O&M_Hydronic_Pumps_-_4.2.pdf

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SHHWP 3&4 – MOTOR MANUAL

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Manual of Electric Motors 55

Installation, Operation and Maintenance Manual of Electric Motors

This manual provides information about WEG induction motors fitted with squirrel cage, permanent magnet or hybrid rotors, low, medium and high voltage, in frame size IEC 56 to 630 and NEMA 42 to 9606/10.

The motor lines indicated below have additional information that can be checked in their respective manuals:

g Smoke Extraction Motors;

g Electromagnetic Brake Motors;

g Hazardous Area Motors.

These motors meet the following standards, if applicable:

g NBR 17094-1: Máquinas Elétricas Girantes - Motores de Indução - Parte 1: Trifásicos g NBR 17094-2: Máquinas Elétricas Girantes - Motores de Indução - Parte 2: Monofásicos g IEC 60034-1: Rotating Electrical Machines - Part 1: Rating and Performance g NEMA MG 1: Motors and Generators g CSA C 22.2 N°100: Motors and Generators g UL 1004-1: Rotating Electrical Machines – General Requirements

If you have any questions regarding this manual please contact your local WEG branch, contact details can be found at www.weg.net.

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TABLE OF CONTENTS

1. TERMINOLOGY

2. INITIAL RECOMMENDATIONS

2.1. WARNING SYMBOL

2.2. RECEIVING INSPECTION

2.3. NAMEPLATES

3. SAFETY INSTRUCTIONS

4. HANDLING AND TRANSPORT

4.1. LIFTING

4.1.1. Horizontal motors with one eyebolt

4.1.2. Horizontal motor with two eyebolts

4.1.3. Vertical Motors

4.1.3.1. Procedures to place W22 motors in the vertical position

4.1.3.2. Procedures to place HGF motors in the vertical position

4.2 PROCEDURES TO PLACE W22 VERTICAL MOUNT MOTORS IN HORIZONTAL POSITION

5. STORAGE

5.1. EXPOSED MACHINED SURFACES

5.2. STORAGE

5.3. BEARINGS

5.3.1. Grease lubricated bearings

5.3.2. Oil Lubricated bearings

5.3.3. Oil Mist lubricated bearings

5.3.4. Sleeve Bearing

5.4. INSULATION RESISTANCE

5.4.1. Insulation resistance measurement

6. INSTALLATION

6.1. FOUNDATIONS

6.2. MOTOR MOUNTING

6.2.1. Foot mounted motors

6.2.2. Flange mounted motor

6.2.3. Pad mounted motors

6.3. BALANCING

6.4. COUPLINGS

6.4.1. Direct coupling

6.4.2. Gearbox coupling

6.4.3. Pulley and belt coupling

6.4.4. Coupling of sleeve bearing motors

6.5. LEVELING

6.6. ALIGNMENT

6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS

6.8. CONNECTION OF THE COOLING WATER SYSTEM

6.9. ELECTRICAL CONNECTION

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6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES

6.11. RESISTANCE TEMPERATURE DETECTORS (PT-100)

6.12. STARTING METHODS

6.13. MOTORS DRIVEN BY FREQUENCY INVERTER

6.13.1. Use of dV/dt filter

6.13.1.1. Motor with enameled round wire

6.13.1.2. Motor with prewound coils

6.13.2. Bearing insulation

6.13.3. Switching Frequency

6.13.4. Mechanical speed limitation

7. COMMISSIONING

7.1. INITIAL START-UP

7.2. OPERATING CONDITIONS

7.2.1. Limits of vibration

8. MAINTENANCE

8.1. GENERAL INSPECTION

8.2. LUBRICATION

8.2.1. Grease lubricated rolling bearings

8.2.1.1. Motor without grease fitting

8.2.1.2. Motor with grease fitting

8.2.1.3. Compatibility of the Mobil Polyrex EM grease with other greases

8.2.2. Oil lubricated bearings

8.2.3. Oil mist lubricated bearings

8.2.4. Sleeve bearings

8.3. MOTOR ASSEMBLY AND DISASSEMBLY

8.3.1. Terminal box

8.4. DRYING THE STATOR WINDING INSULATION

8.5. SPARE PARTS

9. ENVIRONMENTAL INFORMATION

9.1. PACKAGING

9.2. PRODUCT

10. TROUBLESHOOTING CHART X SOLUTIONS

11. WARRANTY

12. DECLARATION OF CONFORMITY

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1. TERMINOLOGY

Balancing: the procedure by which the mass distribution of a rotor is checked and, if necessary, adjusted to ensure that the residual unbalance or the vibration of the journals and/or forces on the bearings at a frequency corresponding to service speed are within specified limits in International Standards.

[ISO 1925:2001, definition 4.1]

Balance quality grade: indicates the peak velocity amplitude of vibration, given in mm/s, of a rotor running free-in-space and it is the product of a specific unbalance and the angular velocity of the rotor at maximum operating speed.

Grounded Part: metallic part connected to the grounding system.

Live Part: conductor or conductive part intended to be energized in normal operation, including a neutral conductor.

Authorized personnel: employee who has formal approval of the company.

Qualified personnel: employee who meets the following conditions simultaneously:

g Receives training under the guidance and responsibility of a qualified and authorized professional;

g Works under the responsibility of a qualified and approved professional.

Note: The qualification is only valid for the company that trained the employee in the conditions set out by the authorized and qualified professional responsible for training.

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2. INITIAL RECOMMENDATIONS

For practical reasons, it is not possible to include in this Manual detailed information that covers all construction variables nor covering all possible assembly, operation or maintenance alternatives.

This Manual contains only the required information that allows qualified and trained personnel to carry out their services. The product images are shown for illustrative purpose only.

For Smoke Extraction Motors, please refer to the additional instruction manual 50026367 available on the website www.weg.net.

For brake motors, please refer to the information contained in WEG 50006742 / 50021973 brake motor manual available on the website www.weg.net.

For information about permissible radial and axial shaft loads, please check the product technical catalogue.

Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious injury to people during normal operation. Therefore, it is recommended that transportation, storage, installation, operation and maintenance services are always performed by qualified personnel.

Also the applicable procedures and relevant standards of the country where the machine will be installed must be considered.

Noncompliance with the recommended procedures in this manual and other references on the WEG website may cause severe personal injuries and/or substantial property damage and may void the product warranty.

The user is responsible for the correct definition of the installation environment and application characteristics.

During the warranty period, all repair, overhaul and reclamation services must be carried out by WEG authorized Service Centers to maintain validity of the warranty.

Warning about safety and warranty.

2.2. RECEIVING INSPECTION

All motors are tested during the manufacturing process.

The motor must be checked when received for any damage that may have occurred during the transportation.

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

You must inspect the product:

g Check if nameplate data complies with the purchase order;

g Remove the shaft locking device (if any) and rotate the shaft by hand to ensure that it rotates freely.

g Check that the motor has not been exposed to excessive dust and moisture during the transportation.

Do not remove the protective grease from the shaft, or the plugs from the cable entries. These protections must remain in place until the installation has been completed.

2.1. WARNING SYMBOL

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2.3. NAMEPLATES

The nameplate contains information that describes the construction characteristics and the performance of the motor. Figure 2.1 and Figure 2.2 show nameplate layout examples.

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Figure 2.1 – IEC motor nameplate.

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Figure 2.2 – NEMA motor nameplate

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3. SAFETY INSTRUCTIONS

The motor must be disconnected from the power supply and be completely stopped before conducting any installation or maintenance procedures. Additional measures should be taken to avoid accidental motor starting.

Professionals working with electrical installations, either in the assembly, operation or maintenance, should use proper tools and be instructed on the application of standards and safety requirements, including the use of Personal Protective Equipment (PPE) that must be carefully observed in order to reduce risk of personal injury during these services.

Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious injury to people during normal operation. It is recommended that transportation, storage, installation, operation and maintenance services are always performed by qualified personnel.

Always follow the safety, installation, maintenance and inspection instructions in accordance with the applicable standards in each country.

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Figure 4.1 – Correct tightening of the eyebolt Figure 4.2 – Incorrect tightening of the eyebolt.

4. HANDLING AND TRANSPORT

Eyebolts provided on the frame are designed for lifting the machine only. Do not use these eyebolts for lifting the motor with coupled equipment such as bases, pulleys, pumps, reducers, etc.

Never use damaged, bent or cracked eyebolts. Always check the eyebolt condition before lifting the motor.

Eyebolts mounted on components, such as on end shields, forced ventilation kits, etc. must be used for lifting these components only. Do not use them for lifting the complete machine set.

To move or transport motors with cylindrical roller bearings or angular contact ball bearings, use always the shaft locking device provided with the motor.

All HGF motors, regardless of bearing type, must be transported with shaft locking device fitted.

Before lifting the motor ensure that all eyebolts are tightened properly and the eyebolt shoulders are in contact with the base to be lifted, as shown in Figure 4.1. Figure 4.2 shows an incorrect tightening of the eyebolt.

Ensure that lifting machine has the required lifting capacity for the weight indicated on the motor nameplate.

The center-of-gravity may change depending on motor design and accessories. During the lifting procedures the maximum allowed angle of inclination should never be exceeded as specified below.

Individually packaged motors should never be lifted by the shaft or by the packaging. They must be lifted only by means of the eyebolts, when supplied. Use always suitable lifting devices to lift the motor. Eyebolts on the frame are designed for lifting the machine weight only as indicated on the motor nameplate. Motors supplied on pallets must be lifted by the pallet base with lifting devices fully supporting the motor weight.

The package should never be dropped. Handle it carefully to avoid bearing damage.

Handle the motor carefully without sudden impacts to avoid bearing damage and prevent excessive mechanical stresses on the eyebolts resulting in its rupture.

4.1. LIFTING

4.1.1. Horizontal motors with one eyebolt

For horizontal motors fitted with only one eyebolt, the maximum allowed angle-of-inclination during the lifting process should not exceed 30º in relation to the vertical axis, as shown in Figure 4.3.

30° Max.

Figure 4.3 – Maximum allowed angle-of-inclination for motor with one eyebolt.

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4.1.2. Horizontal motor with two eyebolts

When motors are fitted with two or more eyebolts, all supplied eyebolts must be used simultaneously for the lifting procedure.

There are two possible eyebolt arrangements (vertical and inclined), as shown below:

g For motors with vertical lifting eyebolts, as shown in Figure 4.4, the maximum allowed lifting angle should not exceed 45° in relation to the vertical axis. We recommend to use a spreader bar for maintaining the lifting elements (chain or rope) in vertical position and thus preventing damage to the motor surface.

45° Max.

Figure 4.4 – Maximum resulting angle for motors with two or more lifting eyebolts.

Figure 4.5 – Maximum resulting angle for horizontal HGF motors

Figure 4.6 – Use of a spreader bar for lifting.

g For HGF motors, as shown in Figure 4.5, the maximum resulting angle should not exceed 30° in relation to the vertical axis.

g For motors fitted with inclined eyebolts, as shown in Figure 4.6, the use of a spreader bar is required for maintaining the lifting elements (chain or rope) in vertical position and thus preventing damage to the motor surface.

30° Max.

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4.1.3. Vertical Motors

For vertical mounted motors, as shown in Figure 4.7, the use of a spreader bar is required for maintaining the lifting element (chain or rope) in vertical position and thus preventing damage to the motor surface.

4.1.3.1. Procedures to place W22 motors in the vertical position

For safety reasons during the transport, vertical mounted Motors are usually packed and supplied in horizontal position.

To place W22 motors fitted with eyebolts (see Figure 4.6), to the vertical position, proceed as follows:

1. Ensure that the eyebolts are tightened properly, as shown in Figure 4.1;

2. Remove the motor from the packaging, using the top mounted eyebolts, as shown in Figure 4.9;

Figure 4.7 – Lifting of vertical mounted motors.

Figure 4.8 – Lifting of HGF motors.

Figure 4.9 – Removing the motor from the packaging.

Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the mounting position. See Figure 4.8.

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3. Install a second pair of eyebolts, as shown in Figure 4.10;

4. Reduce the load on the first pair of eyebolts to start the motor rotation, as shown in Figure 4.11. This procedure must be carried out slowly and carefully.

These procedures will help you to move motors designed for vertical mounting. These procedures are also used to place the motor from the horizontal position into the vertical position and vertical to horizontal.

Figure 4.10 – Installation of the second pair of eyebolts.

Figure 4.11 – End result: motor placed in vertical position.

Figure 4.12 – Lifting HGF motor with two hoists.

4.1.3.2. Procedures to place HGF motors in the vertical position

HGF motors are fitted with eight lifting points: four at drive end and four at non-drive end. The HGF motors are usually transported in horizontal position, however for the installation they must be placed in the vertical position.

To place an HGF motor in the vertical position, proceed as follows:

1. Lift the motor by using the four lateral eyebolts and two hoists, see Figure 4.12;

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2. Lower the hoist fixed to motor drive end while lifting the hoist fixed to motor non-drive end until the motor reaches its equilibrium, see Figure 4.13.

3. Remove the hoist hooks from the drive end eyebolts and rotate the motor 180° to fix the removed hooks into the two eyebolts at the motor non-drive end, see Figure 4.14.

4. Fix the removed hoist hooks in the other two eyebolts at the non-drive end and lift the motor until the vertical position is reached, see Figure 4.15.

These procedures will help you to move motors designed for vertical mounting. These procedures are also used to place the motor from the horizontal position into the vertical position and vertical to horizontal.

Figure 4.13 – Placing HGF motor in vertical position

Figure 4.14 – Lifting HGF motors by the eyebolts at the non-drive end.

Figure 4.15 – HGF motor in the vertical position

4.2 Procedures to place W22 vertical mount motors in horizontal position

To place W22 vertical mount motor in horizontal position, proceed as follows:

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3. Install the second pair of eyebolts, as shown in Figure 4.17;

4. Reduce the load on the first pair of eyebolts for rotating the motor, as shown in Figure 4.18. This procedure must be carried out slowly and carefully.

5. Remove the first pair of eyebolts, as shown in Figure 4.19.

Figure 4.16 – Install the first pair of eyebolts

Figure 4.17 – Install the second pair of eyebolts

Figure 4.18 – Motor is being rotated to horizontal position

Figure 4.19 – Final result: motor placed in horizontal position

1. Ensure that all eyebolts are tightened properly, as shown in Figure 4.1;

2. Install the first pair of eyebolts and lift the motor as shown in Figure 4.16;

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5. STORAGE

If the motor is not installed immediately, it must be stored in a dry and clean environment, with relative humidity not exceeding 60%, with an ambient temperature between 5 ºC and 40 ºC, without sudden temperature changes, free of dust, vibrations, gases or corrosive agents. The motor must be stored in horizontal position, unless specifically designed for vertical operation, without placing objects on it. Do not remove the protection grease from shaft end to prevent rust.

If the motor are fitted with space heaters, they must always be turned on during the storage period or when the installed motor is out of operation. Space heaters will prevent water condensation inside the motor and keep the winding insulation resistance within acceptable levels. Store the motor in such position that the condensed water can be easily drained. If fitted, remove pulleys or couplings from the shaft end (more information are given on item 6).

5.1. EXPOSED MACHINED SURFACES

All exposed machined surfaces (like shaft end and flange) are factory-protected with temporary rust inhibitor. A protective film must be reapplied periodically (at least every six months), or when it has been removed and/or damaged.

5.2. STORAGE

The stacking height of the motor packaging during the storage period should not exceed 5 m, always considering the criteria indicated in Table 5.1:

Notes:

1) Never stack larger packaging onto smaller packaging.

2) Align the packaging correctly (see Figure 5.1 and Figure 5.2).

The space heaters should never be energized when the motor is in operation.

Table 5.1 – Max. recommended stacking height

Packaging Type Frame sizes Maximum stacking quantity

Cardboard box IEC 63 to 132 NEMA 143 to 215

Indicated on the top side of the cardboard box

Wood crate

IEC 63 to 315 NEMA 48 to 504/5 06

IEC 355

NEMA 586/7 and 588/9 03

HGF IEC 315 to 630 HGF NEMA 5000 to 9600 Indicated on the packaging

X Figure 5.1 – Correct stacking Figure 5.2 – Incorrect stacking

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5.3 BEARINGS

5.3.1 Grease lubricated bearings

We recommend rotating the motor shaft at least once a month (by hand, at least five revolutions, stopping the shaft at a different position from the original one). If the motor is fitted with shaft locking device, remove it before rotating the shaft and install it again before performing any handling procedure. Vertical motors may be stored in the vertical or in horizontal position. If motors with open bearings are stored longer than six months, the bearings must be relubricated according to item 8.2 before commissioning of the motor.

If the motor is stored for longer than 2 years, the bearings must be replaced or removed, washed, inspected and relubricated according to item 8.2.

5.3.2 Oil Lubricated bearings

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be ensured. It should be in the center of the sight glass.

During the storage period, remove the shaft locking device and rotate the shaft by hand every month, at least five revolutions, thus achieving an even oil distribution inside the bearing and maintaining the bearing in good operating conditions. Reinstall the shaft locking device every time the motor has to be moved.

If the motor is stored for a period of over six months, the bearings must be relubricated according to Item 8.2 before starting the operation. If the motor is stored for a period of over two years, the bearings must be replaced or removed, washed according to manufacturer instructions, checked and relubricated according to Item 8.2. The oil of vertical mounted motors that are transported in horizontal position is removed to prevent oils leaks during the transport. These motors must be stored in vertical position after receiving and the bearing must be lubricated.

3) The feet of the crates above should always be supported by suitable wood battens (Figure 5.3) and never stand on the steel tape or without support (Figure 5.4).

4) When stacking smaller crates onto longer crates, always ensure that suitable wooden supports are provided to withstand the weight (see Figure 5.5). This condition usually occurs with motor packaging above IEC 225S/M (NEMA 364/5T) frame sizes.

Figure 5.5 – Use of additional battens for stacking

Figure 5.3 – Correct stacking Figure 5.4 – Incorrect stacking

X X

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5.3.3 Oil Mist lubricated bearings

The motor must be stored in horizontal position. Lubricate the bearings with ISO VG 68 mineral oil in the amount indicated in the Table 5.2 (this is also valid for bearings with equivalent dimensions). After filling with oil, rotate the shaft by hand, at least five revolutions) During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at least five revolutions, stopping it at a different position from the original one. Reinstall the shaft locking device every time the motor has to be moved. If the motor is stored for a period of over two years, the bearings must be replaced or removed, washed according to manufacturer instructions, checked and relubricated according to item 8.2.

5.3.4 Sleeve Bearing

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be ensured. It should be in the middle of the sight glass. During the storage period, remove the shaft locking device and rotate the shaft by hand every month, at least five revolutions, and at 30 rpm, thus achieving an even oil distribution inside the bearing and maintaining the bearing in good operating conditions. Reinstall the shaft locking device every time the motor has to be moved.

If the motor is stored for a period of over six months, the bearings must be relubricated according to the Item

8.2 before starting the operation.

If the motor is stored for a period longer than the oil change interval, or if it is not possible to rotate the motor shaft by hand, the oil must be drained and a corrosion protection and dehumidifiers must be applied.

The oil must always be removed when the motor has to be handled. If the oil mist system is not operating after installation, fill the bearings with oil to prevent bearing rusting. During the storage period, rotate the shaft by hand, at least five revolutions, stopping it at a different position from the original one. Before starting the motor, all bearing protection oil must be drained from the bearing and the oil mist system must be switched ON.

Table 5.2 – Amount of oil per bearing

Bearing Size Amount of Oil (ml) Bearing Size Amount of Oil (ml)

6201 15 6309 65

6202 15 6311 90

6203 15 6312 105

6204 25 6314 150

6205 25 6315 200

6206 35 6316 250

6207 35 6317 300

6208 40 6319 350

6209 40 6320 400

6211 45 6322 550

6212 50 6324 600

6307 45 6326 650

6308 55 6328 700

5.4. INSULATION RESISTANCE

We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage conditions should be evaluated and corrected, where necessary.

5.4.1. Insulation resistance measurement

We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage conditions should be evaluated and corrected, where necessary.

The insulation resistance must be measured in a safe environment.

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The insulation resistance must be measured with a megohmmeter. The machine must be in cold state and disconnected from the power supply.

The reading of the insulation resistance must be corrected to 40°C as shown in the Table 5.4.

It is recommended to insulate and test each phase separately. This procedure allows the comparison of the insulation resistance between each phase. During the test of one phase, the other phases must be grounded.

The test of all phases simultaneously evaluates the insulation resistance to ground only but does not evaluate the insulation resistance between the phases.

The power supply cables, switches, capacitors and other external devices connected to the motor may considerably influence the insulation resistance measurement. Thus all external devices must be disconnected and grounded during the insulation resistance measurement.

Measure the insulation resistance one minute after the voltage has been applied to the winding. The applied voltage should be as shown in Table 5.3.

Table 5.3 – Voltage for the insulation resistance

Table 5.4 – Correction Factor for the Insulation Resistance corrected to 40°C

To prevent the risk of an electrical shock, ground the terminals before and after each measurement.

Ground the capacitor (if any) to ensure that it is fully discharged before the measurement is taken.

Winding rated voltage (V) Testing voltage for measuring the insulation resistance (V)

< 1000V 500

1000 - 2500 500 - 1000

2501 - 5000 1000 - 2500

5001 - 12000 2500 - 5000

> 12000 5000 - 10000

Measuring temperature of the insulation resistance (°C)

Correction factor of the insulation resistance corrected to 40°C

10 0.125

11 0.134

12 0.144

13 0.154

14 0.165

15 0.177

16 0.189

17 0.203

18 0.218

19 0.233

20 0.250

21 0.268

22 0.287

23 0.308

24 0.330

25 0.354

26 0.379

27 0.406

28 0.435

29 0.467

30 0.500

Measuring temperature of the insulation resistance

(°C)

Correction factor of the insulation resistance corrected to 40°C

30 0.500

31 0.536

32 0.574

33 0.616

34 0.660

35 0.707

36 0.758

37 0.812

38 0.871

39 0.933

40 1.000

41 1.072

42 1.149

43 1.231

44 1.320

45 1.414

46 1.516

47 1.625

48 1.741

49 1.866

50 2.000

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The motor insulation condition must be evaluated by comparing the measured value with the values indicated in Table 5.5 (corrected to 40 °C):

The values indicated in the table should be considered only as reference values. It is advisable to log all measured values to provide a quick and easy overview on the machine insulation resistance.

If the insulation resistance is low, moisture may be present in the stator windings. In this case the motor should be removed and transported to a WEG authorized Service Center for proper evaluation and repair (This service is not covered by the warranty). To improve the insulation resistance through the drying process, see section 8.4.

Table 5.5 – Evaluation of the insulation system

Limit value for rated voltage up to 1.1 kV (MΩ)

Limit value for rated voltage above 1.1 kV (MΩ) Situation

Up to 5 Up to 100 Dangerous. The motor can not be operated in this condition

5 to 100 100 to 500 Regular

100 to 500 Higher than 500 Good

Higher than 500 Higher than 1000 Excellent

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Figure 6.1 – Detail of the rubber drain plug mounted in closed and open position.

6. INSTALLATION

Check some aspects before proceeding with the installation:

1. Insulation resistance: must be within the acceptable limits. See item 5.4.

2. Bearings:

a. Rolling bearings: oxidized bearings must be replaced. If no oxidation is detected, lubricate the bearings as described in Item 8.2. If the motor is stored for a period of over two years, the bearings must be replaced before starting the motor.

b. Sleeve bearing: if sleeve bearing motors are stored longer than the recommended oil change interval, the oil must be changed before machine starting. Don’t forget to remove the dehumidifiers when you drain the oil from the motor and to fill it again with new oil before starting the machine. For more details, see item 8.2.

3. Operating conditions of the start capacitors: If single-phase motors are stored for a period of over two years, it is recommended to change the start capacitors before motor starting since they lose their operating characteristics.

4. Terminal box:

a. the inside of the terminal box must be clean and dry.

b. the contacts must be correctly connected and corrosion free. See 6.9 and 6.10.

c. the cable entries must be correctly sealed and the terminal box cover properly mounted in order to ensure the degree of protection indicated on the motor nameplate.

5. Cooling: the cooling fins, air inlet and outlet openings must be clean and unobstructed. The distance between the air inlet openings and the wall should not be shorter than ¼ (one quarter) of the diameter of the air inlet. Ensure sufficient space to perform the cleaning services. See item 7.

6. Coupling: remove the shaft locking device (where fitted) and the corrosion protection grease from the shaft end and flange just before installing the motor. See item 6.4.

7. Drain hole: the motor must always be positioned so the drain hole is at the lowest position (If there is any indication arrow on the drain, the drain must be so installed that the arrow points downwards).

Motors supplied with rubber drain plugs leave the factory in the closed position and must be opened periodically to allow the exit of condensed water. For environments with high water condensation levels and motor with degree of protection IP55, the drain plugs can be mounted in open position (see Figure 6.1).

For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position (see Figure 6.1), being opened only during the motor maintenance procedures.

The drain system of motors with Oil Mist lubrication system must be connected to a specific collection system (see Figure 6.11).

The insulation resistance must be measured in a safe environment.

Closed position Open position

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8.Additional recommendations:

a. Check the direction of motor rotation, starting the motor at no-load before coupling it to the load.

b. Vertical mounted motors with shaft end down must be fitted with drip cover to protect them from liquids or solids that may drop onto the motors.

c. Vertical mounted motors with shaft end up must be fitted with water slinger ring to prevent water penetration inside the motor.

The motors may be mounted on:

g Concrete bases: are most used for large-size motors (see Figure 6.2);

g Metallic bases: are generally used for small-size motors (see Figure 6.3).

Remove or fix the shaft key before starting the motor.

Please consider for the foundation dimensioning all stresses that are generated during the operation of the driven load.

The user is responsible for the foundation designing and construction.

6.1. FOUNDATIONS

The foundation is the structure, structural element, natural or prepared base, designed to withstand the stresses produced by the installed equipment, ensuring safe and stable performance during operation. The foundation design should consider the adjacent structures to avoid the influences of other installed equipment and no vibration is transferred through the structure

The foundation must be flat and its selection and design must consider the following characteristics:

a) The features of the machine to be installed on the foundation, the driven loads, application, maximum allowed deformations and vibration levels (for instance, motors with reduced vibration levels, foot flatness, flange concentricity, axial and radial loads, etc. lower than the values specified for standard motors).

b) Adjacent buildings, conservation status, maximum applied load estimation, type of foundation and fixation and vibrations transmitted by theses constructions.

If the motor is supplied with leveling/alignment bolts, this must be considered in the base design.

Figure 6.2 – Motor installed on concrete base Figure 6.3 – Motor installed on metallic base

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The metallic and concrete bases may be fitted with sliding system. These types of foundations are generally used where the power transmission is achieved by belts and pulleys. This power transmission system is easier to assemble/disassemble and allows the belt tension adjustment. Other important aspect of this foundation type is the location of the base locking screws that must be diagonally opposite. The rail nearest the drive pulley is placed in such a way that the positioning bolt is between the motor and the driven machine. The other rail must be placed with the bolt on the opposite side (diagonally opposite), as shown in Figure 6.4 .

To facilitate assembly, the bases may have the following features:

g shoulders and/or recesses;

g anchor bolts with loose plates;

g bolts cast in the concrete;

g leveling screws;

g positioning screws;

g steel & cast iron blocks, plates with flat surfaces.

Figure 6.4 – Motor installed on sliding base

After completing the installation, it is recommended that all exposed machined surfaces are coated with suitable rust inhibitor.

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6.2. MOTOR MOUNTING

6.2.1. Foot mounted motors

The drawings of the mounting hole dimensions for NEMA or IEC motors can be checked in the respective technical catalogue.

The motor must be correctly aligned and leveled with the driven machine. Incorrect alignment and leveling may result in bearing damage, generate excessive vibration and even shaft distortion/breakage.

For more details, see section 6.3 and 6.6. The thread engagement length of the mounting bolt should be at least 1.5 times the bolt diameter. This thread engagement length should be evaluated in more severe applications and increased accordingly.

Figure 6.5 shows the mounting system of a foot mounted motor indicating the minimum required thread engagement length.

Figure 6.5 – Mounting system of a foot mounted motor

L = 1.5 x D

D

6.2.2. Flange mounted motors

The drawings of the flange mounting dimensions, IEC and NEMA flanges, can be checked in the technical catalogue.

The coupling of the driven equipment to the motor flange must be properly dimensioned to ensure the required concentricity of the assembly.

Depending on the flange type, the mounting can be performed from the motor to the driven equipment flange (flange FF (IEC) or D (NEMA)) or from the driven equipment flange to the motor (flange C (DIN or NEMA)).

For the mounting process from the driven equipment flange to the motor, you must consider the bolt length, flange thickness and the thread depth of the motor flange.

For flange mounting the thread engagement length of the mounting bolt should be at least 1.5 times the bolt diameter. In severe applications, longer thread engagement length may be required.

In severe applications or if large motors are flange mounted, a foot or pad mounting may be required in addition to the flange mounting (Figure 6.6). The motor must never be supported on its cooling fins.

If the motor flange has tapped through-holes, the length of the mounting bolts must not exceed the tapped through-hole length of the motor flange, thus preventing damage to the winding head.

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6.2.3. Pad mounted motors

Typically, this method of mounting is used in axial fans. The motor is fixed by tapped holes in the frame. The dimensions of these tapped holes can be checked in the respective product catalogue. The selection of the motor mounting rods/bolts must consider the dimensions of the fan case, the installation base and the thread depth in the motor frame.

The mounting rods and the fan case wall must be sufficiently stiff to prevent the transmission of excessive vibration to the machine set (motor & fan). Figure 6.7 shows the pad mounting system.

Figure 6.6 - Mounting method of flange mounted motors with frame base support

Figure 6.7 – Mounting of the motor inside the cooling duct

Note:

When liquid (for example oil) is likely to come into contact with the shaft seal, please contact your local WEG representative.

The balance quality grade meets the applicable standards for each product line.

The maximum balancing deviation must be recorded in the installation report

The transmission elements, such as pulleys, couplings, etc., must balanced with “half key” before they are mounted on the motor shaft.

6.3. BALANCING

Unbalanced machines generate vibration which can result in damage to the motor. WEG motors are dynamically balanced with “half key” and without load (uncoupled). Special balancing quality level must be stated in the Purchase Order.

6.4. COUPLINGS

Couplings are used to transmit the torque from the motor shaft to the shaft of the driven machine. The following aspects must be considered when couplings are installed:

g Use proper tools for coupling assembly & disassembly to avoid damages to the motor and bearings.

g Whenever possible, use flexible couplings, since they can absorb eventual residual misalignments during the machine operation.

g The maximum loads and speed limits informed in the coupling and motor manufacturer catalogues cannot be exceeded.

g Level and align the motor as specified in sections 6.5 and 6.6, respectively.

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Motors designed with sleeve bearings have 3 (three) marks on the shaft end. The center mark is the indication of the magnetic center and the 2 (two) outside marks indicate the allowed limits of the rotor axial movement, as shown in Figure 6.8.

The motor must be so coupled that during operation the arrow on the frame is placed over the central mark indicating the rotor magnetic center. During start-up, or even during operation, the rotor may freely move between the two outside marks when the driven machine exerts an axial load on the motor shaft. However, under no circumstance, the motor can operate continuously with axial forces on the bearing.

6.4.1. Direct coupling

Direct coupling is characterized when the Motor shaft is directly coupled to the shaft of the driven machine without transmission elements. Whenever possible, use direct coupling due to lower cost, less space required for installation and more safety against accidents.

6.4.2. Gearbox coupling

Gearbox coupling is typically used where speed reduction is required.

Make sure that shafts are perfectly aligned and strictly parallel (in case of straight spur gears) and in the right meshing angle (in case of bevel and helical gears).

6.4.3. Pulley and belt coupling

Pulleys and belts are used when speed increase or reduction between motor shaft and driven load is required.

6.4.4. Coupling of sleeve bearing motors

Remove or fix the shaft key firmly when the motor is operated without coupling in order to prevent accidents.

Do not use roller bearings for direct coupling, unless sufficient radial load is expected.

Excessive belt tension will damage the bearings and cause unexpected accidents such as breakage of the motor shaft.

Motors designed with sleeve bearings must be operated with direct coupling to the driven machine or a gearbox. Pulley and belts can not be applied for sleeve bearing motors.

Axial Clearance

Figure 6.8 – Axial clearance of motor designed with sleeve bearing

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The sleeve bearings used by WEG were not designed to support axial load continuously.

Under no circumstance must the motor be operated continuously at its axial clearance limits.

Figure 6.9 – Typical misalignment condition

* For Motors in accordance with API 541, the total axial clearance is 12.7 mm

For coupling evaluation consider the maximum axial bearing clearance as shown in Table 6.1.

The axial clearance of the driven machine and coupling influence the maximum bearing clearance.

Table 6.1 – Clearance used for sleeve bearings

Bearing size Total axial clearance (mm)

9* 3 + 3 = 6

11* 4 + 4 = 8

14* 5 + 5 =10

18 7,5 + 7,5 = 15

6.5. LEVELING

The motor must be leveled to correct any deviations in flatness arising from the manufacturing process and the material structure rearrangement. The leveling can be carried out by a leveling screw fixed on the motor foot or on the flange or by means of thin compensation shims. After the leveling process, the leveling height between the motor mounting base and the motor cannot exceed 0.1 mm.

If a metallic base is used to level the height of the motor shaft end and the shaft end of the driven machine, level only the metallic base relating to the concrete base.

Record the maximum leveling deviations in the installation report.

6.6. ALIGNMENT

The correct alignment between the motor and the driven machine is one of the most important variables that extends the useful service life of the motor. Incorrect coupling alignment generates high loads and vibrations reducing the useful life of the bearings and even resulting in shaft breakages. Figure 6.9 illustrates the misalignment between the motor and the driven machine.

Alignment procedures must be carried out using suitable tools and devices, such as dial gauge, laser alignment instruments, etc. The motor shaft must be aligned axially and radially with the driven machine shaft.

The maximum allowed eccentricity for a complete shaft turn should not exceed 0.03 mm, when alignment is made with dial gauges, as shown in Figure 6.10. Ensure a gap between couplings to compensate the thermal expansion between the shafts as specified by the coupling manufacturer.

Motor shaft Driven machine shaft Max.

misalignment

Driven machine offset (mm)

Motor offset (mm)

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If alignment is made by a laser instrument, please consider the instructions and recommendations provided by the laser instrument manufacturer.

The alignment should be checked at ambient temperature with machine at operating temperature.

Pulley and belt couplings must be so aligned that the driver pulley center lies in the same plane of the driven pulley center and the motor shaft and the shaft of the driven machine are perfectly parallel.

After completing the alignment procedures, ensure that mounting devices do not change the motor and machine alignment and leveling resulting into machine damage during operation.

It is recommended to record the maximum alignment deviation in the Installation Report.

Figure 6.10 – Alignment with dial gauge.

The coupling alignment must be checked periodically

6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS

When oil lubricated or oil mist lubricated motors are installed, connect the existing lubricant tubes (oil inlet and oil outlet tubes and motor drain tube), as shown in Figure 6.11. The lubrication system must ensure continuous oil flow through the bearings as specified by the manufacturer of the installed lubrication system.

Parallel alignment Angular alignment

Reference

GAP

Line

Dial gauge

Inlet

Drain

Outlet

Figure 6.11 – Oil supply and drain system of oil lubricated or oil mist lubricated motors

6.8. CONNECTION OF THE COOLING WATER SYSTEM

When water cooled motors are installed, connect the water inlet and outlet tubes to ensure proper motor cooling. According to item 7.2, ensure correct cooling water flow rate and water temperature in the motor cooling system.

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If motors are supplied without terminal blocks, insulate the cable terminals with suitable insulation material that meets the power supply voltage and the insulation class indicated on the motor nameplate.

Ensure correct tightening torque for the power cable and grounding connections as specified in Table 8.7

The clearance distance (see Figure 6.12) between non-insulated live parts with each other and between grounded parts must be as indicated in Table 6.2.

6.9. ELECTRICAL CONNECTION

Consider the rated motor current, service factor, starting current, environmental and installation conditions, maximum voltage drop, etc. to select appropriate power supply cables and switching and protection devices.

All motors must be installed with overload protection systems. Three-phase motors should be fitted with phase fault protection systems.

Before connecting the motor, check if the power supply voltage and the frequency comply with the motor nameplate data. All wiring must be made according to the connection diagram on the motor nameplate. To prevent accidents, check if motor has been solidly grounded in accordance with the applicable standards.

Clearance distance

Clearance distance

Clearance distance Clearance distance

Figure 6 -12 – Clearance distance representation

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Even when the motor is off, dangerous voltages may be present inside the terminal box used for the space heater supply or winding energization when the winding is used as heating element.

Motor capacitors will hold a charge even after the power has been cut off. Do not touch the capacitors and/or motor terminals, before discharging the capacitors completely.

Unused cable inlet holes in the terminal box must be properly closed to ensure the degree of protection indicated on the motor nameplate.

The cable inlets used for power supply and control must be fitted with components (for example, cable-glands and conduits) that meet the applicable standards and regulations in each country.

If the motor is fitted with accessories, such as brakes and forced cooling systems, these devices must be connected to the power supply according to the information provided on their nameplates and with special care as indicated above.

Do not apply test voltage above 2.5 V on thermistors and current above 1 mA on RTDs (Pt-100) according to IEC 60751 standard.

After the motor connection has been completed, ensure that no tool or foreign body has been left inside the terminal box.

All protection devices, including overcurrent protection, must be set according to the rated machine conditions.

These protection devices must protect the machine against short circuit, phase fault or locked rotor condition.

The motor protection devices must be set according to the applicable standards.

Check the direction of rotation of the motor shaft. If there is no limitation for the use of unidirectional fans, the shaft rotation direction can be changed by reversing any two of the phase connections. For single-phase motor, check the connection diagram indicated on the motor nameplate.

Figure 6.13 and Figure 6.14 show the connection diagram of the bimetal thermal protector (thermostats) and thermistors, respectively.

6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES

If the motor is supplied with temperature monitoring devices, such as, thermostat, thermistors, automatic thermal protectors, Pt-100 (RTD), etc., they must be connected to the corresponding control devices as specified on the accessory nameplates. The non-compliance with this procedure may void the product warranty and cause serious material damages.

Table 6.2 – Minimum clearance distance (mm) x supply voltage.

Voltage Minimum clearance distance (mm)

U ≤ 440 V 4

440 < U ≤ 690V 5.5

690 < U ≤ 1000V 8

1000 < U ≤ 6900V 45

6900 < U ≤ 11000V 70

11000<U ≤ 16500V 105

Figure 6.13 – Connection of the bimetal thermal protectors (thermostats)

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The alarm temperature limits and thermal protection shutdowns can be defined according to the application;

however these temperature limits can not exceed the values in Table 6.3.

Figure 6.14 – Thermistor connection

Table 6.3 – Maximum activation temperature of the thermal protections

Component Insulation class Maximum temperature of the protection setting (°C)

Alarm Tripping

Winding

B - 130

F 130 155

H 155 180

Bearing All 110 120

Notes:

1) The number and type of the installed protection devices are stated on the accessory nameplate of the motor.

2) If the motor is supplied with calibrated resistance, (for example, Pt 100), the motor protection system must be set according to the operating temperatures indicated in Table 6.3.

6.11. RESISTANCE TEMPERATURE DETECTORS (Pt-100)

The thermocouples Pt-100 are made of materials, whose resistance depends on the temperature variation, intrinsic property of some materials (usually platinum, nickel or copper), calibrated resistance. Its operation is based on the principle that the electric resistance of a metallic conductor varies linearly with the temperature, thus allowing a continuous monitoring of the motor warm-up through the controller display ensuring a high level of precision and answer stability. These devices are widely used for measuring temperatures in various industry sectors.

In general these devices are used in installations where precise temperature control is required, for example, in installation for irregular or intermittent duty.

The same detector may be used for alarm and tripping purposes.

Table 6.4 and Figure 6.15 show the equivalence between the Pt-100 resistance and the temperature.

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Table 6.4 – Equivalence between the Pt-100 resistance and the temperature.

ºC Ω ºC Ω ºC Ω ºC Ω ºC Ω -29 88.617 17 106.627 63 124.390 109 141.908 155 159.180 -28 89.011 18 107.016 64 124.774 110 142.286 156 159.553 -27 89.405 19 107.404 65 125.157 111 142.664 157 159.926 -26 89.799 20 107.793 66 125.540 112 143.042 158 160.298 -25 90.193 21 108.181 67 125.923 113 143.420 159 160.671 -24 90.587 22 108.570 68 126.306 114 143.797 160 161.043 -23 90.980 23 108.958 69 126.689 115 144.175 161 161.415 -22 91.374 24 109.346 70 127.072 116 144.552 162 161.787 -21 91.767 25 109.734 71 127.454 117 144.930 163 162.159 -20 92.160 26 110.122 72 127.837 118 145.307 164 162.531 -19 92.553 27 110.509 73 128.219 119 145.684 165 162.903 -18 92.946 28 110.897 74 128.602 120 146.061 166 163.274 -17 93.339 29 111.284 75 128.984 121 146.438 167 163.646 -16 93.732 30 111.672 76 129.366 122 146.814 168 164.017 -15 94.125 31 112.059 77 129.748 123 147.191 169 164.388 -14 94.517 32 112.446 78 130.130 124 147.567 170 164.760 -13 94.910 33 112.833 79 130.511 125 147.944 171 165.131 -12 95.302 34 113.220 80 130.893 126 148.320 172 165.501 -11 95.694 35 113.607 81 131.274 127 148.696 173 165.872 -10 96.086 36 113.994 82 131.656 128 149.072 174 166.243 -9 96.478 37 114.380 83 132.037 129 149.448 175 166.613 -8 96.870 38 114.767 84 132.418 130 149.824 176 166.984 -7 97.262 39 115.153 85 132.799 131 150.199 177 167.354 -6 97.653 40 115.539 86 133.180 132 150.575 178 167.724 -5 98.045 41 115.925 87 133.561 133 150.950 179 168.095 -4 98.436 42 116.311 88 133.941 134 151.326 180 168.465 -3…