NAT26306-SANDBYPAS-appF.pdf

WEG ELECTRIC MOTOR

OPERATION AND

MAINTENANCE MANUAL

Indian River Inlet Sand Pump Replacement

27070 Coastal Highway

Bethany Beach, DE 19930

October 13th, 2025

OWNER

Delaware Dept. of Natural Resources & Environmental Control

285 Beiser Boulevard, Suite 102

Dover, DE 19904

GENERAL CONTRACTOR

Chesapeake Turf

418 Coles Cir. Suite A

Salisbury, MD 21804

Phone: 410-341-4363

MOTOR SUPPLIER

Hill’s Industrial

3901 Vincent Rd.

Linkwood, MD 21835

410-228-4447 (P)

410-463-8341 (M)

ARCHITECT/ENGINEER

Century Engineering, Inc.

550 Bay Rd.

Dover, DE 19901

MASTER TABLE OF CONTENTS

1. Manufacturer Published IO&M Manual........................................................................ Pg. 2

2. Product Data and Shop Drawings................................................................................. Pg. 61

2.1. 400 HP Electric Motor SUBMITTAL REVIEW FORMS............................................. Pg. 62

2.1.1. Submittal........................................................................................................ Pg. 63

2.2. DATA SHEET(S) | 400 HP Electric Motor ............................................................... Pg. 64

2.2.1. TORQUE AND CURRENT VS SPEED CURVE ................................................... Pg. 65

2.2.2. LOAD PERFORMANCE CURVE........................................................................ Pg. 66

2.2.3. THERMAL LIMIT CURVE................................................................................. Pg. 67

2.2.4. VFD OPERATION CURVE................................................................................ Pg. 68

2.3. Shop Drawings | 400 HP Electric Motor................................................................ Pg. 69

2.3.1. Motor Tag...................................................................................................... Pg. 70

2.4. DATA SHEET(S) | 600 HP Electric Motor............................................................... Pg. 71

2.4.1. DATA SHEET.................................................................................................. Pg. 72

2.4.2. TORQUE AND CURRENT VS SPEED CURVE................................................... Pg. 73

2.4.3. LOAD PERFORMANCE CURVE....................................................................... Pg. 74

2.4.4. THERMAL LIMIT CURVE................................................................................ Pg. 75

2.4.5. VFD OPERATION CURVE............................................................................... Pg. 76

2.5. Shop Drawings | 600 HP Electric Motor.............................................................. Pg. 77

2.5.1. Motor Tag.................................................................................................... Pg. 78

2.6. Bearing Protector Assembly................................................................................ Pg. 79

2.6.1. Bearing Protection Kits..................................................................................... Pg. 80

2.7. Go-Flex® Couplings Submittal.............................................................................. Pg. 82

2.7.1. Go-Flex® Couplings....................................................................................... Pg. 83

2.7.2. Go-Flex® Inserts............................................................................................ Pg. 85

2.7.3. Go-Flex®........................................................................................................ Pg. 87

2.7.4. Quick Selection Guide.................................................................................. Pg. 88

2.7.5. Go-Flex® with Standard Cover Dimensions/Ratings.................................... Pg. 89

3. Warranties................................................................................................................... Pg. 90

3.1. One Year Extended Warranty Confirmatio........................................................... Pg. 91

Section 1 Manufacturer Published

IO&M Manual

Manual of Electric Motors 56

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English EN

Español ES

Manual of Electric Motors 57

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.

http://www.weg.net/

Manual of Electric Motors 58

TABLE OF CONTENTS

1. Terminology

2. Initial Recommendations

2.1 Warning Symbol

2.2 Receiving Inspection

2.3 Nameplates

3. Safety Instructions

4. Handling and Transport

4.1 Lifting

4.1.1 Horizontal motors with one eyebolt

4.1.2 Horizontal motor with two eyebolts

4.1.3 Vertical motors

4.1.3.1 Procedures to place W22/WEG General Purpose/WIN motors in the vertical position

4.1.3.2 Procedures to place HGF, W50 and W51 HD motors in the vertical position

4.2 Procedures to place W22/WEG General Purpose/WIN vertical mount motors in horizontal position

5. Storage

5.1 Exposed Machined Surfaces

5.2 Storage

5.3 Bearings

5.3.1 Grease lubricated bearings

5.3.2 Oil lubricated bearings

5.3.3 Oil Mist lubricated bearings

5.3.4 Sleeve bearing

5.4 Insulation Resistance

5.4.1 Insulation resistance measurement

6. Installation

6.1 Foundations

6.2 Motor Mounting

6.2.1 Foot mounted motors

6.2.2 Flange mounted 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

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

7.1 Initial Start-up

7.2 Operating conditions

7.2.1 Limits of vibration

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8. Maintenance

8.1 General Inspection

8.2 Lubrication

8.2.1 Grease lubricated rolling bearings

8.2.1.1 Motor without grease fitting

8.2.1.2 Motor with grease fitting

8.2.1.3 Compatibility of the Mobil Polyrex EM grease with other greases

8.2.1.4 Oil lubricated bearings

8.2.1.5 Oil mist lubricated bearings

8.2.1.6 Sleeve bearings

8.3 Motor assembly and disassembly

8.3.1.1 Terminal box

8.4 Drying the stator winding insulation

8.5 Spare parts

9. Environmental Information

9.1 Packaging

9.2 Product

10. Troubleshooting chart x solutions

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

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

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

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

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

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.

Qualified personnel: employee previously qualified and registered with the competent class council.

Qualified personnel: employee who proves completion of a specific course in the electrical area by the official education system.

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.

2. INITIAL RECOMMENDATIONS

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

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

It is essential that the entire process of installing and handling the motor is carried out by a qualified professional.

The motors are supplied with the number of components specified in the documentation. The use of additional components or tools not supplied by WEG—even if mentioned in the manual—must be evaluated and provided by the installer. The responsibility for any adaptation or use of additional items lies with the person or company responsible for the installation.

For special applications and operating conditions(50026367 manual for Smoke Extraction Motors, 50021973 manual for Brake Motors, 50078700 manual for Electronically Conmutated Motors, 14629920 manual for Roller Table motors, 50106963 manual for WEG Lift Gearless motors) refer to the applicable manual on the website www.weg.net or contact WEG.

For motors supplied with WEG Motor Scan sensor, see installation guidelines Overview of Receipt to Operation Manual (10008475131) available on www.weg.net.

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

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Warning about safety and warranty.

When rotating the shaft, it is necessary to certify that the terminals are insulated to eliminate the risc of electric shock from induced voltage.

2.1 WARNING SYMBOL

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. The shaft might not rotate freely in WMagnet and WQuattro motors, due to alignment torque from the magnets. It might be necessary to use a lever;

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.

2.3 NAMEPLATES

The nameplate contains information that describes the construction characteristics and the performance of the motor. Figure 1, Figure 2 and Figure 3 show nameplate layout examples.

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Figure 1 - IEC motor nameplate

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96.3/96.3/95.7 -www.weg.net WE!Q

IX)

a, 01MAR22 0000000000

W2-2 U2-2 V2-2

W2-1 tU2-1 tV2-1

:fl 3 355H/G-04 DUTY S1 IP55 DES N 3211kg 1OOOm.a.s.l. INS cl. F DT BOK on

IEC 60034-1

AMB 40'C SF 1.00

1/ 100%/75%/50%

U1-2 V1-2 W1-2 t

UH VH WH

!ill L2 L3

_ 6322-C3 {60g)

-6319-C3 {45g)

)t' MOBIL POLYREX EM (7267h)

Figure 2 - IEC motor nameplate m z G)

:I:

3f FOR SAFE AREA

Mod.TEIBFOXON

CC029A

MODEL O7518ETJE365T-W22

_J N Inverter Duly Motor

For use on 60Hz Class I, Div 2, Gr A, 8, C and D - 13 Class I, Zone 2, IIC - 13

EnergyVe<ilied Class II, Div 2, Gr F and G - 14 For use on PWM: Gr. A, 8, C, D and F, VT 1000:1, CT 10:1, 1.00SF - 13A

<( I"--- Severe Duly

PH3 60Hz Fr. 364 ST 1OOOm.a.s.I. IP55 TEFC 926Ib z V 230/ 460 A 174/87.2 w- - HP 75 kW 55

SF 1.25 SFA 718/109

JII 1112

\J:5 116

TIO

i[II JIZ .TIO

}5 16 ,14 118 19 ,17

}2 "(:T3 'DT1

L2 L3 LI

380, 160V

T8 '919 17 -2 ,Tl Tl

M L2 L3 LI

208 230V r _ 6314 C3 (27g)

::;;: RPM 1780 PF 0.83

k

AMB 40'C INS cl. F DTSOK NEMA I0M EFF 95.4% .5314-e3 (219J

DUTY CONT. DES B Code G

MOBIL POLYREX EM (12000h)

USABLE @208V 186A SF I. 10 SFA 205

75HP 55kW 50Hz 380V 106A 1470RPM SF I.DO EFF 93.6% (IE2)

PJ :r1- "ffll!l

MODEL 01018ET3E215T-W22

For use on 60Hz Class I, Div 2, Gr A, B, C and D - T3 Class I Zone 2, IIC - T3 Class Ii, Div 2, Gr F and G T4

EnergyVenried For use on PWM: Gr. A, B, C, D and F, VT 1000:1, CT 20:1, I.OOSF T3A

Inverter Duty Motor FOR SAFE AREA Severe Duty Mod.TEI BFOXON

CC029A

PH3 60Hz Fr. 213/ST 1000m.a.s.l. IPSS TEFC 176Ib V 230/460 A 24.8/12.4 HP 10 kW 7.5

SF 1.25 SFA 31.0/15.5

RPM 1765 PF 0.83

AMB 40'C INS cl. F DTSOK HMH0M EFF 91.7% DUTY CONT. DES B Code H

USABLE @208V 27.4A SF 1.15 SFA 31.5

I OHP 7.5kW 50Hz 380V 15.0A 1450RPM SF I. 15 SFA 17.3 EFF 88.5% (IE1)

T4 TS T6 T4 TS T6 - 6308 ZZ

T1 _TS T9 T7 ITS I T9 1===i- 6207 ZZ

T1 T2 YT3 T1 T2 T3 MOBIL POLYREX EM

t,t, L1 L2 L3 t, L1 L'2 L'3 QI;'_(

208 230V 380 460V l!!llll!ZZZZ

I 63 Manual of Electric Motors www.weg.net

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

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

Pacemaker users and unqualified personnel shall not open WMagnet and WQuattro motors, because high energy magnets are used.

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.

3. SAFETY INSTRUCTIONS

Figure 3 - NEMA motor nameplate

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

4. HANDLING AND TRANSPORT

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.

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.

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Do not handle the motors by the polymeric components: fan cover, drip cover, terminal box and / or terminal box cover.

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, W50, W51 HD and W60 motors, regardless of bearing type, must be transported with shaft locking device fitted.

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.

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. Figure 5 shows an incorrect tightening of the eyebolt.

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

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

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

Figure 4 - Correct tightening of the eyebolt Figure 5 - Incorrect tightening of the eyebolt

4.1.1 Horizontal motors with one eyebolt

For horizontal motors fitted with only one eyebolt, the maximum allowed angle-of-inclination during the lifting process should not exceed 30º in relation to the vertical axis, as shown in Figure 6.

Figure 6 - Maximum allowed angle-of-inclination for motor with one eyebolt

30° Max.

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45° Max.

30° Max.

4.1.2 Horizontal motor with two eyebolts

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

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

For motors with vertical lifting eyebolts, as shown in Figure 7, 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;

Figure 7 - Maximum resulting angle for motors with two or more lifting eyebolts

For HGF, W40, W50 and W51 HD motors, as shown in Figure 8, the maximum resulting angle should not exceed 30° in relation to the vertical axis;

Figure 8 - Maximum resulting angle for horizontal HGF, W40, W50 and W51 HD motors

For W60 motors, as shown in Figure 9, 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.

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Figure 9 - Lifting for W60 motors with paralel chains

For motors fitted with inclined eyebolts, as shown in Figure 10, 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.

Figure 10 - Use of a spreader beam for lifting

4.1.3 Vertical motors

For vertical mounted motors, as shown in Figure 11, 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.

Figure 11 - Lifting of vertical mounted motors

Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the mounting position. See Figure 12.

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Figure 12 - Lifting of HGF, W50 and W51 HD motors.

4.1.3.1 Procedures to place W22/WEG General Purpose/WIN 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/WEG General Purpose/WIN motors fitted with eyebolts (see Figure 10), to the vertical position, proceed as follows:

1. Ensure that the eyebolts are tightened properly, as shown in Figure 4;

2. Remove the motor from the packaging, using the top mounted eyebolts, as shown in Figure 13;

Figure 13 - Removing the motor from the packaging

3. Install a second pair of eyebolts, as shown in Figure 14;

Figure 14 - Installation of the second pair of eyebolts

4. Reduce the load on the first pair of eyebolts to start the motor rotation, as shown in Figure 15. This procedure must be carried out slowly and carefully.

Figure 15 - End result: motor placed in vertical position

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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.

For motors of IEC 112 to 200 frame (and equivalent NEMA), WEG has a kit of devices to facilitate the motor tipping to the vertical, with the point up or down (as shown in Figure 16 and Figure 17).

Figure 16 - Eyebolt to place the motor in vertical position, with the shaft end up (V6/V36)

Figure 17 - Eyebolts with extension fixed at NDE side to place the motor in vertical position, with the shaft end down (V5/V35)

4.1.3.2 Procedures to place HGF, W50 and W51 HD motors in the vertical position HGF motors are fitted with eight lifting points: four at drive end and four at non-drive end. W50 and W51 HD 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 18;

Figure 18 - Lifting of HGF, W50 and W51 HD motors with two hoists

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 19;

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Figure 19 - Placing HGF, W50 and W51 HD motors in vertical position

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 20;

Figure 20 - Lifting HGF, W50 and W51 HD motors by the eyebolts at the non-drive end

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 21.

Figure 21 - HGF, W50 and W51 HD motors in the vertical position

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.

4.2 PROCEDURES TO PLACE W22/WEG GENERAL PURPOSE/WIN VERTICAL MOUNT MOTORS IN

HORIZONTAL POSITION

To place W22/WEG General Purpose/WIN vertical mount motor in horizontal position, proceed as follows:

1. Ensure that all eyebolts are tightened properly, as shown in Figure 4;

2. Install the first pair of eyebolts and lift the motor as shown in Figure 22;

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Figure 22 - Install the first pair of eyebolts

3. Install the second pair of eyebolts, as shown in Figure 23;

Figure 23 - Install the second pair of eyebolts

4. Reduce the load on the first pair of eyebolts for rotating the motor, as shown in Figure 24. This procedure must be carried out slowly and carefully;

Figure 24 - Motor is being rotated to horizontal position

5. Remove the first pair of eyebolts, as shown in Figure 25.

Figure 25 - Final result: motor placed in horizontal position

For IEC 112 to 200 (and NEMA equivalents), WEG has a device kit available to facilitate the procedure of tipping the motor for instalation in a vertical shaft up or shaft down position.

For Easy Maintenance, Wash, Brake motors, motors with forced ventilation, encoder or painting plan 212 or

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X

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

213, please contact WEG.

5. STORAGE

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

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

5.1 EXPOSED MACHINED SURFACES

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

5.2 STORAGE

The stacking height of the motor packaging during the storage period should not exceed 5 m, always considering the criteria indicated in Table 1:

Packaging type Frame sizes Maximum stacking quantity

Cardboard box IEC 56 to 132

NEMA 143 to 215 Indicated on the top side of the cardboard box

Wood crate

IEC 56 to 315 NEMA 48 to 504/5 06

IEC 355

NEMA 586/7 and 588/9 03

W40 / W50 / W60 / W51 HD / HGF IEC 315 to 630 W40 / W50 / W51 HD / HGF NEMA 5000 to 9600 Indicated on the packaging

Table 1 - Maximum recommended stacking height

Notes:

1) Never stack larger packaging onto smaller packaging;

2) Align the packaging correctly (see Figure 26 and Figure 26);

Figure 26 - Correct stacking Figure 26 - Incorrect stacking

3) The feet of the crates above should always be supported by suitable wood battens (Figure 27) and never stand on the steel tape or without support (Figure 27);

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X Figure

When rotating the shaft, it is necessary to certify that the terminals are insulated to eliminate the risc of electric shock from induced voltage.

Figure 27 - Correct stacking 27

4) When stacking smaller crates onto longer crates, always ensure that suitable wooden supports are provided to withstand the weight (see

Figure 28). This condition usually occurs with motor packaging above IEC 225S/M (NEMA 364/5T) frame sizes.

Figure 28 - Use of additional battens for stacking

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). The shaft might not rotate freely in WMagnet and WQuattro motors, due to alignment torque from the magnets. It might be necessary to use a lever.

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.

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 2 (this is also valid for bearings with equivalent dimensions). After filling with oil, rotate the shaft by hand, at least five revolutions)

- Incorrect stacking

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The insulation resistance must be measured in a safe environment.

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.

During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at least five revolutions, stopping it at a different position from the original one. Reinstall the shaft locking device every time the motor has to be moved. If the motor is stored for a period of over two years, the bearings must be replaced or removed, washed according to manufacturer instructions, checked and relubricated according to item 8.2.

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

Table 2 - Amount of oil per bearing

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

5.3.4 Sleeve bearing

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

If the motor is stored for a period 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 dehumidifiers must be applied.

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

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

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

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

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

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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

The insulation resistance must be measured in a safe environment.

Measure the insulation resistance one minute after the voltage has been applied to the winding. The applied voltage should be as shown in Table 3.

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

Table 3 - Voltage for the insulation resistance

The reading of the insulation resistance must be corrected to 40 °C as shown in the Table 4.

Table 4 - Correction factor for the insulation resistance corrected to 40 °C

The motor insulation condition must be evaluated by comparing the measured value with the values indicated in Table 5 (corrected to 40 °C):

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

Table 5 - Evaluation of the insulation system

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.

6. INSTALLATION

Check some aspects before proceeding with the installation:

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

Remove or fix the shaft key before starting the motor.

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 fins, air inlet and outlet openings must be clean and unobstructed. The distance between the air inlet openings and the wall should not be shorter than ¼ (one quarter) of the diameter of the air inlet.

Ensure sufficient space to perform the cleaning services. See item 7.

6. Coupling: remove the shaft locking device (where fitted) and the corrosion protection grease from the shaft end, including the grounding brush area, and flange immediately 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, threaded drain or any other open/close drain plugs 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 29).

For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position (see Figure 29), being opened only during the motor maintenance procedures.

The drain system of motors with Oil Mist lubrication system must be connected to a specific collection system (see Figure 29).

Closed position Open position

Figure 29 - Detail of the rubber drain plug mounted in closed and open position

8. Additional recommendations:

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

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

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

d. The fixing elements mounted in the threaded through holes in the motor enclosure (for example, the flange) must be properly sealed.

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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.

F1 F1

F2

A F2

6.1 FOUNDATIONS

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

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

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

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

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).

The motors may be mounted on:

Concrete bases: are most used for large-size motors (Figure 30);

Metallic bases: are generally used for small-size motors (Figure 31).

Figure 30 - Motor installed on concrete base

Figure 31 - Motor installed on metallic base

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 32.

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;

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Footless motors supplied with transportation devices, according to Figure 33, must have their devices removed before starting the motor installation.

Steel & cast iron blocks, plates with flat surfaces.

Figure 32 - Motor installed on sliding base

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

6.2 MOTOR MOUNTING

Figure 33 - Detail of the transportation devices for footless motors

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.

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In cases that use polymer flanges with a built-in nut or the aluminum flange with hexagonal hole, the length of the motor fixing screw must not exceed the length of the hole, thus avoiding misalignment and clearance of the coupling.

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

D

Figure 34 - Mounting system of a foot mounted motor

6.2.2 Flange mounted motors

The drawings of the flange mounting dimensions, IEC and NEMA flanges, can be checked in the technical catalogue. The coupling of the driven equipment to the motor flange must be properly dimensioned to ensure the required concentricity of the assembly.

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

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

Motors with aluminum frame and/or flange can be supplied with hexagonal holes for flange mounting.

These holes are suitable for receiving cylindrical screws compatible with standardized coupling dimensions, with attention to the minimum screw strength class according to the product catalog.

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

Figure 35 - Mounting method of flange mounted motors with frame base support

In severe applications or if large motors are flange mounted, a foot or pad mounting may be required in addition to the flange mounting (Figure 35). The motor must never be supported on its cooling fins.

The tightening torques indicated in Table 6 must be respected when:

- fixing a polymeric foot and/or flange to the customer equipment for W12/WEG General Purpose motors;

- installing polymeric fan covers for WEG General Purpose and WIN motors and/or changing/rotating the position of the terminal box for W12/WEG General Purpose motors.

For installation of W12/WEG General Purpose motors in frame sizes IEC56, W63 and W71 in the vertical position with the shaft upwards, the foot must be locked axially by the fixing of a flat head screw as indicated.

The hexagonal holes in the C-DIN flanges of W12/WEG General Purpose motors in frame sizes IEC56/W63/W71 are suitable for the screws indicated in Table 6.

L = 1.5 x D

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

Frame Component Bolt/Screw specification (Thread size x length) Torque (Nm)

IEC56

Polymeric Foot

M5x12 8 W63/W71 M5x16 8

IEC56/W63/ W71

Polymeric Flange - 8 C-80 M5 5 C-105 M6 6

160/180/200/W225/225/250/W280 Fan cover M8 / M10 6 to 8 IEC 56/W63/W71 Terminal box/Grounding M5 1,8 to 2,4

71/W80/90/W100/112/132 Terminal box/Grounding M5 5

Table 6 - Tightening torque and screw specification for W12/WEG General Purpose motors.

Note:

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

For WFL motors, the flange has hexagonal holes suitable for M6 screws (maximum torque 8 Nm), and the screws must have at least a 5.6 resistance class. The length of the screws that will be used in the ap-plication to fix the motor to the equipment must not exceed the thickness of the endshield wall where they are mounted, at the risk of damaging the motor coil head and causing electric shock. The application screw must be embedded into the endshield with a minimum depth of 7 mm and a maximum of 9 mm.

6.2.3 Pad mounted motors

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

The mounting rods and the fan case wall must be sufficiently stiff to prevent the transmission of excessive vibration to the machine set (motor & fan). Figure 35 shows the pad mounting system.

Figure 36 - Mounting of the motor inside the cooling duct

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.

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

The maximum balancing deviation must be recorded in the installation report.

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 flexible 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 specified in sections 6.5 and 6.6, respectively.

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

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

clearance

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

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 36 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.

Figure 37 - Axial clearance of motor designed with sleeve bearing.

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

Motors designed with sleeve bearings must be operated with direct coupling to the…