Manual VF150 English

Operation & Maintenance ManualThe Sala Series of Vertical Slurry Pumps VF150 O4 NR/NR Pump No 340-PP-075/076 Supplier / Order No Metso Minerals Industries Inc. / 200002004 Customer Name Minera Gold Fields, Peru 2006-10-04 Slurry Pump 1. GENERAL 1.1 About this manual 1.2 Transport and storage 1.3 Pump specification 1.4 Customer service 2. DESCRIPTION 2.1 Product and warning signs 2.2 Applications 2.3 Design 2.4 Materials and max. working pressure 2.5 Surface treatment 2.6 General arrangement 2.7 Capacity curves 2.8 Certificates and test results 3. HEALTH AND SAFETY 4. DESCRIPTION OF OPERATION 5. CONTROL SYSTEM 6. INSTALLATION 6.1 General 6.2 Foundation requirements 6.3 Tools required for installation 6.4 Pipe connections and pump sump 6.5 Shaft seal 6.6 Motor and drive 7. STARTING UP 7.1 Checks before starting 7.2 Checks during initial operating period 8. OPERATING INSTRUCTIONS 8.1 Starting 8.2 Stopping Kap0 VFen_4.doc JAN 03-W22 Contents 1/2 5 Setting pump clearances 9.1 Removal and fitting of the pump's hydraulic components 9.5.2 Subcontractor's documentation Kap0 VFen_4.1 Safety measures 9.1 Recommended stocks of spare parts 10.Slurry Pump 9.4 Removal of the pump's drive 9.6 Fault tracing schedule 10.1 Tables with specified tightening torques for bolted joints 11.4 Lubrication instructions 9.4 Spare part drawing 10.doc JAN 03-W22 Contents 2/2 .5.3 Removal and fitting of shaft and bearing 9.5 Parts list 10.5.6 Special tools 11.3 Ordering spare parts 10. SPARE PARTS 10.2 Preventive maintenance and service schedule 9. CARE & MAINTENANCE 9.2 Removal and fitting of bearing assembly 9.5 Removal and fitting of components 9.2 Stocking of spare parts 10.5.3 Tools and special equipment for care and maintenance 9.5. APPENDICES 11. excluding motor and drive. in case of re-sale.2 Transport and storage WARNING! When loading and unloading. Information contained in this manual is specific to the equipment and is correct at the date of publication. The pump should be transported and stored in a horizontal position. General 1.doc JAN 03-W02 General 1/2 . Bolt the support plate (1) in place with 4 bolts (2). the total weight of the pump unit is given on the sign. 1.6. section 2. The contents of this manual must not be reproduced without the prior written permission of Metso Minerals (Sala) AB. It is written for the use of installers. and on the weight sign affixed to the pump. follow "Health and safety". commissioning engineers. It should be kept for the life of the equipment and. Section 3. The weight of the pump. © 2003 — Metso Minerals (Sala) AB. a support plate (1) should be mounted to secure the pump shaft (3) in position. see figure below. See "Special tools" in section 10. Kap1 VFen_4.6 for the part number.Slurry Pump 1. passed on to any subsequent purchaser. is stated on the "Dimension sheet". Metso Minerals reserve the right to make alterations to the equipment design and specification without giving prior notice. operators and maintainers. If the pump is supplied with motor and drive. During transport or storage. As improvements are continually being made. Any amendments issued by Metso Minerals should be promptly inserted into this manual.1 About this manual This manual is a part of the equipment to which it relates. In conditions of extreme cold these types of rubber may harden to such an extent that cracks could develop and handling damage occur. If the pump is to be stored for longer than two months. Unpainted machined surfaces are to be treated with a corrosion inhibiting agent. Chloroprene rubber does not regain its normal hardness when the ambient temperature rises but must be reconditioned. such as chloroprene rubber (CR). Certain types of rubber. The pump should be covered over to keep out dust and dirt.doc JAN 03-W02 General 2/2 . The pump shaft should be rotated a few turns every month.Slurry Pump If the pump has to be stored for a lengthier period of time before being used. Contact Metso Minerals for further information. it should be kept in a dry place. Kap1 VFen_4. harden at temperatures below +5o. the belt drive should be removed to avoid damage during storage. 0 21. quality: Special design: Painting: Capacity m³/h: Total head m lc: Pump speed rpm: Specific gravity kg/m3: Input power kW: Motor: Special req. NATURAL RUBBER Standard design.00 X 4-E E X 2-1/8 5V11.A.0 1191 1180 Qty 2 50HP 326T None WEG Metso Minerals 5V8.: Motor supplied by: Drive supplied by: Drive sheave: Drive bushing: Driven sheave: Driven bushing: V-belts: Instruction: Description 200002004 SA234674-M7 VF 150 O4 NRNR 1751 340-PP-075/076 Concentrate Thickener Feed Conical Froth Pump Minera Gold Fields S.Pump VF 150 O4 NRNR Pump specification Headline Order part no: Complete pump: Pump type: Product code: Pump no: Customer: Wear parts. 26347002000 Edition 1 JAN 06-W40 General 1/1 . MP15 120.80 X 4-E E X 60MM 5V X 710 P/N: 101322 P/N: 520009 P/N: 104766 P/N: 555259 P/N: 520408 QTY: 1 QTY: 1 QTY: 1 QTY: 1 QTY: 1 Contact CSP for instructions. 3. South Sierra Madre (80903) USA Metso Minerals (Sala) AB Norrängsgatan 2 Box 302 S-73325 SALA Sweden Tel: Fax: (+1) 719 471 3443 (+1) 719 471 4469 Tel: Fax: (+46) 224 374 00 (+46) 224 169 69 Please provide the following information: 1. approximate date of purchase.Slurry Pump 1.4 Customer service For any inquiry regarding the servicing and repair of Metso Minerals Slurry pumps please contact the local Metso Minerals Branch. 4. contact one of the Metso Minerals Global Sites listed below: Metso Minerals Industries. Inc. CustomerServiceCOSen_1. P O Box 340 COLORADO SPRINGS CO 80901 621. serial number. details of enquiry. apparent fault etc.. For information on the Metso Minerals Branch closest to you. 2. model and size of equipment.doc JAN 04-W08 General 1/1 . doc JAN 04-W22 Description 1/8 .Slurry Pump 2. When the pump is supplied without motor and drive. A pump delivered with motor has a machine sign with CE-mark. only the weight of the pump is stamped on the sign. Weight sign Weight of motor Weight of V-belt drive Weight of pump Total weight The sign is mounted next to the machine sign. Description 2. The CE-mark is included in the pump delivery.1 Product and warning signs Machine sign Pump delivered without motor Pump delivered with motor Space for CE-mark Pump type Pump number Year of manufacture A machine sign containing information as above is affixed to the pump. Kap2 VFen_6. When the pump is delivered without motor the CE-mark has to be affixed when the motor is assembled. In such case the total weight is to be stamped on the sign by the mechanic who fits the motor and drive on the pump. Warning sign for absence of V-belt guard WARNING The V-belt guard must always be mounted during operation The sign is mounted on the V-belt guard. Incorrect rotation can seriously damage the pump. The V-belts should always be removed before the motor's direction of rotation is checked. The V-belt guard should always be fitted when the pump is in operation. If the V-belt guard is to be removed.1 " Safety measures ". On VT pumps the sign is fitted on the front of the pump tank. In the section where the shaft is leaving the bearing housing and is entering the tank.doc JAN 04-W22 Description 2/8 . it is unprotected. Warning sign for rotating shaft WARNING Rotating shaft 224787-en This sign is only applicable for VT and VF pumps. check that the motor is disconnected from the mains or that the main switch is turned off and locked so that the motor cannot be started inadvertently. direction of rotation 224799-1 The sign is mounted on the V-belt guard and shows the direction of rotation viewed from the V-belt guard. The guard must always be refitted before the pump is started. See also 9. Kap2 VFen_6.Slurry Pump Sign. Kap2 VFen_6. The complete bearing is axially adjustable in the pump frame and can be removed as a complete unit.Slurry Pump 2. The impeller's diameter.5 "Parts list" for details of the materials in your pump. contact Metso Minerals for correct dimensioning of the pump.4.2 Applications Metso Minerals Slurry Pumps are primarily designed for pumping abrasive media containing particles.3 Design The basic version of the pump is supplied: • With semi-open impeller. number of vanes. These parts are supplied in a metallic or elastomer material. Bearing assembly The pump shaft runs in roller bearings. See also recommendations and limitations in section 1. Note that the capacity curves in section 2.6 "Dimension sheet". section 2. Under other conditions. Working pressure".7 are based on trials with clean water. Note that in practice it is the density of the particle. If the pumped medium is severely abrasive. Impeller mounting The end of the impeller's shaft is threaded and the torque is transmitted by the threads. Wear parts The pump's hydraulic components consist of pump casing. Maximum particle diameter is the theoretically largest sphere than can pass through the impeller. 2. and section 2.3 "Pump specifications". The bearings are mounted in a bearing housing of cartridge type. which limits what can be pumped. See section 1. impeller and inlet. The pump is designed for use up to the largest flow shown on the capacity curve at the rpm in question.4 "Materials and max. For maximum working pressure. see section 2. the maximum flow should be reduced.3 "Pump specifications" and section 10.doc JAN 04-W22 Description 3/8 . type of impeller and maximum particle diameter are shown at the head of the capacity curve. Vibration The pumps are classified as Class IV according to ISO 2372. The largest motor than can be mounted on the motor plate is specified in the "Dimension sheet". Kap2 VFen_6. Commonly occurring causes of excessive vibration are: • • • • insufficiently tightened retaining elements poorly tensioned V-belts misalignment in the drive impeller blocked by a foreign object. the noise level may exceed 70 dBa. VF50 and VF80) can be stood on the floor without any special floor anchorage. section 2. If desired. After starting up.Slurry Pump Setting up No special foundation is necessary and the pump can be mounted directly on the floor. the pump's motor is the main source of noise. When the pump is new the vibration level should not exceed 7. Should the vibration level exceed 18 mm/second the pump must be stopped immediately. As a rule of thumb.6. annex A. it may be assumed that the total noise level in the majority of properly functioning installations is that of the motor plus 2 dBa. The larger pumps (VF100 and larger models) should be anchored by means of foundation bolts of expander type or similar and then aligned so that no stresses arise when the bolts are tightened. Noise level At certain installations and operating conditions away from the optimum operating point. the smaller pumps (VF40.1 mm/second at all bearings.doc JAN 04-W22 Description 4/8 . the foundation bolts must be checked and retightened as necessary. however. Under normal working conditions. 3.doc JAN 04-W22 Description 5/8 .0038 8. This section lists the materials of construction and working pressures for STANDARD duty applications. washers.4 Materials and maximum working pressure Metso Minerals Slurry Pumps are constructed from materials selected to give excellent wear characteristics over the full range of pumping duties.Slurry Pump 2.8 NBR NR Material Standard EN 1561 EN 10089 EN 10025 ISO 898/1 - Kap2 VFen_6. pump casing. Materials of construction Item Castings. galvanized Nitrile rubber Natural rubber Material Code JL1040 1. Other materials are also used for specialist applications or as specified by the customer – see section 1.1191 1. such as bearing housing. nuts O-rings Gaskets Wear parts of Natural rubber For example: Impeller. inlet Impeller core Other cores Rubberizing Wear parts of White cast iron alloy Impeller Pump casing Inlet White cast iron JN3049 EN 12513 Grey cast iron Steel Natural rubber JL1040 1.0038 NR EN 1561 EN 10025 Material type Grey cast iron Steel Steel Steel. cover Shaft Frame Motor plate Pump tank Bolts. Wear parts of white cast iron alloy are sealed with gaskets of natural rubber. Larger particles can be accepted at low rpm or when occurring together with a large proportion of finer particles. The material is a high-chromium white cast iron alloy called MetaChrome with a nominal hardness of 600 HB. The wear parts are resistant to liquids having a pH of between 5 and 14.doc JAN 04-W22 Description 6/8 . alkaline solutions. Contact Metso Minerals for more detailed recommendations concerning the material's limitations. The peripheral velocity of the impeller should not exceed 27 m/sec.Slurry Pump Wear parts of natural rubber Natural rubber (NR) and polyurethane (PU) (certain pump types) are ideal materials for wear protection when the slurry contains fine particles.e. These materials can be used for liquids having temperatures up to 60oC and are resistant to weak acids. the majority of organic acids and alcohols. particles up to 3-5 mm. Wear parts of white cast iron alloy Wear parts in white cast iron alloy are used for coarser particles and other applications where elastomer wear parts are unsuitable. Natural rubber does not withstand petroleum products or ozone. Kap2 VFen_6. i. doc JAN 04-W22 Description 7/8 .Slurry Pump Maximum working pressure Pump Size VF50 O4 VF50 O4 VF80 O4 VF80 O4 VF80 C4 VF80 C4 VF100 O4 VF100 O4 VF100 O5 VF100 O5 VF150 O4 VF150 O4 VF150 O5 VF150 O5 VF150 C VF150 C VF200 O5 VF200 O5 VF250 O5 VF250 O5 (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) (NR) (JN3049) Bar 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Working pressure kPa 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 Kap2 VFen_6. Priming of protective covers with epoxy primer. Finish painting with applicable type of paint and film thickness. unpainted surfaces have temporary delivery protection as below Wax-based anti-corrosion agent. brush or roller. 120 µm Machined. which leaves a sticky film when the solvent has evaporated. 100 µm Internal wear parts and linings Type: Film thickness: Oil-resistant paint on alkyd base min. Priming of other painted surfaces with synthetic red lead. alkali or steam. hot water. Applied on clean and dry surfaces by spray gun. Min. application temperature + 10oC.doc JAN 04-W22 Description 8/8 . Removed with white spirit. about 50 µm.Slurry Pump 2. Kap2 VFen_6. about 50 µm.5 Surface treatment Standard finish: Protective covers Colour: Type: Film thickness: Yellow Ral 1032 (warning colour) Epoxy powder min. Protective factor at 50 µm: Outdoors about 12-20 months. Two-pack oxirane ester. Recommendations for touch-up and maintenance painting Scraping and wire brushing or sanding followed by degreasing. indoors about 60 months. 25 µm Other painted surfaces Type: Film thickness: Two-pack oxirane ester min. . . Pump VF150 O4 Performance curve Full impeller dia Vane diameter Vane config Impeller type No. of vanes Max sphere Impeller material Liner material 360 mm 360 mm Full Semi open 4 50 mm Elastomer Elastomer 25 1200 r/min 40% 1100 50% 55% 58% 60% BEL 20 1000 60% H (m) 15 900 58% 800 10 700 600 5 55% 50 Based on clear water tests correct for other conditions 100 150 200 250 1200 20 1100 15 P (kW) 10 800 5 600 50 100 150 Q (m³/h) 255-4-1E Edition 2 JAN 99-W10 Description 1/1 200 250 700 900 1000 . Pump VF150 O4 Performance curve Full impeller dia Vane diameter Vane config Impeller type No. of vanes Max sphere Impeller material Liner material 360 mm 360 mm Full Semi open 4 50 mm Elastomer Elastomer 1200 r/min 80 1100 40% 50% 55% 58% 60% BEL 60 1000 60% H (ft) 900 58% 40 800 700 600 55% 20 200 30 25 Based on clear water tests correct for other conditions 400 600 800 1000 1200 1200 1100 20 P (US hp) 1000 15 900 10 5 700 600 200 400 600 Q (US gpm) 255-4-1E Edition 2 JAN 99-W10 Description 1/1 800 1000 1200 800 . 8 Certificates and test results DECLARATION BY THE MANUFACTURER PROHIBITION TO PUT INTO SERVICE We Metso Minerals (Sala) AB.doc Edition5 JAN 04-W24 Description 1/1 .Slurry Pump 2. 2004-06-07 in Sala. SWEDEN declare that the slurry pump Manufacturer Pump type Pump number Year of manufacturing Metso Minerals (Sala) AB VF150 O4 NR/NR 26007502001-002 2006 is intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by Directive 98/37/EG. and that following harmonized standards have been applied EN 292-1 EN 292-2 EN 809 Safety of machinery – Basic terminology. methodology Safety of machinery – Technical principles and specifications Pumps and pump units for liquids . A pump delivered with motor has a machine sign with ce-mark. Norrängsgatan 2. When the pump is delivered without motor the ce-mark has to be affixed when the motor is assembled. Slurry pump division 100mfg_en. as amended. Sweden Space for ce-mark Pump type Pump number Year of manufacture Name: Position: Jan Andersson General manager. 733 25 SALA. This refers to the equipment as a whole. The ce-mark is included in the pump delivery.common safety requirements and furthermore declare that it is not permitted to put the slurry pump into service until the machinery into which it is to be incorporated has been found and declared to be in conformity with the provisions of Directive 98/37/EG and with relevant national legislation. does therefore not in every respect comply with the provisions of this directive. including the machinery referred to in this declaration. is stated on the "Dimension sheet". The pump may be used in liquids that are harmful to your health. excluding motor and drive.doc JAN 03-W02 Health and safety 1/2 . Check the capacity of the lifting equipment against the weight of the pump.Slurry Pump 3. If this is the case. working pressure The pump is designed for pressures of up to 0. section 2. If the pump is supplied complete with motor and drive. make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. the total weight of the pump unit will be given on the weight sign. Health and Safety Follow all local health and safety instructions: • Use approved lifting equipment • Fence off the area round the workplace so that unauthorized persons will not be injured The weight of the pump. Max. and to avoid injury to eyes and skin. WARNING! Before starting work. When working on or in the vicinity of the shaft with the pump in operation. The pump should be lifted in accordance with the illustration in the "Dimension sheet". check that the motor is disconnected from the mains or switched off and locked so that it cannot be started unintentionally. observe the following points: • Always wear goggles and rubber gloves • Flush the pump thoroughly with clean water before starting work • Rinse the parts in clean water after dismantling them All electrical work must be carried out by a qualified electrician.6. All electrical work must be carried out by a qualified electrician.6 and on the weight sign affixed to the pump. Work with care and exercise good judgement. section 2. WARNING! Freely rotating shaft. Kap3 VFen_4. motor and drive.6 Mpa (6 bar). Under normal working conditions.Slurry Pump Noise level At certain installations and operating conditions away from the optimum operating point. the motor must be disconnected from the mains or the main switch turned off and locked so that the pump cannot be started inadvertently. Wear heavy-duty gloves and use other suitable safety equipment.doc JAN 03-W02 Health and safety 2/2 . Installation The largest motor that may be mounted on a standard motor plate is specified on the dimension drawing. it may be assumed that the total noise level in the majority of properly functioning installations is that of the motor plus 2 dBa. The weights of the pump components are given in the spare parts list.6. Work with care and exercise good judgement. make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. the pump's motor is the main source of noise. As a rule of thumb. It will sometimes be necessary to work with the pump in operation when greasing the bearing and adjusting the shaft seal. WARNING! Worn parts may have extremely sharp edges. See section 2. WARNING! Before any work is started. however. Maintenance A mechanical hoist or the like should be used when lifting parts weighing more than 30 kg. Kap3 VFen_4. When working in the vicinity of the freely rotating shaft. the noise level may exceed 70 dBa. In simple terms. To obtain the best wear properties the pump can be provided with different materials in the parts exposed to the greatest wear. As the flow increases. it is important to understand how the pump interacts with the piping system in which it is installed. A radial centrifugal pump has a descending discharge/flow curve for each rpm. To choose a pump that works close to its best efficiency line (BEL). Kap4 VFen_4. a pump and its piping system act as two communicating vessels. Description of operation General Centrifugal pumps work best with minimum wear and other mechanical stress if the operating point is close to the pump's best efficiency point (BEP). We recommend using Pumpdim™ for Windows™ for our pump applications. affects the curves of the piping system and pump. at zero flow. It is therefore important to calculate the piping system's resistance curve correctly and to take into account the manner in which the admixture of solid particles.Slurry Pump 4. See diagram below. for example. The piping system has a resistance curve that starts at the static delivery head.doc JAN 03-W02 Description of operation 1/5 . the resistance increases with pipe friction. The pump's operating point (DP) at a given pump speed is the point of intersection between the piping system's resistance curve and the pump's discharge/flow curve. uniform pressure is obtained in the casing which in its turn eliminates radial forces on the impeller. resulting in small radial forces which in their turn exert little load on bearings and cause little shaft deflection.Slurry Pump Best efficiency point Pressure conditions in the pump casing are shown in Fig. The force subsequently diminishes up to BEP where it is close to zero. When the pump operates at best efficiency point. At flows above BEP the force changes direction. When the pump operates at low capacity and not at BEP. In addition. the differential pressure over the impeller gives rise to the transport of slurry between the impeller and the inlet liner. Kap4 VFen_4. uniform pressure in the pump casing will not be obtained and this results in a radial force F on the impeller.doc JAN 03-W02 Description of operation 2/5 . When the pump's flow capacity is not utilized. The magnitude of the radial force F is greatest when the pump runs against closed valve = 0 flow. differential pressure builds up over the casing volute. This gives rise to a radial force F on the impeller which is a function of the differential pressure (Pa) and the impeller's projected area (mm2). 1. 1 When the pump is not operating at BEP the bearings will have a shorter service life on account of shaft deflection. At the BEP there is even pressure round the impeller. Fig. causing rapid wear of the liner. Kap4 VFen_4.doc JAN 03-W02 Description of operation 3/5 .Slurry Pump Hydraulic effects of operation at and outside the pump's best efficiency point Impeller vane inlet Pump casing nose At best efficiency point fig. The slurry's inflow angle coincides with the impeller's vane angle and no erosive vortices occur. 2 Impeller vane inlet At low load Pump casing nose fig. 2 1. Abrasion on the pump casing nose. 5. Impeller vane inlet On overloading Pump casing nose fig. 8. The slurry's flow angle harmonizes with the angle of the pump casing nose and no erosive vortices occur. Abrasion caused by particles striking and bouncing against the surface. This is of decisive importance in slurry pumping. Kap4 VFen_4. 10. Vortices are formed on the discharge side of the impeller vane. Abrasion on the impeller vane's discharge side. Hydraulic efficiency is a function of hydraulic turbulence . The way in which the hydraulic work is affected when the pump does not operate at BEP is shown in Fig.the more turbulence.doc JAN 03-W02 Description of operation 4/5 . Vortices. Vortices occur on the vane's vacuum side. the less efficiency. 3. 6. Abrasion occurs on the vacuum side of the vane tip. The rasping wear or high-pressure wear that occurs between the impeller and suction side liner is lower. The rate of abrasion is low and the wear is spread evenly over the surfaces. 4. In slurry pumping. since the evenly distributed hydraulic pressure reduces recirculation. a high level of efficiency is therefore important Little hydraulic turbulence is formed at BEP and the abrasion is chiefly of a sliding nature. 2.Slurry Pump 2. since the differential pressure is low when the slurry passes through the impeller and pump casing. 9. Vortices. 2 7. This causes local wear damage and the service life of these components is severely shortened. which gives rise to turbulence and results in recirculation of slurry in the channel. oversized pumps which do not operate at BEP result in bearing breakdown. hydraulic turbulence occurs and the solid particles in the slurry strike and rasp the impeller and pump casing. causing turbulence to occur immediately after the pump casing nose.Slurry Pump When the full capacity of the pump is not used and its efficiency is less than at BEP.doc JAN 03-W02 Description of operation 5/5 . shaft fracture and unevenly worn inlet and pump casing liners with deep wear marks at the casing nose. choose the pump size which operates as close as possible to the pump's best efficiency point (BEP). At the inlet to the impeller the slurry's flow angle is not the same as the pump vane angle. In the worst case. Choice of pump size For preference. Kap4 VFen_4. At the pump casing nose the flow from the impeller does not harmonize with the shape of the casing. Slurry Pump 5. Kap5 VFen_4.doc JAN 03-W02 Control system 1/1 . Control system Not included in the delivery. A pipe with drainage facilities should be mounted immediately after the outlet flange so that the pump can be drained in the event of a stoppage.6. If necessary.Slurry Pump 6. Check the capacity of the lifting equipment against the weight of the pump. The weight of the pump.6.1 General Follow local health and safety instructions.3 Tools required for installation A fitter's regular toolkit plus suitable hexagonal Allen keys and sockets. For normal non-frothing media it is advantageous if the feed to the pump can be arranged tangentially to the pump's direction of rotation.4 Pipe connections and pump sump The pump has no fixed inlet connection. After starting up. section 2.1 for the correct tightening torque. is stated on the "Dimension sheet". section 2. motor and drive.2 Foundation requirements No special foundation is necessary and the pump can be mounted directly on the floor.5 Shaft seal Tank pumps of VF type have no shaft seal. Kap6 VFen_5. the foundation bolts must be checked and retightened as necessary. For pumping of frothy media it is better if the feed is arranged in the direction of pump rotation. it is also possible to fit a fixed inlet connection to the sump pump.1a in section 11. 6. If desired.6 and on the weight sign affixed to the pump. 6. the total weight of the pump unit will be given on the weight sign. 6. All electrical work must be carried out by a qualified electrician. For flange and bolt dimensions. section 2. 6. Use approved lifting equipment. Metso Minerals recommends bolts of strength class 8.doc JAN 03-W45 Installation 1/5 . excluding motor and drive. Installation 6. When bolts of this strength class are used. The feed can be arranged freely through an open hose or pipe. If the pump is supplied complete with motor and drive. The discharge pipe from the pump should be anchored and mounted so that the pump casing is not subjected to unnecessary stresses. see table 11. see "Dimension sheet". The pump should be lifted in accordance with the illustration in the "Dimension sheet". The larger pumps (VF 100 and larger models) should be anchored by means of foundation bolts of expander type or similar and then aligned so that no stresses arise when the bolts are tightened. and VF 80) can be stood on the floor without any special floor anchorage. the smaller pumps (VF 50. a torque wrench and suitable lifting equipment will be adequate for installation.8 as per ISO 898/1. The V-belt guard's lower section has a protection plate (C) for the motor shaft. the protection plate will be pre-drilled. Fit a suitable lifting hook (J) on the motor shaft. Mark the position of the motor shaft on the protection plate and drill a hole with a diameter that is 10 mm larger than the motor shaft. make sure that the motor is disconnected from the mains and cannot be started unintentionally. Mounting the motor on overhead motor plate Determine the weight of the motor as specified by the manufacturer and stamp it on the pump's weight sign as described in section 2. Suspend the protection plate round the motor shaft.Slurry Pump 6. which is mounted on the motor plate. Note that no free part of the motor shaft should protrude outside the V-belt guard. Lift the motor so that the protection plate (C) can be mounted level with the rear part (G) of the bearing housing.doc JAN 03-W45 Installation 2/5 . Kap6 VFen_5. Pumps ordered without a motor are supplied with the V-belt guard detached and it must be fitted before the V-belt drive is mounted. If the size of the motor is specified in the order.1 "Product and warning signs". Attach a suitable lifting device to the lifting eyebolt.6 Motor and drive WARNING! Before starting any work on the pump. Slurry Pump Check that the shafts of the motor and pump are parallel. • Remove the V-belt guard cover (A) from the lower section (B). Get a qualified electrician to connect the motor to the mains supply in accordance with the motor manufacturer's instructions.doc JAN 03-W45 Installation 3/5 . Kap6 VFen_5. NOTE: this should be checked with the V-belts removed. Remove the protection plate (C) and lift the motor away. Check the motor's direction of rotation. When viewed from the drive end. • Mount the V-belt guard's lower section (B) on the pump. The position numbers refer to the figure on the previous page. using the retaining bolts (D). Mark the motor's mounting holes on the motor plate. the pump should rotate clockwise. Drill holes in the motor plate (H). cut threads in them and fit the motor with nuts and bolts in accordance with the motor manufacturer's recommendations. Also fit the protection plate (C). It is therefore important to ensure that the V-belts of a given drive all have the same length tolerance. bush and groove surfaces. Use a straightedge to check that the V-belt pulley grooves are in alignment. shaft hole. • Clean and degrease the shaft.doc JAN 03-W45 Installation 4/5 . The easiest fitting procedure is as follows: • Use the adjustment facilities of the motor base plate to reduce the centre distance until the V-belts can be fitted on the pulleys without undue force. some manufacturers classify them in different length tolerances.1 "Product and warning signs". Shafts not parallel Pulleys misaligned Fitting the V-belts In their production of V-belts. V-belt drives require careful alignment in order to transmit the design power and minimize wear of the drive.Slurry Pump Fitting the V-belt pulleys Determine the weight of the complete V-belt drive as specified by the manufacturer and stamp it on the pump's weight sign as described in section 2. The Vbelt pulleys should be positioned as close to the shaft shoulders as the lower section of the V-belt guard allows. • Fit the V-belt pulley/bush unit on the shaft and align it in the intended position. • Never use a tool to force the V-belts into the grooves. Kap6 VFen_5. • Fit the belt pulley to the bush. • Use a tensiometer as shown in the figure to measure the force (P) necessary to deflect the V-belt 16 mm per metre of distance between the shafts when the force is applied at right angles to the V-belts and approximately midway between the pulleys. dd 67-95 100100-140 150160-265 280224-355 375Deflection force P for arrow height 16 mm/m distance between shafts (N) V = 0-10 m/s 18 26 32 48 56 72 102 132 JAN 03-W45 V = 10-20 m/s 16 24 26 40 50 64 90 120 V = 20-30 m/s 14 22 22 34 42 58 80 110 Installation 5/5 Kap6 VFen_5.doc .Slurry Pump • Calculate the peripheral speed of the belt pulley in accordance with V = peripheral speed [m/s] dd = diameter of small pulley [mm] n1 = speed of small pulley [rpm] • Measure the distance between the shafts. • Use the adjustment facilities of the motor base plate to tension the belts to the value of P in the table below. • Fit the V-belt guard's cover (A). Belt Profile SPZ SPA SPB SPC Small Pulley Diameter. 7. After 100 running hours: WARNING! Before any work is started. When viewed from the drive end. Kap7 VFen_5. This applies to the foundation. If the pump has not been used for some time. Check the condition of the drive. flanged connections and other pump retaining elements.Slurry Pump 7.1 Checks before starting Check that all nuts and bolts are tightened to the correct torque.doc JAN 03-W34 Starting up 1/2 . see section 9. if any. The V-belts should always be removed before the motor's direction of rotation is checked. the pump should rotate clockwise. lubricate the bearings.2 Checks during initial operating period 1.4. Remove foreign objects from the pump tank. if any. Starting up WARNING! Read section 3 "Health and Safety" before starting to carry out any work on the pump. its direction of rotation should be checked. check that the motor is disconnected from the mains or switched off and locked so that it cannot be started inadvertently. If the motor has been disconnected from the mains. NOTE: Follow applicable parts of these instructions. Check that the valves. WARNING! Incorrect rotation can seriously damage the pump. Follow the instructions in section 6. For correct tightening torques.6. see tables 11.1 a-c in section 11.1. 7. are open. 4.6 under the heading "Fitting the V-belts".Slurry Pump • In the case of V-belt drive. 3. Follow the lubricating instructions. section 9. check the belt tension as the V-belts become slightly elongated during the initial period of operation. Follow section 9.doc JAN 03-W34 Starting up 2/2 . see section 6. and the recommended grades of grease.2 "Preventive maintenance and service schedule". 2. Keep the area round the pump clean. Kap7 VFen_5. Due to their design. 2. When the pump is stopped.6 "Fault tracing schedule". 3.doc JAN 03-W02 Operating instructions 1/1 . Start the pump.Slurry Pump 8. Stop the pump. the pumps are insensitive to air and can even be run for short periods with no feed to the sump at all.2 Stopping 1. Operating instructions 8. 8. Check that the pump is running smoothly and steadily. Kap8 VFen_4. Rinse the pump tank clean. If it is not.1 Starting 1.3. the sump must be emptied to avoid sedimentation in the pump casing. see "Transport. 2. 3. see section 9. Check that the capacity of the pump corresponds to the operating conditions in question. If the pump is not going to be used for a lengthier period of time. If the pump runs continually with no level in the sump it may nonetheless be advisable to reduce pump speed somewhat by changing the transmission ratio of the V-belt drive. storage" in section 1. Consult Metso Minerals if necessary. observe the following points: • Always wear goggles.1 Safety measures WARNING! Before any work is started. Care and maintenance 9. check that the motor is disconnected from the mains or switched off and locked so that it cannot be started inadvertently. and to avoid injury to eyes and skin.Slurry Pump 9. make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. When working on or in the vicinity of the shaft with the pump in operation. WARNING! Freely rotating shaft. Follow all local health and safety instructions: • Use approved lifting equipment • Fence off the area round the workplace so that unauthorized persons will not be injured The pump may be used in liquids that are harmful to your health. • Rinse the parts in clean water after dismantling them Kap9 VF200 OLen_6. If this is the case. • Rinse the pump and tank thoroughly with clean water before starting work. Work with care and exercise good judgement.doc JAN 03-W24 Care and maintenance 1/25 . doc JAN 03-W24 Care and maintenance 2/25 . Suitable lifting equipment should be available for removing and fitting components. Check the tightening torque of the bolted joints. NOTE: If the cores in elastomer hydraulic components are visible. accelerated wear can be expected. X V-belt drive Direct drive Bolted joints X X X 9. motor and drive Pump casing. Contact Metso Minerals or our representative for further recommendations concerning your installation.2 Preventive maintenance and service schedule The following routine maintenance schedule specifies the points that should be checked to ensure safe. Rectify as necessary. Check for leakage.6 Check the shaft coupling's alignment and condition.5. Check the pump's clearances.3 Tools and special equipment for care and maintenance A fitter's regular toolkit plus suitable hexagonal Allen keys and sockets and a torque wrench will be adequate for carrying out care and maintenance. Inspection of Action Inspection interval (hours) 100 X X X 500 1000 3000 Pump.5 "Setting pump clearances" Check the hydraulic components for wear and assess their probable service life. see table 11. Check the belt tension. See section 9. Hydraulic components should be changed if holes are present in the liners or if impeller wear affects performance.Slurry Pump 9. Kap9 VF200 OLen_6. The specified checking intervals are general recommendations and should be adapted according to your own experience of the installation in question. For the correct tightening torque. See "Fitting V-belts" in section 6. Excessive pump clearances could lead to poorer performance and accelerated wear.1a. piping and connections Pump clearances Pump wear parts Keep the pump unit and the area round it clean and free from slurry and dirt.1 "Removal and fitting of the pump's hydraulic components". See section 9.5. reliable operation and high availability. At bearing temperatures above 70oC the bearings must be lubricated more frequently. bearing temperature may be slightly high during a running-in period. do not check the temperature until the bearings have been in use for about 2 hours of pump operation. each bearing and bearing space should be packed with grease in accordance with the table below (grease quantity).4 Lubrication instructions The pump has two lubricating points marked with a lubrication symbol on the "Spare parts drawing". For maintenance lubrication the quantity of lubricant in the table below (periodic lubrication) should be applied at each lubrication point. Table 9. the above basic prerequisites in the composition of the lubricant must be followed. The lubricating nipples are of a type conforming to SS 2628/DIN 71412 standards. and also with two signs having the same symbol on the pump itself. Bearing temperatures around 100oC and above will damage the bearings. NOTE: When the pump is new or when the bearings have been changed and freshly greased. For each 15oC increase in temperature the above lubrication intervals should be halved. For this reason.4. When changing bearings. For correct pump type or section 2.Slurry Pump 9. As supplied.4a Pump type Periodic lubrication grease quantity g/bearing 600 600-800 Pump speed. The lubrication intervals depend on operating conditions and pump speed.6 "Dimension sheet". section 10. rpm grease quantity g/bearing when changing bearings 12001500 >1500 800-1000 10001200 Lubrication interval after operating hours for bearing temperature 70oC VF200 VF250 100 100 3000 3000 2000 2000 1500 1500 1000 1000 500 500 2000 2000 The specified lubrication intervals are for bearing temperatures up to 70oC. Kap9 VF200 OLen_6. the bearings are lubricated with SKF LGMT3 grease having the following basic prerequisites in the composition of the lubricant: Thickening agent: Base oil type: Lithium soap Mineral oil Base oil viscosity at 40oC 120 cST Consistence NLGI: 3 NOTE: If grease from other manufacturers is used. The pump should be lubricated for the first time after about 300 operating hours and then in accordance with the table below.doc JAN 03-W24 Care and maintenance 3/25 . and on the weight sign affixed to the pump. is given on the "Dimension sheet".6. E (motor) and F (Vbelt guard). Kap9 VF200 OLen_6.Slurry Pump 9.5 Removal and fitting of components WARNING! Worn parts may have extremely sharp edges. The figure below is a general view of the pump's principal components: A (pump hydraulic components). C (upper frame).doc JAN 03-W24 Care and maintenance 4/25 . section 2. B (pump tank). The following section describes how to remove and refit the various parts of the pump. Mechanical lifting equipment should be used when components weighing more than 30 kg have to be lifted. The weights of pump components are given on the "Spare parts drawing". D (bearing assembly).4. The pump's total weight. excluding motor and drive. section 10. Wear heavy-duty gloves and use other suitable safety equipment. inlet (6).Slurry Pump Hydraulic components include the upper pump casing half (2). Kap9 VF200 OLen_6. Remove discharge pipes. impeller (4). lower pump casing liner (1).doc JAN 03-W24 Care and maintenance 5/25 . if any. lower pump casing half (3). from the pump casing. Preparations Remove the motor cables. Drain the pump tank and flush it and the casing clean. The shaft (5) is positioned as shown in the figure. upper pump casing liner (7) and the sealing parts for these components. Slurry Pump 9.5.1 Removal and fitting of the pump's hydraulic components The pump is fitted with hydraulic components of elastomer material (e.g. rubber or polyurethane). See under "Special tools" in section 10.6 for the part numbers of the requisite lifting tools. Removal NOTE: The parts should be removed in the order they are named below. PUMP CASING (53 and 54) - - Place a garage jack (N) under the carrying arm (34). Drive out the wedges (7) using a hammer. Move the yoke (6) aside. The carrying arm (34) can then be lowered and swung out, carrying the pump casing (53, 54) with it. Note that the pump casing (53, 54) rests loosely on the carrying arm. Kap9 VF200 OLen_6.doc JAN 03-W24 Care and maintenance 6/25 Slurry Pump PUMP CASING LINERS (1 AND 7) Remove the nuts and bolts (96). Lift the upper pump casing half (54) away, using lifting tongs (J), and place it on two wooden blocks. - Undo the nuts (90) and remove the upper pump casing liner (7). Press out the liner (7). - Remove the shaft spacer (95). Remove the nut (91) securing the lower casing liner (1). Remove the pump casing liner (1) from the lower casing half (53). Kap9 VF200 OLen_6.doc JAN 03-W24 Care and maintenance 7/25 Slurry Pump IMPELLER (50) AND INLET (9) - Place two blocks of wood (S) on the carrying arm (34). Raise the carrying arm (34) by means of the jack (N) so that the wooden blocks are partly under the impeller (50). Lock the pump shaft in a suitable manner. Alternatively, the drive can be removed as described in section 9.5.4 and a counter-hold spanner (R) fitted as shown in the figure. See the tool list in section 10.6 for the part number of the counter-hold spanner (R). Unscrew the impeller (50) by rotating it anticlockwise, viewed from the impeller side. Warning! Take care when doing this so that the impeller and inlet do not come loose unexpectedly and fall to the floor. Lower the carrying arm (34) down with the jack (N). Swing the carrying arm out and lift the impeller (50) away. Raise the carrying arm (34) by means of the jack (N) so that the wooden blocks are partly under the impeller (9). Remove the inlet (9) by twisting it so that it comes away from the pump tank. Lower the carrying arm (34) with the jack (N). Swing out the carrying arm and lift the inlet (9) away. JAN 03-W24 Care and maintenance 8/25 Kap9 VF200 OLen_6.doc Fit the inlet by lifting it up and twisting it so that it engages with the hooks on the underside of the pump tank.6 for the part number of the counter-hold spanner (R). viewed from the impeller side. Swing out the carrying arm (34) and place the jack (N) under the carrying arm (34). NOTE: WARNING! Make sure that the inlet is fitted properly in place before lowering the carrying arm. using the jack (N). Place two blocks of wood (S) on the carrying arm (34). Place the inlet (9) on the carrying arm. Change worn components as necessary. - - Lower the carrying arm by means of the jack (N).4 and a counter-hold spanner (R) fitted as shown in the figure on the previous page.5. Kap9 VF200 OLen_6. Press the carrying arm and inlet up against the impeller shaft. Lift the impeller (50) into place and screw it on clockwise. the drive can be removed as described in section 9. which should be washed off. using the jack (N). Lock the pump shaft in a suitable manner. INLET (9) AND IMPELLER (50) Clean the thread of the shaft end and impeller. Swing out the carrying arm (34). Note that the thread of a new impeller is treated with corrosion inhibitor. Press the carrying arm and impeller up against the impeller shaft. Remove the counter-hold spanner (R). Grasp the impeller (50) and tighten it with a sudden movement so that the thread is prestressed. Swing the carrying arm in so that it is lined up with the pump shaft.Slurry Pump Assembly All components should be thoroughly rinsed and cleaned before they are fitted in place. Place the impeller on the wooden blocks (S). Use hot water. Alternatively. The position numbers under "Assembly" refer to the figures under "Removal". See the tool list in section 10.doc JAN 03-W24 Care and maintenance 9/25 . an alkaline solution or white spirit as necessary. the impeller must be adjusted forwards. 54) on the carrying arm. Swing the carrying arm in so that it is lined up with the pump shaft.1a in section 11 for the correct tightening torque. Fit the shaft spacer (95). Press the liner (1) into the lower pump casing half (53). 54) is centred in relation to the impeller (50) and that the gaskets fit properly round the pump casing.doc JAN 03-W24 Care and maintenance 10/25 . Twist the liner into its correct position in the casing. making sure that the studs (90) enter the holes correctly. Check that the pump casing is correctly located and mounted.5 "Adjusting pump clearances". Fit the nuts and bolts (96) See table 11. Close the pump by raising the carrying arm by means of the jack (N) until the pump casing abuts against the inlet (9). PUMP CASING (53 and 54) - - Swing out the carrying arm (34) and place the jack (N) under the carrying arm. Fit the discharge pipe back in place. Tighten the nut (91) that secures the liner in the casing. using a lifting tool (J) and suitable lifting equipment. Lift the upper pump casing half (54) onto the lower casing half (53).Slurry Pump PUMP CASING LINERS (1 AND 7) Before inserting a new liner (1).1 for the correct tightening torque. Check that the impeller (50) can rotate freely. follow the instructions in section 7 "Starting up".5. Adjust the pump clearances as described in section 9. Move the yoke (38) in. If it binds against the inlet (9). See table 11.1a in section 11. Tighten the nuts (32) and drive the wedges (7) in so that the pump casing (53. On restarting.1c in section 11 for the correct tightening torque. Fit the pump casing liner (7) in the upper casing half (54). inspect the inside of the cast iron casing. Tighten the nuts (90). Kap9 VF200 OLen_6. See table 11. Place the pump casing (53. Any unevenness and sharp edges must be ground down. This saves lifting height as at (A).Slurry Pump 9.doc . NOTE: Read all through the instructions before starting the work. See "Removal and fitting of the pump's hydraulic components" in section 9. JAN 03-W24 Care and maintenance 11/25 Alternative 2 Kap9 VF200 OLen_6. which corresponds to the length of the upper frame. the entire upper frame and bearing assembly (D) can be removed with the bolts (45).5. pump drive and lower section of the V-belt guard have been removed.1 and "Removal of the pump's drive" in section 9. inlet. It is assumed in the instructions that the impeller.5. pump casing.4. Removal Depending on how much clearance there is for raising the bearing assembly (D).2 Removal and fitting of shaft with bearing The section describes how to remove the complete bearing from the pump frame after the hydraulic parts have been removed.5. then either: (See figure on next page) Alternative 1 the bearing assembly (D) can be raised without necessitating removal of the upper frame. Slurry Pump Alternative 1 Slacken the bolt in the clamping joint (42). see previous page. If necessary. Kap9 VF200 OLen_6. Remove the upper frame and bearing assembly with the bolts (45).doc JAN 03-W24 Care and maintenance 12/25 . Pull the bearing assembly vertically out of the upper frame as shown in the figure (alternative 1). Make a mark on the bearing housing and clamping joint (P) so that the bearing housing will be fitted in the corresponding place on reassembly. the bolts (43) could be tightened to facilitate dismantling. see next page. Secure a suitable means of attachment to the eyebolt. Fit a lifting eyebolt to the shaft's drive end (J). Remove the grease nipple on the bearing (23). Position a supporting stand at A. Attach a lifting device to the eyebolt. - Alternative 2 Fit lifting eyebolts (J) in the upper frame's bolt holes. Lift out the upper frame and bearing assembly (D) and place them on a horizontal surface. Make a mark on the bearing housing and clamping joint (P) so that the bearing housing will be fitted in the corresponding place on reassembly. - - WARNING! Make sure that the pump lies on a firm surface before starting to remove the shaft and bearing. See figure on next page. Remove the locking bolts (41). Undo the bolt in the clamping joint (42). Attach the eyebolt to suitable lifting equipment. the bolts (43) may be tightened to facilitate dismantling.Slurry Pump - Remove the locking bolts (41). See section 9.1 Fit the bolts in the clamping joint (42) and tighten them to the correct torque. See table 11. Fit the grease nipple (23). Lift the bearing out of the frame as shown in the figure. Fit a lifting strap with noose round the shaft's impeller end nearest the bearing housing as shown in the shaded figure. Fit a lifting eyebolt to the shaft's drive end (J). Lift the entire bearing assembly and lower it vertically into the upper frame.1a in section 11. If necessary. Attach a lifting device to the eyebolt. Pull the bearing assembly horizontally out of the upper frame. Assembly The position numbers under "Assembly" refer to the figures under "Removal". Remove the grease nipple on the bearing (23). see removal. Fit the bolts (41) and tighten them to the correct torque. Alternative 1 Screw a lifting eyebolt (J) into the drive and of the shaft. When the shaft's impeller end (M) is resting in the frame's rear bearing housing support frame (S).1 Kap9 VF200 OLen_6.3 for further dismantling of the bearing.1c in section 11.doc JAN 03-W24 Care and maintenance 13/25 . Turn the bearing housing until it is opposite the mark on the clamping joint (P). place the bearing on a supporting stand (C) as shown in the figure. see table 11.5. Lift the bearing and rest the bearing housing's (D) front bearing position in the frame's rear bearing housing support frame (S) and on a supporting frame (C) as shown in the figure. see table 11. see removal. Remove the lifting strap with noose from the shaft's impeller end and slide the bearing horizontally into the frame with the lifting strap fitted in the lifting eyebolt (J) as shown in the figure. On restarting. Lift the upper frame and the bearing assembly on the tank.1 Fit lifting hooks (J) in the upper frame's bolt holes.Slurry Pump Alternative 2 Screw a lifting eyebolt (J) into the drive end of the shaft. Fit the upper frame and bearing assembly by means of the bolts (45). Fit the grease nipple (23).1 Fit the bolts in the clamping joint (42) and tighten them to the correct torque. Turn the bearing housing until it is opposite the mark on the clamping joint (P). - - - Fit the protection plate.doc JAN 03-W24 Care and maintenance 14/25 . see "Removal and fitting of the pump's hydraulic components" in section 9. Fit a lifting strap through the lifting eyebolt (J) and another lifting strap with noose round the impeller end of the shaft nearest the bearing housing. pump drive and V-belt guard. Secure a suitable means of attachment to the eyebolt. inlet.6. as shown in the shaded figure.1 and "Motor and drive" in section 6.1c in section 11. impeller.5. Fit the bolts (41) and tighten them to the correct torque. See table 11. follow the instructions in section 7 "Starting up". Check that the two guide pins are correctly positioned so that the pump shaft is centred. Kap9 VF200 OLen_6.1a in section 11. 3 Removal and fitting of shaft and bearing The section describes shaft and bearing replacement. section 10.5. Undo the bolts (21) in the slinger (22).2 "Removal and fitting of shaft with bearing". Remove the grease nipple (23). - Remove the V-ring (20).5. see section 9. Screw a lifting eyebolt (J) into the drive end of the shaft. Remove the slinger (22). Remove the V-ring (27). Remove the V-ring (24). The position numbers in this section refer to the figures below. See also "Spare parts drawing".Slurry Pump 9. NOTE: Read all through the instructions before starting the work.4. It is assumed in the instructions that the complete bearing has been removed from the pump's frame.doc JAN 03-W24 Care and maintenance 15/25 . Kap9 VF200 OLen_6. Removal Place the complete bearing on a level surface and make sure that it cannot roll away or sustain damage. Disconnect the lifting devices.doc JAN 03-W24 Care and maintenance 16/25 . Remove the bolts (25) as shown in the figure on the previous page. The bearing's (35) shrink-fit inner race (36) accompanies the shaft. Rest the shaft on a level surface. Attach the lifting device to the eyebolt and lift the shaft (38) out of the bearing housing (37). Lift up the bearing housing and place it horizontally on a level surface. Rest the bearing in a sturdy supporting frame (H) as shown in the figure above.Slurry Pump - Attach a lifting device to the eyebolt (J) and lift up the bearing so that it is suspended vertically. Kap9 VF200 OLen_6. - - - WARNING! Take care to ensure that the bearing housing does not slip out of the noose or tip out of the supporting frame. raise the bearing slightly off the supporting frame and tap the bearing housing with a plastic mallet to drive it down onto the supporting frame. Remove the cover (26). Lift it carefully so that the shaft-end threads are not damaged. If the bearing (30) is stuck in the bearing housing (37). Fit a lifting strap with noose round the bearing housing's (37) "waist". Make sure that it is firmly positioned and secure the bearing with the adjusting bolts (I). If the bearings have been removed.doc JAN 03-W24 Care and maintenance 17/25 . Kap9 VF200 OLen_6. Prise the lockwasher's (32) locking tab out of the shaft nut's (31) groove. Remove the grease retainer (28). Thoroughly wash used parts that are going to be re-used. Remove the lockwasher (32).Slurry Pump - Remove the key (29). Remove the inner race (36) by cutting a groove in it and splitting it open with a chisel. using a hook spanner. Change damaged or worn parts. discard them and fit new ones. Remove the bearing (30) from the shaft using a puller. Remove the bearing (35). using a puller. Remove the shaft nut (31). Use a suitable degreasant. NOTE: Take care to avoid damaging the shaft's bearing position. NOTE: Take care not to damage the shaft's bearing position. - Remove the bolts (33). Remove the cover (34). Fit the V-ring (27). Lift the bearing housing vertically in the assembly stand. observing the utmost cleanliness. Carefully lift the shaft assembly into the bearing housing. Attach the lifting device to the eyebolt and lift the shaft assembly. dust-free premises away from machinery which generates chips and dust. degreased and free from dust and dirt. JAN 03-W24 Care and maintenance 18/25 Kap9 VF200 OLen_6. Fit the cover (34). Higher temperatures can cause structural transformations in the material.Slurry Pump Assembly The position numbers under "Assembly" refer to the figures under "Removal". Fit a lifting strap with noose round the bearing housing's (37) "waist". using a hook spanner. If possible. assembly work should be carried out in dry. Fit the key (29). Carry out assembly right away and without interruption as soon as the packaging for the bearings is opened so that they are not exposed to dust and dirt unnecessarily. Pack the bearing seat (P) with grease. which result in dimensional changes. Roller bearings are precision components and must be handled with care. . induction heating apparatus or an oil bath. Fit the bearing (35). Fit the shaft nut (31). Fit the cover (26). Detach the lifting device. Press grease into the bearing seat (Q) so that the bearing (30) will slide more easily into place. Fit the inner race (36) of the bearing (35) on the shaft (38) as follows: . using a rubber mallet. NOTE: Make sure that the bearing housing is facing in the right direction. NOTE: The ring must not be heated to a temperature above 125°C.doc . Fit the grease retainer (28) onto the shaft. The bearing will slide easier onto the shaft if grease is used. Fit the bearing on the shaft (30). such as a heating chamber. taking care to avoid damaging the end of the shaft. WARNING! Take care to ensure that the bearing housing does not slip out of the noose or tip out of the supporting frame.Heat the inner race to 110°C using a heat source giving an even distribution of heat. NOTE: Make sure that the lubrication hole in the cover is opposite the lubrication hole in the bearing housing. Fit the lockwasher (32). Check that used bearing components are thoroughly clean. Fit the bolts (25).Press the inner ring into place and allow it to cool. Fit the bolts (33). making sure that it stands firm and steady. Help it along with a rubber mallet if necessary. Fit the grease nipple (23). Slurry Pump Fit the V-ring (24). Fit the V-ring (20).doc JAN 03-W24 Care and maintenance 19/25 . Tighten the bolts (21) in the slinger (22). Kap9 VF200 OLen_6. Fit the slinger (22). 6 "Motor and drive".5. - Remove the nuts (50) and lift off the V-belt guard's cover (F). For assembly.6 "Motor and drive". see figure above. Undo the locknut (51) and unscrew the bolt (52) until the motor baseplate can be swung in towards the pump. Remove the V-belts (54).Slurry Pump 9. see section 6.4 Removal of the pump's drive The section describes how to remove the pump's drive. Covers weighing more than 30 kg are fitted with a lifting eyebolt. Kap9 VF200 OLen_6. Remove the bolts (56) and the lower section (55) of the V-belt guard.doc JAN 03-W24 Care and maintenance 20/25 . Fitting the drive is described in section 6. Remove the V-belt pulleys (53). Remove the bolts from the V-belt pulleys and fit them in the clamp bushing's puller holes. 5.Slurry Pump 9. Remove the V-belt cover and remove the V-belts or drive. Clearance K is now zero. Screw up the "shaft with bearing" assembly (D) so that the impeller's vanes make contact with the inlet. Do this by slackening the bolts (43). Read all through the instructions before starting the work.1.1b in section 11. see section 9.5a).4. the "shaft with bearing" (D) is axially adjustable. To allow this adjustment to be made. JAN 03-W24 Care and maintenance 21/25 Kap9 VF200 OLen_6. Lock the bolts (60) and tighten the clamping joint (42) to the correct torque.5 Setting pump clearances The section describes how to adjust the pump for optimum performance and minimum wear. see table 11. Undo the clamping joint (42) and locking bolts (60).5.doc . Do this by tightening the bolts (43) while rotating the pump shaft. Screw the "shaft with bearing" assembly (D) down so that clearance K assumes the lowest value (see table 9. The position numbers below refer to the figure above. The clearance between the impeller and the inlet/casing's inlet side K is adjusted. 0 Kap9 VF200 OLen_6.Slurry Pump When the clearance is correctly adjusted: check that the impeller can rotate freely.0-4. If it cannot rotate freely. carry out adjustment of the clearance once again. Table 9.5a Clearance position K Clearance (mm) 2.doc JAN 03-W24 Care and maintenance 22/25 . 5. Make sure that nobody is in danger of being injured before switching on the power. In the instructions it is assumed that the pump and installation have previously been working satisfactorily. NOTE: An authorized electrician must carry out electrical installation work. except for checks that cannot otherwise be performed. See section 9.doc JAN .5.No open circuit in motor cable. Can the pump be started manually? NO ⇓ YES ⇒ Check the cause: . 1. if any.Follow the instructions for the monitoring equipment.3 and the motor manufacturer's instructions. .Fault in level control equipment. See section 9. Rinse out the pump and sump. Pump fails to start Is the installation without power? NO ⇓ YES ⇒ Check that: . a test lamp and a circuit diagram. WARNING! Fault tracing should be carried out with the power supply disconnected. Contact Metso Minerals Remove the drive's protection plate and rotate the pump shaft Remove the pump and clean behind the impeller.6 Fault tracing schedule Use the following schedule as a fault-tracing aid.Overload cut-out reset. . .All phases are live. and change defective components. Remove the drive and check that both motor and pump shaft can be rotated. if any.Slurry Pump 9. .Operating current present for starting. In order to carry out fault tracing on the electrical equipment it will be necessary to have a universal instrument (multimeter). . Change the bearing if necessary. Follow local installation directives and observe "Health and safety". . section 3. .Fault in other monitoring or control equipment.The main switch is turned on. 03-W24 Care and maintenance 23/25 Is the pump jammed? NO ⇓ YES ⇒ Kap9 VF200 OLen_6.The machine and its fuses are intact. 5. Has any leakage occurred in the installation? Kap9 VF200 OLen_6. Check that the pump clearances are correctly adjusted.5. See section 9. Pump runs but produces little or no flow Has the operating data or pipe routing been changed? NO ⇓ YES ⇒ Change the operating data and pipe routing or resize the drive. motor and pump according to the new operating conditions.5. Is the motor overload cut-out set too low? NO ⇓ YES ⇒ Check against the motor sign and adjust as necessary.5. See section 9. See section 9. 3. Rinse out the pump and sump. Is the pump shaft hard to turn or is it jammed? NO ⇓ YES ⇒ - Contact Metso Minerals Remove the V-belt guard and check that the drive can be rotated.doc JAN 03-W24 Care and maintenance 24/25 . Change or rectify leaky components. Remove the pump and clean behind the impeller. motor and pump according to the new operating conditions. Pump starts but motor overload cutout trips Has the flowchart or pipe routing been changed? NO ⇓ YES ⇒ Change the flowchart and pipe routing or resize the drive. Change the bearing as necessary. Remove the drive and check that both motor and pump shaft can be rotated.Slurry Pump 2.3 and the motor manufacturer's instructions. are open and intact. That the valves.5 for its removal.Slurry Pump Check: Pump direction of rotation. Clean the impeller as necessary. That the impeller is not clogged. NO ⇓ YES ⇒ Adjust the feed to the pump or resize the drive. Check that the valves. Pump runs unevenly or vibrates Check that the feed to the pump and the pump itself do not suck air. See section 9. see section 6.doc JAN 03-W24 Care and maintenance 25/25 . see section 9. if any. Special valves of rubber sleeve type which are mounted on the inlet side can be sucked in at high flow rates and block the inlet. Note that valves on the inlet side should always be fully open when the pump is running. That hydraulic components are so worn that they impair pump performance. That the pump clearance is correctly adjusted. See section 9. - - 4. Clean the impeller as necessary. motor and pump according to the operating conditions. The bearing and hydraulic components are stressed to a far greater extent if the pump rotates in the wrong direction and the risk of a breakdown is high. Change worn components. the pump may give up to 60% of the flow it produces with the correct direction of rotation.5.5.5 for its removal. Kap9 VF200 OLen_6. With the wrong direction of rotation. If the correct clearance cannot be obtained. are open and intact and that the lines are not blocked NO ⇓ YES ⇒ Rectify Check that the impeller is not clogged. if any. change worn hydraulic components. Certain types of rubber such as chloroprene rubber (CR) harden at temperatures below +5°C. and also in connection with welding. Impeller Complete set of gaskets and O-rings Pump casing liner (1) Inlet Bearing assembly 10. They should be stored in undeformed state and protected from ozone-generating sources. Metso Minerals recommends keeping the following parts in stock.Slurry Pump 10. 310204-M1 Kap10 VFen_4. see section 10. 10. In conditions of extreme cold these types of rubber harden to such an extent that they could develop cracks and be damaged by handling. protected from dust and dirt. electric motors. Example: 1 impeller. rubber-lined. Designation. see the machine sign on the pump.3 Ordering spare parts The best way of avoiding misunderstandings and ensuring correct delivery is to provide as extensive information as possible. part No. Therefore state the following in your spare parts order: Pump type designation and serial number. etc.doc JAN 03-W02 Spare parts 1/2 .3. Machined surfaces of metallic components are treated with corrosion inhibitor before delivery and this must be removed before assembly. Chloroprene rubber does not regain its normal hardness when the ambient temperature rises but has to be reconditioned.1 Recommended spare parts stock To maintain as high a level of pump availability as possible. Spare parts 10. protected from direct sunlight.2 Stocking of spare parts Rubber components should be stored in a cool place. material and part number of the part. see example below. For part numbers. Ozone is generated by high-tension discharges in switchgear. other components should be stored in a dry place. Used for removing and fitting the bearing assembly * VF350 with rubberized shaft.6 Special tools Pump size VF 50 80 100 150 200 250 350 350* 1 2 Support plate 1 195428-M1 193727-M1 180976-M1 180976-M1 193842-M1 233180-M1* Lifting tongs 228250-M1 228250-M1 224860-M1 224860-M1 224858-M1 224858-M1 - Counter-hold spanner 219592-M1 235302-M1 219595-M1 219595-M1 219596-M1 219596-M1 - Lifting eyebolt 2 951255 952828 952828 952828 954685 954685 952828 952828* Used in connection with transport and storage of the pump. Pump size VF 350 Service trolley 1 233116-M1 Lifting eyebolts 2 952828 1 2 Use a suitable garage jack when using the service trolley. Used in connection with removing and fitting pump casing halves.Slurry Pump 10.doc JAN 03-W02 Spare parts 2/2 . Kap10 VFen_4. Pump VF150 Parts drawing 255-501_1 255-501 Edition 1 JAN 06-W06 Spare parts 1/ 2 . Pump VF150 Parts drawing 255-551_1 255-551 Edition 1 JAN 06-W06 Spare parts 2/ 2 . 00 2.27 0.00 3.04 53.40 4.50 5.02 0.01 0.00 5. Description Wear parts Case liner Impeller Inlet door Bearing assembly parts Bearing/shaft assembly Shaft Key Nut Washer Bearing cylinder housing End cover End cover Flinger Distance sleeve Bearing Bearing V-ring V-ring Screw Spare parts Case Qty Unit weight Kg 1 1 1 8.30 1.15 0.Pump VF150 O4 NRNR Parts list Item Part No.00 124.00 0.80 12.25 0.00 26347002000 Edition 1 JAN 06-W40 Spare parts 1/1 .01 006 SA110275-1 1 71.50 007 008 009 SA110276-M1 SA234612-M1 SA193756-M1 053 201 207 209 210 212 213 214 215 216 217 218 219 220 222 SA234694-M2 SA234679-M1 SA899018-100 SA954181 SA954132 SA093788-A SA093789-A SA093792-A SA093791-A SA115472-1 SA954037 SA953957 SA950206 SA953332 SA950975 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 200.00 8. Thread M16 M20 M24 M30 Tightening torque (Nm) ±10% 115 175 200 300 Tightening torque (Nm) ±15% 5.7 9. Strength class 8. Appendices 11. Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 b) Tightening torques for clamping joints. Strength class 8.8 as per ISO 898. Strength class A4-80 as per ISO 3506.doc JAN 03-W02 Appendices 1/2 .Slurry Pump 11.8 24 47 81 197 385 665 1310 2280 Kap11 VFen_4.1 Tables with specified tightening torques for bolted joints Table 11 a) Tightening torques for regular bolted joints. Strength class A4-80 as per ISO 3506.8 as per ISO 898. Slurry Pump c) Tightening torques for studs. Strength class A4-80 as per ISO 3506.doc JAN 03-W02 Appendices 2/2 . DIN 939. Strength class 8. Thread M10 M12 M16 M20 M24 Tightening torque (Nm) ±15% 29 51 123 240 416 Kap11 VFen_4.8 as per ISO 898. doc JAN 04-W09 Appendices 3/2 .2 Reference publications WEG Installation and Maintenance Manual for Electric Motors WH26HREAAA1us_03c.Slurry Pump 11. By virtue of the prominent role the electric motor plays in the comfort and welfare of mankind. maintain and preserve the most important component of all equipment: THE ELECTRIC MOTOR! WEG .260. THE WEG ELECTRIC MOTOR INSTALLATION AND MAINTENANCE MANUAL provides the necessary information to properly install. as virtually all machines and many renowned inventions depend upon it. Its installation and routine maintenance require specific care to ensure perfect operation and longer life of the unit. This means that the electric motor should receive proper attention. it must be regarded and treated as a prime power unit embodying features that merit special attention. including its installation and maintenance.02/0501 INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS T he electric motor is the item of equipment most widely used by man in his pursuit of progress. INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 2 . ........1..........Basic Instructions ..5 Bearing Load (Stresses on the bearings) .......1...........................................1 Standard Three-phase Motor Failures....................................................................2...........2.27 4................2 Repair Procedure and Precautions ..........18 3.......25 4....05 2..2 Troubleshooting Chart ...21 3....................................29 5...1...........1 Mechanical Aspects .......2 Starting of Electric Motors ....4 Bearing Failures .......................................................................Spare Parts and Component Terminology ..30 6 ........29 5.........................................................................................6 Unbalanced V-Belt Drives..5 Shaft Fractures .......25 4...28 5.................................1 Periodical Lubrication ...............................INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Contents 1 ...........................................1 Preliminary Inspection .........................3 Rotor Failures ...........2 The First Start-up.......27 4............................3 Air Gap Checking.....................................3 Storage ..............27 5 ...31 3 .......07 3...............26 4...............2 Types of bases .........07 3.......................16 3.26 4..08 3..............................2.....................3......09 3...25 4....3 Alignment...2..Introduction 03 2 ........1.25 4....4 Coupling ....1 Feed System ........................29 5...............2 Quality and Quantity of Grease ...........16 3...............................................27 4............1..............19 3................05 2.3...........21 4 .........2............05 2...........................05 2..........1 Short Circuits Between Turns ..25 4........1 Cleanliness ...........1 Foundation........28 5..........3 Operation.........................4.................................4 Replacement of Bearings .3 Lubricating Instructions.....29 5.......................3 Motor Protection .............1 Drying the Windings ................4...............................1.........................................Malfunctioning .....07 3..................................2 Delivery .........4 Stopping ...............1...1........................................................2............1 Objective...1..................3 Miscellaneous Recommendations.....28 5..2 Winding Failures..........2 Lubrication .......3...................Maintenance.............29 5..................1...............25 4....................Installation 07 3..........................16 3..................3..................06 3 ....................1..........1..........................28 5............1 Safety Instructions.....................................10 3.2 Electrical Aspects............4..................21 3..........3 Start-up19 3................................2..................3......................7 Damage Arising from Poorly Fitted Transmission Parts or Improper Motor Alignment ...............4 Explosion Proof Motor Repair Steps................. 4 . Introduction T his manual covers all the three-phase and single-phase asynchronous squirrelcage induction motors. from 140T to 580T frame sizes. The motors described in this manual are subject to continuous improvement and all information is subject to change without notice. For further details. please consult WEG.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 1. either handling.1 Safety Instructions All personnel involved with electrical installations. The weight of the rotor in an inactive motor tends to expel grease from between the 5 . operating and maintaining the equipment. operation and maintenance. 2) With rotor locked. Raising and lowering must be steady and joltless. Other objects should not be placed on or against them. Bearings and lubricant deserve special attention during prolonged periods of storage. 2. apply low voltage and gradually increase current through windings until temperature measured with thermometer reaches 194 degrees F. Do not exceed this temperature. it is the responsibility of the person in charge to ascertain that these have been duly complied with and to alert his personnel of the inherent hazards of the job in hand. Basic Instructions 2. · avoid extended exposure in close proximity to machinery with high noise levels. both the nearest WEG sales office and the carrier should be notified without delay. Upon receipt. When a motor is not immediately put into service it should be protected against moist.minimum recommended insulation resistance in M W with winding at 40°C Vn .3 Storage Motors should be raised by their eyebolts and never by their shafts. If the motor is stored for an extensive period. gases and corrosive atmosphere. Fire fighting equipment and notices concerning first aid should not be lacking at the job site. They are packed in boxes or bolted to a wooden base. it is best to check the insulation resistance of the stator winding with a megohmeter. free of dust. If the resistance is lower than ten megohms the windings should be dried in one of the two following ways: 1) Bake in oven at temperatures not exceeding 194 degrees F until insulation resistance becomes constant. Depending on the length and conditions of storage it may be necessary to regrease or change rusted bearings.s temperature of the winding with the aid of Figure 2. It is difficult to prescribe rules for the true insulation resistance value of a machine as resistance varies according to the type. When motors are not immediately installed. method of construction and the machine’s insulation antecedents. and · follow consistently any instructions and product documentation supplied when they do such work. thus avoiding damage to insulation resistance. Insulation resistance Rm is obtained by the formula: Rm = Vn + 1 Where: Rm . If the motor has been in storage more than six month or has been subjected to adverse moisture conditions. the value must be corrected to 40°C using an approximated curve of insulation resistance v.1. they should be stored in their normal upright position in a dry even temperature place. A lot of experience is necessary in order to decide when a machine is ready or not to be put into service. Periodical records are useful in making this decision. lifting.2 Delivery Prior to shipment. Motors stored over long periods are subject to loss of insulation resistance and oxidation of bearings.rated machine voltage in kV In case the test is carried out at a temperature other than 40°C. be sure that all power sources are disconnected from the motor and accessories to avoid electric shock. motors should not be stored near machines which cause vibrations. a periodical inspection is recommended during storage. installing. Before initiating maintenance procedures. 2. The following guidelines show the approximate values that can be expected of a clean and dry motor. Insulation resistance fluctuates widely with temperature and humidity variations and the cleanliness of components. In the event of damage and in order to guaranty insurance coverage. It is important that high rating three-phase motors be raised by their eyebolts. Should the ambient conditions be very humid. it’s possible verify that resistance practically doubles every 10°C that insulating temperature is lowered. and every 3 month their shafts should be rotated manually. Before work commences. these should be visible and accessible at all times. at 40°C test voltage in applied during one minute. As a preventive measure against the formation of corrosion by contact. size and rated voltage and the state of the insulation material used.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 2. the rotor must be periodically rotated. otherwise bearings may be harmed. · avoid by-passing or rendering inoperative any safeguards or protective devices. should be wellinformed and up-to-date concerning the safety standards and principles that govern the work and carefully follow them. · use proper care and procedures in handling. It is recommended that these tasks be undertaken only by qualified personnel and they should be instructed to: · avoid contact with energized circuits or rotating parts. lifting. bearing surfaces thereby removing the protective film that impedes metal-to-metal contact. motors are factory-tested and balanced. we recommend careful handling and a physical examination for damage which may have occurred during transportation. high temperatures and impurities. lower values are often attained due to solvents present in the insulating varnishes that later evaporate during normal operation.02 M W Correction to 40°C R 40°C = R 50°C x K 50°C R 40º C = 1. An overly high final temperature as well as a fast temperature increase rate can each generate vapour harmful to the insulation. It is extremely important that the interior of the motor be well ventilated during the drying operation to ensure that the dampness is really removed.440 + 1 Rm = 1. energization of the space heater (optional). motors should be subjected to a drying process. During the early stages of the drying process.3 R 40º C = 1. serves as a better indication of insulation condition than that of the value derived from a single test. Any substantial or sudden reduction is suspect and the cause determined and corrective action taken. but the resistance will increase again when the insulation becomes dryer.1. A comparison of the values recorded in previous tests on the same motor under similar load. The rate of temperature rise should not exceed 5°C per hour and the temperature of the winding should not exceed 105°C. This does not necessarily mean that the motor is not operational. insulation resistance will decrease as a result of the temperature increase. Temperature should be accurately controlled during the drying process and the insulation resistance measured at regular intervals. and only by qualified personnel. temperature and humidity conditions.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Example: Ambient temperature = 50°C Motor winding resistence at 50°C = 1. The drying process should be extended until sucessive measurements of insulation resistance indicate that a constant value above the minimum acceptable value has been attained. This operation should be carried out with maximum care.440 M W On new motors. On motors which have been in service for a period of time much larger values are often attained. Heat for drying can be obtained from outside sources (an oven). 6 . Winding Temperature (ºC) R40 ºC = Rt x Kt 40 ºC Figure 2.326 M W The minimum resistence Rm will be: Rm = Vn + 1 Rm = 0. since insulating resistance will increase after a period of service. In the event that insulation resistance is inferior to the values derived from the above formula. Insulation resistance is usually measured with a MEGGER.02 x 1. or introducing a current through the actual winding of the motor being dried. keep in mind that the motor may occasionally be run at a torque above that of the rated full load torque. The choice of base will depend upon the nature of the soil at the place of erection or of the floor capacity in the case of buildings. When dimensioning the motor base.1 Foundation The motor base must be levelled and as far as possible free of vibrations. the rails are fixed. such as NEC Art.Base stresses 7 .213 Tmáx/A) F2 = 0. it is essential to ensure an adequate degree of protection. A concrete foundation is recommended for motors over 100 HP. as shown in Figure 3.1 .Positioning of slide rails for motor alignment Figure 3. Machines fitted with external ventilation should be at least 50cm from the wall to permit the passage of air. Figure 3.009 x g x G + 213 Tmax/A ) After the alignment. The belt should not be overly stretched. should be undertaken according to appropriate and governing codes. pipes or other objects. corrosive or contain flammable substances or particles. gases or dusts.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 3.2 . The drive pulley is aligned such that its center is on a plane with the center of the driven pulley and the motor shaft and that of the machine be parallel. Where: F1 and F2 g G Tmax A Lateral stress (Lb) Force of gravity (32. The place of installation should allow for air renewal at a rate of 700 cubic feet per minute for each 75 HP motor capacity.2247 (0.1 Mechanical Aspects 3. Under no circumstances can motors be enclosed in boxes or covered with materials which may impede or reduce the free circulation of ventilating air. subject to fire or explosion.2 Types of Bases a) Slide Rails When motor drive is by pulleys the motor should be mounted on slide rails and the lower part of the belt should be pulling. The rail nearest the drive pulley is positioned in such a manner that the adjusting bolt be between the motor and the driven machine. see Figure 3. The other rail should be positioned with the bolt in the opposite position. Ft) Obtained from the dimensional drawing of the motor (in) Sunken bolts or metallic base plates should be used to secure the motor to the base.18 ft/s2) Weight of motor (Lb) Maximum torque (Lb .1. Inc.1.11.) Standards. The opening for the entry and exit of air flow should never be obstructed or reduced by conductors. The installation of motors in environments where there are vapours. Based upon Figure 3.2247 (0. foundation stresses can be calculated by using the following formula: F1 = 0. - 3.1. Installation Electric machines should be installed in order to allow an easy access for inspection and maintenance. 500 (National Electrical Code) and UL-674 (Underwriters Laboratories. Should the surrounding atmosphere be humid.009 x g x G .2. flammable or combustible materials. The motor is bolted to the rails and set on the base. 3. After accurate alignment and levelling of the motor.5 . Figure 3.5. providing that the couplings are perfect and centered .1. and bring about loosening. one reading radially and the other 8 . If the installer is sufficiently skilled. Figure 3.3 .Alignment with a steel ruler Figure 3.8 inches be used between the foundation studs and the feet of the motor for replacement purposes.6a) and concentricity deviations (Figure 3. exially .6c.Deviation from parallel Figure 3.Deviation from concentricity Figure 3.Alignment with dial gauges Thus.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS b) Foundation Studs Very often. An incorrect alignment can cause bearing failure vibrations and even shaft rupture.Motor mounted on a concrete base with foundation studs 3. It is recommended that shim plates of approximately 0.Figure 3.6c . particularly in cases of direct coupling.02 inches. The best way to ensure correct alignment is to use dial gauges placed on each coupling half. simultaneous readings are possible and allow for checking for any parallel (Figure 3. he can obtain alignment with feeler gauges and a steel ruler.6b . particularly when drive is by flexible coupling the motor is anchored directly to the base with foundation studs.3 Alignment The electric motor should be accurately aligned with the driven machine.Figure 3.6a .6b) by rotating the shafts one turn. These shim plates are useful when exchanging one motor for another of larger shaft height due to variations allowed by standard tolerances. the foundation studs are cemented and their screws tightened to secure the motor. Gauge readings should not exceed 0. Foundation studs should neither be painted nor rusted as both interfere with to the adherence of the concrete. 9. a flexible coupling. no belt slippage and lower accident risk.4 Coupling a) Direct Coupling Direct coupling is always preferable due to its lower cost. Figure 3.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 3. Perfect gear engagement can be checked by the insertion of a strip of paper on which the teeth marks will be traced after a single rotation.8 .1. due care must be given to perfect shaft alignment: exactly parallel in the case of straight gears. Poorly aligned gear couplings are the cause of jerking motions which bring about the vibration of the actual drive and vibrations within the motor. space economy. the devices illustrated in Figure 3.8 may be employed.8a .7 .Pulley mounting device Figure 3.9 . c) Belt and Pulley Coupling Belt coupling is most commonly used when a speed ratio is required. On shafts without threaded end holes the heating of the pulley to about 80°C is recommended. The fitting of bearings with the aid of hammers leaves blemishes on the bearing races. The correct positioning of a pulley is shown in Figure 3. CAUTION: Carefully align the shaft ends using. Therefore.A type of direct coupling Figure 3. Figure 3. These initially small flaws increase with usage and can develop to a stage that completely impairs the bearing.Pulley extractor b) Gear Coupling Hammers should be avoided during the fitting of pulleys and bearings. and at the correct angle for bevel or helical gears. Assembly of Pulleys: To assemble pulleys on shaft ends with a keyway and threaded end holes the pulley should be inserted halfway up the keyway merely by manual pressure. whenever feasible.Correct positioning of pulley on the shaft 9 . it is also common to use a direct coupling with a reducer (gear box). or alternatively. In the case of speed ratio drives. 31 6.97 7.49 4.73 8.54 4.87 11.79 46.41 2.62 7.72 3. Figure 3.94 4.62 4.Correct pulley alignment Laterally misaligned pulleys. transmit alternating knocks to the rotor and can damage the bearing housing.23 1.32 6. Belt slippage can be avoided by applying a resin (rosin for example).7 3.16 3.93 3.Belt tensions Table 1 .79 1.28 5.24 Important: 1) Peripheral speeds for solid grey cast iron pulleys FC 200 is V = 115 ft/s 2) Use steel pulleys when peripheral speed is higher than 115 ft/s 3) V-belt speed should not exceed 115 ft/s.13 NU 319 4.10).INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS RUNNING: To avoid needless radial stresses on the bearings it is imperative that shafts are parallel and the pulleys perfectly aligned.34 11.15 3.3 3.81 2.57 1.59 5.95 10.97 4.23 23. when running.33 7. Figure 3.10 .66 45.11).12 25.54 24. an analysis should be requested from the WEG engineering.46 1.77 5.61 13.19 7.51 4.87 11.15 4.97 5.31 4.72 4.08 7.72 3.73 NU 322 10. these cause shaft flexion because belt traction increases in proportion to a decrease in the pulley size.17 6.51 8.85 4.85 3.00 4.16 12.08 Size X Inches 1.82 11.33 4.90 4.57 Roller Bearing Bearing NU 316 Size X Inches 1.86 2.00 3.67 4.96 11.06 4.22 4.73 3.95 9.91 4.67 14.94 9. Beyond frame size 600.Maximum acceptable radial load (Lbf) 10 . Belt tension should be sufficient to avoid slippage during operation (Figure 3.02 NU 319 6.44 8.92 4.36 2 3.75 12.17 11.27 4.18 9.76 9.94 5.39 12.11 . (Figure 3.11 5.Minimum pitch diameter of pulleys Ball bearings Frame 140 W 180 180 W 210 210 W 250 250 280 320 360 Frame 400 440 500 5008 580 Bearing 6205-Z 6206-Z 6307-Z 6308-Z 6308-Z 6309 C3 6309 C3 6311 C3 6312 C3 6314 C3 Poles II IV-VI-VII II IV-VI-VIII II IV-VI-VIII II IV-VI-VIII II IV-VI-VIII Size X Inches 0.37 4.34 25.65 8.15 7.69 1.50 8. Pulleys that are too small should be avoided.47 7. and Tables 2 and 3 refer to the maximum stresses acceptable on motor bearings up to frame 580.76 Ball Bearing Bearing 6314 C3 6314 C3 6314 C3 6319 C3 6314 C3 6319 C3 6314 C3 6322 C3 6314 C3 6322 C3 57 58 59 60 44. Table 1 determines minimum pulley diameters.98 48.47 7.52 NU 322 8.03 1. Table 2 .69 4.82 7. NEMA 56 Frames .078 1.303 1.481 1909 1.60Hz Position / Construction Form F R A M E II 103 108 149 196 189 282 273 355 374 890 877 842 769 791 679 IV 141 145 207 264 257 372 368 480 498 1.865 II 112 154 269 329 324 471 463 621 703 890 877 842 769 791 679 IV 152 209 370 447 443 620 615 826 930 1.190 2029 597 II 105 141 253 310 295 430 410 540 597 745 705 568 355 728 033 IV 143 194 352 421 405 564 557 736 793 985 890 884 721 1548 474 VI 174 240 421 518 493 685 672 838 937 1.406 VI 185 255 443 544 533 734 727 959 1.323 1.60Hz Position / Construction Form F R A M E II 56 A 56 B 56 D 68 66 63 IV 90 90 88 II 83 81 105 IV 112 110 145 II 63 63 59 IV 85 83 81 II 79 77 101 IV 108 105 138 11 .109 2029 597 140 W 180 180 W 210 210 W 250 250 280 320 360 400 440 500 5008 580 Open Motors .303 1.18 2 59 59 59 59 70 70 80 LMS 80 MMS 80 SMS 90 LMS II II II II IV 355 359 357 427 555 - Table 3 .109 844 1808 549 VIII 198 269 480 582 553 743 749 961 1.091 1.181 1.481 1909 1.488 1.Maximum acceptable axial load (Lbf) IP55 Totally Enclosed Motors .250 1624 1.521 1.060 1.649 VIII 207 286 500 610 599 811 813 1.563 1.375 1.144 1.148 1.406 VI 167 180 249 326 315 443 436 551 588 1.821 1.323 1.728 2137 1.144 1.060 1.347 1.563 1.821 1.649 VIII 187 202 286 368 357 485 485 624 668 1.488 1.181 1.241 1.241 1.521 1.082 1.728 2137 1.144 1.232 1.109 844 1808 549 VIII 178 183 266 339 310 414 421 502 511 1.347 1.148 1.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Nema 56 Motors Frame 56A 56B 56D Poles II IV II IV II IV Saw Arbor Motors Radial Force (Lbf) Distance X 1 88 88 88 86 127 141 1.552 1.250 1624 1.865 II 99 94 136 176 160 240 220 275 266 745 705 568 355 728 033 IV 132 130 189 238 220 317 310 388 366 985 890 884 721 1548 474 VI 158 165 229 297 275 394 379 427 432 1.323 1. Maximum radial load in relation to the diameter and pulley width. this bearing withstands a radial load of 130 Lb.Maximum radial load on bearings. INSTRUCTIONS ON HOW TO USE THE GRAPHS 1 . 12 . Frame : 145T Fr : 110Lb X : 2 inches 1 . Example: Verify whether a 2HP motor. 60Hz withstands a radial load of 110Lb.Half of pulley width (inches) Fr. Where: X . by graphs.Find out line N = 3600 for bearing Based on the above. II Pole.Maximum radial load on shaft. 2 . considering a pulley width of 4 inches.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS The maximum radial load for each frame are determined.Mark the distance X 2 . INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 13 . INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 14 . 15 .INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Note: For frames 600 and above. consult your engineering representative. 5A b) Closest value on table 6:55A c) Minimum gauge: 6 AWG 3. mining machines etc) Variable 1. whether branch or distribution circuits.50 1. To determine the conductor gauge proceed as follows: a) Determine the current by multiplying the current indicated on the motor nameplate by 1.25 x 42A = 52. Example: Size the conductors for a 15 HP. This method is called Directon-Line (DoL) starting.20 0.85 0. should be based on the rated current of the motors as per NFPA-70 Standard article 430.2.10 0. a) Current to be located: 1.85 1. tools.1 Feed System Proper electric power supply is very important.90 Continuous 1.10 0. Duty Classification Short (operating valves.2.Running cycle factor Motor short time rating 5min 15min 30 at 60min 1.2 Starting of Electric Motor Direct Starting Induction motors can be started by the following methods: Whenever possible a three-phase motor with a squirrel cage rotor should be started directly at full supply voltage by means of a contactor (Connection diagram a). motor located 200 feet from the main supply with cables laid in conduits.2 Electrical Aspects 3.25 and then locate the resulting value on the corresponding table.50 0. activating contacts etc) Intermittent (passenger or freight elevators.40 b) Locate the rated voltage of the motor and the feed network distance in the upper part of the corresponding table. 230V.00 16 . pumps. rolling bridges etc) Cyclic (rolling mills.95 1.90 1.20 0. In the case of variable speed motors. 42A. the conductors should have a current carrying capacity equal or greater. and to the type of installation (Overhead or in ducts). When motor operation is intermittent.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 3.25 times the rated current of the largest motor plus the rated current of the other motors. The point of intersection of the distance column and the line referring to current will indicate the minimum required gauge of the conductor.85 1. three-phase. the value to be sought on the table should be equal 1. to the product of the motor rated current times the running cycle factor shown on Table 7. The choice of motor feed conductors. Table 7 . the highest value among the rated currents should be considered. 5 and 6 show minimum conductor gauges sized according to maximum current capacity and maximum voltage drop in relation to the distance from the distribution center to the motor. If the conductor feeds more than one motor. Tables 4.40 2. 17 .Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits) Supply Voltage 115 230 460 575 Current (A) 15 20 30 40 55 70 95 125 145 165 195 215 240 265 280 320 12 12 10 8 6 4 2 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 12 10 8 8 6 4 2 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 12 10 8 6 6 4 2 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 10 10 8 6 4 4 2 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 10 8 6 6 4 2 2 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 85 170 340 420 102 204 408 501 120 240 480 590 137 274 548 670 Distance of motor from distribution centre (feet) 171 342 684 840 205 410 820 1010 240 480 960 1181 273 546 1092 1342 308 616 1232 1515 342 684 1368 1680 428 856 1712 2105 514 1028 2056 2530 Cable gauge (conductor) 8 8 6 4 4 2 1/0 1/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 8 6 6 4 2 2 1/0 2/0 2/0 3/0 4/0 250M 300M 350M 400M 500M 8 6 4 4 2 1/0 1/0 2/0 3/0 3/0 4/0 250M 300M 350M 400M 500M 6 6 4 2 2 1/0 1/0 3/0 3/0 4/0 250M 250M 300M 350M 400M 500M 6 6 4 2 1/0 1/0 2/0 3/0 4/0 4/0 250M 300M 300M 350M 400M 500M 6 4 2 2 1/0 2/0 3/0 4/0 250M 250M 300M 350M 400M 500M 400M 500M 4 4 2 1/0 1/0 2/0 4/0 250M 300M 350M 350M 400M 500M 500M --- Note: The above indicated values are orientative. contact the Local Power Company. For guaranteed values.Wire and cable gauges for three-phase motor installation .INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Table 4 .aerial conductors with 25cm spacing (voltage drop < 5%) Supply Voltage 115 230 460 575 Current (A) 15 20 30 40 55 70 100 130 175 225 275 320 14 14 14 12 10 8 6 4 2 1/0 2/0 3/0 14 14 12 10 10 8 6 4 2 1/0 2/0 3/0 14 12 10 10 8 6 4 4 2 1/0 2/0 3/0 12 12 8 8 8 6 4 2 1/0 2/0 4/0 4/0 12 10 8 8 6 4 2 1/0 2/0 3/0 --51 102 204 250 69 138 276 338 85 170 340 420 102 204 408 501 Distance of motor from distribution centre (feet) 137 274 547 670 171 342 684 840 205 410 820 1010 240 480 960 1181 273 546 1092 1342 308 616 1232 1515 342 684 1368 1680 428 856 1712 2105 514 1028 2056 2530 685 1370 2740 3350 Cable gauge (conductor) 10 10 8 6 4 2 2 1/0 3/0 ---10 8 6 4 4 2 1/0 2/0 ----10 8 6 4 2 2 2/0 4/0 ----8 8 4 4 2 1/0 3/0 -----8 6 4 2 2 1/0 4/0 -----8 6 4 2 1/0 2/0 4/0 -----6 4 2 2 2/0 3/0 ------6 4 2 1/0 3/0 -------4 2 1/0 2/0 --------- Table 6 .Wire and cable gauges for single-phase motor installation (voltage drop < 5%) (in conduits) Supply Voltage 115 230 460 575 Current (A) 5 10 15 20 30 40 55 70 95 14 14 12 12 10 8 6 4 2 14 14 12 12 10 8 6 4 2 14 14 12 12 10 8 6 4 2 14 14 12 10 8 8 6 4 2 14 12 12 10 8 6 6 4 2 34 69 138 170 51 102 204 250 69 138 276 338 85 170 340 420 Distance of motor from distribution centre (feet) 102 204 408 501 137 274 548 670 171 342 684 840 205 410 820 1010 240 480 960 1181 273 546 1092 1342 308 616 1232 1515 342 684 1368 1680 428 856 1712 2105 514 1028 2056 2530 Cable gauge (conductor) 14 12 10 8 6 6 4 2 2 14 10 8 8 6 4 4 2 1/0 12 10 8 6 6 4 2 2 1/0 12 10 6 6 4 2 2 1/0 1/0 12 8 6 6 4 2 1/0 1/0 2/0 12 8 6 4 2 2 1/0 2/0 3/0 10 8 6 4 2 2 1/0 2/0 3/0 10 6 4 4 2 1/0 1/0 2/0 4/0 8 6 2 2 1/0 2/0 2/0 2/0 250M Table 5 . it will be necessary to: a) Remove all locking devices and blocks used in transit and check that the motor rotates freely. . The detector terminals are connected to a control panel. c) Ascertain that voltage and frequency correspond to those 3. RTD type resistance which dispense with independent devices. usually fitted with a temperature gauge. Starting with a compensating switch (auto-transformer starting) Should direct on line starting not be possible. Subject to the desired degree of safety and the client’s specification. During starting by the DOL method. Initial locked rotor current (LRC) in induction motors reach values six to eight times the value of the full load current. for the indicated voltage. Star-Delta starting It is fundamental to star-delta starting that the three-phase motor has the necessary numbers of leads for both connections: 6 leads for Y/Δ or 12 leads for YY/ΔΔ All the connections for the various voltages are made through terminals in the terminal box in accordance with the wiring diagram that accompanies the motor. a test resistance and a terminal changeover switch. b) Motor locked rotor current is low with no effect on the networks. THERMOSTAT (THERMAL PROBE): bimetallic thermal detectors with normally closed silver contacts. reduced voltage indirect starting methods can be employed to lower the locked rotor current. low voltage. two types of protection: motor . locked rotor. either due to restrictions imposed by the power supply authority or due to the installation itself. usually a fixed or adjustable thermal relay equal or less than to the value derived from multiplying the rated feed current at full load by: . inadequate motor ventilation) such as a thermostat (thermal probe).3 Start-up 3. depending upon the type. or actuates an alarm system. thermistor (PTC). This can be achieved under one of the following situations: a) The rated main supply current is high enough for the locked rotor current not to be proportionally high. This diagram may be shown on the nameplate or in the terminal box. circuit breaker or combined alarm and circuit breaker. b) Check that the motor is firmly secured and that coupling elements are correctly mounted and aligned. are series or parallel-connected to a control unit that cuts out the motor feed. with two leads from the terminal box to the alarm or circuit breaker system and four for the combined system (alarm and circuit breaker). or by an independent device. There are DOL starter assemblies available combining a threepole contactor. 3.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS overload. The RTD operates on the principle that the electrical resistance of a metallic conductor varies linearly with the temperature. Only three terminals of the motor are connected to the switch. such that during the starting cycle no supply disturbance to others on the power network is caused by the voltage drop in the main supply. The star-delta connection is usually used only in low-voltage motors due to normally available control and protection devices. In this method of starting the locked rotor current is approximately 30% of the original LRC. in principle.15 for motors with service factor equal to 1. Some motors are optionally fitted with overheating protective detectors (in the event of overload.3. THERMISTORS: Semi-conductor heat detectors positive temperature coeficient (PTC) that sharply change their resistance upon reaching a set temperature.1 Preliminary Inspection Before starting a motor for the first time. and a fuse (short circuit protection on branch circuit). For this reason.1.PT 100 The resistance type heat detector (RTD) is a resistance element usually manufactured of copper or platinum. The main electrical supply should be rated sufficiently. Thermostats are series connected directly to the contactor coil circuit by two conductors.3 Motor Protection 18 Motor circuits have. when the locked rotor current (LRC) does not influence the main electric supply lines. consequently. Table 9 compares the two methods of protection. Thermistors.. c) The motor is started under no-load conditions with a short starting cycle and. locked rotor and protection of branch circuit from short circuits.2. in response to the thermistors reaction. only feasible however.25 for motors with a service factor equal or superior to 1. a bimetal relay (overload protection device). The locked rotor torque is reduced proportionally as well. the other being interconnected as per diagram.1.15 or. three (one per phase) or six (two per phase) protective devices can be fitted to a motor for the alarm stems.0. These open at pre-determined temperatures. The single line connection diagram (C) shows the basic components of a compensating switch featuring a transformer (usually an autotransformer) with a series of taps corresponding to the different values of the reduced voltage. Resistance temperature detectors (RTD) . a low locked rotor current with a transient voltage drop tolerable to other consumers. it is very important before deciding to use star-delta starting to verify if the reduced locked rotor torque in “STAR” connection is enough to accelerate the load. starting current can reach these high levels. DOL starting is the simplest method. Motors in continuous use should be protected from overloading by means of a device incorporated into the motor. Obstructed ventilation Caption: unprotected partially protected totally protected 19 . reversals and frequent starts 4. Frequency fluctuation on main supply 9. the motor must be grounded in accordance with prevalent standard for grounding electrical machines. Table 9 . Locked rotor 6.2 times rated current 2. This screw is generally to be found in the terminal box or on one foot of the frame. f) Check that motor leads connecting with the mains. h) Start the motor uncoupled to ascertain that it is turning in the desired direction. The screw identified by the symbol should be used for this purpose. Operating with more than 15 starts p/hour 5.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS indicated on the nameplate. d) Check that connections are in accordance with the connection diagram shown on the nameplate and be sure that all terminal screws and nuts are tight.Comparison between motor protection system Current-based protection Fuse only Fuse and thermal protector Protection with probe thermistor in motor Causes of overheating 1. g) If the motor has been stored in a damp place. External heating caused by bearings. Motor performance will be satisfactory with main supply voltage fluctuation within ten per cent of the value indicated on the nameplate or a frequency fluctuation within five per cent or. e) Check the motor for proper grounding. yet. as well as the control wires and the overload protection device. Duty cycles S1 to S8 IEC 34. 11. High voltage motors bearing an arrow on the frame indicating rotation direction can only turn in the direction shown. invert two terminal leads of the mains supply. Overload with 1. To reverse the rotation of a three-phase motor. EB 120 3. Providing that there are no specifications calling for ground-insulated installation. with a combined voltage and frequency variance within ten per cent. Excessive ambient temperature 10. Fault on one phase 7. Brakings. Execessive voltage fluctuation 8. or has been stopped for some time. are in accordance with Nema Standards. pulleys etc. measure the insulating resistance as recommended under the item covering storage instructions. belts. INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS CONNECTION DIAGRAMS a) Direct starting POWER NETWORK b) Star-Delta starting POWER NETWORK c) Auto-transformer starting POWER NETWORK 20 . a) Three-phase motor with cage rotor: Open the stator circuit switch. also shown on the nameplate.3.2 The First Start-up Three-Phase Motor with Cage Rotor After careful examination of the motor. 21 . All measuring and control instruments and apparatus should be continuously checked for anomalies. With the motor at a complete stop.3 Operation Drive the motor coupled to the load for a period of at least one hour while watching for abnormal noises or signs of overheating. reset the auto-transformer. 3.4 Stopping Warning: To touch any moving part of a running motor. even though disconnected. Under continuous running conditions without load fluctuations this should not exceed the rated current times the service factor. to the “start” position. if any. follow the normal sequence of starting operations listed in the control instructions for the initial start-up.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 3. Compare the line current with the value shown on the nameplate. 3. and any irregularities corrected.3.3. is a danger to life and limb. E.) 6202 Z 6202 Z 6202 Z 6202 Z / 6203 Z 6204 ZZ 6204 ZZ 6206 ZZ 6206 ZZ 6205 ZZ 6205 ZZ 6207 ZZ 6207 ZZ 6207 ZZ 6207 ZZ 6209 Z-C3 6209 Z-C3 6209 Z-C3 6209 Z-C3 6211 Z-C3 6211 Z-C3 6212 Z-C3 6212 Z-C3 6314-C3 6314-C3 6314-C3 6314-C3 6314-C3 6414-C3 6316-C3 6314-C3 6316-C3 6314-C3 6316-C3 6314-C3 6319-C3 6314-C3 6316-C3 6314-C3 6316-C3 6314-C3 6319-C3 6314-C3 6319-C3 6314-C3 6319-C3 6314-C3 ODP Motors Nema-T frames E143/5T F143/5T 182 T 184 T 213/5T 254 T 256 T 284 T 284 TS 286 T 286 TS 324 T 324 TS 326 T 326 TS 364 T 364 TS 365 T 365 TS 404 T 404 TS 405 T 405 TS 444 T 444 TS 445 T 445 TS Mounting Bearings Front (D.D.D.Bearing specifications by type of motor NEMA Frames B48 and C48 56 and A56 B56 and C56 D56 and F56H/G56H 143 T 145 T 182 T 184 T W 182 T W 184 T 213 T 215 T W 213 T W 215 T 254 T 256 T W 254 T W 256 T 284 T and TS 286 T and TS 324 T and TS 326 T and TS 364 T and TS 365 T and TS 404 T 404 TS 405 T 405 TS 444 T 444 TS 445 T 445 TS 447 T 447 TS 449 T 449 TS 504 T 504 TS 505 T 505 TS 5008 T 5008TS 586 T 586 TS 587 T 587 TS Saw Arbor motor frame 80 S MS 80 M MS 80 L MS 90 L MS Mounting Bearings Rear (O.L 100 L 112 M 132 S .M 160 M .L 200 M .E.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Table 11 .) 6307 ZZ 6307 ZZ 6307 ZZ 6308 ZZ Rear (O.D.E.) 6205 ZZ 6205 ZZ 6206 ZZ 6202 ZZ 6208 ZZ 6309 Z-C3 6309 Z-C3 6311 Z-C3 6311 Z-C3 6311 Z-C3 6311 Z-C3 6312 Z-C3 6312 Z-C3 6312 Z-C3 6312 Z-C3 6314 C3 6314 C3 6314 C3 6314 C3 NU 316 C3 6314 C3 NU 316 C3 6314 C3 NU 319 C3 6314 C3 NU 319 C3 6314 C3 Rear (O.) Rear (O.L 225 S/M 250 S/M 280 S/M 315 S/M 355 M/L HORIZONTAL MOUNTING ONLY Bearings Front (D.) 6207 ZZ 6207 ZZ 6207 ZZ 6208 ZZ Front (D.) Totally enclosed fan cooled motors 6201 ZZ 6201 ZZ 6203 ZZ 6202 ZZ 6204 ZZ 6203 ZZ 6205 ZZ 6204 ZZ 6206 ZZ 6205 ZZ 6307 ZZ 6206 ZZ 6308 ZZ 6207 ZZ 6309-C3 6209 Z-C3 B3 6311-C3 6211 Z-C3 6312-C3 6212 Z-C3 6314-C3 6314-C3 6314-C3 6314-C3 6314-C3 6314-C3 6316-C3 6316-C3 6314-C3 6314-C3 6319-C3 6316-C3 6314-C3 6314-C3 NU 322-C3 6319-C3 Mounting Bearings B3 22 .D.) 6204 ZZ 6204 ZZ 6205 ZZ 6205 ZZ 6206 ZZ 6209 Z-C3 6209 Z-C3 6211 Z-C3 6211 Z-C3 6211 Z-C3 6211 Z-C3 6212 Z-C3 6212 Z-C3 6212 Z-C3 6212 Z-C3 6314 C3 6314 C3 6314 C3 6314 C3 6314 C3 6314 C3 6314 C3 6314 C3 6316 C3 6314 C3 6316 C3 6314 C3 Totally enclosed fan cooled motors 6205 ZZ 6205 ZZ 6307 ZZ 6307 ZZ 6206 ZZ 6206 ZZ 6308 ZZ 6308 ZZ 6308 ZZ 6308 ZZ 6309-C3 6309-C3 6309-C3 6309-C3 6311-C3 6311-C3 6312-C3 6312-C3 6314-C3 6314-C3 NU 316-C3 6314-C3 NU 316-C3 6314-C3 NU 319-C3 6314-C3 NU 319-C3 6314-C3 NU 319-C3 6314-C3 NU 322-C3 6314-C3 NU 319-C3 6314-C3 NU 319-C3 6314-C3 NU 322-C3 6314-C3 NU 322-C3 6314-C3 NU 322-C3 6314-C3 ALL FORMS Mounting ALL FORMS Front (D.) Open drip proof motors 6203 Z 6203 Z 6203 Z 6204 Z IEC frame 63 71 80 90 S .E.E.E.L 180 M .E.E. 61 0.Lubrication Intervals > 20.47 1.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Table 12 .86 0.25 0.29 0.22 1.07 0.39 0.07 0.SINGLE-ROW FIXED BALL BEARINGS Lubrication intervals (running hours) Bearings Characteristics Ref.54 0. 2) Bearings for motors of X and XII poles .50 0.32 0.07 0.96 1. 23 .14 1) Lubrication periodicity valid for NLG 1 and lithium based bearing lubricant.000.18 0.11 0.32 1.14 0.25 0. 6200 6201 6202 6203 6 2 S E R I E S 6204 6205 6206 6207 6208 6209 6210 6211 6212 6213 6214 6215 6216 II Pole 60Hz 3600 rpm 12500 11700 10500 9800 8700 8000 7300 6600 5900 5300 4900 4300 3800 3100 1100 1000 700 50Hz 3000 rpm 13800 13000 11900 11200 10100 9400 8700 8100 7400 6900 6400 5900 5400 4900 2000 1800 1600 16600 15400 14500 13300 12600 12000 11400 10800 10400 9700 9500 9300 8900 4100 4400 4100 18400 17100 16200 14800 14100 13400 12700 12000 11600 11000 10900 10300 10100 5000 5000 4700 19500 18500 17100 16200 15400 14500 13700 13400 12900 12700 12400 12200 5900 5600 5700 19100 18200 17200 16300 15300 15000 14600 14400 14300 14000 6500 6300 6500 19300 18300 17300 16300 16000 15600 15300 15200 14800 6900 6700 6800 19200 18200 17800 17300 17000 16500 16100 7600 7600 7500 > 20000 IV Pole 60Hz 1800 rpm 50Hz 1500 rpm VI Pole 60Hz 1200 rpm 50Hz 1000 rpm VIII Pole 60Hz 900 rpm 50Hz 750 rpm X Pole 60Hz 720 rpm 50Hz 600 rpm XII Pole 60Hz 600 rpm 50Hz Amount 500 of grease rpm (oz) 0.29 0.68 6304 6305 6306 6307 6308 6 3 S E R I E S 6309 6310 6311 6312 6313 6314 6315 6316 6317 6318 6319 6320 6321 6322 8700 8000 7300 6600 5900 5300 4900 4300 3800 3100 1100 1000 700 800 - 10100 9400 8700 8100 7400 6900 6400 5900 5400 4900 2000 1800 1600 1300 1000 800 - 13300 12600 12000 11400 10800 10400 9700 9500 9300 8900 4100 4400 4100 3900 3800 3700 3600 3400 3100 14800 14100 13400 12700 12000 11600 11000 10900 10300 10100 5000 5000 4700 4700 4600 4500 4300 4200 4000 17100 16200 15400 14500 13700 13400 12900 12700 12400 12200 5900 5600 5700 5600 5500 5400 5300 5100 5000 19100 18200 17200 16300 15300 15000 14600 14400 14300 14000 6500 6300 6500 6300 6200 6100 6000 5800 5700 19300 18300 17300 16300 16000 19500 15300 15200 14800 6900 6700 6800 6700 6600 6500 6300 6200 6100 19200 18200 17800 17300 17000 16500 16100 7600 7600 7500 7400 7200 7100 7000 6800 6700 18600 18200 17700 17400 16800 16400 7700 7900 7700 7500 7400 7300 7100 7000 6900 19900 19500 19000 18200 17900 8600 8900 8500 8300 8200 8000 7900 7800 7700 19500 19000 18200 17900 8600 8900 8500 8300 8200 8000 7900 7800 7700 19700 9600 9900 9500 9300 9100 8900 8800 8700 8600 > 20000 0.46 0.14 0.46 0.Bearing lubrication intervals and amount of grease 1 .39 0.82 2.61 1.00 2.14 0.54 0.75 0.32 0.21 0.07 1.64 0. INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS Table 13 - Bearing lubrication intervals and amount of grease 2 - CYLINDRICAL ROLLER BEARINGS Lubrication intervals (running hours) Bearings Characteristics Ref. NU309 N U 3 NU310 NU311 NU312 NU313 NU314 NU315 S E R I E S NU316 NU317 NU318 NU319 NU320 NU321 NU322 II Pole 60Hz 3600 rpm 2800 2400 2000 1600 1500 700 50Hz 3000 rpm 4000 3600 3200 2700 2500 1100 900 800 600 IV Pole 60Hz 1800 rpm 8300 7900 7400 6900 6600 3100 2900 2800 2600 2100 2300 2000 1900 1900 50Hz 1500 rpm 9500 9100 8700 8300 8100 3900 3800 3600 3500 3300 3200 3000 2800 2600 VI Pole 60Hz 1200 rpm 10700 10300 10000 9600 9400 4600 4500 4400 4300 4300 4100 4000 4000 3900 50Hz 1000 rpm 11800 11400 11000 10700 10500 5200 5100 5000 4900 4900 4700 4700 4600 4400 VIII Pole 60Hz 900 rpm 12500 12200 11800 11400 11200 5500 5500 5400 5300 5300 5100 5000 4900 4800 50Hz 750 rpm 14100 13700 13300 12800 12700 6200 6200 6100 6000 5900 5800 5700 5600 5500 X Pole 60Hz 720 rpm 14500 14000 13600 13200 13000 6400 6300 6200 6100 6000 6000 5900 5700 5600 50Hz 600 rpm 16300 15800 15400 14900 14700 7200 7100 7000 6900 6700 6700 6600 6500 6400 XII Pole 60Hz 600 rpm 16300 15800 15400 14900 14700 7200 7100 7000 6900 6700 6700 6600 6500 6400 50Hz Amount 500 of grease rpm (oz) 18200 17700 17200 16800 16500 8100 7900 7800 7700 7500 7500 7300 7200 7100 0,46 0,54 0,64 0,75 0,86 0,96 1,07 1,22 1,32 1,47 1,61 1,82 2,00 2,14 1) Lubrication periodicity valid for NLG 1 and 2 lithium based bearing lubricant. 24 INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 4. Maintenance A well-designed maintenance program for electric motors can be summed up as: periodical inspection of insulation levels, temperature rise, wear, bearing lubrication and the occasional checking of fan air flow. Inspection cycles depend upon the type of motor and the conditions under which it operates. period. Lubrication intervals, the amount of grease and the type of bearing used in frames 140T to 580T are to be found in Tables 11, 12 and 13. Lubrication intervals depend upon the size of the motor, speed, working conditions and the type of grease used. 4.2.2 Quality and Quantity of Grease 4.1 Cleanliness Motors should be kept clean, free of dust, debris and oil. Soft brushes or clean cotton rags should be used for cleaning. A jet of compressed air should be used to remove non-abrasive dust from the fan cover and any accumulated grime from the fan and cooling fins. Oil or damp impregnated impurities can be removed with rags soaked in a suitable solvent. Terminal boxes fitted to motors with IP55 protection should be cleaned; their terminals should be free of oxidation, in perfect mechanical condition, and all unused space dust-free. Motors with IPW 55 protection are recommended for use under unfavourable ambient conditions. Correct lubrication is important! Grease must be applied correctly and in sufficient quantity as both insufficient or excessive greasing are harmful. Excessive greasing causes overheating brought about by the greater resistance encountered by the rotating parts and, in particular, by the compacting of the lubricant and its eventual loss of lubricating qualities. This can cause seepage with the grease penetrating the motor and dripping on the coils. A lithium based grease is commonly used for the lubrication of electric motor bearings as it has good mechanical stability, is insoluble in water and has a drip point of approximately 200°C. This grease should never be mixed with sodium or calcium based greases. GREASES FOR MOTOR BEARINGS For operating temperatures from - 20 to 130°C Frame 143T-215T 254T to 586/7 Substitutes Supplier Mobil ESSO Atlantic Texaco Molikote Inisilkon Grease Mobilith SHC100 Beacon 2 Litholine 2 Multifak 2 BG 20 L5012 Temperature Range -40 to 177ºC -20 to 130ºC -20 to 130ºC -20 to 130ºC -45 to 180ºC -20 to 200ºC Supplier Esso Shell Grease Alvania R3 Unirex N2 Temperature range -20 to 130ºC -30 to 165ºC 4.2 Lubrication Proper lubrication extends bearing life. Lubrication Maintenance Includes: a) Attention to the overall state of the bearings; b) Cleaning and lubrication; c) Critical inspection of the bearings. Motor noise should be measured at regular intervals of one to four months. A well-tuned ear is perfectly capable of distinguishing unusual noises, even with rudimentary tools such as a screw driver, etc., without recourse to sophisticated listening aids or stethescopes that are available on the market. A uniform hum is a sign that a bearing is running perfectly. Bearing temperature control is also part of routine maintenance. The temperature of bearings lubricated as recommended under item 4.2.2 should not exceed 70°C. Constant temperature control is possible with the aid of external thermometers or by embedded thermal elements. WEG motors are normally equipped with grease lubricated ball or roller bearings. Bearings should be lubricated to avoid metallic contact of the moving parts, and also for protection against corrosion and wear. Lubricant properties deteriorate in the course of time and mechanical operation: furthermore, all lubricants are subject to contamination under working conditions. For this reason lubricants must be renewed and any lubricant consumed needs replacing from time to time. Note: When changing lubricant, please follow manfacturers instructions 4.2.3 Lubricating Instructions a) Frame 140T to 210T motors Frame 140T to 210T size motors are not fitted with grease nipples. Lubrication is carried out during periodical overhauls when the motor is taken apart. Cleaning and Lubrication of Bearings With the motor dismantled and without extracting the bearings from the shaft, all existing grease should be removed and the bearings cleaned with Diesel oil, kerosene or other solvent, until thoroughly clean. 25 4.2.1 Periodical Lubrication WEG motors are supplied with sufficient grease for a long INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS running Refill the spaces between the balls or rollers and the bearing cages with grease immediately after washing. Never rotate bearings in their dry state after washing. For inspection purposes apply a few drops of machine oil. During these operations maximum care and cleanliness is recommended to avoid the penetration of any impurities or dust that could harm the bearings. Clean all external parts prior to reassembly. Nipples must be clean prior to introduction of grease to avoid entry of any alien bodies into the bearing. For lubricating use only a manual grease gun. Bearing Lubrication Steps 1. Cleanse the area around the grease nipples with clean cotton fabric. 2. With the motor running, add grease with a manual grease gun until the lubricant commences to be expelled from the bleeder outlet, or until the quantity of grease recommended in Tables 12 or 13 has been applied. 3. Allow the motor to run long enough to eject all excess grease. b) Frame 360T to 580T Motors Motors above 360T frame size are fitted with regreasable bearing system. The lubrication system from this frame size upwards was designed to allow the removal of all grease from the bearing races through a bleeder outlet which at the same time impedes the entry of dust or other contaminants harmful to the bearing. This outlet also prevents injury to the bearings from the wellknown problem of over-greasing. It is advisable to lubricate while the motor is running, to allow the renewal of grease in the bearing case. Should this procedure not be possible because of rotating parts in the proximity of the nipple (pulleys, coupling sleeves, etc.) that are hazardous to the operator the following procedure should be followed: - Inject about half the estimated amount of grease and run the motor at full speed for approximately a minute; switch off the motor and inject the remaining grease. The injection of all the grease with the motor at rest could cause penetration of a portion of the lubricant through the internal seal 4.2.4 Replacement of Bearings The opening of a motor to replace a bearing should only be carried out by qualified personnel. Damage to the core after the removal of the bearing cover can be avoided by filling the gap between the rotor and the stator with stiff paper of a proper thickness. Providing suitable tooling is employed, disassembly of a bearing is not difficult. The extractor grips should be applied to the sidewall of the inner ring to be stripped, or to an adjacent part. To ensure perfect functioning and to prevent injury to the bearing parts, it is essential that the assembly be undertaken under conditions of complete cleanliness and by competent personnel. New bearings should not be removed from their packages until the moment of assembly. Prior to fitting a new bearing, ascertain that the shaft has no rough edges or signs of hammering. Figure 4.2 - A bearing extractor of the bearing case and hence into the motor. Figure 4.1 - Bearings and lubrication system During assembly bearings cannot be subjected to direct blows. The aid used to press or strike the bearing should be applied to the inner ring. 26 emery papers or tools be used that could affect the dimensions of any part during cleaning. see that the outlets and areas around the cables are perfectly sealed. Protective varnish on machined parts should be removed soon after treating with impregnating varnish. STRIPPING OF WINDINGS This step requires great care to avoid knocking and/or denting of enclosure joints and. Assemble using a rubber headed mallet and a bronze bushing after ascertaining that all parts are perfectly fitted. in many areas it is required that explosion proof motors ONLY be repaired by licensed personnel or in licensed facilities authorized to do this type of work.4. Bolts should be positioned with corresponding spring washers and evenly tightened. 4. Mount the terminal box and paint the motor. Miscellaneous Recommendations 27 . consult WEG. The gap variation at any two vertically opposite points must be less than 10% of the average gap measurement.1 Objective In view of the heavy liability associated with burning of motors of this type. MOUNTING THE TERMINAL BOX Prior to fitting the terminal box all cable outlets on the frame should be sealed with a sealing compound (Ist layer) and an Epoxy resin (ISO 340) mixed with ground quartz (2nd layer) in the following proportions: 340A resin 340B resin Ground quartz 50 parts 50 parts 100 parts 4.4 Explosion Proof Motor Repair Steps 4. • Should any doubts arise. disassemble all parts and clean them with kerosene.2 Dismantle the damaged motor with appropriate tools without hammering and/or pitting machined surfaces such as enclosure joints. ASSEMBLY Inspect all parts for defects. when removing the sealing compound from the terminal box.ISOLASIL). safeguards. Protect all machined parts against oxidation by applying a coating of vaseline or oil immediately after cleaning. damaged threads and other potential problems. Under no circumstances should scrapers. this product has been designed and manufactured to high technical standards.4. This operation should be carried out manually without using tools. damage or cracking of the frame.3 • Any damaged parts (cracks. pittings in machined surfaces. The position of the fan cover should be suitably marked prior to removal so as to facilitate reassembly later on. Repair Procedure and Precautions Drying time for this mixture is two hours during which the frame should not be handled and cable outlets should be upwards.4. When dry. such as cracks. and guidelines must be followed in order to ensure repaired explosion proof motors operate as intended. defective threads) must be replaced and under no circumstances should attempts be made to recover them. and the joint between terminal box and frame. 4. Air Gap Checking (Large Rating Open Motors) 4. The following general procedures. • Upon reassembling explosion proof motors IPW55 the substitution of all seals is mandatory. Carry out running tests as for standard motors. by coating it with a non-adhesive varnish (ISO 287 . and all joints in general. In addition.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS IMPREGNATION Protect all frame threads by inserting corresponding bolts. joint incrustations.3 Upon the completion of any work on the bearings check the gap measurement between the stator and the rotor using the appropriate gazes. under rigid controls. TESTING Rotate the shaft by hand while examining for any drag problems on covers or fastening rings. fastening holes. Examine the motor’s general condition and. if necessary. steps should be taken to restrain and suffocate it by covering the ventilation vents. The absorted current will be so high that the winding will burn out in a few seconds if the fuses or a wrongly set protective switch fail to react promptly. In the event of fire. detection and repairs. When failures of an electric or mechanical nature arise. a magnetic hum becomes audible. b) starting with or without load. As it only develops 1/3 of its torque. The perfect functioning of motor operating under these conditions is only assured when the following values are heeded: a) number of starts per hour. there follows a summary of possible failures and their probable causes. Probable cause 3 The star-delta switch is not commutated and the motor continues to run for a time connected to the star under overload conditions. A protective switch placed before the motor would easily solve this problem. 0ne of the winding phases remains currentless while the others absorb the full voltage and carry an excessive current. sudden changes of bearing temperatures. Probable cause 4 Failures from this cause arise from thermal overload. sparking or unusual slip ring or brush wear. In some cases. the three-phase current imbalance can be so insignificant that the motor protective device fails to react. Probable cause 2 Motor incorrectly connected. Consequently. tolerate a voltage surge of 30% at the time of testing for shorting between turns. In most instances.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 5. the protective switch will not react. may not exceed the rated value for the delta connection. the motor cannot reach rated speed. declining insulation resistance. The increased slip results in higher ohmic losses arising from the Joule effect. A short circuit between turns. For example: A motor with windings designed for 230/400V is connected through a star-delta switch to 400V connection. As the stator current. fails in one main conductor. and later fail due to humidity. Consequent to increased winding and rotor losses the motor will overheat and the winding burn out. Most winding defects arise when temperature limits. it nearly always occurs during the early stages of operation. dust or vibration. the current will increase from 3.5 times in the remaining winding with a simultaneous marked fall in speed. even the best quality wires can have weak spots. Malfunctioning Most malfunctions affecting the normal running of electric motors can be prevented by maintenance and the appropriate precautions. Depending on the intensity of the short. c) mechanical brake or current inversion. cleanliness and careful maintenance are the main factors ensuring long motor life. While ventilation. due to too many starts under intermittent operation or to an overly long starting cycle. and phases to ground due to insulation failure is rare. c) Three burnt winding phases Probable cause 1 Motor only protected by fuses. The slip almost doubles. speed during acceleration and braking. the first step to be taken is to stop the motor and subsequent examination of all mechanical and electrical parts of the installation. The continuous effort exerted by the rotor during intermittent 5. These defects are identified by the darkening or carbonizing of wire insulation. dry chemical or C02 extinguishers should be used . or the result of defects arising simultaneously on two adjacent wires. progressive carbonizing of the wires and insulation culminate in a short circuit between turns.1 Standard Three-Phase Motor Failures Owing to the widespread usage of asynchronous three-phase motors in industry which are more often repaired in the plant workshops. As wires are randomly tested. due to current overload. b) Two burnt winding phases This failure arises when current fails in one main conductor and the motor winding is star-connected. To extinguish a fire. 5.never water. Weak spots can.1. In the event of fire within the motor itself. are surpassed throughout the winding or even in only portions thereof. which is normally done by turning off the respective switches. 5. and even so. on occasion. this defect is due to the absence of a protective switch. an overload on the motor will be the cause of the trouble. Current rises from 2 to 2. or a short against the frame occurs.1. If the motor stops. shaft knock. or else the switch has been set too high.1 Short Circuits Between Turns A short circuit between turns can be a consequent of two coinciding insulation defects. smoke or fire. Motors are generally designed to Class B or F insulation and for ambient temperatures up to 40°C. the installation should be isolated from the mains supply. a further essential factor is the prompt attention to any malfunctioning as signalled by vibrations. d) acceleration of rotating masses connected to motor shaft e) load torque vs.2 Winding Failures a) One burnt winding phase This failure arises when a motor runs wired in delta and current 28 . consistent with the load.5 to 4 times its rated value. As a rule.1. this practice fails to consider the load on the bearing and the result is bearing failure within a short time. will be an unsymmetrical rotor winding. In squirrel-cage motors the cause will nearly always be a break in one or more of the rotor bars. Underestimating the distance between the drive pulley and the driven pulley is a common occurrence. by too many starts or overlong starting cycles. in most cases. Under certain circumstances with the motor idle there is a possibility that the stator winding is subjected to damage as a result of the heating of the motor. Avoid additional drilling the shaft (fastening screw holes) as such operations tend to cause stress concentration. Shaft fracture can occur in more serious cases. Any used. This failure can also arise from insufficient main voltage. while new and unstretched belts are placed on the same drive turning farther from the bearing. 5.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS As a consequence of alternating bending stress induced by a rotating shaft. fractures occur right behind the drive end bearing. Additionally there is the possibility of the shaft being subjected to unacceptably high loads when the motor is fitted with a pulley that is too wide. 5. Keyways with edges pitted by loosely fitted keys can also bring about shaft failures.1.6 Unbalanced V-Belt Drives 5. couplings or pinions. Within a short while these malpractices cause the deterioration of the bearings and the enlargement of the bearing cover bracket located on the drive end side. Poorly aligned couplings cause knocks and radial and axial shaking to shaft and bearings. In such a case. This can be caused by overly high slip.3 Rotor Failures If a motor running under load conditions produces a noise of varying intensity and decreasing frequency while the load is increased. starting brings about heavier losses which provoke overheating. When the rotor stack acquires a blue or violet coloration. and are often interpreted as such. can augment shaft stress. Should there be failures in various contiguous bars. simultaneously. Admittably. a slip ring motor is recommended as a large portion of the heat (due to rotor losses) is dissipated in the rheostat. The substitution of only one of a number of other parallel belts on a drive is frequently the cause of shaft fractures.1. periodical stator current fluctuations may be recorded. However. The arc of contact of the belt on the drive pulley thus becomes inadmissibly small and thereby belt tension is insufficient for torque transmission. In spite of this it is quite usual to increase belt tension in order to attain sufficient drive.5 Shaft Fractures Although bearings traditionally constitute the weaker part. fractures travel inwards from the outside of the shaft until the point of rupture is reached when resistance of the remaining shaft cross-section no longer suffices. In most cases. this is feasible with the latest belt types reinforced by synthetic materials. 5. this defect appears only in molded or die cast aluminum cages. The defect is recognized by the scratches that appear on the shaft or the eventual scalelike flaking of the shaft end. 5. it is a sign of overloading. as well as being malpractice. especially those closest to the motor.1. vibrations and shuddering can occur as if due to an unbalance.4 Bearing Failures Bearing damage is a result of overloading brought about by an overly taut belt or axial impacts and stresses. 29 . Failures due to spot heating in one or another of the bars in the rotor stack are identified by the blue coloration at the affected points. There parts “knock” when rotating.1. and consequently stretched belts retained on the drive. and the shafts are designed with wide safety margins. the reason.7 Damage Arising from Poorly Fitted Transmission Parts or Improper Motor Alignment Damage to bearing and fracture in shafts often ensue from inadequate fitting of pulleys. it is not beyond the realm of possibility that a shaft may fracture by fatigue from bending stress brought about by excessive belt tension. Excessive axial or radial strain on belt Deformed shaft Rough bearing surface Loose or poorly fitted motor end shields 6. Unbalance 2. High noise level 1. Wrong control connections 4.No voltage supply 2. • Reduce belt tension. • Balance rotor statically and dynamically. Low voltage supply 3. • Compare connections with the wiring diagram on the motor nameplate. Unbalanced electrical load (burnt fuse. 4. 3. replace bearing. • Check voltage supply and ascertain that voltage remains within 10% of the rated voltage shown on the motor nameplate. • Have shaft straightened and check rotor balance.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS 5. Incorrect voltages and frequecies 4. If necessary. • Replace bearings before they damage shaft. Excessive grease 2. • Shaft key bent. 6. Reassemble only if rotating and support surfaces are unharmed. • Dismantle motor and remove dirt or dust with jet of dry air. check rotor balance and eccentricity. • If bearing rings are in perfect condition. 3. Lack of grease 7. Bearing rings too tight on shaft and/or bearing housing 4. • Check shaft for warping or bearing wear. • Dismantle motor and clean. there may be an overload condition or a blocking of the starting mechanism. Remove trash or debris from motor vicinity. it is advisable to ascertain that bearing dimensions correspond to manufacturer’s specifications. clean and relubricate the bearing. • Vibrations can be eliminated by balancing rotor. Obstructed cooling system 2. incorrect control) 30 . • Before altering shaft or housing dimensions. • Compare values on motor nameplate with those of mains supply. otherwise. Distorted shaft Incorrect alignment Uneven air gap Dirt in the air gap Extraneous matter stuck between fan and motor casing 7. • Take bearing apart and clean. 5. the load can be unbalanced. • Check bearing wear and shaft curvature. • Check end shields for close fit and tightness around circumference. • Check for unbalanced voltages or operation under single-phase condition. 4. • Tighten all connections. Overload CORRECTIVE MEASURES • Check feed connections to control system and from this to motor. Also check voltage at motor terminals under full load. Foreign material in grease Intense bearing vibration 1. • Exchange motor for another that meets needs. Reduce load to rated load level and increase torque. • Replace bearings. Dirty or worn bearing 3. • Check lubrication. • Clean and dry motor. • Remove grease bleeder plug and run motor until excess grease is expelled. Rotor dragging on stator 6. Frequent inversions 5. • Tighten all foundation studs. realign motor. • Try to start motor under no-load conditions. • Check application. Hardened grease cause locking of balls 8. 5. Overload 3. Unbalanced rotor 2. Loose motor foundation 8. If it starts. measuring voltage and current under normal running conditions. • Add grease to bearing. Extraneous solid particles in bearing Overheating of motor 1. Loose connection at some terminal lug 5. Replace bearing if noise is excessive and continuous. Worn bearings Overheating of bearings 1. • Check motor aligment with machine running. • Flush out housings and relubricate. inspect air vents and windings periodically.2 Troubleshooting chart FAILURE Motor fails to start PROBABLE CAUSE 1. If load is coupled directly to motor shaft. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Nameplate Frame Shaft key Drive end bearing cap Drive end bearing Drive andshield Drive end grease nipple cover Drive endshield washer Drive end endshield fixing bolt Drive end bearing cap washer V’Ring Drive end bearing cap fixing bolt Drain plug Non-drive and grease relief Drive end grease relief Description 31 .W250T .6. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Non-drive end endshield fixing bolt Non-drive end bearing cap washer Non-drive end grease nipple Non-drive end grease nipple cover Non-drive end endshield washer Non-drive endshield Spring washer Non-drive end bearing Non-drive end bearing cap Fan fixing pin Wound stator Rotor and shaft Eyebolt Nameplate fixing rivet Description Part Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Terminal box cover Terminal box cover fixing bolt Terminal box cover gasket Terminal box fixing bolt Terminal box fixing washer Terminal box grounding lug Terminal box Frame grounding lug Terminal box o’ring gasket Fan cover Fan cover washer Fan cover fixing bolt Fan Non-drive end bearing cap bolt V’Ring Description Part Nr.210T and W210T Part Nr. Spare Parts and Component Terminology INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS THREE-PHASE MOTORS IP55 NEMA Frames 140T . 25 26 27 28 29 33 31 Shaft key Drive end bearing Drive endshield Drive endshield washer Drive end endshield fixing bolt V’Ring Drain plug Description THREE-PHASE MOTORS IP55 NEMA Frames 250T . 1 2 3 4 5 6 7 8 9 10 11 12 Terminal box cover Terminal box cover fixing bolt Terminal box cover gasket Terminal box fixing bolt Terminal box fixing washer Terminal box grounding lug Terminal box Frame grounding lug Terminal box o’ring gasket Fan cover Fan cover fixing bolt Fan Description Part Nr.180T . 13 14 15 16 17 18 19 20 21 22 23 24 V’Ring Non-drive end endshield fixing bolt Non-drive end endshield washer Non-drive endshield Spring washer Non-drive bearing Fan fixing pin Wound stator Rotor / shaft assembly Nameplate fixing rivet Nameplate Frame Description Part Nr.W180T .280T and 320T Part Nr. 500T and 580T Part Nr. 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Shaft key Internal drive end bearing cap Drive end bearing Drive endshield Drive end grease nipple cover Drive endshield washer Pre-load spring Drive end endshield fixing bolt External drive end bearing cap Drive end bearing cap washer V’Ring Drive end bearing cap fixing bolt Drain plug External non-drive end bearing cap Non drive end grease relief Non-drive end grease relief Description 32 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Terminal box cover Terminal box cover fixing bolt Terminal box cover washer Terminal box cover gasket Terminal box fixing bolt Terminal box fixing washer Terminal box grounding lug Terminal box Frame grounding lug Terminal box o’ring gasket Nameplate fixing rivet Nameplate Eyebolt Fan cover Fan cover washer Fan cover fixing bolt Fan fixing ring Description Part Nr.400T . 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Fan Non-drive end bearing cap bolt V’Ring Non-drive end bearing cap washer Non-drive end endshield fixing bolt Non-drive end endshield washer Non-drive end grease nipple Non-drive end grease nipple cover Non-drive enshield Bearing cap Non-drive bearing Internal non-drive end bearing cap Fan fixing key Wound stator Rotor / shaft assembly Frame Description Part Nr.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS THREE-PHASE MOTORS IP55 NEMA T Frames 360T .440T . 15 and 16 = 2 pieces 33 .D56 .F56H and G56H Part Nr.C48 . 1 2 3 4 5 6 7 Sticker Terminal box cover fixing bolt Terminal box cover Grounding lug Through bolt fastening nut Non-drive endshield Spring washer Description Part Nr.B56 .D56 .B56 . 2 = 3 pieces.A56 .C56 . 12 13 14 15 16 17 18 19 20 21 22 Stationary switch fastening bolt Centrifugal switch Rubber ring for lead passing hole to capacitor Capacitor cover Capacitor Wound stator Rotor / shaft assembly Frame Through bolt Shaft key Fan Description Part Nr.G56H Part Nr.INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS THREE-PHASE MOTORS NEMA 56 Frames A56 . 8 9 10 11 12 13 Non-drive end bearing Wound stator Rotor / shaft assembly Frame Through bolt Shaft key Description Part Nr.F56H . 2) Part nr. 14 15 16 17 Fan Drive end bearing fastening washer Drive end bearing Drive endshield Description SINGLE-PHASE MOTORS NEMA 56 Frames B48 . 1 2 3 4 5 6 7 8 9 10 11 Note: Sticker Capacitor cover fixing bolt Terminal box cover fixing bolt Terminal box cover Grounding lug Through bolt fastening nut Non-drive endshield Spring washer Non-drive and bearing Non-drive and bearing fastening washer Stationary switch Description Part Nr. 23 24 25 26 27 Drive end bearing fastening washer Drive end bearing Drive endshield Overload thermal protector fixing ring Overload thermal protector Description For F56H and G56H frame motors: 1) Part nr. INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS NOTES: 34 . INSTALLATION AND MAINTENANCE MANUAL FOR NEMA LOW VOLTAGE ELECTRIC MOTORS NOTES: 35 . THE FOLLOWING INSTALLATION AND MAINTENANCE MANUALS ARE AVAILABLE Low and High Voltage Large Motors Induction. 2100 Brighton-Henrietta Townline Road Rochester NY 14623 PHONE: 716-240-1000 FAX: 716-240-1034 . Slip Ring. WEG Electric Motors Corp. M Line. A Line DC Motors Tacho Generator Dynamo Generators “GTA” Line YOU CAN REQUEST THE ABOVE MANUALS FROM YOUR NEAREST WEG SALES OFFICE. H Line.