weg tachogenerator manual english

01

This manual provides basic pro-cedures that apply to WEGTachogenerators. The machinesreferred in this manual are subjectto constant improvements. For thisreason, the information and in-structions herewith contained maychange without prior notice. Formore information, contact themanufacturer.

TABLE OF CONTENTS

1. DESCRIPTION .................................................... 31.1 Applications .................................................... 31.2 Construction ................................................. 3

2. ASSEMBLING ..................................................... 42.1 Transportation, Receiving and storage ................ 42.2 Alignment (1R)/2RC(P) .................................... 42.3 Coupling ........................................................ 4

3. OPERATION ....................................................... 8

4. MAINTENANCE ................................................... 84.1.Cleanliness and general care ............................. 84.2.Rotor disassembly ........................................... 84.3.Tachogenerator bearings 1R(C)/2RC(P) .............. 94.4.Commutator .................................................. 104.5.Brushes ........................................................ 104.6.Temperature compensating circuit for Tachogenerator 1R(C)/2RC(P) ........................ 11

5. CONNECTION DIAGRAM ....................................12

6. SPARE PARTS - 1R(C) ....................................... 12

7. CROSS - SECTIONAL DRAWING POSITION OFCOMPONENTS - 1R(C) ......................................13

8. MAINTENANCE SCHEDULE.................................16

9. TROBLESHOOTING ............................................19

10. WARRANTY TERMS FOR ENGINEERING...............21

02 Installation and Maintenance Manual for WEG Tachogenerators

1. DESCRIPTION1.1.APPLICATIONS

The WEG tachogenerators have been designed for applica-tions on servocontrol operating machines, driving of textilemachines, accelerators, braking of elevators, control and regu-lation of fine adjustments which depend on speed variationand other applications that require continuous and closelycontrolled speed.The tachogenerator gives a continuous voltage sign corre-sponding to the speed actual value of the electric machine towhich it is coupled.

1.2.CONSTRUCTION

The Tachogenerator is fitted with permanent magnets inthe stator with the function of creating a magnetic field. Anamplitude continuous voltage proportional to the speed, whichdepends on the rotation direction, is generated in the woundrotor.

a) Tachogenerator Type 1R (C) 2RC (P)

This tachogenerator is fitted with flange and shaft with key,where the coupling arrangement is made through a flexiblecoupling. The types 1RC/2RC (P) are built with terminalbox. The �C� and �P� indicate that the tachogeneratorsare built with feet or T-box.

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IMPORTANT:Due to the characteristics of the permanent magnets used,this tachogenerator should not be disassembles. Whenthe rotor is removed from the stator, the magnets be-come partially demagnetized and then the tachogeneratorwill not supply the voltage rated value.

b) Tachogenerator Type TCW

This tachogenerator is built with hallow shaft where the ro-tor is installed over a conic extension of the machines shaftto which is coupled. The magnetic material of the magnetsis a stabilized AlNiCo, which does not become demagnetizedwhen tachogenerator is dismantled/mounted.

Installation and Maintenance Manual for WEG Tachogenerators

2. ASSEMBLING

2.1. TRANSPORTATION, RECEIVING, STORAGE

The WEG tachogenerators are packed in isopor boxes for safetransportation .If the tachogenerator is not put into operationimmediately, it must be kept in the shipping box, in a dryambient free of dust and under uniform temperature. I caseof any abnormal situation, contact the transportation com-pany and WEG Máquinas immediately.

2.2. ALIGNMENT (1R)/2RC(P)

The shafts of the tachogenerator and the machine to which itis coupled must form a perfect parallelism and concentricityto avoid vibrations.

2.3. COUPLING �

The WEG DC motors up to frame 132 (inclusive) are built withthe shaft prepared to couple either the tachogenerator 1R(C)/2RC(P) or the TCW. For WEG DC motors in frames 160 and up,a shaft extension is required.

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Figure 1 - Tapered shaft for DC motor up to frame 132.


Figure 2 - Shaft extension for DC motors in frame 160 and up.

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Figure 3 - Shaft end 1R(C)/2RC(P)


Figure 4 - Flexible coupling

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Figure 5 - Coupling Arrangement


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a) Tachogenerator 1R(C)/2RC(P)

Tachogenerator 1R (P) 2RC(P) requires a suitable flexiblecoupling to compensate vibrations and small mounting in-accuracies (supplied optionally).- The tachogenerator1R (P) and 2RC(P) are supplied with feet and flange.- Contact the manufacture for belt driving.

b) Tachogenerator TCW

The TCW tachogenerator is fitted with tapered shaft and itmust be fixed on the machine shaft extension to which it iscoupled.The fixation of the rotor on the machine shaft is made by

using an MC x 20 bolt and a pressure washer (supplied

with the tachogenerator).The TCW frame is fixed on the motor endshield.

Figure 6 - TCW Tachogenerator coupling arrangement


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4. MAINTENANCE

4.1. CLEANLINESS AND GENERAL CARE

Particular care should be taken when maintaining and install-ing the tachogenerator as it is a measuring device, which issubject to shocks and excessive vibrations. Inspections atregular intervals depend on the best way to prevent thetachogenerator from anti-economical breakdowns and long-time repairs. The tachogenerator must be kept free of dustcoming from brushes and eventual penetration of any foreignbody. After 2500 hours of continuous operation, a completecheck-up of brushes and terminals is recommended for re-moval of possible carbon dust originated from the brushes.On the tachogenerators type 1R (C) 2RC (P), the ND endshieldmust be mounted in such way that the connection lead goesout through the bottom side to prevent entering of any liquid.From time to time, brushes and brush holders must be re-moved and cleaned to ensure they move freely.

4.2. ROTOR DISASSEMBLY

a) Tachogenerator TCW

In order to remove the rotor from the shaft extension, re-move the M6 fixing bolt and, tightening the M8 bolt on theshaft end, slide the tachogenerator rotor outward.

3. OPERATION

Before the assembly, turn shaft manually and make sure it isfree of any thrust as this could cause problem to good rotoroperation. Before starting, make sure that outlet lead boltsand washers are securely tightened.Check that the brushes can freely move in the brush holderand that they have perfect contact with the commutation, re-move all foreign bodies and dust from the brushes.


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4.3.TACHOGENERATOR BEARINGS 1R(C)/2RC(P)

Tachogenerators are fitted with permanently lubricated bear-ings not requiring any type of maintenance. In case of wear orbreakdown, bearings must be replaced. Under normal opera-tion (approx. 8 hours per day) the lubrication grease lasts forseveral years. Then bearings must be replaced.Type of bearings used:

- Drive end: 6201 2RS- Non-drive end: 608 ZZ- For 2RC(P): Non-drive end: 6001-2RS

DISASSEMBLY

a) D.E. Bearing

In order to replace the D.E. bearing, the rotor must beremoved from the frame. As this process causes demagne-tization, the bearing must be replaced at the factory.

b) N.D.E. Bearing

1.Remove the N.D.E. protection cover.2.Remove the brushes.3.Remove the brush holder�s cover using an extractor.4.Extractor is also to be used to remove the bearing. Dur-ing this operation, care must be taken for not damagingthe shaft end center hole.

NOTE:The rotor must not be moved from its original positionso that demagnetization is avoided.

b) Tachogenerator 1R(C)/2RC(P)

Never remove the tachogenerator rotor from the frame asthis will cause demagnetization as well as drop of gener-ated voltage. Therefore, servicing can only be done at thefactory or by authorized Repair Shops specialized fortachogenerators.


4.4. COMMUTATOR

Periodical checks on the commutator are fundamental for thegood performance of the tachogenerator. Hence, the commu-tator must be kept free from dust, oil and dirt.The slots between each commutator profile must be keptcleaned.A dark brown or a slightly black coloring indicates good opera-tion of the commutator. However, if the surface is rough andshining, it is possible that there are problems in thetachogenerator. In this case, contact the manufacturer.If the surface is covered by a black dense patina, this must beremoved using sandpaper nº 220 or artificial pumice-stone.

4.5. BRUSHES

a) Tachogenerator 1R(C)/2RC(P)

This tachogenerator is fitted with 4 electrographite brushes

measuring 3 x 4 x 12.5mm. The types accepted by WEG

are:

- GHS 431 (Carbono Lorena)

- RE 54 (Seecil-Ringsdorff)

- EG 0 (Carbono Lorena)

Special tachogenerators for high autlet voltage linearity

are fitted with silver-graphite brushes.

- RS 35 (Seecil-Ringsdorff)

- CA 35 (Carbono Lorena)- MH 37 (Carbono Lorena)

IMPORTANT:In the same tachogenerator, different quality brushes cannot be installed. When 2/3 of their length has been worn,brushes must be replaced. Before setting them in the brushholder, they should be ground with sandpaper to ensurethat they have full and even surface contact with the com-mutator. Set into the brush holder, the brushes are pressedthrough a helicoidal spring for permanent adjustment. Inthe outer part, brushes are provided with a protecting cover.


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b) Tachogenerator TCW

This tachogenerator is fitted with 4 silver-graphite brushesmeasuring 6.3 x 4 x 12.5mm. The types accepted by WEGare:- RS 35 (Seecil-Ringsdorff)- CA 35 (Carbono Lorena)- MH 37 (Carbono Lorena)The brushes should be seen at the brush holder inspectionopening, that is, when only the spring can be seen.

4.6. TEMPERATURE COMPENSATING CIRCUIT FORTACHOGENERATOR 1R(C)/2RC(P)

a) Operating

Composed by an electronic device, it operates as a resistantcircuit. As the resistance varies linearly with thetemperature, this circuit keeps the out going voltageconstant even under fluctuation of ambient temperature.

b) Installation

It is installed on the brush holder terminals where it receivesand compensates the voltage signal coming from the

commutator.

c) Failures

In case of failure or burn out of components, the complete

circuit must be replaced maintaining the original design

characteristics.

Note: In case the circuit is shipped to the factory for replace-

ment, inform the type of machine it will be applied to.


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6. SPARE PARTS - 1R(C)

When ordering spare parts, always indicate the sequencialnumber shown on the component list.

5. CONNECTION DIAGRAM


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7.CROSS - SECTIONAL DRAWINGPOSITION OF COMPONENTS - 1R(C)

LIST OF COMPONENTS - Tachogenerator (1R - 1RC)

1. Frame - 1R2. Frame - 1RC3. Ball bearings - Drive end (A.S)4. Ball bearings - Non drive end (N.S)5. Retaining ring6. Pole core7. Permanent magnet8. Spring washer9. Wound rotor10. Commutator protecting cover11. Protecting cover- 1R12. Protecting cover - 1RC13. Festening ring for pole core14. Key15. Brush holder16. Insulated brush cover17. Brushes18. Fastening bolt for brush holder19. Fastening bolt for protection cover20. Flat washer21. Rubber ring for lead passage22. Commutator23. Fastening bolt for connection lead24. Bracket25. Rubber ring26. Terminal box cover - 1RC27. Fastening bolt for terminal box28. Terminal block29. Rubber gasket30. Cable gland Pg. 931. Fastening bolt for terminal block32. Through bolt33. Hexagonal nut34. Flat washer35. Fastening bolt for magnet36. Connection lead37. Plastic cover



Detail of brush holder

Detail of connection outlet lead

15Installation and Maintenance Manual for WEG Tachogenerators

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8. PLANO DE MANUTENÇÃO

Components

Brushes andbrushholders (1R(C)/2RC(P)/ TCW)

- Check wear mobility of brushes;- Control the brush holder condition.

Monthly

Bearings(1R(C)/2RC(P)Brushes andbrush holders(1R(C)/2RC(P)

Commutators(1R(C)/2RC(P)/TCW)

- Check all bearings for possible noise.

- Check length of brushes.- Replace brushes when wear has reached

2/3 of their size.- Use same or equivalent makes of brush

for replacement.- Check wear and mobility of brushes as

well as lead contact and possiblebreaking.

- Remove some brushes and check thecontacts on the commutator surface. Darkcoloring on the commutator meanscommutation problems.

− Clean the brushes and brush holders toremove the dust coming from the brushesby using a jet of dry compressed air.

Inspection ormaintenance services

Weekly

- Check wears and condition of thecommutator.

− Check the roughness of theCommutator.

− Loose brushes cause overheating anexcessive wears to the commutator.

− Check the rings on the commutatorsurface. If smooth and with no grooves- OK.

Commutator(1R(C)/2RC(P)/TCW)


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Commutators(1R(C)/2RC(P)/

TCW)

Bolts (1R(C)/2RC(P)/TCW)

Noise andVibrations (1R(C)/

2RC(P)/TCW)

- Check for loose bolts, parts or electricconnections.

- Strange noise or vibrations must becarefully checked.

Brushes (1R(C)/2RC(P)/TCW)

- Check terminals and the pressure onthe brushes.

Every 3 Months

− In case the grooves keep increasing,contact WEG.

− Check the commutator wear, grooves,copper friction and deformation of thecopper plates.

− The un round shape of thecommutator can not exceed 0.05mmand the height difference of a copperplate with its adjacent can not behigher than 0.005mm.If this occurs, the commutator mustbe machined.

Bearings (1R(C)/2RC(P)

Commutator(1R(C)/2RC(P)/

TCW)

Bolts (1R(C)/2RC(P)/TCW)

- Check all bearings for possible noise.

- Check if cracks have occurred. If so,check also shaft end (cracks are aresult of vibration and torsion in theoperating system).

- Check the electric connections.- Check if there are bad contacts.

Every 6 Months


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Bearings(1R(C)/2RC(P)

Cleanliness(1R(C)/2RC(P)/ TCW)

- Perform careful control ofbearings.

- Replace bearings, if required.

- Clean all the accessible parts of thetachogenerator.

Yearly

- Check if there are cracks on theexposed parts of the shaft end andkeys due to high vibration ortorsion.

- Check balancing and alignment ofthe tachogenerator in relation tothe motor to detect possiblevibrations.

- If vibration can not be noticedduring operation, check thesigns, which could cause thevibration such as loose parts,dust etc.

Shaft (1R(C)/2RC(P)

Vibration (1R(C)/2RC(P)/ TCW)


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9. TROBLESHOOTING

Failure Probable Cause CorrectiveMeasures

Ov e rhea t i n gunder operation(1R(C)/2RC(P)/TCW)Overheating ofb e a r i n g s(1R(C)/2RC(P)/TCW)Sparking on thebrushes (1R(C)/2RC(P)/ TCW)

- Short in thearmature winding.

- Bearings in badoperation condition.

- Bad contact. Particlesof impurities get-offfrom the brushes orcopper plates andstart sparking.

- Short in the armaturewinding.

- Rotor was removedfrom the frame.

- Rupture of windings,armature orcommutator places.

- Bad contact ofbrushes.

- Tachogeneratorwithout temperaturecompensating circuit.

- Ship thetachogeneratorto the factory.

- Replace bearings(NDE)

- Send the tacho tothe factory (DE)

- Set the brushescorrectly.

- Clean thecommutator andall brush devices.

- If required, use adifferent type ofbrush aftergettingauthorizationfrom WEG.

- In this casecontact thefactory.

- Send the tachoge-nerator to thefactory for repairand magnetiza-tion.

- Set the brushescorrectly.

- Keep the ambienttemperature at40°C and

Copper platesturned black(1R(C)/2RC(P)/TCW)Demagnetiza-tion (1R(C)/2RC(P)/ TCW)

Fluctuation ofoutgoing volta-g e ( 1 R ( C ) /2RC(P)/ TCW)


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Failure Probable Cause CorrectiveMeasures

1000masl orinstall tempera-ture compensa-ting circuit.

- Replace thetemperaturecompensatingcircuit.

- Tachogeneratorwith temperaturecompensatingcircuit


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WARRANTY TERMS FOR ENGINEER-ING PRODUCTS

These products, when operated under the conditions stipulated byWEG in the operating manual for such product, are warrantedagainst defects in workmanship and materials for twelve (12)months from start-up date or eighteen (18) months from manu-facturer shipment date, whichever occurs first.However, this warranty does not apply to any product which hasbeen subject to misuse, misapplication, neglect (including withoutlimitation, inadequate maintenance, accident, improper installa-tion, modification, adjustment, repair or any other cases origi-nated from inadequate applications).The company will neither be responsible for any expenses incurredin installation, removal from service, consequential expenses suchas financial losses nor transportation costs as well as tickets andaccommodation expenses of a technician when this is requestedby the customer.The repair and/or replacement of parts or components, when ef-fected by WEG within the Warranty period do not give Warrantyextension, unless otherwise expressed in writing by Weg.This constitutes WEG�s only warranty in connection with this saleand is in lieu of all other warranties, expressed or implied, writtenor oral.There are no implied warranties of merchantability or fitness for aparticular purpose that apply to this sale.No employee, agent, dealer, repair shop or other person is autho-rized to give any warranties on behalf of WEG nor to assume forWEG any other liability in connection with any of its products.In case this happens without WEG�s authorization, Warranty isautomatically cancelled.


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LIABILITY

Except as specified in the foregoing paragraph entitled �Warranty Termsfor Engineering Products�, the company shall have no obligation orliability whatsoever to the purchaser, including, without limitation, anyclaims for consequential damages or labor costs, by reason of any breachof the express warranty described therein.The purchaser further hereby agrees to indemnify and hold the com-pany harmless from any causes of action (other than cost of replacingor repairing the defective product as specified in the foregoing para-graph entitled �Warranty Terms for Engineering Products�, arising di-rectly or indirectly from the acts, omissions or negligence of the pur-chaser in connection with or arising out of the testing, use, operation,replacement or repair of any product described in this quotation andsold or furnished by the company to the purchaser.


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Note


weg tachogenerator manual english

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