Installation, Operation

and Maintenance of

Large AC Motors
6800 Frame
Horizontal Footless
Mounting. Water Cooled
Explosion Proof Mining Motor.

Instruction Manual B B-3741-1

January 2007

Table of Contents
SECTION 1: GENERAL DESCRIPTION ................................................................................................. 1
INTRODUCTION ................................................................................................................................ 1
RECEIVING AND ACCEPTING ......................................................................................................... 1
STORAGE .......................................................................................................................................... 2
SECTION 2: INSTALLATION .................................................................................................................. 3
INSTALLATION .................................................................................................................................. 3
HANDLING ......................................................................................................................................... 3
INSPECTION ...................................................................................................................................... 3
LOCATION ......................................................................................................................................... 4
MOUNTING ........................................................................................................................................ 4
PRE-INSTALLATION CHECKS ......................................................................................................... 4
COUPLING ......................................................................................................................................... 5
COUPLING ALIGNMENT ................................................................................................................... 5
COUPLING ALIGNMENT PROCEDURE .......................................................................................... 5
LUBRICATION ................................................................................................................................... 6
ANTI-FRICITON BEARINGS (Grease Lubricated) ............................................................................ 6
ELECTRICAL CONNECTION ............................................................................................................ 6
GROUNDING .................................................................................................................................... 6
SECTION 3: OPERATION ....................................................................................................................... 7
PRE-OPERATION CHECK ................................................................................................................ 7
VARIABLE FREQUENCY DRIVE APPLICATIONS ... 7
INITIAL START ................................................................................................................................... 7
TEMPERATURE LIMITS .7
VIBRATION LIMITS ........................................................................................................................... 8
STARTING DUTY ............................................................................................................................. 8
SECTION 4: ROUTINE MAINTENANCE ................................................................................................ 9
SCHEDULED MAINTENANCE .......................................................................................................... 9
PERIODIC INSPECTION ................................................................................................................... 9
BEARING LUBRICATION ................................................................................................................ 10
ANTI-FRICTION BEARING REMOVAL/REPLACEMENT................................................................ 14
ROTOR AND STATOR REMOVAL ................................................................................................. 14
WINDING MAINTENANCE .............................................................................................................. 14
RENEWAL PARTS ........................................................................................................................... 16

SECTION 1: GENERAL DESCRIPTION

tors, stators, enclosures and insulation systems, to the smallest component...carefully selected and mated for optimum performance.
The result is a product that is indeed, more than
a motor... more like a system.

INTRODUCTION
DANGER
HIGH VOLTAGE AND ROTATING PARTS CAN
CAUSE SERIOUS OR FATAL INJURY. THE USE
OF ELECTRIC MACHINERY, LIKE ALL OTHER
UTILIZATION OF CONCENTRATED POWER AND
ROTATING EQUIPMENT, CAN BE HAZARDOUS.
INSTALLATION, OPERATION, AND
MAINTENANCE OF ELECTRIC MACHINERY
SHOULD BE PERFORMED BY QUALIFIED
PERSONNEL. FAMILIARIZATION WITH NEMA
MG2 SAFETY STANDARD FOR CONSTRUCTION
AND GUIDE FOR SELECTION, INSTALLATION
AND USE OF INTEGRAL HP MOTORS,
NATIONAL ELECTRICAL CODE AND SOUND
LOCAL PRACTICES IS RECOMMENDED.

Reliance 6800 Frame Motors are designed for

easy disassembly, re-assembly, and inspection.
These common accessories are available:

Bearing temperature detectors

Winding temperature detectors
Vibration monitors
Special conduit boxes

This manual contains the information that you

need to get the most out of your Reliance 680
Frame Motor. Please read it carefully and
thoroughly before unpacking and installing
motor.

IMPORTANT
The motor shaft must be blocked to prevent axial
movement whenever the motor is moved

RECEIVING AND ACCEPTING

Warning

THE
PRODUCTS
DESCRIBED
IN
THIS
INSTRUCTION MANUAL ARE MANUFACTURED
BY RELIANCE ELECTRIC COMPANY.

EYEBOLTS OR LIFTING LUGS ARE INTENDED

FOR LIFTING THE MOTOR ONLY WITH THE
STANDARD
ACCESSORIES
SUCH
AS
TACHOMETER, ETC., MOUNTED BY RELIANCE
ELECTRIC. THE LIFTING MEANS ON THE
MOTOR MUST NOT BE USED TO LIFT THE
MOTOR PLUS ADDITIONAL EQUIPMENT SUCH
AS GEARS, PUMPS, COMPRESSORS, OR
OTHER DRIVEN EQUIPMENT. THE LIFTNG
MEANS ON THE MOTOR CANNOT BE USED TO
LIFT ASSEMBLIES OF MOTOR AND OTHER
EQUIPMENT MOUNTED ON A COMMON BASE.

These instructions do not cover all details or

variations in equipment nor provide every
possible contingency or hazard to be met in
connection with installation, operation and
maintenance. Should further information be
desired or should particular problems arise
which are not covered within this manual, the
matter should be referred to Reliance Electric
Industrial Company.
Reliance 6800 Frame Motors are designed
and built to provide you with a drive power
system composed of matched components.
Such a system is capable of delivering the
horsepower, torque, speed and power efficiency characteristics that are needed for
reliable production machinery.

In all cases, care should be taken to assure

lifting in the direction intended in the design of
the lifting means. Lift using all lugs provided.
Likewise, precautions should be taken to
prevent
hazardous
overloads
due
to
deceleration, acceleration or shock forces.
Angle of lift with rope or chain should never be
less than 45 degrees from the horizontal.

This systems approach was used not only in

the design of the motor, but also in the state-ofthe-art manufacturing used to produce and test
these rugged and dependable machines. It extends from the major assemblies such as ro-

Upon receipt, thoroughly inspect the wrapping

and crate for any sign of damage. If any damage is evident, do not accept the motor until
the freight or express agent makes an ap1

propriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight or
express agent at once and request him to make
an inspection.

Motors subject to extended storage must be

handled and treated per the requirements of
Reliance Service Bulletin B-8018-2 available
from your Reliance District Sales Office.

STORAGE
Do not unpack until ready for use. If the motor
is to be stored for a period of any time prior to
installation, it should be placed in an area
which is clean, dry and warm.

Caution
Sleeve bearing motors are shipped without oil. Fill
bearing reservoirs to the proper level before rotating
the shaft. Failure to observe this precaution could
result in damage to or destruction of the equipment.

The motor should be inspected periodically and

the insulation resistance checked and recorded
monthly. If there is a significant change in
insulation resistance, it should be investigated
and corrective action should be taken. Consult
your local Reliance Sales Office for additional
data.
Reliance 6800 anti-friction bearing motors are
shipped with the proper amount of grease in
each bearing.
At 30 day intervals of storage, remove only
enough packing to expose the shaft and remove the shaft shipping brace, rotate the shaft
(by hand) 10 to 15 revolutions. This distributes
the grease, preventing bearing corrosion due to
condensation, or to the presence of
contaminating gases near the motor. After
rotating the shaft replace protective packing
and shaft shipping brace.
If the motor is stored and directly exposed to
weather conditions, it is important that the bearing grease be inspected for the presence of water at the grease drain. If the grease is contaminated with water, the motor must be disassembled, grease removed from the bearing(s)
and housing(s) and bearing(s) inspected for
corrosion. If corrosion is present, the bearing(s)
must be replaced. If there is no corrosion, repack the bearing(s) / housing(s) with grease as
instructed in Section 4 under Bearing Lubrication.
2

SECTION 2: INSTALLATION
DIRECTION INTENDED IN THE DESIGN OF THE
LIFTING MEANS.
LIKEWISE, PRECAUTIONS
SHOULD BE TAKEN TO PREVENT HAZARDOUS
OVER LOADS DUE TO DECELERATION,
ACCELERATION OR SHOCK FORCES.

INSTALLATION
Warning
INSTALLATION SHOULD BE IN ACCORDANCE
WITH THE NATIONAL ELECTRIC CODE AND
CONSISTENT WITH ALL LOCAL CODES.

Should additional handling or shipment of

motors be required, be certain to block the shaft
as it was blocked at the Reliance Factory.
Blocking the shaft limits the rotor movement
both axially and radially
which prevents
damage to the bearings.

COUPLING, BELT, AND CHAIN GUARDS

SHOULD BE INSTALLED AS NEEDED TO
PROTECT AGAINST ACCIDENTAL CONTACT
WITH MOVING PARTS. MACHINES
ACCESSIBLE TO THE PUBLIC SHOULD BE
FURTHER GUARDED BY SCREENING, GUARD
RAILS, ETC., TO PREVENT PERSONNEL FROM
COMING IN CONTACT WITH THE EQUIPMENT.

INSPECTION
Before installing the motor, make the following
checks:

The assurance of successful startup depends

upon the use of good handling, inspection, and
installation practices. The motor should be
mounted with adequate stiffness and mass to
maintain system resonant frequencies removed
from excitation frequencies by 15%. The need
for closer alignment and heavier bases becomes more critical with higher speed operation
and large motors.

1. Inspect for any damage resulting from

shipment. Refer to paragraphs on receiving
and storage. (Refer to Section 1 under
Receiving and Accepting and Storage).

2. If the motor has been in storage for an

extended period or had been subjected to
adverse moisture conditions, check the
insulation resistance of the stator winding.
(Refer to Section 4 under Checking
Insulation Resistance).

HANDLING
Carefully remove the motor from packaging.
Lifting provisions are provided as eyebolts on
top of the motor. Place a lifting hook in each of
the lifting means provided and carefully lift the
motor from its packing. Use a hoist with
adequate capacity.

3.

Warning
LIFTING MEANS ARE PROVIDED FOR HANDLING
THE MOTOR, AND SHOULD NOT BE USED TO
LIFT
THE
MOTOR
PLUS
ADDITIONAL
EQUIPMENT SUCH AS GEARS, PUMPS,
COMPRESSORS,
OR
OTHER
DRIVEN
EQUIPMENT. IN THE CASE OF ASSEMBLIES ON
A COMMON BASE, ANY LIFTING MEANS
PROVIDED ON THE MOTOR OR GENERATOR
SHOULD NOT BE USED TO LIFT THE ASSEMBLY
AND BASE BUT, RATHER, THE ASSEMBLY
SHOULD BE LIFTED BY A SLING AROUND THE
BASE OR BY OTHER LIFTING MEANS PROVIDED
ON THE BASE. IN ALL CASES CARE SHOULD
BE TAKEN TO ASSURE LIFTING IN THE

Examine the motor nameplate data to

make sure it agrees with the power circuit to
which it will be connected. The motor is
guaranteed to operate successfully at line
frequency not more than 5%, and line
voltage not more than 10%, above or below
the nameplate ratings, or a combined
variation of voltage and frequency of not
more than 10% above or below nameplate
ratings. Efficiency, power factor and current
may vary from nameplate data.

4. Check to make sure that direction of motor

rotation is correct for the intended
application and motor requirement.
5. Remove shaft blocking before energizing
motor.
3

LOCATION

COUPLING

The motor must be located in an environment

that satisfies local codes and National Board of
Fire and Underwriters regulations.
The
following additional considerations should also
govern its location.

1. In preparation for making the coupling

alignment, wash off the rust-protective
coating on the motor shaft with solvent. Any
factory-installed couplings should also be
cleaned with solvent prior to installation on
the shaft.

Exposure to high ambient temperatures,

humidity and atmospheric contamination should
be avoided. Acids, alkalis and gases also have
detrimental effects on electrical machinery. The
location of installation should be accessible for
routine maintenance and inspection.

2. Cylindrical bore couplings should be heated

for proper mounting. Do not press or drive
this type of coupling onto the shaft. Tapered
bored couplings should be installed per the
coupling manufacturers recommendations.

Permanent handling equipment to facilitate

major service and repair without complete
disassembly of the individual units should be
considered.

COUPLING ALIGNMENT
There are a number of different procedures in
alignment of the motor to the driven equipment.
The end result depends upon the accuracy of
the parts in roundness, flatness, runout of the
reference surfaces, rigidity of the mounting
platform, and the skill of the set-up-person. The
motor mounting surface must be flat and
perpendicular to the shaft axis.

MOUNTING
The dimensions for mounting are shown on the
outline drawing supplied with the motor
software and should be referred to.

PRE-INSTALLATION CHECKS
COUPLING ALIGNMENT PROCEDURE
Before operating, the motor should be checked
for any changes resulting from improper
handling during shipment, storage, installation
or by an unsatisfactory foundation. Failure to
check or do the necessary work as mentioned
above could cause misalignment resulting in
vibration. Before shipment, every Reliance
motor is given a running test to check
operation. Although complete factory tests have
been made, motors should be verified to
prevent premature bearing failure.

Refer to accepted procedures for coupling

alignment such as double-dial indicator or
laser alignment. Coupling alignment shall
be within the following limits:
MAXIMUM
PERMISSIBLE
ANGULAR
MISALIGNMENT = .001 inch per inch of
coupling hub diameter.
MAXIMUM PERMISSIBLE PARALLEL
MISALIGNMENT = .002 inch TIR (Total Indicated Runout).

Before the motor is checked for alignment,

remove all shipping blocks and supports
installed at the factory. The shaft should turn
over freely with minor resistance due to the
contact lip seals used within this design. The
degree of accuracy required in the alignment
depends on the rated speed of the machine.
The greater the speed, the greater the care and
accuracy necessary for proper alignment.

The motor mounting bolts should be SAE

Grade #8, 1.00 inch ( ISO Class 8.8, M24)
torqued to 125 +25/-00 lb-ft (170 +34/-00
Nm).
Caution
Do not use the coupling to compensate for poor
alignment. This can result in vibration, noise, cou4

pling wear, overloaded bearings and early failure.

Failure to properly ground the motor could cause

severe bodily injury or loss of life.

All large motors should be grounded with the

grounding conductor equipped with a brazed
copper terminal, or with a suitable solderless
terminal fastened to the motor.
Soldered
terminals should not be used. A washer should
be used between bolt head and terminal lug.
The other end should be fastened with suitable
clamps or terminals to rigid metallic conduit or
to the nearest available ground. Grounding
conductor size should be in accordance with
the following National Electrical Code.

LUBRICATION
NOTE:
The lubrication system should be
checked in preparation for rotating the shaft
during the alignment operation

ANTI-FRICITON BEARINGS GREASE

LUBRICATED
Bearing chambers are packed with grease
during assembly, and do not normally need
additional grease at the time of installation
unless the unit has been in storage for 6
months or longer. If the motor has been kept in
extended storage, lubricant must be added per
Section 4, Table II.

ELECTRICAL CONNECTION
DANGER
THE
USER
IS
RESPONSIBLE
FOR
CONFORMING WITH THE NATIONAL ELECTRIC
CODE AND ALL OTHER APPLICABLE LOCAL
CODES.
WIRING PRACTICES, GROUNDING
DISCONNECTS
AND
OVERCURRENT
PROTECTION
ARE
OF
PARTICULAR
IMPORTANCE. FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.

The motor is provided with a quick disconnect

socket or other suitable means for connection
to the power source. Typically the customer
provides the mating plug or approved packing
gland parts. The customer side power and
ground cable should be sized in accordance
with the given countries applicable electrical
and mine authorities electric code.

A main terminal box may be provided for power

lines to the stator. Other terminal boxes for all
other electrical connections may be provided.

GROUNDING
Warning
5

SECTION 3: OPERATION
8. Replace all panels and covers.

PRE-OPERATION CHECK
9. Check direction of rotation by momentarily
applying power to the motor.

Caution
THIS EQUIPMENT IS AT LINE VOLTAGE WHEN
A-C POWER IS CONNECTED. DISCONNECT
AND
LOCKOUT
ALL
UNGROUNDED
CONDUCTORS OF THE AC POWER LINE
BEFORE PROCEEDING. FAILURE TO OBSERVE
THESE PRECAUTIONS COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.

INITIAL START

Before starting the motor for the first time the

following checks must be made:
1. Hold-down bolts must be tightened to 125
+25/-00 lb-ft (170 +34/-00 Nm).

1. When alignment is correct and motor is

properly lubricated, prepare for no load
uncoupled startup. The coupling should be
uncoupled and a solo plate should be
installed if required.

2. If the motor has been idle for a long period

of time after installation, check the
insulation resistance. Refer to Section 4
under Checking Insulation Resistance

2. Inspect the motor carefully. Make the initial

start by following the regular sequence of
starting
operations
in
the
control
instructions.

3. Check the incoming power to be sure that line

voltage, frequency and phase are correct for the
motor (refer to the motor nameplate).

3. After starting, check that the motor is

running smoothly and with the proper direction of rotation. If the motor shows
excessive vibration, shut down immediately
and investigate. Check for coupling and key
unbalance, lack of lubrication, and structural
resonance.

Caution
Read and fully understand each of the steps in the
following procedure before attempting to start the
motor.

4. Inspect all electrical connections for correct

termination, clearance, mechanical strength,
and electrical continuity.
5. Check to be sure that the shipping brace
has been removed from the motor shaft.

4. If bearing temperature detectors are provided, check the temperatures frequently

during the initial hour of operation. At initial
start, the bearing temperature rate of rise
will be high. This rate of rise should
decrease within 30 minutes. If this rate of
rise does not decrease or the temperature
exceeds 130C, stop the motor.

7. Manually turn the shaft to make sure that it

rotates freely.

Caution
When the driven equipment is likely to be damaged
by the wrong direction of rotation, it is best to uncouple the motor from its load during the check for
rotation and/or during the initial start.

5. Check to make sure that the protective

controls are functioning properly before any
prolonged operation.

Some motors are designed for a single direction of rotation

as indicated by nameplates. Running those units in the
wrong direction will reduce airflow causing overheating.
Check to see that both the motor and driven equipment
are operating in the correct direction of rotation. If it is necessary to change rotation, disconnect and lockout all input
power and interchange any two input power phases.

6. Run the motor for at least two hours if no

problems are encountered.
Warning
6

TO INSURE THAT THE MOTORS ARE NOT

UNEXPECTEDLY STARTED, TURN OFF AND
LOCK OUT OR TAG POWER SOURCE BEFORE
PROCEEDING. FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.

Caution
Repeated starts and/or jogs can greatly reduce the
life of an induction motor. If it is necessary to repeatedly start or jog a motor, check the application
with your local Reliance Electric sales office.

After this initial start and no load run has been

completed, assemble and lubricate the coupling
the
manufacturers
recommended
with
lubricant. Check to see that the coupling is not
binding.

From ambient temperature, the motor is

normally capable of making two starts in
succession while coasting to rest between
these starts.

After the coupling has been assembled and

lubricated, repeat steps 2 through 6 under the
initial start section of this manual. Check to see
that the driven equipment is not transmitting
vibration back to the motor through the coupling
or the base.

The motor is also normally capable of making

one start from its rated load operation
temperature. For cooling time required before
additional starts can be made consult your local
Reliance Electric Sales Office or the motor
starting nameplate if one is provided.

VIBRATION LIMITS
Condition

If more starts or less time between starts than

defined above are attempted, severe damage
to the motor electrical windings and rotor may
result.

AMPLITUDE
ON BRACKET
In/sec
.2
.3

Warning
Shutdown

The starting conditions listed above apply only if

the inertia of the connected load, the load
torque during acceleration, the applied voltage,
and the starting method are those for which the
motor was designed. For starting situations not
covered here, consult your local Reliance
Electric Sales Office before proceeding. Refer
also to the motor nameplate which may list
starting conditions.

The vibration levels listed above are only

guidelines.

TEMPERATURE LIMITS
Condition

Warning
Shutdown

Bearing
RTD

Winging
RTD

C
120
130

C
125
135

The temperature levels listed above are only

guidelines.

STARTING DUTY
(Jogging and Repeated Starts)
7

SECTION 4: ROUTINE MAINTENANCE

Warning

PERIODIC INSPECTION

DO NOT USE SOLVENTS CONTAINING TRICHLOROETHANE TO CLEAN INTERIOR OR

EXTERIOR OF MOTOR.
DAMAGE MAY
OCCUR TO PAINT AND INSULATION
SYSTEMS.

Warning
DISCONNECT AND LOCKOUT POWER BEFORE
TOUCHING ANY INTERNAL PART.
HIGH
VOLTAGE MAY BE PRESENT EVEN WHEN THE
MACHINE IS NOT ROTATING. FAILURE TO
OBSERVE THIS PRECAUTION COULD RESULT
IN SEVERE BODILY INJURY OR LOSS OF LIFE.

Warning

EXTERNAL SURFACES MAY BE HOT, CARE

SHOULD
BE
TAKEN
WHEN
MAINTENANCING MOTORS THAT HAVE
BEEN RUNNING TO AVOID BURNS.

Every 3 months or 500 operating hours,

whichever comes first:

SCHEDULED MAINTENANCE

1. Listen for any abnormal noises and check

cause immediately.

Inspections which are important to the proper

operation and maintenance of a Reliance
motor, should occur every 3 months or 500
operating hours, whichever comes first. In
addition, the following should always be
observed.

2. Check for excessive vibration.

3. Check to see that all covers are in place
and secure.
4. Check for proper lubrication.

Provide adequate ventilation

Avoid sharp blows and excessive axial
thrust loads on the output shaft.
Maintain proper lubricant level (check
weekly on oil-lubricated units).

5. Check bearing temperature rise.

6. Check voltage and frequency variations.
Unbalanced voltage or single-phase operation of polyphase motors will cause
excessive heating and ultimately failure.
Only a slight unbalance of voltage applied to
a polyphase motor will cause large
unbalance currents and result in overheating.
Check power supply total
harmonic distortion to avoid overheating.
Periodic checks of phase, voltage,
frequency, and power consumption of an
operating motor are recommended.

Reliance Electric 6800 Frame motors, when

properly applied, require minimal routine
maintenance. Since clearances and fits are
precisely machined, no periodic mechanical
adjustments are required. Like any precision
machine, periodic inspection and simple routine
maintenance will prolong your motors life and
help detect potentially damaging conditions.
The minimal time spent performing the simple
procedures below cannot begin to compare with
the cost of lost productivity and time consuming
major repairs incurred through neglect or
routine inspection and maintenance.

These checks can also provide an excellent

indication of the load from the driven
equipment. Comparisons of this data with
previous no load and full load power demands
will give an indication of the performance of the
driven machine.

SERVICE CONDITIONS

BEARING LUBRICATION
The motor is equipped with anti-friction
bearings. When properly cared for, (i.e. inspection and lubrication) bearings will provide
Use the
years of uninterrupted service.
following lubrication procedure.

Anti-Friction
cated)

Bearing

(Grease

Standard
Conditions
Severe
Conditions

Lubri-

Extreme
Conditions

6800 Frame motors are designed with the

exclusive Reliance PLS Positive Lubrication
System which routes new grease directly into
the bearing.

Eight hours per day, normal or light

loading, clean ambient air at -18 c
(-32 f) TO 40C (104F)
Twenty four hours per day operation
or shock loading, vibration, ambient
air containing dirt or dust at 40-50C
(100-120F).
Heavy shock or vibration, ambient
air containing dirt, dust or high humidity and temperatures in excess
of 40 C (104 F)

TABLE II

The re-lubrication periods shown in Table II are

offered as a guide for varying service
conditions, speeds, bearing types and operating
hours using standard motor grease.

RELUBRICATION INTERVALS
ANTI FRICTION BEARINGS EQUIPPED MOTORS
Speed
Standard
Severe
Extreme
(RPM)
Conditions
CondiConditions
tions
3000 &
6 months
3 months
2 months
above
Below 3000
6 months
3 months
3 months

Cleanliness is important in lubrication. Any

grease used to lubricate anti-friction bearings
should be fresh and free from contamination.
Similarly, care should be taken to properly
clean the grease inlet areas of the motor prior
to lubricating to prevent grease contamination.

ROLLER BEARING EQUIPPED MOTORS

Below 3000

4 months

2 months

1.5 months

RELUBRICATION VOLUME
VOLUME IN CUBIC INCHES

IMPORTANT
Mixing of lubricants must not be done. Lubricants
from different manufacturers and of different compositions may not be compatible, resulting in inadequate lubrication and bearing failure. Do not use
automotive greases, greases with EP additives or
greases other than those specifically listed on the
motor lubrication nameplate and this instruction
manual. Failure to follow these instructions may result in lubrication breakdown and bearing failure. If a
lubricant other than that listed on the motor nameplate and/or this instruction manual is desired to be
used, consult your local Reliance Sales Office for
approval prior to its use.

DRIVE
METHOD

3000 & 3600

RPM

BELOW 3000
RPM

Coupled Duty
1.5
3.0
Belted Duty
-----------4.0
Data contained on a lubrication nameplate on the motor takes precedent over this Table

Recommended Lubricant
Refer to the motor Lubrication Nameplate for
the type of lubricant to be used. If there is no
Lubrication Nameplate on the motor, use a
polyurea base hydrocarbon oil lubricant.

Lubrication Instructions
1 Select Service Conditions from Table I
2. Select Lubrication Frequency and
ommended volume fill from Table II.

Note: The Lubrication Nameplate on the motor

takes precedent over this data. Use only clean,
fresh grease from clean containers.

rec-

Grease Lubrication Procedure

TABLE I
9

Reliance anti-friction bearings may be lubricated with the motor running or stationary,
however, stationary with the motor warm is
preferred.

ANTI-FRICTION BEARING
REPLACEMENT
1. For anti-friction bearing motors the inner
cap bolts must be removed before removing
the motor bracket.

Warning
IF RE-LUBRICATION IS DONE WHILE THE
MOTOR IS RUNNING, STAY CLEAR OF
ROTATING PARTS. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.

2. Remove all bolts that secure the bracket to

the frame.
3. Using a hoist, support the bracket.

1. Locate the grease inlet, remove all caked

grease and dirt from the fitting. There is
one grease inlet per bearing.

4. Jacking holes have been provided in the

bracket mounting lugs to facilitate the
removal of the bracket from the frame
rabbet fit. Tighten the jack bolts evenly to
avoid mis-alignment of the bracket during
removal.

There is one
1. Remove relief plug.
grease relief plug per bearing. Remove
all hardened grease from the relief plug
area. Remove caked grease from the
grease drain pipe with a screw driver, if
possible. If severe caking appears in
the grease drain pipe, run the motor
until the bearing housing is warm,
permitting free flow of grease through
the housing.

5. At this stage, the bearing is still seated in

the bracket bearing bore. Remove the
bracket from the bearing by rocking the
bracket from side-to-side while applying an
axial force on the bracket. After the bracket
has cleared the bearing, use the hoist to
move the bracket off of the shaft and away
from the motor.

3. Add the recommended volume of the

recommended lubricant per the motor
Lubrication Nameplate or the above chart
using a hand operated grease gun.

6. The bearing can now be removed by using

a conventional bearing puller. Locate the
puller arms behind the bearing outer race
for ball bearings and behind the bearing
inner race for roller bearings. Protect the
shaft center by using a spacer block of
brass or some other soft material between
the shaft and bearing puller. Remove the
bearing by applying axial force with the
bearing puller.

4. Start the motor and run with the relief plug

open for several minutes. Some grease
should be purged from the grease drain
pipe.
5. Replace plugs and wipe off any excess
grease.

7. With roller bearings, the bearing rolling

elements and outer race are contained
within the bearing bracket bore.
This
bearing assembly can be removed from the
bracket bearing bore by pulling on the
rolling elements or by tapping on the outer
race through the shaft bore in the bracket.

TABLE V
FASTENER TORQUE VALUES
TORQUE VALUE
FASTENER

LB-FT

Nm

Flange Mounting
Bracket Mounting
Inner Bearing Cap
Frame Covers

125
80
55
15

170
108
75
20

8. Clean and inspect all parts. Remove all old

grease from the inner caps, brackets,
grease inlet and drain piping and shaft.
Replace all shaft and cap seals.

All torque values have a tolerance of plus 20%

and minus zero.
10

9. All shaft bearing shoulders and journals

should be free of nicks before replacing
bearing. Dress shaft with emery cloth or
stone as necessary. Assemble the bearing
inner caps onto the shaft.

portions of the windings will provide a good indication of their general condition. To thoroughly inspect and clean the windings it may be
necessary to remove the rotor.
There are numerous methods for cleanings
windings. The following methods are most
commonly used, in order of preference.

10. Heat bearing to 250F (120C) for at least

30 minutes.

NOTE: Before cleaning the windings check for

loose blocking, evidence of damage to insulation, distortion or movement of coils, etc. If any
of these conditions exist, contact your local Reliance Electric Service Engineer for recommendations.

11. Place bearing onto shaft. Make certain that

the bearing is contacting the locating
shoulder on shaft. DO NOT use impact
force on bearing.
12. Let the bearing cool. Protect the bearing
from contamination. Fill the outboard side
cavity of the bearing, cage and rolling
element area of the bearing, 100% with
grease. Fill the bearing inner cap cavities
and bracket bearing housing cavity with
grease to 60% full. Fill the grease inlet pipe
100% with grease.

DRY WIPING

13. Assemble the brackets in reverse order of

Steps 1 through 6. Torque bolts per table
V.

This method is satisfactory when the surfaces

to be cleaned are accessible and when only dry
dirt is to be removed. Use a clean dry, lint-free
cloth. The lint will adhere to the insulation and
increase dirt collection. Lint is particularly
objectionable on high voltage insulation
systems as it tends to concentrate corona
discharge.

ROTOR AND STATOR REMOVAL

BRUSHING AND SUCTION CLEANING

Consult Reliance Electric for proper removal

procedures.

Remove the dry dust and dirt by brushing with a

bristle brush, followed by a vacuum suction
cleaning. DO NOT USE WIRE BRUSHES.

WINDING MAINTENANCE
BLOWING

Warning

Dry dirt and dust can be removed from inaccessible crevices by using a jet of low pressure,
oil free compressed dry air.

SOLVENTS CAN BE TOXIC AND / OR

FLAMMABLE. FOLLOW MANUFACTURERS
SAFETY PROCEDURES AND DIRECTIONS.
FAILURE TO OBSERVE THIS PRECAUTION
COULD RESULT IN BODILY INJURY.

Caution
To avoid damage to the windings do not use air
pressures greater than 30 psi (200 kPa). Avoid
directing the air in such a way that the dirt will
be blown into inner crevices.

Caution
Do not use solvents containing trichloroethane
to clean interior or exterior of motor. Damage
may occur to paint and insulation system.

Warning
USE OF AN AIR JET MAY CAUSE FLYING
DEBRIS AND GENERATE PARTICULATE
MATTER. WEAR SUITABLE SKIN, EYE AND
RESPIRATORY PROTECTION. FAILURE TO
OBSERVE THIS PRECAUTION COULD

De-energize motor by opening manual disconnect and locking out. To inspect the ends and
outside surface of the windings, remove the
brackets from the motor. Inspection of these
11

RM = Minimum insulation resistance in

mega ohms at 40C of the entire machine
winding.

RESULT IN BODILY INJURY.

SOLVENT CLEANING

KV = Rating machine potential, in kilovolts.

Caution
Do not use solvents with trichloroethane. Damage
may occur to paint and insulation system.

For machines in good condition, insulation and

resistance readings of 10 to 100 times RM are
common. If the insulation resistance is lower
than that calculated from the formula, the
windings should be dried out as follows:

CLEANING WITH WATER AND DETERGENT

Windings can be cleaned by hose washing or
by pressure spray from a low pressure steam
generator or shop steam line.

Bake in an oven (preferably a circulating

air oven) at a temperature not over 90C
until
insulation
resistance
remains
constant.

Caution
To avoid damage to the windings, jet pressure
and temperature should not exceed 30 psi (200
Kpa) and 90C respectively.

RENEWAL PARTS

Oil, grease, tar and wax can be removed by

adding a NON-CONDUCTIVE DETERGENT to
the wash water. After washing, it is necessary
to dry the windings in an oven. Bake in an oven
(preferably a circulating air oven) at a
temperature not over 90C until insulation
resistance remains constant.

The high productivity expected in industry today

demands a well planned maintenance program.
The success of which often can depend on the
number and type of spare parts on hand.
Serious consideration should be given to having
all vital replacement components on hand to
protect the units against costly down time.

RECONDITIONING WINDINGS
A detailed parts list, which gives Reliance
Electrics recommendations for spare parts that
should be stocked for your motor, can be
ordered from the following offices:

If after cleaning with solvent or water and detergent, the insulation shows signs of dryness, it
may be necessary to re-impregnate the windings.
Consult your local Reliance Electric Service
Engineer for proper type and method of reinsulating the windings.

CHECKING INSULATION RESISTANCE

If the motor 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 megger or
an insulation resistance meter.

1.

Nearest Reliance Electric Sales Office.

2.

Nearest Reliance Electric Distributor.

3.

Reliance Renewal Parts, Greenville, SC.

Be sure to include complete nameplate data,

purchase order number, serial number, model
number, rating, etc., for your motor when
ordering the spare parts list.

The minimum insulation resistance (RM) can be

determined from the following formula:

Parts can be obtained from your nearest distributor or directly from our factory. When ordering parts for which a part number is not
available, give complete description of part and
purchase order number, serial number, model

RM = KV + 1
Where

12

number, etc. of the equipment on which the part

is used.

SECTION 5: APPLICATION SPECIFICS

ICDS SYSTEM SNAPSHOT

The ICDS motor is a 1250 HP, 1.15 SF, 4160

volt three phase induction motor with on board
temperature monitoring and real time power
measurement. The motor has sensors and
electronics located in the main conduit box as
well as four other small X/P boxes located on
top of the motor. The main conduit box is
located on the drive end of the motor and is
One
divided into three compartments.
compartment for electronics, a center
compartment for the main power leads and
current transformer, and a third compartment
for the potential transformers.

BASIC TROUBLESHOOTING

Note: The troubleshooting tips below require the explosion proof

covers be removed to access devices inside the conduit boxes.
Refer to proper mine site and
MSHA regulations for proper servicing of devices inside an XP
conduit box.

ACCESSIBLE MOTOR SENSORS

RTDs

See assembly drawing for locations.

Potential Transformers
35:1 ratio PT (2 total)
Current Transformer
300:5 ratio CT
Water In Temperature
100 ohm RTD
Water Out Temperature
100 ohm RTD
XP Enclosure Temperature
100 ohm RTD
DE Vibration Probe
0-25mm/sec probe
ODE Vibration Probe
0-25mm/sec probe

1. If values displayed are exceptionally

high (greater than 185 C winding or 145
C water and bearing temperatures) a
loose wire could be the culprit. All
RTDs terminate on one of two modules
on the CompactLogix rack. Confirm
placement and secure leads.
No
external
surface
temperature
readings (water RTDs) should ever
exceed 145 C or motor must be deenergized and allowed to cool.
Confirm proper water flow is going
through motor.
2. Numbers greater than 800 C indicate an
RTD that has been disconnected,
broken wires or the temperature element has failed.
3. Disconnect RTD from CompactLogix
module and check resistance with an
ohmmeter. Values of the RTD should
be less than 250 ohms. If resistance
values show infinity then the RTD has
failed or the wires between the element
and terminals are broken.
Replace
wires or RTD if possible. If resistance
values show close to zero or less than
100 ohms then check the leads you are

ACCESSIBLE ELECTRONICS

Winding Temperatures (one per phase)

100 ohm RTDs (3 total)
Bearing Temperatures (one per bearing)
100 ohm RTDs (2 total)

See assembly drawing for location

PowerMonitor 3000
CompactLogix Controller
1606 XLP Power supply
12 volt DC supply
DBT UOI Isolator

INTERNAL MOTOR SENSORS

13

measuring. Measure between the red

and white leads (or black and white
leads on water RTDs). Check wiring
harness on water RTDs for proper continuity and signs of any damage. If
measurements with an ohmmeter are
correct confirm proper color placement
on terminal strip and tighten leads.
Confirm that no external motor surface temperatures ever exceeds
145C.

POWER MONITOR
If problems exists with the readings on either
voltage, current, real power output, or reactive
power output then the PowerMonitor 3000
should be checked for problems
1. Check the configuration of the PowerMonitor with the external display unit.
These values are:
a. Confirm that configuration is set
for Open Delta 3 CT.
b. Confirm that the potential
transformer ratio is set for 4160
primary and 120 secondary.

VIBRATION MONITORS
If problems exist with the vibration probe
readings the following should be checked.

1. Check +24 volts output from PLC

terminal.
2. Check 1 amp fuses for continuity with
an ohmmeter
3. Check wiring harness for continuity with
an ohmmeter on each of the three
leads.
4. Check remaining wiring between PLC,
analog module, and probes.
5. If only one probe is not functioning,
swap the working probe with the non
working probe to eliminate the probe as
the possible cause of problem. If probe
still does not operate then replace
probe.

www.baldor.com

www.ptplace.com

www.dodge-pt.com

c. Confirm the current transformer

ratio is set for 300 primary and
5 secondary.
d. Confirm that the neutral current
I4 CT is set for 5 primary and
5 secondary.
2. Check for proper wiring from the CTs
and PTs to the PowerMonitor. Review
against wiring diagram.

COMPACTLOGIX PLC
If no data is being received from the PLC
confirm the problems.
1. Confirm all the proper lights are on the
PowerMonitor, each PLC module, and
the PLC itself. The activity light of the
Powermonitor and the PLC should be
continuously blinking.
2. Confirm that the receive and transmit
lights on the DBT UOI are blinking.
3. Confirm the DBT PMC-D and PMC-V
are operating properly.
4. Reload the program from compact flash
if no activity lights are blinking. Insert
compact flash card in appropriate slot
and cycle 120 volt power on the PLC.

www.reliance.com

Baldor Electric Company Headquarters

P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.648.5792, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Baldor - DODGE/Reliance
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, FAX: (1) 864.281.2433
5/07

Copyright 2007 Baldor Electric Company

All Rights Reserved. Printed in USA.

This material is not intended to provide operational instructions. Appropriate instruction manuals and precautions
should be studied prior to installation, operation or maintenance of equipment.
.

B-3741-1