RB-300-8 Prop Motor.pdf

339P0480-H08 5/99 Volume VIII

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

ELECTRICAL, PROPULSION & CENTRAL

MACHINERY CONTROL SYSTEM

For

NOAA-AGOR RIV RONALD H. BROWN

GENERAL ELECTRIC COMPANY

MAY 1999

NOAA/AGOR LIST OF TABS 339P0480-H01 thru H09

36 Genius I/0 Block Configuration Sheets GEK-90486 (Rl0-10)

37 MSC I/0 Data Base

38 GE Technical Training GEH-6005 AC/DC2000 Digital Adjustable Speed Drive C, CX, G, J, K and M Frames Operation and Maintenance

39 ST2000 Tool Kit (MS DOS) GEH-5860A

VOLUME VIII

TAB SUBJECT PUB/DWG. NO.

40 DC2000 SCR and Associated Equipment 246B5846AA Drawings

41 Propulsion and Bow thruster Motors- GEH-5359 Instructions CD and MCD DC Motor Frames Type 6000

42 Starboard Propulsion Motor Drawings 5CD696SA800A800

43 Port Propulsion Motor Drawings 5CD696SA800A801

44 Bow Thruster Motor 5CD696MA800A800

45 Trerice Water Regulating Valve CAT NO. 150

46 Propulsion Motor-Factory Report

47 Prop. Motor Heat Exch, Blower and 93139 Motor Control Panel

48 Switchboard Operation and maintenance Manual

49 VGA Portable Computer Handbook

50 P0608 Vac Panel Drawings (AGOR 24) 3245-MB-XXX

51 Propulsion Blower Motor (AGOR 25 94129

52 480 Vac Distribution Switchboard 0204-DB-000 Drawings (AGOR 25/NOAA)

53 480 Vac Emergency Switchboard 0204-EB-000 Drawings (AGOR 25/NOAA)

54 480 Vac Clean Power Switchboard 0204-CP-000 Drawings (AGOR 25/NOAA)

VOLUME IX

TAB SUBJECT PUB/DWG. NO.

55 Protective Device Coordination Study with Circuit Breaker Settings iii

TAB41

lnstmctions

CD and MCD Direct-Current Motors Frames Type 6000 - 6200, 6700 - 6900

(. l (.

GE Motors

CD and MCD Direct Current Motors, GEH-5359

SAFETY PRECAUTIONS

WARNING

High voltage and rotating parts can cause serious or fatal injury. The use of electric machinery, like all other utilizations of concentrated power and rotating equip ment, can be hazardous. Installation, operation, and maintenance of electric machinery should be performed by qualified personnel, in accordance with applicable provisions of the National Electrical Code and sound local practice.

For equipment covered by this instruction book, it is important to observe safety precautions to protect per sonnel from possible injury. Among the many consid erations, personnel should be instructed to:

• Avoid contact '"'ith energized circuits or rotating parts,

• Avoid by-passing or· rendering inoperative any safe guards or protection devices,

• Avoid extended exposure in close proximity to ma chinery with high noise levels, and

• Use proper care and procedures in handling,lifting, installing, operating and maintaining the equipment.

Safe maintenance practices with qualified personnel is imperative. Before starting maintenance procedures, be positive that:

• Equipment connected to the shaft will not cause me chanical rotation,

• All machine windings have been disconnected and secured from all electrical power sources, and

• All accessory devices associated ''ith the work area have been de-energized.

If high potential insulation test is required, procedures and precautions outlined in NEMA standards MG-1 should be followed.

Failure to properly ground the frame of this machine can cause serious or fatal injury to personnel. Ground ing of the machine frame and structure should be in accordance with the National Electrical Code and con sistent with sound local practice.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further informatio n be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to GE Motors.

© 1992 General Electric Company

CONTENTS

SUBJECT PAGE

INTRODUCTION

RECEIVING, HANDLING, STORAGE

Receiving Handling Storage

DESCRIPTION

Classifications

INSTALLATION

Location Ventilation Protection Mounting Alignment

Coupled Drives Couplings V-Belt Drive Motor-Generator and Multiple Motor Sets Grouting Alignment Procedure Thrust Loads

OPERATION

Inspection Before Starting

Bearings and Couplings Insulated Bearings and Couplings Insulation Commutator and Brushes Shaft Grounding Brushes ........... .... .. .... .. ...... .......................................... :

Rectified Power Supplies Power Supply Identification ...................... , Circuit Inductance Connections Protective Devices

Space Heaters Speed Limit Device Thermostats Ventilation System General Mechanical Inspection Tighten ing Bolted Joints Inspection After Starting Bearings Noise and Vib ration Before Putting Machine In Service spect ion After Short Time In Service

.• ,AINTENANCE

- Productive Maintenance ......................................................................................................... ;

CONTENTS (cont.)

SUBJECT PAGE

MAINTENANCE PROCEDURES

Repair Failure Armature Removal

Special Tools Procedure

Armature Installation Anti-Friction Bearing Removal

Drive End Bearing Commutator End Bearing

Reassembling Ball Bearing Brush Maintenance Commutation Adjustment Commutator Maintenance Commutator Diameters

V-Ring Commutator Maintenance-Commutator Tightening Commutator Turn ing, Stoning, and Sanding Commutator Film Care Commutator Clean-Up by Air-Cure Method Procedure

Hydraulically Removable Keyless Couplings Assembly Removal

Insulation Testing Methods

Visual Inspection Insulation Resistance Measurement

Cleaning of Windings Field Service Cleaning (Assembled Machines)

Dry Dusts Oily Dirt ..................................................................... :

Drying of Windings

Service Shop Cleaning ............................ ..... ...................................................................................... -.. :

SUGGESTED MAINTENANCE SCHEDULE

Monthly Every Six Months

LUBRICATION

Ball and Roller Bearing Relubrication Troubleshooting Guide Lubrication of Flexible Couplings Brush Rigging Reversal Shaft Grounding Kits

General Mounting Notes

RENEWAL PARTS

LITERATURE INDEX · ............................. .. .................... ............................................. ................ ................. .. ~

LIST OF ILLUSTRATIONS

·- SUBJECT PAGE

1. Typical Brazed Pole Face Compensating Winding As Used On CD6700-6900 Frames

2. Selecting the Proper Key Length

3. Commutator

4. Cutaway Sections of Hydraulically Removable Flexible Coupling

5. Removal of the Coupling Using a Hand Puller and Wrench

6. Typical Air Nozzle for Cleaning Machines

7. · Pulling Back the Bearing Cap and Grease Metering Plate·

8. Typical CD6000-CD6200 Brush Rigging

9. Typical CD6700-CD6900 Brush Rigging

10. Typical Mounting CD6000-CD6200

11. Typical Mounting CD6700-CD6900

12. Typical CD6000 - CD6200 Motor or Generator

13. Typical CD6700-CD6900 Motor or Generator

14. Type CD & MCD Renewal Parts (Exploded View)

LIST OF TABLES

SUBJECT PAGE

1 Typical Weights 2 Maximum Radial Load at End of Shaft 3 Thrust Capacity 4 Bolt Tightening Torque Values - Non-Metallic Parts to Metallic Parts 5 Speed Limit Device-- Maximum Current.Ratings 6 Lead Markers .................................................................................................................................... :::

7 Maximum Current Ratings for Thermostats 8 Bolt Tightening Torque Values -- Metallic Parts 9 Commutator Diameters

10 100o/o Commutator Bolt or Nut Torque 11 Recommended Commutator Conditioning Procedure 12 Effect of Temperature on Insulation Resistance 13 Recommended Regreasing Periods 14 Sources of Supply for Bearing Greases 15 Metric Conversion Factors 16 Shaft Grounding Kit 17 Recommended Spare Parts 18 Standard Bearing Description

CD and MCD Direct Current M otors, GEH-5359

CD and MCD DIRECT CURRENT MOTORS

FRAMES TYPE 6000 - 6200, 6700 - 6900

INTRODUCTION

This instruction book covers the Type CD and MCD, frames 6000-6200, 6700-6900, line of DC motors and gen erators.

These instructions do not purport to cover all details or variation in equipment or to provide for every possible contingency or hazard to be met in connection with instal lation, operation and maintenance. Should further infor mation be desired or should particular problems arise which are not covered sufficiently for the purchasers' purposes, the matter should be referred to GE Motors.

RECEIVING, HANDLING,

STORAGE

Receiving The equipment should be placed under adequate cover immediately upon receipt as packing coverings are not suitable for out-of-doors or unprotected storage. This in cludes adequate protection from construction dirt, dur ing and after installation.

Each shipment should be carefully examined upon arri val. Any damage should be reported promptly to the carrier and to the nearest office of GE Motors.

Handling The individual motors or generators can be lifted by using hooks or slings in the lifting lugs on the frame. These lugs are designed to safely carry the weight of the whole machine, including normal machine mounted accesso ries. Blowers should be protected with spreader bars as necessary. Ventilating h oods may need to be removed to clear hooks. Do not lift the machine by the shaft exten sions. (Refer to Table 1 for approximate weights.)

WARNING: , Before attempting . to lift any , machine;-·check the outline drawing for the 1 ·:~( rJh t; J .,. • • ,. .. ,'4·· ·~· . ...,. ~ •· • lifting points: Unless. othenvise specified on ~- ''ilie outline dra~, liiting'dCviees are intended to support ~~~Y· the par~. to:.which th~y are .attache~. Lifting devices on accessories are not sui tab!~ · for ').ifting the iocil weight of the assembled machine. Mac:Jllne liftirig devices

'are not to' ?e us~d to lift the machine plus .

additional equipment such as pumps or other drive~ equip~en~

Failu~e to observe thes~ precautions may result in damage to the equipment, injury to personnel, or both.

When MG sets are supplied, lifting holes, to be used ~ith spreader bars or hooks, are provided in each base. Care must be taken in handling to avoid twisting bases. The handling of individual armatures or machine parts is described in the Maintenance section of this Instruction

Book.

Storage If a machine, or any part of a machine, is not to be installed immediately, it should be stored in a clean, dry area and protected from variations in temperature, high humidity, and dust. If possible, sudden change in tem perature and humidi ty should be avoided. If the tempera ture of the storage room varies to such an extent that the windings and coils are exposed to moisture condensa tion, the machine should be protected by a safe, reliable heating system such as space heaters, which will keep the temperature of the machine slightly above that of the storage room. Brushes should not remain in contact with the commutator during prolonged storage. Otherwise, corrosion may occur and later result in flat spots on the commutator, with corresponding poor and destructive commutation. Motors are shipped with a protective mylar wrapping around the commutator which prevents brush contact.

TABLE 1

TYPICAL WEIGHTSu

APPRO X. APPROX. ARM

FRAME NET WEIGHT NET WEIGHT

lbs. kgs lbs. kgs

C06050 3900 1770 1100 500 C06052 4200 1910 1200 540

CD6054 4100 1860 1300 600

CD6055 4700 2130 1400 640

CD6057 4500 2040 1500 680

C06058 5300 2400 1500 680

CD6059 5000 2270 1600 730

CD6062 6000 2720 1700 770

CD6063 5600 2540 1800 820

CD6066 6300 2860 1900 860

C06154 5800 2630 1700 770 C06157 6500 2950 1900 860

CD6160 7300 3310 2200 1000

CD6163 6300 2860 2400 1090

CD6164 8300 3760 2500 1130

CD6165 7000 3180 2500 1 130

CD6168 7800 3540 2700 1230

CD6169 9500 4310 2800 1270

CD6173 8800 3990 3000 1360

CD6177 10000 4540 3200 1450

CD6259 9800 4450 2700 1230

CD6262 11100 5040 3100 1410

CD6266 12700 5760 3600 1630

CD6268 10400 4720 3700 1600

CD6270 11700 5310 4000 1810

CD6271 14500 6580 4100 1860

CD6275 13300 6030 4300 1980

CD6280 15200 6890 4500 2040

If the machine has been exposed to low temperatures for an extended period of time, unpacking it before it has reached room temperature will cause condensation to form.

If visible moisture is present on machine surfaces, take steps to thoroughly dry the machine prior to operation to avoid the possibility of electrical failures. (Refer to the

Drying of Windings, and Insulation-Resistance Measure ment section of this Instruction Book.)

All exposed machined steel parts are coated with a rust preventive before shipment. These surfaces should be examined carefully for signs of rust and moisture, and recoated if necessary. Once started, rust will continue if the surface is recoated without first removing all rust and

APPRO X. APPROX. ARM

FRAME NET WEIGHT NET WEIGHT

lbs. kgs lbs. kgs

C06766 12100 5490 3565 1620 C06770 14000 6350 3915 1780

CD6771 12400 5630 3835 1740

CD6774 15200 6900 4410 2000

CD6776 14000 6350 4185 1900

CD6778 15600 7080 4685 2130

C06779 17200 7810 4920 2230

CD6785 17600 7990 5205 2360

CD6873 16000 7260 4730 2150

C06876 17700 8040 5120 2320

CD6881 20300 9220 6090 2560

C06882 16800 7630 5250 2380 C06885 18500 8400 5640 2860 C06887 23500 10670 7440 3380 C06890 21000 9530 6610 3000

CD6896 23500 10670 7960 3610

CD6977 23400 10620 5925 2690

CD6981 26000 11800 6685 3030

C06985 28700 13030 7540 3420

CD6986 24300 11030 6480 2940

CD6990 26900 12210 7240 3290

C06991 31700 14390 8770 3980 C06996 29600 13440 8095 3680

CD6999 34400 15620 .9325 4230

**Approximate weights for typi ca I motors in eacr frame size. Does not include weight of accessorie~ such as tachometers, blowers, heat exchangers, etc For specific weights, refer to certified outline.

moisture. Rust may be removed by careful use of fine abrasive paper. Slushing compound can be removed by using a solvent such as mineral spirits.

WARNING: Mineral spiritS are flammable and moderately toxic. The usual precautions for handling chemicals of this type should be observed. These include:

1. Avoid excessive contact with skin,

2. Use in well ventilated areas, and

3. Take necessary precautions to prevent fire or explosion hazards.

I"

I·

CAUTION: Care must be taken when cleaning

19 ~avoid ~ru:naging m~hined surfaces. Extreme ;care mus.t be exercised to prevent these parts from rusting since it is difficult, and sometimes impossible, to remove rust from these surfaces without ~amaging or deforming the surface. If

· • . burrs or bumps result from careless handling, ·· ·~_carefully remove them, using a fine file or

CJ!.UTI<?~: Machines in swrage should have ;;the insulation resistance checked at frequent . ~ ' •• ,;j< ail.? regular in~rvals with an instrument such -as a megger. A log should be kept of pertinent da~. If the log indicates a decreasing insulation resisLance, the motor should be moved to a drier location.

·.,;fA-UTI ON: When stored, the armature must

~be rotated every three months to prevent loss of gr~ase protection on the bearings and races.

;,Loss ~f grease protection causes rust. Before

~·rotating, inspect ccmmutator for protective -~ylar wrapping. Rotate in the direction which wilf not snag the mylar end. Insure the end of

":the mylar is taped in place to prevent snagging

• and rolling up. ... ··· .

DESCRIPTION

The general line has a family resemblance even though it covers a wide range of sizes. A variety of accessories and modifications is available to tailor the machine to a p:u-ticular application.

The armature is a complete unit assembly which may be removed from the frame once the bearing brackets and brush rigging have been disassembled.

All standard machines are equipped with a shaft exten sion and key on the drive end. A shaft extensiun suitable for mounting a speed limit device or tachom l.! ter is stan dard on the commutator end.

Motors in frame sizes 6000,6100, and 6200 have conven tional stator windings. The 6700- 6900 frame size mowrs are equipped with pole face compensating windings.

These motor designs have pole face connections which are resistance brazed. (Refer to Fig. 1.)

Classifications Type CD motors and generators are standard DC ma chines designed for general industrial seiYice. These motors are defined by NEMA par. MG 1-23.01 and MG 1- 24.01.

Fig. 1 Typical Brazed Pole Face Compensating Winding As Used On CD6700-6900 Frames

Type MCD motors are metal rolling mill DC motors de signed particularly for metal rolling mill service. These motors are defined by NEMA par. MG 1-23.02.

INSTALLATION

:. ·:~1~wARN:INca;lstallation should be in accor~ce !'' 't,ici{ili'iNaclonal Electrical Code and consistent qV~-'~~tfi'ijll()cai codes .. Coupling, belt, and chain

' ;. -~g~:i£~i~h'~~id be io.sta}led as needed to protect ' '

;< .·" :. ag~~i~~~c~idental co~t~.'ct with moving parts.

'·'·~§chines' .accessible to the public should be

: rther~gmirc:led_by screening, guard rails, etc., ~o. pz:~w!nt· the public from coming in contact .. 1"ith-the equipment. Failure to observe these

·,i;l?p;eca~ti~ns may result in injury to personnel: .

WARNING: Disconnect po~er before touching

_a[ly internal part; High voltage may be present '''?;o;\ren when the machine is not rotating. If used with a rectified excitation supply, disconnect all

. AC line connections to the excitation source.

: .. With odl'er e~cltatioh··~upplies, disconnect all DC field connections: Frul~re to observe these .

.. · precautions may result in injur;' to personnel.

Location Motors and generators should be installed where they \\ill be readily accessible for inspection and maintenance.

They should be installed where they will not be exposed to moisture, escaping steam, dripping pipes, paint over spray, acid, alkali, oil, gas, dust, dirt, lint, silicone vapors, or other injurious substances.

·' WARNING: The use of electrical equipment in

·· hazardoUs locations is restricted by the National

Electrical Code, Articles 500-504. This includes ' locations where fire or hazard may exist due to flammable gases, vapors, or liquids, combustible dust, or ignitable fibers or flyings. Standard

,motor$ and generators are not designed to be suitable for use in hazardous locations such as these, and should not be used in such locations.

gonsult Articles 500-504 and local codes and authorities for details of hazardous locations and application of electrical equipment and motors therein.

CO and MCO Direct Current Motors, GEH-5359

Ventilation A supply of clean air must be available to the machine during operation. Unless othenvise specified, the tem perature of the air entering the machine should be warmer than 1 o·c, but not greater than 40"C. To avoid collection of condensation in the machine, the dewpoint of the air should be lower than the minimum surface temperature of any upstream air cooler. Contaminated cooling air must be aYoided. Moisture and dust contaminants and liquids such as oil are easily recognized and can be elimi nated. Gaseous contamination such as silicone vapor is difficult to detect, but must be guarded against.

CAUTION: Silicone vapor may be present and originate from sealing compounds, electrical cables, and room transformers. TheS(! sources must be eliminated. Silicone vapod~terferes 'with commutation and high brush wear may result.

Protection

· ~UTION: Windings, commutator, brush rigging, and bearings should be ·· carefully protected duriiifinstallation to avoid damage from paint sprny, weld- ~platter, welding:rod butts, or metal chips from files and grinders.

. Metal particles which lodge in windingt'can cause either immediate or prem.ature failures.

P~nt or o il on commutators can be ._very detrimental to good commutation.

Mounting

.i

Motors and generators should be mounted on rigid and solid foundations. Level the base (or the machine). Hold down bolts should be inspected regularly and kept tight.

The feet of the machine may be doweled to the founda tion plates or base when alignment procedures are com pleted. Sliding bases, when used, should be securely an chored to the foundation. Jacking holes are located in all motor feet for ease of alignment.

ALIGNMENT

.-:: ~UTI ON: Be sure to align, ?T check aligrunent, carefully ~ on either,:. motors or MG sets.

Misalignment can cause excessive vibration and

-· damaging forces on shaft and bearings.

Time taken to assure good alignment will be returned in reduced downtime.

Coupled Drives When a motor and a driven unit together have four or more bearings, flexible couplings should be used to facili tate alignment. Three-bearing construction requires a rigid coupling.

, . CAUTION: c.ireful alignment of machines when >I ...

_:;,!lsing eitper solid (rigid) or flexible couplings

. Js .essential to p~event excessive vibration, hot

~;LJ?earings, or ~haft failures.

Couplings Couplings must be properly sized to be capable of driving maximum machine torque. Interference fits should be used between motor shaft and coupling and the key installed of proper length. (Refer to Fig. 2.)

V-Belt Drive The driving and driven shafts should be located so that they are parallel and the sheaves aligned. If properly aligned, there is minimum wear on the belts and no excessive thrust on the machine bearings. The sheave should be mounted as close as possible to the motor bearing. The following recommendations should be fol lowed concerning the minimum sheave pitch diameter which can be used for the particular motor. The belt manufacturer should be consulted for the maximum speed ratio and belt for the particular application.

The following formula and data can be used to select the

MINIMUM allowable sheave diameter from the stand point of bearing life and shaft stress. A larger sheave \\ill further reduce the shaft stress and bearing loading. This data is based upon the belts being tightened to a maxi mum total pull ofl.5 times that is required to transmit the load used in the sheave diameter calculation. Belts should never be tightened more than necessary to transmit this torque.

D

Purpose: When motors are balanced in the factory a half height key is employed. In the field when couplings or hubs are added, the key length should be adjusted accordingly to preserve the orignal balance.

Procedure: Measure the length of the flat cutaway portion of the keyway. Measure the length of the bore of the accessory or coupling to be mounted.

The key should then be cut to a length equal to half of the bore length of the accessory plus half the difference in the two pre vious mea surements.

A::ACCESSORY BORE

LENGTH

C:KEYWAY LENGTH

B

-- (C+A) _ PROPER

--KEY

2 LENGTH

1.--- e A --~ 1~-'--- c

Fig. 2 Selecting the Proper Key Length

HP 189000

= X RPM w

Where:

D Minimum sheave pitch diameter in inches for\' belt application

HP

RPM = Maximum ratio of horsepower, including over loads, to the speed at which that power occurs

W Maximum allowable radial load from Table 2

Belt-driven machines may be equipped with sliding rails.

Proper and constant belt tension is easily maintained and the replacement of belts is simplified. This reduces the operating cost and increases the efficiency. Sliding rails are to be used for floor mounting only.

Belt idlers reduce the life of the belts and should not be used if any other method is available. The belts should never be forced over the sheaves. When the drive is started

TABLE 2

MAX. RADIAL LOAD (WJ

AT END OF SHAFT (LBS)

Horizontal Mtg. Horizontal Mtg.

Standard D.E. Standard D.E.

Ball Bearing Roller Bearing

DE Re- DE Re- Frame Brg.l com Max Brg./ com Max

6000 6224 II 00 1700 ~U224 3900 5300

6100 6228 1300 1800 ~U228 4800 5600

6200 6232 NONE 1500 ~U232 5000 7500

Vertical Mtg.

DE Angula~ Contac Cont Peak

Beanng rpm rpm

DE

Brg./

Re- MAX MAX c?m

Max 2500 1600 2200 2700 1400 1800 3000 1200 1500

Not recommended for use with belt drive.

Belt load must be radial and applied within 90 degrees of the direction of the armature weight loading (i.e.; NOT a horizontal mounting, Arm load= DOWN, with a vertical UP belt load.) Maxi mum limits may be due to shaft deflection limits at either the belt load or the bearings, or shaft endurance stress limits under combined bending and torsion (at 150% P.U. Torque), using standard materials and keyed shafts.

RECOMMENDED RADIAL LOAD should provide an ADJUSTED L10 bearing fatigue life (materials, speed, lubricant, and temperature considered) of 30,000 hours.

MAXIMUM RADIAL LOAD should provid e an AD JUSTED L10 bearing fatigue life (materials, speed, lubricant, and temperature considered) of 10,000 hours.

MAXIMUM CONTINUOUS RPM is the maximum speed which can be held continuously and still meet the above listed limits.

MAXIMUM PEAK RPM is the maximum speed that the machine can be allowed to attain during belt (or gea r) loaded applications.

and operating at full speed and full load, the take-up should be adjusted until only a slight bow appears in the slack side. If slippage occurs after the belt tension has been correctly adjusted, the belts and pulleys have not been chosen properly for the job.

CAUTION: Over-tightening to avoid this slippage may result in early failures of belts, 1 shafts, and bearings.

Belt tension should be checked and adjusted following the belt manufacturer's recommendations.

CD and MCD Direct Current Motors, GEH-5359

T;1ere is normally a drop in tension during the first 24 to

48 hours of operation. During this "run in" period, the belts seat themselves in the sheave grooves and initial stretch is removed. Belt tension should be rechecked after a day or two of operation.

Matched belts run smoother, look better, and last longer.

Longer belt life results if the belts and sheaves are kept clean and the belts are prevented from rubbing against the belt guards or other obstructions.

Motor-Generator and Multiple Motor Sets MG sets are properly aligned before shipment. Check the alignment before operating a set to be sure that shipping, handling, and installation have not misaligned the units.

Parallel and angular misalignment should not exceed

.002 inches. (.05mm).

Two kinds of MG set bases are used. One is called "non self-supporting" and, as the name implies, is not as rigid as the "self-supporting" base. The non-self-supporting base is designed to act only as a spacer between the foundation and the units of the MG set, and must not be trusted to carry any weight unless well supported at all of the mount ing pads on its underside. This type of base must be securely bolted to the foundation and grouted in after alignment.

CAUTION: Be careful not to distort the base during handling or else the ability to properly align the MG set will be destroyed.

The self-supporting base has pads on its underside for support. A self-supporting base is rigid enough so that it requires support only at the pads. The entire weight of the set is supported on just these points, and the foundation must be designed to withstand these concentrated loads.

Two kinds of couplings are used to connect units of MG sets. Some sets will be made up of two-bearing units coupled together with flexible couplings. Others \'ill use single-bearing units connected with rigid (solid) cou plings. With each kind of coupling and each kind of base design, a slightly different alignment procedure is required.

(See Alignment Procedure in this Instruction Book.)

Grouting On concrete foundations, a minimum of one inch should be allowed for grouting.

A rich, non-shrink grout should be used. High-grade grout mixtures are available commercially. If the grout is to be prepared at the site, a cement-sand ratio ofl:2 is rec ommended. Just enough water should be used to give a stiff mixture. The clean, but rough surface of the founda tion should be wet and the grout rammed or puddled under the base.

Alignment Procedure Flexibly Coupled Drives

Level all mounting base supports before setting the base in position. Before grouting the base, the alignment should be checked as follows:

1. Remove all coupling bolts and slide the shells back so that the hub faces are exposed.

2. Check the coupling hub spacing in accordance with the outline dimensions with the units in the mechanical center of their end play.

3. Start with the coupling next to the largest unit (usually the motor) or near the middle of multiple units.

Check the radial alignment by using a straightedge across the two hubs at vertical and horizontal. Or by clamping a dial indicator to one hub and indicating the other on its outside diameter. Be sure that the dial indicator supports do not bend or sag, since this will give inaccurate readings. The maximum variation should not exceed .002 inches (0.05 mm) .

4. Insert feeler gage or use dial indicator at hub faces.

Measure the gap between hub faces at 0, go, 180 &

270° and record. Rotate both shafts together goo.

Repeat ~he gap readings. Continue rotation in goo increments until five sets of readings are taken. The flfth set of readings is a check on the first set of readings to assure that data is reliable. The readings should not vary by more than .002 inches (0.05 mm) between the four readings taken at each coupling position.

5. Correct the horizontal alignment by shifting frames on the base and the vertical alignment by shimming between the machines and the base.

6. Repeat Steps# 2, 3 and 4 on each coupling, working away from the motor or center unit.

7. Recheck the couplings on long sets after completing the above checks, because shimming when checking subsequent units may affect those already checked.

After the set has been aligned within the specified limits, the coupling shells may be bolted together.

The motor feet may be doweled to the base if desired.

Thrust Loads Machines are expected to have no continuous external thrust (a.xial) loads. If thrust loads are expected, the maxi mum permissible continuous load, in the horizontal con figuration, is tabulated in Table 3 by frame diameter.

For applications requiring greater horizontal thrust loads or vertical mounting thrust loads, consult GE Motors through a local GE Sales Office.

TABLE 3

THRUST CAPACITY

HORIZONTAL MOUNTING

FRAME

SIZE LB.* N*

6000 1200 5340 6100 1400 6230 6200 1400 6230 6700 1700 7560 6800 1700 7560 6900 2000 8900

*Based on an adjusted L

Life of 10,000 hours.

OPERATION

WARNING: High yoltage electric shock can cause seriou~ or fat;aJ injury. Disconnect power before touch.inganyintemal part. High voltage may be present even when the mac?in(: is not ro_tating. If used with a re.:tified power supply, disconnect all AC line connections- to power supply: With other power supplies, disconnect all DC line and field connections. Also disconnect power from auxiliary devices. Failure to observe the~e precautions may result in damage to the equipment, injury to p~rsonnel,, or both. -

·WARNING: Ground the machine properly to avoid serious injury to··personriel; Grounding ';ho~ld>be· in accordance with the National

Electri~ Code and consistent with sound local ·.PE~1etice~~: ·~;

Inspection Before Starting These inspection procedures should be followed before starting the machine for the first time, after an extended shutdown, or after a teardown for extensive maintenance or repair.

Bearings and Couplings Machines with ball or roller bearings are greased at the factory and will not require attention until relubrication is necessary as suggested in the Maintenance section of this Instruction Book.

Flexible couplings should be checked to see that they contain the proper amount of lubricant.

Make sure that all oil and grease plugs are tight.

Insulated Bearings and Couplings Some of the larger MG sets are driven by synchronous motors, which may require that the motor shaft be electri cally insulated from the base or from adjacent generators.

This insulation prevents damaging shaft currents which are caused by slight flux unbalances in the motor mag netic circuit. These currents, if allowed to flow through anti-friction bearings, can cause enough damage to make bearing replacement necessary.

MG sets requiring insulated motor shaft systems will have insulated flexible couplings next to the motor. In such cases, the insulation resistance should be checked. (Refer to the Insulation Resistance Measurement section of this

Instruction Book.) A grounding brush may be used to prevent the shaft system from running above ground po tential, and this must be removed after disconnecting all power during the shaft-system insulation resistance test. If the insulation resistance from shaft to ground is not at least 20,000 ohms, the exposed surfaces of the insulation probably have oil and dirt on them which forms a shorting path. Clean these surfaces to obtain a satisfactory resis tance reading. Persistently low readings may be due to im bedded dirt or chips.

CO and MCD Direct Current Motors, GEH-5359

"":.,...... - .., .... ~ .,... ~~-"' .·'-•o;'!'"" .-...... ~" " . •

_;; -w~G: Replace~groundi"ng-brusnbero"re ·· ;;.

. ·- - . -operating. ~- " . . ·~·

Insulation Check and record the insulation resistance of each ma chine (Refer to Insulation section of this Instruction Book.)

Commutator and Brushes Remove protective mylar wrapping from commutator before attempting to operate motor.

Brushes should be worn in to have at least 85 percent contact over the brush surface and continuous contact from heel to toe . The commutator surface and undercut mica should be clean and free from dirt, grease, paint spots, and brush dust.

Brushes should be free to move in the holders and all springs should be down and latched. Brush pigtail con nections should be tight and the pigtails should not interfere with the action of the spring or brush and should be clear of any part of the machine.

Shaft Grounding Brushes Some CD6000 motors are equipped with brushes in tended to form a conducting path from the armature shaft to the motor frame (and then to ground). Small brush holders can be mounted on one of the endshields, and the brushes ride on the surface of the shaft. Check to see that the brushes are solidly mounted and electrically connected and that the brushes are free to move in their brushholders. Internally mounted grounding brushes are indicated on a nameplate sticker on an adjoining access cover.

Rectified Power Supplies When DC motors are operated from rectified power sup plies, the pulsating voltage and current wave forms affect the motor performance by increasing motor heating and degrading commutation. Because of these effects, it is necessary that the motors be designed or specially se lected to suit this type of operation.

The ratings of DC motors intended for operation from rectified power supplies are based upon motor tests using a suitable power supply. The specific characteristics for three-phase rectified power supplies described in the

Power Supply Identification section are in common use.

For operation of motors from rectified power supplles other than those given in this section, refer to GE Motors.

A motor may, under some conditions, be operated from a powersupplydifferentfrom that indicated on the name plate. Because the letters used to identify power supplies in common use have been chosen in alphabetical order of increasing magnitude of ripple current, a motor rated on the basis of an "E" power supply may be operated from a "C" or "D" power supply, and a motor rated on the basis of a "D" power supply, may be operated from a "C" power supply, but not necessarily from an "E" power supply. If it is desired to use a motor rated on the basis of a "C" power supply on either a "D" or "E" power supply, it may be nec essary to add an inductance externally to the motor to limit the ripple current to the magnitude implied in the rating.

Power Supply Identification The nameplates of DC motors intended for operation from rectified power supplies will be stamped with a Power Supply Identification as described below.

1. When the test power supply used as the basis of rating is one of the three described below, a single letter "C", "D", or "E" will be used to identify the test power supply.

Letter "'C"

This designates a three-phase, 60 hertz input, full-wave power supply having six total (controlled) pulses per cycle.

The power supply has no free wheeling and no series inductance added externally to the motor armature cir cuit inductance. The input line-to-line AC voltage to the rectifier shall be 230 volts for 240-volt DC motor ratings, and 460 volts for 500- or 550-volt DC motor ratings.

Letter "'D"

This designates a three-phase, 60 hertz input, semi-bridge power supply having three controlled pulses per cycle.

The supply has free wheeling with no series inductance added externally to the motor armature circuit. The input line-to-line AC voltage to the rectifier shall be 230 volts for 240-volt DC motor ratings and 460 volts for 500- or 550-volt DC motor ratings.

Letter "E"

This designates a three-phase, single-way {half-wave) power supply having three total pulses per cycle and three controlled pulses per cycle. The power supply has no free wheeling and no series inductance added externally to the motor armature circuit inductance. The input line-to line AC voltage to the rectifier shall be 460 volts for 240-volt DC motor ratings.

2. When intended for use on a power supply other than "C", "D", or "E" the motor will be identified as follows:

M/ NF-V-H-L

where, M =a digit indicating total pulses per cycle

N= a digit indicating controlled pulses per cycle

F = free wheeling (this letter appears only iffree wheel ing is used)

V = three digits indicating nominal line-to-line AC volt age to the rectifier

H = two digits indicating input frequency in hertz

L = one, two, or three digits indicating the series induc tance in millihenries (may be zero) to be added ex ternally to the motor armature circuit inductance

If the input frequency "H" is 60 hertz and no series inductance "L" is added externally to the motor armature circuit, these quantities need not be indicated and may be omitted from the identification of the powe: ~upply. If one of these quantities is indicated, both of them shall appear to avoid confusion.

EXAMPLE: "6/3 F-380- 50- 0" defines a power supply having six total pulses per cycle, three controlled pulses per cycle, with free wheeling, with 380 volts, 50 hertz input, and no externally added series inductance to the motor armature circuit inductance.

Circuit Inductance Motors rated 1500 HP and above, operating on rectified power supplies, must have armature current ripple lim ited to assure reliable operation. Armature current ripple is determined by power supply type, ratio of De to AC voltage, and total circuit inductance. For three phase, full wave power supplies, minimum total circuit inductance required can be calculated from the following formulas:

For 500 and 550 volt DC motors:

(460 VAC)

Total Circuit Inductance = 0.34 Rated DC Current

For 700 and 750 volt DC motors:

(575/600 VAC)

Total Circuit Inductance = 0.43 Rated DC Current where the current is in amperes and the inductance is in henries.

Once the required total circuit inductance has been calculated, circuit elements such as transformers and cabling can be selected so that the total circuit inductance

(including motor inductance) meets the calculated mini mum. In some cases, an external reactor will be required to meet the calculated minimum.

Connections All terminal connections should be checked against the machine's connection diagrams to be certain that the polarity or direction of rotation will be correct. Insure bolted connections are tight and that adequate clear ances exist between conductors of opposite polarity and between conductors and ground. Bolted connections of flexible cable must be insulated. For correct bolt torque, see Tables 4 and 8. Refer to Table 6 for identification of winding leads.

Protective Devices

~ CAUf!ON: _See _that all protective devices (overipeed devices, bearing temperature relays, · etc. f are connected and ~I fu'nction properly.

· ··· ~e sure all coupling guards, 'shaft protectors} grounding connectors, covers, and c;>ther safety

~evices are properly attached.

Space Heaters Space heaters are furnished in machines when ordered.

They should be energized with the correct AC voltage as shown on the nameplate.

CD and MCD Direct Current Motors, GEH-5359

TABLE 4

BOLT TIGHTENING TORQUE VALUES-

NON-METALLIC PARTS TO METALLIC PARTS

Hex Head Medium Carbon Steel (Yokes, Brush Studs, Coil Supports)

TORQUE

Wrench Thread Size Size UNC-2A Lb.-Ft. N-m

7/16 1/4-20 5-7 7-9 1/2 5/16-18 7-9 10-12 9/16 3/8-16 13-17 18-23 3/4 1/2-13 24-30 33-41 15/16 5/8-11 60-75 81-100

WARNING:Thesurfaceofaspaceheaterblocf

··becomes hot when the heater .is energized; The temperature rise: above ambient temperaiure:c ,.,,·::6nay tie ~as high ~-:,7~ooF. (4oo;,c)'. Energized ·"; ' heater blockS will ·~_iu~~ burns it touched. Keep .

heater block surfaces free of combU.stible material

.. such as dust and lint to preventfin!,'expf8si'on, :

-and hea~e~ bum ou~c-, ·· ;, Speed Limit Device The mechanical speed limit device is factory adjusted to trip at 115 percent (±2 percent) of rated top speed and requires manual resetting.

Both normally open and normally closed contacts are present and have current ratings as shown in Table 5.

TABLE 5

SPEED LIMIT DEVICE- MAXIMUM

CURRENT RATINGS

(Normally open or normally closed contacts)

115 VAC 230 VAC 120 VDC 240 VDC

3.0 amps 1.5amps 2.5 amps 0.8 amps

TABLE 6

LEAD MARKERS

FUNCTION WINDING

Armature A 1, A2, A3, A4, ETC.

Control Signal Lead Attached To Commutating c Winding- One Lead Only

More Than One Signal Lead C1,C2,C3,C4, ETC.

Magnetizing Winding (For Initial and Maintenance) E1, E2, E3, E4, ETC.

Magnetization and De-Magnetization of Permanent Note: E1, E3 or other odd-numbered terminals Magnet Fields should be attached to the positive terminal of the magnetizing power supply for magnetization and to the negative terminal for de-magnetization.

Field (Shunt) F1, F2, F3, F4, ETC.

Alternating Current Rotor Winding (Collector M 1, M2, M3, M4, ETC.

Rings)- 3 Wire Generator

Field (Series) S1,S2,S3,S4,ETC.

Stator, AC Machines Only (Type AN Tachometer T1, T2, T3, T4, ETC.

Generator)

ACCESSORIES AND SPECIAL DEVICE TERMINAL MARKINGS

Tachometer Generator, Direct Current, A 1, A2, A3, A4, ETC.

to Terminal Board

Brake Coil Leads B 1, B2, 83, B4, ETC.

Heater, Brake Space Heater BH1, BH2, BH3, BH4, ETC.

Brake Interlock Switch BS1,BS2,BS3, BS4,ETC.

Heater, Space Heater in the Machine H 1, H2, H3, H4, ETC.

Heater, Oil Reservoir in the Bearing Pedestal L 1, L2, L3, L4, ETC.

Thermostat P1, P2, P3, P4, ETC.

Resistance Temperature Detector, (RTD) R1,R2,R3,R4, ETC. - · Thermistor, Thermocouple RT1, RT2, RT3, RT 4, ETC.

Resistor (Shunt Field Adjusting)- External to Unit and Connected in the Shunt Field Circuit V1,V2, V3,V4,ETC.

(Temperature Compensated Generator)

MD Motor (Split Frame)- Connector to Open Thyristor Circuit When Splitting the Frame w MD Motor (Split Frame)- Connector to Open Armature Circuit When Splitting Frame X

MD Motor (Split Frame) - Connector to Open Shunt Field Circuit When Splitting the Frame y

MD Motor (Split Frame)- Connector to Open Series Field Circuit When Splitting the Frame z Note: Connect multiple leads labeled the same together

Thermostats The thermostat is a protective device.lt is not intended to limit motor loading or provide normal insulation life.

When supplied, it is mounted in contact with a commu tating coil, which is the only accessible part of the arma ture circuit. Since factors such as shaft speed, ventilation

(blower or shaft fan), current ripple (SCR phase-back) and short-time overload affect the temperature relation ship between armature and commutating field, complete protection from all conditions resulting from overtem perature is not possible. The device is especially useful in guarding against loss of normal ventilation air, high ambient temperature, and prolonged operation of self ventilated motors at very low speeds.

Thermostats may be used in alarm or relay circuits within rating limits shown in Table 7.

TABLE 7

MAXIMUM CURRENT RATINGS FOR

THERMOSTATS

(Normally open or normally closed contacts)

LOAD 125 VAC 250 VAC 600 VAC 30VDC

Resistive 5AMPS 2.5AMPS 1 AMP 5AMPS

*Inductive 3AMPS 1.5 AMPS 0.5AMP 1.5AMPS

* Suitable for pilot duty only (relay coils).

WARNING: Thermostats automatically reset afteor the motor has cooled somewhat In order to pr~ent property damage or injury- to l l~~ ct &,~el, the control ci:rcuitshould be designed ·'· ;'.''·.:"' to prevent the automatic starting of the motor -_,', when the thermostat resets.

Ventilation System Insure that blowers or central systems are ready to supply cooling air. Air filters should be in place. BLOWERS

SHOULD BE CHECKED FOR CORRECT ROTATION.

Verify that all unused motor openings at the air inlet end are covered, including those on the bottom. Separately ventilated motors are shipped with all solid drive end covers. Remove and discard the cover over the intended air entrance. Motor openings at the opposite end should have appropriate covers for the type of air exit intended.

CD and MCD Direct Current Motors, GEH-5359

General Mechanical Inspection Check the inside of the machine for tools, metal chips, or any other foreign material that may have accumulated during storage or installation. Make sure that all rotating parts have enough clearance from any stationary parts.

Turn the machine over by hand, if possible, and check for scraping noises or any other sign of mechanical interfer ence. Check the tightness of the bolts in the feet, cou plings, conduit box cables, bearing housings, and any other bolts that may have been disturbed.

Tightening Bolted Joints Since loose bolts can cause both electrical and mechani cal failures, all bolts and nuts must be kept tight. The maintenance schedules include the checking ofbolt tight ness. Table 8 gives the torque values to be used in this maintenance procedure.

The information in Table 8 applies to all bolted joints, except when non-metallic parts (e.g., fluid bed parts, polyester glass moldings) are bolted to metallic parts.

Lower torque values as listed in Table 4 are recom mended to prevent fracturing non-metallic parts.

The following precautions, which apply to the tightening of bolted joints, should be observed in maintenance pro cedures:

l. Use a torque wrench for tightening only. When necessary to loosen bolts, use another type of\\Tench.

2. The pressure bearing surfaces and the threads of nuts and bolts should be clean, dry, and free from oil and grease when torqued to the \"alues given. Oiled threads require that torque values be reduced 10 percent.

3. In initially tightening a bolted joint, the final turn must be tightened with the torque wrench to obtain an accurate setting.

4. In checking the tightness ofboltedjoints, the torque wrench should be applied at the higher value of torque given in the Tables to ensure adequate tighmess.

Loose pole bolts and commutating coil-cable bolts will cause serious failures on industrial equipment Even though all of the bolts are torqued to the specified values during manufacture, they must be checked on site periodically.

Experience has shown that bolted joints are subject to loosening during shipping. Experience also has shown that both vibration and the heating and cooling of bolted joints cause them to loosen.

TABLE 8

BOLT TIGHTENING TORQUE VALUES- METALLIC PARTS (See Table 4 for Non-Metallic Parts)

Hex Head Medium Carbon

Steel (Hold Down, Thread Elect. Connections, Hex Head

Wrench Sizes Main Pole Non-Magnetic Steel Size (UNC-2A) Bolts, Etc.) (Comm. Pole Bolts)

ln. Lb. Ft.

7/16 1/4-20 7-9 1/2 5/16-18 13-17 9/16 3/8-16 24-30 3/4 1/2-13 60-75 15/16 5/8-11 120-150 1-1/8 3/4-10 210-260 1-3/16 7/8-9 320-400 1-1/2 1-8 460-580

For these reasons, the pole bolts should be checked according to the recommendations below:

1. Before start up, make a visual inspection and spot check main and commutating pole bolt tightness with a torque wrench.

2. Mter 24 hours of service, all main and commutating pole bolt torques should be checked.

3. Mter three months of service, again check all main and commutating pole bolt torques.

4. Then, every six months or as often as experience dictates, check all main and commutating pole bolt torques.

NOTE: It may be difficult to use a torque wrench on some pole bolts due to machine location or mounted accessories. A good method of checking the torque on these bolts is to first get the feel of the desired torque with a torque wrench on an accessible bolt. Then, immediately check the difficult bolt using a normal wrench with approximately the same lever arm. Most mechanics will come within 10 percent of the desired value.

Inspection After Starting The following items should be checked after the machine is running:

N-m Lb.-Ft. N-m

10-12 5-6 7-8 18-23 9-11 12-15 33-40 16-20 22-27 80-100 36-45 49-61 160-200 72-90 98-120 280-350 100-125 140-170 430-540 155-195 210-260 620-790 210-260 290-350 wARNING: A~bid ~ci~~tr-~Wiili:~~oWlgTor' : .

... :'-:~ ._· ..; ~ ~-.: .. ' .-~-=; .• ~'T.!- • - ..;· .;

.£ · e!ectriqilly hot parts.jVhen. ~o!J?ngWi¢_rotatirig · ;: . electri~ maclunes, avoid.~t:arh'1g loose::ciothlrig

' :,~o~~'W~.··-~:.~-~~J-,:,_ - · · ~~~.

Bearings Place thermometers on all bearing housings so that bear ing temperatures can be watched for a few hours. Ball- or roller-bearing housing temperatures should be not more than 2s•c (45.F) above room temperature or a maxi mum of6S•c (149.F) on the bearing housing at the air inlet end. The maximum is so•c (176. F) on the bearing housing at the air discharge end. Higher ternperatures than this indicate trouble. Check alignment and lubrica tion. Do not overgrease.

Noise and Vibration Check for unusual vibration or noises that m ight indicate rubbing or interference. New machines may smell warm or have the odor of varnish, but should not smell scorched.

Vibration of new machines should not exceed .002 in.

(0.05 mm) at the bearing housings. The most likely cause of vibration in new machines is misalignment due to improper installation, loose foot bolts, uneven shimming under feet, or damage to the machine during shipment or installation. Current ripple due to rectified power supply may also be a source of vibration and audio noise.

Before Putting Machine In Service Run at light loads or at no load for a few hours to determine that no unusual bearing temperatures occur, that no localized electrical heating results, and (in the case of machines with unseated brushes) that the brushes get the proper fit. Be sure that any carbon dust resulting from brush seating is cleaned up before full-load opera tion. Check for satisfactory commutation when load is first applied.

Inspection After Short Time In Service Mter a machine has…