Installation, Operation And Maintenance of. AC and DC Mine Motors

Transcription

1 Installation, Operation And Maintenance of AC and DC Mine Motors Instruction Manual B June, 2003

2

3 Table of Contents General Safety/Acceptance Instructions..2 Installation Instructions. 3 Operating Instructions Maintenance Instructions Lubrication..5 Appendix 1 (Reliance Document ) Reproduction of this publication by any means either mechanical or electrical, including photo copying is prohibited without the express written consent of the publisher. 1

4 AC and DC MINE MOTORS INSTALLATION MAINTENANCE INSTRUCTIONS GENERAL SAFETY/ACCEPTANCE INSTRUCTIONS These motors are designed to comply with all European Directives in effect at the time of manufacture, including ATEX Directive 94/9/EC, Low Voltage Directive 73/23/EEC, and EMC Directive 89/336/EEC and designed considering the Machinery Directive 98/37/ EC. It is assumed that the installation of these motors by the OE Machinery manufacturer has been carried out in accordance with this Directive and the standard EN : Safety of Machinery - Electrical Equipment of Machines. Any repairs by the end user, unless expressly approved by Reliance Electric, release Reliance Electric from responsibility to conformity. Authorized and qualified personnel only must perform repairs. These motors are designed in accordance with appropriate governmental regulatory agencies. They meet the technical requirements of the appropriate agencies at completion of manufacturing and have been issued approval numbers and nameplates. Any changes to these motors, without the consent of Reliance Electric and the regulatory agencies, may void these approvals and render these motors non-conforming and dangerous for use. These motors are suitable for the ATEX Group and Category marked on the equipment nameplate. These motors are designed for normal mining applications and are in compliance with the above safety directives when operated within the parameters identified on the motor nameplate. Typical motor marking for AC and DC Mine Motors is as follows: Specific motor type, frame designation, model number, date code, electrical specifications, and serial number are marked on a separate nameplate. Special Conditions are indicated on the motor nameplate as a suffix X on the certificate number. Details of this condition can be found on the motor approval certificate. ACCEPTANCE INPECTION All motors should be inspected for damage prior to connecting the motor to an electrical supply. All covers should be in place and access cover bolts torqued to their proper levels. On motors received with the shaft blocked by the factory, remove blocking before operating the motor. If motor is to be reshipped, alone or installed to another piece of equipment, the shaft must again be blocked against axial movement to prevent brinelling of the bearings during shipment. 2

5 INSTALLATION Strict compliance with all local and national laws, regulations, and practices regarding the safe operation and maintenance of underground mining equipment is necessary to assure the personal safety of those working on, or around this equipment. Rotating parts, such as couplings, pulleys, internal-external fans and unused shaft extensions should be permanently guarded against accidental contact with hands or clothing. For installations requiring the use of belts and pulleys, the potential for electrostatic discharge must be eliminated prior to operation in areas subject to the risk of explosion. Eyebolts, lifting lugs or lifting openings, if provided, are intended only for lifting the motor and standard motormounted accessories not exceeding, in total, 30% of the motor weight. These lifting provisions should never be used when lifting or handling the motor and other equipment (i.e., gears, pumps or other driven equipment) as single unit. Eyebolt lifting capacity rating is based on a lifting alignment coincident with eyebolt centerline. Eyebolt capacity reduces as deviation from this alignment is increased. Be sure eyebolts are seated tight and prevented from turning before lifting. For motors without lifting provision, only qualified persons should lift and install motors into the OE machinery equipment. Where the motor is an integral part of the mining machine, it should be mounted as prescribed by the OE machinery manufacturer. Where motors are separately mounted, a foundation sufficiently rigid to prevent excessive vibration should be utilized. After careful alignment, bolt motor securely in place. Use shims to fill any unevenness in the foundation. All motor feet should sit solidly on foundation before mounting bolts are tightened. The OE machinery manufacturer or user must select a motor starter and overcurrent protection suitable for this motor and its application. Consult motor starter application data as well as applicable national and local codes. Frames and accessories of motors must be earth bonded in accordance with recommended national and local codes. Motors must be properly grounded to earth by the OE mining equipment manufacturer and by qualified electricians during the field installation of replacement motors. Connect the motor to the power supply of identical characteristics, according to the connection diagram on the motor nameplate. Use Reliance Electric Connection Diagram (Appendix 1) to cross-reference NEMA to IEC nomenclature. This equipment must be connected to suitably certified glands. OPERATION OF MOTORS AC and DC Mine Motors are designed to operate in a normal mining environment. Loading and operation of motors should be in accordance with the nameplate data. The motor has been designed based on rating information, application data, and duty cycle analysis provided by the OE machinery manufacturer. Proper motor cooling is required for normal operation of the motor. Operation in excess of nameplate parameters is not recommended and may result in damage to the equipment and potential injury to operators and persons near the equipment. SAFETY RELATED SWITCHING UTILIZED BY THE OE MACHINERY MANUFACTURER MUST IN GENERAL DIRECTLY ACTUATE THE RELEVANT CONTROL DEVICES WITHOUT INTERMEDIATE SOFTWARE COMMAND. 3

6 ! ATTENTION! THESE MOTORS ARE DESIGNED TO OPERATE AT OR BELOW THE MAXIMUM SURFACE TEMERATURE STATED IN THE ATEX DIRECTIVE IN A NORMAL MINING APPLICATION. OPERATION OF THESE MOTORS IN EXCESS OF THE NAMEPLATE PARAMETERS MAY CAUSE THE MAXIMUM ALLOWABLE SURFACE TEMPERATURE TO BE EXCEEDED. THE FOLLOWING CONDITIONS ARE EXAMPLES OF IMPROPER MOTOR OPERATION: 1. LOAD IMPOSED ON THE MOTOR EXCEEDS ITS NAMEPLATE VALUE OR MOTOR POWER RATING. 2. AMBIENT TEMPERATURES THAT EXCEED THE NAMEPLATE TEMPERATURE VALUE. 3. VOLTAGES IN EXCESS OF +/- 10% OF THE VOLTAGE (S) SPECIFIED ON THE MOTOR NAMEPLATE. 4. VOLTAGE UNBALANCED CONDITIONS. 5. LOSS OF PROPER VENTILATION AND/OR INSUFFICIENT OR LOSS OF COOLANT FLOW. 6. VARIABLE FREQUENCY OPERATION FOR MOTORS DESIGNED FOR SINE WAVE POWER ONLY. 7. ALTITUDE ABOVE 3000 FEET/1000METERS. 8. SEVERE DUTY CYCLES AND/OR REPEATED STARTS. 9. MOTOR STALL. 10. MOTOR REVERSING 11. POLYPHASE MOTORS BEING OPERATED IN SINGLE PHASE CONDITION Temperature detection devices may be provided in these motors. The OE machinery manufacturer determines the control setup to insure operation within the thermal limit characteristics of the motor. EXTENDED STORAGE If any of these motors has been in storage for an extensive period or has been subjected to adverse moisture conditions, check the insulation resistance of the stator winding with a megohmeter. If the resistance is lower than one megohm, the windings should be dried in one of the two following ways: 1) Bake in oven at temperatures not exceeding 90 degrees C until insulation resistance becomes constant. 2) With rotor locked, apply low voltage and gradually increase current through windings until temperature measured with thermometer reaches 90 degree C. Do not exceed this temperature. Depending on the length and conditions of storage, it may be necessary to lubricate or change the motor bearings. MAINTENANCE AC/DC MOTORS Prior to any maintenance of a motor, it should be isolated before any work is performed. The motor should be inspected periodically for the build up of dust or other foreign material. Any build-up of dust or foreign material should be removed prior to energizing the motor. Motor bearings should be changed at least annually, or in the presence of adverse conditions, sooner. If unusual bearing noise or vibration is experienced, then the bearings should be replaced. Only qualified persons should repair or replace bearings. If motor is totally enclosed, fan cooled, or non-ventilated, the condensation drain plugs, if equipped, should be periodically removed and condensation allowed to drain, and drain plugs should be reinstalled promptly, unless the motor has special stainless steel drains. All drains if applicable are located in the lowest portion of the end shields. 4

7 MAINTENANCE DC MOTORS ONLY Brush pressure is correctly established at the factory and maintained at the correct value throughout the life of the brush by means of a constant pressure design. Brushes and brushholders should be clean so that the brushes are free to move in the holders. Replace brushes with new brushes of the same grade before wear permits the rivet or tamped pigtail to score the commutator. It is recommended to replace all brushes at one time. LUBRICATION The following is the recommended re-lubrication procedure unless stated differently by the OE machinery manufacturer s maintenance procedures. Motors are properly lubricated when installed. If the motor has been in storage for a period of six months or more, lubricate before starting. Lubrication of motor anti-friction bearings should be done as a part of a planned maintenance schedule. The recommended Lubrication Frequency (Table 2) should be used as a guide to establish this schedule. Where provisions are provided for relubrication of motor anti-friction bearings, use only grease recommended by the OE machinery manufacturer. Any grease used to lubricate anti-friction bearings should be fresh and free from contamination. Care should be taken to properly clean the grease inlet area of the motor to prevent grease contamination. LUBRICATION FREQUENCY (BALL BEARINGS) Kilowatts 1 through 10, 1800 RPM & slower 6 months 11 through 100, 1800 RPM & slower 3 months Greater than 100, 1800 RPM & slower 1 months All over 1800 RPM 1 months ROLLER BEARINGS For Roller Bearings divide the time periods above by 2. LUBRICATION PROCEDURE Select Lubrication Frequency from Table 2. Bearings should be lubricated while stationary and the motor is warm. 1. Locate the grease inlet, clean the area and replace the pipe plug with a grease fitting. 2. Locate and remove the grease drain plug, if provided. 3. Add lubricant until clean grease appears at the grease drain, at the grease relief, or along the shaft opening. 4. Replace the grease inlet plug and run the motor for 15 minutes. 5. Replace the grease drain plug. SPARE PARTS REQUIREMENTS For motor spare parts needs, contact the OE machinery manufacturer. 5

8 APPENDIX 1 6

9 7

10 8

11 9

12 10

13 11

14 12

15 13

16 Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, USA, Tel: (1) , Fax: (1) Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC USA, Tel: (1) , Fax: (1) Europe/Middle East/Africa: Rockwell Automation, Brühlstraße 22, D Elztal-Dallau, Germany, Tel: (49) , Fax: (49) Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore , Tel: (65) , Fax: (65) Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI USA, Tel: (1) , Fax: (1) Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) , Fax: (32) Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) , Fax: (852) /03 1C-K B Copyright 2003 Rockwell Automation. All rights reserved. Printed in USA. RELIANCE ELECTRIC is a trademark of Rockwell Automation.