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l 10061218 – DC Motors – D Series

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Installation, Operation and Maintenance Manual

Document Number: 10061218

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

DCE, DCX, DCA and DCW

Language: English

Review 6

September 2012

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Dear Customer,

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

levels which ensure an outstanding performance.

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

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

storage, installation and maintenance.

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

configurations and operation of the motor.

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

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

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

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

ATTENTION

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

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

NOTES

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

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

WEG EQUIPAMENTOS ELÉTRICOS S.A.

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INDEX

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1.1 TERMINOLOGY

D N F 160 . 190 S

SPECIFIES A DIRECT CURRENT MACHINE

COMPENSATION

N – Non compensated motors C – Compensated motors COOLING TYPES

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

CORE LENGTH IN mm

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

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

DANGER

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

ATTENTION

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

NOTE

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

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

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

2.2 SAFETY INSTRUCTIONS

DANGER

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

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

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

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

ATTENTION

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

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

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

The specific determinations and conditions for local installation;

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

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

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

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

IEC NBR NEMA

Specification 60034-1 5116 MG1-1,10,20

Dimensions 60072 5432 MG1-4,11

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

Cooling 60034-6 5110 MG1-6

Mounting 60034-7 5031 MG1-4

Noise 60034-9 7565 MG1-9

Mechanical vibration 60034-14 5165 MG1-7

2.4 CHARACTERISTICS OF THE ENVIRONMENT

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

protection.

ATTENTION

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

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

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

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3 RECEIVING, STORAGE AND HANDLING

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

ATTENTION

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

ATTENTION

Parts supplied in additional packages must be checked upon receipt.

When lifting a package (or container), the correct

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

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

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

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

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

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

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

ATTENTION

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

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

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

ATTENTION

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

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

ATTENTION

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

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

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

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

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

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

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

not be subject to sudden temperature variations; Relative humidity <50%; Protection against dirt and dust accumulation; It must feature a fire detection system; The location must have power to supply the space

heaters. In case the storage location does not meet any of these requirements, WEG recommends that additional protections be incorporated to the motor package during the storage period, as follows: Closed wooden crate or similar with proper electrical

installation, providing power to the space heaters. If there is risk of infestation and fungus growth, the

package must be protected on the site by spraying or painting it with proper chemical agents;

Package preparation must be carefully executed by experienced personnel.

3.2.4.1.2 Outdoor storage

ATTENTION

Outdoor storage is not recommended (weather).

In case outdoor storage is unavoidable, the motor must be packed in a specific package for such condition, as follows: For outdoor storage, besides the packaging

recommended for internal storage, the package must be covered with a protection against dust, moisture and other foreign materials, using a resistant canvas or plastic.

The package must be placed on platforms or foundations, ensuring protection against dirt and moisture and keeping the motor from sinking into the soil;

After the motor is covered, a shelter must be constructed in order to protect it against direct rain, snow and excessive sun heat.

ATTENTION

In case the motor remains stored for long periods of time, it is recommended to inspect it regularly as specified in item Maintenance plan during storage of this manual.

3.2.4.2 Separate parts In case separate parts have been supplied (terminal

boxes, covers, etc.), these must be packed as specified in items Indoor Storage and Outdoor Storage of this manual;

Air relative humidity inside package must not exceed 50%.

3.2.4.3 Space heater The motor space heaters must remain powered during storage to avoid moisture condensation inside the motor and ensure that the windings insulation resistance remains within acceptable levels.

ATTENTION

The motor space heater must be powered on while it is stored in a place with temperatures < 5°C and air relative humidity >50%.

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

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

perform the tests in the motor.

ATTENTION

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

After 6 months of storage and before starting the

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

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

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

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

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

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

ATTENTION

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

After 6 months of storage and before starting the

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

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

3.2.4.6.3 Sleeve bearing Depending on the mounting position and lubrication

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

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

ATTENTION

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

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

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

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

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

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

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

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

Close the bearing with the upper sight glass. If the storage period exceeds 6 months. Repeat the procedure described above; Put new dehumidifier bags (silica gel) inside the bearing.

If the storage period exceeds 2 years. Disassemble the bearing; Preserve and store the bearing component parts.

3.2.4.7 Brushes The brushes must be lifted on the brush holders, since their contact with the collector rings during the storage period may cause oxidation of the commutator. 3.2.4.8 Terminal box When the insulation resistance in the motor windings is measured, the main junction box and the other terminal boxes must also be inspected, especially considering the following aspects: The inner part must be dry, clean, and free of any dust

accumulation; The contact elements cannot be corroded; The sealing must remain under appropriate conditions; The cable inlets must be correctly sealed.

If any of these items is not correct, the parts must be cleaned or replaced.

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

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

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

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

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

NOTE

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

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

3.2.4.10 Inspections and records during storage

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

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

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

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

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

Monthly Every 2 months

Every 6 months

Every 2 years

Before starting

operation Note

Storage location

Inspect cleanliness conditions X X

Inspect humidity and temperature conditions X

Check signs of insects X

Measure vibration level X

Package

Inspect physical damages X

Inspect relative humidity inside X

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

Space heater

Check operating conditions X

WHOLE MOTOR

Clean external part X X

Check paint conditions X

Check oxidation inhibitor in the exposed machined parts

X

Reapply oxidation inhibitor X

Windings

Measure insulation resistance X X

Measure polarization index X X

Terminal box and grounding terminals

Clean the inner part of the boxes X X

Inspect the seals

Grease or oil rolling bearing

Spin the shaft X

Relubricate the bearing X X

Disassemble and clean the bearing X

Sleeve bearings

Spin the shaft X

Apply anticorrosive and dehumidifier X

Clean the bearings and relubricate them X

Disassemble and store the parts If the storage period

exceeds 2 years

Brushes

Lift brushes During storage

Lower brushes and check contact with the commutator

X

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

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

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

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

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

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

ATTENTION

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

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

3.3.1 Handling of horizontal motors

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

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

purpose only. 3.3.2 Handling of vertical motors

Figure 3.2: Handling of vertical motors

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

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

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

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

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

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

ATTENTION

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

Máximo 30º

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4 INSTALLATION

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

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

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

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

protection degree.

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

ATTENTION

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

4.3 INSULATION RESISTANCE 4.3.1 Safety Instructions

DANGER

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

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

4.3.3 Measurement on the windings

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

Winding rated voltage (V)

Insulation resistance test - continuous voltage (V)

< 1000 500

1000 - 2500 500 - 1000

2501 - 5000 1000 - 2500

5001 - 12000 2500 - 5000

> 12000 5000 - 10000

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

Measure the winding insulation resistance as follows: Commutation/compensation winding:

Terminal B2 and frame; Excitation winding:

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

ATTENTION

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

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20

Table 4.2: Insulation resistance referential limits in electric machines

Insulation resistance value Insulation evaluation

2MΩ or less Bad

< 50MΩ Dangerous

50...100MΩ Regular

100...500MΩ Good

500...1000MΩ Very Good

> 1000MΩ Excellent

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

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

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

NOTE

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

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

Figure 4.1: Insulation resistance variation coefficient according to the temperature

NOTE

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

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

Temperatura do enrolamento ºC R40ºC = Rt x Kt40ºC

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

coefficient (Kt)

Coe

ffici

ent o

f ins

ulat

ion

resi

stan

ce v

aria

tion

Kt 4

0ºC

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

Insulation class F H

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

Difference between the hottest spot and the average temperature

°C 10 15

Total: hottest spot temperature °C 155 180

ATTENTION

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

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

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

Maximum temperature set for protections (ºC)

Class of Temperature - UL508

Alarm Tripping F 130 155 H 155 180

Table 4.5: Maximum temperature of the bearings

Maximum temperature set for protections (ºC) Alarm Tripping

110 120

ATTENTION

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

ATTENTION

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

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

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

10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40

20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28

30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15

40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01

50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86

60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69

70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51

80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32

90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12

100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91

110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68

120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45

130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20

140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94

150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67

Formula: Ω - 100 = °C 0.386

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22

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

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

NOTE

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

NOTE

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

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

ATTENTION

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

4.5.1.1 Heat exchangers for application with

seawater

ATTENTION

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

Figure 4.2: Heat exchanger with sacrificial anodes

NOTE

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

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

Sacrificial Anodes

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NOTE

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

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

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

ATTENTION

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

NOTE

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

ATTENTION

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

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

ATTENTION

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

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

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24

4.6.2 Wiring Diagram 4.6.2.1 Main terminal box

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

Clockwise rotation

Clockwise rotation

Counterclockwise rotation

Counterclockwise rotation.

Wiring diagram with series excitation – Code 9202

Clockwise rotation

Counterclockwise rotation

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

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

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

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

XA - B - C

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4.6.2.2 Accessory terminal box

ATTENTION

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

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

NOTE

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

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

XA - B - CDE

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

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

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

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

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

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26

Table 4.7: Codes of the terminology of accessories and instruments

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

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

NOTE

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

4.6.2.3.1 Thermostat wiring diagram

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

XA-B

-1TB

1

1TB

XA-B

-1T B

2

XA-B

-2TB

1

2TB

XA-B

-2TB

2

XA-B

-3T B

1

3TB

XA-B

-3TB

2

X A-B

-4TB

1

4TB

XA-B

- 4TB

2

XA-B

-5TB

1

5TB

XA-B

-5T B

2

XA-B

- 6TB

1

6TBXA

-B-6

TB2

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

X A-B

-9TB

1

9TB

XA-B

-9TB

2

XA-B

-10T

B1

10TB

XA-B

- 10T

B2

XA-B

-7TB

1

7TB

XA-B

-7TB

2

XA-B

-8T B

1

8TB

XA-B

-8TB

2

X A-B

-11T

B 1

11TB

XA-B

-11T

B2

XA-B

- 12T

B1

12TB

XA-B

- 12T

B2

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

series) - Code 9227 One per bearing – Code 9230

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

series) - Code 9228

XA-B

-13T

B1

13TB

XA-B

-13T

B2

XA-B

-14 T

B1

14TB

XA-B

- 14T

B2

XA-B

-1TB

11TB 7TB

XA-B

-7TB

2

DE bearing NDE bearing

XA-B

-1TB

1

1TB 7TB

XA-B

-15T

B2

15TB

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

XA-B

-15 T

B1

15TB

XA-B

-15T

B2

X A-B

-16T

B 1

16TB

XA-B

-16 T

B2

XA-B

- 17T

B1

17TB

XA-B

-17T

B 2

XA-B

-18T

B1

18TB

XA-B

-18T

B2

X A-B

-19T

B 1

19TB

XA-B

-19 T

B2

XA-B

- 20T

B1

20TB

XA-B

-20T

B 2

4.6.2.3.2 Thermistor (PTC) wiring diagram

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

XA-B

-1TP

1

1TP

XA-B

-1T P

2

XA-B

-2TP

1

2TP

XA-B

-2TP

2

XA- B

-3TP

1

3TP

XA-B

-3TP

2

XA-B

-4TP

1

4TP

XA-B

-4TP

2

t° t° t° t°

XA-B

-5TP

1

5TPXA

-B-5

TP2

XA-B

-6TP

1

6TP

XA-B

-6TP

2

t° t°

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

XA-B

-9T P

1

9TP

XA-B

-9TP

2

XA-B

-10T

P1

10TP

XA-B

-10T

P 2

t° t°

XA-B

-7TP

1

7TP

XA-B

-7TP

2

XA- B

-8TP

1

8TP

XA-B

-8TP

2

t° t°

XA-B

-11T

P1

11TP

XA-B

-11T

P2

XA-B

-12 T

P1

12TP

XA-B

-12T

P2

t° t°

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28

Two on the commutating winding and one on the excitation winding

- Code 9224 One per bearing – Code 9239

XA-B

-13T

P1

13TP

XA-B

-13T

P2

XA-B

- 14T

P1

14TP

XA-B

-14T

P 2

t° t°

XA-B

- 1TP

1

1TP

XA-B

-1TP

2

XA-B

-2TP

1

2TP

XA-B

-2TP

2

XA- B

-7TP

1

7TP

XA-B

- 7TP

2

t° t° t°



XA-B

-15 T

P1

15TP

XA-B

-15T

P2

XA-B

- 16T

P1

16TP

XA-B

-16T

P2

X A-B

-17T

P 1

17TPXA

-B-1

7 TP2

XA-B

-18 T

P1

18TP

XA-B

-18T

P2

t° t° t° t°

XA-B

-19T

P1

19TP

XA-B

-19T

P2

XA-B

-20T

P1

20TP

XA-B

-20T

P2

t° t°

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

XA- B

-1TP

1

1TP

XA-B

-1TP

2

XA-B

-7TP

1

7TP

XA-B

-7TP

2

XA-B

-15T

P1

15TP

XA-B

-15T

P2

t° t° t°

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4.6.2.3.3 Thermosensor (Pt-100) wiring diagram

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

-B-1

R1

1RXA

-B- 1

R2

XA-B

-2R1

2R

XA-B

-2R2

XA-B

-3R1

3R

XA-B

-3R2

XA-B

-4R1

4R

XA-B

-4R2

t° t° t° t°XA

-B- 1

R2

XA-B

-2R2

XA-B

-3R2

XA-B

-4R2

XA-B

-5R1

5R

XA-B

-5R2

XA-B

-6R1

6R

XA-B

-6R2

t° t°

XA-B

-5R2

XA-B

-6R2

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

XA-B

-9R 1

9R

XA-B

-9R2

XA-B

-10R

1

10R

XA-B

-10 R

2

t° t°

XA-B

-9R2

XA-B

-10R

2

XA- B

-7R1

7R

XA-B

-7R2

XA-B

-8R 1

8R

XA-B

-8R2

t° t°

XA-B

-7R 2

XA-B

-8R2

XA- B

-11R

1

11R

XA-B

-11R

2

XA-B

-12R

1

12R

XA-B

-12R

2

t° t°

XA-B

-11R

2

XA-B

-12R

2


XA-B

-15R

1

15R

XA-B

-15R

2

XA-B

-16R

1

16R

XA-B

-16R

2

XA-B

- 17R

1

17R

XA-B

-17R

2

XA-B

-18R

1

18RXA

-B-1

8R2

t° t° t° t°

XA-B

-15R

2

XA-B

-16R

2

XA-B

-17R

2

XA-B

-18R

2

XA-B

-19R

1

19R

XA-B

-19R

2

XA-B

-20R

1

20R

XA-B

-20R

2

t° t°

XA-B

-19R

2

XA-B

-20R

2

One on the commutating winding, one on the excitation winding

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

XA-B

-13R

1

13R

XA-B

-13R

2

XA- B

-14R

1

14RXA

-B-1

4R2

t° t°

XA-B

-13 R

2

X A-B

-14R

2

XA-B

-1R 1

1R

XA-B

-1R2

XA-B

- 7R1

7R

XA-B

-7R2

XA-B

-15R

1

15R

XA-B

-15R

2

t° t° t°

XA-B

-1R2

X A-B

-7R2

XA-B

-15R

2


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30

4.6.2.3.4 Space heater wiring diagram

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

2 Connector bridges 1 Connector bridge

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

1HE 2HE

XA-B

4-4H

E2

XA-B

2 -3H

E1

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4.7 MECHANICAL CHARACTERISTICS

4.7.1 Foundations The foundation or structure where the motor will be

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

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

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

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

ATTENTION

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

NOTE

The user is responsible for dimensioning and building the foundation.

4.7.2 Forces on the foundations Based on Figure 4.3, the forces on the foundation can be calculated by the equations: Where: F1 and F2 - Reaction of the feet on the base (N) g - Gravity acceleration (9.81m/s²) m - Motor mass (kg) Cmax - Maximum torque (Nm) A - Obtained from the motor dimension drawing (m)

Figure 4.3: Forces on the foundations

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

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

)(max)4(...5.01 A

CgmF ++=

)(max)4(...5.02 A

CgmF −+=

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

These natural frequencies must be in accordance with the specified below: Natural frequency of the first order of the foundation ≥

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

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

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

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

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

Horizontal Mount Vertical M

Radial measurement

Parallel misalignment

Horizontal Mount Vertical Mount

Axial measurement

Angular misalignment

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

ATTENTION

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

NOTES

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

commissioning; Incorrect electric connections.

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

ATTENTION

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

8: of coupling (E)

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

belts

Figure 4.9: Coupling by means of pulleys and belts When a speed ratio is necessary, the drive by belt is the most commonly used. In order to avoid unnecessary radial force on the bearings, the shafts and pulleys must be perfectly aligned. Belts that work diagonally convey impacts to the rotor and may damage the bearing seat. Belt slippage can be prevented by applying some resin such as pitch. The belt tension must be just enough to prevent slippage during operation.

NOTE

Belts too tensioned increase the stress on the shaft end, causing vibration and fatigue, or even the break of the shaft.

Avoid using too small pulleys; they cause bends in the motor because the tension increases in the belt as the diameter of the pulley decreases.

ATTENTION

In each specific case of the pulley dimensioning, WEG must be consulted to ensure correct application.

NOTE

Always use pulleys properly balanced. Avoid, in all cases, parts of the key, because they represent an increase of the unbalancing mass. If this is not observed, there will be an increase in vibration levels.

Correct Incorrect Incorrect

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4.7.5.4 Coupling of motors equipped with sleeve bearings

Figure 4.10: Sleeve bearing Motors equipped with sleeve bearings must operate with direct coupling to the driven machine or by means of a gear box. This kind of bearing does not allow coupling by pulleys and belts. Motors equipped with sleeve bearings have three marks on the shaft end, seeing that the central mark (painted red) is the indication of the magnetic center, and the two external marks indicate the allowed limits of axial movement of the rotor.

Figure 4.11: Magnetic center mark For the motor coupling, the following factors must be taken into account: Bearing axial clearance; Axial displacement of the driven machine (if applicable); The maximum axial clearance allowed by the coupling.

ATTENTION

Move the shaft fully forward and then properly measure the axial clearance;

Carefully align the shaft ends, and, whenever possible, use flexible coupling, leaving a minimum clearance of 3 to 4 mm between the couplings.

NOTE

If it is not possible to move the shaft, you must consider the shaft position, the travel of the shaft forward (according to the marks on the shaft) and the axial clearance recommended for the coupling.

Before starting operation, you must check if the motor

shaft allows free axial movement within the clearance conditions aforementioned;

In operation, the arrow must be positioned on the central mark (red), which indicates that the rotor is in its magnetic center;

During the start, or even in operation, the motor may move freely between the two external limit marks.

ATTENTION

Under no circumstances can the motor operate constantly under axial force on the bearing.

The sleeve bearings used are not designed to stand

constant axial stress. After aligning the set and having assured a perfect alignment (both, cold and hot), the motor must be fixed on the anchor plate or on the base, as shown in Figure 4.12.

Figure 4.12: Fixing of the motor

Bearing shell

Axial clearance

Axial clearance

Shaft

Axial clearance

Weld in 4 spots

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5 START The start of DC motors may be classified by the types of drives, as described below:

5.1 POWER SUPPLIES In order to obtain a DC voltage of variable level, you can use various methods, some listed below: a. Starting Switches The armature and field current can be set by means of variable resistances on scales. The disadvantage is the high heat losses generated. b. Ward-Leonard system The requirement for drives with fast regulation of the rotation without scaling was met by the Ward-Leonard regulation system. Rotation of the DC motor can be changed continuously by varying the exciting current of the generator. Its disadvantage is the use of at least 3 machines. c. Static converters These converters basically consist of a thyristor rectifier bridge that provides DC voltage with variable tension from a variable DC voltage. The converters can be powered by three-phase network in 220, 380 or 440V or by single-phase network, connected between phase and neutral or between phase and phase. This will basically depend on the motor power and its application in the system to drive. Table 5.1: Usual voltages – DC Drives

Power Supply (V) Single phase Three phase

220 380 440 220 380 440

Armature voltage

170

230

260

300

340

400

460 460

520

Field voltage

190 190

310 310

ATTENTION

In case of doubt about the converter, refer tothe manufacturer of this equipment.

d. Pure DC (Battery bank ) In case of pure DC or battery bank start, WEG recommends that you use start resistors to drive the DC motor. The use of start resistors is intended to limit the current of the DC motor during its start.

AR

AU

X

X

3

3

2

2

1

1

R

K

R

K

R

K

R

K

VtiE

Figure 5.1: Electric diagram of DC motor by resistance

ATTENTION

The start by means of battery accumulators without using a start resistor may cause damage to the DC motor, due to the high start current, and, depending on the number of starts, it can decrease the battery useful life.

{R1, R2,...Rx - Resistors} - {K1, K2,...Kx - Connectors}

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6 COMMISSIONING

6.1 PRELIMINARY INSPECTION Before the first motor start or after a long time out of operation, the following items must be checked: 1. The motor fixing bolts must be tightened; 2. Measure the insulation resistance of the windings,

making sure they are within the specified value; 3. Check if the motor is clean and if the packages,

measuring instruments and alignment devices were removed from the motor operating area;

4. Check if coupling connecting components are in perfect operating conditions, duly tightened and greased, when necessary;

5. The motor must be properly aligned; 6. Check if the bearings are properly lubricated. The

lubricant must be of the type specified on the nameplate.

7. Check the oil level in the motors with oil-lubricated bearings. Bearings with forced lubrication must have the oil pressure and flow as specified in their nameplate;

8. Inspect the cable connections of accessories (thermal protectors, grounding, space heaters, etc.);

9. Check if all electric connections comply with the motor wiring diagram;

10. The motor must be properly grounded; 11. The conductors connected to the main terminals

must be properly tightened to make a short circuit impossible or that they eventually get loose;

12. Inspect the cooling system. In motors with water cooling, inspect the operation of the heat exchanger water supply system. In motors with independent ventilation, check the direction of rotation of the fans;

13. Motor air inlets and outlets must be clear; 14. Check if the air cleaner is clean; 15. The movable parts of the motor must be protected

to prevent accidents; 16. The terminal box covers must be properly fastened; 17. All the motor bolts must be properly fastened; 18. Check if the supply is in accordance with the data of

the motor nameplate; 19. Check the conditions of the brush holder and

commutator; 20. Check if the brushes are well settled, aligned with

the commutator and if they easily slide inside the brush holders;

6.2 INITIAL START-UP After all the inspections described above have been made, the following procedures must be followed to perform the motor initial start-up: 1. Disconnect all space heaters; 2. Adjust the protections in the control panel; 3. In oil-lubricated bearings, check the oil level; 4. In forced-lubrication bearings, start the oil circulation

system and check the level, the flow and oil pressure, ensuring they comply with the data on the nameplate.

5. If the system has an oil flow detection device, you must wait for the flow return signal of the circulation system of both bearings, which ensures the oil has reached the bearings;

6. Start the cooling industrial water system and check the required flow and pressure (motors with air-water heat exchanger);

7. Turn on the fans (motors with forced ventilation); 8. Rotate the motor shaft slowly to make sure there are

no parts dragging or unusual noises are occurring; 9. After the above steps have been completed

satisfactorily, you can proceed with the star sequence of the motor;

10. Start the motor, by first applying the excitation voltage (field);

11. Soon after, apply voltage on the armature, accelerating the motor up to the rated speed;

12. Check the direction of rotation with the motor uncoupled;

13. The direction of rotation of the motor can be changed by reversing the polarity of the power supply of the excitation or the armature.

ATTENTION

The inversion of the field can only occur with the machine off. Motors supplied with a single direction of rotation must not operate in the opposite direction. In order to operate the motor in the opposite direction, please contact WEG.

14. Keep the motor turning at the rated speed and record

the bearing temperatures at 1-minute intervals until they become constant. Any sudden increase in bearing temperature indicates lubrication or friction surface issues;

15. Monitor the bearing temperature, oil level of the bearings and the vibration levels. If there is a significant variation of any value, interrupt the start of the motor, detect the possible causes and make corrections;

16. When bearing temperatures stabilize, you can continue with the other steps to operate the motor.

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ATTENTION

The noncompliance with the procedures described above may jeopardize the motor performance, cause damages and even lead to a burnout, voiding the warranty.

6.3 OPERATION The operating procedures vary considerably due to the application of the motor and type of equipment and control used. Only general procedures are described in this manual. For the operating procedures of the control system, you must refer to the specific manual of this equipment. 6.3.1 General After the first successful start test, couple the motor and the load driven and then the start procedure can be restarted as follows: Start the motor coupled to the load, first applying the

excitation voltage (field) by means of the AC/DC excitation converter.

Soon after, apply voltage on the armature, using the acceleration ramp in accordance with the maximum current of the parameterized start on the AC/DC converter, accelerating the motor up to the rated speed

Keep the motor running until it reaches its thermal stability and observe if unusual noises and vibrations or excessive heating are occurring. If there are significant vibration variations from the initial working condition to the condition after it reaches its thermal stability, it is necessary to check the alignment and leveling.

Measure and compare the consumed electric current to the value indicated on the nameplate;

In continuous duty, without load oscillation, the value of the current measured must not exceed the value indicated on the plate multiplied by the duty factor;

All measurement and control instruments and devices must be permanently monitored to detect occasional alterations, determine the causes and make the proper corrections.

ATTENTION

Check the real condition of the load that the motor will be submitted in working duty and, if necessary, resize the brush set. If you have any questions, contact WEG.

6.3.2 Data record The following data must be collected and recorded periodically during the motor operation: Temperature of the bearings; The oil level of the bearings (oil-lubricated bearings). Temperature of the excitation, commutation and

compensation winding; Temperature of the air inlet and outlet of the motor; Motor vibration level; Armature and field voltage and current.

At the start of operation, the values must be checked every 15 minutes. After some hours of operation, check those values every hour, progressively increasing. Make these records daily during a period of 5 to 6 weeks. The temperatures of the commutation and compensation windings, which are connected in series with the armature, depend on the load condition of the engine. Therefore, the values of armature voltage and current must be monitored during the motor operation too. 6.3.3 Temperatures The temperature of the bearings, poles and ventilation

air must be monitored while the motor is running; The temperature of the bearings and poles must

stabilize in a period of four to eight hours of operation; 6.3.4 Bearings The system start must be monitored carefully, as well as the first hours of operation. Before starting the motor, check: If the external lubrication system (if applicable) is ON; If the lubricant used complies with all specifications; Lubricant characteristics; The oil level (oil-lubricated bearings). The alarm and shutdown temperatures set for the

bearing; During the first start-up, it is important to inspect for

unusual vibrations or noises; If the bearing is not running silently and smoothly, the

motor must be immediately shutdown; The motor must operate for several hours until bearing

temperatures stabilize within the previously specified limits;

In case of overtemperature, the motor must be immediately shutdown, bearings and temperature sensors must be inspected and the causes corrected;

After the bearing temperatures stabilize, check if there are no leaks through the plugs, gaskets or shaft end.

6.3.5 Heat exchangers To control the temperature at the heat exchanger inlet

and outlet and, if necessary correct the water flow; Set the water pressure just the necessary to overcome

the resistance imposed by the pipes and heat exchanger;

In order to control the motor operation, it is recommended to install thermometers at the heat exchanger air and water inlet and outlet and record those temperatures at certain time intervals;

When installing the thermometers, you may also install recording or signaling instruments (siren, light bulbs) in certain places.

Inspection of the performance of the heat exchanger In order to control the operation, it is recommended to

measure the temperatures at the heat exchanger water and air inlet and outlet and record them periodically.

The heat exchanger performance is expressed by the temperature difference between the cold water and cold air during normal operation. This difference must be periodically controlled. If an increase in this difference is observed after a long period of normal

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operation, probably the heat exchanger must be cleaned.

A reduction of performance or damage to the heat exchanger may also occur by air accumulation inside it. In this case, removing the air from the heat exchanger and pipes may correct the problem;

The pressure difference on the water side may be considered an indicator of the need of cleaning the heat exchanger;

We also recommend measuring and recording the pressure difference of the water before and after the heat exchanger. Periodically, the new values measured are compared to the original value, and an increase of the pressure difference indicates the need of cleaning the heat exchanger.

6.3.6 Vibration The acceptable vibration levels must be directly obtained in the standard referring to the motor. Figure 6.1: Standards to evaluate the vibration in coupled motors

Application Measurement in non-rotating parts

Measurement in rotating

parts DC Motors ISO 10816-3 ISO 7919-3

Common causes of vibration are: Misalignment between the motor and the equipment; Inadequate fixation of the motor to the base, with

"loose shims" under one or more of the motor feet, and loose fixation bolts;

Inadequate or not sufficiently strong base; External vibrations from other devices.

ATTENTION

Operating the motor with vibration levels above the values provided above may jeopardize its useful life and/or performance.

6.3.7 Tripping The tripping of the motor depends on its application, but the main directions are: Reduce the load on the driven equipment, if possible; Reduce the armature voltage until the motor stops

and disconnect the armature supply; Disconnect the excitation supply Use regenerative or counter-current braking, according

to the options of the AC/DC converter. In case of battery supply, first disconnect the armature voltage and after the excitation voltage.

Shut down the oil circulation system of the bearings (if applicable) after complete stop;;

Shut down the water supply system for the heat exchanger heat exchangers (if applicable).

Shutoff the forced ventilation system (if applicable). Turn on the space heater (if applicable) if it is not

automatically done by control devices;

DANGER

While the motor is turning, even after disconnected, there is life danger when touching any of the active parts of the motor.

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7 MAINTENANCE

7.1 General A proper motor maintenance plan, when properly executed, includes the following recommendations: Keep the motor and all related equipment clean; Periodically measure the insulation resistance; Routinely measure the temperature of windings,

bearings and ventilation system; Inspect wear, operation of the lubrication system and

useful life of the bearings; Check possible wear of the brushes and commutators; Check the ventilation system to ensure air is flowing

correctly; Inspect the heat exchanger; Measure the machine vibration levels; Inspect the associated equipment (hydraulic unit,

water system etc.) Check all of the motor accessories, protections and

connections, ensuring that they are operating properly;

ATTENTION

Noncompliance with the recommendations aforementioned may cause undesired stops of the equipment. The frequency with which such inspections are performed depends on local application conditions. Where it is necessary to transport the motor, care should be taken not to damage the bearings. Use the device supplied with the motor to lock the shaft. If the motor requires reconditioning or replacement of any damaged parts, please contact WEG.

7.2 GENERAL CLEANING The frame must be kept clean, without oil or dust built

up on its external part in order to make the heat exchange with the ambient easier.

The interior of the motor must also be kept clean, and free from dust, debris and oils;

For cleaning, use brushes or clean cotton cloths. If the dust is not abrasive, an industrial vacuum cleaner must be used to remove the dirt from the fan cover and the excess of dust on fan blades and on the frame;

Debris impregnated with oil or moisture may be removed with a cloth soaked in appropriate solvents;

It is also recommended to clean the terminal boxes. Terminals and connectors must be kept clean, rust-free and in perfect operating conditions. Avoid contact between connecting parts and grease or verdigris.

7.3 INSPECTIONS IN THE WINDINGS The measurements of the insulation resistance of the windings should be made at regular intervals, mainly during wet times or after prolonged motor stops. The windings must undergo a careful visual inspection at frequent intervals, recording and fixing any damage or default observed. Low values or sudden variations in the insulation resistance must be carefully investigated. At points where the insulation resistance may be low (due to an excess of dust or moisture), it may be increased back to the required values by removing the dust and drying up humidity on the windings.

7.4 WINDING CLEANING For satisfactory operation and longer useful life of insulated winding, it is recommended to keep them free of dirt, oil, metallic dust, contaminants, etc. In order to do so, it is necessary that the winding be periodically inspected and cleaned and that it operates in clean air. If re-impregnation is necessary, contact WEG. The winding may be cleaned with industrial vacuum cleaner with a non-metallic thin tip or just a dry cloth. Winding drying time after cleaning varies depending on weather conditions, such as temperature, humidity, etc.

DANGER

Most solvents currently used are highly toxic and/or flammable.

Inspections The following inspections must be performed after the winding is carefully cleaned: Check the connections and winding insulation. Check if spacers, bindings, groove wedges, bandages

and supports are fixed correctly. Check if there were no breaks, if there are no faulty

welds, short circuit between turns and against the mass in the coils and connections. In case of detecting any irregularity, immediately contact WEG.

Ensure that all cables are properly connected and that terminal fixation components are duly tightened. If necessary, do the retightening.

Re-impregnation If any layer of resin on the windings is damaged during cleaning or inspection, such parts must be corrected with adequate material (in this case, please contact WEG). Insulation resistance Insulation resistance must be measured after all maintenance procedures have been performed.

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ATTENTION

Before putting the motor into operation, in case it remained out of operation for some time, it is essential to measure the insulation resistance of the windings and ensure that the values meet the specifications.

7.5 CLEAN BRUSH COMPARTMENT The dust from the brush compartment must be

cleaned with a vacuum cleaner, removing dust from the brushes out of the motor ;

The commutator must be cleaned with a dry clean cloth which does not release lint;

The spaces between blades must be cleaned with a vacuum cleaner hose;

Do not use solvents to clean the commutator , because the vapor of such products jeopardizes the operation of the brushes and commutator;

Do not remove the film formed by the deposit of material of the brushes on the commutator (patina) since this is beneficial for the motor commutation.

Clear supports of the brush holders and the brush connection terminals, which can be covered with dust brushes;

Remove the brushes and clean them to ensure that they move freely in the enclosure;

Air filters (if applicable) must be removed and cleaned every two months or before if necessary.

7.6 MAINTENANCE OF THE COOLING SYSTEM

The air-air heat exchanger pipes (if applicable) must be

kept clean and unblocked in order to ensure a perfect heat exchange. In order to remove the dirt accumulated inside the pipes, a rod with round brush on the tip can be used.

For air-water heat exchangers, it is necessary to periodically clean he heat exchanger pipes to remove any crusts.

NOTE

If the motor is equipped with filters in the air inlet and/or outlet, they should be cleaned with a compressed air application If the dust is difficult to remove, wash the filter in cold water with mild detergent and dry it in the horizontal position.

7.6.1 Maintenance of heat exchangers Using clean water, the heat exchanger may remain in operation for several years, without having to be cleaned. With too dirty water, it is necessary to clean it every 12 months. The level of dirt in the heat exchanger may be detected by the air temperatures increase in the outlet. When the temperature of the cold air, in the same operating conditions, exceeds the specified value, you can assume the pipes are dirty. If corrosion is observed, it is necessary to provide a proper protection against corrosion (for instance, zinc anodes, cover with plastic, epoxy or other similar protection products) in order to prevent greater damages to the affected parts. The external surface of all parts of the heat exchanger must be always kept in good conditions. Instructions for removing and maintaining the heat exchanger In order to remove the heat exchanger for maintenance, follow the steps below: 1. Close all the water inlet and outlet valves after

stopping the ventilation; 2. Drain the heat exchanger water through the drain

plugs; 3. Loosen the heads and keep the bolts, nuts and

washers and gaskets together in a safe place; 4. Carefully brush the pipes inside with nylon brushes to

remove the residue. If during the cleaning operation, damages to the heat exchanger pipes are observed, they must be repaired;

5. Reassemble the heads, replacing the gaskets if necessary.

7.7 Commutator The good condition of the commutator is essential for the perfect behavior of the direct current machine. Therefore, it is important its periodic observation. The commutator must be kept free of the presence of oil and grease and the furrow among the blades must be kept clean. In normal operation, the patina that is formed on the commutator will present a dark brown or lightly black coloration. If the surface is bright, glossy or rough, it is likely that the type of brushes must be replaced. On the other hand, a layer of thick black coloration, which generally occurs with prolonged overloads, in the presence of moisture, indicates an excessive deposition of the material on the commutator. In these cases this layer must be removed by means of pumice (artificial) or fine sandpaper (no. 220). When leaving the factory, the commutator is machined and the patina is preformed in the test. Therefore, it does not need any treatment on its surface before the motor is put into operation. The commutator wear normally occurs uniformly along the tracks. If it is determined visually an uneven wear along the periphery of the commutator, contact WEG immediately. The commutator wear is measured on the lane position of the brushes in relation to the area not used. Whenever this difference exceeds 0.1mm, the commutator should be reconditioned.

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If the difference in height among any adjacent blades is greater than 0.005mm, the commutator must be repaired. The commutator ovalization must not surpass 0.1mm. The reconditioning of the commutator basically consists of a fine lathing and the subsequent lowering of the mica-blades. The Table below indicates the minimum “wear diameter” that the commutator can have after successive machining. For a smaller diameter than the indicated, it is necessary to replace the commutator. Table 7.1: Diameter of the Commutator (mm)

DIAMETER OF THE COMMUTATOR (mm) FRAME

NEW WEAR

90 85 82

100 85 82

112 92 89

112 105 102

132 125 121

160 145 137

180 170 162

160 152 200

190 180

225 180 170

250 (C )* 210 200

250 210 200

280 (C )* 240 228

280 240 228

315 270 258

355 270 258

400 320 306

450 380 364

* Offset machine The under cutting of mica should be such that the dept P of the slot between lanes is between 0.7 and 1.2 mm. This operation must be performed with utmost care, and a cylindrical milling machine or a flat blade should be used .milling machine Conical tools should not be used for this operation. The burrs formed must be removed by keeping the bevels

Figure 7.1: Lowering of mica Note that no rest of mica remains in the slot walls. The best way is to use a magnifying glass. Only the sharp

edge of the edges of the plates must be broken, therefore remove a minimum amount of copper.

ATTENTION

It should be noted that the continuity of operation with a worn commutator may cause sparking in excessive levels, and could damage the motor completely.

7.7.1 Checking the commutation A successful commutation is defined as the quality of commutation that does not result in damage and to the commutator and the brushes. The total lack of a visible sparking does not mean essentially a successful commutation. For the verification of the commutation, you should apply load to the motor and note the sparking, attempting to determine if it is normal or not. In case of unusual sparking from level1 3/4 (Figure 7.2), you must determine the cause or causes and eliminate them. Sparks resulting from an unsatisfactory commutation may have mechanical causes, as vibrations on the machine, deformation on the commutator, inadequate pressure on the brushes, etc. Electric causes such as poor contact between brush and commutator, problems in the windings of the commutation poles or the armature, current peaks, inadequate air-gap, etc and physicochemical aspects, such as excessive air moisture and the existence of corrosive gases or vapors in the environment or the deposition of oils or dust on the commutator. The air-gap of the commutation poles (for machines with retractable poles) is adjusted at the factory, as well as the neutral zone.

ATTENTION

In case you need to extract the poles, you must necessarily respect the original air-gap, at the mounting time, and the brush holder rings must be adjusted at the neutral position.

,

BLADE

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Figure 7.2: Sparking levels

7.8 BRUSH HOLDER The enclosures must allow the free movement of the brushes, but excessive clearances provoke trepidations and hence sparking. The spring pressure should range between 200 and 250 g / cm ², except in special cases. The distance between the brush holder and the commutator surface should be approximately 2mm to avoid breakage of the brushes and damage to the commutator.

Figure 7.3: Brush holders The sets of brush holders are adjusted in the factory in the most favorable position for the commutation. This position (neutral zone) is indicated by reference marks on the brush holder support. Once the set brush holder is adjusted, you should not change its position, because it serves to any load value. In case of need of disassembling the set, respect the mark for the assembly.

7.8.1 Adjustment of the neutral zone When the rotor is replaced or reconditioned, it is possible that the position of the brush holder has to be changed. In order to adjust the brushes in the neutral position (liming brushes), proceed as follows (practical method)” Thick adjustment: 1. Loosen the bolts holding the ring of the brush

holder; 2. Power up the armature (50 to 80% of the rated

current for 30 seconds at most), field remains disconnected. In order to limit the current, use a low voltage, for example, of battery;

ATTENTION

The maximum time of 30 seconds must be respected; otherwise you can damage the commutator.

3. If the neutral zone is maladjusted, the rotor will tend

to rotate. In order to adjust the neutral position, rotate the ring of the brush holder in the opposite direction of the rotation of the motor

4. The neutral zone will be adjusted when the rotor is stopped.

NOTE

If when you turn the brush holder ring to the right, the rotor turns the opposite way, the cables of the commutation poles that are connected to the brush holder are inverted. Connect the cables correctly and proceed as in items 1, 2, and 3.

Thin adjustment: 1. After neutral zone is adjusted (thick adjustment),

start the motor with rated voltage (if possible, rated current);

2. Check the two directions of rotation, the difference cannot be greater than 1%;

3. If the difference is greater than 1%, observe which way the rotation is greater. To decrease the rotation, turn the brush holder ring in the same direction of rotation of the rotor;

4. To increase the rotation, in a certain direction, turn the brush holder ring in the opposite direction of rotation of the rotor.

7.9 BRUSHES To each direct current machine is intended previously one quality of brush, and it should always be used the same type and amount of brush originally supplied (attend to that described in section 7.9.1). Brushes of different types should not be mixed. The choice of the type of brush is made according to the characteristics of each machine such as: speed, voltage, current, etc.

1 ¼ Intermittent sparks

1 ½ Some sparks

1 ¾ Numerous sparks

2 Sparks with some projections

2 ¼ Sparks with some projections

2 ¾ Sparks with numerous projections

3 Sparks with accented projections

1 Black

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NOTE

Any change in the type and quantity of brushes should be done under WEG’s guidance, because different types of brushes cause changes in the behavior of the machine when in operation.

The brushes should be constantly observed during operation; look mainly for the following items: Make sure that all the brushes have the same quality; Make sure that all the brushes have flexible braids

with the same length. Neither short nor too long to allow a free sliding;

Check if there is free movement in the brush holders and if there is no material embedded in its internal surface, which damages the movement of the brushes;

Lay-in the brushes with sandpaper placed between the surface of the commutator and brushes with the abrasive face facing the brush contact surface. Also use pumice;

In order to control the brush wear, observe the mark embossed on the side (axial) Figure 4.3. The minimum height that the brush must have so that damages do not occur to the commutator is the one in which the wearing mark is still visible;

When replacing brushes, always replace the complete kit;

When replacing worn brushes by others of the same granulation, the existing patina on the commutator should not be removed if it has a normal aspect;

When replacing brushes by others of different quality, one must necessarily remove the existing patina on the commutator, using fine sandpaper.

7.9.1 Adequacy of brushes to load conditions Performance of the brushes depends on them working within the normal conditions of the machine. If the power permanently required from the machine is lower than the rated power, there is the need of an adaptation of the brushes considering the operating load condition.

Figure 7.4: Representation of the dimensions of the brushes

ATTENTION

If the above is not observed, excessive wear of the brushes may occur, insulation marks and damage the insulation of the engine, damaging it completely.

NOTE

WEG DC- motors are manufactured to work in normal rated load or according to the customer In case the customer uses the motor with a different load from the one specified, it is his responsibility to do the correct adaptation of the brushes.

ATTENTION

WEG is not responsible for the adequacy of the brushes with a different load from the specified.

7.10 MOTOR OUT OF OPERATION The following special measures must be taken in case the motor remains out of operation for long. Turn on the space heaters (if applicable) so that the

temperature inside the motor be kept slightly above the ambient temperature, avoiding moisture condensation and consequent drop of the winding insulation resistance and oxidation of metallic parts;

The heat exchangers and all water pipes (if applicable) must be drained in order to reduce corrosion and build-up of suspended material in the cooling water;

Follow the other procedures described in the chapter “Extended Storage” of this manual. Storage of the heat exchanger after operation When the heat exchanger remains for a long period out of operation, it must be drained and dried. The drying may be done with pre-heated compressed air. During winter, if there is risk of freezing, the heat exchanger must be drained even in short periods out of operation to prevent deformation or damages.

NOTE

During short stoppages, it is recommended to keep the water circulation at low speeds instead of interrupting its circulation through the heat exchanger without its draining, ensuring that harmful products, such as ammonia compounds and hydrogen sulfide, will be taken out of the heat exchanger and will not settle inside.

Wear mark

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7.11 SHAFT GROUNDING DEVICE In some motors, depending on application, a brush is used to ground the shaft. This device prevents the circulation of electric current through the bearings, which is highly harmful to their operation. The brush is put in contact with the shaft and connected by a cable to the motor frame, which must be grounded. Make sure the fixation of the brush holder and its connection to the frame have been done properly.

Figure 7.5: Brush for grounding the shaft In order not to damage the motor shaft during transportation, it must be protected with drying oil. In order to ensure the proper operation of the grounding brush, this oil, as well as any residue between the shaft and the brush, must be removed before starting the motor. The brush must be constantly observed during the operation and, at the end of its useful life, it must be replaced by another one of the same quality (granulation).

7.12 BEARING MAINTENANCE 7.12.1 Grease rolling bearings

Figure 7.6: Horizontal grease rolling bearing

Figure 7.7: Vertical grease rolling bearing

7.12.1.1 Lubrication instruction The lubrication system was projected so that during the lubrication of the bearings, all the old grease is removed from the bearing tracks and expelled through a drain which allows it to come out, but prevents the income of dust or other harmful contaminants into the bearing. This drain also prevents damages to the bearings due to excessive lubrication. It is recommended to make the lubrication with the motor in operation, ensuring the renewal of grease in the bearing enclosure. If that is not possible due to the presence of rotating parts near the grease nipple (pulleys, etc.) which may put the operator at risk, follow the procedures below: With the motor stopped, inject approximately half the total estimated amount of grease and put the motor into operation for about one minute at rated speed;

Stop the motor and inject the rest of the grease. The injection of all the grease with the motor stopped may lead to the penetration of part of the lubricant into the motor through the internal seal of the bearing case;

ATTENTION

It is important to clean the grease nipples before lubrication in order to prevent foreign material from coming into the bearing. For lubrication, use manual grease gun only.

NOTE

The bearing data, amount and type of grease and lubrication interval are informed on a nameplate fixed onto the motor. Check this information before making the lubrication.

The lubrication intervals informed on the plate refer to bearing working temperature of 70ºC;

Based on the operating temperature ranges listed below, apply the following ratio-corrector factors for the bearing lubrication intervals:

Operating temperature lower than 60ºC: 1.59. Operating temperature of 70ºC to 80ºC: 0.63. Operating temperature of 80ºC to 90ºC: 0.40. Operating temperature of 90ºC to 100ºC: 0.25 Operating temperature of 100ºC to 110ºC: 0.16.

7.12.1.2 Procedure to lubricate the rolling

bearings 1. Remove the drain cover; 2. Clean with a cotton cloth the area around the grease

nipple; 3. With the rotor operating, inject the grease with a

manual grease gun until grease starts coming out from the drain or until the proper amount of grease informed on the bearing nameplate is injected.

4. Leave the generator running long enough for the grease excess to drain;

5. Inspect the bearing temperature to make sure there was no significant change.

6. Put the drain plug back on.

Grease inlet

Grease outlet

Grease inlet

Grease outlet

Shaft

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7.12.1.3 Bearing lubrication with spring device to remove the grease

In order to lubricate the bearings, the removal of the old grease is done by the spring device installed in each bearing. Procedures for lubrication: 1. Before beginning the bearing lubrication procedure,

clean the grease nipple with a cotton cloth; 2. Remove the rod with spring to remove the old grease,

clean the spring and put the rod back; 3. With the motor running, inject the amount of grease

specified on the bearing nameplate by means of a manual grease gun;

4. The grease excess comes out through the lower drain of the bearing and settles on the spring;

5. Leave the motor running long enough for the grease excess to drain;

6. That grease must be removed pulling the rod of the spring and cleaning the spring. This procedure must be repeated as many times as necessary until the spring will not hold grease;

7. Inspect the bearing temperature to make sure there was no significant change.

7.12.1.4 Grease type and quantity The bearing relubrication must be always done with the original grease specified on the bearing nameplate and on the motor documentation.

ATTENTION

WEG does not recommend the use of grease different from the motor original grease.

7.12.1.5 Optional greases If not possible to use original grease, the optional greases listed in Table 7.2 can be used, since the following conditions are met: 1. The lubrication interval must be corrected by

multiplying the interval informed on the nameplate of the bearings by the multiplication factor informed in Table 7.2;

2. Use the correct procedure to change the grease, according to item 7.12.1.6 of this manual.

Table 7.2: Options and characteristics of the optional greases for normal applications

Manufacturer Grease (°C)

Multiplication factor

Exxon Mobil UNIREX N3

(Lithium Complex Soap)

(-30 to +150) 0.90

Shell ALVANIA RL3 (Lithium Soap) (-30 to +120) 0.85

Petrobras

LUBRAX INDUSTRIAL

GMA-2 (Lithium Soap)

(0 to +130) 0.85

Shell STAMINA RL2 (Diurea Soap)

(-20 to +180) 0.94

SKF LGHP 2

(Polyurea Soap) (-40 to +150) 0.94

7.12.1.6 Procedure for changing the grease To replace the grease POLYREX EM103 by one of the optional greases, the bearings must be opened to remove the old grease and then filled with new grease. If it is not possible to open the bearings, you must purge all the old grease by applying new grease until it shows in the outlet drawer with the motor running. To replace the grease STABURAGS N12MF by one of the optional greases, it is necessary that the bearings be opened and the old grease totally cleaned and then filled with new grease.

ATTENTION

As there is no compatible grease with STABURAGS N12MF grease, you should not inject other grease in the attempt of purging it. Through this procedure it is not possible to completely expel the old grease, or prevent their mixture, which may cause damage to the bearings.

7.12.1.7 Low-temperature greases Table 7.3: Grease for use in low temperatures

Manufacturer Grease

Application

Exxon Mobil MOBILITH SHC 100

(Lithium Soap and Synthetic Oil)

(-50 to +150)Low

Temperature

NOTE

In order to use optional greases in low-temperature applications in place of grease MOBILITH SHC 100, consult WEG.

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ATTENTION

1. In case the bearing is open, inject new grease through the grease nipple to expel the old grease that is in the grease inlet pipe and apply the new grease to the bearing, to the internal ring and external ring, filling 3/4 of the empty spaces. In case of double bearings (ball + roller), also fill 3/4 of the empty spaces between the intermediate rings;

2. Never clean the bearing with cotton cloths, because they may release lint as solid particles;

3. It is important to perform a correct lubrication, that is, apply the correct grease and in the proper quantity, because either an insufficient lubrication or an excessive lubrication has harmful effects.

4. Excessive lubrication makes the temperature rise due to the great resistance against the movement of the revolving parts and especially due to the beating of the grease, which eventually completely loses its lubrication properties.

NOTE

WEG is not responsible for changing the grease, or even for occasional damages caused by the change.

ATTENTION

Greases with different types of base must never be mixed. Example: Lithium-based greases must never be mixed with others with sodium or calcium base.

7.12.1.8 Grease compatibility The compatibility of different types of grease may cause a problem. You can say the greases are compatible when the properties of the mixture lie within the property ranges of the greases individually. In general, greases with the same type of soap are compatible with each other, but depending on the proportion of the mixture, there might be incompatibility. Therefore, it is not recommended the mixture of different types of grease without consulting the grease supplier or WEG. Some thickeners and basic oils cannot be mixed with each other, because they do not form a homogeneous mixture. In this case, you cannot disregard the possibility of hardening or, on the other hand, softening of the grease or fall of the dropping point of the resulting mixture.

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7.12.1.9 Horizontal bearing assembly and disassembly

Figure 7.8: Parts of the grease rolling bearing Before disassembling: Remove the extension pipes form the grease inlet and outlet;

Clean carefully the external part of the bearing; Remove the grounding brush (if applicable); Remove the bearing temperature sensors and provide a support for the shaft to prevent damages to the rolling bearing.

Disassembly Take special care to prevent damages to the balls, rollers and surfaces of the bearing and shaft. In order to disassemble the bearing, follow the instructions below carefully, keeping all the parts in a safe place: 1. Remove the screws (4) that fix the closing cap (12); 2. Remove the taconite seal (6); 3. Remove the bolts (3 ) that fix the bearing caps (1 and

5); 4. Remove external bearing cap (5); 5. Remove the screw (7) that fixes the grease

centrifuge (8); 6. Remove the grease centrifuge (8); 7. Remove the D-endshield; 8. Remove the bearing (10); 9. Remove the internal bearing cap (1) if necessary.

Assembly Clean the bearings completely and inspect the disassembled parts and the inside of the bearing caps;

Make sure the bearing, shaft and bearing cap surfaces are perfectly smooth;

Fill with the recommended grease up to ¾ of the internal and external fixation cap deposit (Figure 7.11) and lubricate the rolling bearing with grease enough before assembling it;

Before assembling the bearing on the shaft, heat it to a temperature between 50ºC and 100ºC;

For the full assembly of the bearing, follow the instructions for disassembly in the reverse order.

1. Internal bearing cap 2. White felt 3. Ring fixing bolt 4. Disk fixing bolt 5. External bearing cap 6. Taconite seal 7. Centrifuge fixing bolt 8. Grease centrifuge 9. Grease outlet chamber 10. Rolling Bearing 11. Grease nipple 12. Thermal Protector 13. External shutdown disk

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7.12.1.10 Vertical bearing assembly and disassembly

Figure 7.9: Lower bearing Figure 7.10: Upper bearing

1. Temperature sensor 2. Grease nipple 3. Grease outlet chamber 4. Screw 5. Protection disk 6. Taconite seal 7. Screw 8. External bearing cap 9. Screw 10. Grease centrifuge 11. Lower shield 12. Rolling Bearing 13. Spring 14. Internal bearing cap

Before disassembling the bearings: Remove the extension pipes form the grease inlet and outlet;

Clean carefully the external part of the bearing; Remove the grounding brush (if applicable); Remove temperature sensors.

Lower bearing disassembly: Take special care to prevent damages to the balls, rollers and surfaces of the bearing and shaft. In order to disassemble the bearing, follow the instructions below carefully, keeping all the parts in a safe place: 1. Place the motor in the horizontal position; 2. Remove the bolts (4), the protection disk (5) and the

taconite seal (6) 3. Remove the bolts (7 ) that fix the external and internal

fixation caps of the bearing (8 and 14); 4. Remove external bearing cap (8); 5. Remove the bolt (9) that fixes the grease centrifuge

(10); 6. Remove the grease centrifuge (10); 7. Remove the lower shield(11); 8. Remove the bearing (12); 9. Remove the internal bearing cap (14) if necessary.

1. Grease Cup 2. Grease inlet pipe 3. Temperature sensor 4. Grease outlet chamber 5. Grease outlet pipe 6. Screw 7. External bearing cap 8. Spring 9. KMT nut 10. Spacer ring 11. Screw 12. Screw 13. Bearing hub 14. Upper shield 15. Rolling Bearing 16. Intermediate ring 17. Grease centrifuge 18. Guidance ring 19. Internal bearing cap

Upper bearing disassembly: Take special care to prevent damages to the balls, rollers and surfaces of the bearing and shaft. In order to disassemble the bearing, follow the instructions below carefully, keeping all the parts in a safe place: 1. Backstop the motor shaft; 2. Remove the screws (6) of the external bearing cap; 3. Remove external bearing cap (7); 4. Remove KMT nut (9); 5. Remove the screws (11 and 12) and remove the

bearing hub; 6. Remove the upper shield(14); 7. Move the intermediate ring and the internal fixation

cap, deviate them from the rolling bearing to obtain space to place the device to remove the rolling bearing;

8. Remove the bearing (15); 9. Remove the grease centrifuge (17), the intermediate

ring and the internal bearing cap, if necessary.

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Assembly Clean the bearings completely and inspect the disassembled parts and the inside of the bearing caps;

Make sure the bearing, shaft and bearing cap surfaces are perfectly smooth;

Fill with the recommended grease up to ¾ of the internal and external fixation cap deposit (Figure 7.11) and lubricate the rolling bearing with grease enough before assembling it;

Before assembling the bearing on the shaft, heat it to a temperature between 50ºC and 100ºC;

For the full assembly of the bearing, follow the instructions for disassembly in the reverse order.

Figure 7.11: External bearing cap

Rolling bearing replacement The disassembling of the bearings must be done by using proper tools (bearing extractor). The arms of the extractor must be placed on the internal ring side surface of the rolling bearing to be disassembled or on an adjacent part.

Figure 7.12: Device to remove the rolling bearing 7.12.2 Oil rolling bearings

7.12.2.1 Lubrication instruction Oil removal: When it is necessary to change the bearing oil, remove the oil outlet plug (3) and drain the oil completely. To put oil in the bearing: Close the oil outlet with the plug (3); Remove the oil or filter inlet cap (1); Fill with the specified oil up to the level indicated in the

oil sight glass.

NOTES

1. All threaded holes that are not used must be closed with plugs and no connections can present leak;

2. The oil level is reached when the lubricant can be seen approximately in the middle of the sight glass;

3. The use of a larger amount of oil will not damage the bearing, still it can cause leaks through the shaft seals;

4. Do not use or mix hydraulic oil with the lubricant oil of the bearings;

7.12.2.2 Oil types………………… The type and quantity of lubricant oil to be used are specified on the nameplate fixed onto the motor. 7.12.2.3 Oil Change……………… The oil change of the bearings must be carried out observing the Table below, according to the bearing working temperature:

Below 75ºC = 20,000 hours

Between 75 and 80ºC = 16,000 hours





The useful life of the bearings depends on their operating conditions, on the motor operating conditions and on the maintenance procedures. The following recommendation must be observed: The oil selected for the application must have the

proper viscosity for the bearing working temperature. The type of oil recommended by WEG already considers those criteria;

Insufficient quantity of oil may damage the bearing; The minimum oil level recommended is reached when

the lubricant can be seen in the lower part of the oil sight glass with the motor stopped.

ATTENTION

The oil level must be inspected daily and must remain in the middle of the oil sight glass.

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7.12.2.4 Bearing operation The system start must be monitored carefully, as well as the first hours of operation. Before the start check: If the oil used complies with the specification on the

nameplate; Lubricant characteristics; Oil level; The alarm and shutdown temperatures set for the

bearing. During the first start-up, it is important to inspect for unusual vibrations or noises; if the bearing is not running silently and smoothly, the motor must be immediately shutdown; The motor must operate for several hours until the bearing temperatures stabilize within the previously mentioned limits. In case of overheating, the motor must be shut down for inspection of the bearings and temperature sensors. After the bearing working temperature is reached, check if there are no leaks through the plugs, gaskets or through the shaft end. 7.12.2.5 Bearing operation In order to obtain the part list, assembling and disassembling instructions and maintenance details, refer to the specific installation and operation manual of the bearings. 7.12.3 Sleeve bearings 7.12.3.1 Bearing data………………… The characteristic data, such as oil flow, quantity and type are indicated on the bearing nameplate and must be strictly observed; otherwise, overheating and damages to the bearings may occur. Hydraulic installation (for bearings with forced lubrication) and oil supply for the motor bearings are responsibility of the user. 7.12.3.2 Oil change………………….. Self-lubricated bearings The oil change of the bearings must be carried out observing the Table below, according to the bearing working temperature:

Below 75ºC = 20,000 hours






Bearings with (external) oil circulation The oil of the bearings must be changed every 20,000 hours of operation or whenever the lubricant presents modifications in its characteristics. The oil viscosity and pH must be checked regularly.

NOTE

The oil level must be inspected daily and must remain in the middle of the oil sight glass.

The bearings must be lubricated with specific oil,

always observing the flow values informed on their nameplate.

All threaded holes that are not used must be closed with plugs and no connections can present leak;

The oil level is reached when the lubricant can be seen approximately in the middle of the sight glass. The use of a larger amount of oil will not damage the bearing, still it can cause leaks through the shaft seals.

ATTENTION

The care with the lubrication will determine the useful life of the bearings and the safety during the motor operation. Therefore, it is extremely important to observe the following recommendations: The selected oil must be the one with proper viscosity for the working temperature of the bearings; That must be observed in each oil change or in periodical maintenances;

Never use or mix hydraulic oil with the lubricant oil of the bearings;

Lack of lubricant, due to incomplete filling or the not monitoring of the level, can damage the bearing shells.

The minimum oil level is reached when the lubricant can be seen touching the lower part of the sight glass with the motor out of operation.

7.12.3.3 Seals……………………… In case of maintenance of the bearings, when adjusting them again, the two halves of the taconite seal must be joined by a garter spring. This spring must be inserted in the ring seat in such way that the locking pin fits into its fillister in the upper half of the frame. Improper installation destroys the seal. Before assembling the seals, clean the surfaces that touch the ring and its seat carefully, and cover them with a non-hardening sealing component. The drain holes located in the lower half of the ring must be cleaned and cleared. When installing this half of the sealing ring, press it slightly against the shaft lower part.

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7.12.3.4 Bearing operation The operation of motors equipped with sleeve bearings is similar to the operation of motors equipped with rolling bearings. The system start must be monitored carefully, as well as the first hours of operation. Before the start, check: If the lubricant used complies with all specifications; Lubricant characteristics; Oil level; The alarm and shutdown temperatures set for the

bearing. During the first start-up, it is important to inspect for unusual vibrations or noises; if the bearing is not running silently and smoothly, the motor must be immediately shutdown. The motor must operate for several hours until the bearing temperatures stabilize within the previously mentioned limits. In case of overheating, the motor must be shut down for inspection of the bearings and temperature sensors. After the bearing working temperature is reached, check if there are no leaks through the plugs, gaskets or through the shaft end. 7.12.3.5 Bearing maintenance The sleeve bearing maintenance includes: Periodic check of the oil level and lubricant conditions; Check the bearing noise and vibration levels; Monitor the working temperatures and retighten the

fixing and assembling bolts; The frame must be kept clean, without oil or dust built

up on its external part in order to make the heat exchange with the ambient easier.

The NDE bearing is electrically insulated. The spherical seat surfaces of the bearing shell on the frame are covered with insulating material. Never remove this cover;

The anti-rotation pin is also insulated, and the seals are made out of non-conducting material;

Temperature control devices that are in contact with the bearing shell must also be properly insulated.

7.12.3.6 Assembly and disassembly of the

bearings In order to obtain the part list, assembling and disassembling instructions and maintenance details, refer to the specific installation and operation manual of the bearings.

7.12.4 Bearing protection 7.12.4.1 Protection adjustments

ATTENTION

The following temperatures must be adjusted on the bearing protection system: ALARM 110ºC – SHUTTING DOWN 120ºCThe alarm temperature must be adjusted 10ºC above the working duty temperature, not exceeding the limit of 110ºC.

7.12.4.2 Disassembly/assembly of the bearing

temperature sensors

Figure 7.13: Pt100 on the bearings

Instructions for disassembly: If necessary to remove the Pt100 for bearing maintenance, the following procedures must be adopted: Remove the Pt100 with care, locking the locknut (3) and unscrewing just from the bulb adjustment (4);

The parts (2) and (3) must not be disassembled. Instructions for assembly: Before performing the assembly of the Pt100 on the bearing, check if it does not contain dents or any other damage that may compromise its operation. Insert the Pt100 on the bearing; Lock the locknut (3) with a wrench; Screw the bulb (4), adjusting it so that the end of the Pt100 touches the outer surface of the bearing.

NOTES

The assembly of the Pt100 on non-insulated bearings must be done directly on the bearing, without the insulating adapter (4);

The tightening torque to assemble the Pt100 and the adapters must not be exceed 10Nm.

Non-Insulated Bearing

Insulated Bearing

Conduit Conduit

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8 MOTOR DISASSEMBLY AND ASSEMBLY All the services referring to repairs, disassembly and assembly must be executed by duly qualified and trained personnel. The disassembly and assembly sequence depends on the motor model.

8.1 DISASSEMBLY

DANGER

Before touching any interior part of the machine, make sure that there are no voltages, opening all the armature and field supply cables.

Below are listed some of the cares that must be taken when disassembling a synchronous motor: 1. Use proper tools and devices to disassemble the

motor; 2. Before disassembling the motor remove the heat

exchanger or sirocco (if applicable). Disconnect the pipes in air-water heat exchangers (if applicable);

3. Uncouple the tacogenerator (if applicable) according to item 8.1.1;

4. Remove the brushes;

NOTE

It is recommended that an analysis on the condition of brushes, seeking to determine any anomalies. If the brushes have use conditions, put them in a safe place. 1. Protect the commutator with cardboard or

the like so that it does not get damaged during disassembly.

2. Remove the rear external fixing ring , release the NDE-endshield and extract it;

3. Remove the rotor together with the DE-endshield, from inside the motor.

5. Disconnect the electrical and accessory connections; 6. Remove the temperature sensors from the bearings

and grounding brush (if applicable); 7. In order to prevent damages to the rotor, provide a

support to hold the shaft on the front and back sides; 8. To disassemble the bearings, follow the procedures

described in this manual; 9. The removal of the rotor from inside the motor must

be done with a proper device and with extreme care for the rotor not to scrape the stator core or the coil heads, preventing damages.

8.1.1 Tacogenerator Disassembly Tacogenerator 1R: The tacogenerator 1R can be fixed by flange or by feet, and it is coupled to the motor through a flexible coupling. In order to remove it, disconnect the supply cables, release the fixing bolts with the motor and remove the complete tacogenerator. Extract the half-coupling of the motor shaft. Tacogenerator TCW: Up to 132-frame motors, the TCW rotor is assembled directly on the motor shaft and the TCW frame fixed on the motor endshield. Above the 132-frame, the TCW rotor is assembled on a Puller and this is fixed to the motor shaft. TCW frame is fixed to the endshield as in the previous case.

8.2 ASSEMBLY Below are listed some of the cares that must be taken when assembling an electric motor: 1. Use proper tools and devices to assemble the motor; 2. To assemble the motor, follow the disassembly

procedures in the reverse order; Any damaged part (cracks, dents on machined parts, faulty threads) must be preferably replaced, always avoiding restorations. Table 8.1 shows the tightening torques of the bolts recommended for the assembly of the motor or its parts: Table 8.1: Bolt tightening torque

Strength class 4.6 5.8 8.8 12.9

Diameter Tightening torque (Nm) – tolerance ±10% M6 1.9 3.2 5.1 8.7 M8 4.6 7.7 12.5 21

M10 9.1 15 25 41 M12 16 27 42 70 M16 40 65 100 175 M20 75 125 200 340 M24 130 220 350 590

NOTE

The strength class is usually indicated on the head of the hexagonal bolt.

When there is no marking on the bolt, it indicates that the strength class of the bolt is 4.6;

Allen-type hexagon socket cap bolts have strength class 12.9.

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8.3 MEASUREMENT OF THE AIR-GAP After the motor disassembly and assembly, check the air-gaps of the excitation and commutation poles. The original air-gaps must be exactly kept.

8.4 GENERAL RECOMMENDATIONS

ATTENTION

All services described herein must be performed by specialized and experienced personnel; otherwise, personal injuries or damages to the equipment may occur. If you have any questions, contact WEG.

8.5 SPARE PARTS WEG recommends keeping in stock the following spare parts: One DE bearing and one NDE bearing (motor with rolling bearings)

One bearing shell for DE bearing and one bearing shell for the NDE bearing (motor with sleeve bearings)

Temperature sensor for each bearing (if applicable); Space heater; Filter felts (if applicable); Complete set of brushes and brush holders; Shaft grounding brush (if applicable) Lubricant for the bearings Filter (if applicable)

The spare parts must be stored in clean, dry, well-ventilated environments and, if possible, at constant temperature.

8.6 LIST OF PARTS 1. Fixing ring, external drive end. 2. Lubrication nipple 3. Nipple protector 4. Grease Collection box 5. Grease centrifuge, drive end 6. Rolling bearing, drive end 7. D-endshield

7.1. Lateral opening shield 7.2. Eyebolt;

8. Fixing ring, internal drive end. 9. Compensation winding: 10. Excitation winding: 11. Commutation winding: 12. Frame

12.1. Frame ring, drive end 12.2. Frame ring, non drive end

13. Complete rotor 13.1. Rotor balancing ring

14. Commutator 14.1. Commutator flag

15. Complete brush holder 15.1. Brush 15.2. Brush edge 15.3. Brush edge retaining ring

16. Fixing ring, internal non drive end. 17. Upper opening covered

17.1. Multi-leaf damper 17.2. Upper plate

18. Rolling bearing, non drive end 19. Grease centrifuge, non drive end 20. Fixing ring, external non drive end. 21. Sealing disk 22. Air inlet screen 23. Air direction adjuster 24. Fan housing 25. Fan

25.1. Hub fixing bolt 25.2. Hub mounting plate 25.3. Fan hub

26. Motor fan 27. Terminal box

27.1. Cable output cover 27.2. Connection plate for fixing cables 27.3. Connector fixing rail 27.4. Grounding

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Air

Out

let

Air

Inle

t

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9 Maintenance plan The maintenance plan described in Table 9.1 is only referential, considering that the intervals between each maintenance intervention may vary according to the motor location and operating conditions. Table 9.1: Maintenance plan

EQUIPMENT Weekly Monthly

3

months

6 months

annually

3 years Note

STATOR:

Stator visual inspection x

Cleaning control X

Inspection of the slot wedge (offset machines) x

Stator terminal control x

Measure the winding insulation resistance x

ROTOR

Cleaning control x

Visual inspection x

Shaft inspection (wear, incrustations)

x

BEARINGS

Noise, vibration, oil flow, leak and temperature control x

Lubricant quality control x

Inspect the bearing shell and shaft track (sleeve bearing) x

Change the lubricant According to the characteristic indicated on the bearing nameplate

AIR-WATER HEAT EXCHANGER

Inspection of the heat exchangers x

Clean the heat exchangers x

Inspect sacrificial anodes of the heat exchangers (if applicable)1

x Sacrificial anodes are used in heat exchangers with seawater

Change the gaskets of the heat exchanger heads x

AIR-AIR HEAT EXCHANGER

Clean the ventilation pipes x

Inspect the ventilation x

BRUSHES, BRUSH HOLDER

Inspect and clean x

Check brush contact area x

Check free movement inside the brush holder

x

Check the wear of the brushes and change them if necessary x

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EQUIPMENT Weekly Monthly

3

months

6 months

annually

3 years

Note

COMMUTATOR

Inspect and clean the commutator compartment

x

Check commutator contact area x

Check commutator state and wear and patina formation

x

Check the wire drawing machine of the brushes x

AIR FILTER(S)

Inspect, clean and replace if necessary X

PROTECTION AND CONTROL EQUIPMENT

Test operation x

Record values x

Disassemble and test its operation x

COUPLING

Inspect alignment x

Inspect fixation x Check after first week of operation

WHOLE MOTOR

Inspect noise and vibration x

Drain condensate water x

Retighten the bolts x

Clean terminal boxes x

Retighten electric and grounding connections

x

1) If excessive corrosion is found in the sacrificial anode, frequency of inspection must be increased in order to determine the corrosion period and a plan with proper change intervals must be prepared then.

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10 ANOMALIES, CAUSES AND SOLUTIONS

10.1 MOTORS

NOTE

The instructions of Table 10.1 present only a basic list of abnormalities, causes and corrective actions. If you have any questions, contact WEG.

Table 10.1: Basic list of abnormalities, causes and corrective actions

ANOMALY POSSIBLE CAUSES CORRECTION

Interrupted armature circuit Examine input and terminal conductors

Coil, commutation or armature in short circuit Identify the short circuit and recover it

Defective drive system Check if there is interruption or default

in the drive system.

Brush holder out of neutral zone Adjust the neutral zone

Motor will not start with no load

Interrupted field circuit Eliminate interruption

Defective drive system Remedy the default.

Short-circuit among turns in armature Refurbish the armature. Motor starts jolting

Short-circuit among commutator blades Examine commutator and eliminate the

short circuit

Short-circuits among turns in armature Refurbish the armature.

Voltage fall. Check the network demand.

Brushes displaced from the neutral zone. Readjust the position of the brushes in

the neutral zone as indicated on the dent

Motor does not accept load.

Drive system bad set.

Set drive current

Brushes displaced from the neutral zone. Reset the position of the brushes,

obeying the dent.

Interrupted field circuit or field rheostat with excessive resistance

Remedy the interruption. Adjust the resistor correctly

Motor runs too fast and oscillates when facing load.

Series winding, auxiliary, wrongly connected Check the connection and correct it

Overload Test voltage and current Eliminate

overload

Volume of coolant air is not sufficient. Check cooling direction of rotation.

Clean air and/or filter ducts. Substitute filters if necessary.

Short circuit in the armature and field windings.

Check the windings and welding points. Repair coils.

Unusual heating in service

Open inspection cover beside the fan. Close it.

Excessive grease. Remove excess.

Bad or incorrect grease. Relubricate with correct grease.

Bearings in poor condition. Replace rolling bearing.

Unusual heating of the rolling bearings.

Excessive speed or load. Decrease speed or remove excessive

load.

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ANOMALY POSSIBLE CAUSES CORRECTION

Ovalized commutator. Machine, undercut mica and break the edges

of the lamellas

Very dirty commutator surface. Clean commutator.

Formation of grooves on the commutator surface.

Adequate the brushes considering load.

Insulation between protruding blades (mica). Lower mica and break the edges of the

lamellas

Insufficient pressure on the brushes. Check, if necessary, contact WEG.

Little contact between the brush terminal and brush holder.

Retighten the fixing bolts of the brush terminals.

Worn brushes. Replace by other of the same type.

Inadequate type of brush. Make sure that only brushes of the specified

type considering the load are used.

Broken brush edges. Replace brushes.

Brushes are not well seated. Sand the brush and mold it according to the

commutator curve.

Brushes stuck in their compartments. Check the dimensional tolerance of brushes.

Brushes out of the neutral zone. Adjust them obeying the dent.

Sparking on the brushes when the motor faces load.

Short-circuit among commutator blades Identify the short circuit and eliminate it.

Check the quadrature of the brush holder.

Check uniformity of the air-gap of the commutation poles.

Sparking on all the brushes and on some arms of the

brush holder.

Error in the distribution of brushes. Unequal distribution of current. Bad contacts.

Retighten the bolts.

Projection of sparks. Impure particles get loose from the brushes or blades and catch fire.

Clean commutator and all brush holders. If necessary, adequate the type of brush considering the load.

Sparking of the brushes when the load increases. Overload Adjust the values of allowable overload.

Sparking on the brushes when rotation increases

excessively. * Excessive rotation. Adjust speed correctly.

Blackening of certain blades. Contact WEG.

ATTENTION

The motors referenced herein are improved constantly, so the information in this manual is subject to change without notice.

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11 WARRANTY These products, when operated under the conditions stipulated by WEG in the operating manual for such product, are warranted against defects in workmanship and materials for twelve (12) months from start-up date or eighteen (18) months from manufacturer shipment date, whichever occurs first. However, this warranty does not apply to any product which has been subject to misuse, misapplication, neglect (including without limitation, inadequate maintenance, accident, improper installation, modification, adjustment, repair or any other cases originated from inadequate applications). The company will neither be responsible for any expenses incurred in installation, removal from service, consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation expenses of a technician when this is requested by the customer. The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do not give Warranty extension, unless otherwise expressed in writing by WEG. This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed or implied, written or oral. There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale. No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG nor to assume for WEG any other liability in connection with any of its products. In case this happens without WEG's authorization, Warranty is automatically cancelled. LIABILITY Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any claims for consequential damages or labor costs, by reason of any breach of the express warranty described therein. The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action (other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or repair of any product described in this quotation and sold or furnished by the company to the purchaser.

WEG Group - Energy Business Unit Jaraguá do Sul - SC - Brazil Phone: 55 (47) 3276-4000

[email protected] www.weg.net

1013.03/0709

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NOTES

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WEG Group - Energy Business Unit Jaraguá do Sul - SC - Brazil Phone: 55 (47) 3276-4000 [email protected] www.weg.net

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