(010)Capstan.pdf

FRV40-226-010-010

REV 1

DESCRIPTION, OPERATION, AND

MAINTENANCE INSTRUCTIONS

Capstan

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-010-010

REV 1

DESCRIPTION, OPERATION, AND

MAINTENANCE INSTRUCTIONS

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

28 June 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-004-010

TITLE OF MANUAL: Anchor Windlass

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1 -00031 FRV40-26 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226004-010 to be provided under contract 50-SPNA- 1 -00031 has been approved by the approval data shown above.

Date:

Chand, LLC Mathews, LA 70375

CAGE CODE: 0D5X4

JillD Text Box

APPROVAL DATA FOR: FRV40-226-010-010

TITLE OF MANUAL: Capstan

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-010-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

JillD Text Box

APPROVAL AND PROCUREMENT RECORD PAGE

JillD Line

JillD Line

JillD Line

JillD Line

JillD Text Box Date:________________ Chand, LLC Mathews, LA 70375

CAGE CODE: 0D5X4

JillD Line

VALIDATION PERFORMANCE

Title of Publication

Capstan

Contractor Sub-Contractor (If Performing Validation)

Halter Marine, Inc. Chand, LLC.

Contract No.(s) and Purchase Orders, If Applicable

50-SPNA-1-00031

Chapter Section Paragraph Date Validation Completed

Check here if Not Validated

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

JillD Text Box

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226-010-010 Capstan. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Capstan. The text is broken down as follows:

Section 1 - Capstan

Section 2 - Planetary Gearbox

Section 3 - Electric Motor

Section 1 - Capstan

Built For: VT-HALTER nsr o r McELROY / CATCHOT

WINCH COMPANY

TABLE OF CONTENTS I

SECTION 1

a Safety a Safety Tags a Installation a Operation......................................................................................................5-8 a Lubrication a Maintenance a Recommended Spares

SECTION 2

a General Arrangement a Winch Assembly Drawings a Component Data Sheets

SAFETY: I

Safety, based on years of experience has been built into your Coastal Marine Equipment, Inc. product. This technical manual is provided to instruct the owner and operator of the proper and safe operation of this equipment. The owner and operators should be familiar with the contents of this manual before operating this equipment.

Proper periodic maintenance of this equipment will help prevent accidents and keep it functioning properly. Ultimately it is the operator's responsibility to know the correct operation of the equipment and location of all personnel in the work area.

GENERAL SAFETY RULES:

S This equipment is not approved for or designed as a personnel lift.

S Do not wear loose clothing while operating this equipment.

S Do not operate this equipment in any manner other than the purpose it was designed for.

s Never operate this equipment alone.

s Do not stand in the path of the rope while the unit is under load.

S Do not try to perform any repair or maintenance on the equipment while it is running.

s The foundation should be able to withstand the breaking strength of the rope / chain.

s Most likely the manufacturer will not perform the installation. It is recommended that sufficient safety guards be placed on or near the equipment to prevent personnel from coming in contact with the end of the rope / chain under load.

s The manufacturer assumes no responsibility for the design or installation of safety guards.

S Keep all personnel not involved with the operation of this equipment clear of moving cable and rotating parts.

CAUTION

1. NEVER PULL EQUIPMENT

FOUNDATION TO DECK

FOUNDATION DURING

INSTALLATION.

2. USE SHIMS OR CHOCKFAST

BETWEEN EQUIPMENT AND DECK

FOUNDATION TO MAINTAIN

ALIGNMENT PRIOR TO SECURING

EQUIPMENT TO FOUNDATION.

3. FAILURE TO ALIGN EQUIPMENT

DURING INSTALLATION CAN

CAUSE BEARING AND GEAR

FAILURE AND VOID ALL

WARRANTIES PROVIDED BY THE

MANUFACTURER.

4. WELDING OF FRAME DURING

INSTALLATION CAN CAUSE

DISTORTION AND MISALIGNMENT

OF EQUIPMENT. IT IS

RECOMMENDED TO SECURE

FOUNDATION TO THE DECK WITH

THE MOUNTING HOLES

PROVIDED.

5. KEEP FINGERS AND TOOLS

AWAY FROM ROTATING PARTS

DURING OPERATION.

6. GOOD SAFETY PRACTICES

SHOULD BE FOLLOWED AT ALL

TIMES.

7. CHECK LUBRICATION BEFORE

OPERATING EQUIPMENT.

INSTALLATION:________________I

GENERAL INSTALLATION REQUIREMENTS:

Electrical Requirements:

15 HP, 575V, 3 PH, 60 HZ

FOUNDATION;

The vessel's equipment foundation should be a level, flat, smooth surface rigid enough to withstand the breaking strength of the rope.

LIFTING:

Never lift the equipment by the gearbox. Use lifting eye provided.

MOUNTING:

Any gaps between the equipment mounting pads and vessel foundation must be eliminated with the use of shims or chocking compound. This is to assure that the equipment frame is not pulled or twisted. The equipment should be attached to the foundation with the proper sized mounting bolts.

CATHEAD OPERATION; I

1. Wrap load end closest to the cathead base.

2. Wrap three to five wraps on cathead

3. To pull load apply tension to the operator end of Ihe rope

4. To stop pulling, let slack on the operator end so head will turn within rope coils.

LINE UNDER TENSION CAN RECOIL.

AVOID POSSIBLE ENTANGLEMENT IN LINE.

DO NOT LIFT LOADS WITH CATHEAD.

TO OPERATOR

\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\y\y) (\\\\\\\y\\\\V\\\\\)(\\\\\\\\\\\\\\\\\\)

TO LOAD

C\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\

LUBRICATION: I

Failure to perform regular periodic preventative maintenance can result in premature failure of equipment components. Due to the severe operating conditions experienced in the marine environment a regular maintenance schedule will greatly extend the life expectancy of your equipment. The equipment should be inspected before each use and periodically during times of dormancy.

Your equipment was properly lubricated prior to shipment from the manufacturing facility but should be checked frequently and before each use. The recommendations listed below are averages based on daily use. These recommendations should be adjusted based on your operating conditions and environmental extremes. Do not mix different brands and types of lubricants. Improper lubrication can be avoided by using good judgment based on the operating conditions.

LUBRICATION SCHEDULE

1 i 1 \ 1 i

Item / Lubrication Point Cathead Planetary Reducer Electrical Motor Bearings \

Type #1 #2 #2 i

Intervals Each Use Each Use** Each Use

Quantity

12.5 Pints |

** Change every 6 months

LUBRICANT TYPE

#1-Shell Alvania EP2 or Equal

#2-Shell Omala 220 or Equal

MAINTENANCE:_______________I

Regular periodic inspection and maintenance is the key safe operation and extended equipment life. Below you will find some recommended areas of inspection but you may find it necessary to add other areas of inspection based on your particular usage.

BASIC CHECK POINTS:

1. In general, check for damaged, deformed, cracked, corroded, loose, worn or missing parts, fasteners and welds.

2. Touch-up any damaged painted surfaces to prevent excessive corrosion.

3. Inspect the rope regularly for signs of fatigue.

4. Check gear reducers for leaks.

RECOMMENDED SPARES J

PARTS

Dip Stick Upper Bushing Lower Bushing Hatch Gasket Oil Check Gasket :

Brake Disc Kit Brake Spring Kit Thrust Washer Reducer / Brake 0-ring / Seal kit Electric Motor Repair Kit :

QTY

Two Two Two Two Two One One Two Two One

SECTION 2

a GENERAL ARRANGEMENT a ASSEMBLY DRAWINGS a COMPONENT DATA SHEETS

PROPRIETARY NOTICE

THIS DRAWING, SKETCH OR TEXT CONTAINS CONCEPTS,

DESIGN, PRODUCTS IINFDRNATIQN THAT IS PROPRIETARY

WMWROY/CAmOT & HAY NOT BE REPRODUCED OR GIVEN

TD A THIRD PARTY WITHOUT THE WRITTEN CONSENT OF

WLROY/CATCHOT TMCH CO., DfC.

REV SCET MIC APPROVE!

BENDING MOMENT:

51,700 W. IBS. ORATED LOAD

124,080 IN. LBS. 0 STALL

CAST STEEL CATHEAD

MOUNTUG PLATE

15 HP ELECTRIC MOTOR

2,000 LBS

(DEADWEIGHT)

9,400 IBS

9,400 LBS (SHEAR)

DRILL .812* DIA. (8-PUCES) EQ. SP. ON

27.50* D.B.C, FOR 3/4' DIA. GR. 8 MOUNTING

BOLTS (SHIPYARD SUPPLIED)

PLAN VIEW

CAUTION

READ CAREFULLY BEFORE INSTALLING THIS EQUPMENT.

1) DECK DOUBl£R AND/OR FOUNDATION SHOULD BE AS PUT AS

POSSIBLE,

2) F GAPS EXIST BEMEN EQUIPMENT FOUNDATION AND DECK

DOUBLER/FOUNOATON, THESE GAPS MUST BE ELJMWAO BY USE

OF SHIMS OR CHOCKING TO AVOD DISTORTION OF EQUIPMENT

FRAME.

3) FAILURE TO SHM OR CHOCK BETWEEN EQUIPMENT FOUNDATION

AND DECK DOUBLER/FOUNDATION, WEN REQUIRED CAN CAUSE

BEARING AND GEARBOX FAILURE AND mi VOID All WARRANTIES

PROVIDED BY THE MANUFACTURER.

PERFORMANCE

9,400 LBS UNE PULL AT 48 FPM

ELECTRICAL REQUIREMENTS

575 V., 3 PH., 60 HZ.

15 HP ELECTRIC MOTOR

CERTIFIED FOR CONSTRUCTION 2/26/04

g?M

J& ""*"* ttflk

T3

OCX

2/26/14 MJtadm

VT.

MCFIRO)/CATCHOT WINCH COMPANY

PO 30X W P OX Vi 39535 '53? DU (? ̂ 87-) ^ 1

D 1C3 1

REVBBM

ITEM NO

QTY PART NO

40039

^0013

6003^

C0020 15

^0016 05

60020 05

BILLS OF MATERIAL

DESCRIPTION

\T NG P

COVFR H Alt

THRt ST WA^HFR

6 CA HHAD VA Hl\ I

CA"TJRr Dl Air

Al SA B^AK

I — CS M ? 75 x fQ

1 3/4

SITS 1/2

TAIN

n AIM

CP\

JM^Sb 0 (f RW E bPri r D A L LMLNSONi ARE 0 B N INCH S

AC IONS I /J2

) CMALS X +(H1

XX 0 ̂

XXX ^2

3 \D RAD o2

LEE 5 & ROU S C6

JRFA F pi Jb vb

BRFAK A L SHARP FJ

W CH ^ 7

FNG C/

\ A

1Y \t B

A^POVED BY A%

MCELROY/CATCHOT WINCH COMPANY

0 POX 48V ^ OX MS ̂ 5^ 4632 PH ( ») 87 6^7

16" CAPSTAN ASSEMBLY

MODEL MCF-16-15EB

1 El

A F o/?/°5

A1 jr/ AR 0

20060

Section 2 - Planetary Gearbox

PLANETARY GEARBOX

PART isio.60033

SERIES 2000

POS.

24-035 C080021 C030061 11-378

FG0395

C1 20009 C080095 C010024 C 173001 C030060 C 172002 C1 74001 26-619 C140065 C085060 14-016 18-025 C1 10045 C080042 02-283 C1 65027 C 142259 C142251 C 165026 C200411 C200863 C010045 C1 25024 C169001 40-034 C 140065

OLD P/N

15B2601 154B2934 154-2522 154-5566 154-2932 154B2446 154-2459 154-2312 154-3115 154-2521 154-3099 154-2712 154-5962 154B3010 154-2489 154-1548 154-1672 154-2704 154-2446 154-3503 154B3670 154B3659 154B3656 154B3669 154-5970 154B2833 154-2376 154B3608 154-3502 154B3388 154B3010

NEW P/N

SAE "C" COUPLING

RETAINING RING INT.

SOCKET HEAD CAP SCREW

SAE "C" FLANGE

GASKET

RING OIL SEAL

RETAINING RING

BALL BEARING

OIL BREATHER

INT.

SOCKET HEAD CAP SCREW

SIGHT GAUGE

MAGNETIC TAP

RF-5 CLOSING COVER

"O" RING

RETAINING RING

SPRINGRF5/21

EXT.

RF-5/21-RF5/130 BRAKE PISTON

EXPANSION CAP

RETAINING RING INT.

INPUT SHAFT RF-5 BRAKE

PARBAK RING

"O" RING

"O" RING

PARBAK RING

STEEL DISC

SINTERED DISC

BALL BEARING

RING OIL SEAL

PLASTIC TAP

RFF-5 BRAKE HOUSING

"O" RING

DESCRIPTION

Planetary Gearbox

QTY.

Section 3 - Electric Motor

ELECTRIC MOTOR

PARTN0.60013

Standard Induction Motors

Installation, Operation, & Maintenance Instructions

11} 12 (13) 14 15 16 17 18) 19 120

FOR VERTICAL CUTAWAY MOTOR & MOTOR PARTS DESCRIPTION - SEE SB247

ITEM

1.

2.

3, 4, S.

6.

7.

8.

9.

10.

DESCRIPTION

Frame Vent Screen Conduit Box Bottom Conduit Box Top*Holding Screw Conduit Box Top Conduit Box Bottom-Holding Bolt *Bali Bearing O.P.E, Pre-loading Spring Inner Bearing Cap O.P.E.

Grease Plug inner Bearing Cap Solt

ITEM

11.

12.

13.

14.

15.

16.

17.

18, 19.

20.

DESCRIPTION

Bracket O.P.E, Baffle Plate O,P.E.

Rotor Core Lifting Eye Bolt Stator Core Frame Stator Winding Baffel Plate Holding Screw Baffle Plate P,E.

Bracket P.E.

ITEM

21.

22.

23, 24.

25.

26.

27.

28.

29.

DESCRIPTION

Bracket Holding Bolt Inner Bearing Cap P.E, Inner Bearing Cap Bolt Grease Plug "Ball Bearing P.E.

Shaft Extent ion Key Shaft Drain Plug (grease}

* * Bracket Screen

P.E. = Pulley End O.P.E. = Opposite Pulley End

* = Bearing Numbers are shown on motor nameplate when requesting information or parts always give complete motor description, model and serial numbers.

** = Bracket and frame screens are optional.

WARNING

These instructions must be followed to ensure safe and proper installation, operation and maintenance of the motor. They should be brought to the attention of all persons who install, operate or maintain this equipment

GENERAL INFORMATION

Marathon Electric motors are all fully factory tested and inspected before shipping Damage during shipment and storage can occur Motors not correctly matched to the power supply and/or the load will not operate properly These instructions are intended as a guide to identify and eliminate these problems before they are overlooked or cause further damage

ACCEPTANCE

Check carefully for any damage that may have occurred in transit If any damage or shortage is discovered, do not accept until an appropriate notation on the freight bill is made Any damage discovered after receipt of equipment should be immediately reported to the carrier

STORAGE

A Keep motors clean

1 Store indoors 2 Keep covered to eliminate airborne dust and dirt 3 Cover openings for ventilation, conduit connections, etc to prevent entry of rodents, snakes, birds, and insects, etc

B Keep motors dry 1 Store in a dry area indoors 2 Temperature swings should be minimal to prevent condensation 3 Space heaters are recommended to prevent condensa-tion 4 Treat unpainted flanges, shafts, and fittings with a rust inhibitor 5 Check insulation resistance before putting motor into service (Consult manufacturerforguidelmes) C Keep Bearings Lubricated

1 Once per month, rotate shaft several turns to distribute grease in bearings

2 If unit has been stored more than one year, add grease before start-up (Refer to lubrication procedure)

INSTALLATION

UNCRATING AND INSPECTION

After uncrating, check for any damage which may have been incurred in handling The motor shaft should turn freely by hand Repair or replace any loose or broken parts before attempting to use the motor

Check to be sure that motor has not been exposed to dirt, grit, or excessive moisture in shipment or storage before installation

Measure insulation resistance (see operation) Clean and dry the windings as required

Never start a motor which has been wet without having it thoroughly dried

SAFETY

Motors should be installed, protected and fused in accordance with latest issue of National Electrical Code, NEMA Standard Publication No MG 2 and local codes

Eyebolts or lifting lugs are intended for lifting the motor only These lifting provisions should never be used when lifting or handling the motor with other equipment (i e pumps, gear boxes, fans or other driven equipment) as a single unit Be sure the eyebolt is fully threaded and tight in its mounting hole

Eyebolt lifting capacity ratings is based on a lifting align-ment coincident with the eyebolt centerhne Eyebolt capacity reduces as deviation from this alignment increases See

NEMA MG 2

Frames and accessories of motors should be grounded in accordance with National Electrical Code (NEC) Article 430 For general information of grounding referto NEC Article 250

Rotating parts such as pulleys, couplings, external fans, and shaft extensions should be permanently guarded

LOCATION

In selecting a location for the motor, consideration should be g iven to environment and ventilation A motor with the proper enclosure for the expected operating condition should be selected

The ambient temperature of the air surrounding the motor should not exceed 40°C (104°F) unless the motor has been especially designed for high ambient temperature applica-tions The free flow of air around the motor should not be obstructed

The motor Should never be placed'in a room with a hazardous process, or where flammable gases or combustible material may be present, unless it it specifically designed for this type of service 1 Dnpproof (open) motors are intended for use indoors where atmosphere is relatively clean, dry and non-corrosive

2 Dnpproof (open) fire pump motors are to be installed in a Type 2 dnpproof environment as defined in NEMA 250

3 Totally enclosed motors may be installed where dirt, moisture and corrosion are present, or in outdoor locations

4 Explosion proof motors are built for use in hazardous locations as indicated by Underwriters' label on motor Consult UL, NEC, and local codes for guidance

Referto Marathon Electric for application assistance

FLOOR MOUNTING

Motors should be provided with a firm, rigid foundation, with the plane of four mounting pads flat within 010 for 56 to 210 frame, 015' from 250 through 500 frame This may be accomplished by shims under the motor feet For special isolation mounting, contact Marathon Electric for assistance

V-BELT DRIVE

1 Select proper type and number of belts and sheaves

Excessive belt load will damage bearings Sheaves should be in accordance to NEMA Spec MG-1 or as approved by the manufacturer for a specific application

2 Align sheaves carefully to avoid axial thrust on motor bearing The drive sheave on the motor should be positioned toward the motor so it is as close as possible to the bearing

3. When adjusting belt tension, make sure the motor is secured by all mounting bolts before tightening belts.

4. Adjust belt tension to belt manufacturers recommenda-tions. Excessive tension will decrease bearing life.

5. For more information see Marathon Electric Publication

SB588.

DIRECT CONNECTED DRIVE

Flexible or solid shaft couplings must be properly aligned for satisfactory operation. On flexible couplings, the clearance between the ends of the shafts should be in accordance with the coupling manufacturer's recommendations or NEMA standards for end play and limited travel in coupling.

MISALIGNMENT and RUN-OUT between direct con-nected shafts will cause increased bearing loads and vibra-tion even when the connection is made by means of a flexible coupling. Excessive misalignment will decrease bearing life.

Proper alignment, perthe specifications of the coupling being used, is critical.

Some large motors are furnished with roller bearings.

Roller bearings should not be used for direct drive.

ELECTRICAL CONNECTIONS

CAUTION

Install and ground per local and national codes.

Consult qualified personnel with questions or if repairs are required.

WARNING

1. Disconnect power before working on motor or driven equipment.

2. Motors with automatic thermal protectors will automatically restart when the protector temperature drops sufficiently. Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment.

3. Motors with manual thermal protectors may start unexpectedly after protector trips. If manual protector trips, disconnect motor from power line. After protector cools (five minutes or more) it can be reset and power may be applied to motor.

4. Discharge all capacitors before servicing motor.

5. Always keep hands and clothing away from moving parts.

6. Never attempt to measure the temperature rise of a motor by touch. Temperature rise must be measured by thermometer, resistance, imbedded detector, or thermocouple.

7. Electrical repairs should be performed by trained and qualified personnel only.

8. Failure to follow instructions and safe electrical procedures could result in serious injury or death.

9. If safety guards are required, be sure the guards are in use.

1. All wiring, fusing, and grounding must comply with National Electrical Codes and local codes.

2. To determine proper wiring, rotation and voltage connections, refer to the information and diagram on the nameplate, separate connection plate or decal. If the plate or decal has been removed, contact Marathon Electric for assistance.

3. Use the proper size of line current protection and motor controls as required by the National Electrical Code and local codes. Recommended use is 125% of full load amps as shown on the nameplate for motors with 40°C ambient and a service factor over 1.0. Recommended use is 115% of full load amps as shown on the nameplate for all other motors. Do not use protection with larger capacities than recommended. Three phase motors must have all three phases protected.

THERMAL PROTECTOR INFORMATION

The nameplate will indicate one of the following:

1. Motor is thermally protected

2. Motor is not thermally protected

3. Motor is provided with overheat protective device

For examples, refer to paragraphs below:

1. Motors equipped with built-in thermal protection have 'THERMALLY PROTECTED" stamped on the nameplate.

Thermal protectors open the motor circuit electrically when the motor overheats or is overloaded.

The protector cannot be reset until the motor cools. If the protector is automatic, it will reset itself. If the protector is manual, press the red button to reset.

2. Motors without thermal protection have nothing stamped on nameplate about thermal protection.

3. Motors that are provided with overheat protective device that does not open the motor circuit directly will indicate

"WITH OVERHEAT PROTECTIVE DEVICE".

A. Motors with this type of "Overheat Protective Device" have protector leads brought out in the motor conduit box marked "P1" and "P2". These leads are intended for connection in series with the stop button of the 3-wire pilot circuit for the magnetic starter which controls the motor. See Figure 1.

B. The circuit controlled by the above "Overheat Protective Device" must be limited to a maximum of 600 volts and 360 volt-amps.

NORMALLY CLOSED PROTECTORS

NORMALLY OPEN

PROTECTORS

Normally Open (N/O) Motor Thermostats may be used in con-junction with controls installed by Original Equipment Manufacturers.

FIGURE 1A

CHANGING ROTATION

1. Keep hands and clothing away from rotating parts.

2. Before the motor is coupled to the load, determine proper rotation.

3. Check rotation by jogging or bumping. Apply power to the motor leads for a short period of time, enough to just get motor shaft to rotate a slight amount to observe shaft rotating direction.

4. Three phase - interchange any two (2) of the three (3) line leads. Single phase- reconnect perthe connection diagram on the motor.

REDUCED VOLTAGE STARTING

Motors used on reduced voltage starting, should be carefully selected based upon power supply limitations and driven load requirements. The motors starting torque will be reduced when using reduced voltage starting. The elapsed time on the start step should be kept as short as possible and should not exceed 5 seconds. It is recommended that this time be limited to 2 seconds. Refer to Marathon Electric for application assistance.

OPERATION

WARNING

Disconnect and lock out before working on motor or driven equipment

BEFORE INITIAL STARTING

1. If a motor has become damp in shipment or in storage, measure the insulation resistance of the stator winding.

Minimum Insulation Resistance In Megohms 1 +

Rated Voltage

Do not attempt to run the motor if the insulation resistance is below this value.

2. If insulation resistance is low, dry out the moisture in one of the following ways:

a. Bake in oven at temperature not more than 90°C (194°F).

b. Enclose motor with canvas orsimilar covering, leaving a hole at the top for moisture to escape, and insert heating units or lamps.

c. Pass a current at low voltage (rotor locked) through the stator winding. Increase the current gradually until the winding temperature, measured with a thermometer, reaches 90°C (194°F). Do not exceed this temperature.

3. See that voltage and frequency stamped on motor and control nameplates correspond with that of the power line.

4. Check all connections to the motor and control with the wiring diagram.

5. Be sure rotor turns freely when disconnected from the load.

Any foreign matter in the air gap should be removed.

6. Leave the motor disconnected from the load for the initial start (see following caution). Check for proper rotation.

Check for correct voltage (within ± 10% of nameplate value) and that it is balanced within 1% at the motor terminals.

After the machine is coupled to the load, check that the nameplate amps are not exceeded. Recheck the voltage level and balance under load per the above guidelines.

Shut down the motor if the above parameters are not met or if any other noise or vibration disturbances are present.

Consult NEMA guidelines or theequipment manufacturer if any questions exist before operating equipment.

CAUTION

For motors nameplated as "belted duty only", do not run motor without belts properly installed.

COLLECTOR RINGS (Wound Rotor Motors Only) The collector rings are sometimes treated at the factory to protect them while in stock and during shipment. The brushes have been fastened in a raised position. Before putting the motor into service, the collector rings should be cleaned to remove this treatment. Use a cleaning fluid that is made for degreasing electrical equipment. All of the brushes must be released and lowered to the collector surface. Keep the rings clean and maintain their polished surfaces. Ordinarily, the rings will require only occasional wiping with a piece of canvas or non-linting cloth. Do not let dustordirtaccumulate between the collector rings.

BRUSHES (Wound Rotor Motors Only) See that the brushes move freely in the holders and at the same time make firm, even contact with the collector rings.

The pressure should be between 2 and 3 pounds per square inch of brush surface.

When installing new brushes, fit them carefully to the collector rings. Be sure that the copper pigtail conductors are securely fastened to, and make good contact with, the brushholders.

ALLOWABLE VOLTAGE AND

FREQUENCY RANGE

If voltage and frequency are within the following range, motors will operate, but with somewhat different characteris-tics than obtained with correct nameplate values.

1. Voltage: Within 10% above or below the value stamped on the nameplate. On three phase systems the voltage should be balanced within 1%. A small voltage unbalance will cause a significant current unbalance.

2. Frequency: Within 5% above or below the value stamped on the nameplate.

3. Voltage and Frequency together: Within 10% (providing frequency above is less than 5%) above or below values stamped on the nameplate.

CLEANLINESS

Keep both the interior and exterior of the motorfree from dirt, water, oil and grease. Motors operating in dirty places should be periodically disassembled and thoroughly cleaned.

CONDENSATION DRAIN PLUGS

All explosion proof and some totally enclosed motors are equipped with automatic drain plugs, they should be free of oil, grease, paint, grit and dirt so they don't clog up. The drain system is designed for normal floor (feet down) mounting. For other mounting positions, modification of the drain system may be required, consult Marathon Electric.

SERVICE

WARNING

Disconnect power before working on motor or driven equipment. Motors with automatic thermal protectors will automatically restart when the protector cools. Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment.

CAUTION

Overgreasing bearings can cause premature bearing and/or motor failure. The amount of grease added should be carefully controlled.____________

NOTE

If lubrication instructions are shown on the motor nameplate, they will supersede this general instruction.

Marathon Electric motors are pregreased with a polyurea mineral oil NGLI grade 2 type grease unless stated otherwise on the motor nameplate. Some compatible brands of polyurea mineral base type grease are: Chevron SRI #2, Rykon Premium #2, Exxon Polyrex EM or Texaco Polystar RB.

Motors are properly lubricated at the time of manufacture.

It is not necessary to lubricate at the time of installation unless the motor has been in storage for a period of 12 months or longer (refer to lubrication procedure that follows).

LUBRICATION PROCEDURES

1. Stop motor. Disconnect and lock out of service.

2. Remove contaminants from grease inlet area.

3. Remove filler and drain plugs.

4. Check filler and drain holes for blockage and clean as necessary.

5. Add proper type and amount of grease. See the

Relubrication Time Intervals table for service schedule and Relubrication Amounts table for volume of grease required.

6. Wipe off excess grease and replace filler and drain plugs (see following warning).

7. Motor is ready for operation.

WARNING

If motor is nameplated for hazardous locations, do not run motor without all of the grease or drain plugs installed.

RELUBRICATION TIME INTERVAL

(For motors with regreasing provisions).

Service Condition

Standard

Severe

Seasonal

NEMA FRAME SIZE

140-180

1800RPM

and less

3yrs.

1yr.

Over 1800

RPM

6 months

3 months

210-360

1800 RPM

and less

2yrs.

1yr.

Over 1800

RPM

6 months

3 months

400-510

1800 RPM

and less

1yr.

6 months

Over 1800

RPM

3 —- n M*^ mmonTns

1 month

See Note 2.

NOTE

1. For motors nameplated as "belted duty only" divide the above intervals by 3.

2. Lubricate at the beginning of the season.

Then follow service schedule above.

SEASONAL SERVICE: The motor remains idle for a period of 6 months or more.

STANDARD SERVICE: Up to 16 hours of operation per day, indoors, 100°F maximum ambient.

SEVERE SERVICE: Greater than 16 hours of operation per day. Continuous operation under high ambient temperatures (100° to 150°F) and/or any of the following:

dirty, moist locations, high vibration (above NEMA standards), heavy shock loading, or where shaft extension end is hot.

RELUBRICATION AMOUNTS

(For motors with regreasing provisions).

NEMA FRAME SIZE

VOLUME cu.

.25 .50 .75 1.00 1.25 1.50 1.75 2.25 2.75 3.00

in. (fluid oz.)

(.14)

(.28) (.42) (.55) (.69) (-83) (.97) (1.2)

(1.5) (1.7)

TROUBLESHOOTING

WARNING

1. Disconnect power before working on motor or driven equipment.

2. Motors with automatic thermal protectors will automatically restart when the protector temperature drops sufficiently. Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment.

3. Motors with manual thermal protectors may start unexpectedly after protector trips. If manual protector trips, disconnect motor from power line. After protector cools (five minutes or more) it can be reset and power may be applied to motor.

4. Discharge all capacitors before servicing motor.

5. Always keep hands and clothing away from moving parts.

6. Never attempt to measure the temperature rise of a motor by touch. Temperature rise must be measured by thermometer, resistance, imbedded detector, or thermocouple.

7. Electrical repairs should be performed by trained and qualified personnel only.

8. Failure to follow instructions and safe electrical procedures could result in serious injury or death.

9. If safety guards are required, be sure the guards are in use.

If trouble is experienced in the operation of the motor, make sure that:

1. The bearings are in good condition and operating properly.

2. There is no mechanical obstruction to prevent rotation in the motor or in the driven load.

3. The air gap is uniform. (Consult manufacturer for specifications).

4. All bolts and nuts are tightened securely.

5. Proper connection to drive machine or load has been made.

In checking for electrical troubles, be sure that:

1. The line voltage and frequency correspond to the voltage and frequency stamped on the nameplate of the motor.

2. The vojtage is actually available at motor terminals.

3. The fuses and other protective devices are in proper condition.

4. All connections and contacts are properly made in the circuits between the control apparatus and motor.

These instructions do not cover all details or variations in equipment nor provide for every possible condition to be met in connection with installation, operation or maintenance. Should additional information be desired for the purchaser's purposes, the matter should be referred to the nearest Marathon Electric Manufacturing Corp. sales office listed on the back page.

MOTOR TROUBLE SHOOTING CHART

Your motor service and any trouble shooting must be handled by qualified persons who have proper tools and equipment.

TROUBLE

Motor fails to start

Motor stalls

Motor runs and then dies down Motor does not come up to speed

Motor takes too long to accelerate and/or draws high amp

Wrong rotation Motor overheats while running under load

Motor vibrates

Unbalanced line current on polyphase motors during normal operation Scraping noise

Noisy operation

Hot bearings general

Hot bearings ball

CAUSE

Blown fuses Overload trips Improper power supply

Improper line connections Open circuit in winding or control switch

Mechanical failure

Short circuited stator Poor stator coil connection Rotor defective Motor may be overloaded One phase may be open Wrong application Overload Low voltage Open circuit Power failure

Not applied properly Voltage too low at motor terminals because of line drop Starting load too high Broken rotor bars or loose rotor

Open pnmary circuit Excessive load Low voltage during start Defective squirrel cage rotor Applied voltage too low Wrong sequence of phases Overload Frame or bracket vents may be clogged with dirt and prevent proper ventialation of motor Motor may have one phase open Grounded coil Unbalanced terminal voltage Motor misaligned Weak support Coupling out of balance Dnven equipment unbalanced Defective bearings Bearings not in line Balancing weights shifted Polyphase motor running single phase Excessive end play Unequal terminal volts Single phase operation Unbalanced voltage

Fan rubbing air shield Fan striking insulation Loose on bedplate Airgap not uniform Rotor unbalance Bent or sprung shaft Excessive belt pull Pulleys too far away Pulley diameter too small Misalignment Insufficient grease Deterioration of grease or lubircant contaminated Excess lubricant Overloaded beanng Broken ball or rough races

WHAT TO DO

Replace fuses with proper type and rating Check and reset overload in starter Check to see that power supplied agrees with motor nameplate and load factor Check connections with diagram supplied with motor Indicated by humming sound when switch is closed Check for loose wmng connections Also see that all control contacts are closing Check to see if motor and dnve turn freely Check bearings and lubrication Indicated by blown fuses Motor must be rewound Remove end bells, locate with test lamp Look for broken bars or end nngs Reduce load Check lines for open phase Change type or size Consult manufacturer Reduce load See that nameplate voltage is maintained Check connection Fuses blown, check overload relay, stator and pushbuttons Check for loose connections to line, to fuses and to control

Consult supplier for proper type Use higher voltage on transformer terminals or reduce load Check connections Check conductors for proper size Check load motor is supposed to carry at start Look for cracks near the nngs A new rotor may be required as repairs are usually temporary Locate fault with testing device and repair Reduce load Check for high resistance Adequate wire size Replace witffnew rotor Get power company to increase power tap Reverse connections at motor or at switchboard Reduce load Open vent holes and check for a continuous stream of air from the motor

Check to make sure that all leads are well connected Locate and repair Check for faulty leads, connections and transformers Realign Strengthen base Balance coupling Rebalance dnven equipment Replace beanng Line up property Rebalance motor Check for open circuit Adjust beanng or add shim Check leads and connections Check for open contacts Correct unbalanced power supply

Remove interference Clear fan Tighten holding bplts Check and correct bracket fits or bearing^ Rebalance Straiahten or replace shaft Decrease belt tension Move pulley closer to motor beanng Use larger pulleys Correct by realignment of dnve Maintain proper quantity of grease in beanng Remove old grease, wash bearings thoroughly in kerosene and replace with new grease Reduce quantity of grease, beanng should not be more than 1/2 filled Check alignment, side and end thrust Replace beanng first clean housing thoroughly

A- EE7300R

SINGLE VDLTAGE THREE PHASE

MDTDR WITH 2 LEADS OUT FRDM

SPACE HEATERS,

SPACE HEATER

SPACE HEATERS

CDNNECTED IN PARALLEL

SPACE HEATERS CDNNECTED

IN SERIES PARALLEL

HI

Tl

T2

T3 H2

VIEW DF TERMINAL END

IF MDTDR HAS

6 LEADS

Tl - Tl - T2.

TE.

T3-

REV

08-07-19%

BATE

REDRAWN ON CADD

CN 22509

CHANGE

PGK

NAME

N/

MAX, SURFACE ROUGHNESS

UNLESS NOTED OTHERWISE

MATL SPEC

FINISH

REFERENCE DRW,

UNLESS OTHERWISE SPEC!

TDL, DN XX± ,02 XXX*

ARC IN INC HES

005 XXXX±,0005 ANGLES ± 7'30"

WAUSAU, WISCONSIN 54401

PART NAME CONNECTION DIAGRAM

30 - SINGLE VDLTAGE

DRAWN pG|<

CHKD

BY ML

TB

08-06-1996

08-07-1996

08-07-1996

DRWG NO

A- I ISHDP BOOK PURCHASED DISTRIBUTIDN - WA - LB - WP - LM - BR CADD FILE NO, EE7300R

The Metric System and Equivalents

Linear Measure Liquid Measure

1 centimeter =10 millimeters = 39 inch 1 decimeter =10 centimeters = 3 94 inches 1 meter =10 decimeters = 39 37 inches 1 dekameter = 10 meters = 32 8 feet 1 hectometer = 10 dekameters = 328 08 feet 1 kilometer = 10 hectometers = 3,280 8 feet

Weights

1 centigram = 10 milligrams =15 gram 1 decigram = 10 centigrams = 1 54 grams 1 gram = 10 decigram = 035 ounce 1 dekagram = 10 grams = 35 ounce 1 hectogram = 10 dekagrams = 3 52 ounces 1 kilogram = 10 hectograms = 22 pounds 1 quintal = 100 kilograms = 220 46 pounds 1 metric ton = 10 quintals = 1 1 short tons

1 centiliter = 10 milhters = 34 fl ounce 1 deciliter =10 centiliters = 3 38 fl ounces 1 liter = 10 deciliters = 33 81 fl ounces 1 dekaliter =10 liters = 2 64 gallons 1 hectoliter = 10 dekaliters = 26 42 gallons 1 kiloliter = 10 hectoliters = 264 18 gallons

Square Measure

1 sq centimeter = 100 sq millimeters = 155sq inch 1 sq decimeter = 100 sq centimeters = 15 5 sq inches 1 sq meter (centare) = 100 sq decimeters = 10 76 sq feet 1 sq dekameter (are) = 100 sq meters = 1,076 4 sq feet 1 sq hectometer (hectare) = 100 sq dekameters = 2 47 acres 1 sq kilometer = 100 sq hectometers = 386 sq mile

Cubic Measure

1 cu centimeter = 1000 cu millimeters = 06 cu inch 1 cu decimeter = 1000 cu centimeters = 61 02 cu inches 1 cu meter = 1000 cu decimeters = 35 31 cu feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound-feet pound-inches centimeters 2 540 meters 305 meters 914 kilometers 1 609 square centimeters 6 451 square meters 093 square meters 836 square kilometers 2 590 square hectometers 405 cubic meters 028 cubic meters 765 milhliters 29,573 liters 473 liters 946 liters 3 785 grams 28 349 kilograms 454 metnc tons 907 newton-meters 1 356 newton-meters 11296 ounce-inches centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milhliters liters liters liters grams kilograms metric tons newton-meters inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons

007062

1 094

10764 1 196

35315 1 308

1 057

1 102

Temperature (Exact)

°F Fahrenheit temperature

5/9 (after subtracting 32)

Celsius °C temperature