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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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Installation, Operation and Maintenance Manual | 7
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 Inspections and records during storage ............................................................................... 15
3.2.4.10 Maintenance plan during storage ......................................................................................... 16
3.2.4.11 Preparation for commissioning ............................................................................................ 17
3.2.4.11.1 Cleaning ......................................................................................................... 17
3.2.4.11.2 Bearing inspection .......................................................................................... 17
3.2.4.11.3 Bearing lubrication .......................................................................................... 17
3.2.4.11.4 Checking the insulation resistance .................................................................. 17
3.2.4.11.5 Brushes .......................................................................................................... 17
3.2.4.11.6 Others ............................................................................................................ 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 .......................................... 22
4.4.1.5 Space heater ....................................................................................................................... 22
4.4.2 Water leak sensor ............................................................................................................................... 22
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4.5 COOLING ....................................................................................................................................... 23
4.5.1 Water heat exchangers .......................................................................................................................23
4.5.1.1 Heat exchangers for application with seawater ....................................................................23
4.5.2 Independent fans ................................................................................................................................23
4.6 ELECTRICAL CHARACTERISTICS ................................................................................................. 24
4.6.1 Electric connections ............................................................................................................................24
4.6.1.1 Main connection ..................................................................................................................24
4.6.1.2 Grounding ...........................................................................................................................24
4.6.2 Wiring Diagram ...................................................................................................................................25
4.6.2.1 Main terminal box ................................................................................................................25
4.6.2.2 Accessory terminal box .......................................................................................................26
4.6.2.3 General identification of the accessories and instrument ......................................................26
4.6.2.3.1 Thermostat wiring diagram ..............................................................................27
4.6.2.3.2 Thermistor (PTC) wiring diagram .....................................................................28
4.6.2.3.3 Thermoresistance (Pt-100) wiring diagram.......................................................30
4.6.2.3.4 Space heater wiring diagram ...........................................................................31
4.7 MECHANICAL CHARACTERISTICS ................................................................................................. 32
4.7.1 Foundations .........................................................................................................................................32
4.7.2 Forces on the foundations .....................................................................................................................32
4.7.3 Base types ...........................................................................................................................................32
4.7.3.1 Concrete base .....................................................................................................................32
4.7.3.2 Sliding base .........................................................................................................................32
4.7.3.3 Metal base ..........................................................................................................................32
4.7.3.4 Anchors ...............................................................................................................................32
4.7.4 Foundation natural frequency ..............................................................................................................33
4.7.5 Alignment and leveling .........................................................................................................................33
4.7.6 Couplings ...........................................................................................................................................34
4.7.6.1 Direct coupling ....................................................................................................................34
4.7.6.2 Coupling by gears ...............................................................................................................34
4.7.6.3 Coupling by means of pulleys and belts ...............................................................................34
4.7.6.4 Coupling of motors equipped with sleeve bearings ..............................................................35
5
START.............................................................................................................. 36
5.1 POWER SUPPLIES ......................................................................................................................... 36
5.1.1 Starting Switches ................................................................................................................................36
5.1.2 Ward-Leonard system .........................................................................................................................36
5.1.3 Static converters .................................................................................................................................36
5.1.4 Pure DC (Battery bank ).......................................................................................................................36
6
COMMISSIONING ............................................................................................. 37
6.1 PRELIMINARY INSPECTION .......................................................................................................... 37
6.2 INITIAL START-UP .......................................................................................................................... 37
6.3 OPERATION ................................................................................................................................... 38
6.3.1 General ...............................................................................................................................................38
6.3.2 Data record .........................................................................................................................................38
6.3.3 Temperatures......................................................................................................................................38
6.3.4 Bearings .............................................................................................................................................38
6.3.5 Heat exchangers .................................................................................................................................38
6.3.6 Vibration .............................................................................................................................................39
6.3.7 Tripping ..............................................................................................................................................39
7
MAINTENANCE ................................................................................................. 40
7.1 GENERAL ....................................................................................................................................... 40
7.2 GENERAL CLEANING ..................................................................................................................... 40
7.3 INSPECTIONS IN THE WINDINGS ................................................................................................... 40
7.4 WINDING CLEANING ...................................................................................................................... 40
7.5 CLEAN BRUSH COMPARTMENT .................................................................................................. 41
7.6 MAINTENANCE OF THE COOLING SYSTEM ................................................................................. 41
7.6.1 Maintenance of heat exchangers .........................................................................................................41
7.7 COMMUTATOR .............................................................................................................................. 41
7.7.1 Checking the commutation ...................................................................................................................42
7.8 BRUSH HOLDER ............................................................................................................................ 43
7.8.1 Adjustment of the neutral zone ..............................................................................................................43
7.9 BRUSHES ...................................................................................................................................... 43
7.9.1 Adequacy of brushes to load conditions .................................................................................................44
7.10 MOTOR OUT OF OPERATION ......................................................................................................... 44
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7.11 SHAFT GROUNDING DEVICE ......................................................................................................... 44
7.12 BEARING MAINTENANCE ................................................................................................................ 45
7.12.1 Grease rolling bearings ......................................................................................................................... 45
7.12.1.1 Lubrication instruction ......................................................................................................... 45
7.12.1.2 Procedure to lubricate the rolling bearings ........................................................................... 45
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 ................................................................................................................. 46
7.12.1.6 Procedure for changing the grease ...................................................................................... 46
7.12.1.7 Low-temperature greases ................................................................................................... 46
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
TROUBLESHOOTING ....................................................................................... 57
10.1 MOTORS ......................................................................................................................................... 57
11
DECLARATION OF CONFORMITY ..................................................................... 59
12
WARRANTY ..................................................................................................... 60
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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 an
d
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
h
andling 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: -15 ºC to +40 ºC;
Altitude up to 1,000 m.a.s.l.;
Environment according to the motor degree of
p
rotection.
ATTENTION
For motors with water cooling, the ambient
temperature should not be lower than +5 ºC.
At temperatures
below +5 ºC, 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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Installation, Operation and Maintenance Manual | 13
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 co
mply 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 shortl
y
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
m
ust 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 3.2.4.10
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 3.2.4.1.1 and 3.2.4.1.2 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: Protective oil Anticorit BW
Manufacturer: Fuchs
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Installation, Operation and Maintenance Manual | 15
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.
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 (e.g.: TECTYL 511 or
equivalent) inside the bearing;
Close the bearing with the upper sight glass.
If the storage period exceeds 6 months.
Repeat the procedure described above;
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.
3.2.4.9
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
3.2.4.1
.
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l Installation, Operation and Maintenance Manual
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3.2.4.10
Maintenance plan during storage
During the storage period, the motor maintenance must be performed and recorded in accordance with the plan described
in Table 3.1.
Table 3.1: 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 dehum
idifier 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
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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Installation, Operation and Maintenance Manual | 17
3.2.4.11
Preparation for commissioning
3.2.4.11.1
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.
3.2.4.11.2
Bearing inspection
ATTENTION
If the motor storage period exceed six months,
the sleeve bearings must be disassembled,
inspected and cleaned before starting the
motor.
The sleeve bearings without oil tank (dry sump),
regardless of the motor storage time, should
necessarily be disassembled, inspected and
cleaned before starting the motor.
Reassemble the sleeve bearings and carry out
the lubrication.
Contact WEG to perform this procedure.
3.2.4.11.3
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 7.12 of this manual,
always considering the relevant type of bearing.
3.2.4.11.4
Checking the insulation resistance
Before operating the motor, the insulation resistance
must be measured according to the item 3.2.4.4 of this
manual.
3.2.4.11.5
Brushes
Before installing and operating the motor, the brushes
should be lowered back to their original position.
3.2.4.11.6
Others
Follow the remaining procedures described in item 6 of
this manual before operating the motor.
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l Installation, Operation and Maintenance Manual
18
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.
Maximum 30º
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Installation, Operation and Maintenance Manual | 19
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 50 mm above the
f
loor 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 shut down 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 a
brupt reductions
in the insulation resistance are considered
suspicious.
Table 4.2: Insulation resistance referential limits in electric
machines
Insulation resistance value Insulation evaluation
2 MΩ or less Bad
< 50 MΩ
Dangerous
50...100 MΩ
Regular
100...500 MΩ Good
500...1000 MΩ Very Good
> 1000 MΩ
Excellent
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l Installation, Operation and Maintenance Manual
20
4.3.4
Minimum insulation resistance
If the measured insulation resistance is below 100 MΩ at
40 ºC, 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 therm
ores
istors 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.
The ambient temperature is normally, at most, 40 °C.
Above this value, the working conditions are considered
special.
Win
ding temperature °C
R
40ºC
= Rt x Kt
40ºC
To convert the measured insulation resistance
(Rt) for 40ºC, multiply it by the temperature
coefficient (Kt)
Coefficient of insulation resistance variation Kt
40ºC
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