Keeping Industry Turning Installation & Maintenance

1 KeepingIndustr y Turning20115 EInstallation& MaintenanceSpareparts,installationandmai ntenanceof ac motors2 Installation & MaintenanceIn troduction/ StorageIInnttrroodduuccttiioonnYou r Brook Crompton motor is designedfor long life, and low running c ful Installation and maintena nc e will ensurethat y ou achieve reliable opera ti on and rreeqquuiirreemmeennttssWWAARRNNIINNGGH andling and lifting of electric motors must only beundertaken by authorise d pers onnel. Full productdocumentation and operating instructions must beavailable together with tools and equipmentnecessa ry for safe working prac ti any motor is accepted on site it should beinspected carefu lly for damage or loss incurredduring materials may be damaged includingshe eting and crate o perations may have d amaged fan cowls,te rminal boxes or an in stance of droppage or loss is evident orsuspect ed, it may be necessary to unpack the goodsto establish the full extent of the possible, damage should be recorded,photographed and any damage to the carriers andBrook Cr ompton as s oon as possible,quoting the item number and consignmen t notere ference.

2 LLiiffttiinnggEyebolts and/or lifting trunnions supplied with themotor are designed to support only the weight of themotor, n ot the weight of the motor and any ancillaryequipment attached to it. Be absolutely sure th atcranes, jack s, slings and lifting beams are capableof carrying the weight of equipment to be an eyebolt is provided with the motor, thisshould be screwed down until its shoulder is firmlyagainst the face of the s ta tor f rame to be are n ormally designed for a vertical lift. SSttoorraaggeeIf motors have to be s tored before Installation ,pr eca ut io ns should be taken to on the site c onditions it may benecessa ry to create a s ui table stores area to holdthe motor prior to i ns ta llati on. Packing cases arenot s hould be stored i n a dry, vi bration free andclean area at normal a mbients ( 20 C to 40 C),unless other arrangements have been agreed withBrook Cr lo w temperature ambient storage isan ti cipated, special preca ut ions should be takenwith the typ e of grease, no plastic parts e tc.

3 Toen sure trouble fre e start-up. Motors must be stored away fromcor rosive or che mically damaging placing motors into storage, mach inedcomponents should be carefully inspected. Bearingsand shafts are normally cover ed wi th a corrosionre sistive barrier. If this coating is damaged it shouldbe made good. The component should be cl eanedand the protective coating no circumstanc es should rust be merelycovered hhoolleessMotors provided with drain holes have drain plugsprovided loose in the terminal box u p to frame size180, and fit ted on frames si ze 200 and above. Position the drain holes at the lowest avoid sta tic indentation the storage ar ea shouldbe vibration free. If this is not possible it is stronglyre commended that the motors be stood on thickblocks of rubber or other soft material. Shaftsshould be rotate d by hand one quarter of are voluti on the exposure to some vibrati on isunavoidable the shaft should be locked in position toavoid static indentation of the bearings.

4 Rollerbe ar ings may be fitted with a shaft loc king should be kept in place during fi tted bearings use a lithium based greasewith a recommended shelf l ife of two years. If storedfor a longer period, g rease may need to bere pl ac ed.**Shielded bearings have a storage life of fiv e yearsand a further two years operational life followinginstallation.**Wash all bearing parts with a noncontamin ati ngsolvent. Lightly pack the bearings with greaseapplying a 33% fill by volume into the bearing andhousingsHHeeaatteerrssWhere space hea ters are fitted, and the storageen vironment has wi de humidity and temperaturevariat ions, it is strongly recommended they been er should be placed on the motors to makeoperatives aware of the live heaters. Supplies arenormally 220-240 volt single phase, from a 380-415volt three phase supply. See terminal box li d forde ta ils. A low voltage DC supply could be used as rreessiissttaanncceeDuring extended storage a three monthly insulationtest is recommended to avoid possible lengthydrying out periods when installing.

5 Use a 500 Megger. The insulation resistance betweenphases and between the windings and the frameshould be insulation resis ta nce should be maintainedab ov e 10 megohm. If a lower reading is mea sured,use one of the drying out methods recommended onpa ge 3 unt il an acceptable reading is obtained. Ifheaters are fitted but not energised, they should b eused in future. IInnssttaallllaattiioonnWWoorrkk oonn hhaazzaarrddoouuss aarreeaa mmoottoorrss sshhoouulldd oonnllyy bbeeccaarrrriieedd oouutt bbyy BBrrooookk CCrroommppttoonn hhoollddiinngg aapppprroopprriiaatteehhaazzaarrddoouuss ttoo ffoollllooww tthhee iinnssttrruuccttiioonnss ccoouulldd rreessuulltt iinnsseerriioouuss ppeerrssoonnaall iinnjjuurryy,, ddeeaatthh aanndd // oorr && SSaaffeettyy aatt WWoorrkk eettcc AAcctt 11997744 IItt iiss eesssseennttiiaall eeqquuiippmmeenntt iiss iinnssttaalllleedd,, eeaarrtthheedd aannddgguuaarrddeedd iinn aaccccoorrddaannccee wwiitthh ccuurrrreenntt lleeggiissllaattiioonnLLooccaattiioonnMo t or s must be installed with adequate access forroutine Maintenance .

6 A minimum of ofworki ng space around the motor is space a round the motor, particularly atthe fan inlet (50mm), is also neces sary to several motors are installed in closepr oximity, care must be taken to ensure that there isno recirculation of exhausted warm must be solid, rigi d and & MaintenanceMechanical / Electrical connectionMMeecchhaanniiccaallDDrraaiinn hhoolleessPrior to Installation remove drain plugs if fitted. Ifan y water ha s accumulated, the integrity of allgaskets, sealants etc. should be checked. Drainplu gs should be put back into place after drainin the application calls for direct coupling, thesh afts must be correctly aligned in all three alignmen t can be a major source of noise andvi br ation. Allowance must be made for shaftend-float and thermal expansion in both axial andvertical planes. It is preferable to use flexible lleevveellssThe noise levels published i n current SalesSpecifications are equal to or less than th e limitingvalu es for rotating machines specified InternationalStandards IEC most cases noise levels also meet limiting valuesfor exposure t o noise in the work is the responsibility of the purchaser to ensurethat o ther overriding lower noise l evels if required,eg Machinery Directive, are speci fi ed at th e time oforder, or that the Installation incorporates noiseattenuating rroottaattiioonnThe rotor must be free to rotate within its une ven or bumpy rotation occurs thebearings should be i ns pecte d to establish that theyhave not been damaged during transportation ((IIMM33660011)) && BB3344 ((IIMM22110011))

7 Where a motor is fitted with a C face flange, ie B14or B34 mounted, care must be taken to ensuremount in g bolts do not protude beyond the C facecasting ccoonnnneeccttiioonnThe connection diagram is shown on the leafletenclosed in the motor terminal box or the diagraminside the terminal box lid. The cables used shouldbe capable of carrying the full load current of themotor (see motor name-plate) without overheatingor u ndue voltag e tteerrmmiinnaattiioonnssAll cable t erminations should be tightly lead terminal lugs should be in fac e to facecontact with the motor lead lugs and securing nutsand lockwashers screwed firmly over theconnection. There should be no nuts or loc kwashersfitted be tween the mains and motor should be carri ed out or checked by aqualifie d ele ctrician and equipment must be earthedin accordance with curren t regulations. Theequipment must be correctly fuse d and covers must be in position prior to olate power supply to motor before commen cingany routine cle aning or Maintenance oouutt pprroocceedduurreessIt is pre ferable to dismantle the motor to the pointwhere the rotor is removed.

8 This is not esse ntial butthe drying out process will take longer in theassembled temperature of the windings and the insulati onre sistance s hould be monitored at reg ular initial application of heat the insulation resist-ance will drop quickly and then start to rise slowlyuntil l evel. On dis continuation of the drying process,a further rise in resistance will are several methods which can be used:11place the mot or in a warm (typically 40 C), dryairst re am (fan or convector heater) or in a warmoven with a temperature not exceeding 80 C. Thismethod is pre ferred if the motor i s dismantl t he motor to a low voltage* three phasesupply and inject a current not exceeding 50% of thefull load current into the sta tor winding(* approximat ely 10% of the line voltage). If this iscarried out on an assembled motor, it is possiblethough unlikely that the motor will turn. If so therotor should be locked in positi two phases in parallel, and the third inseries.

9 Apply a low voltage or s upply up to amaximum of 50% of full load current. The statorwinding temperatur e must not be allowed to exceed80 C. In practice the frame should not be hot to thetouch, to guard against internal overheating andconsequent damage to the heaters are fitted these can be is important that a motor i s operated within thelimits of its design volta ge and fr motors for the UK will operate withoutdamage on any voltage in the range 94% to 106% ofthe nameplate voltage. The supply cables must becapable of carrying the ful l l oad current of the motor(s ee motor na mepl ate) without overheating orexcessive voltag e drop under starting condi motors are fitted with an earthing terminal, in oradjacent to the terminal box, to enable connection toan effective earthing bond. The terminal is designedfor connecting the correct size of copper earthconnector. If a different material is to be usedplease refer to Brook motor must be earthed by connecting theshortest possi ble length of cable to the earthScrews.

10 The cable must have a capacity at least thatof the main connections up to 16mm2phaseconductors. Between 16 and 35mm2phas econductors, the earth should be a minimum of16mm2. Above 35mm2pha se conductors, the earthconductor should be a minimum of half the eeaarrtthhiinngg bboonndd sshhoouulldd nnoott bbee tteerrmmiinnaatteedd uunnddeerrtthhee mmoottoorr ffiixxttuurree bboollttss oorr tteerrmmiinnaall ccoovveerr eeaarrtthh lleeaadd ccoouulldd bbee oovveerr--llooookkeedd oonnrreeccoonnnneeccttiioonn aafftteerr mmaaiinntteennaanncceeHHeeaatteerr ccoonnttiinnuuiittyyHeaters should be checked for continuity p rior toconnection to the control circuitr r continuity If fitted, it is recommendedth at thermistors be connected to the control rs provide good thermal eelleeccttrriiccaall iitteemmssWhere auxiliaries are fitted, the characteristicsshould be :RTDs (Resistance Temperature Detectors) shouldha ve thei r resistances checked againstmanufacturer s not megger across the thermistor.