(004)Anchor_Windlass_rev2.pdf

FRV40-226-004-010

REV 2

DESCRIPTION, OPERATION, AND

MAINTENANCE INSTRUCTIONS

Anchor Windlass

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-004-010

REV 2

DESCRIPTION, OPERATION, AND

MAINTENANCE INSTRUCTIONS

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

13 June 2008

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-004-010

TITLE OF MANUAL: Anchor Windlass

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

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

REMARKS:

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

Date:

Chand, LLC Mathews, LA 70375

CAGE CODE: 0D5X4

JillD Text Box

APPROVAL DATA FOR: FRV40-226-004-010

TITLE OF MANUAL: Anchor Windlass

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

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

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-004-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

JillD Text Box

APPROVAL AND PROCUREMENT RECORD PAGE

JillD Line

JillD Line

JillD Line

JillD Line

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

CAGE CODE: 0D5X4

JillD Line

VALIDATION PERFORMANCE

Title of Publication

Anchor Windlass

Contractor Sub-Contractor (If Performing Validation)

Halter Marine, Inc. Chand, LLC.

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

50-SPNA-1-00031

Chapter Section Paragraph Date Validation Completed

Check here if Not Validated

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

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

FOREWORD

JillD Text Box

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226-004-010 Anchor Windlass. Users are urged to report instances noted wherein the manual does not achieve this objective.

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

Section 1 - Anchor Windlass

Section 2 - Electric Motor

Section 3 - Failsafe Brake

Section 4 - Parallel Shaft Gearbox

Section 1 - Anchor Windlass

Built For: VT-HALTER

MCELROY / CATCHOT

WINCH COMPANY

TABLE QF CONTENTS I

SECTION 1

• Safety 1

• Safety Tags 2

• Installation 3

• Operation 4-6

• Lubrication 7

• Maintenance 8

• Recommended Spares 9

SECTION 2

• General Arrangement

• Windlass Assembly Drawings

• Component Data Sheets

SAFETY: J

Safety, based on years of experience has been built into your Coastal Marine Equipment, Inc.

product. This technical manual is provided to instruct the owner and operator of the proper and safe operation of this equipment. The owner and operators should be familiar with the contents of this manual before operating this equipment.

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

GENERAL SAFETY RULES:

s This windlass is not approved for or designed as a personnel lift.

S Do not wear loose clothing while operating this equipment.

s Do not operate this equipment in any manner other than the designed purpose.

S Never operate this equipment alone.

s Do not operate the brakes while the unit is in the haul in mode.

s Do not stand in the path of the rope / chain.

S Do not use feet or hands to guide the chain onto the wildcat.

s Do not operate the equipment without the proper safety guards installed.

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

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

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

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

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

THIS EQUIPMENT IS DESIGNED WITH

BRAKES TO CONTROL PAYOUT AND

HOLD THE LOAD. DO NOT OPERATE

THE BRAKE WHILE THE UNIT IS IN THE

HAUL IN MODE. THIS CAN CAUSE

DAMAGE TO THE EQUIPMENT AND / OR

INJURY TO PERSONNEL.

DANGER

THE GUARDS ON THIS EQUIPMENT

HAVE BEEN INSTALLED TO PROTECT

THE OPERATOR. DO NOT REMOVE

THESE GUARDS AS THE RISK OF

ACCIDENT OR INJURY IS GREATLY

INCREASED. THESE GUARDS DO NOT

RELIEVE THE OPERATOR OF THE

RESPONSIBILITYOF BEING CONCIOUS

OF THE DANGERS ASSOCIATED WITH

THE OPERATION OF THIS EQUIPMENT.

CARELESS MISUSE OF THIS

EQUIPMENT CAN CAUSE ACCIDENTS

AND INJURY TO PERSONNEL.

CAUTION

NEVER PULL EQUIPMENT FOUNDATION TO

DECK FOUNDATION DURING INSTALLATION.

USE SHIMS OR CHOCKFAST BETWEEN

EQUIPMENT AND DECK FOUNDATION TO

MAINTAIN ALIGNMENT PRIOR TO SECURING

EQUIPMENT TO FOUNDATION.

FAILURE TO ALIGN EQUIPMENT DURING

INSTALLATION CAN CAUSE BEARING AND

GEAR FAILURE AND VOID ALL WARRANTIES

PROVIDED BY THE MANUFACTURER.

WELDING OF FRAME DURING INSTALLATION

CAN CAUSE DISTORTION AND

MISALIGNMENT OF EQUIPMENT. IT IS

RECOMMENDED TO SECURE FOUNDATION

TO THE DECK WITH THE MOUNTING HOLES

PROVIDED.

KEEP FINGERS AND TOOLS AWAY FROM

ROTATING PARTS DURING OPERATION.

GOOD SAFETY PRACTICES SHOULD BE

FOLLOWED AT ALL TIMES.

CHECK LUBRICATION BEFORE OPERATING

EQUIPMENT.

DO NOT MOOR/ANCHOR

WITH CLUTCH ENGAGED.

DISENGAGE CLUTCH AND

USE DRUM BRAKE ONLY. DO

NOT ATTEMPT TO ENGAGE

OR DISENGAGE CLUTCH

WHILE EQUIPMENT IS IN

MOTION. SERIOUS

EQUIPMENT DAMAGE OR

PERSONNEL INJURY MAY

OCCUR.

Li

DO NOT ATTEMPT TO ENGAGE

OR DISENGAGE CHAIN

STOPPER WHILE EQUIPMENT IS

IN MOTION. SERIOUS

EQUIPMENT DAMAGE OR

PERSONNEL INJURY MAY

OCCUR.

INSTALLATION: J

General Installation Requirements:

FOUNDATION:

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

LIFTING:

Never lift the windlass by the gearbox. Use lifting slings around the wildcats or use lifting lugs if provided. Distribute the loads evenly to keep the unit from tilting. Caution must be exercised when lifting so that accessories mounted on the reducer are not damaged.

MOUNTING;

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

NOTE: Verify gear and bearing alignment after installation.

GUARDING:

After installation adequate safety guards should be placed on or around the windlass to prevent personnel from getting near the working chain.

CHAIN INSTALLATION:

Each shot should be laid out to eliminate most of the twist from being stacked on pallets. The chain should be fed up through the hawse pipe, through the chain stopper and over the wildcat. Use the windlass to feed the chain into the chain locker. Connect toe second and subsequent shots to each other as the leading shot is nearing complete installation. Installation in this manner will eliminate chain twist in the chain locker.

OPERATION: I

PERFORMANCE:

35,500 lbs @ 31 fpm (continuous) 44,400 lbs @ 31 fpm (intermittent) 39,100 lbs @ 31 fpm (110% full load motor torque)

BRAKE HOLDING:

110,100 lbs (maximum)

ELECTRICAL REQUIREMENTS:

40Hp575V,3PH,60Hz

FEATURES:

JAW CLUTCH:

The jaw clutch is lever operated and designed to engage and disengage the wildcat. The mechanism is designed to remain engaged without the aid of a latch and incorporates a latch to lock the clutch in the out position to prevent engagement while in the freewheel mode.

iMSSSE

DO NOT MOOR/ANCHOR WITH CLUTCH ENGAGED. DISENGAGE CLUTCH AND USE DRUM BRAKE

ONLY. DO NOT ATTEMPT TO ENGAGE OR DISENGAGE CLUTCH WHILE EQUIPMENT IS IN

MOTION. SERIOUS EQUIPMENT DAMAGE OR PERSONNEL INJURY MAY OCCUR.

The band brake is hand wheel operated. It sets with a clockwise rotation and releases with a counterclockwise rotation. It is designed to control the freewheel payout of the windlass and to be set to hold a load. The brake is not designed to control the windlass under power.

THIS EQUIPMENT IS DESIGNED WITH BRAKES TO CONTROL PAYOUT AND HOLD THE LOAD.

DO NOT OPERATE THE BRAKE WHILE THE UNIT IS IN THE HAUL IN MODE. THIS CAN CAUSE

DAMAGE TO THE EQUIPMENT AND / OR INJURY TO PERSONNEL.

CHAIN STOPPER:

The chain stopper is designed to be set while riding at anchor or to be used when the anchor is in the stowed position.

DO NOT ATTEMPT TO ENGAGE OR DISENGAGE CHAIN STOPPER WHILE EQUIPMENT IS

MOTION. SERIOUS EQUIPMENT DAMAGE OR PERSONNEL INJURY MAY OCCUR.

ANCHOR DEPLOYMENT:

1. Inspect equipment to make sure it is ready for operation.

2. Energize circuit breaker.

3. Make sure hand brake is tightly set.

4. Jog to align clutch jaws.

5. Unlock clutch lockout pin and engage clutch.

6. Release hand brake.

7. Jog winch in the haul-back mode to relieve load on the chain stopper.

8. Disengage chain stopper.

9. Set hand brake.

10. Jog drive to take load off of clutch so clutch can be disengaged.

11. Disengage jaw clutch.

12. Slowly relieve tension on the hand brake to allow the anchor to be deployed while controlling the freefall with the hand brake.

DO NOT ALLOW THE ANCHOR TO DROP IN AN UNCONTROLLED FREE FALL AS THIS COULD

CAUSE DAMAGE TO THE EQUIPMENT AND/OR PERSONNEL INJURY.

13. After setting anchor, engage chain stopper and allow wildcat to rotate in the payout direction until the chain stopper engages chain link.

14. Set band brake.

15. Leave clutch disengaged.

ANCHOR RETRIEVAL:

1. Inspect equipment to make sure it is ready for operation.

2. Jog to align clutch jaws.

3. Unlock clutch lockout pin and engage clutch.

4. Release hand brake.

5. Jog wildcat in the haul-back direction until chain stopper can be moved to the out position.

6. Move vessel under it's own power over anchor while taking up chain with windlass.

7. Once vessel is above the anchor, take up slack in the chain.

8. Engage chain stopper and allow wave action to dislodge anchor.

CAUTION

DO NOT ALLOW JAW CLUTCH TO TRANSMIT WAVE SURGE TO WINDLASS DRIVE TRAIN.

9. Haul in the anchor in the normal manner.

10. When the anchor is in the stowed position, engage chain stopper, set hand brake and disengage jaw clutch.

CATHEAD OPERATION: J

1. Wrap load end closest to the cathead base.

2. Wrap three to five wraps on cathead.

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

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

LINE UNDER TENSION CAN RECOIL.

AVOID POSSIBLE ENTANGLEMENT IN LINE.

DO NOT LIFT LOADS WITH CATHEAD.

TO OPERATOR

cwwwwwwuuvo TO LOAD

LUBRICATION: J

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

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

LUBRICATION SCHEDULE

Item / Lubrication Point

(2) Jaw Clutch

(4) Wildcat Bushings

(2) Main Shaft Bearing

(2) Threaded Brake Nut

Gear Reducer

Type Lubricant

#1

#1

#1

#1

#2

Lubrication Interval

Each Use

Each Use

Each Use

Each Use

Check Each Use Change Every (6) Months

Quantity

21 Gallons

Lubricant Type

#1-Shell Alvania EP2 or Equal

#2-Shell Omala 150 or Equal

MAINTENANCE: J

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

BASIC CHECK POINTS;

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

2. Check brake lining for wear. Make sure the fasteners are not near scoring the brake drum. Do not allow liner to have less than 1/16" clearance from screw threads.

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

4. Inspect brake components for signs of cracking, deformation and fatigue.

5. Inspect the chain regularly for signs of fatigue.

6. Check gear reducers for leaks.

RECOMMENDED SPARES: I

Jaw Clutch Engagement Brake Liners Brake Band Assembly Brake Band Bolts Brake Repair Kit Flange Bearing Motor Coupling Complete Wildcat Bushings Motor Seal Kit Gearbox Seal Kit

QTY

1 :

-9-

Section 2 - Electric Motor

ELECTRIC MOTOR

PART NO. 61378

Standard Induction Motors

Installation, Operation, & Maintenance Instructions

11 12) (13 14 15 16 17 18 19) {20

ITEM

1.

2.

3, 4.

5.

6.

7.

8.

9, ID.

FOR VERTICAL CUTAWAY MOTOR & MOTOR PARTS DESCRIPTION

DESCRIPTION

Frame Vent Screen Conduit Box Bottom Conduit Box Top-Holding Screw Conduit Box Top Conduit Box Bottom-Holding Bolt *Ba!l Bearin^O.P.E.

Pre-loading Spring inner Bearing Cap 0.P.E.

Grease Plug Inner Bearing Cap Bolt

ITEM

11.

12, 13.

14.

15.

16.

17.

18.

19.

20.

DESCRIPTION

Bracket CLP.E, Baffle Plate (XP.E.

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

Bracket P.E.

ITEM

21.

22.

23, 24.

25.

26, 27.

28.

29,

- SEE SB247 ̂ -^

DESCRIPTION

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

Shaft Extention Key Shaft Drain Plug (grease)

*• Bracket Screen

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

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

** = Bracket and frame screens are optional.

WARNING

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

GENERAL INFORMATION

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

ACCEPTANCE

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

STORAGE

A. Keep motors clean

1. Store indoors

2. Keep covered to eliminate airborne dust and dirt.

3. Cover openings for ventilation, conduit connections, etc.

to prevent entry of rodents, snakes, birds, and insects, etc.

B. Keep motors dry

1. Store in a dry area indoors

2. Temperature swings should be minimal to prevent condensation.

3. Space heaters are recommended to prevent condensa-tion.

4. Treat unpainted flanges, shafts, and fittings with a rust inhibitor.

5. Check insulation resistance before putting motor into service. (Consult manufacturerforguidelines).

C. Keep Bearings Lubricated

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

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

INSTALLATION

UNCRATING AND INSPECTION

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

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

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

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

SAFETY

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

Eyebolts or lifting lugs are intended for lifting the motor only.

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

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

NEMA MG 2.

Frames and accessories of motors should be grounded in accordance with National Electrical Code (NEC) Article 430.

For general information of grounding refer to NEC Article 250.

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

LOCATION

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

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

The motor Should never be placed In a room with a hazardous process, or where flammable gases or combustible material may be present, unless it it specifically designed for this type of service.

1. Dripproof (open) motors are intended for use indoors where atmosphere is relatively clean, dry and non-corrosive.

2. Dripproof (open) fire pump motors are to be installed in a Type 2 dripproof environment as defined in NEMA 250.

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

4. Explosion proof motors are built for use in hazardous locations as indicated by Underwriters' label on motor.

Consult UL, NEC, and local codes for guidance.

Refer to Marathon Electric for application assistance.

FLOOR MOUNTING

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

V-BELT DRIVE

1. Select proper type and number of belts and sheaves.

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

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

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

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

5 For more information see Marathon Electric Publication

SB588

DIRECT CONNECTED DRIVE

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

MISALIGNMENT and RUN-OUT between direct con-nected shafts will cause increased bearing loads and vibra-tion even when the connection is made by means of a flexible coupling Excessive misalignment will decrease bearing life Proper alignment, per the specifications of the coupling being used, is critical Some large motors are furnished with roller bearings

Roller bearings should not be used for direct drive

ELECTRICAL CONNECTIONS

CAUTION

Install and ground per local and national codes.

Consult qualified personnel with questions or if repairs are required.

WARNING

1. Disconnect power before working on motor or driven equipment 2 Motors with automatic thermal protectors will automatically restart when the protector temperature drops sufficiently. Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment.

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

4. Discharge all capacitors before servicing motor.

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

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

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

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

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

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

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

3 Use the proper size of line current protection and motor controls as required by the National Electrical Code and local codes Recommended use is 125% of full load amps as shown on the nameplate for motors with 40°C ambient and a service factor over 1 0 Recommended use is 115% of full load amps as shown on the nameplate for all other motors Do not use protection with larger capacities than recommended Three phase motors must have all three phases protected

THERMAL PROTECTOR INFORMATION

The nameplate will indicate one of the following

1 Motor is thermally protected 2 Motor is not thermally protected 3 Motor is provided with overheat protective device For examples, refer to paragraphs below 1 Motors equipped with built-in thermal protection have THERMALLY PROTECTED" stamped on the nameplate Thermal protectors open the motor circuit electrically when the motor overheats or is overloaded.

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

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

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

"WITH OVERHEAT PROTECTIVE DEVICE".

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

B The circuit controlled by the above "Overheat Protective Device1' must be limited to a maximum of 600 volts and 360 volt-amps

I I ; ; i

NORMALLY CLOSED PROTECTORS

NORMALLY OPEN

PROTECTORS

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

FIGURE 1A

CHANGING ROTATION

1 Keep hands and clothing away from rotating parts 2 Before the motor is coupled to the load, determine proper rotation 3 Check rotation by jogging or bumping Apply power to the motor leads for a short period of time, enough to just get motor shaft to rotate a slight amount to observe shaft rotating direction

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

REDUCED VOLTAGE STARTING

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

OPERATION

WARNING

Disconnect and lock out before working on motor or driven equipment

BEFORE INITIAL STARTING

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

Minimum Insulation Resistance _ Rated Voltage In Megohms + 1000

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

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

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

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

c. Pass a current at low voltage (rotor locked) through the stator winding. Increase the current gradually until the winding temperature, measured with a thermometer, reaches90°C(194°F). Do not exceed this temperature.

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

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

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

Any foreign matter in the air gap should be removed.

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

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

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

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

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

CAUTION

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

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

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

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

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

ALLOWABLE VOLTAGE AND

FREQUENCY RANGE

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

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

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

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

CLEANLINESS

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

CONDENSATION DRAIN PLUGS

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

SERVICE

WARNING

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

CAUTION

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

NOTE

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

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

Motors are properly lubricated at the time of manufacture.

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

LUBRICATION PROCEDURES

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

2. Remove contaminants from grease inlet area.

3. Remove filler and drain plugs.

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

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

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

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

7. Motor is ready for operation.

WARNING

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

RELUBRICATION TIME INTERVAL

(For motors with regreasing provisions).

Service Condition

Stsndwd

Severe

Seasonal

NEMA FRAME SIZE

140-180

1800 RPM

and less

3yrs.

1yr.

Over 1800

RPM

6 months a mOnulS

210-360

1800 RPM

and less

2yrs.

lyr.

Over 1800

RPM

6 months

3 months

400-510

1800 RPM

and less

1yr.

6 months

Over 1800

RPM

3 months

1 month

See Note 2.

NOTE

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

2. Lubricate at the beginning of the season.

Then follow service schedule above.

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

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

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

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

RELUBRICATION AMOUNTS

(For motors with regreasing provisions).

NEMA FRAME SIZE

VOLUME cu. in. (fluid oz.)

.25 (.14) .50 (.28) .75 (.42)

1.00 (.55)

1.25 (.69)

1.50 (.83)

1.75 (.97)

2.25 (1.2)

2.75 (1.5)

3.00 (1.7)

TROUBLESHOOTING

WARNING

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

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

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

4. Discharge ail capacitors before servicing motor.

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

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

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

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

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

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

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

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

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

4. All bolts and nuts are tightened securely.

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

In checking for electrical troubles, be sure that:

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

2. The vojtage is actually available at motor terminals.

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

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

A- EZE7300R

SINGLE VDLTAGE THREE PHASE

MDTDR WITH 2 LEADS BUT FRDM

SPACE HEATERS.

SPACE HEATER

SPACE HEATERS

CDNNECTED IN PARALLEL

SPACE HEATERS CDNNECTED

IN SERIES PARALLEL

HI

HI

Tl

T2

T3 H2

VIEW DF TERMINAL END

IF MDTDR HAS

6 LEADS

Tl .

T l •

T2.

T2.

T3"

REV

08-07-19%

BATE

REDRAWN DN CADI)

CN E2509

CHANGE

PGK

NAME

MAX, SURFACE RDUGHNESS

UNLESS NOTED OTHERWISE

MATL SPEC

FINISH

REFERENCE DRV.

UNLESS OTHERWISE SPECII

TOL. ON XX± .02 XXX± 005

ARC VfCINCHES

X XXX* .000 5 ANGLES ± 7'30"

PART NAME CDNNECTIDN DIAGRAM

30 - SINGLE VDLTAGE

CHKD M i

BY ML

TB

08-06-1996

08-07-1996

08-07-1996

DRWG NO

A-EE7300R

SHDP BDDK I PURCHASED I DISTRIBUTION - WA - LB - VP - LM - BR | CAUD FILE ND. | EE7300R

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

MOTOR TROUBLE SHOOTING CHART

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

TROUBLE

Motor fails to start

Motor stalls

Motor runs and then dies down

Motor does not come up to speed

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

Wrong rotation Motor overheats while running under load

Motor vibrates

Unbalanced line current on polyphase motors dunng normal operation

Scraping noise

Noisy operation

Hot bearings general

Hot bearings ball

CAUSE

Blown fuses Overload tnps Improper power supply

Improper line connections Open circuit in winding or control switch

Mechanical failure

Short circuited stator Poor stator coil connection Rotor defective Motor may be overloaded

One phase may be open Wrong application Overload Low voltage Open circuit

Power failure

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

Open pnmary circuit

Excessive load Low voltage dunng start Defective squirrel cage rotor Applied voltage too low Wrong sequence of phases Overload Frame or bracket vents may be clogged with dirt and prevent proper ventialation of motor Motor may have one phase open Grounded coil Unbalanced terminal voltage

Motor misaligned Weak support Coupling out of balance Driven equipment unbalanced Defective bearings Beannas not in line Balancing weights shifted Polyphase motor running single phase Excessive end play Unequal terminal volts Single phase operation Unbalanced voltage

Fan rubbma air shield Fan striking insulation Loose on bedplate Airgap not uniform Rotor unbalance

Bent or sprung shaft Excessive belt pull Pulleys too far away Pulley diameter too smalt Misalignment Insufficient grease Deterioration of grease or lubircant contaminated Excess lubricant Overloaded beanng Broken ball or rough races

WHATTO DO

Replace fuses with proper type and rating Check and reset overload in starter Check to see that power supplied agrees with motor name plate and load factor Check connections with diagram supplied with motor Indicated by humming sound when switch is closed Check for loose wmng connections Also see that all control contacts are closing Check to see if motor and dnve turn freely Check bearings and lubrication Indicated by blown fuses Motor must be rewound Remove end bells, locate with test lamp Look for broken bars or end rings Reduce load

Check lines for open phase Change type or size Consult manufacturer Reduce load See that nameplate voltage is maintained Check connection Fuses blown, check overload relay, stator and pushbuttons

Check for loose connections to line, to fuses and to control

Consult supplier for proper type Use higher voltage on transformer terminals or reduce load Check connections Check conductors for proper size Check load motor is supposed to carry at start Look for cracks near the rings A new rotor may be required as repairs are usually temporary Locate fault with testing device and repair

Reduce load Check for high resistance Adequate wire size Replace witrTnew rotor Get power company to increase power tap

Reverse connections at motor or at switchboard Reduce load Open vent holes and check for a continuous stream of air from the motor

Check to make sure that all leads are well connected Locate and repair Check for faulty leads, connections and transformers

Realign Strengthen base Balance coupling Rebalance driven equipment Replace beanng Line up properlv Rebalance motor Check for open circuit Adjust beanng or add shim Check leads and connections Check for open contacts Correct unbalanced power supply

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

Section 3 - Failsafe Brake

FAILSAFE BRAKE

PART NO.60006

® Spring-Set Disc Brakes P/N 8-078-928-01 effective 7/16/04

Installation and Service Instructions for 87,000 & 87,100 Series Self-Adjust Brakes (rev. B)

Tools required for installation and servicing:

3/8" hex wrench 1/4" screwdriver 5/16" hex wrench 8" adjustable wrench 3/16" hex wrench external snapnng tool 5/16' nut driver

Typical Nameplate

Stearns

SEE INSTALLATION AND S

INSTALLATION LABEL INSII

INSTALLING OPERATING OR S

Rev

B Mode nurrber

108705100BQB

Torque Ib h Mount ng

20 \ HORIZ

Volts \ 230 \ 460 \

Rexnord Industres Inc Stearns Dtv sion Cudafy Wl 53-101414 2~2 1100

Serial number

36155C

Amps no ding

Note \

MODEL NUMBER

will appear on brake nameplate

REVISION CONTROL

(if applicable) and brake serial numbnumber

Important Please read these instructions carefully before installing, operating, or servicing your Stearns Brake Failure to comply with these instructions could cause injury to personnel and/or damage to property if the brake is installed or operated incorrectly For definition of limited warranty/liability, contact Rexnord Industries, Inc , Stearns Division, 5150 S International Dr, Cudahy, Wl 53110, (414)272-1100

Caution 1 Installation and servicing must be made in compliance with all local safety codes including Occupational Safety and Health Act (OSHA) All wiring and electrical connections must comply with the National Electric Code (NEC) and local electric codes in effect

2 Do not install the brake in atmospheres containing explosive gases or dusts

3 To prevent an electrical hazard disconnect power source before working on the brake If power disconnect point is out of sight, lock disconnect in the off position and tag to prevent accidental application of power

4 Make certain power source conforms to the requirements specified on the brake nameplate

5 Be careful when touching the exterior of an operating brake Allow sufficient time for brake to cool before disassembly Surfaces may be hot enough to be painful or cause injury

6 Do not operate brake with housing removed All moving parts should be guarded

7 Installation and servicing should be performed only by qualified personnel familiar with the construction and operation of the brake

8 For proper performance and operation, only genuine Stearns parts should be used for repairs and replacements

9 After usage, the brake interior will contain burnt and degraded friction material dust This dust must be removed before servicing or adjusting the brake DO NOT BLOW OFF DUST using an air hose It is important to avoid dispersing dust into the air or inhaling it, as this may be dangerous to your health

a) Wear a filtered mask or a respirator while removing dust from the inside of a brake

b) Use a vacuum cleaner or a soft brush to remove dust from the brake When brushing, avoid causing the dust to become airborne Collect the dust in a container, such as a bag, which can be sealed off

General Description These series of brakes are spring-set, electrically released They contain one or more rotating friction discs (4) driven by a hub (16) mounted on the motor or other shaft Operating Principle These series contain one or more friction discs (4) assembled alternately between the endplate (2) friction surface, stationary disc(s) (3) and pressure plate (5) The stationary components are restrained from rotating by being keyed into the endplate With the brake released, all disc pack components are free to slide axially and the friction disc(s) to rotate Brake release occurs when the solenoid coil is electrically energized, causing the solenoid plunger to travel a specified distance and through a lever system, overcoming the pressure spring force This action releases the clamping force on the disc pack, thereby allowing the friction disc(s) and brake hub to rotate Brake sets and torque is produced when electric current to the solenoid coil is interrupted, thereby collapsing the solenoid magnetic field The solenoid plunger returns to its original de-energized position allowing the lever arm to move forward by virtue of the compressed torque springs This action compressed the disc pack components which applies a retarding torque to the brake hub and ultimately restores the brake to a spring-set static condition Caution! While the brake is equipped with a manual release to allow manual shaft rotation the motor should not be run with the manual release engaged, to avoid overheating the friction disc(s)

BRAKE MOUNTING

Remove manual release knob.

Remove housing screws.

Remove housing.

counter-clockwise

A. Push plunger down.

B. Pull manual release to hold plunger.

C. Remove support plate screws.

counter-clockwise

Lift off support plate.

Remove disc pack. © A. Position hub on shaft as shown.

B. Tighten set screws to motor shaft.

Torque to: 5/16" - 156 in-lb;

3/8" - 288 in-lb;

1/2" - 625 in-lb.

C-face —-

A. Position endplate on motor register.

B. Insert four mounting bolts and tighten.

C. Reassemble disc pack in reverse* order of removal.

*For vertical brakes, refer to Figure 2, page 3.

A. Route lead wires through conduit hole.

B. Position support plate on endplate.

C. Insert three mounting screws;

tighten to: 50 in-lb.

Coil wiring. Refer to nameplate for voltage rating*.

Caution: Keep wiring away from pinch points.

Coil Wiring

For DC voltages see sheet 8-078-950-00.

-connect line

- voltage here

Single Voltage twist lines 1 & 3 „ connect line .-voltage here twist lines 2 & 4

Dual Voltage Coil at Low Voltage twist lines 3 & 4 and use wire nut

Dual Voltage Coil at High Voltage

Replace housing.

Tighten housing screws and release knob to 50-55 in-lb.

clockwise

Installation Notes:

Note 1: If motor is to be ceiling mounted after assembly, entire brake will have to be rotated 180° or "upside down" so it wil be positioned with solenoid plunger (29) above frame when final assembly is mounted on ceiling. Similarly, for horizontal wall mounting, rotate 90°.

Note 2: The brake nameplate states mounting position; "horizontal, vertical above or vertical below." The brake must be mounted in that position. Horizontal brkes rated 35 Ib-ft and less do not require modification to be mounted vertical below.

Note 3: A dimple drilled into the motor shaft for the hub set screw (16S), 90° from the key is recommended for vertical mounting.

General Maintenance Warning! Any mechanism or load held in position by the brake should be secured to prevent possible injury to personnel or damage to equipment before any disassembly of the brake is attempted or before the manual release knob or lever is operated on the brake. Observe all cautions listed at the beginning of this manual.

Note 1: To obtain correct replacement parts for the Series 87,000 Marine Duty, obtain brake serial number and consult factory.

Note 2: Replace friction disc in single disc brakes when wear surface area is one-half the original disc thickness. In multiple disc brakes, replace all friction discs when throat of lever arm (17) is within 1/16" of touching teeth of pinion (32).

Troubleshooting A. If brake does not stop properly or overheats, check the following:

1. Is manual release engaged, and is motor energized?

2. Friction discs may be excessively worn, charred or broken.

3. Hub may have become loose and shifted on shaft.

4. Are controls which govern start of braking cycles operating properly?

5. On vertically mounted brakes, are springs in place in disc pack?

6. Is solenoid air gap adjusted correctly?

See Air Gap Adjustment, Page 4.

7. Solenoid lever stop (22) must be in place on support plate.

8. Solenoid may not be energizing and releasing the brake. Check voltage at the coil and compare to the coil and/or nameplate voltage rating.

9. Check that heads of mounting bolts do not extend above wear surface of endplate.

10. If stopping time is more than two seconds, the brake torque rating may be insufficient. If the brake stops high inertial loads and/or brake stops more than five times per minute, check thermal requirements of application versus thermal capacity rating of brake.

11. Use Loctite® 242 to secure link screw nut (13N) to link screw (13C) if vibration causes nut to loosen.

12. Check pressure spring length to insure correct compressed height. Original spring lengths are given in the following Table so that correct setting may be verified and corrected if necessary. With worn friction discs, add amount of wear to the approximate spring length shown.

Color

Black White Orange Purple

Torque (Ib-ft)

25&50 35, 75 & 105

Compressed Spring Length

3-1/4" 3-1/4" 3-1/4" 3-1/4"

13. If a heater is supplied and excess rusting has occurred in brake, check power source to heater to be sure it is operating and that heater is not burned out.

B. If brake hums, solenoid pulls in slowly, or coil burns out, check the following:

1. Voltage supply at coil versus coil rating.

2. Is solenoid air gap excessive? See Air Gap Adjustment, Page 4.

3. Solenoid frame and plunger may be excessively worn.

4. Solenoid mounting screws may have become loose, causing frame to shift and plunger to seat improperly.

Vertical Spring Assembly Note: For vertical brakes refer to Figure 2 for proper stationary disc positioning. Discs must be inserted spring side first. Also refer to instruction sheet 8-078-937-06.

For brakes with brass stationary components, refer to instruction sheet 8-078-937-07.

r r i ''' ~

Disc

Vertical Above pressure

^^ - plate ^ ^ ^ ^ b l u e ' •" f.'

' ', r-ir; ,red

2 Disc

Vertical Below

? _. endplste • • •r~~\ i1 •-kzz—— blue }

• <3T i

&4 red

1 <\ pressure ^J^-plate '

2 Disc

3 Disc

~r—^H—' f^-i-i—blue ,^sU—red [l^S^Lf— purple i ' > 3 Disc

Figure 2

Figure 1

AIR GAP AJUSTMENT

Loosen two locking screws.

Slide bracket outward to increase or inward to decrease air gap.

Tighten screws to 45-55 in-lb.

increase air gap

I decrease air gapI air gap = 7/8" -15/16"

COIL REPLACEMENT

Disconnect coil lead wires from power source and pull them out of the brake.

A. Remove solenoid mounting screws.

B. Lift solenoid frame away from plunger.

counter-clockwise

A. Remove guide screws, if used.

B. Lift guides out of coil.

C. Push coil out of frame.

A. Insert new coil.

B. Press plunger guides into place.

C. (Guide screws are no longer required with plastic guides.)

A. Slide coil assembly onto plunger.

B. Insert mounting screws and tighten to 50-55 in-lbs.

Reroute coil wires and reconnect to power supply.

B_

Information required when ordering replacement parts:

• Give part number of parts or kits needed, brake model number, and brake serial number. The brake model and serial number may identify special brakes not covered by this parts list.

• Description items in CAPITALIZED BOLD ITALICS are recommended spare parts. One set per 5 brakes in service is recommended.

• For 87,100 Series see Table 2.

Circled items are contained in kit Item A, Table 4.

For installation and service instructions, see P/N 8-078-937-06.

Detailed service instruction sheet is included with each kit

Support Plate (see back page)

Old

2.75" square

Configurations c 24 tooth o)

4.24 diameter

New Patented Design

Rev. B

20 tooth 3.12 diameter

Vertical Mounting

Stearns' SFF INSTA! I AT ON AND SFRViCE SHFFT OR NSTALLATION LABEL INSIDfc OF HOUSKG BEFORE NSTALLIKC OF-bK*TING OK SEPVICINC bRAKh

108705100EQB B

Serial number

» holding

» LRu254

Note:

- MODEL NUMBER

will appear on brake nameplate

-…