APPENDIX I - Newburyport District Court - WEG CHW Pump Motor.pdf

MASSACHUSETTS TRIAL COURT | REGION 3 CHILLER

SERVICE AGREEMENT

Region 3 Chiller Service Agreement RFP | Page 19 of 30

COMMONWEALTH OF MASSACHUSETTS

MASSACHUSETTS TRIAL COURT

REQUEST FOR PROPOSALS

Region 3 Chiller and Associated HVAC Equipment Preventive Maintenance and Repair Service Agreement

APPENDIX I

Newburyport District Court - WEG CHW Pump Motor O&M Manual

This appendix is incorporated by reference into the Region 3 Chiller Service Agreement Request for Proposals.

Facilities Management & Capital Planning

Manualslib.com - The Global Manuals Library

Manuals / Brands / WEG Manuals / Engine / W22 Premium / Installation, operation and maintenance manual / PDF

WEG W22 PREMIUM INSTALLATION,

OPERATION AND MAINTENANCE MANUAL

Available languages

EN ES

Quick Links Nameplates Grease Lubricated Bearings Electrical Connection Lubrication https://www.manualslib.com/ https://www.manualslib.com/ https://www.manualslib.com/brand/ https://www.manualslib.com/brand/weg/ https://www.manualslib.com/brand/weg/engine.html https://www.manualslib.com/products/Weg-W22-Premium-14612375.html https://www.manualslib.com/manual/3779421/Weg-W22-Premium.html https://static-data2.manualslib.com/product-images/16b/3779421/weg-w22-premium.jpg

Table of Contents Table of Contents

INITIAL RECOMMENDATIONS

WARNING SYMBOL

RECEIVING INSPECTION

NAMEPLATES

SAFETY INSTRUCTIONS

HANDLING AND TRANSPORT

LIFTING

Horizontal motors with one eyebolt Horizontal motor with two eyebolts Vertical motors Procedures to place W22 motors in the vertical position Procedures to place HGF motors in the vertical position Procedures to place W22 vertical mount motors in horizontal position

STORAGE

EXPOSED MACHINED SURFACES

BEARINGS

Grease lubricated bearings Oil lubricated bearings Oil Mist lubricated bearings Sleeve bearing

INSULATION RESISTANCE

Insulation resistance measurement

INSTALLATION

FOUNDATIONS

Foot mounted motors Flange mounted motors

MOTOR MOUNTING

Pad mounted motors

BALANCING

COUPLINGS

Direct coupling Gearbox coupling Pulley and belt coupling Coupling of sleeve bearing motors

LEVELING

ALIGNMENT

CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED

MOTORS

CONNECTION OF THE COOLING WATER SYSTEM

ELECTRICAL CONNECTION

CONNECTION OF THE THERMAL PROTECTION DEVICES

RESISTANCE TEMPERATURE DETECTORS (PT-100)

CONNECTION OF THE SPACE HEATERS

STARTING METHODS

MOTORS DRIVEN BY FREQUENCY INVERTER

Use of dV/dt filter Motor with enameled round wire Motor with prewound coils Bearing insulation Switching frequency Mechanical speed limitation

COMMISSIONING

INITIAL START-UP

OPERATING CONDITIONS

Limits of vibration

MAINTENANCE

GENERAL INSPECTION

LUBRICATION

Grease lubricated rolling bearings Motor without grease fitting Motor with grease fitting Compatibility of the Mobil Polyrex EM grease with other greases Oil lubricated bearings Oil mist lubricated bearings Sleeve bearings

MOTOR ASSEMBLY AND DISASSEMBLY

Terminal box

DRYING THE STATOR WINDING INSULATION

SPARE PARTS

ENVIRONMENTAL INFORMATION

PACKAGING

PRODUCT

TROUBLESHOOTING CHART X SOLUTIONS

RECOMENDACIONES INICIALES

SENÃLES DE ADVERTENCIA

VERIFICACION EN LA RECEPCION

PLACAS DE CARACTERÍSTICAS

SEGURIDAD

MANIPULACION Y TRANSPORTE

ELEVACIÓN

Motores horizontales con un cáncamo de elevación Motores horizontales con dos o más cáncamos de elevación Motores verticales Procedimiento para colocación de motores W22 en posición vertical Procedimiento para colocación de motores HGF en posición vertical

PROCEDIMIENTO PARA VIRADA DE MOTORES W22

VERTICALES

ALMACENAMIENTO

SUPERFICIES MECANIZADAS EXPUESTAS

APILAMIENTO

COJINETES

Cojinetes de rodamiento lubricados con grasa Cojinetes de rodamiento con lubricación por aceite Cojinetes de rodamiento con lubricación de tipo neblina de aceite Cojinetes de deslelevación

RESISTENCIA DE AISLAMIENTO

Procedimiento para medición de la resistencia de aislamiento

INSTALACION

CIMIENTOS PARA EL MOTOR

FIJACION DEL MOTOR

Fijación por las patas Fijación por brida Fijación por pad

EQUILIBRADO

ACOPLAMIENTOS

Acoplamiento directo Acoplamiento por engranaje Acoplamiento por poleas y correas

Acoplamiento de motores equipados con cojinetes de deslelevación

NIVELACION

ALINEAMIENTO

CONEXION DE MOTORES LUBRICADOS A ACEITE O DE TIPO OIL

MIST

CONEXION DEL SISTEMA DE REFRIGERACION POR AGUA

CONEXION ELECTRICA

CONEXION DE LOS DISPOSITIVOS DE PROTECCION TERMICA

TERMORESISTORES (PT-100)

CONEXION DE LAS RESISTENCIAS DE CALDEO

METODOS DE PUESTA EN MARCHA

MOTORES ALIMENTADOS POR CONVERTIDOR DE FRECUENCIA

Uso de filtros (dV/dt) Motor con alambre circular esmaltado Motor con bobina preformada Aislamiento de los cojinetes Frecuencia de conmutación Límite de la rotación mecánica

PRUEBA DE FUNCIONAMIENTO

ARRANQUE DEL MOTOR

CONDICIONES DE PRUEBA DE FUNCIONAMIENTO

Límites de las Vibraciones

MANTENIMIENTO

INSPECCION GENERAL

LUBRICACION

Cojinetes de rodamiento lubricados a grasa Motores sin accesorio de engrase Motores con accesorio de engrase Compatibilidad de la grasa Mobil Polyrex EM con otras grasas Cojinetes de rodamiento lubricados con aceite Cojinetes de rodamiento con lubricación de tipo Oil Mist Cojinetes de deslelevación

DESMONTAJE Y MONTAJE

Caja de conexión

PROCEDIMIENTO PARA ADECUACION DE LA RESISTENCIA DE

AISLAMIENTO

PARTES Y PIEZAS

DATOS MEDIOAMBIENTALES

EMBALAJE

PRODUCTO

PROBLEMAS Y SOLUCIONES

Other ManualsLib Projects

Motors | Automation | Energy | Transmission & Distribution | Coatings

Installation, operation and maintenance manual of electric motors

Manual general de instalación, operación y mantenimiento de motores eléctricos

Manual of Electric Motors 57

E N

G L

IS

H www.weg.net

Português 2

English 57

Español 111

Manual of Electric Motors58 www.weg.net

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 sizes 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:

Smoke Extraction Motors;

Electromagnetic Brake Motors;

Hazardous Area Motors.

These motors meet the following standards, if applicable:

NBR 17094-1: Máquinas Elétricas Girantes - Motores de Indução - Parte 1: trifásicos.

NBR 17094-2: Máquinas Elétricas Girantes - Motores de Indução - Parte 2: monofásicos.

IEC 60034-1: Rotating Electrical Machines - Part 1: Rating and Performance.

NEMA MG 1: Motors and Generators.

CSA C 22.2 N°100: Motors and Generators.

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.

Manual of Electric Motors 59

N

G L

IS

H www.weg.net

TABLE OF CONTENTS

1. TERMINOLOGY 61

2. INITIAL RECOMMENDATIONS 62

2.1. WARNING SYMBOL

2.2. RECEIVING INSPECTION

2.3. NAMEPLATES

3. SAFETY INSTRUCTIONS 66

4. HANDLING AND TRANSPORT 67

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 73

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 78

6.1. FOUNDATIONS

6.2. MOTOR MOUNTING

6.2.1. Foot mounted motors

6.2.2. Flange mounted motors

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

Manual of Electric Motors60

N

G L

IS

H www.weg.net

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

6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES

6.11. RESISTANCE TEMPERATURE DETECTORS (PT-100)

6.12. CONNECTION OF THE SPACE HEATERS

6.13. STARTING METHODS

6.14. MOTORS DRIVEN BY FREQUENCY INVERTER

6.14.1. Use of dV/dt filter

6.14.1.1. Motor with enameled round wire

6.14.1.2. Motor with prewound coils

6.14.2. Bearing insulation

6.14.3. Switching frequency

6.14.4. Mechanical speed limitation

7. COMMISSIONING 95

7.1. INITIAL START-UP

7.2. OPERATING CONDITIONS

7.2.1.Limits of vibration

8. MAINTENANCE 99

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 109

9.1. PACKAGING

9.2. PRODUCT

10. TROUBLESHOOTING CHART X SOLUTIONS 110

Manual of Electric Motors 61

N

G L

IS

H www.weg.net

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:

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

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.

Manual of Electric Motors62

N

G L

IS

H www.weg.net

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 qualifi ed 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 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 qualifi ed 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 defi nition 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:

Check if nameplate data complies with the purchase order;

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

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

Manual of Electric Motors 63

N

G L

IS

H www.weg.net

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.

Manual of Electric Motors64

N

G L

IS

H

Figure 2.1 - IEC motor nameplate

Manual of Electric Motors 65

N

G L

IS

H

Figure 2.2 - NEMA motor nameplate

Manual of Electric Motors66

N

G L

IS

H www.weg.net

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 qualifi ed personnel.

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

Manual of Electric Motors 67

N

G L

IS

H www.weg.net

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 fi tted.

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 specifi ed 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

30° Max.

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

For horizontal motors fi tted 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.

Vertical mounted motors with oil-lubricated bearings must be transported in the vertical position. If necessary to move or transport the motor in the horizontal position, install the shaft locking device on both sides (drive end and non-drive end) of the motor.

Manual of Electric Motors68

N

G L

IS

H www.weg.net

4.1.2. Horizontal motor with two eyebolts

When motors are fi tted 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:

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 beam 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, W40 and W50 motors

Figure 4.6 - Use of a spreader beam for lifting

For HGF, W40 and W50 motors, as shown in Figure 4.5, the maximum resulting angle should not exceed 30° in relation to the vertical axis;

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

30° Max.

Manual of Electric Motors 69

N

G L

IS

H www.weg.net

4.1.3. Vertical motors

For vertical mounted motors, as shown in Figure 4.7, the use of a spreader beam 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 fi tted 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 and W50 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.

Manual of Electric Motors70

N

G L

IS

H www.weg.net

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 of HGF and W50 motors with two hoists

4.1.3.2. Procedures to place HGF and W50 motors in the vertical position

HGF motors are fitted with eight lifting points: four at drive end and four at non-drive end. W50 motors are fitted with nine lifting points: four at drive end, one in the central part and four at non-drive end. The motors are usually transported in horizontal position, however for the installation they must be placed in the vertical position.

To place an these motors in the vertical position, proceed as follows:

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

Manual of Electric Motors 71

N

G L

IS

H www.weg.net

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 and W50 motors in vertical position

Figure 4.14 - Lifting HGF and W50 motors by the eyebolts at the non-drive end

Figure 4.15 - HGF and W50 motors 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:

Manual of Electric Motors72

N

G L

IS

H www.weg.net

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;

Manual of Electric Motors 73

N

G L

IS

H www.weg.net

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 specifi cally 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 fi tted 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 fi tted, 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 fl ange) are factory-protected with temporary rust inhibitor. A protective fi lm 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

IEC 355

NEMA 586/7 and 588/9

W40 / W50 / HGF IEC 315 to 630

W40 / W50 / HGF NEMA 5000 to 9600 Indicated on the packaging

X Figure 5.1 - Correct stacking Figure 5.2 - Incorrect stacking

Manual of Electric Motors74

N

G L

IS

H www.weg.net

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 equal or longer than the oil change interval, the oil must be replaced 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 is removed to prevent oils leaks during the transport. After receiving the motor the bearings 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

Manual of Electric Motors 75

N

G L

IS

H www.weg.net

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 fi lling with oil, rotate the shaft by hand, at least fi ve revolutions)

During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at least fi ve 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 fi ve 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 equal or longer than the oil change interval, the oil must be replaced, according to 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 dehumidifi ers 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, fi ll the bearings with oil to prevent bearing rusting. During the storage period, rotate the shaft by hand, at least fi ve 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.

Manual of Electric Motors76

N

G L

IS

H www.weg.net

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 infl uence 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)

< 1000 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

Manual of Electric Motors 77

N

G L

IS

H www.weg.net

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

Manual of Electric Motors78

N

G L

IS

H www.weg.net

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:

If the motor is installed without running immediately, proceed as described in item 5.3.

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 fi ns, 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 suffi cient space to perform the cleaning services. See item 7.

6. Coupling: remove the shaft locking device (where fi tted) and the corrosion protection grease from the shaft end and fl ange 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 specifi c collection system (see Figure 6.12).

The insulation resistance must be measured in a safe environment.

Closed position Open position

Manual of Electric Motors 79

N

G L

IS

H www.weg.net

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 fi tted with drip cover to protect them from liquids or solids that may drop onto the motors;

c. Vertical mounted motors with shaft end up should be fi tted with water slinger ring to prevent water ingress inside the motor.

Remove or fi x 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 infl uences of other installed equipment and no vibration is transferred through the structure

The foundation must be fl at 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 fl atness, fl ange concentricity, axial and radial loads, etc. lower than the values specifi ed for standard motors).

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

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

The foundation stresses can be calculated by using the following equations (see Figure 6.2):

F1 = 0,5 * g * m - (4 * Tb / A) F2 = 0,5 * g * m + (4 * Tb / A)

Where:

F1 and F2 = lateral stresses (N);

g = gravitational acceleration (9,8 m/s2);

m = motor weight (kg);

Tb = breakdown torque (Nm);

A = distance between centerlines of mounting holes in feet or base of the machine (end view) (m).

Changes on the motor construction (features), such as installation of extended grease fi ttings or modifi cation of the lubrication system, installation of accessories at alternative locations, etc., can be carried out only after prior written consent from WEG.

Manual of Electric Motors80

N

G L

IS

H www.weg.net

The motors may be mounted on:

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

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

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:

Shoulders and/or recesses;

Anchor bolts with loose plates;

Bolts cast in the concrete;

Leveling screws;

Positioning screws;

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.

Figure 6.2 - Motor installed on concrete base Figure 6.3 - Motor installed on metallic base A

F1 F1

F2 F2 A

Manual of Electric Motors 81

N

G L

IS

H www.weg.net

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

Figure 6.6 - Mounting system of a foot mounted motor

L = 1.5 x D

D

6.2.2. Flange mounted motors

The drawings of the fl ange mounting dimensions, IEC and NEMA fl anges, can be checked in the technical catalogue.

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

Depending on the fl ange type, the mounting can be performed from the motor to the driven equipment fl ange

(fl ange FF (IEC) or D (NEMA)) or from the driven equipment fl ange to the motor (fl ange C (DIN or NEMA)).

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

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

6.2. MOTOR MOUNTING

Footless motors supplied with transportation devices, according to Figure 6.5, must have their devices removed before starting the motor installation.

Figure 6.5 - Detail of the transportation devices for footless motors

Manual of Electric Motors82

N

G L

IS

H www.weg.net

For fl ange 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 fl ange mounted, a foot or pad mounting may be required in addition to the fl ange mounting (Figure 6.7). The motor must never be supported on its cooling fi ns.

6.2.3. Pad mounted motors

Typically, this method of mounting is used in axial fans. The motor is fi xed 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 suffi ciently stiff to prevent the transmission of excessive vibration to the machine set (motor & fan). Figure 6.8 shows the pad mounting system.

Figure 6.7 - Mounting method of fl ange mounted motors with frame base support

Figure 6.8 - 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:

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

Whenever possible, use fl exible couplings, since they can absorb eventual residual misalignments during the machine operation;

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

Level and align the motor as specifi ed in sections 6.5 and 6.6, respectively.

Manual of Electric Motors 83

N

G L

IS

H www.weg.net

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 6.9.

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 fi x the shaft key fi rmly when the motor is operated without coupling in order to prevent accidents.

Do not use roller bearings for direct coupling, unless suffi cient 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 6.9 - Axial clearance of motor designed with sleeve bearing

Manual of Electric Motors84

N

G L

IS

H www.weg.net

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 6.10 - 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 infl uence 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 fl atness arising from the manufacturing process and the material structure rearrangement. The leveling can be carried out by a leveling screw fi xed on the motor foot or on the fl ange 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 6.10 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 6.11. Ensure a gap between couplings to compensate the thermal expansion between the shafts as specifi ed by the coupling manufacturer.

Motor shaft Driven machine shaft

Max.

misalignment

Driven machine offset (mm) Motor offset (mm)

Figure 6.11 - Alignment with dial gauge

Parallel alignment Angular alignment

GAP

Dial gauge

Line

Reference

Manual of Electric Motors 85

N

G L

IS

H www.weg.net

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.

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 6.12. The lubrication system must ensure continuous oil fl ow through the bearings as specifi ed by the manufacturer of the installed lubrication system.

Inlet

Drain

Outlet

Figure 6.12 - 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 fl ow rate and water temperature in the motor cooling system.

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 fi tted 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. Please consider the connection diagrams in the Table 6.2 as reference value.

To prevent accidents, check if motor has been solidly grounded in accordance with the applicable standards.

Manual of Electric Motors86

N

G L

IS

H…