zinc or manganese) according to Figure 4.2. In this application, anodes are corroded during operation of the heat exchanger, protecting the exchanger heads. In order to keep the integrity of the heads, these anodes must be periodically replaced, according to the corrosion degree presented.

Figure 4.2: Heat exchanger with sacrificial anodes

NOTE

The type, quantity and position of the sacrificial anodes may vary from application to application.

4.5.2 Independent fans Independent fans (when used) normally feature a three-phase asynchronous motor for the drive. The terminal box of this motor is normally located on its frame. The characteristic data (frequency, voltage, etc.) are indicated on the nameplate of this motor and the direction of rotation is generally indicated by a plate with an arrow fixed to the fan housing or close to it.

Sacrificial Anodes

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NOTE

Inspect visually the direction of rotation of the independent fan before starting the machine. If the fan is turning in the wrong direction, the connection of two phases of the fan must be inverted.

Also, the air filters that protect the motor inside against contamination must be checked periodically. The filters must be kept in perfect conditions to ensure the proper operation of the cooling system and safe protection of the sensitive internal parts of the motor.

4.6 ELECTRICAL CHARACTERISTICS 4.6.1 Electric connections 4.6.1.1 Main connection The motor stator terminals are fixed in insulators in the main terminal box or by means of copper terminals, depending on the mounting style of the motor. The location of the terminal boxes is identified in the specific dimension drawing of each motor. The connections to the terminals must be done according to the specific connection diagram for the motor. Make sure the section and insulation of the connection cables are suitable for the motor current and voltage. The identification of the terminals and the corresponding connection are indicated in the connection diagram specific for each motor, in compliance with IEC60034-8 or NEMA MG1 standards. The direction of rotation of the motor can be changed by reversing the polarity of the power supply of the excitation or the armature. The motor must rotate in the direction of rotation specified on the indicative connection plate fixed on the motor.

ATTENTION

The inversion of the field can only occur with the motor off.

NOTE

The direction of rotation is determined looking at the shaft end from the drive end of the motor. Motors with a single direction of rotation must only turn in the indicated direction, since the fans and other devices are unidirectional. In order to operate the motor in the direction of rotation opposite the specified, contact WEG.

ATTENTION

Before making the connections between the motor and the electric energy, it is necessary to measure carefully the winding insulation resistance.

In order to connect the motor main power supply cables, unscrew the stator terminal box cover, cut the sealing rings (standard motors without cable gland) according to the diameter of the cables to be used and insert the cables inside the sealing rings. Cut the power supply cables to the necessary length, strip the ends and mount the terminals to be used. 4.6.1.2 Grounding The motor frame and the main terminal box must be grounded before connecting the motor to the supply system. Connect the metal cover of the cables (if applicable) to the common grounding conductor. Cut the grounding conductor to the proper length and connect it to the connector in the terminal box and/or frame. Fasten all connections firmly.

ATTENTION

Do not use steel washers or another low electric conductivity material to fasten the terminals.

Before making connections, apply protective grease on all connections of the contacts. Insert all the sealing rings in the respective slots. Close the terminal box cover, always observing if the sealing rings are correctly placed.

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24

4.6.2 Wiring Diagram 4.6.2.1 Main terminal box

Wiring diagram with independent excitation Code 9201 Wiring diagram with additive compound excitation - Code 9213

Clockwise rotation

Clockwise rotation

Counterclockwise rotation

Counterclockwise rotation.

Wiring diagram with series excitation Code 9202

Clockwise rotation

Counterclockwise rotation

When the terminals F1+ and F2 are connected to a rail with connectors (terminal block), the cable identification is performed with sleeve and label, with an indication in accordance with the diagram Y: Diagram 4.1: Identification of excitation cables (sleeves and labels)

C: WEG Symbols, used to indicate the excitation terminals. The terminals are F1+, F2-, as per connection diagrams above.

B: Indicates the connector number (terminal) to which the excitation terminal is connected.

X: Indication of rail with connectors (terminal block); A: Indicates the number of the rail with connectors where the excitation terminal is connected.

XA - B - C

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4.6.2.2 Accessory terminal box

ATTENTION

In case of anticipation of terminal box for accessories, there will be the connecting terminals of the thermal protectors and other accessories. Otherwise, the terminals of the accessories will be in the main box.

4.6.2.3 General identification of the accessories and instrument All the accessory and instrument cables are identified through sleeves with labels. These sleeves with labels are mounted in the accessory and instrument cables and are located near the rail with connectors. The identification of the accessory and instrument cable is performed by means of the encoding system according to Diagram 4.2.

NOTE

When supplied the wiring diagram of the machine accessories and instrument, the information of the diagram prevails in relation to the information contained in this item of the manual.

Diagram 4.2: Identification of the instrument cables (sleeves and labels)

XA - B - CDE

WEG Terminology, based in international standards, used to denote accessories and instruments and their cables. This nomenclature is composed by: C: Number assigned to the instrument or accessory. When the instrument is for measuring temperature, it is attributed:

1 to 6 Installation on the commutation pole(s); 7 to 12 - Installation on the excitation pole(s); 13 and 14 Installation on the bearing(s); 15 to 20 Installation on the compensation poles;

D: Letter(s)that defines the type of accessory or instrument, according toTable 4.7. E: Number corresponding to the accessory or instrument cable.

B: Indicates the connector number (terminal) to which the accessory or instrument cable is connected.

X: Indication of rail with connectors (terminal block); A: Indicates the number of the rail with connectors where the connector to which the accessory or instrument cable is connected is locaed.

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Table 4.7: Codes of the terminology of accessories and instruments

ORDER CODE ACCESSORY / INSTRUMENT 1 TP Thermoresistance (PTC) 2 TN Thermoresistance (NTC) 3 R Thermoresistance (Pt-100) 4 TC Thermocouple 5 TB Thermostat 6 TE Thermometer with electric contacts 7 HE Space heater 8 SE Tachometric dynamo (tacogenerator) 9 SZ Pulse generator (Encoder)

10 SY Rotation sensor 11 CR Water leak sensor of the heat exchanger 12 BA AC brake 13 BD DC brake 14 F1+, F2- Main excitation 15 FW Water flow switch 16 FO Oil flow switch 17 FA Air flow switch 18 PW Pneumatic pressure switch 19 PO Differential pneumatic pressure switch 20 LW Level sensor 21 VS Vibration transducer (displacement) 22 VE Vibration transducer (speed) 23 VP Vibration transducer (acceleration)

NOTE

The column Order of Table 4.7 indicates the mounting sequence of the cables on the rail with connectors according to the accessory or instrument type.

4.6.2.3.1 Thermostat wiring diagram

On the commutation pole (one per pole) - Code 9225.

XA-B

-1TB

1

1TB

XA-B

-1T B

2

XA-B

-2TB

1

2TB

XA-B

-2TB

2

XA-B

-3T B

1

3TB

XA-B

-3TB

2

X A-B

-4TB

1

4TB

XA-B

- 4TB

2

XA-B

-5TB

1

5TB

XA-B

-5T B

2

XA-B

- 6TB

1

6TBXA

-B-6

TB2

On the excitation pole (one per pole) - Code 9226.

X A-B

-9TB

1

9TB

XA-B

-9TB

2

XA-B

-10T

B1

10TB

XA-B

- 10T

B2

XA-B

-7TB

1

7TB

XA-B

-7TB

2

XA-B

-8T B

1

8TB

XA-B

-8TB

2

X A-B

-11T

B 1

11TB

XA-B

-11T

B2

XA-B

- 12T

B1

12TB

XA-B

- 12T

B2

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One on the commutating pole and one on the excitation pole (connected in

series) - Code 9227 One per bearing Code 9230

One on the commutating winding, one on the excitation winding and one on the compensation winding (connected in

series) - Code 9228

XA-B

-13T

B1

13TB

XA-B

-13T

B2

XA-B

-14 T

B1

14TB

XA-B

- 14T

B2

XA-B

-1TB

11TB 7TB

XA-B

-7TB

2

DE bearing NDE bearing

XA-B

-1TB

1

1TB 7TB

XA-B

-15T

B2

15TB

On the compensation winding (one per pole) - Code 9231

XA-B

-15 T

B1

15TB

XA-B

-15T

B2

X A-B

-16T

B 1

16TB

XA-B

-16 T

B2

XA-B

- 17T

B1

17TB

XA-B

-17T

B 2

XA-B

-18T

B1

18TB

XA-B

-18T

B2

X A-B

-19T

B 1

19TB

XA-B

-19 T

B2

XA-B

- 20T

B1

20TB

XA-B

-20T

B 2

4.6.2.3.2 Thermistor (PTC) wiring diagram

On the commutation winding (one per pole) - Code 9222

XA-B

-1TP

1

1TP

XA-B

-1T P

2

XA-B

-2TP

1

2TP

XA-B

-2TP

2

XA- B

-3TP

1

3TP

XA-B

-3TP

2

XA-B

-4TP

1

4TP

XA-B

-4TP

2

t t t t

XA-B

-5TP

1

5TPXA

-B-5

TP2

XA-B

-6TP

1

6TP

XA-B

-6TP

2

t t

On the excitation winding (one per pole) - Code 9223

XA-B

-9T P

1

9TP

XA-B

-9TP

2

XA-B

-10T

P1

10TP

XA-B

-10T

P 2

t t

XA-B

-7TP

1

7TP

XA-B

-7TP

2

XA- B

-8TP

1

8TP

XA-B

-8TP

2

t t

XA-B

-11T

P1

11TP

XA-B

-11T

P2

XA-B

-12 T

P1

12TP

XA-B

-12T

P2

t t

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28

Two on the commutating winding and one on the excitation winding

- Code 9224 One per bearing Code 9239

XA-B

-13T

P1

13TP

XA-B

-13T

P2

XA-B

- 14T

P1

14TP

XA-B

-14T

P 2

t t

XA-B

- 1TP

1

1TP

XA-B

-1TP

2

XA-B

-2TP

1

2TP

XA-B

-2TP

2

XA- B

-7TP

1

7TP

XA-B

- 7TP

2

t t t



XA-B

-15 T

P1

15TP

XA-B

-15T

P2

XA-B

- 16T

P1

16TP

XA-B

-16T

P2

X A-B

-17T

P 1

17TPXA

-B-1

7 TP2

XA-B

-18 T

P1

18TP

XA-B

-18T

P2

t t t t

XA-B

-19T

P1

19TP

XA-B

-19T

P2

XA-B

-20T

P1

20TP

XA-B

-20T

P2

t t

One on the commutating winding, one on the excitation winding and one on the compensation winding - Code 9238

XA- B

-1TP

1

1TP

XA-B

-1TP

2

XA-B

-7TP

1

7TP

XA-B

-7TP

2

XA-B

-15T

P1

15TP

XA-B

-15T

P2

t t t

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4.6.2.3.3 Thermosensor (Pt-100) wiring diagram

On the commutation winding (one per pole) - Code 9219 XA

-B-1

R1

1RXA

-B- 1

R2

XA-B

-2R1

2R

XA-B

-2R2

XA-B

-3R1

3R

XA-B

-3R2

XA-B

-4R1

4R

XA-B

-4R2

t t t tXA

-B- 1

R2

XA-B

-2R2

XA-B

-3R2

XA-B

-4R2

XA-B

-5R1

5R

XA-B

-5R2

XA-B

-6R1

6R

XA-B

-6R2

t t

XA-B

-5R2

XA-B

-6R2

On the excitation winding (one per pole) - Code 9221

XA-B

-9R 1

9R

XA-B

-9R2

XA-B

-10R

1

10R

XA-B

-10 R

2

t t

XA-B

-9R2

XA-B

-10R

2

XA- B

-7R1

7R

XA-B

-7R2

XA-B

-8R 1

8R

XA-B

-8R2

t t

XA-B

-7R 2

XA-B

-8R2

XA- B

-11R

1

11R

XA-B

-11R

2

XA-B

-12R

1

12R

XA-B

-12R

2

t t

XA-B

-11R

2

XA-B

-12R

2


XA-B

-15R

1

15R

XA-B

-15R

2

XA-B

-16R

1

16R

XA-B

-16R

2

XA-B

- 17R

1

17R

XA-B

-17R

2

XA-B

-18R

1

18RXA

-B-1

8R2

t t t t

XA-B

-15R

2

XA-B

-16R

2

XA-B

-17R

2

XA-B

-18R

2

XA-B

-19R

1

19R

XA-B

-19R

2

XA-B

-20R

1

20R

XA-B

-20R

2

t t

XA-B

-19R

2

XA-B

-20R

2

One on the commutating winding, one on the excitation winding

and one on the compensation winding (one per pole) - Code 9234 One per bearing Code 9236

XA-B

-13R

1

13R

XA-B

-13R

2

XA- B

-14R

1

14RXA

-B-1

4R2

t t

XA-B

-13 R

2

X A-B

-14R

2

XA-B

-1R 1

1R

XA-B

-1R2

XA-B

- 7R1

7R

XA-B

-7R2

XA-B

-15R

1

15R

XA-B

-15R

2

t t t

XA-B

-1R2

X A-B

-7R2

XA-B

-15R

2


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30

4.6.2.3.4 Space heater wiring diagram

B1 B2 B3 B4 B1 B2 B3 B4.... ...... ..

2 Connector bridges 1 Connector bridge

Arrangement layout with two space heaters Arrangement layout with four space heaters

1HE 2HE

XA-B

4-4H

E2

XA-B

2 -3H

E1

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4.7 MECHANICAL CHARACTERISTICS

4.7.1 Foundations The foundation or structure where the motor will be

installed must be properly strong and flat, free of external vibration and capable to stand the mechanical forces it will undergo during the start or short circuit of the motor;

The type of foundation will depend on the kind of soil at the assembly site or on the floor resistance;

If the dimensioning of the foundation is not carefully done, serious vibration problems may affect the foundation set, motor and driving machine;

The structure dimensioning of the foundation must be done based on the dimension drawing, on the information regarding the mechanical forces on the foundations, and on the form of fixing the motor.

ATTENTION

Use shims of different thicknesses (total thickness of approximately 2 mm) between the motor feet and the foundation surfaces so that later you can make a precise vertical alignment.

NOTE

The user is responsible for dimensioning and building the foundation.

4.7.2 Forces on the foundations Based on Figure 4.3, the forces on the foundation can be calculated by the equations: Where: F1 and F2 - Reaction of the feet on the base (N) g - Gravity acceleration (9.81m/s) m - Motor mass (kg) Cmax - Maximum torque (Nm) A - Obtained from the motor dimension drawing (m)

Figure 4.3: Forces on the foundations

4.7.3 Base types 4.7.3.1 Concrete base The concrete bases are the most widely used for the installation of these motors. The type and size of the foundation, bolts and anchoring plates depend on the motor size and type. 4.7.3.2 Sliding base In pulley drive, the motor must always be mounted on the sliding base (rails) and the lower part of the belt must be tractioned. The closest rail to the driving pulley must be mounted so that the positioning bolt stays between the motor and the driven machine. The other rail must be mounted with the bolt in the opposite position as shown in Figure 4.4. The motor is bolted on rails and positioned on the foundation. The driving pulley is then aligned so as its center is in the same plane as that of the driven pulley and the motor and machine shafts are parallel. The belt must not be too tensioned. After the alignment, the rails are fixed.

Figure 4.4: Sliding base 4.7.3.3 Metal base The motor feet must be settled evenly on the metal base so as to prevent deformations of the frame. Occasional height errors of the motor foot rest surface can be corrected with shims (a maximum height of 2 mm is recommended). Do not remove the machines from the common base to align them. The base must be leveled on the foundation itself by using spirit levels or other leveling devices. When a metal base is used to adjust the height of the motor shaft end with the machine shaft end, it must be leveled on the concrete base. After the base is leveled, the anchors tightened and the couplings checked, the metal base and the anchors are cemented. 4.7.3.4 Anchors Anchors are devices to fix motors directly on the foundation, when the motors are applied with elastic coupling. This kind of coupling is characterized by the absence of force on the bearings, besides presenting lower investment costs. Anchors must not be painted, neither present rust, as this would be detrimental to the adherence of the concrete and would cause their take-up.

)(max)4(...5.01 A

CgmF ++=

)(max)4(...5.02 A

CgmF +=

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32

Figure 4.5: Anchors 4.7.6 Foundation natural frequency In order to ensure a safe operation, besides a solid foundation, the motor must be precisely aligned with the equipment it is coupled with, and the component parts mounted on its shaft must be properly balanced. With the motor mounted and coupled, the relations between the natural frequencies of the foundation are: The motor rotation frequency; The double of the rotation frequency; The double of the line frequency. These natural frequencies must be in accordance with the specified below: Natural frequency of the first order of the foundation

+25% or -20% in relation to the frequencies above; Natural frequencies of the foundation of higher orders

+10% or -10% in relation to the frequencies above. 4.7.4 Alignment and leveling The motor must be correctly aligned with the driven machine, mainly when using the direct coupling. Incorrect alignment can damage the bearings, generate excessive vibration and even break the shaft. The alignment must be carried out according to the recommendations of the coupling manufacturer. Especially in direct couplings, the motor and driven machine shafts must be aligned in the axial and radial directions, as shown in Figure 4.6 and Figure 4.7.

Figure 4.6: Parallel alignment Figure 4.6 shows the parallel misalignment of the two shaft ends and a practical form to measure it by using proper dial gauges. Measurement is performed in four points with a 90 displacement from each other and with the two half-couplings spinning together in order to eliminate the effects of irregularities on the support surface on the tip of the dial gauge. Choosing a vertical point greater than 0,

half the difference of the dial gauge measurement in the 0 and 180 points represents the vertical coaxial error. In case of deviation, it must be properly corrected, adding or removing assembly shims. Half the difference of the dial gauge measurement in the 90 and 270 points represents the horizontal coaxial error. This measurement indicates when it is necessary to lift or lower the motor, or move it to the right or to the left on the driven side in order to eliminate the coaxial failure. Half the difference of the dial indicator maximum measurement in a complete turn represents the maximum found run out. The misalignment in a complete turn of the rigid or semi-flexible coupling cannot exceed 0.03 mm. When flexible couplings are used, values that are greater than those indicated above are acceptable, provided that they do not exceed the acceptable value specified by the coupling manufacturer. Maintaining a safety margin for these values is recommended.

Figure 4.7: Angular alignment Figure 4.7 shows the angular misalignment and a practical form to measure it. Measurement is performed in four points with a 90 displacement from each other and with the two half-couplings spinning together in order to eliminate the effects of irregularities on the support surface on the tip of the dial gauge. Choosing a vertical point greater than 0, half the difference of the dial indicator measurement in the 0 and 180 points represents a vertical misalignment. In case of deviation, it must be properly corrected, adding or removing assembly shims from the motor feet. Half of the dial indicator measurement difference in the 90 and 270 points represents a horizontal misalignment, which must be adequately corrected by displacing the motor in the lateral/angular direction. Half the difference of the dial indicator maximum measurement in a complete turn represents the maximum angular misalignment found. The misalignment in a complete turn of the rigid or semi-flexible coupling cannot exceed 0.03 mm. When flexible couplings are used, values that are greater than those indicated above are acceptable, provided that they do not exceed the acceptable value specified by the coupling manufacturer. Maintaining a safety margin for these values is recommended.

Horizontal Mount Vertical M

Radial measurement

Parallel misalignment

Horizontal Mount Vertical Mount

Axial measurement

Angular misalignment

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In the alignment/leveling, the influence of temperature on the motor and driven machine must be taken into account. Different dilatations of the component parts may change the alignment/leveling conditions during operation. 4.7.5 Couplings Only proper couplings must be used, which convey only torque, without generating transversal forces. The centers of the motor and driven machine shafts must be in a single line for elastic and rigid couplings as well. Elastic couplings aim at mitigating the residual misalignment effects and preventing vibration transmission between the coupled machines, which does not happen when you use rigid couplings. The coupling must be assembled or removed with the aid of proper devices and never by means of rudimentary tools, such as hammers, mallets, etc.

ATTENTION

Pins, nuts, washers and leveling shims may be supplied with the motor when requested by the customer in the purchase order.

NOTES

The user is responsible for installing the motor. WEG is not liable for damages to the motor, associated equipment and installation occurred due to: Excessive vibration transmission; Poor installations; Faulty alignment; Improper storage conditions; Noncompliance with the instructions before

commissioning; Incorrect electric connections.

4.7.5.1 Direct coupling Because of costs, space, absence of belt sliding, and greater safety against accidents, direct coupling must be used whenever possible. Also in case of using reduction gearing, direct coupling is recommended.

ATTENTION

Carefully align the shaft ends, and, whenever possible, use flexible coupling, leaving a minimum clearance of 3 mm between the couplings as shown in Figure 4.8.

8: of coupling (E)

4.7.5.2 Coupling by gears Coupling by gears poorly aligned generate vibration in its transmission and motor. Therefore, the shafts must be perfectly aligned, precisely parallel in the case of straight gears and in the precise angle in the case of helical or bevel gears. The perfect gear alignment can be controlled by inserting a paper strip which will show the trace of all the teeth after a complete turn of the gear. 4.7.5.3 Coupling by means of pulleys and

belts

Figure 4.9: Coupling by means of pulleys and belts When a speed ratio is necessary, the drive by belt is the most commonly used. In order to avoid unnecessary radial force on the bearings, the shafts and pulleys must be perfectly aligned. Belts that work diagonally convey impacts to the rotor and may damage the bearing seat. Belt slippage can b

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