TABLE DES MATIERES INTRODUCTION SAFETY TRANSPORT, HANDLING AND STORAGE INSTALLATION AND OPERATION... 7

Size: px

Start display at page:

Download "TABLE DES MATIERES INTRODUCTION SAFETY TRANSPORT, HANDLING AND STORAGE INSTALLATION AND OPERATION... 7"

William Horton
5 years ago
Views:

1 MANUEL D INSTRUCTIONS 1

2 TABLE DES MATIERES INSTRUCTIONS MANUAL INTRODUCTION SAFETY TRANSPORT, HANDLING AND STORAGE INSTALLATION AND OPERATION Operating conditions Location and cooling Foundation Drains Balancing Alignment Wiring and electric connections Connection Terminal box Cables Cables termination Cable glands Supply Earthing Thermisors Electric auxiliary Control gear Connection diagrams Terminals and direction of rotation Operating speed Running

3 TABLE DES MATIERES INSTRUCTIONS MANUAL 4. EXPLOITATION Motor for application on speed variator Introduction Current bearings Wiring Operating speed Motor for operating in hazardous area EC declaration Generalities and obligations Marking Installation and operation MAINTENANCE Regular maintenance Periodic maintenance Lubrication Machines greased for life Machines equipped with lubrication device Warning Lubricants AFTER-SALES SERVICE Spare parts Rewinding Bearings WARRANTY TERMS ENVIRONMENTAL CONSTRAINTS MOTOR TROUBLESHOOTING CHART

4 Introduction This manual is intended to supply important topics that must be followed during transportation, installation, operation and maintenance of electric motor. Therefore, we recommend reading carefully this manual before installing and use by qualified personnel, familiar with health and safety requirements and national legislation. Ignoring these instructions may invalidate all applicable warranties. EC Declaration See appendix page 24. Validity The instructions are valid for the following SNE electrical machines. SNE reserves the right to modify the characteristics of these products at any time in order to incorporate modifications. The information contained in this document may therefore be changed without notice. 4

5 1. Safety The machine is intended for installation and use by qualified personnel, familiar with health and safety requirements and national legislation. Safety equipment necessary for the prevention of accidents at the installation and operating site must be provided in accordance with local regulations. Make sure that electric motors are switched off before starting any maintenance service. Points to observe: Don t step on the motor, Don t touch the motor before run off because the outer casing may be too hot, Be aware of rotating parts of the motor, Don t open the terminal boxes while energized. SAFETY 5

6 2. Transport, Handling and Storage 1.1 Check of receipt On receipt of your motor, check that it has not suffered any damage in transit. If there are obvious signs of knocks, contact the carrier (you may able to claim on their insurance) and after a visual check, turn the motor with your hand to detect any malfunction. Make sure the motor wasn t exposed dirt and moisture during transportation and storage. 1.2 Transport and storage During transport, shocks, falls and humidity should be avoided. Motors fitted with roll bearings must be fitted locking devices during transport. 1.3 Lifting All the motors SNE above 20 Kg are equipped with lifting lugs or eyebolts. Only the main lifting lugs or eyebolts of the motor should be used for lifting the motor. They must not be used to lift the motor when it s attached to other equipment. It s very important to check: Lifting lugs must not be used, must be tightened before lifting, ensure that proper lifting equipment is used and that the sizes of the hooks are suitable for the lifting lugs. 1.4 Storage Place the equipment in a clean dry area, protected from impacts, vibrations (<0.5mm/s), temperature extremes and in an environment with relative humidity less than 90% and temperature more than -20 C. TRANSPORT, HANDLING AND STORAGE For very long storage periods the motor can be placed in sealed plastic package containing sachets of desiccant. Don t remove the rotor blocking device for roller bearings. Unprotected machined surfaces (shaft-ends and flanges) should be treated against corrosion. It s recommended that shafts are rotated periodically by hand to prevent grease migration 6

7 3. Installation and Operation INSTRUCTIONS MANUAL 3.1 Operating conditions Standard electric motors are designed to operate at ambient temperatures ranging from - 20 C to 40 C and up to an altitude of 1000 meters above sea. 3.2 Location and cooling Motor is cooled by its surface, using ambient fluid air flowing along the machine with fan cover. Motor must be installed in an adequately ventilated area, with clearance for the air intake and outlet of ¼ of frame size. Warm air cannot be return to the motor. Obstruction of the fan cover has an adverse effect on motor operation. If the motor run in vertical position, with the shaft extension facing down, using a drip cover to prevent penetration by any foreign bodies. For externally installed, the motors should be always protected against weathering. 3.3 Foundation Foundations must be designed and dimensioned to avoid the transfer of vibration and resonance to the motor. Metals foundations should be painted to avoid corrosion. The purchaser is fully responsible for the foundation. 3.4 Drains Make sure drains are placed at the lower motor position when the mounting configuration differs from that specified. INSTALLATION AND OPERATION 3.5 Balancing All motors SNE are dynamically balanced at the factory with half key motor. Transmission such as pulleys and coupling must be dynamically balanced. Mounting and using suitable equipment and tools which do not damage the bearings and seals. If the motor started without device having fitted carefully immobilise the key. 7

8 3.6 Alignment Correct alignment is essential to avoid bearing, vibration and possible shaft failures. A correct alignment can be insured with use of dial gauges. If considering a complete shaft rotation misalignment should not exceed 0,05 mm. Re-check the alignment after final tightening of the bolts. When you used belt drives, Check that the slide rails is correct alignment. Check that the motor shaft is parallel with the drive shaft. Excessive belt tension will damage bearings and can cause shaft damage. Belts must be tensioned according to the instructions of the supplier of the driven equipment. However, don t exceed the maximum belt forces stated in the relevant product catalogues. 3.7 Wiring and electric connections Connection Cables must be connected off-line by qualified personnel Terminal box The terminal box on standard single speed motors normally contains six winding terminals and at least one earth terminal. 8

9 3.7.3 Cables The cables used must withstand the full load current of the motor (see motor nameplate) without overheating or voltage drop. The drop in voltage during starting phase must be less than 3% Cables termination All cable ends must be firmly fixed. Line drivers pods must be in contact with the engine drivers lugs and fastening nuts and washers must be firmly screwed on the connection. Wiring must be done or checked by a qualified electrician and equipment must be earthed in accordance with existing regulations. The engine must be protected by fuses and isolated. All caps must be in place before starting the engine Cable glands If not otherwise specified, cable entry threads are metric. IP class of the cable gland must be least the same as those of the terminal boxes. Unused cable entries must closed with blanking elements according to the IP class of the terminal box. Use appropriate cable glands and seals in the cable entries according to the type and diameter of the cable Supply It s important that a motor is operated within the limits of its design voltage and frequency. Tolerance for supply voltage is ± 5% and ± 2% for the frequency from norm IEC If these limits are exceeded, motor data and constructor data must be check Earthing All motors are fitted with an earthing terminal, in or adjacent to the terminal box, to enable connection to an effective earthing bond. The motor must be earthed by connecting the shortest possible length of cable to the earth screws Thermistors If fitted, it s recommended that thermistors be connected to the control circuit. Thermistors provide good thermal overload protection. 9

10 3.7.9 Electric auxiliary Accessories should be checked (Thermistor PT100, heater, etc ) before connection Control gear Ensure all control gear and associated protection overload trips and emergency shutdown circuits have been checked fully Connection diagrams 10

11 Terminals and direction of rotation Before coupling the motor to the drive, run the motor briefly to check rotation. To reverse rotation interchange any two supply leads Operating speed For speeds higher than the nominal speed stated on the motor s rating plate or in the respective product catalogue, ensure that either the highest permissible rotational speed of the motor of the critical speed of the whole application is not exceeded Running After one hour of running, check the general vibration level. If these are excessive, check alignment and belt tensioning. Some initial bearing noise may be present during the running in period. The noise should disappear after a few hours of operation. Check that the motor runs up smoothly and within the permitted run-up time. Note that repeated starting in quick succession may lead to a thermal overload of the motor. 11

12 4. Exploitation 4.1 Motor for application on speed variator Introduction This part of the manual provides instructions for motors used in frequency converter supply Current bearings Insulated bearings or bearings constructions, and suitable cabling and grounding methods must be used according to the following instructions. It s recommended to connect PTC thermistors to the frequency converter. Insulated bearings are recommended for power 100 Kw and frame size 315mm. The user is responsible for protecting the motor and driven equipment from bearings currents Wiring To provide proper grounding and to ensure compliance with any applicable requirements, motors shall be cabled by shielded symmetrical cables and glands cable providing 360 bonding at all termination points Operating speed For speeds higher than the nominal speed stated on the motor s rating plate, ensure that either the highest permissible rotational speed of the motor or critical speed of the whole application isn t exceeded. EXPLOITATION Application on speed variator 12

13 4.2 Motor for operating in hazardous area INSTRUCTIONS MANUAL EC declaration All SNE motors with CE mark on the rating plate comply with the Atex directive 94/9/CE. See appendix page Generalities and obligations An Atex explosive atmosphere is defined as a mixture of dangerous substances with air, under atmospheric conditions, in the form of gases, vapors, mist or dust in which, after ignition has occurred, combustion spreads to the entire unburned mixture. The European directive 1999/92/CE compels employers: To eliminate or control the risks from explosive atmospheres in the workplace To classify hazardous areas into zone To take technical and/or organizational measures appropriate to provide protection against explosions and to prevent the formation of explosive atmosphere To select all new equipment intended for use in explosive atmospheres, second the directive 94/9/CE and also to protective systems To put in place coordination when workers from several undertakings are present at the same workplace To write documents in accordance with the protection against the Atex. Classification table Atex probability Description Gas and vapors High level Explosive atmospheres are present continuously or for lengthy periods Medium and low level Explosive atmospheres are likely to occur Exceptional Explosive atmosphere unlikely to occur or occurs infrequently or occurs for only a short period of time Improbable Non-hazardous atmosphere Zone 0 Zone 1 Zone 2 Out of zone EXPLOITATION Operating in hazardous area Dusts Zone 20 Zone 21 Zone 22 Out of zone 13

Group I: Mining equipment Group II: Non-mining equipment Category 1 = Zone 0/20 Category 2 = Zone 1/21 Category 3 = Zone 2/22 INSTRUCTIONS MANUAL SNE Electric motors can be installed in Zone 22, non

14 Group I: Mining equipment Group II: Non-mining equipment Category 1 = Zone 0/20 Category 2 = Zone 1/21 Category 3 = Zone 2/22 INSTRUCTIONS MANUAL SNE Electric motors can be installed in Zone 22, non conductive dust category 3D, IP55. In normal working, we warranty a temperature of surface at 125 C with a maximum room temperature 40 C Marking SNE motor ATEX marking: ATEX II 3D T 125 c Installation and operation See paragraph 3 Particular comments: Drives and sensors junction pieces must be placed out of dangerous zones (out of zones 20, 21 and 22) Packing boxes must be certified Atex. An earth strap is also supplied and connected. 14

15 5. Maintenance The capacitor in single phase motors can retain a charge that appears across the motor terminals, even when the motor has reached standstill. A motor with frequency converter supply may energize even if the motor is at standstill. 5.1 Regular maintenance A regular regime of inspection is recommended to ensure minor problems don t escalate to breakdowns. This can initially be determined experimentally and must then be strictly adhered to. Checklist: No loose fasteners No excessive vibration No significant corrosion of the lifting lugs No accumulation of dust or fibres on the frame or around the fan inlet No visible damage or crack Cables and earths are sound Sealing of the motor and gland plate in good condition MAINTENANCE Insulation resistance adequate, imperative this is checked after a prolonged shut-down Regrease required, particularly high speed motors Bearing condition 5.2 Periodic maintenance Remove the cover and the fan located to the shaft extension. Loosen and remove the end shields should then be eased of their spigots. The rotor can be carefully withdrawn from the stator, taking care not damage the stator bore and both stator windings. Having dismantled the motor, maintenance can be carried out to remove all dirt. For this purpose, the use of an air line supplying dry compressed air under comparatively low pressure is best, as a high velocity air stream can force dirt into the spaces between the windings and insulation. Grease-removing solvents should only be used very sparingly to avoid damage to impregnating varnish or insulation. Motors should be re-assembled in the reverse order from dismantling remembering to ease end shields to bearings and spigots. Don t use force. 15

Before starting, check that the rotor revolves freely. Ensure that the electrical connections are correct and terminal nuts tight (see section electrical connection) 5.

16 Before starting, check that the rotor revolves freely. Ensure that the electrical connections are correct and terminal nuts tight (see section electrical connection) 5.3 Lubrication Beware of all rotating parts! Grease can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturer. 5.4 Machines greased for life Machines up to frame size 160 are normally fitted with permanently greases bearings. Bearings types are specified in the respective product catalogue Machines fitted with Z bearing can be regreased by dismantling the motor, cleaning the bearings and bearings housing, and filling these with new grease to 50-70%. Guidelines for regreasing intervals are duty hours for 4 pole machines duty hours for 2 and 2/4 pole machines. The shorter times are valid for larger frame sizes. 5.5 Machines equipped with lubrication device Lubricate motor while running. If grease outlet plug is fitted, remove temporarily when lubricating, or permanently with automatic lubrication. If the motor is fitted with a lubrication information plate, follow the values given, otherwise use values as follows Ball bearings Lubrication intervals in duty hours The table is prepared for horizontally mounted machines. Lubrification intervals for vertical machines are half of the above values. The grease amount in the table is used if small quantities of fresh grease are replaced at regular intervals as above. As an alternative when machine is fitted with grease expected valves, fresh grease may be pressed into the bearings until the old grease is totally replaced. The table values are based on 80 C bearing temperature. If the maximum bearing temperature is 70 C, the table values may be doubled. 16

17 Frame size Amount of grease 3600 r/min 3000 r/min 1800 r/min 1500 r/min 1000 r/min r/min 112/ / / / /400/ / / /400/ Warning The maximum operating temperature of the grease and bearing mustn t be exceeding. Higher speed operation, e.g. frequency converter application, or slower speed with heavy loading will require shortened lubrication intervals. Consult SNE in such cases. Typically a double of speed will require a reduction of lubrication intervals to approximately 40% of values tabulated above. 5.7 Lubricants When regreasing, use only special ball bearings grease with the following properties: Good quality lithium complex grease Base oil viscosity at 40 C Consistency NLG1 grade 2 or 3 Temperature range -30 C / +120 C continuously. Grease with the correct properties is available from all the major lubricant manufactures. If the makeup of grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to displace the old grease. Highly loaded and/or slowly rotating bearings require EP-grease. If lubrication intervals are short due to bearing temperature of 80 C or above, use high temperature grease which normally permit approximately 15K higher temperature. If the ambient temperature is below 25 C, consult manufacturer regarding the possibility to use of low temperature grease. Si la température ambiante est inférieure à -25 C, consulter SNE ou utiliser une graisse basse température. 17

18 Note: For high speed machines (e.g. larger 2 pole machines), check that the FN factor of the grease is sufficiently high. FN=Dm * n Dm= average bearing diameter (mm) n= rotational speed (tr/min) Warning: Much grease can cause skin irritated and eye inflamed. Follow all safety precautions specified by the manufacturer. 18

19 6. After-sales Service 6.1 Spare parts When consult spare parts, specified full type designation on rating plate. For more information, please contact directly SNE. 6.2 Rewinding Rewinding should always be carried out by qualified repair factory. 6.3 Bearings These must be removed using pullers and fitted by heating or using specifically tools. 7. Warranty Terms SNE warrants its products against defects in workmanship and materials for 12 months from delivery when the items are fulfilled accordingly: Transport, handling and correct storage. Installation based on the specified ambient environmental conditions. Operation under motor capacity limits AFTER-SALES SERVICE WARRANTY TERMS Observation and periodical maintenance Repair effected only by personal authorized in writing by SNE. The repair, replacement of parts or components, when affected by SNE will not give warranty extension. The warranty service will be only carried out at SNE authorized repair factory. No extended warranty when replacing any component. 19

20 8. Environmental Constraints INSTRUCTIONS MANUAL Noise level Smaller machines have sound pressure level which doesn t exceed 70 db(a). The following table indicates those frame sizes whose sound pressure level 1m from the machine surface can exceed 70 db(a). Values for specific machines can be found in the relevant product catalogue. The values in the table based on 50 Hz sinusoidal supply. For 60 Hz sinusoidal supply, add 4 db(a) to the above values. Guideline sound pressure level db(a) Size 2 poles 4 poles 6 poles 8 poles ENVIRONMENTAL CONSTRAINTS MOTOR TROUBLESHOOTING CHART 20

21 9. Motor troubleshooting Chart INSTRUCTIONS MANUAL Your motor service and any troubleshooting must be handled by qualified persons who have proper tools and equipment. TROUBLE CAUSE WHAT TO DO Blown fuses Replace fuses with proper type and rating. Overload tripping Check and reset overload in starter. Improper power supply Improper line connections Check to see that power supplied agrees with motor rating plate and load factor. Check connections against diagram supplied with motor. Motor fails to start Motor stalls Motor runs and then dies down Motor does not come up to nominal speed Motor takes too long to accelerate and/or draws high current Open circuit in winding or control switch Mechanical failure Short circuited stator Poor stator coil connection Rotor defective Motor may be overloaded One phase may be open Wrong application Overload Low voltage Open circuit Power failure Not applied properly Voltage too low at motor terminals because of line drop Starting load too high Broken rotor bars or loose rotor Open primary circuit Excessive load Low voltage during start Defective squirrel cage rotor Applied voltage too low Indicated by humming sound when switch is closed. Check for loose wiring connections. Also ensure that all control contacts are closing. Check to see if motor and drive turn freely. Check bearings and lubrication. Indicated by blown fuses. Motor must be rewound. Remove end shields, locate fault. Look for broken bars or end rings. Reduce load. Check lines for open phase. Change type or size, consult equipment supplier. Reduce load. Ensure the rating plate voltage is maintained. Check connection. Fuses blown, check overload replay, stator and push buttons. Check for loose connections to line, to fuses and to control. Consult equipment supplier for proper type. Use higher voltage or transformer terminals or reduce load. Check connections. Check conductors for proper size. Check the start load of the motor. Look for cracks near the rings. A new rotor may be required, as repairs are usually temporary. Locate fault with testing device and repair. Reduce load. Check for high resistance. Make sure that adequate cable size is used. Replace with new rotor. Correct power supply. 21

22 Wrong rotation direction Motor overheats while running Motor vibrates Scraping noise Noisy operation Hot bearings Wrong sequence of phases Overload Frame or ventilation openings may be full of dirt and prevent proper ventilation of motor Motor may have one phase open Grounded coil Unbalanced terminal voltage Motor misaligned Weak support Coupling out of balance Driven equipment unbalanced Defective bearings Bearings not in line Balancing weights shifted Contradiction between balancing of rotor and coupling (half key - full key) Polyphase motor running single phase Excessive end play Fan rubbing end shield or fan cover Loose on bedplate Air gap not uniform Rotor unbalance Bent or sprung shaft Excessive belt pull Pulleys too far away from shaft shoulder Pulley diameter too small Misalignment Insufficient grease Deterioration of grease or lubricant contaminated Excess lubricant Overloaded bearing Broken ball or rough races Reverse connections at motor or at switchboard. Check the current consumption in relation to that indicated on the motor name plate. Reduce load. Open vent holes and check for a continuous stream of air from the motor. Check to make sure that all leads are well connected. Motor must be rewound. Check for faulty leads, connections and transformers. Realign. Strengthen base. Balance coupling. Rebalance driven equipment. Replace bearings. Repair motor. Rebalance motor. Rebalance coupling or motor. Check for open circuit. Adjust bearing or add shim. Correct fan mounting. Tighten holding bolts. Check and correct end shield fits or bearing fits. Rebalance rotor. Straighten or replace shaft. Decrease belt tension. Move pulley closer to motor bearing. Use larger pulleys. Correct by realignment of the drive. Maintain proper quality and amount of grease in bearing. Remove old grease, wash bearings thoroughly in kerosene and replace with new grease. Reduce quantity of grease, bearing should not be more than half full. Check alignment, side and end thrust. Replace bearing, clean housing thoroughly first. 22

23 Notes : 23

24 A. Déclaration de conformité INSTRUCTIONS MANUAL ANNEXES 24

25 25

MOUNTING & MAINTENANCE INSTRUCTIONS FOR

9 Pages / Page 1 MOUNTING & MAINTENANCE INSTRUCTIONS FOR THREEPHASE INDUCTION MOTORS - TYPES DM1 / DMA1 / DMA2 TABLE OF CONTENTS page 1 General information 2 2 Delivery 2 3 Mounting 2 4 Coupling 2 4.1.