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Operation Manual
PLANT: CBI JOB: CBI DOC. N:
PUENTE NUEVO POWER PLANT 7.1627 7.1627-INO-001
ESITO SUPERVISIONE
Supervision Outcome
CLIENTE
Client Viesgo Grupo Enel
JOB no : M55C Doc. no. PBPNU59858
DODGE - SLEEVE OIL RTL PILLOW BLOCKS - Installation and Pag. 182
Maintenace Manual
DODGE - SLEEVE OIL RTL PILLOW BLOCKS - Manual de Instalacion
y mantenimiento
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Contents
1 Receiptoffans/RecepcinVentilador...................................................................................................................4
1.1 Inspections/Recepcin..................................................................................................................................4
2 Storage....................................................................................................................................................................4
2.1 Generalrules/ElGeneralGobierna...............................................................................................................4
2.2 Boardlabelsandnameplates/CartelesEnLaMquina................................................................................5
2.3 Fanswithgreasebearings/Losventiladoresconengrasacojinetes.............................................................5
2.3.1 Maintenanceduringscheduledstop/Elmantenimientoduranteparadaprogramada....................5
2.3.2 Maintenanceduringoperation/Elmantenimientodurantelaoperacin..........................................6
2.4 Fanswithoilbearings/Losventiladoresconcojinetesaaceitelubricante...................................................6
2.4.1 Completelyassembled/Completamentereunido..............................................................................6
2.4.2 Withseparatelyshippedrotor/Conrotorseparadamenteenviado...................................................7
2.5 Fanoutage/Ventileaapagn.......................................................................................................................7
3 Handling/Manejo...................................................................................................................................................8
4 Assembly/instalacin.............................................................................................................................................8
4.1 Foundations/Cimientos.................................................................................................................................8
4.2 FansassembledbyCBI/Ventiladoresyaensamblados...............................................................................14
4.3 Fanswithseparaterotor/Ventiladoresconrotorseparados......................................................................14
4.4 Fansmountedonfoundationplinth/Ventiladoresconapoyosobreplinto...............................................15
4.5 Fanswithdampers/Ventiladoresconamortiguadores...............................................................................16
4.5.1 Rubberdampers/Amortiguadoresdegoma....................................................................................16
4.5.2 Springdampers/Amortiguadoresdemuelles...................................................................................16
4.5.2.1 assemblyanddisassemblyinstruction/asambleaeinstrucciondedesmontaje..............................18
5 Checksbeforestartup/c o n t r o l e s p r e v i o s a l a p u e s t a e n m a r c h a .........................................19
5.1 Couplingalignment/Emparejarlaalineacin.............................................................................................20
6 Startup/puestaenmarcha..................................................................................................................................21
6.1 Checks/Controles........................................................................................................................................21
6.2 Readings/Lecturas.......................................................................................................................................22
7 Lockpin/Fijacindelossoportes..........................................................................................................................23
7.1 Pillowblocklockpin/Fijacindelossoportes...............................................................................................23
8 Possibletroubles/problemasposibles.................................................................................................................23
8.1 Vibrationsofmechanicalorigin/Lasvibracionesdelorigenmecnico.......................................................23
8.1.1 Duetorotorunbalance/Desequilibriodelrodete.............................................................................23
8.1.2 Couplingmotormisalignment/DesajustedeEmparejardelmotorelctrico...................................23
8.1.3 Bearings/cojinetes.............................................................................................................................24
8.1.4 Shaftdeformation/Deformacinderbol........................................................................................24
8.1.5 Foundationscrewsloosening/Labaseenroscaaflojamiento..........................................................25
8.1.6 Loadsduetoinletandoutletducts/Lascargasdebidoaconductosdecalaysalida......................26
8.1.7 Foundations/Bases............................................................................................................................26
8.1.8 Electricmotor/motorelctrico.........................................................................................................26
8.1.9 Foreignmatters/Asuntosextranjeros..............................................................................................26
9 Aerodynamicvibrations/vibracionesaerodinamicas..........................................................................................27
10 PoorPerformance/pocorendimiento..................................................................................................................28
11 Maintenance/mantenimiento.............................................................................................................................29
11.1 Periodicalchecks/Verificaperidica...........................................................................................................29
12 Disassemblyoperations/OperacionesDeDesmontaje........................................................................................29
12.1 Rotor/Rotor.................................................................................................................................................29
12.2 Coupling/Emparejar....................................................................................................................................29
13 Tables/Tabla........................................................................................................................................................30
13.1 Torquewrenchsetting/Colocacindellaveinglesademomentodetorsin.............................................30
13.1.1 Applications/Aplicaciones................................................................................................................30
13.2 Radialinternalclearanceofsphericalrollerbearingswithtaperedbore/Elespaciolibreinternoradial
decojinetesesfricosderodilloconestrechadoaburre................................................................................................30
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14 Ancillaryequipmentassemblydiagram/Montajereguladoresdecapacidadycompuertasdealetas.........33
14.1.1 Variableinletvanes/reguladoresdecapacidadaspirantes(Dapo).................................................33
14.1.2 Inletdamper/compuertasdealetas.................................................................................................34
14.1.3 Constantoillevelindicatorsforbearings/ndicadoresdenivelconstanteparasoportesdeaceite..35
15 Anomalousvibrations/vibracionesanomalas.....................................................................................................37
15.1 Causesandinterventions/Causaseintervenciones....................................................................................37
16 Documentation/documentacion.........................................................................................................................37
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1 RECEIPT OF FANS / RECEPCIN VENTILADOR
2 STORAGE
Si ventiladores son al aire libre almacenados, es necesario proporciona para cubrir ellos con
medios convenientes. Si ellos son almacenados en un rea refugiada seca no cuidado particular
es requerido
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2.2 Board labels and nameplates / Carteles En La
Mquina
The fan is provided with labels indicating:
En la mquina se encuentran diversos pictogramas de sealizacin, que no deben ser retirados.
When the lubrication time is approx. 8,000 hours, make maintenance during the
plant scheduled stop.
During the fan stop, remove the grease and provide to internal clean of pillow blocks
or bearing housing using suitable solvents.
During these operations check of grease seals and replace if necessary.
After this operations replace with new grease. The grease type is specified on the
assembly drawing.
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2.3.2 Maintenance during operation / El mantenimiento
durante la operacin
Bearings in pillow block or bearing housing can be lubricated during fan operation.
The lubrication time is specified on the assembly drawing.
Fans with oil bearings are shipped without oil to prevent oil leakages during transport and
handling.
At receipt of fans and in any case before storing, provide for lubrication with oil type
specified on the assembly drawing.
Bearings are always equipped with constant oil level gauge and fixed oil level gauge.
Check that oil level gauge connections didnt loosen during transport and on site handling,
in this case it will has oil leakages. Provide to tighten the connections.
Bearing cavity has to be filled with oil up to the centerline of the lower roller.
This height is the static oil level marked on the oil level gauge and shown on the drawing.
This is measured from bottom of block base to meniscus on oil sight gauge (non-rotating
mode).
Considering that the oil level may drop or rise during operation, depending on the direction
of rotation of the bearing.
For this reason both static oil level and running oil level should be marked on the oil sight
gauge and properly identified, considering that normally the oil filling will be carried out
with fan in operation.
Los ventiladores con cojinetes de petrleo son enviados sin el petrleo para prevenir
mermas de petrleo durante el transporte y el manejo.
En recibo de ventiladores y en cualquier caso antes de almacenar, preve la lubricacin
con de tipo petrleo especific en el dibujo de la asamblea.
Cojinetes siempre son equipados con el calibrador constante de nivel del aceite y
calibrador fijo de nivel del aceite.
Verifique esas conexiones del calibrador de nivel del aceite no aflojaron durante el
transporte y en el manejo del sitio, en este caso hace tiene mermas de petrleo.
Proporcione para apretar las conexiones.
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Soportar la cavidad tiene que ser llenada del petrleo hasta la lnea central del rodillo
ms bajo. Esta altura es el nivel del aceite constante marcado en el calibrador de nivel del
aceite y mostrado en el dibujo. Esto es medido del fondo de la base del bloque al menisco
en el petrleo el calibrador vidente (el modo de no-girando).
Teniendo en cuenta que el nivel del aceite puede dejar caer o puede subir durante la
operacin, dependiendo de la direccin de la rotacin del cojinete. Para esta razn ambos
nivel del aceite constante y nivel del aceite corriente deben ser marcados en el petrleo el
calibrador vidente y apropiadamente identificados, teniendo en cuenta que normalmente
el relleno de petrleo ser llevado a cabo con ventilador en la operacin.
Same as a.m. paragraph, with the exception of the oil level gauges that are supplied
separately; therefore they have to be assembled on site.
El prrafo mismo que anterior, a excepcin de los calibradores de nivel del aceite que son
suministrados separadamente; por lo tanto ellos tienen que ser reunidos en el sitio.
Despus de que una apagn en la planta o almacene, el lubricante (grasa o petrleo) debe
ser quitado por medio de detergentes convenientes y entonces reemplaza con nuevo
lubricante.
Los ventiladores deben ser almacenados en un cubri y seca el lugar, protegido del polvo
y la corrosin.
La almohada bloquea y soportando envoltura puede ser protegida con tapas plsticas o
graba sin sellar para prevenir la humedad adentro a los cojinetes.
La causa de la humedad daa. La temperatura de rea de tienda no debe exceder 60 C,
con humedad relativa de 80%.
El rotor debe ser girado para acerca de diez minutos para permitir cada diez das la
lubricacin homognea de cojinetes
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3 HANDLING / MANEJO
4 ASSEMBLY / INSTALACIN
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Diagram 1
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Diagram 2 Fan with vibration isolators
on reinforced concrete foundations
No-flat and no-leveled
No- flat surface superfice non planare
surface
superficeexecution
WRONG non planare e non in execution
WRONG bolla
esecuzione ERRATA esecuzione ERRATA
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El tipo de cimientos recomendado es el de cemento armado, o con estructura de acero.
En todo caso se deben calcular en funcin de la carga esttica y dinmica del ventilador, cuyos valores se
indican en el diseo del conjunto.
Para no comprometer el buen funcionamiento de la mquina, las vigas de acero, o la base de cemento
armado en la que se apoya el ventilador, deben ser niveladas y con la mxima planaridad, como se describe
a continuacin. vea los esquemas siguientes 1-2-3
Diagrama 1
Ventiladores enventilatore
base de cemento
conarmado
basesininamortiguadores
cemento armato
superfice non
superficie no planare
planar y no nivelada
superficie nonon
superfice planar
planare e ejecucin INCORRECTA
non in bolla
ejecucin INCORRECTA esecuzione ERRATA
esecuzione ERRATA
superfice planare
superficie planar pero no nivelada
superficie planar
superfice y nivelada
planare ed in bolla ma non in bolla
ejecucin CORRECTA ejecucin INCORRECTA
esecuzione CORRETTA esecuzione ERRATA
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Diagrama 2
Ventiladores en base de cemento armado con amortiguadores
superfice
superficie nonon planare
planar y no nivelada
superficie nonon
planar eejecucin
non in bolla
superfice planare INCORRECTA
ejecucin INCORRECTA
esecuzione ERRATA esecuzione ERRATA
superfice planare
superficie planar y nivelada superficie planar pero no nivelada
superfice planare ed in bolla ma non in bolla
ejecucin CORRECTA ejecucin INCORRECTA
esecuzione CORRETTA esecuzione ERRATA
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Diagrama 3
superfice planare
superficie planar y nivelada superficie planar pero no nivelada
superfice planare ed in bolla ma nonINCORRECTA
in bolla
ejecucin CORRECTA ejecucin
esecuzione CORRETTA esecuzione ERRATA
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4.2 Fans assembled by CBI / Ventiladores ya ensamblados
Level out the fan using a centesimal water level operating on the fan shaft or coupling.
For fans with dampers see paragraph 4.5.1 and 4.5.2
Adems de la nivelacin del grupo con instrumento centesimal, tomando como referencia
el eje o el acoplamiento de transmisin, el montaje de los ventiladores ensamblados no
necesita ninguna solucin especial.
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4.4 Fans mounted on foundation plinth / Ventiladores
con apoyo sobre plinto
Refer to the assembly drawing to operate in the correct way as follows:
1. Place the rotor on foundation plinth (the rotor is assembled with its bedplate), proceed to
leveling using sheetsteel shims where necessary, and fix it accurately.
2. Place the anchor bolts into the suitable holes.
3. Fill up with suitable mortar and allow drying according to the instructions contained in
packaging used.
4. Once a suitable footing form has been realized, proceed to cast the leveling mortar that must
be of excellent quality, i.e. with excellent resistance and lowest coefficient of expansion. The
leveling mortar must homogeneously fill up all free spaces around the bedplate.
5. After the time needed, tighten the bolts by means of a torque wrench.
6. Place the lower casing sector screw according the above instructions.
7. Assembly the inlet bell.
8. Check the mounting clearance indicated on the assembly drawing, i.e.:
Impeller-inlet bell (radial and axial)
Seal-shaft (radial)
9. Assembly other casing sectors
10. Tighten the bolts:
Anchor bolts
Motor fastening bolts
Bearings bolts
11. Align the coupling;
12. Assembly the ancillary equipment, if any.
Para una correcta ejecucin del montaje, referirse al diseo del conjunto y operar de la manera
siguiente:
1. Colocar el rotor en el plinto de la base (el rotor es reunido con su bedplate), contina a nivelar que
utiliza hojacalces de acero donde necesario, y lo fija exactamente.
2. Colocar los bulones de anclaje a los cimientos en los especficos puntos de anclaje
3. Llenar los puntos de anclaje con mortero idneo y dejar secar segn las instrucciones del producto.
4. Una vez realizado un adecuado encofrado, realizar la colada de mortero de nivelacin que debe ser de
ptima resistencia mecnica con un bajo coeficiente de dilatacin.
5. Una vez transcurrido el tiempo necesario, apretar los bulones de anclaje a los cimientos con llave
dinamomtrica.
6. Colocar el sector inferior de la cclea con el mismo procedimiento del apoyo
7. Montar la tobera
8. Comprobar los juegos de montaje indicados en el diseo del conjunto, y precisamente:
Rodete-tobera (radial y axial)
Junta de estanqueidad-eje (radial)
9. Montar los sectores de cclea restantes.
10. Efectuar el apriete de los bulones:
de anclaje a los cimientos
motor
soportes
11. Alinear acoplamiento de transmisin
13. Montar eventuales accesorios.
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4.5 Fans with dampers / Ventiladores con amortiguadores
These dampers are usually mounted on fan baseframe. In this case no special care is
necessary.
It is very important that the foundation is according to specified in diagrams of
paragraph 4.1.
These dampers are usually mounted on fan baseframe. In this case no special care is
necessary.
When the spring dampers are shipped separately, they are ready to assembly them on
fan baseframe, as shown on the following diagram.
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Diagram 4
Dampers supplied separately. Position marking
marca de la posicin
contrassegno per lade los amortiguadores
posizione cuando se suministran
degli ammortizzatori
quando vengono
separadamente fornitialseparatamente
respecto ventilador
al ventilatore
Fastening screw between aluminium
section bar and fanper
viteria frame
bloccaggio profilo
tornillos para fijard'alluminio
el perfil de aluminio
al telaio al
ventilatore
bastidor del ventilador
Screws
viteria per for damper longitudinal translation
lo scorrimento
tornillos para eldegli
longitudinale deslizamiento longitudinal de los amortiguadores
ammortizzatori
Anchor
bulloni bolts
di fondazione
bulones de anclaje a los cimientos
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4.5.2.1 ASSEMBLY AND DISASSEMBLY INSTRUCTION /
ASAMBLEA E INSTRUCCION DE DESMONTAJE
In case that the electric motor is not delivered to CBI in account of manufacture and
therefore mounted on site, the assembly of dampers is simplified by the geometry of
the aluminium section bar that allows the longitudinal translation.
After assembly of dampers, place the fan on foundation and check that the height of
each damper corresponds to or is within the tolerance limit indicated in the assembly
drawing.
Lift the fan and correct the damper position up to optimization of set height values.
Transport
tiranti fastening
di bloccaggio tie rods. Remove after in site
presenti
assembly
per il trasporto,
datirantes de fijacin
eliminare presentes
durante il para el transporte, a eliminar durante el
montaje en in
montaggio la obra
cantiere
Screws
viteria forscorrimento
per lo damper longitudinal translation
tornillos para el
longitudinale deslizamiento longitudinal de los amortiguadores
degli
ammortizzatori
bulloni di fondazione
Anchor bolts
bulones de anclaje a los cimientos
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5 CHECKS BEFORE STARTUP / CONTROLES PREVIOS A LA
PUESTA EN MARCHA
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10. Aplicar en los soportes los accesorios de los que est dotado.
11. Prestar especial atencin al montaje del grupo aceitador de nivel constante (cuando se
suministra separado por motivos de transporte)
12. Verifique la presencia de lubricantes en los cojinetes.
13. Retirar eventuales cuerpos extraos que se encuentren en la cclea.
14. Cerrar las puertecillas
15. Comprobar la correcta apertura y cierre de compuertas, reguladores de caudal.
16. Controlar la correcta colocacin de los finales de carrera
17. Asegurarse de que todas las partes rotatorias, o donde est previsto, estn dotadas de
proteccin
18. Asegurarse de que los conductos sobre la aspiracin e impulsin no afecten el ventilador, y
que los acoplamientos antivibracin que se encuentran en las bocas permitan la eventual
dilatacin.
19. Comprobar el sentido de rotacin del motor con eventuales ruedas libres desactivadas
20. Activar las eventuales ruedas libres
Durante el control de la rotacin prestar atencin a que no se produzca ningn ruido extrao o
irregularidad; en caso contrario intervenir para solucionar el problema indicado en el captulo 8.
Verifica el apretar correcto de todos componentes, es decir el apretar del motor elctrico, de
cojinetes, de los sellos de tnel, y de cerrojos de ancla antes del llevar a cabo la alineacin
final.
La alineacin tiene que ser llevada a cabo como especificado en la asamblea que dibuja o
encerr la documentacin.
20
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6 STARTUP / PUESTA EN MARCHA
1. En caso de que no estn previstos en la mquina los instrumentos para el control de velocidad,
temperatura y vibraciones, es oportuno tener a disposicin instrumentos porttiles.
2. Recomienda las canillas de la presin de soldadura ro arriba y ro abajo el conducto de ventilador,
las canillas posicionan ser accesible a un Pitot atraviesa tubo para medir el flujo, cundo necesario.
3. Una vez que se haya comprobado que todos los controles dan un resultado positivo, proceder a la
puesta en marcha
3. Measurement of:
Flowrate
Pressure
Fluid temperature
Rpm
Absorbed power
Compare the values with fan characteristic curve.
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Despus de la puesta en marcha efectuar los siguientes controles:
1. Vibraciones en los soportes: horizontal-vertical-axial, segn tablas COAER 109, o ISO 14695.
2. Temperatura cojinetes ( mx. 90 C, medida en la superficie de los soportes).
Despus de una fase de aumento, la temperatura de los cojinetes debe estabilizarse en los valores
nominales 90 C, medidos en la caja del soporte con un instrumento adecuado.
Si los valores de vibracin y temperatura encontrados no son satisfacientes, detener la mquina,
identificar las causas y eliminar las anomalas. Vea el prrafo 8.
Una vez que las operaciones necesarias han sido hechas, continen a nuevo inicio de ventilador.
3. La medida de:
a. la cantidad de aire
b. la Presin
c. la temperatura
d. velocidad de rotacin
e. Absorbi el poder Compara los valores con ventilador curva tpica
Los valores de vibraciones y temperatura tienen que ser registrados cada diez minutos
por lo menos por una hora
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7 LOCKPIN / FIJACIN DE LOS SOPORTES
Despus de varias puestas en marcha y controles finales, incluida la comprobacin de alineacin del
acoplamiento o de la transmisin por correas, efectuar la fijacin de los soportes que se debe realizar
despus de un perodo de funcionamiento de 24 horas.
Clean the impeller / Controlar que no haya polvo u otros materiales sobre las
partes rotativas.
Check impeller structural condition and if necessary, repair it or replace the
impeller / Controlar erosin o corrosin del rodete, si el rodete est seriamente
daado debe ser sustituido.
Balance the rotor / Equilibre el rotor.
Check the tightness of electric motor and pillow block (or bearing housing) bolts /
Verifique la estrechez del bloque motor elctrico y la almohada (o soportando
envoltura) cerrojos.
Check the tightness of coupling bolts / Verifique la estrechez de emparejar
cerrojos.
Proceed to realignment / Emparejar la alineacin.
Proceed to bearings and motor lockpin / Fijacin de los soportes y motor elctrico
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8.1.3 Bearings/ cojinetes
Verifique lo Siguiente:
La Condicin de rodillos o pelotas, y compite.
Los espacios libres radiales Residuales segn las mesas del fabricante de cojinetes; vea
el prrafo 13,2.
Liberta cojinete debe deslizar sin dificultad.
La Lubricacin. El bloque de Almohada o soportar la casa que nivela.
La Estrechez de bloques de almohada (o soportando envoltura) cerrojos con la llave
inglesa del momento de torsin segn los valores indicados en las mesas del prrafo
13,1
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Impossibility of correct bearing slide; check that the free bearing can slide without
difficulty.
Loosening of pillow block (or bearing housing), electric motor, and bedplate bolts.
Shifting of the electric motor shims or fan bedplate shims.
Shaft seals friction.
Check the tightness according to the values indicated in table 1, paragraph 13.1.
The tightness difficulty may be due to the shifting of plates used for the leveling or to
foundation settling.
Take the necessary measures.
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8.1.6 Loads due to inlet and outlet ducts / Las cargas
debido a conductos de cala y salida
Inlet and outlet ducts must not force the fan position and the flexible connections must
work in suitable way to prevent vibration and noise transmission.
Settling and formation foundations supporting the fan may cause vibrations. Check the
foundations and take proper measures, if necessary.
Asentar y bases de formacin que apoya el ventilador puede causar las vibraciones.
Verifique las bases y tome las medidas apropiadas, si necesario
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9 AERODYNAMIC VIBRATIONS / VIBRACIONES
AERODINAMICAS
These vibrations usually change with fan and/or circuit characteristics and may be
caused by:
Resonance of ducts at definite flowrates.
Sudden section variations.
Unfit duct stiffenings transmit vibrations to the fan casing and consequently to the
impeller and bearings.
Provide to stiffening as necessary.
Some of above-mentioned troubles could make difficult to determine the cause and find
proper measures.
Contact CBI for assistance.
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10 POOR PERFORMANCE / POCO RENDIMIENTO
The performance must always refer to the fan design point and circuit design point.
Record the following parameters:
Rpm
Flow temperature
Barometric pressure
Relative humidity
Dampers setup
Static pressure upstream and downstream of the fan, in an place without
turbulences
Absorbed power
The records shall be repeated several times changing the circuit resistance, for instance,
changing the dampers setup when the other parameters unchanged.
Compare the obtained results with fan characteristic curves.
El rendimiento siempre debe referirse al punto del diseo del ventilador y el punto del
diseo del circuito.
Registre los parmetros siguientes:
velocidad de rotacin
la temperatura del Flujo
la presin Baromtrica
humedad Relativa
arreglo de Amortiguadores
la presin Constante ro arriba y ro abajo del ventilador, en un lugar sin
turbulencias
Absorbi el poder que
Los registros sern repetidos varias veces cambiando la resistencia de circuito, por
ejemplo cambiando el arreglo de amortiguadores cuando los otros parmetros iguales.
Compare los resultados obtenidos con ventilador curvas tpicas.
Los valores diferentes deben ser encontrados debido a las razones siguientes:
La rotacin Equivocada de impeller.
Reunir Equivocado de amortiguador de cala (verifica la posicin de hojas). Vea el
prrafo 14.1.2.
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11 MAINTENANCE / MANTENIMIENTO
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13 TABLES / TABLA
For the other elements that are part of CBIs supply but of external supply, the
instructions contained in the manufacturer catalogues have to be followed.
Para los otros elementos que forman parte del suministro de CBI pero del
suministro externo, las instrucciones contenidas en los catlogos del fabricante tienen
que ser seguidas.
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Tab. 1
Material class / Clase material
Torque wrench setting [Nm]
Colocacin de llave inglesa de momento de
torsin [Nm]
Screw 8.8 10.9 12.9
8 24 34 41
10 50 70 84
12 90 127 153
16 214 302 362
18 308 434 520
20 431 607 728
24 731 1030 1230
27 1070 1500 1800
30 1480 2080 2490
Tab. 2
SN bearings 1 torque [Nm] 2 torque [Nm] Monobloc 3 torque [Nm]
Soportes SN torsin torsin torsin
513 80 220 P0-30 80
515 80 220 P1-35 150
516 80 430 P2-45 200
517 80 430 P3-55 300
518 150 430 P4-65 430
519 150 430 P1-35L 150
520 200 750 P2-45L 200
522 200 750 R1-40 150
524 200 750 R2-55 200
526 350 750 R3-65 300
528 350 1400 R4-80 430
530 350 1400
532 350 1400
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Tab. 3
SND bearings 1 torque [Nm] 2 torque [Nm]
Soportes SND torsin torsin
513 81 220
515 81 220
516 203 430
517 203 430
518 203 430
519 203 430
520 415 750
522 415 750
524 415 750
526 415 750
528 720 1400
530 720 1400
532 720 1400
The radial internal clearance of spherical roller with tapered bore is expressed in m.
For other types of bearings, see the manufacturer tables.
Los juegos radiales residuales expresados en m, para cojinetes de rodillos con orificio cnico se
indican en la tabla siguiente.
juego residual
giu
oc
o re
sid
uo
Tab. 4
Hole Normal Normal
C3 C3
orificio Juego normal Juego normal
Over mm Up to mm Min. m Max. m Min. m Max. m
50 65 55 75 75 95
65 80 70 95 95 120
80 100 80 110 110 140
100 120 100 135 135 170
120 140 120 160 160 200
140 160 130 180 180 230
32
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14 ANCILLARY EQUIPMENT ASSEMBLY DIAGRAM /
MONTAJE REGULADORES DE CAPACIDAD Y COMPUERTAS DE ALETAS
orientamento 9 16
Open /
abierto
aperto
chiuso
Closed
cerrado
chiuso
aperto
Closed
cerrado
33
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14.1.2 Inlet damper/ compuertas de aletas
orientamento
Fan orientation /1orientacin
8 18
Closed
chiuso
closed
cerrado
aperto
Open /
abierto
Open
a
/
p
abiertoerto
chiuso
Closed
cerrado
34
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14.1.3 Constant oil level indicators for bearings/ ndicadores
de nivel constante para soportes de aceite
The constant oil level indicator supplied by CBI is with safety cage type.
Assembly the level correctly observing the A and B dimensions and applying the
Teflon tape on all the threads.
Fill it with oil according to the values indicated in the assembly drawing and as
described in picture 1.
The B dimension must correspond to the dimension indicated in the assembly
drawing; if not, act on the connection pipes until the nominal values are reached.
It is possible to check the B dimension on the square level indicator.
An excessive oil quantity may cause leakages from the seals as well as a bearing
temperature rise.
Once the correct indicator position has been checked, the perfect tightening of all
components has to be checked again, so as to prevent the accidental loosening during the
fan handling.
Check the tightening of locking squares on the level connection pipes.
Montar correctamente el grupo, respetando las cotas A-B, y colocando cinta de tefln en todas las
roscas de las piezas pequeas.
Llenar con aceite respetando los valores indicados en el diseo del conjunto y de la manera
indicada en la figura.
La cota B debe corresponder a la indicada en el diseo del conjunto; en caso contrario, actuar
sobre los tubos de racor hasta alcanzar los valores nominales.
Por comodidad se puede comprobar la cota B en el indicador de nivel de escuadra.
Una excesiva cantidad de aceite causa la salida del mismo de las uniones estancas y el aumento
de la temperatura de los cojinetes.
Una vez comprobada la correcta posicin del indicador, controlar el perfecto apriete de todos los
componentes, de manera que evite el aflojamiento incluso casual durante el desplazamiento de la
mquina.
Comprobar el apriete de las escuadras de bloqueo en los tubos de conexin del indicador.
35
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Posicin aceitador respecto a la
rotacin
Oil level delindicator
rodete visto desde el
position
ladoposizione
motor to
according oliatore rispetto
fan rotation
alla rotazione girante
Drive end
visto lato view
motore
90
90
B A B A
Bracket / estribo de
B 7 A
36
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15 ANOMALOUS VIBRATIONS / VIBRACIONES ANOMALAS
16 DOCUMENTATION / DOCUMENTACION
37
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WEG - ELECTRIC MOTOR
Installation and Maintenace Manual
Transforming energy
into solutions
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THREE-PHASE INDUCTION MOTORS
FOREWORD
The electric motor is the equipment widely used by man in the industrial development as most of
the machines he has been inventing depend on it.
Taking into consideration the prominent role the electric motor plays on people's life, it must be
regarded as a prime power unit embodying features that require special care including its installation and
maintenance in order to ensure perfect operation and longer life to the unit.
Its installation and maintenance demand specific cares, to guarantee the perfect functioning and
longer life to the motor.
The installation and maintenance manual for LOW AND HIGH VOLTAGE THREE-PHASE
INDUCTION MOTORS intends to assist those who deal with electric machines facilitating their task to
preserve the most important item of the unit:
9300.0009 I/8
November 2006
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THREE-PHASE INDUCTION MOTORS
INDEX
1. INTRODUCTION.......................................................................................................................................................................6
2. GENERAL INSTRUCTIONS.......................................................................................................................................................7
2.1. SAFETY INSTRUCTIONS................................................................................................................................................ 7
2.2. UNPACKING.................................................................................................................................................................. 7
2.3. STORAGE ..................................................................................................................................................................... 7
2.3.1. INDOOR STORAGE......................................................................................................................................... 7
2.3.2. OUTDOOR STORAGE...................................................................................................................................... 7
2.3.3. VERTICAL MOTORS STORAGE......................................................................................................................... 8
2.3.4. OTHER CARES DURING STORAGE................................................................................................................... 8
2.3.5. INSULATION RESISTANCE.............................................................................................................................. 8
2.3.6. POLARIZATION INDEX ................................................................................................................................... 9
2.4. PROLONGED STORAGE ............................................................................................................................................... 10
2.4.1. INTRODUCTION........................................................................................................................................... 10
2.4.2. GENERALITIES............................................................................................................................................. 10
2.4.3. STORAGE PLACE .......................................................................................................................................... 10
2.4.3.1. INTERNAL STORAGE...................................................................................................................... 10
2.4.3.2. EXTERNAL STORAGE ..................................................................................................................... 11
2.4.5. SPARE PARTS .............................................................................................................................................. 11
2.4.6. SPACE HEATER ............................................................................................................................................ 11
2.4.7. INSULATION RESISTANCE............................................................................................................................ 11
2.4.8. EXPOSED MACHINED SURFACES................................................................................................................... 11
2.4.9. BEARINGS ................................................................................................................................................... 12
2.4.9.1. ANTIFRICTION BEARING LUBRICATED BY GREASE ......................................................................... 12
2.4.9.2. ANTIFRICTION BEARING LUBRICATED BY OIL................................................................................ 12
2.4.9.3. SLEEVE BEARING .......................................................................................................................... 12
2.4.10. BRUSHES................................................................................................................................................... 12
2.4.11. CONNECTION BOX: .................................................................................................................................... 13
2.4.12. PREPARATION FOR SERVICE AFTER LONG TERM STORAGE ......................................................................... 13
2.4.12.1. CLEANING................................................................................................................................... 13
2.4.12.2. BEARINGS LUBRICATION............................................................................................................. 13
2.4.12.3. ISOLATION RESISTANCE VERIFICATION....................................................................................... 13
2.4.12.4. OTHER........................................................................................................................................ 13
2.4.13. MAINTENANCE PLAN FOR STORAGE............................................................................................................ 14
2.5. HANDLING ................................................................................................................................................................. 15
2.5.1. HANDLING H LINE MOTORS ...................................................................................................................... 15
2.5.2. HANDLING M LINE MOTORS...................................................................................................................... 15
2.5.3. VERTICAL MOTORS HANDLING..................................................................................................................... 16
2.5.4. VERTICAL MOTORS POSITIONING ................................................................................................................ 16
3. INSTALLATION ......................................................................................................................................................................17
3.1. MECHANICAL ASPECTS ............................................................................................................................................... 17
3.1.1. MOUNTING.................................................................................................................................................. 17
3.1.2. FOUNDATIONS ............................................................................................................................................ 17
3.1.2.1. TYPES OF BASES........................................................................................................................... 18
3.1.3. ALIGNMENT/LEVELING................................................................................................................................. 20
3.1.4. COUPLINGS ................................................................................................................................................. 21
3.1.4.1. COUPLING ARRANGEMENT FOR SLEEVE BEARING MOTORS - AXIAL CLEARANCE ............................. 22
3.2. ELECTRICAL ASPECTS................................................................................................................................................. 23
3.2.1. SUPPLY SYSTEM........................................................................................................................................... 23
3.2.2. CONNECTION .............................................................................................................................................. 23
3.2.3. GENERAL CONNECTION DIAGRAMS.............................................................................................................. 24
3.2.4. CONNECTION DIAGRAMS FOR STATORS AND ROTORS.................................................................................. 25
3.2.4.1. CONNECTION DIAGRAMS FOR STATORS AND ROTORS (Standard IEC 60034-8)............................... 25
3.2.4.2. CONNECTION DIAGRAMS FOR STATORS AND ROTORS (Standard NEMA MG1)................................. 26
3.2.5. ACCESSORIES CONNECTION DIAGRAMS....................................................................................................... 27
3.2.6. ELECTRICAL MOTORS STARTING.................................................................................................................. 29
3.2.6.1. STARTING SQUIRREL-CAGE MOTOR............................................................................................ 29
3.2.6.2. FREQUENCY OF DIRECT STARTINGS.............................................................................................. 29
3.2.6.3. LOCKED ROTOR CURRENT (Ip/In).................................................................................................. 29
3.2.6.4. STARTING OF SLIP RING MOTORS WITH RHEOSTAT...................................................................... 29
3.2.7. MOTOR PROTECTION................................................................................................................................... 30
3.2.7.1. TEMPERATURE LIMITS FOR WINDINGS.......................................................................................... 30
3.2.7.2. SPACE HEATERS............................................................................................................................ 32
3.2.7.3. VIBRATION LIMITS........................................................................................................................ 32
3.2.7.4. SHAFT VIBRATION LIMITS............................................................................................................. 32
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3.3. COMMISSIONING........................................................................................................................................................ 33
3.3.1. PRELIMINARY INSPECTION .......................................................................................................................... 33
3.3.2. START-UP.................................................................................................................................................... 33
3.3.3. OPERATION................................................................................................................................................. 34
3.3.4. SHUTDOWN PROCEDURE ............................................................................................................................. 34
3.4. ACOUSTICAL PROPERTIES.......................................................................................................................................... 34
3.5. MOTOR USED ON HAZARDOUS AREA EXPLOSIVE GAS ATMOSPHERES.......................................................................... 34
3.5.1. GENERAL CARE WITH HAZARDOUS LOCATION MOTORS................................................................................ 35
3.5.2. ADDITIONAL CARE RECOMMENDED FOR HAZARDOUS LOCATION MOTORS.................................................... 35
4. MAINTENANCE.......................................................................................................................................................................36
4.1. CLEANLINESS............................................................................................................................................................. 36
4.1.1. PARTIAL CLEANING...................................................................................................................................... 36
4.1.2. COMPLETE CLEANING .................................................................................................................................. 36
4.2. LUBRICATION............................................................................................................................................................. 37
4.2.1. GREASE LUBRICATED BEARINGS .................................................................................................................. 37
4.2.1.1. LUBRICATION INTERVALS ............................................................................................................. 37
4.2.1.2. TYPE AND AMOUNT OF GREASE..................................................................................................... 40
4.2.1.3. QUALITY AND QUANTITY OF GREASE ............................................................................................ 40
4.2.1.4. COMPATIBILITY ............................................................................................................................ 40
4.2.1.5. LUBRICATING INSTRUCTIONS ....................................................................................................... 41
4.2.1.6. BEARING LUBRICATION STEPS ...................................................................................................... 41
4.2.1.7. SPRING DEVICE FOR GREASE REMOVAL......................................................................................... 41
4.2.1.8. REPLACEMENT OF BEARINGS......................................................................................................... 42
4.2.2. ANTIFRICTION BEARIGS LUBRICATED BY GREASE VERTICAL MOTORS ....................................................... 42
4.2.2.1. CHARACTERISTICS........................................................................................................................ 42
4.2.2.2. RELUBRICATION STEPS................................................................................................................. 42
4.2.2.3. DISASSEMBLY / ASSEMBLY OPPOSITE DRIVE-END BEARING ........................................................ 43
4.2.2.4. DISASSEMBLY / ASSEMBLY DRIVE-END BEARING......................................................................... 44
4.2.3. ANTIFRICTION BEARING LUBRICATED BY OIL............................................................................................... 45
4.2.3.1. LUBRICATION INSTRUCTIONS....................................................................................................... 45
4.2.3.2. BEARING OPERATION.................................................................................................................... 45
4.2.3.3. THERMAL PROTECTIONS SETTING................................................................................................. 45
4.2.3.4. BEARING MAINTENANCE ............................................................................................................... 46
4.2.4. SLEEVE BEARINGS ....................................................................................................................................... 47
4.2.4.1. GENERAL INSTRUCTIONS.............................................................................................................. 48
4.2.4.2. DISASSEMBLY OF THE SLEEVE BEARING SYSTEM (TYPE "EF")......................................................... 48
4.2.4.3. SLEEVE BEARING ASSEMBLY.......................................................................................................... 49
4.2.4.4. SETTING OF THERMAL PROTECTIONS (PT100)............................................................................... 49
4.2.4.5. WATER COOLING SYSTEM ............................................................................................................. 50
4.2.4.6. LUBRICATION ............................................................................................................................... 50
4.2.4.7. SHAFT SEALS................................................................................................................................ 50
4.2.4.8. OPERATION .................................................................................................................................. 51
4.3. AIR GAP CHECKING (LARGE ODP MOTORS) .................................................................................................................... 51
4.4. SLIP RINGS (FOR SLIP RING MOTORS) ............................................................................................................................. 51
4.5. BRUSH-HOLDERS AND BRUSHES (FOR WOUND ROTOR MOTORS)......................................................................................... 51
4.5.1. SHAFT GROUNDING DEVICE......................................................................................................................... 52
4.6. LIFTABLE BRUSH HOLDERS......................................................................................................................................... 53
4.6.1. CONNECTION DIAGRAM............................................................................................................................... 53
4.6.2. PROCEDURE FOR MOTOR STARTING ............................................................................................................ 55
4.6.3. PROCEDURE AFTER MOTOR STARTING......................................................................................................... 55
4.6.4. ASSEMBLY ................................................................................................................................................... 57
4.6.4.1. BRUSH HOLDER LIFTING DEVICE................................................................................................... 57
4.6.4.2. SHORT-CIRCUIT BUSHING MOVEMENT SET.................................................................................... 58
4.6.4.3. BRUSH HOLDER OPERATION SET................................................................................................... 58
4.6.4.3. BRUSH HOLDER OPERATION SET................................................................................................... 59
4.6.4.4. RETURN PIN SET........................................................................................................................... 60
4.6.4.5. BRUSH HOLDER SET...................................................................................................................... 60
4.6.5. DISASSEMBLY.............................................................................................................................................. 61
4.6.6. BRUSHES LIFTING SYSTEM ADJUSTMENT ..................................................................................................... 61
4.7. DRYING OF THE WINDINGS........................................................................................................................................ 61
4.8. DESMANTLING AND REASSEMBLY ............................................................................................................................... 61
4.8.1. " MASTER" LINE........................................................................................................................................... 61
4.8.1.1. ROTOR REMOVING........................................................................................................................ 62
4.8.2. A LINE......................................................................................................................................................... 62
4.8.3. F LINE ......................................................................................................................................................... 62
4.8.4. H LINE......................................................................................................................................................... 63
4.8.5. TIGHTENING TORQUES FOR SCREWS........................................................................................................... 64
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THREE-PHASE INDUCTION MOTORS
1. INTRODUCTION
IMPORTANT:
This manual concerns all Weg three-
phase asynchronous squirrel cage
and slip ring motors. Motors with
specialties can be supplied with
specific documents (drawings, connection
diagram, characteristic curves). These
documents must be carefully evaluated together
with this manual, before proceeding the
installation, operation or maintenance of the
motor.
For motors built with high number of special
features, contact WEG whenever an additional
support is required.
All standard and procedures included in this
manual must be followed accordingly to ensure a
proper operation to the equipment as well as to
ensure safety conditions to the personnel involved
in the motor operation.
Following these procedures is also important for
the warranty policy as explained at the end of this
manual.
Therefore, we strongly recommend to any user of
Weg motors to read carefully this manual before
motor installation and operation. In case you still
have further doubts, please contact WEG.
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The instructions for long term storage described In order to provide the best storage conditions
as follow are valid for motors to be long term to the motor during long standstill periods, the
stored and/or long periods of standstill before storage location should obey rigorously the
the commissioning. criteria described as follow:
The existing tendency, especially during the - Closed storage room with roof;
construction of the plant, of storing the motors - The location must be protected against
for several years before commissioning or to humidity, vapors, aggressive fumes discharge,
install immediately some units, results that the fast heat changes, gnawing and insects.
motors are exposed to influences that cannot be - It must not present corrosive gases such as
evaluated in advance for this time's period. chlorine, sulfur dioxide or acid;
It is difficult to evaluate the different forms of - It must not present continuous or intermittent
stress (atmospheric, chemical, thermal, and severe vibrations.
mechanic) imposed to the motor, which might - To have ventilation system with filter;
happen during storage maneuvers, assembly, - It must not present quickly changes of
initial tests and storage until the temperature;
commissioning. - Ambient temperature (5 C, > t < 60 C) and
Other essential factor is the transportation, for must not present quickly changes of
example, the general contractor may transport temperature;
the motor or the complete unit with motor as - Relative air humidity < 50%;
joint transportation to the installation location. - To have prevention against dirt and dust
The motor internal gaps (air gap, bearings and deposits;
interior of connection box) are exposed to the - To have fire detection system.
atmospheric air and temperature fluctuations. - Electrical supply for space heater and
Due to the air humidity, it is possible the liquid illumination must be provided;
condensation and, depending on the kind and If some of these requisites do not be attended
air contamination degree, aggressive substances by the storage environment, WEG suggests that
may penetrate into these spaces. additional protections be incorporated in the
As a consequence after long periods, the motor packing during the storage period, like
internal components such as the bearings might follows:
get rust, the insulation resistance can decrease - Closed wooden or similar box with electrical
to under the admissible values and the grease installation, enable to the space heaters
lubricant capacity in the bearings is adversely supply;
affected. This influence increases the damage - Closed wooden box or similar with installation
risk before commissioning of the plant. that allows the space heaters be energized;
- If there is a risk of fungus infestation and
To keep manufacturer's warranty, should formation, the packing must be protected in
be insured that the described preventive the storage location by spraying or painting it
measures in this instructions, as: with appropriated chemical agents.
constructive aspects, preservation, - Preparation of packing must be done with
packing, storage and inspections, be greatest care by an experienced person. A
followed and registered. reliable packing company must take over of
the packing.
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THREE-PHASE INDUCTION MOTORS
The outdoor storage of the motor is not - During the storage period, the winding
recommended. insulation resistance of the motor should be
If the external storage cannot be avoided, the measured according to item 2.3.5 of this
motor should be packed in specific packing for manual and registered every 3 months and
this condition, as described bellow. before the motor installation.
- For outdoor storage, besides the packing - Eventual drops in the insulation resistance
recommended above, we recommend to cover level must be investigated.
completely this packing with a protection
against dust, humidity and other strange
materials. 2.4.8. EXPOSED MACHINED SURFACES
- Place the packing in pallets, wooden bunches
or foundations that guarantee the protection - At factory, all exposed surfaces (for example,
against the soil humidity. the shaft edge and flanges) are protected with
- Prevent the packing sink itself in the soil. a temporary protective agent (rust inhibiter).
- After covering the machine, a shed should be - This protective coating should be reapplied
build to protect it of rain, snow and excessive every 6 months at least. When this coating is
sun heat. removed and/or damaged, the same
preventive action must be done.
IMPORTANT
It is recommendable check the storage local Recommended products:
conditions and the motors condition according to Name: Dasco Guard 400 TX AZ, Manufacturer:
the maintenance plan for long term storage, D.A. Stuart Ltda.
described in this manual. Name: TARP, Manufacturer: Castrol.
11
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THREE-PHASE INDUCTION MOTORS
2.4.9. BEARINGS
2.4.9.1. ANTIFRICTION BEARING If is not possible to rotate the shaft of the motor,
LUBRICATED BY GREASE the follow procedure should be used to protect
internally the bearing and the contact surfaces
The bearings are lubricated in the factory for against corrosion:
make the motor tests. - Drain the whole bearing oil;
During the storage period, every two months is - Dismantle the bearing, following the procedure
necessary to remove the shaft brake device and described in the item 4.2.4.2 of this manual;
turn the shaft manually to conserve the bearing in - Clean the bearing;
good conditions. - Apply the anti-corrosive (ex.: TECTIL 511,
After 6 months of storage and before starting in Valvoline or Dasco Guard 400TXAZ) in the
operation, the bearings should be regreased, as bearing, bearing line (top and bottom half)
item 4.2.1.5 of this manual. and in the shaft contact surface of the motor;
If motor is kept in storage for approximately 2 - Assemble the bearing, following the procedure
years or more, the bearings must be inspected described in the item 4.2.4.3 of this manual;
and regreased according to item 4.2 of this - Close all tapped holes with screw plugs;
manual. - Seal the gaps between the shaft and bearing
seal and between bearing seal and bearing
housing by using self-adhesive permanent
2.4.9.2. ANTIFRICTION BEARING tape;
LUBRICATED BY OIL - Connecting flanges (Ex.: Oil inlet and outlet)
must be covered with blank plates.
- Depending on the position, the motor can be - Remove the bearing top sight glass and spray
transported with or without oil in your the corrosion inhibitor on the bearing.
bearings. - Put some desiccant (silica gel) inside of the
- The motor must be stored in its original bearing. The desiccant absorbs the humidity
position of operation and with oil in the and prevents the formation of moisture and
bearings; water condensation inside the bearing.
- The oil level should be respected, remaining in - Close the bearing tightly with the top sight
the half the oil sight glass. glass.
During the storage period, every two months is
necessary to remove the shaft brake device and In case the standstill period is longer then 6
turn the shaft manually to conserve the bearing in months:
good conditions. - Repeat the procedures described above.
After 6 months of storage and before starting in - Replace the desiccant (silica gel) into the
operation, the bearings should be relubricated, as bearing each six months.
item 4.2.3.1 of this manual.
If motor is kept in storage for approximately 2 In case the standstill period is longer than 2
years or more, the bearings must be inspected years:
and relubricated according to item 4.2 of this - Dismantle the bearing;
manual. - Preserve and store the bearing parts.
- Depending on the position, the motor can be - The brushes of the slip rings motors should be
transported with or without oil in your lifted in the brush-holder, because should not
bearings; remain in contact with the slip-rings during the
- The motor must be stored in its original storage period, avoiding thus the slip-rings
position of operation and with oil in the oxidation.
bearings; - Before the motor installation and
- The oil level should be respected, remaining in commissioning, the brushes should come back
the half the oil sight glass; to the original position.
- During the storage period, every two months is
necessary to remove the shaft brake device
and rotate at about 30 rpm for the oil
circulation and to conserve the bearing in good
conditions.
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2.4.12.1. CLEANING
13
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During the storage period, the motor maintenance must be executed and registered according to the plan
described in the table below:
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THREE-PHASE INDUCTION MOTORS
H LINE
Notes:
1) Lifting lugs on the frame are designed for
lifting machine only. Do not use for lifting
coupled equipment such as pumps,
compressors, gears or other equipment;
2) The chains or handles of hoisting must
have on maximum angle of 30 with
regard to vertical line:
3) Use all of eyebolts fixed in the frame,
supplied together with the motor;
4) Failure to observe these precautions may Notes:
result in damage to the equipment, injury 1) Do not the motor by the heat exchanger;
to personnel or both. 2) Lifting without heat exchanger;
3) If gravity center is not exactly in the
middle of the lifting lugs, use one of the
ways as per item 3.
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Electric motors should be installed in locations of The motor base must be level and free from
easy access for inspection and maintenance. If vibrations. For this reason, concrete foundation is
the surrounding atmosphere contains humid, recommended.
corrosive or flammable substances or particles, it The type of base to be built will depend on the
is essential to ensure an adequate degree of nature of the soil at the installation site or on the
protection. The installation of motors in ambient floor capacity.
where there are vapours, gases or dusts, When designing the motor foundation, it must be
flammable or combustible materials, subject to taken into consideration the fact that the motor
fire or explosion, should be done in accordance might, occasionally, be submitted to a torque
with ABNT NBR, NEC Art. 500 (National Electrical higher than the rated torque. If such designing is
Code) and UL-674 (Underwriters Laboratories, not correctly made, vibration problems can occur
Inc.) Standard. to the unit (foundation, motor and driven
Under no circumstances, motors can be enclosed machine).
in boxes or covered with materials which may
impede or reduce the free circulation of cooling NOTE: On the concrete base, a metallic plate to
air. Motors fitted with external cooling must be support the leveling bolt must be provided.
located at least 50mm from the ground to permit
free air circulation. The air inlet and outlet should Based on figure 3.1, the forces over the
never be obstructed or reduced by conductors, foundation can be calculated by the following
pipes or other objects. The installation site should formulas:
permit conditions of air renewal at a rate of 30m (4C max)
per minute for each 100kW motor output.
F1 = +0.5.m.g . +
( A)
(4C max)
F2 = +0.5.m.g.
3.1. MECHANICAL ASPECTS ( A)
Where:
3.1.1. MOUNTING F1 and F2 - Forces on the base (N).
g - Gravity acceleration (9.81m/s).
In order to ensure the adequate operation, in m - Motor mass (kg).
additional to a stable foundation, the motor must Cmax - Breakdown torque (Nm).
be precisely aligned with the coupled equipment A - Taken from motor dimensional drawing (m).
and the components mounted on the shaft end
must be adequately balanced.
Notice:
With the machine mounted and coupled, the
relation between the foundation natural frequency
and:
- The motor speed frequency;
- The double speed frequency;
- The double line frequency.
Foundation natural frequency of higher order: NOTE: The drawing above shows the forces over
- +10% or -10% in relation to the above the motor when running clockwise. For counter
frequencies. clockwise rotation, forces are reversed (F1, F2,
4.Cmax.).
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Steel or iron blocks, plane surfaces blocks with 3.1.2.1. TYPES OF BASES
anchorage devices can be fitted in the concrete
foundation to fix the motor feet as suggested in a) Concrete bases
figure 3.2. It is important that all the structure As mentioned above, the concrete bases are the
equipment are made in such a way that they can most commonly used for the fixation of these
transmit any force or torque which may occur motors.
during the operation. The type and size of the foundation - as well as
other fixing devices for this purpose will depend
on the type and size of the motor.
The motors can be mounted on a concrete base
with four foundation blocks. See dimensions of
the installation components in the table below.
Installation and examples:
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THREE-PHASE INDUCTION MOTORS
Mounting dimensions
Thread
s t u v w
M26 and M30 50 450 220 265 315
M36 70 539 240 300 350
M42 70 600 270 355 400
Table 3.1. - Anchorage measurements (example of installation).
Examples of preparation:
Remove all dirt from the foundation blocks in
order to ensure a perfect anchorage between
the foundation blocks and the motor. Fix the
foundation blocks at the motor feet by means of
bolts.
Provide shims of different thickness (total
trickiness of about 2mm) between the motor
feet and the foundation base to ensure a further
accurate alignment vertically.
Inside the feet holes, the fastening bolts must
be covered with a metal sheet or presspan in
order to center the foundation blocks exactly to
the feet holes and perform an accurate
alignment horizontally.
Figure 3.3 - Example 1. Place shims or leveling bolts under the
foundation blocks in order to obtain a perfect
motor leveling and alignment between the
motor and the driven machine. After introducing
the concrete, make an accurate control of the
alignment. Eventual small corrections can be
done by washers or metal plates or by means of
a new adjustment of the fastening bolt
clearences. Tighten now firmly all fastening
bolts.
Make sure all motor feet surfaces are supported
uniformly without damaging motor frame. After
completing the test, introduce two tapered pins
for correct fastening. For this purpose, use the
pre-drilled holes in the feet.
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Figure 3.5.
c) Metallic bases
The metallic bases must have a flat surface under
motor feet in order to avoid frame deformation.
The bearing housing surface should be so Figure 3.6b Concentricity deflection.
determined that under the feet of the motor one
can place shim plates of approximately 2mm On the alignment/leveling it is important to take
thickness. into consideration the effect of the temperature
Motor should not be removed from their common over the motor and driven machine. The different
metallic bases for alignment, the metallic bases expansion levels of the coupled machines can
should be leveled on the actual foundation. modify the alignment/leveling during motor
When a metallic base is used to adjust the height operation.
of the motor shaft end with the machine shaft
end, it should be leveled on the concrete base. After the set (motor and base) is perfectly aligned
After the base has been leveled, foundation studs either at cold or at hot, motor must be bolted, as
tightened, and the coupling checked, the metal shown in figure 3.7. There are instruments which
base and the studs are then cemented. use visible laser ray added by specific computer
programs that can perform and ensure high
precision alignment.
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THREE-PHASE INDUCTION MOTORS
Figure 3.7.
3.1.4. COUPLINGS
Figure 3.10.
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RUNNING: Avoid unnecessary thrusts on the Due to the existing tensions on the belts, there is
bearings by ensuring that the shafts are parallel a reaction acting as radial load over the motor
and the pulleys perfectly aligned (figure 3.11). shaft end.
Laterally misaligned pulleys, when running, The data to calculate such reaction (radial force)
transmit alternating knocks to the rotor and can are:
damage the bearing housing. Belt slippage can be - Output transmitted [kW] (P);
avoided by applying a resin type material such as - Motor speed [rpm] (RPM);
rosin. - Diameter of driven pulley [mm] (DPMV);
- Diameter of driven pulley [mm] (DPMT);
- Distance between centers [mm] (I);
- Friction coefficient [-] (MI) - (normally 0.5);
- Slip coefficient [-] (K);
- Belt contact angle on smaller pulley [RAD]
(alfa);
- FR: Radial force acting over the shaft end [N]
(FR).
DPMV DPMT
ALFA =
1
(MIxALFA ) + 1
K = 1. 1x
(MIxALFA ) 1
18836, 25N K 2 x[1 COS ( ALFA ] + 1.21x[1 + COS ( ALFA )]
FR = x
DPMTxRPM 2
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3.2.2. CONNECTION
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The following connection diagrams show terminals identification in the connection box and the possible
connections for stator (phases) and rotor of the three-phase induction motors.
The described numbers in each diagram of the table below, serves for the user identify the correspondent
motor connection diagram through the nameplate fixed on the motor, where are described the code
numbers correspondent to the stator, rotor and accessories connection diagrams.
3.2.4.1. CONNECTION DIAGRAMS FOR STATORS AND ROTORS (Standard IEC 60034-8)
3 TERMINALS
+ NEUTRAL
9121
LOWER HIGHER LOWER LOWER HIGHER
SPEED SPEED SPEED SPEED SPEED
9 TERMINALS 12 TERMINALS
9107 9108 9109 9110 9111 9112 9113 9114
YY Y YY Y
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3.2.4.2. CONNECTION DIAGRAMS FOR STATORS AND ROTORS (Standard NEMA MG1)
3 TERMINALS
+ NEUTRAL
9221
LOWER LOWER HIGHER
LOWER HIGHER
SPEED SPEED SPEED
SPEED SPEED
9 TERMINALS 12 TERMINALS
9207 9208 9209 9210 9211 9212 9213 9214
YY Y YY Y
DIRECTION OF ROTATION
- The direction of rotation is described on the motor nameplate and shall be that of the shaft observed
when facing the D-end.
- Machines with terminal markings according to the chapter 3.2.4.1 and 3.2.4.2 of this manual have a
clockwise direction of rotation.
To invert the direction of the rotation must be inverted the connection of two phases. The motors with only
one direction of rotation, shown by the motor nameplate and an arrow located on the frame possess
unidirectional fan and must only operate in the specified direction. If is really necessary to invert the
direction of the rotation, WEG must be consulted.
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The following connection diagrams shown terminals identification in the connection box and the connection
diagrams for accessories of the three-phase induction motors.
The described numbers in each diagram of the table below, serves for the user identify the accessories
connection diagram through the nameplate fixed on the motor, where are described the code numbers
correspondent to the stator, rotor and accessories connection diagrams.
ALARM TRIPPING
9032 9036
IN WINDING IN THE BEARINGS
2 PER PHASE IN SERIES 1 PER BEARING
THERMISTORS
9025 9026 9027
IN WINDING IN WINDING IN WINDING
1 PER PHASE 1 PER PHASE IN SERIES 2 PER PHASE
ALARM TRIPPING
9028 9035
IN WINDING IN THE BEARINGS
2 PER PHASE IN SERIES 1 PER BEARING
FRONT REAR
ALARM TRIPPING
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ALARM TRIPPING
SUPPLEMENTARY ACCESSORIES
In motors with more than 1 bearing for support, the sensor of temperature used in the extra bearing is
identified with the corresponding number to the first bearing preceded of the number 1 (for 1 extra bearing)
or 2 (for 2 extra bearings) Example: Motor with rear support composed of 2 bearings - 1 PT100 with 3 wires
for bearing. The first bearing is identified with numeration 70 - 70 - 71 and the second bearing with
numeration 170 - 170 - 171.
The same rule described above applies also for extra sensors in the stator or extra thermometers in the
bearings.
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If direct starting is not feasible, either due to For starting of slip ring motors an external
restrictions imposed by the utility or due to the rheostat is connected to the rotor by means of a
installation itself, reduced voltage indirect starting set of brushes and slip rings.
methods can be used in order to reduce the The extra rotor resistance is held in the circuit
starting current. during the starting to reduce the starting current
and increase torque. Furthermore, it is possible to
These indirect starting methods (reduced voltage) regulate the external resistance so as to have a
are: starting torque equal to, or close to the motor
- Wye-delta switch; breakdown torque.
- Series-parallel switch;
- Compensating Switch or self-transformer; NOTE: Every time customers intend to use other
- Static starting switch or soft-start; than direct starting, inform WEG Mquinas in
- Frequency Inverter. advance so we can analyze the starting torques
required by the load.
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1. Overload with 1.2 times the rated current. unprotected totally protected totally protected
4. Operation with more than 15 starts p/hour. unprotected partially protected totally protected
C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
NOTE: When motors are supplied with accessories T-box, the connection terminals for thermal protectors
and other accessories are fitted in this T-box.
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Vibration Levels (mm/s RMS) Operate the motor with shaft vibration
Rated speed 355 values close to alarm and tripping values
(rpm) Frame < 355 to > 630 can damage bearing liners.
630
Alarm 4.5 4.5 5.5 The main reasons to cause increase of vibration
600 n 1800 are:
Tripping 7.0 7.0 8.0
- Unbalance coupling problems and others that
Alarm 3.5 4.5 5.5 can affect the machine;
1800 < n 3600
Tripping 5.5 6.5 7.5 - Shaft manufacturing problems, which are
minimized during the manufacturing;
Table 3.5.
- Residual voltage or magnetism on the shaft
surface where measurement is made;
Vibration causes most frequently found on the
- Scratches, knocks or vibrations when finishing
field are:
the shaft where measurement is made.
- Misalignment between motor and driven
machine;
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3.3. COMMISSIONING
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Run the motor coupled to the load for a period of Day by day, electrical motors are increasingly
at least one hour to check if abnormal noises or used in offices and homes. Under these
sign of overheating occur. If there will be circumstances, it is essential that motors operate
excessive vibrations in the unit between the initial silently and safe without contributing to ambient
operation condition and the condition after discomfort. The solution lies in the ever closer
thermal stability, alignment and leveling must be collaboration of the user and the motor
rechecked. Compare the line current drawn with manufacturer.
the value shown on the nameplate. The proper planning of home, office and factory
Under continuous duty without load fluctuation, acoustics requires knowledge of the sources of
this should not exceed the rated current times the motor noises and how they affect the ambient
service factor, also shown on the nameplate. noise level wherever motors are located.
All measuring instruments and devices should be The following parts of a motor can generate noise
continuously checked in order to correct any within the audio-frequency range:
abnormal operation, if required. 1) Cooling system.
On slip-ring motors, the real load condition of the 2) Brushes.
motor in duty, must be investigated, and if 3) Bearings.
necessary, specify again the set of brushes. In 4) Magnetic circuit.
case of doubt consult WEG Mquinas.
The part of the motor mainly responsible as noise
source depends on its size, speed, degree of
3.3.4. SHUTDOWN PROCEDURE mechanical protection (casing) and of the driven
machine design. Cooling system noise is airborne
and usually affects only the noise level in the
Before proceed any tasks on the motor, it is ambient where motor is installed. How ever, it is a
extremely important to observe the following: to different matter if the noise source is in the
touch any moving part on a running motor, even bearings or in the magnetic circuit. In this case,
switched-off, is a danger to life. the noise is due to mechanical vibration of the
part itself, or of the entire motor, and the sound
a) THREE-PHASE SQUIRREL CAGE MOTORS: is spreaded through the foundation, walls or
It suffices to open stator circuit switch, and ducts. This type of sound propagation, via
with the motor stopped, reset the structural components of an installation, can be
auto-transformer, if any, to the "start" reduced by installing the motor on suitable
position; designed vibration dampers. It is important to
note that improper dampers can even increase
vibration.
b) THREE-PHASE SLIP RING MOTORS: Open
the stator circuit switch. When the motor is
stopped, reset the rheostat to the "start"
position. 3.5. MOTOR USED ON HAZARDOUS
AREA EXPLOSIVE GAS ATMOSPHERES
*** WARNING ***
The motor connection boxes equipped Motors designed for hazardous areas are fitted
capacitors do not have to be opened with additional safety features which are defined
before the discharge time: in specific standards for each type of hazardous
Time of discharge of the capacitors: 5 location, based on its classification.
minutes after the disconnection of the The general requirements for electrical apparatus
motor. for hazardous locations are described in the
following Brazilian and foreign standards,
respectively:
NBR 9815 = Electrical apparatus for explosive gas
atmospheres.
General requirements (specifications)
IEC 79-0 = Electrical apparatus for explosive gas
atmospheres.
EN 50014 = Electrical apparatus for potentially
explosive atmosphere.
General requirements
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4.2.1. GREASE LUBRICATED BEARINGS WEG motors are supplied with POLYREX EM
103 grease (Supplier: Esso) up to frame 450 and
The purpose of this maintenance is to lengthen STABURAGS N12MF grease (Supplier Klber)
bearing life. for frame 500 and above, enough for the
operating time period indicated on the data sheet
Maintenance includes: and on the bearing identification nameplate.
a) Attention to the overall status of the bearings;
b) Cleaning and lubrication; Lubrication intervals depend on the size of the
c) Inspection in details of the bearings. motor, speed, working conditions, type of grease
used and working temperature.
Motor noise should be measured at regular The lubrication period and type of bearings are
intervals of one to four months. A well-tuned ear indicated on the motor nameplate.
is perfect capable of distinguishing unusual Motors kept in stock should be
noises, even with rudimentary tools such as a relubricated every six months. Once
screwdriver, etc. For a more reliable analysis of each 2 months, shaft must be in
the bearings, sophisticated equipment is required. order to have the grease
homogenized.
Bearing temperature control is also Lubrication intervals, amount of grease and
part of routine maintenance. The bearings used on the motors are indicated in
temperature rise of grease Tables 4.2a and 4.2b, as reference values.
lubricated bearings as
recommended under item 4.2.1.2 should not
exceed 60C (T = 60C/max. ambient = 40C, The bearings data, amount and type of
absolute temperature = T + ambient) measured grease and lubrication interval informed
at the external bearing cap. in the nameplate attached in the motor.
Before the procedure of bearings
Constant temperature control can be done by lubrication, we recommend that these
means of external thermometers or by embedded data are verified.
thermal elements.
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MAXIMUM LUBRICATION INTERVALS (IN HURS) FOR HORIZONTALLY MOUNTED MOTORS - 60Hz
NDE Bearing NDE Bearing slip NDE Bearing slip
DE Bearing (with
DE Bearing (squirrel cage ring motor (Fixed ring rotor
Frame Poles pulley)
rotor) brushes) (Lifting brushes)
Bearing Relubr. Bearing Relubr. Bearing Relubr. Bearing Relubr. Bearing Relubr.
2 6314 3.400 6314 3.400
4 6.400 2.000 8.900 6.600 6.600
315
6 6320 10.000 NU322 4.500 6316 10.000 6222 10.000 6222 10.000
8 10.000 6.400 10.000 10.000 10.000
2 6314 3.400 6314 3.400
4 4.800 1.600 6.400 5.800 5.800
355
6 6322 8.700 NU324 3.900 6320 10.000 6224 10.000 6224 10.000
8 10.000 5.800 10.000 10.000 10.000
4 2.200 1.400 6.400 5.100 3.400
400 6 NU224 4.900 NU228 3.700 6320 10.000 6226 9.300 6230 6.900
8 6.800 5.500 10.000 10.000 9.800
4 2.200 4.800 3.400 6234 2.500
450 6 NU224 4.900 6322 8.700 6230 3.400 5.600
6234
8 6.800 10.000 3.400 8.400
4 1.800 4.800 3.400 2.500
500 6 NU226 4.300 6322 8.700 6230 6.900 6234 5.600
8 6.200 10.000 9.800 8.400
4
6 NU228 3.700 5.500 3.100 2.300
8 5.500 7.500 4.900 3.900
560 NU222 NU230 NU234
4
6 NU232 2.700 5.500 3.100 2.300
8 4.400 7.500 4.900 3.900
4
6 1.200 4.900 3.100 2.300
8 23032 2.200 6.800 4.900 3.900
10 3.100 8.100 6.300 5.200
12 3.800 9.000 7.300 6.200
630 NU224 NU230 NU234
4
6
8 23036 1.600 6.800 4.900 3.900
10 2.400 8.100 6.300 5.200
12 3.100 9.000 7.300 6.200
6
8 1.600 6.200 4.400 3.900
23036
10 2.400 7.500 5.700 5.200
12 3.100 8.400 6.700 6.200
710 NU226 NU232 NU234
6
8 1.300 6.200 4.400 3.900
23040
10 2.000 7.500 5.700 5.200
12 2.600 8.400 6.700 6.200
Grease: Polyrex EM 103 (Esso) Grease: Staburags N12MF (Klber)
Table 4.2a.
NOTES:
- Normal relubrication interval for ambient temperature of 40C and types of grease specified above;
- For vertically mounted motors, reduce relubrication intervals by half;
- Bearing operating temperature = 70C;
- Apply correction factors given below for relubrication intervals of table above on the following cases:
- Operating temperature below 60C: 1.59.
- Operating temperature of 70C to 80C: 0.63.
- Operating temperature of 80C to 90C: 0.40.
- Operating temperature of 90C to 100C: 0.25.
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MAXIMUM LUBRICATION INTERVALS (IN HURS) FOR HORIZONTALLY MOUNTED MOTORS - 50Hz
NDE Bearing NDE Bearing slip NDE Bearing
DE Bearing (with
DE Bearing (squirrel cage ring motor (Fixed slip ring rotor
Frame Poles pulley)
rotor) brushes) (Liftable brushes)
Bearing Relubr. Bearing Relubr. Bearing Relubr. Bearing Relubr. Bearing Relubr.
2 6314 4.900 6314 4.900
4 8.300 3.000 10.000 8.500 8.500
315
6 6320 10.000 NU322 5.700 6316 10.000 6222 10.000 6222 10.000
8 10.000 7.600 10.000 10.000 10.000
2 6314 4.900 6314 4.900
4 6.500 2.500 8.300 7.700 7.700
355
6 6322 10.000 NU324 5.100 6320 10.000 6224 10.000 6224 10.000
8 10.000 6.900 10.000 10.000 10.000
2 6317 3.400 6317 3.400
4 3.300 2.300 8.300 6.900 4.800
400
6 NU224 6.100 NU228 4.900 6320 10.000 6226 10.000 6230 8.700
8 7.900 6.700 10.000 10.000 10.000
4 3.300 6.500 4.800 6234 3.700
450 6 NU224 6.100 6322 10.000 6230 8.700 7.300
6234
8 7.900 10.000 10.000 10.000
4 2.800 6.500 4.800 3.700
500 6 NU226 5.500 6322 10.000 6230 8.700 6234 7.300
8 7.300 10.000 10.000 10.000
4 2.300 3.900 1.900 1.300
6 NU228 4.900 6.800 4.300 3.300
8 6.700 8.600 6.100 5.000
560 NU222 NU230 NU234
4
6 NU232 3.800 6.800 4.300 3.300
8 5.500 8.600 6.100 5.000
4
6 1.800 6.100 4.300 3.300
8 23032 2.900 7.900 6.100 5.000
10 3.800 9.000 7.300 6.200
12 4.400 9.600 8.000 7.100
630 NU224 NU230 NU234
4
6 1.300 6.100 4.300 3.300
8 23036 2.300 7.900 6.100 5.000
10 3.100 9.000 7.300 6.200
12 3.700 9.600 8.000 7.100
6 1.300 5.500 3.800 3.300
8 2.300 7.300 5.500 5.000
23036
10 3.100 8.400 6.700 6.200
12 3.700 9.100 7.600 7.100
710 NU226 NU232 NU234
6 1.000 5.500 3.800 3.300
8 1.800 7.300 5.500 5.000
23040
10 2.600 8.400 6.700 6.200
12 3.200 9.100 7.600 7.100
Grease: Polyrex EM 103 (Esso) Grease: Staburags N12MF (Klber)
Table 4.2b.
NOTES:
- Normal relubrication interval for ambient temperature of 40C and types of grease specified above;
- For vertically mounted motors, reduce relubrication intervals by half;
- Bearing operating temperature = 70C;
- Apply correction factors given below for relubrication intervals of table above on the following cases:
- Operating temperature below 60C: 1.59.
- Operating temperature of 70C to 80C: 0.63.
- Operating temperature of 80C to 90C: 0.40.
- Operating temperature of 90C to 100C: 0.25.
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Grease options
CONSTANT OPEARATING
SUPPLIER GREASE APPLICATION
TEMEPRATURE (C)
ESSO UNIREX N2 (LITHIUM BASE) (-35 to +175)
PETROBRAS LUBRAX GMA-2 (LITHIUM BASE) (0 to +130) NORMAL
ALVNIA R3 (LITHIUM BASE) (-35 to +130)
SHELL
AEROSHELL 7 (MICROGEL) (-55 to +100)
LOW TEMEPRATURE
ESSO BEACON 325 (LITHIUM BASED) (-50 to +120)
Table 4.3b.
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To avoid any possible incompatibility grease For lubrication, use only a manual grease gun.
problem we recommend performing an
appropriate lubrication which can be summarized
as follows: after removing the old grease and
caring out a complete cleanliness of the grease
cavity, new grease must be pumped in. When this
procedure is not allowed, pump in new grease by
pressure. This must be repeated until new grease
is drained out through the grease relief.
As a general rule, greases with same soap type
are compatible. However depending on the
mixture rate, they can then be recommended to
mix different types of grease before contacting a
service agent and/or WEG.
Same and basic oils can not be mixed as they will
not produce a homogeneous mixture. In this case, Figure 4.2. - Bearings and lubrication system.
either a hardening or a softening (or drop of the
resulting mixture melting point) can occur.
4.2.1.6. BEARING LUBRICATION STEPS
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6. This grease must be removed by pulling the During assembly, bearings cannot be subjected to
spring through bolt and then cleaning the direct blows. To make the assembly easier, it is
spring. This procedure must be carried out as recommended to heat up (inductive heater) the
many times as it is required up to the point no bearing.
grease is on the spring. The aid used to press or strike the bearings
7. Check bearing temperature to make sure there should be applied to the inner ring.
has not been any major modification.
4.2.2.1. CHARACTERISTICS
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Before disassembly
- Remove the prolongation tubes of the grease Opposite drive-end bearing reassembly
inlet and outlet; - Clean the bearings completely and inspects the
- Remove the sun shade, cover, fan and other removed parts and the interior of the caps.
components that are in the rear side as sun as - Certify that the bearing, shaft and bearing
the shaft end becomes free for bearing caps surfaces be smooth.
removing. - Put the recommended grease
- Clean completely the outside of bearings. on of the external and
- Remove the temperature detectors from the internal bearing cap deposit and
bearings and provide a prop for support the lubricate the bearing with
shaft and avoid damages. sufficient quantity of grease before reassemble
it.
Opposite drive-end bearing disassembly - Before place the bearing on the shaft, heat the
Care must be taken to avoid damage on the ball bearing to a temperature between 50C and
or roller and shaft surface. 100C. For reassembling the bearings, follow
For disassemble the bearing, follows carefully the the instructions of disassembly in the inverse
instructions below: order.
Keeps all the parts disassembled in an insurance
local.
1) Remove the fixation nut (16)
2) Remove the grease relief (17);
3) Remove the closed external ring (6);
4) Remove the screws (12) which fasten the
external bearing cap;
5) Remove the external bearing cap (2);
6) Remove the screws (11 and 13);
7) Remove the rear cover (8);
8) Remove the external bearing (14), separator
ring (4) and internal bearing (15);
9) Remove the screw which fasten the grease
valve (3) and remove it;
10) Remove the internal bearing cap (1) if
necessary.
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4.2.3. ANTIFRICTION BEARING - The oil selected for the application must have
LUBRICATED BY OIL the adequate viscosity for the bearing
operating temperature. The type of oil
4 recommended by WEG already considers these
criteria.
1 1- Oil inlet
- Insufficient amount of oil can damage the
2- Oil sight glass bearings.
- The minimum recommended oil level is
2 reached when the lubricant can be seen
3- Oil outlet
touching the bottom part of the oil sight glass,
4- Temperature sensor with the motor in the idle condition.
3 The oil level must be checked
daily, being kept approximately
4.2.3.1. LUBRICATION INSTRUCTIONS in the middle of the oil sight
glass.
Oil removal
When re-lubrication is necessary, please remove
4.2.3.2. BEARING OPERATION
the oil outlet (3) and oil inlet (1) plugs and quit
The operation of motors equipped with oil-
the oil completely.
lubricated bearings is similar to the operation of
motors equipped with grease-lubricated bearings.
For oil insertion in the bearing:
The bearings performance during start up must
- Close the oil outlet (3) with the drain plug;
be carefully checked as well as their performance
- Remove the filter in the oil inlet (1), if any.
during the first running hours.
- Add the type and amount of oil up to the level
Before running the motor, check:
indicated in the oil sight glass.
- If the oil being used is the same as the oil
recommended on the bearings nameplate.
NOTES:
- The oil characteristics;
1) Make sure that all the openings are closed and
- The oil level;
that there is no indication of oil leakage in the
- The alarm and trip point for bearings
oil reservoir or seals.
temperatures;
2) The proper oil level is obtained when the
During the first starting, pay special attention for
lubricant can be seen in the middle of the oil
excessive vibration or noise when the motor is
sight glass.
running uncoupled. The motor and bearings
3) Excessive amount of oil will not damage the
should operate quietly and under low vibration.
bearings, but it can cause the oil to leak
Have a copy of the factory vibration test report so
through the seals.
you can compare the results obtained during the
test with the results obtained after the
Oil characteristics installation. The motor must run for several hours
The type of lubricant, lubrication interval and type until the temperature of the bearings stabilize.
of bearings are indicated on the motor nameplate If abnormal bearing operating temperature is
like to the bearing. noticed, the motor must be shut down and the
Oil change - The change of the oil in the installation, bearings and sensors must be re-
bearings should be made according to the table checked. Check the whole bearing system (oil
below, referring the bearing working temperature: reservoir, seals) to make sure there is no oil
leakage.
Below of 75C = 20,000 hours
Between 75 and 80C = 16,000 hours
Between 80 and 85C = 12,000 hours 4.2.3.3. THERMAL PROTECTIONS SETTING
Between 85 and 90C = 8,000 hours Each bearing is fitted with a Pt100 temperature
Between 90 and 95C = 6,000 hours detector installed directly in the bearing liner near
Between 95 and 100C = 4,000 hours the point where the load is applied. This device
must be connected to a controlling panel with the
IMPORTANT:
purpose of detecting overheating and protect the
The bearings lifetime, their operating conditions
bearing when operating under high temperature.
and motor operating conditions will depend on the
procedures followed by the maintenance
IMPORTANT: The following
personnel. The following recommendations must
temperature must be set on the
be observed.
bearing protecting system:
ALARM 100C / TRIPPING OFF 120C
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To disassemble the drive-end bearing, please 9) Remove the spherical roller bearing (7);
follow carefully the instructions given below. 10) If it is necessary to completely disassemble
the bearing, remove the internal bearing cap
Before disassembling (6) and the internal oil reservoir (2).
- Clean completely the outside of bearing;
- Remove the drain plug (12); Opposite drive-end bearing reassembly
- Remove all of the oil from the bearings; - Clean the bearings completely and inspect the
- Remove the temperature detectors (15) from parts and the bearing cap.
the bearing; - Certify that the bearing, shaft and bearing cap
- Remove the grounding brush (if any); surfaces are smooth, with no sign of pitting or
- Provide a support to the shaft so it can rest scratches.
during disassembly. - Before inserting the bearing to the shaft, heat
the bearing to a temperature between 50C
Opposite drive-end bearing disassembly: and 100C.
- Use extra caution to avoid any damage to the - To reassemble the bearing, follow the
balls, rollers and shaft surface. instructions of disassembling in the reverse
- To disassemble the bearing, carefully follow order.
the instructions below:
- Keep all the parts disassembled in a safe and Attention
dust free environment. When reassembling, apply Curril T to seal the
1) Remove the screw (9) that fixes the ring to surfaces of the oil reservoir.
the labyrinth seal (8);
2) Remove the ring with the labyrinth seal (8); NOTE: The motors can be supplied with filter
3) Remove the screws (16) that fixes the (10) in the location indicated on the drawing
external oil reservoir (1); above or in the oil inlet.
4) Remove the external oil reservoir (1);
5) Remove the screw (14) that fixes the
external bearing cap (3);
6) Remove the external bearing cap (3);
7) Remove the screws (5) that fix the oil
retaining ring (4) and remove it;
8) Remove the rear cover (17);
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Figure 4.5.
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4.2.4.1. GENERAL INSTRUCTIONS - Loosen and remove the bolts (6) that join the
top and bottom half of the bearing housing (2
Sleeve bearing performance is dependent on and 5).
proper installation, lubrication and maintenance. - Use the lifting eyebolts (9) to lift (by hand or
hoist) the top half of bearing housing(5)
Before assembling the bearing carefully read all
straight up, so that the cap is completely
instructions contained herein to become familiar disengaged from the lower halves of the
with the complete bearing assembly procedure. stationary baffle (11) labyrinth seals, labyrinth
A proper maintenance of sleeve bearings include seal carrier (20) , and the bearing liner (12).
periodical checking of the level and actual - Pull the top bearing housing forward out of
condition of the lubricating oil, checking of noise and away from the bearing area. Loosen and
level and vibration of the bearings, follow-up of remove the bolts (19) securing the top half of
the operating temperature, and fastening of the the stationary baffle. Loosen and remove the
fixing and assembly bolts. The frame must be bolts (10) securing the upper half of the seal
kept clean, free from dust, oil and dirt to facilitate carrier (20).
- Lift (by hand or hoist) the upper half of the
cooling system.
bearing liner (13) and remove it.
Threaded holes for connecting the thermometer, - Loosen and remove the bolts at the split line of
oil sight glass, oil inlet, and immersion heater, or the oil ring (14). Carefully disengage the
cooling coil (for oil sump thermometer or dowels holding the oil ring halves together and
circulating pump with adapter) are provided on remove the oil ring.
either side, so that all connections can be made - Remove the garter springs that encircle the
on the right or left side of the bearing housing as labyrinth seals and remove the top half of each
required. seal. Rotate the bottom half of each seal out
The oil drain plug is located centrally on the of the grooves in the seal carrier and bearing
underside of the bearing housing. housing and remove them.
In case of circulating oil lubrication, the outlet - Disconnect and remove RTD's, thermocouples,
or any other temperature detecting
connection should be screwed into the threaded instruments that enter the lower half of the
hole of an oil sight glass. bearing liner.
If the bearing is electrically insulated, the - Using a hoist or jack, raise the shaft slightly so
spherical liner seat surfaces in the housing are that the lower half of the bearing liner can be
lined with a non-conducting material. rolled out of the bearing housing.
Do not remove this lining. IMPORTANT: To make that feasible it is
The antirotation pin is also insulated and the shaft necessary that bolts 4 and 6 of the other bearing
seals are manufactured from a special non- half be loose.
conducting material. - Roll out (be careful not to use excessive force)
Temperature monitoring instruments with contact the lower half of the bearing liner and remove
it.
to the bearing liner should be insulated
- Loosen and remove the bolts (19) securing the
appropriately (i.e., insulated protection tubes, bottom half of the stationary baffle (11) to the
synthetic fittings, etc.) seal carrier. Loosen and remove the bolts (10)
Water-cooled bearings are provided with the securing the bottom half of the seal carrier
cooling coil installed. Care must be taken to (20) to the bearing housing. Remove the seal
protect the connections from damage when carrier.
handling the housing prior to installation. - Loosen and remove the bolts (4). Remove the
bottom bearing housing (2).
4.2.4.2. DISASSEMBLY OF THE SLEEVE - Remove the frame cover (3).
BEARING SYSTEM (TYPE "EF") - Loosen and remove the bolts (8) securing the
To disassemble the bearing liner and all machine seal (7) to the frame cover. Remove
associated parts from the bearing housing, carry the machine seal.
out the following instructions. Carefully store all - Thoroughly clean and inspect all individual
disassembled parts in a safe location (see figure parts which have been removed. Clean the
4.5). interior of the bearing housing.
- To reassemble the bearing system, follow the
preceding instructions in the reverse order.
Drive end side:
NOTE: Festening torque of the bearing fixing
- Throughly clean the exterior of the bearing
bolts to the motor = 10 Kgfm.
housing. Loosen and remove the oil drain plug
(1) at the bottom of the bearing housing.
Non drive end side:
Drain the oil from the bearing housing.
- Thoroughly clean the exterior of the bearing
- Loosen and remove the bolts (4) that connect
housing. Loosen and remove the oil drain plug
the top half of the bearing housing (5) to the
(1) at the bottom of the bearing housing.
motor frame cover(3).
Drain the oil from the bearing housing.
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- Loosen and remove the bolts (19) and remove Apply oil to spherical seats in the housing base
the external cover (11). and the shaft and rotate the bottom liner half (12)
- Loosen and remove the bolts (4) that fix the into position. Special care must be taken so that
top bearing housing (5) to the motor frame the axial surfaces of the locating bearing are not
cover(3). damaged.
- Loosen and remove the bolts (6) that join the After the split faces of the bottom liner half and
top and bottom half of the bearing housing (2 the housing base are aligned, lower the shaft into
and 5). place. With a slight hammer blow against the
- Use the lifting eyebolts (9) to lift (by hand or housing base settle the liner into its seating so
hoist) the top half of the bearing housing (5) that the liner axis and shaft axis are parallel. The
straight up, that the cap is completely slight hammer blow produces a high frequency
disengaged from the lower halves of the vibration which reduces the static friction between
bottom bearing housing (2) and the bearing the liner and the housing and allows the correct
liner (12). adjustment of the liner. The self-alignment
- Lift (by hand or hoist) the top half of the feature of the bearing is to compensate for
bearing liner (13) and remove it. normal shaft deflection during the assembling
- Loosen and remove the bolts at the split line of procedure only.
the oil ring (14). Carefully disengage the The loose oil ring is installed next. The ring must
dowels holding the oil ring halves together and be handled with special care as safe operation of
remove the oil ring. the bearing is also dependent on the effective and
- Remove the garter spring that encircles the safe functioning of the oil ring. The bolts must be
labyrinth seal. Remove the top half of the seal,
tightly fastened. Split misalignment must be
then rotate the bottom half of the seal out the
groove in the bearing housing and remove it. avoided and any burrs or edges carefully removed
- Disconnect and remove RTD's, thermocouples, in order to ensure smooth running of the ring. In
or any other temperature detecting any maintenance care must be taken that the ring
instruments that enter the lower half of the is not distorted and its geometrical shape is
bearing liner. maintained.
- Using a hoist or jack, raise the shaft slightly so The outside of the two liner halves is stamped
that the lower half of the bearing liner (12) with identification numbers or marks near the split
can be rolled out of the bearing housing. line. Make sure that these marks align and the
- Roll out (be careful not to use excessive force) split faces are clean when placing the top liner
the bottom half of the bearing liner (12) and
half into position. Incorrect fitting may lead to
remove it.
- Loosen and remove the bolts (4) and remove heavy damage to the bearing liners.
the bottom bearing housing (2). Check to ensure that the loose oil ring can still
- Remove the motor frame cover (3). rotate freely on the shaft. With the top liner half
- Loosen and remove the bolts (8) and remove in place, install the seal on the flange side (see
the machine seal (7). paragraph "Shaft Seals").
- Thoroughly clean and inspect all individual After coating the split faces with a non-hardening
parts which have been removed. Clean the sealing compound, place the housing cap into
interior of the bearing housing. position. Care must be taken that the seal fits
To reassemble the Bearing System, follow he properly into the groove. Ensure also that the
preceding instructions in the reverse order.
anti-rotation pin is seated without any contact
NOTE: Fastening torque of the bearing fixing with the corresponding hole in the liner.
bolts to the motor = 10 Kgfm. NOTE: Housing or liner may be
interchanged as complete assemblies
4.2.4.3. SLEEVE BEARING ASSEMBLY only. Individual halves are not
interchangeable.
Check contact face and mounting recess of the
bracket making sure it is clean and properly
machined. Inspect shaft to ensure it is smooth (Ra 4.2.4.4. SETTING OF THERMAL
0.4, equivalent to 32 micro-inch finish, or better), PROTECTIONS (PT100)
within the dimensions and tolerances given by
RENK and free of burr or any rough spots. Each bearing is fitted with a Pt100 temperature
After removing the upper part of the housing (2) detector installed directly in the bearing liner near
and the bearing liner (12 and 13) the interior of the point where the load is applied. This device
the housing and the running surfaces of the liner must be connected to a controlling panel with the
are to be cleaned thoroughly and checked for any
purpose of detecting overheating and protect the
damage caused in transit.
With the shaft slightly, locate the bearing base bearing when operating under high temperature.
into the mounting recess of the machine end
shield and bolt into position.
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Shaft
Figure 4.7 Brush wear mark. Fig. 4.9 Shaft grounding brush.
On machines that always rotate in the same To avoid shaft damage on WEG motors during
direction, the brushes should be set in a single transportation, shaft ends are protected with
direction only. During the backward movement of protective oil. For a correct Grounding Brush
the shaft the brushes must be lifted (figure 4.8). operation, this protective oil must be removed
from the shaft surface before motor operation as
well as any foreign materials that may be present
between shaft and the brush.
Brush must be checked on permanent basis while
in operation and, when getting to the end of its
life time, must be replaced by another of same
quality (granulation).
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Figure 4.10.
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Figure 4.11.
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MANUAL OPERATION:
4.6.2. PROCEDURE FOR MOTOR STARTING
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2) Before motor start up, make sure CLD, CLE, operates on the control panel of the automatic
CCD and CCE switches are correctly connected brush lifting system.
to the panel.
5) The control and signaling system of the brush
3) When one of the CLE or CLD switches operate, lifting system is not supplied by WEG.
the system must to be reconnected before
checking the reason they have operated. 6) After motor starting, brushes can not remain in
contact with collector rings, which can lead to
4) The end user is supposed to install proper excessive brush and collector ring wear as well
signal indicating how the logical system cause problems to the brush lifting system.
Figure 4.16.
Figure 4.17.
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4.6.4. ASSEMBLY 2. Mount the bearing in the support pin and fix
with a fixing pin which must be fixed with a
4.6.4.1. BRUSH HOLDER LIFTING DEVICE retaining ring.
1. Fix the pin support disc with the lifting set fixer 3. Fix the bearing support pin on the support
on the protection box of the brush holder set. disc.
Figure 4.18.
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4.6.4.2. SHORT-CIRCUIT BUSHING 3. Mount the support pin on the movement lever.
MOVEMENT SET
4. Fix the guide support on the support base and
1. Mount the roll on the roll bearing on short the movement lever on the support. The rolls
bushing movement lever, and then the must be aligved with the short circuit bushing
bearings, the spacing bushing and fix the in such way that both touch the bushing
bearing cover. simultaneously.
2. Fix the upper pins on one of the movement NOTE: Bearing of the movement levers: 6003Z.
levers.
Figure 4.19.
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4.6.4.3. BRUSH HOLDER OPERATION SET 6. Fix the locking device cover on the
electromechanical device and then fix it to the
1. Mount the bearing on the shaft and fix it with device frame.
retaining rings. Then put a retaining ring to
hold the second bearing. After that, mount it 7. Fix the operation set on the brush holder
with retaining ring. protection box.
4. Fix the lifting disc on the operation shaft. 2) All the parts touching mechanically must be
lubricated. After 6 months of use, check the
5. Mount the bushing on the lever operation shaft lubrication of such parts.
and fix it with a retaining ring. Fix the shaft on
the operation disc.
Figure 4.20.
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Figure 4.21.
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For the disassembly of the liftable brush holder, 4.8.1. " MASTER" LINE
proceed in the reserve way in relation to assembly
procedures. A) SQUIRREL-CAGE ROTOR
Drive-End:
4.6.6. BRUSHES LIFTING SYSTEM 1. Remove the heat exchanger (if any).
ADJUSTMENT 2. Remove the temperature detectors from the
bearing (if any).
1. Turn the lifting disc up to the short-circuit 3. Unscrew the bolts which fasten the bearing
position and then turn it a bit more to release assembly.
the rolls to avoid unnecessary thrusts on the 4. Remove the external bearing caps (for roller
roller bearings. bearing motors).
4.1. For ball bearing motors, follow the
2. Fasten the adjusting bolt up to the backstop procedures described in item 4.2.4.2.
disc and then lock the adjusting bolt. 5. Unscrew the bolts of the endshield. After being
removed, the bolts should be screwed
3. Turn the lifting disc up to the position of non endshields in order to force its removing. To
short-circuit (brushes lowered) and repeat the prevent the rotor falling onto the rotor, provide
same procedure carried out for the short a support for it.
circuit position. 6. Remove the bearing(s) (for roller bearing
motors).
7. Remove the internal bearing cap (for roller
4.7. DRYING OF THE WINDINGS bearing motors).
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4.8.2. A LINE
Drive-End:
1. Disconnect the space heater leads from the
terminal boxes.
2. Remove the bearing temperature detectors (if
any).
3. Unscrew the bolts of the bearing assembly.
4. Remove the external bearing caps (for roller
bearing motors).
4.1. For ball bearing motors, follow the
procedures described in item 4.2.2.2.
5. Unscrew the end-shield. By using an
appropriate tool, force the end-shield to
release and at the same time turn it to help
the removal. Make sure that the shaft is held
on a plate and so an eventual fall of the rotor
on the stator is avoided.
6. Remove the bearing(s) (for roller bearing
motors).
7. Remove the internal bearing cap.
Non Drive-End:
1. Remove the fan cover.
2. Release the fan retaining ring.
3. Repeat the procedures from 2 to 7 of item
4.8.2 (A).
NOTE:
1. For removing of rotor, observe section 4.8.1.1.
2. It is not necessary to remove the stator from
the frame to perform an eventual rewinding.
4.8.3. F LINE
Drive-End:
Equal as A and H lines.
Non Drive-End:
1. Repeat the procedures 1 to 3 of item 4.8.2 (B).
2. Remove back protecting cover of the brush
holder.
3. Disconnect the cables from the collector ring.
4. Remove the brushes and dismantle the brush-
holder.
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4.8.4. H LINE
Figure 4.26.
Safety! ASSEMBLY
Ensure that the power cables have 1) Applying proper device, fit the rotor (pos. 11)
been switched-off. into the stator, from the non drive end side of
the motor, and pay attention to avoid that the
rotor rubs on the stator or on the coil heads;
DISASSEMBLY 2) Place the internal bearing caps;
1) Disconnect the temperature sensor cables (pos. 8 3) Fill out with grease the compartment of the
and 19) of the accessory connection box internal bearing caps and bearings (check type
terminals; of grease on the bearing identification nameplate
2) Remove the non drive end fan cover (pos. 26); attached to motor covers);
3) Unfasten the fixing ring of the external non drive 4) Check carefully shaft and cover surfaces where
end bearing cap and remove the fan (pos.25); bearings will be fitted so as to avoid scratches or
4) Unfasten the bolts that fix the external non drive knocks. Also check for correct mechanical
end bearing caps; dimension tolerances;
5) Remove the external drive end and non drive end 5) Heat up and mount the drive end and non drive
bearing caps (pos. 5 and 22); end bearings (pos. 6 and 20);
6) Remove the drive end and non drive end grease 6) Lift the rotor, place supports underneath the
valve (pos. 4 and 21), unfastening the bolts that shaft and mount drive end and non drive end
fix them to the shaft; covers (pos.9 and 18);
7) Place supports underneath the shaft to avoid that 7) Mount the drive end and non drive end grease
the rotor falls on the stator; valve (pos. 4 and 21) and fix them to the shaft;
8) Unfasten and remove the drive end and non drive 8) Mount the external drive end and non drive end
end covers (pos.9 and 18); bearing caps (pos. 5 and 22), fixing them t the
9) Remove drive end and non drive end bearings internal bearing caps (pos. 7 and 16);
(pos.6 and 20) with the application of proper 9) Mount the external non drive end fan (pos. 25)
device; fixing it with a retaining ring;
10) Remove the internal drive end and non drive end 10) Mount the non drive end fan cover (pos. 26);
bearing caps (pos. 7 and 16); 11) Connect the temperature sensor cables (pos. 8
11) Applying proper device, remove the rotor (pos. and 19) to the accessory connection box
11) from the stator through the non drive end side terminals;
of the motor, and pay attention to avoid that the 12) Fill in remaining grease through the drive end
rotor rubs the stator or on coil heads. and non drive end grease fitting (pos. 27 and
28).
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Resistance
4.6 5.8 8.8 12.9
Class
Tightening torque (Nm)
Diameter
tolerance 10%
M6 1.9 3.2 5.1 8.7
M8 4.6 7.7 12.5 21
M10 9.1 15 25 41
M12 16 27 42 70
M16 40 65 100 175
M20 75 125 200 340
M24 130 220 350 590
Notes:
- The resistance class normally is marked in the
head of the hexagonal screws.
- When do not have marking at screws,
indicates that the resistance class is 4.6.
- The internal hexagonal screws (type Allen)
possess resistance class 12.9.
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- Coupling: follow
the maintenance
- After the first week
instructions
of operation: check - Check alignment - Check alignment and
contained in the
the alignment and and fastening. fastening.
manual of the
fastening.
coupling
manufacturer.
- Check the
- Inspect the
cleanliness and
- Slip rings area. cleanliness and
clean it, if
clean it, if required.
required.
Table 4.6.
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5. SPARE PARTS
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NOTE: The following chart presents a list of abnormal situations during motor operation, the probable cause
for such abnormal situations, and the corrective measures. In case of further doubts, contact Weg Mquinas.
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Table 6.2.
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NOTE: The following chart presents abnormal bearing situations and failures during motor operation, the
probable cause for such abnormal situation and the corrective measures. In certain cases, bearing
manufacturer must be contacted to find out the cause of the failure.
- Dark spots on one side of the ball races - Check the condition between coupling
- Excessive axial strength.
subsequently the formation of grooves. and driving.
Table 6.3.
IMPORTANT:
The motors listed in this manual are constantly updated. For this reason,
the information here with included may change without prior notice.
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These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from startup
date or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and
accommodation expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effectuated by WEG within the Warranty
period do not give Warranty extension, unless otherwise expressed in writing by Weg.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties,
expressed or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of
WEG nor to assume for WEG any other liability in connection with any of its products.
In case this happens without Weg's authorization, Warranty is automatically cancelled.
LIABILITY
Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph
entitled "Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or
negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or
repair of any product described in this quotation and sold or furnished by the company to the purchaser.
1013.02/0295
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MANUAL DE INSTALACION
Y MANTENIMIENTO
MOTORES ELECTRICOS DE INDUCCION
TRIFASICOS DE ALTA Y BAJA TENSION
PROLOGO
El motor elctrico es el equipo ms utilizado por el hombre en su caminada en busca del progreso,
ya que la mayora de las mquinas y muchos inventos conocidos dependen de l.
Como desempea un papel muy importante para el conforto y bienestar de la humanidad, el motor
elctrico necesita ser identificado y tratado como una mquina motriz cuyas caractersticas envuelven
determinados cuidados, de los cuales la instalacin y mantenimiento. Esto significa decir que el motor
elctrico debe ser tratado de forma adecuada.
El motor elctrico!
9300.0010 E/4
Octubre 2005
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NDICE
1. INTRODUCCIN ......................................................................................................................................................................5
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1. INTRODUCCIN
IMPORTANTE:
Este manual tiene por objetivo
atender todos los motores trifsicos
de induccin con rotor de jaula y
anillos de la Weg Mquinas. Motores con
especialidades pueden ser fornecidos con
documentos especficos (dibujos, esquema de
conexin, curvas caractersticas...). Estos
documentos deben ser criteriosamente evaluados
juntamente con este manual, antes de proceder la
instalacin, operacin o mantenimiento del motor.
Para los motores con grandes especialidades
constructivas, caso sea necesario alguna
aclaracin adicional, solicitamos entrar en
contacto con Weg Mquinas.
Todos los procedimientos y normas que constan
en este manual deben ser seguidos para
garantizar el buen desempeo del equipo y
seguridad de la persona responsable del mismo.
Seguir correctamente los procedimientos es muy
importante para que el trmino de garanta que
consta en la contra capa de este manual tenga
validez.
Aconsejamos por eso, una lectura detallada de
este manual, antes de instalar y poner en
funcionamiento el motor, en caso de alguna duda,
favor entrar en contacto con Weg Mquinas.
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2.2. RECIBIMIENTO
2.3.2. ALMACENAJE EXTERNA
Los motores suministrados pasan por vigorosos
ensayos y estn en perfectas condiciones de Si posible, elija un local de almacenaje seco, libre
operacin. Las superficies torneadas son de inundaciones y libre de vibraciones.
protegidas contra oxidacin. La caja o container Repare todos los daos al embalaje antes de
deber ser revisado luego despus de su llegada poner el equipo en almacenaje, lo que es
para certificarse del perfecto estado o detectar necesario asegurar condiciones de almacenaje
algn dao causado en el transporte. Los motores apropiadas.
son transportados con un sistema de traba del eje Posicione las mquinas, los dispositivos y los
para prevenir daos en los descansos. Sugerimos embalajes en palletes, gavillas de madera o
que el dispositivo de traba sea debidamente fundaciones que garantizan la proteccin contra la
almacenado para ser usado cuando el motor humedad de la tierra.
necesite ser transportado. Impida el equipo de ahondarse en la tierra. La
Cualquier avera deber ser comunicada a la circulacin del aire debajo del equipo tambin no
empresa transportadora, al seguro y a Weg puede ser impedida.
Mquinas. En caso de no tomar estas La cobertura o lona usada para proteger el equipo
providencias ocasionar la prdida de la contra intemperies no deben hacer contacto con
garanta. las superficies del equipo. Asegure la circulacin
Al levantar el embalaje (o container) se deben de aire adecuada posicionando bloques de
observar los puntos de izamiento, el peso indicado madera espaciadores entre el equipo y tales
en el embalaje y la capacidad del guindaste. coberturas.
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Evaluacin del
ndice de polarizacin
aislamiento
1 o menor Malo
< 1,5 Peligroso
1,5 2,0 Regular
2,0 3,0 Bueno
3,0 4,0 Muy bueno
> 4,0 Excelente
Tabla 2.3b. ndice de polarizacin (relacin entre 10 y 1
minuto).
Figura 2.3.
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LNEA H
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Las mquinas elctricas deben ser instaladas en Las fundaciones donde ser colocado el motor
locales que permitan fcil acceso para inspeccin deben ser planas y, si posible, exentos de
y mantenimiento, principalmente en lo referente a vibraciones.
los cojinetes (relubricacin) e inspeccin de las Se recomienda, por este motivo, una fundacin de
escobillas. concreto. El tipo de fundacin elegido depender
Si la atmsfera es hmeda, corrosiva o contiene de la naturaleza del suelo en el local de montaje,
partculas abrasivas, es importante asegurar el o de la resistencia de los pisos.
correcto grado de proteccin. En el dimensionamiento de las fundaciones del
La instalacin de motores donde existen vapores, motor debe ser considerado el hecho de que el
gases, polvaredas peligrosas, inflamables o motor puede, ocasionalmente, ser sometido a un
combustibles ofreciendo posibilidad de fuego o par mayor que el par nominal. Si este
explosin, debe ser hecha de acuerdo con las dimensionamiento no fuere criteriosamente
Normas ABNT NBR, NEC-Art.500 (National ejecutado podr ocasionar serios problemas de
Electrical Code) y UL-674 (Underwriter's vibracin del conjunto fundaciones-motor y
Laboratories Inc.). mquina accionada.
En ninguna circunstancia los motores podrn ser
cubiertos por cajas u otras coberturas que puedan OBS: En la base de concreto deber ser
impedir o disminuir la libre circulacin del aire de prevista una placa metlica para apoyo del perno
ventilacin. de nivelamiento.
Las mquinas dotadas de ventilacin externa
deben quedarse, como mnimo, a 50mm de altura Con base en la figura 3.1, los esfuerzos sobre la
del piso a fin de dejar pasar el aire. fundacin pueden ser calculados a travs de las
Las aberturas de entrada y salida de aire jams ecuaciones:
debern ser obstruidas o disminuidas por objetos, (4C max)
paredes, pilares, etc. F1 = +0.5.m.g. +
El ambiente en el local de la instalacin deber ( A)
tener condiciones de renovar el aire a orden de
20m por minuto para cada 100kW de potencia (4C max)
F2 = +0.5.m.g .
de la mquina. ( A)
3.1. ASPECTOS MECNICOS Donde:
F1 y F2 - Esfuerzo de los pis sobre la base (N)
3.1.1. MONTAJE g - Aceleracin de la gravedad (9,81m/s).
m - masa del motor (Kg).
Afn de asegurar la operacin adecuada, adems Cmx - Par mximo (Nm).
de una fundacin estable, el motor debe estar A - Se obtiene del dibujo dimensional del motor
precisamente aliado con el equipo acoplado y los (m).
componentes montados en su eje,
adecuadamente balanceados.
Observacin:
Con la mquina montada y acoplada, las
relaciones entre la frecuencia natural de la
fundacin y:
- La frecuencia de giro del motor;
- El doble de la frecuencia de giro;
- El doble de la frecuencia de la lnea.
Deben estar segn especificado abajo:
- Frecuencia natural de 1 orden de la
fundacin: Figura 3.1 - Esfuerzos sobre la base.
+25% o -20% con relacin a las frecuencias
arriba. NOTA: El dibujo arriba indica los esfuerzos en el
- Frecuencias naturales de la fundacin de motor cuando el sentido de giro es horario. Para
rdenes superiores: sentido antihorario. (F1, F2, 4. Cmx).
+10% o -10% con relacin a las frecuencias
arriba.
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Figura 3.5.
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Figura 3.7.
3.1.4. ACOPLAMIENTOS
Figura 3.8 - Montaje de poleas.
a) Acoplamiento directo
Se debe preferir siempre el acoplamiento directo, DESMONTAJE DE POLEAS: Para desmontaje
debido al menor costo, reducido espacio ocupado, las poleas se recomienda el uso de dispositivos
ausencia de deslizamiento (correas) y mayor como es mostrado en la figura 3.9, procedindose
seguridad contra accidentes. En caso de con mucho cuidado para no daar la chaveta y el
transmisin con reduccin de velocidad, es usual asiento de la polea.
tambin el acoplamiento directo a travs de
reductores.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
FUNCIONAMIENTO: Deben ser evitados los Debido a tensiones existentes en las correas,
esfuerzos radiales desnecesarios en los cojinetes, curre una reaccin actuando como carga radial en
situando los ejes paralelos entre s y las poleas la punta del eje del motor.
perfectamente alineadas (figura 3.11).
Correas que trabajan lateralmente alternante al Los datos para calcular esta reaccin (fuerza
rotor, y pueden daar las escoras del descanso. radial), son:
El deslice de la correa puede ser evitado con - Potencia transmitida [kW] (P);
aplicacin de un material resinoso, como la brea, - Rotacin motora [rpm] (RPM);
por ejemplo. - Diametro de la polea movida [mm] (DPMV);
- Diametro de la polea motora [mm] (DPMT);
- Distancia entre los centros [mm] (I);
- Coeficiente del rozamiento [-] (MI) -
(normalmente 0,5);
- Coeficiente de deslizamiento [-] (K);
- ngulo de contacto de la correa en la polea
menor [RAD] (alfa).
DPMV DPMT
ALFA =
1
(MIxALFA) + 1
K = 1.1x
(MIxALFA) 1
18836,25N K 2 x[1 COS ( ALFA] + 1.21x[1 + COS ( ALFA)]
FR = x
DPMTxRPM 2
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3.2.2. CONEXIN
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Los esquemas de conexin a seguir muestran la identificacin de los terminales en la caja de conexin y las
conexiones posibles para el estator (fases) y rotor de los motores de induccin trifsicos.
Los nmeros descritos en cada esquema en la tabla abajo sirven para el usuario identificar el esquema de
conexin correspondiente al su motor a travs de una tarjeta fijada en el motor donde estn descritos los
nmeros de los cdigos correspondientes a los esquemas de conexin del estator, rotor y accesorios:
3 BORNES + NEUTRO
9121
9 BORNES 12 BORNES
9107 9108 9109 9110 9111 9112 9113 9114
YY Y YY Y
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3 BORNES + NEUTRO
9221
9 BORNES 12 BORNES
9207 9208 9209 9210 9211 9212 9213 9214
YY Y YY Y
SENTIDO DE GIRO
- El sentido de giro est descrito en la tarjeta de identificacin y debe ser visto en la extremidad del eje del lado
accionado del motor.
- Motores con la identificacin de los terminales y conexiones descritas en los captulos 3.2.4.1 y 3.2.4.2 de este
manual poseen sentido de giro horario.
- Para invertir el sentido de giro se debe invertir la conexin de dos fases.
- Los motores con sentido nico de giro, indicados en la tarjeta de identificacin por una seta fija en la carcasa,
poseen ventilador unidireccional e deben operar solamente en el sentido especificado.
- Para inversin del sentido de giro de motores unidireccionales, se debe consultar la WEG.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
Los esquemas de conexin a seguir muestran la identificacin de los terminales en la caja de conexin y las
conexiones de los accesorios de los motores de induccin trifsicos.
Los nmeros descritos en cada esquema de la tabla abajo sirven para el usuario identificar la conexin de
los accesorios correspondiente al su motor a travs de una tarjeta fijada en el motor donde estn descritos
los nmeros de los cdigos correspondientes a los esquemas de conexin del estator, rotor y accesorios:
16 a 29 = Resistencia de calentamiento.
20 a 27 = Termoresistencia en el estator.
36 a 43 = Termistores en el estator.
52 a 59 = Termostatos en el estator.
68 a 71 = Termoresistencias en los descansos.
72 a 75 = Termistores en los descansos.
76 a 79 = Termostatos en los descansos.
80 a 82 = Dnamos taquimtricos.
88 a 91 = Termmetros.
92 a 93 = Frenos.
94 a 99 = Transformadores.
ALARMA PARADA
9032 9036
EN EL ESTATOR EN LOS DESCANSOS
2 POR FASE EN SERIE 1 POR DESCANSO
TERMISTORES
9025 9026 9027
EN EL ESTATOR EN EL ESTATOR EN EL ESTATOR
1 POR FASE 1 POR FASE EN SERIE 2 POR FASE
ALARMA PARADA
9028 9035
EN EL ESTATOR EN LOS DESCANSOS
2 POR FASE EN SERIE 1 POR DESCANSO
DELANTERO TRASERO
ALARMA PARADA
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
TERMOSENSORES PT100
9021 9022 9023
EN EL ESTATOR EN EL ESTATOR EN EL ESTATOR
1 POR FASE 1 POR FASE CON 3 CABLES 2 POR FASE
ALARMA PARADA
ACCESORIOS ADICIONALES
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o
C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
Tabla 3.8 - Variacin de la resistencia calibrada de Platino.
OBS.: Cuando exista previsin de una caja de conexin para accesorios, en esta caja estarn los conectores
de instalacin de los protectores trmicos y otros accesorios. Caso contrario, los conectores de los accesorios
estarn en la caja principal.
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Accionar el motor acoplado a la carga hasta llegar Para un buen planeamiento del nivel de conforto
a su estabilidad trmica y observar si aparecen acstico en residencias, oficinas y fbricas, es
ruidos y vibraciones anormales o temperaturas muy importante observar como se origina el ruido
excesivas. Caso aparezcan variaciones de de motores y como afecta el nivel de ruido del
vibraciones significativas en el conjunto, entre la ambiente donde estn instalados. Las siguientes
condicin inicial de funcionamiento y la condicin partes de un motor pueden producir ruido en la
despus de la estabilidad trmica, es necesario faja audible:
reanalizar el alineamiento y el nivelamiento. 1) El sistema de refrigeracin.
Comparar la corriente de linea absorvida, con el 2) Las escobillas.
valor indicado en la placa de identificacin. 3) Los rodamientos.
En regimen continuo, sin oscilacin de carga, este 4) El circuito magntico.
no debe exceder la corriente nominal por el factor
de servicio indicado en la placa. La parte del motor que predomina como fuente
Todos los instrumentos y aparatos de medicin y de ruido depende del tamao de la mquina, de
control, debern quedar sobre observacin su velocidad de giro, del grado de proteccin
permanente a fin de que eventuales alteraciones mecnica (involucro) y de la mquina. El ruido
puedan ser constatadas y sanadas sus causas. debido al sistema de refrigeracin es propagado
En caso de motores de anillos se debe hacer un por aire y generalmente afecta el nivel de ruido
levantamiento real de las condiciones de la carga apenas del ambiente donde est instalado. Pero,
a la que el motor ser sometido en regimen de si el ruido se origina en los rodamientos o en el
trabajo, y si necesario recalcular el conjunto de circuito magntico, la situacin es distinta: el
escobillas. En caso de duda, consultar a Weg ruido se debe a vibraciones mecnicas de parte o
Mquinas. de toda la mquina, y el sonido puede propagarse
a travs de las fundaciones, de las paredes o
tubos de la mquina. Este tipo de propagacin, a
travs de los componentes estructurales de la
instalacin, puede ser reducido por el montaje de
la mquina sobre amortiguadores adecuadamente
3.3.4. DESCONEXIN calculados; se debe tener presente que los
amortiguadores colocados inadecuadamente
Cabe aqu, antes de cualquier situacin, una pueden amplificar las vibraciones.
advertencia muy seria: mientras hay un motor
girando, aunque despus de ser desconectado,
constituye peligro de vida tocar en cualquier
3.5. MOTORES APLICADOS EN AREA DE
parte activa de este.
RIESGO / ATMOSFERAS EXPLOSIVAS
a) MOTOR CON ROTOR DE JAULA:
Los motores especificados para operar en reas
Bastar abrir la llave del circuito estatrico y una
de riesgo poseen caractersticas adicionales de
vez parado el motor, recolocar el
seguridad que estn definidas en normas
autotransformador, si existe, en la posicin de
especficas para cada tipo de rea de riesgo,
arranque.
conforme su clasificacin.
Los requerimientos generales para equipamientos
b) MOTOR CON ROTOR DE ANILLOS:
que operan en reas de riesgo, estn descriptos
Deber ser abierta la cuchilla del circuito
en las siguientes normas brasileas e
estatrico. Despus de la parada, el restato
internacionales respectivamente:
deber ser recolocado en la posicin de
NBR 9518 = Equipamientos Elctricos para
"arranque".
atmsferas explosivas.
Requerimientos generales (especificaciones).
*** ATENCIN *** IEC 79-0 = Electrical Apparatus for explosive gas
Las cajas de conexin de motores atmospheres.
equipados con capacitores no deben ser General Requirements.
abiertas antes del tiempo de descarga: EN 50014 = Electrical apparatus for potentially
Tiempo de descarga de los capacitores: 5 explosive atmospheres.
minutos despus de la desconexin del General Requirements.
motor.
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4.2.1. DESCANSOS CON RODAMIENTO Los motores WEG son suministrados con grasa
LUBRICADOS A GRASA POLYREX EM 103 (Fabricante: Esso) hasta la
carcasa 450 y grasa STABURAGS N12MF
La finalidad del mantenimiento, en este caso, es (Fabricante: Klber) para la carcasa 500 y
prolongar lo mximo, la vida til del sistema de mayores, en cantidad suficiente para el periodo
descansos. de funcionamiento indicado en la hoja de datos y
El mantenimiento requiere: en la tarjeta de identificacin de los rodamientos.
a) Observacin del estado general en que se Los intervalos de lubricacin, cantidad de grasa y
encuentran los descansos. los rodamientos usados en los motores, estn en
b) Lubricacin y limpieza. las tablas anexadas, como valores orientativos.
c) Examen ms minucioso de los rodamientos. El periodo de relubricacin depende del tamao
El ruido en los motores deber ser observado en del motor, de la velocidad de rotacin, de las
intervalos regulares de 1 a 4 meses. Un odo bien condiciones de trabajo, del tipo de grasa utilizado
entrenado es perfectamente capaz de distinguir el y de la temperatura de trabajo.
aparecimiento de ruidos anmalos, aunque El periodo de lubricacin y el tipo de rodamientos
empleando medios bien simples (como un para cada motor estn gravados en la plaqueta
desarmador, etc.). de identificacin colocada en el motor.
Para un anlisis ms confiable de los descansos,
aconsejamos la utilizacin de equipos que El motor que permanecer en
permitan hacer anlisis predictivas. existencia debe ser re-lubricado a
cada 6 meses. Todos los meses se
El control de la temperatura en los debe girar el eje algunas vueltas para
descansos tambin hace parte de la homogeneizar la grasa por los
rutina del mantenimiento. Donde los descansos.
descansos deben ser Los intervalos de lubricacin, cantidad de grasa y
lubrificados los rodamientos usados en los motores, estn en
utilizando grasas recomendados segn el iten las tablas 4.2 a y 4.2 b, como valores orientativos.
4.2.1.2 y la temperatura nunca deber ultrapasar
los 60oC (T = 60C / Ambiente mximo = 40C,
Los datos de los rodamientos, cantidad y
temperatura absoluta = T + ambiente) medido
tipo de grasa y intervalo de lubricacin
en el anillo externo del rodamiento.
son informados en una placa de
identificacin fijada en el motor.
La temperatura puede ser controlada
Antes del procedimiento de lubricacin
permanentemente con termmetros, colocados de
de los descansos, verifique estos datos.
lado de fuera del soporte, o con termo-elementos
embutidos.
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INTERVALO MXIMO DE LUBRICACIN (EN HORAS) PARA MOTORES CON EJE HORIZONTAL 60HZ
Descanso trasero
Descanso Descanso trasero
Descanso Descanso trasero motor de anillos
delantero (con motor de anillos
Carcasa Polos delantero (motor de jaula) (escobillas
polea) (escobillas fijas)
levantables)
Rodamiento Relub Rodamiento Relub Rodamiento Relub Rodamiento Relub Rodamiento Relub
2 6314 3.400 6314 3.400
4 6.400 2.000 8.900 6.600 6.600
315
6 6320 10.000 NU322 4.500 6316 10.000 6222 10.000 6222 10.000
8 10.000 6.400 10.000 10.000 10.000
2 6314 3.400 6314 3.400
4 4.800 1.600 6.400 5.800 5.800
355
6 6322 8.700 NU324 3.900 6320 10.000 6224 10.000 6224 10.000
8 10.000 5.800 10.000 10.000 10.000
4 2.200 1.400 6.400 5.100 3.400
400 6 NU224 4.900 NU228 3.700 6320 10.000 6226 9.300 6230 6.900
8 6.800 5.500 10.000 10.000 9.800
4 2.200 4.800 3.400 6234 2.500
450 6 NU224 4.900 6322 8.700 6230 3.400 5.600
6234
8 6.800 10.000 3.400 8.400
4 1.800 4.800 3.400 2.500
500 6 NU226 4.300 6322 8.700 6230 6.900 6234 5.600
8 6.200 10.000 9.800 8.400
4
6 NU228 3.700 5.500 3.100 2.300
8 5.500 7.500 4.900 3.900
560 NU222 NU230 NU234
4
6 NU232 2.700 5.500 3.100 2.300
8 4.400 7.500 4.900 3.900
4
6 1.200 4.900 3.100 2.300
8 23032 2.200 6.800 4.900 3.900
10 3.100 8.100 6.300 5.200
12 3.800 9.000 7.300 6.200
630 NU224 NU230 NU234
4
6
8 23036 1.600 6.800 4.900 3.900
10 2.400 8.100 6.300 5.200
12 3.100 9.000 7.300 6.200
6
8 1.600 6.200 4.400 3.900
23036
10 2.400 7.500 5.700 5.200
12 3.100 8.400 6.700 6.200
710 NU226 NU232 NU234
6
8 1.300 6.200 4.400 3.900
23040
10 2.000 7.500 5.700 5.200
12 2.600 8.400 6.700 6.200
Grasa Polyrex EM 103 (Esso) Grasa Staburags N12MF (Klber)
Tabla 4.2a.
NOTAS:
- Intervalo de relubricacin normal adoptado para temperatura ambiente de 40C y tipos de grasa
especificados arriba;
- Para aplicacin de los descansos en posicin vertical, disminuir los intervalos a la mitad;
- Temperatura de trabajo del rodamiento = 70C;
- Adoptar los factores de correccin de abajo en los intervalos de lubricacin de la tabla de arriba, en los
siguientes casos:
- Temperatura de operacin menor que 60C: 1,59.
- Temperatura de operacin de 70C hasta 80C: 0,63.
- Temperatura de operacin de 80C hasta 90C: 0,40.
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INTERVALO MXIMO DE LUBRICACIN (EN HORAS) PARA MOTORES CON EJE HORIZONTAL - 50Hz
Descanso trasero
Descanso Descanso trasero
Descanso Descanso trasero motor de anillos
delantero (con motor de anillos
Carcasa Polos delantero (motor de jaula) (escobillas
polea) (escobillas fijas)
levantables)
Rodamiento Relub Rodamiento Relub Rodamiento Relub Rodamiento Relub Rodamiento Relub
2 6314 4.900 6314 4.900
4 8.300 3.000 10.000 8.500 8.500
315
6 6320 10.000 NU322 5.700 6316 10.000 6222 10.000 6222 10.000
8 10.000 7.600 10.000 10.000 10.000
2 6314 4.900 6314 4.900
4 6.500 2.500 8.300 7.700 7.700
355
6 6322 10.000 NU324 5.100 6320 10.000 6224 10.000 6224 10.000
8 10.000 6.900 10.000 10.000 10.000
2 6317 3.400 6317 3.400
4 3.300 2.300 8.300 6.900 4.800
400
6 NU224 6.100 NU228 4.900 6320 10.000 6226 10.000 6230 8.700
8 7.900 6.700 10.000 10.000 10.000
4 3.300 6.500 4.800 6234 3.700
450 6 NU224 6.100 6322 10.000 6230 8.700 7.300
6234
8 7.900 10.000 10.000 10.000
4 2.800 6.500 4.800 3.700
500 6 NU226 5.500 6322 10.000 6230 8.700 6234 7.300
8 7.300 10.000 10.000 10.000
4 2.300 3.900 1.900 1.300
6 NU228 4.900 6.800 4.300 3.300
8 6.700 8.600 6.100 5.000
560 NU222 NU230 NU234
4
6 NU232 3.800 6.800 4.300 3.300
8 5.500 8.600 6.100 5.000
4
6 1.800 6.100 4.300 3.300
8 23032 2.900 7.900 6.100 5.000
10 3.800 9.000 7.300 6.200
12 4.400 9.600 8.000 7.100
630 NU224 NU230 NU234
4
6 1.300 6.100 4.300 3.300
8 23036 2.300 7.900 6.100 5.000
10 3.100 9.000 7.300 6.200
12 3.700 9.600 8.000 7.100
6 1.300 5.500 3.800 3.300
8 2.300 7.300 5.500 5.000
23036
10 3.100 8.400 6.700 6.200
12 3.700 9.100 7.600 7.100
710 NU226 NU232 NU234
6 1.000 5.500 3.800 3.300
8 1.800 7.300 5.500 5.000
23040
10 2.600 8.400 6.700 6.200
12 3.200 9.100 7.600 7.100
Grasa Polyrex EM 103 (Esso) Grasa Staburags N12MF (Klber)
Tabla 4.2b.
NOTAS:
- Intervalo de relubricacin normal adoptado para temperatura ambiente de 40C y tipos de grasa
especificados arriba;
- Para aplicacin de los descansos en posicin vertical, disminuir los intervalos a la mitad;
- Temperatura de trabajo del rodamiento = 70C;
- Adoptar los factores de correccin de abajo en los intervalos de lubricacin de la tabla de arriba,
en los siguientes casos:
- Temperatura de operacin menor que 60C: 1,59.
- Temperatura de operacin de 70C hasta 80C: 0,63.
- Temperatura de operacin de 80C hasta 90C: 0,40.
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Opciones de grasas
TEMPERATURA DE TRABAJO
FABRICANTE GRASA APLICACIN
CONSTANTE (C)
ESSO UNIREX N2 (BASE COMPLEXO DE LTIO) (-35 hasta +175)
PETROBRAS LUBRAX GMA-2 (BASE DE LTIO) (0 hasta +130) NORMAL
ALVNIA R3 (BASE DE LTIO) (-35 hasta +130)
SHELL
AEROSHELL 7 (MICROGEL) (-55 hasta +100)
BAJA TEMPERATURA
ESSO BEACON 325 (BASE DE LTIO) (-50 hasta +120)
Tabla 4.3b.
Rodamiento de rodillos
Rodamiento de esferas Rodamiento de rodillos
Auto compensador
Rodamiento Grasa (g) Rodamiento Grasa (g) Rodamiento Grasa (g)
6222 40 NU222 40 23032 75
6224 45 NU224 45 23036 105
6226 50 NU226 50 23040 130
6230 65 NU228 55 Tabla 4.4c.
6234 85 NU230 65
6314 30 NU232 70
6316 35 NU234 85
6320 50 Tabla 4.4b.
6322 60
Tabla 4.4a.
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Para se evitar cualquier posible problema de no fin de evitar la entrada de materiales extraos en
compatibilidad de grasas, una buena prctica de los rodamientos.
lubricacin consiste en se introducir una nueva
grasa en el equipamiento, eliminndose por Para lubricacin, use exclusivamente pistola
completo la grasa vieja y limpiando perfectamente engrasadora manual.
el local que ser lubricado.
Cuando esto no fuere posible, se debe aplicar
grasa nueva bajo presin, expulsndose la
antigua, hasta salir la grasa limpia por el dreno
del descanso.
En general, grasas con el mismo tipo de jabn
son compatibles entre si, pero dependiendo de la
proporcin de mezcla, puede haber no
compatibilidad. As siendo, no es recomendable la
mezcla de diferentes tipos de grasas, sin antes
consultar el representante tcnico o la WEG.
Algunos espesantes y aceites bsicos, no pueden
ser mezclados entre si. Figura 4.2 - Rodamientos y sistemas de
Se forma entonces una mezcla no homognea. lubricacin.
En este caso, no se puede despreciar una
tendencia al endurecimiento, o al contrario, un 4.2.1.6. ETAPAS DE RELUBRICACIN DE
ablandamiento de la grasa (o cada del punto de LOS RODAMIENTOS
gota de la mezcla resultante). 1. Retirar la tapa del dreno.
2. Limpiar con trapo de algodn las proximidades
4.2.1.5. INSTRUCCIONES PARA del agujero de la grasera.
LUBRICACIN 3. Con el motor en funcionamiento, adicionar la
grasa por medio de la pistola engrasadora
Todos los motores de alta/baja tensin poseen manual hasta que la grasa comiese a salir por
graseras para lubricacin de los rodamientos. El el dreno o hasta haber sido introducida la
sistema de lubricacin fue proyectado para que cantidad de grasa recomendada en la tabla.
en la relubricacin de los rodamientos, toda la 4. Dejar el motor funcionando durante el tiempo
grasa sea retirada de las pistas de los suficiente para que se drene todo el exceso de
rodamientos y expelida a travs de un dreno que grasa.
permita la salida e impide la entrada de polvos u 5. Verifique la temperatura del cojinete para
otros contaminantes nocivos al rodamiento. Este verificar que no ocurri ninguna alteracin
dreno tambin evita el dao de los rodamientos significativa.
por el conocido problema de la relubricacin
excesiva. Es aconsejable hacer la relubricacin 4.2.1.7. DISPOSITIVO DE RESORTE PARA
durante el funcionamiento del motor, de modo a RETIRAR LA GRASA
permitir la renovacin de la grasa en el Cuando la salida de grasa del cojinete no est
alojamiento de rodamiento. Si esto no fuera accesible al operador, algunos motores son
posible debido a la presencia de las piezas provistos con un dispositivo con resorte para
girantes cerca de la engrasadora (poleas, etc.) retirar la grasa durante la relubricacin de los
que pueden poner en riesgo la integridad fsica cojinetes.
del operador, se procede de la siguiente manera: Etapas para relubricacin:
- Se inyecta aproximadamente mitad de la 1. Antes de empezar el procedimiento de
cantidad total estimada de la grasa y se coloca lubricacin del cojinete, limpie la grasera con
el motor a girar durante aproximadamente 1 un trapo de algodn;
minuto en plena rotacin; 2. Retire la varilla con resorte, limpie el resorte y
- Se para el motor y se inyecta el restante de la coloque nuevamente;
grasa. 3. Con el rotor en funcionamiento, adicione la
La inyeccin de toda la grasa con el motor cantidad de grasa especificada en la tarjeta de
parado puede llevar a entrar una parte del identificacin de los rodamientos por medio de
lubrificante en el interior del motor, a travs de la equipamiento engrasador manual.
veda interna de la caja del rodamiento. 4. El exceso de grasa sale por el drenaje inferior
del cojinete y se almacena en el resorte.
OBS.: Es importante mantener las graseras
limpias antes de la introduccin de la grasa con el
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4.2.2.1. CARACTERSTICAS
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Figura 4.5.
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4.2.4.1. INSTRUCCIONES GENERALES - Use los tornillos con ojales (9) para levantar la
parte superior de la carcasa (5)
El mantenimiento de descansos de deslizamiento desencajndola completamente de la inferior
incluye la verificacin peridica del nivel y de las de la veda externa (11), los laberintos de
condiciones del lubrificante, verificar los niveles de veda, de los alojamientos de los laberintos
ruido y de vibraciones del soporte, acompaar el (20) y de casquillo (12).
nivel de temperatura de trabajo y ajuste de los - Siga desmontando la parte superior de la
tornillos de montaje. La carcasa debe ser carcasa sobre una banca. Destornille los
mantenida limpia, sin acumulo de aceite o polvo tornillos (19) y retire la parte superior de la
en la parte externa para facilitar el intercambio de proteccin externa. Remover los tornillos (10)
calor con el medio ambiente. y desencaje la parte superior del alojamiento
Agujeros con rosca para conexin de termmetro, del laberinto (20).
visor de nivel, entrada y salida de aceite, bomba - Desencaje y retire la parte superior del
de circulacin de aceite o termmetro para lectura casquillo (13).
en el depsito son entregados en ambos lados, de - Remover los tornillos que unen las dos partes
manera que las conexiones puedan ser hechas de la anillo pescador (14) y separarlos
por el lado derecho o izquierdo de la carcasa del cuidadosamente y sacarles.
soporte. - Retire los resortes circulares de la anillo
El dreno del aceite esta localizado en la parte laberinto y remover la parte superior de cada
inferior del soporte. anillo. Gire las partes inferiores de las anillos
En caso de descansos con lubricacin por para fuera de sus alojamientos y retiradas.
circulacin de aceite la tubera de salida debe ser - Desconecte y retire el sensor de temperatura
conectada en la posicin del visor de nivel. que est en la parte inferior del casquillo.
Si el soporte es elctricamente aislado las - Usando un levantador o una gata, levantar el
superficies esfricas del asiento del casquillo en la eje apenas unos milmetros para que la parte
carcasa son encapadas con un material aislante. inferior del casquillo pueda girar para fuera de
Nunca retire esta capa. su asiento.
La traba anti-giro tambin es aislada, y los sellos
de veda son hechos de material no conductor. IMPORTANTE: Para esto es necesario que los
Instrumentos de control de temperatura que tornillos 4 y 6 de la otra parte del soporte estn
estn en contacto con el casquillo tambin deben sueltos.
ser debidamente aislados. - Gire cuidadosamente la parte inferior del
Descansos refrigerados con agua son casquillo sobre el eje y retirarla.
suministrados con serpentina de refrigeracin - Desatornille los tornillos (19) y retire la parte
instalada y deben ser manejados con cuidado inferior de la proteccin externa (11).
especialmente para no daar las conexiones - Desatornille los tornillos (10) y remover la
durante el transporte y la propia instalacin. parte inferior del alojamiento del anillo
laberinto (21).
4.2.4.2. DESMONTAJE DEL DESCANSO (TIPO - Retire los tornillos (4) y remover la parte
EF) inferior de la carcasa (2).
- Desatornille los tornillos (8) y remover el sello
Para desmontar el descanso y tener acceso a los mquina (7).
casquillos, bien como a otros componentes siga - Limpie y inspeccione completamente las piezas
cuidadosamente las instrucciones indicadas a removidas y el interior de la carcasa.
seguir. Guardar todas las piezas desmontadas en - Para montar el soporte siga las instrucciones
un local seguro (ver figura 4.5). dadas para desmontar en orden inversa.
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- Destornille los tornillos (4) que fijan la parte cuidando para que las superficies axiales de
superior de la carcasa (5) al motor (3). Retire posicionamiento no sean daadas.
los tornillos (6) que unen las fases bipartidas Despus alinear cuidadosamente las caras de la
de la carcasa del soporte (2 y 5). parte inferior del casquillo y de la carcasa baje
- Use los tornillos de ojales (9) para levantar la con mucho cuidado el eje hasta la posicin de
parte superior de la carcasa (5) trabajo. Con un martillo golpee suavemente en la
desencajndola completamente de la parte carcasa para que el casquillo se posicione
inferior de la carcasa (2), del laberinto de veda correctamente en relacin a su asiento y su eje.
y del casquillo (12). Este procedimiento genera una vibracin de alta
- Desencaje y retire la parte superior del frecuencia que disminuye el rozamiento esttico
casquillo (13). entre el casquillo y la carcasa y facilita el correcto
- Remover los tornillos que unen las dos partes alineamiento. La capacidad de auto-alineamiento
del anillo pescadora (14) y separarlos del soporte tiene la funcin de compensar solo la
cuidadosamente y retirarlas. deflexin normal del eje durante el montaje. En
- Retire el resorte circular del anillo laberinto y seguida debe montarse el anillo pescador, lo que
remover la parte superior del anillo. Gire la tendr que ser hecho con mucho cuidado, pues el
parte inferior del anillo laberinto para fuera de funcionamiento perfecto del soporte depende de
su alojamiento y retirarla. la lubricacin provista por el anillo. Los tornillos
- Desconecte y remueva el sensor de deben ser apretados levemente y cualquier
temperatura que esta en la parte inferior del rebaba cuidadosamente retirada para
casquillo. proporcionar un funcionamiento suave y uniforme
- Usando un levantador o una gata levante el del anillo. En un eventual mantenimiento se debe
eje apenas unos milmetros para que la parte cuidar para que la geometra del anillo no sea
inferior del casquillo pueda girar para fuera de alterada.
su asiento. Las partes inferior y superior del casquillo poseen
- Gire cuidadosamente la parte inferior del nmeros de identificacin o marcaciones para
casquillo (12) sobre el eje y removerlo. orientar su posicionamiento. Posicione la parte
- Retire los tornillos (4) y remueva la parte superior del casquillo alineado con las marcas con
inferior de la carcasa (2). las correspondientes de la parte inferior. Montajes
- Desatornille los tornillos (8) y remueva el sello incorrectos pueden causar serios daos a los
mquina (7). casquillos.
- Limpie e inspeccione completamente las piezas Verifique si el anillo pescador gira libremente
removidas y el interior de la carcasa. sobre el eje. Con la parte inferior del casquillo
- Para montar el soporte siga las instrucciones posicionada instale el sello de veda del lado de la
dadas para desmontar de forma inversa. brida del soporte. (Ver pargrafo "Vedas").
Despus revestir las fases bipartidas de la carcasa
NOTA: Par de apriete de los tornillos de fijacin con un componente de vedas que no endurezca
del soporte al motor = 10 Kgfm. rpidamente, monte la parte superior de la
carcasa (5) cuidando para que los sellos de veda
4.2.4.3. MONTAJE DEL DESCANSO ajusten perfectamente en sus encajes.
Certifquese tambin que el buje anti-giro est
Verificar las superficies del encaje de la brida encajado sin ningn contacto con el agujero
certificndose para que estn limpias, planas y sin correspondiente en el casquillo.
rebabas.
Verifique si las medidas del eje estn dentro de NOTA: Carcasa o casquillo son
las tolerancias especificadas por la Renk y si la intercambiables siempre que
rugosidad esta dentro de lo exigido (< 0,4). considerados completos (mitades
Remueva la parte superior de la carcasa (2) y los individuales no son intercambiables).
casquillos (12 y 13), verifique si no hubo ningn
dao durante el transporte y limpie 4.2.4.4. AJUSTE DE LAS PROTECCIONES
completamente las superficies de contacto. (PT100)
Levante el eje algunos milmetros y encaje la Cada soporte est equipado con un detector de
brida de la parte inferior del bancal en el rebajo temperatura tipo PT100 instalado directamente en
torneado en la tapa de la mquina atornillndola el casquillo, prximo a la zona de la carga. Este
en esta posicin. Aplique aceite en el asiento dispositivo deber ser conectado a un panel de
esfrico de la carcasa y el eje, coloque el casquillo comando con la funcin de indicar
inferior (12) sobre el eje y gire para su posicin sobrecalentamientos y de proteger el soporte de
daos debido al trabajo con temperatura elevada.
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Figura 4.10.
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Figura 4.11.
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OBS.:
LLAVES FIN DE CURSO ADICIONALES PARA 1) El sistema automtico de levantamiento de las
SEALIZACIN escobillas, posee un sistema de proteccin de
CCL1 y CCL2 = Llave fin de curso para indicar sobrecarga del actuador eletromecnico de
cuando las escobillas estuvieren totalmente accionamiento (9), a travs de las llaves de
levantadas. par para desconexin bajo sobrecarga, durante
CCA1 y CCA2 = Llave fin de curso para indicar el asentamiento (CLD) o levantamiento de las
cuando las escobillas estuvieren totalmente escobillas (CLE).
asentadas.
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Figura 4.16.
Figura 4.17.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
PASSADOR RETENTOR
CLAVIJA DEL RODILLO
RODAMIENTO
LA ZONA REBAJADA
DEBE ESTAR EN ESTA
POSICION PARA QUE EL
PASADOR RETENTOR NO
CHOQUE COM EL DISCO
DE LEVANTAMIENTO
DETALLE X
DISCO
SUPORTE DE
FIJADOR DEL CONJUNTO CLAVIJA DE
LAS CLAVIJAS
DE LEVANTAMIENTO LEVANTAMIENTO
Figura 4.18.
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1. Montar el rodillo en el casquillo del rodillo en el 4. Fijar el soporte de encaje en la base del
brazo de movimiento del casquillo de corto y soporte y los brazos de movimiento en el
enseguida, los rodamientos, el casquillo soporte. Los rodillos debern estar alineados
distanciador y fijar la tapa del rodamiento. con el casquillo de cortocircuito de manera que
estos toquen simultaneamente en el casquillo.
2. Fijar los pasadores superiores en un de los
brazos de movimiento. NOTA.: Rodamiento del brazos de movimiento:
6003Z.
RODAMIENTOS
BRAZO DE
MOVIMIENTO
TAPA DEL
CASQUILLO
DETALLE X
CASQUILLO
RODILLO DEL CASQUILLO DISTANCIADOR
DETALLE X
Figura 4.19.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
4. Fijar el disco de levantamiento en el eje de 2) Todas las partes con contactos mecnicos
accionamiento. debern ser lubricados. Despus de 6 meses
de uso, verificar la lubricacin de estas partes.
ACTUADOR ELECTROMECANICO
TORNILLO DE AJUSTE
DISCO BATIENTE
Figura 4.20.
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Figura 4.21.
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4.8.2. LNEA A
Lado accionado:
1. Desconecte los cables de las resistencias de
calentamiento de las cajas de conexin.
2. Retire los detectores de temperatura de los
soportes (si hay).
3. Suelte los tornillos que fijan el conjunto del
soporte.
4. Retire los anillos externos de fijacin (para
motores con descansos de rodamiento).
4.1. Para motores con descansos de
deslizamiento, seguir el procedimiento
descrito en el tem 4.2.2.2.
5. Desatornille la tapa. Por medio de herramienta
adecuada vaya forzando la tapa para que
salga, girndola. Certifquese que el eje este
apoyado para evitar la cada del rotor sobre el
estator.
6. Remueva el(los) rodamiento(s) (para motores
con descansos de rodamiento).
7. Retire el anillo interno de fijacin.
Lado no accionado:
1. Retire la tapa deflectora.
5. Suelte el anillo de retencin del ventilador.
6. Repita las operaciones 2 a 7 del tem 4.8.2(a).
OBS.:
1. Para retirar el rotor observe el tem 4.8.1.2.
2. El estator no necesita ser retirado de la
carcasa para eventual reparos en el bobinado.
4.8.3. LNEA F
Lado accionado:
Idntico lnea A y H.
Lado no accionado:
1. Repetir operaciones 1 a 3 del tem 4.8.2(b).
2. Retire la tapa trasera de la proteccin de los
portaescobillas.
3. Desconecte los cables de las anillos colectores.
4. Retire las escobillas y desmonte el
portaescobillas.
55
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
4.8.4. LNEA H
Figura 4.26.
Seguridad! MONTAJE
Garantir que los cables fuerza 1) Utilizando el dispositivo adecuado, coloque el rotor
fueran desligados. (pos. 11) dentro del estator, insertndolo por la
parte trasera del motor y con los debidos cuidados
para que el rotor no roce en el paquete del estator
DESMONTAJE
o en las cabezas de bobina;
1) Desconecte los cables de los sensores de
2) Coloque los anillos de fijacin internos;
temperatura (pos. 8 y 19) de los terminales de la
3) Llenar con grasa del compartimiento de los
caja de conexin de los accesorios;
anillos internos y del rodamiento (ver tipo de grasa
2) Retire el deflector trasero (pos. 26)
en las tarjetas de caractersticas de los rodamientos,
3) Suelte el anillo de retencin del ventilador trasero
fijados en las tapas del motor);
externo y retire el ventilador (pos.25)
4) Examinar con cuidado las superficies del eje y de las
4) Suelte los tornillos que fijan los anillos de fijacin
tapas donde quedarn alojados los rodamientos
externos de los cojinetes;
verificando que no existan golpes y certificando las
5) Retire los anillos de fijacin externos delantero y
correctas tolerancias de las dimensiones mecnicas;
trasero (pos. 5 y 22);
5) Calentar y colocar los rodamientos delantero y
6) Retire los centrifugadores de grasa delantero y
trasero (pos. 6 y 20)
trasero (pos. 4 y 21), soltando los tornillos que los
6) Levante el rotor, coloque apoyos abajo del eje y
fijan en el eje;
coloque las tapas delantera y trasera (pos. 9 y 18);
7) Colocar apoyos abajo del eje para evitar la cada
7) Coloque el centrifugador de grasa delantero y
del rotor sobre el estator;
trasero (pos. 4 y 21) y fjelos en el eje;
8) Destornille y retire las tapas delantera y trasera
8) Colocar los anillos de fijacin externos delantero y
(pos. 9 y 18);
trasero (pos. 5 y 22) fijndolos junto con los anillos
9) Retire los rodamientos delantero y trasero (pos. 6
de fijacin internos (pos. 7 y 16)
y 20) utilizando un extractor apropiado;
9) Colocar el ventilador trasero externo (pos. 25)
10) Retire los anillos de fijacin internos delantero y
fijndolo con el anillo de retencin
trasero (pos. 7 y 16)
10) Colocar la tapa deflectora trasera (pos. 26);
11) Utilizando el dispositivo adecuado, retire el rotor
11) Conectar los cables de los sensores de temperatura
(pos. 11) de adentro del estator por la parte
(pos. 8 y 19) en los terminales de la caja de
trasera del motor y con los debidos cuidados para
conexin de los accesorios;
que el rotor no roce en el paquete del estator o en
12) Llenar la grasa de los rodamientos a travs de las
las cabezas de bobina.
graseras trasera y delantera (pos. 27 y 28).
56
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
Clase de
4.6 5.8 8.8 12.9
resistencia
Dimetro Par de apriete (Nm) tolerancia 10%
M6 1.9 3.2 5.1 8.7
M8 4.6 7.7 12.5 21
M10 9.1 15 25 41
M12 16 27 42 70
M16 40 65 100 175
M20 75 125 200 340
M24 130 220 350 590
NOTAS:
- La clase de resistencia normalmente est
indicada en la cabeza de los tornillos
sextavados.
- Cuando no hay marcacin en el tornillo, indica
que la clase de resistencia del tornillo es 4.6.
- Los tornillos sextavados internos tipo Allen
son de clase de resistencia 12.9.
57
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
- Cajas de
- Limpiar interior, - Limpiar interior y
conexin,
reapretar tornillos. reapretar tornillos.
conexin a tierra.
- Acoplamiento
(observe las
- Despus de la primera - Verifique
instrucciones de - Verifique alineamiento
semana: verifique alineamiento y
mantenimiento del y fijacin.
alineamiento y fijacin. fijacin.
fabricante del
acoplamiento).
- Si es posible,
- Dispositivos de - Registre los valores de desmontar y hacer test
monitorizacin. la medicin. del modo de
funcionamiento.
- Limpie
- Limpie (cuando - Limpie (vea tem
- Filtro. (cuando
necesario). 4.1.2).
necesario).
- Control de la superficie,
- Anillos.
limpieza y contacto.
- Escobillas
- Control, sustituir
(motores de
cuando del tamao
anillos);
haya sido gastado (vea
- Escobillaa de
marca de desgaste,
tierra del eje (si
figura 4.5).
hay).
- Intercambiador de - Limpiar los tubos del
calor aire-aire. intercambiador.
Tabla 4.6.
58
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
5. REPUESTOS
5.1. PEDIDO
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
Gran parte de las anormalidades que perjudican la a) UNA FASE DE LA BOBINA QUEMADA
operacin normal de las mquinas elctricas, Este dao ocurre cuando el motor trabaja
pueden ser evitadas con providencias y cuidadas conectado en tringulo y falta corriente en un
de carcter preventivo. conductor de la red. La corriente sube de 2 a 2,5
Ventilacin suficiente, limpieza y mantenimiento veces en las bobinas restantes, al mismo tiempo
cuidadoso, son factores de mayor importancia.
en que la rotacin cae acentuadamente. Si el
Otro factor importante es la intervencin
inmediata cuando surge o es notado cualquier motor para, la corriente subir de 3,5 hasta 4
fenmeno, como por ejemplo: vibraciones, golpes veces su valor nominal.
de eje, resistencia de aislamiento La mayora de las veces la ocurrencia de ese
permanentemente decreciente, indicios de humo defecto se debe al hecho de no haber sido
y fuego, chispas o fuerte desgaste en los anillos instalado ningn tipo de proteccin o entonces, el
colectores y escobillas, variaciones bruscas de mecanismo de proteccin a sido regulado con
temperatura en los descansos o en los valores muy altos.
rodamientos.
La primera accin a ser tomada cuando ocurren b) DOS FASES DE BOBINAS QUEMADAS
anormalidades de naturaleza elctrica o mecnica, Este defecto ocurrir en caso de que falte
es desconectar los motores y examinar todas las corriente en un conductor de la red y la bobina
partes mecnicas y elctricas de la instalacin.
del motor este conectado en estrella.
En caso de incendio, la instalacin debe ser
aislada de la red; lo que es hecho generalmente Una de las fases de la bobina queda sin corriente
por la desconexin de las respectivas llaves. mientras que las otras pasam a absorver toda la
En la presencia de fuego en el interior del motor, potencia y a conducir una corriente muy elevada.
se debe tratar de detenerlo y sofocarlo, cubriendo El valor del deslizamiento llega casi a duplicar.
las aberturas de la ventilacin.
Para combatirlo, deben ser usados extintores de c) TRES FASES DE LAS BOBINAS
polvo qumico seco o CO2, pero nunca agua. QUEMADAS
Causa probable 1:
El motor es protegido apenas por fusibles;
6.1. DANOS COMUNES A LOS MOTORES sobrecarga en el motor ser la causa de la
DE INDUCCIN anormalidad.
La consecuencia ser la carbonizacin progresiva
Los motores de la Weg Mquinas. son
normalmente proyectados para clase de de los alambres y del aislamiento terminando en
aislamiento F (155C), y para temperatura cortocircuito entre espiras o corto circuito contra
ambiente de 40C (en conformidad con la placa la carcasa.
de identificacin). Si el motor es protegido por una llave de
La mayora de los defectos en las bobinas se proteccin esta anormalidad puede ser fcilmente
originan cuando son ultrapasadas las
temperaturas lmites en toda la bobina, o en evitada.
partes del mismo, en consecuencia de la
sobrecarga de la corriente. Ellos se revelan a Causa probable 2:
travs de oscurecimiento o carbonizacin del El motor est conectado errado.
aislamiento de los alambres. Veamos por ejemplo: Un motor con bobinas
proyectado para 220/380V es conectado a travs
6.1.1. CORTO CIRCUITO ENTRE ESPIRAS de llave estrella-tringulo a una red elctrica de
380V.
El corto circuito entre espiras puede ser La corriente absorbida ser tan alta que las
consecuencia de coincidir casualmente dos puntos bobinas quemarn en pocos segundos si los
defectuosos del aislamiento de los alambres o fusibles o una llave de proteccin incorrectamente
resultar de defectos provocados simultneamente ajustados no reaccionen inmediatamente.
en dos alambres que estn lado a lado.
En las tres fases, se manifiestan corrientes
desiguales cuya diferencia por tanto, conforme las
circunstancias podrn ser tan pequeas que la
proteccin del motor ni sienta.
Corto circuito entre espiras, contra el hierro o
entre las fases en consecuencia de defectos en el
aislamiento, ocurren raramente y as mismo, casi
siempre en los primeros tiempos despus del
inicio de funcionamiento.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
61
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
62
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
NOTA: Las instrucciones a seguir constituyen una relacin bsica de anormalidades, causas y ciones
correctivas. En caso de duda, favor contactar a Weg Mquinas, Asistencia Tcnica o Servicios.
- La corriente del estator oscila en carga - Verificar y arreglar la bobina del rotor y
con el doble de frecuencia de - Bobina del rotor esta interrumpido. dispositivo de corto circuito.
deslizamiento, el motor presenta - Problemas en las escobillas. - Las escobillas pueden estar gastadas,
zumbido en el arranque. sucias o colocadas incorrectamente.
63
Doc. PBPNU5999001 Pag. 177/458
MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
Tabla 6.2.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
NOTA: Las instrucciones a seguir relacionan las caractersticas bsicas de problemas en rodamientos. En
algunos casos es necesario un anlisis del propio fabricante del rodamiento para determinar la causa del
defecto.
Tabla 6.3.
IMPORTANTE:
Las mquinas referidas en este manual experimentan perfeccionamientos constantes,
por eso las informaciones de este manual estn sujetas a modificaciones sin previo aviso.
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MOTORES ELCTRICOS DE INDUCCIN TRIFSICOS
Estos productos, cuando son operados en las Ningn empleado, representante, revendedor u
condiciones estipuladas por Weg en los manuales otra persona est autorizado para dar cualquier
de operacin de cada producto, tienen garanta garanta en nombre de Weg o para asumir por
contra defectos de fabricacin y de materiales por Weg cualquier otra responsabilidad en relacin
un perodo de doce (12) meses contados a partir con cualquiera de sus productos.
del comienzo de operacin o dieciocho (18) En caso de que esto ocurra, sin la autorizacin de
meses la fecha de fabricacin, lo que primero Weg, la garanta estar automticamente
ocurrir. anulada.
Entretanto, esta garanta no es aplicada para
ningn producto que haya sido sometido a mal RESPONSABILIDADES
uso, mal empleo, negligencia (incluyendo sin Excepto lo especificado en el pargrafo anterior
limitacin, mantenimiento inadecuado, accidente, denominado "Trminos de Garanta Para
instalacin inadecuada, modificaciones, Productos de Ingeniera", la empresa no tendr
adaptaciones, reparaciones o cualquier otro caso ninguna obligacin o responsabilidad para con el
originado por aplicaciones inadecuadas). comprador, incluyendo, sin limitacin, cualquier
La garanta no ser responsable por reclamo con referencia a daos consecuentes o
cualquier/gasto incurrido en la instalacin del gastos con mano de obra por razn de cualquier
comprador, desensamblaje, gastos como violacin de la garanta expresa descripta en este
perjuicios financieros, transporte y de locomocin, fascculo.
bien como hospedaje y alimentacin de los El comprador tambin concuerda en indemnizar y
tcnicos cuando solicitados por el comprador. mantener la Compaa libre de daos
Las reparaciones y/o reemplazo de piezas o consecuentes de cualquier causa de accin
componentes, cuando efectuados a criterio de (excepto gastos de reposicin y reparacin de
Weg durante el periodo de garanta, no productos defectuosos, conforme lo especificado
postergar el plazo de garanta original, a menos en el pargrafo anterior denominado "Trminos
que sea expresado por escrito por Weg. de Garanta Para Productos de Ingeniera",
Esto constituye la nica garanta de Weg con consecuente directa o indirectamente de los
relacin a esta venta y la misma substituye todas actos, de negligencia u omisin del comprador
las dems garantas, expresas o implcitas, con relacin a/o proveniente de pruebas, uso,
escritas o verbales. operacin, reposicin o reparacin de cualquier
No existe ninguna garanta implcita de producto descrito en esta cotizacin y vendido o
negociacin o conveniencia para una finalidad suministrado por la Compaa al comprador.
especfica que sea aplicada a esta venta.
1014.04/0696
66
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DODGE - SLEEVE OIL RTL PILLOW BLOCKS
Installation and Maintenace Manual
1
Doc. PBPNU5999001 Pag. 183/458
Housing caps and liner caps are matched to their bases
and MUST not be interchanged. Housings and liners are to
be interchanged as assemblies only.
Options include: thermocouple, circulating oil kit, heater and Check mounting structure to insure it is rigid, level and
thermostat, vibration detector kit, auxiliary seal kit and end well supported.
closure.
Position housing base on pedestal so oil gauge is in
PRE-ASSEMBLY INSTRUCTIONS position specified on construction drawing. Do NOT
Refer to applicable contract/assembly drawings to verify tighten housing base to pedestal.
that all parts are available prior to assembly.
Disassemble and thoroughly clean all parts of the pillow
block. The installer is the last person to inspect all parts for
fit, damage and cleanliness. Care MUST be taken to avoid
contaminating the internal surfaces of the bearing.
2
Doc. PBPNU5999001 Pag. 184/458
Set liner base in
If clamp-on type
housing base.
thrust collar is used,
remove jam screws
and back off set
screws so they do
not protrude into the
I.D. of the thrust
collar. Remove
clamp screws and
make sure joints of
collar are clean.
If shaft is in place, one cooling pipe from lower liner half will
need to be removed to roll liner into place.
ATTENTION Place both halves of
Care should be taken when reinstalling coolant pipes. thrust collar into
Use pipe sealant and tighten securely. OVER- shaft groove and
TIGHTENING MAY RESULT IN LINER DAMAGE. tighten clamp scre-
Because of the closely controlled liner to housing fit, it may ws alternately and
be necessary to bolt the housing base down to allow the liner evenly to torque
to slip into the housing seat. Do a preliminary alignment value specified in
check at this time. Table 1.
Carefully smooth
any scratches on
babbitted face
INSTALLATION OF OIL RINGS with crocus cloth
(NOT emery cloth or
NOTE: Do NOT use oil rings if liner cap has baffles sandpaper). Oil plate
installed in the oil ring grooves. halves genero-
usly.
4
Doc. PBPNU5999001 Pag. 186/458
Place the other
thrust plate half (half
with two milled slots Install cap
in steel back) screws and
against thrust collar, tighten alte-
making sure bab- rnately to
bitt faces thrust torque given
collar. Clean and oil in Table 2.
the second thrust
plate set and install
NOTE: If liner cap on non-expansion bearing will not drop into
in same manner. It
place, remove cap and reposition thrust plates tightly against
may be necessary
thrust collar. Reinstall liner cap.
to move the shaft
slightly to obtain TABLE 2
enough clearance RT LINER CAP BOLTS
in the liner cavity to SLEEVOIL THREAD TORQUE
install the lower SIZE SIZE (IN.-LBS.)
plate half. 7
3 /16
5
/16 - 18 132
Total axial clearance between thrust plates and thrust collar 15
3 /16
5
/16 - 18 132
is .015 - .030 inches. 7
4 /16
5
/16 - 18 132
15 5
4 /16 /16 - 18 132
INSTALLATION OF LINER CAP 7
5 /16
5
/16 - 18 132
3
6 /8 - 16 240
Apply oil to the bearing area
7 - 13 600
of liner cap. 8 - 13 600
9 - 13 600
10 - 10 2100
12 - 10 2100
ALIGNMENT
Check alignment of
pillow block by noting
clearance between
housing and shaft at
each end of the
housingclearance
should be uniform
within 1/32". Shim
bearing pedestal
where possible;
otherwise, use full
length shims under base as required. Alignment of pillow block
CAREFULLY should be accurate since the self-aligning feature of the
locate liner bearing is to compensate for normal shaft deflection.
cap on liner
base. These Tighten housing base
SLEEVOIL mounting bolts to torque
liners have value given in Table 3.
match-marks Shaft should rotate freely.
permanently
stamped at
the joint near
one end.
These match marks permanently insure that parts stay
paired and critical orientation of assemblies is maintained.
Makes sure oil rings rotate freely. End faces of liner
should have no appreciable offset.
5
Doc. PBPNU5999001 Pag. 187/458
INSTALLATION OF OIL SEALS Back off plunger screw as
Wrap the O-ring far as possible and
(rubber cord) around CAREFULLY locate
the shaft in the seal housing cap on housing
area and cut it to fit base. These SLEEVOIL
the shaft. For most housings have match -
effective sealing, marks permanently
ends of O-ring must stamped on the water pipe
meet. Cementing grommet pad. These match
ends together is marks permanently insure
recommended. that parts stay paired and critical orientation of assemblies is
maintained. Do not damage seals or housing gasket. Torque
Disassemble one housing bolts to value given in Table 4. A non-hardening sealer can
seal and place one be used with the housing gaskets and under bolt heads to eliminate
half on shaft with chances for leakage. The plunger screw must be loose until the
flinger facing liner. housing bolts have been tightened.
Locate O-ring in seal
groove and rotate TABLE 4
seal half around shaft RTL PLUNGER SCREW HOUSING CAP BOLT
SLEEVOIL WRENCH SIZE TORQUE THREAD TORQUE
into housing base SIZE (SOC. HEX) (IN.-LB.) SIZE (IN.-LB.)
groove. 3 7/16 3
/8 850 10 1920
315/16 3
/8 850 10 1920
4 7/16 1260 7
/89 2280
Install other half of 415/16 5
/8 2500 7
/89 2280
seal and tighten 5 7/16 5
/8 2500 18 2640
5
6 /8 2500 18 2640
screws to torque 7 5
/8 2500 11/87 3600
given in Table 3. 8 3600 11/87 3600
Install second seal in 9 3600 17 5040
10 4800 17 5040
same manner. If end 12 4800 16 8880
closure is to be
used, the neoprene Plunger screw will be
disc is to be installed tightened to torque
on one end at this given in Table 4,
time instead of the following procedure
bearing seal. described below.
Consult construc- CAP LOADED
tion drawing. BEARINGS:
TABLE 3 If shaft must be held
RTL HOUSING/PEDESTAL BOLTS SEAL CLAMP SCREWS down to install cap,
SLEEVOIL THREAD TORQU THREAD TORQUE
SIZE SIZE (IN.-LBS.) SIZE (IN.-LBS.)
tighten plunger screw
3 7/16 2100 1024 12 to torque given in
315/16 7
/8 2040 1024 12 Table 4 while shaft is
4 7/16 1 3000 1024 12
415/16 1 3000 1024 12 held down. Mark the
5 7/16 1
1 /8 4200 20 33 position of the plunger
6 1 6000 20 33 screw. Loosen plunger
5
7 1 10000 /1618 65
8 1 11500 5
/1618 65 screw one turn and
9 1 11500 3
/816 120 loosen shaft hold down.
3
10 2 15000
3
/816 120 Next, tighten plunger
12 2 15000 /816 120
screw while tightening
INSALLATION OF HOUSING CAP shaft hold down until
We have replaced plunger screw is tightened to the mark. Do NOT over tighten
SLEEVOIL housing gas - shaft hold down as this can misalign liner. Remove shaft hold
kets with 515 Gasket down and tighten plunger screw locknut.
Eliminator. Apply gasket NOTE: Do NOT tighten plunger screw on accompanying
eliminator to SLEEVOIL base loaded bearing until cap loaded bearing has been
housing base along outer
installed and shaft hold down removed.
contour of joint. NOTE:
Special care should be BASE LOADED BEARINGS: Tighten plunger screw to torque
taken at grommet area. given in Table 4 and secure with locknut.
6
Doc. PBPNU5999001 Pag. 188/458
INSTALLATION OF GROMMETS Install grommet, grommet plate and collar over each inlet
AND OIL GAUGE pipe. Press down on collar and tighten collar set screw.
Install grommet and
grommet plate over
coolant pipes.
7
Doc. PBPNU5999001 Pag. 189/458
Apply sealant to the Remove and reinstall,
pipe plug furnished using sealer, all pipe
and install it in the plugs not previously
remaining hole. removed.
These SLEEVOIL housings and liners have nameplates near an oil ring inspection hole. Housing nameplates are
attached beginning June of 1988 identified by a six-digit pinned to the housing foot parallel to the shaft. Refer to
part number which fully identifies the housing and/or liner. these part numbers when ordering replacement parts.
Liner nameplates are pinned to the SLEEVOIL liner cap
10
Doc. PBPNU5999001 Pag. 192/458
www.baldor.com www.ptplace.com www.dodge-pt.com www.reliance.com
11
Doc. PBPNU5999001 Pag. 193/458
AUMA ELECTRIC MULTI-TURN ACTUATOR
Installation and Maintenace Manual
ISO 9001
ISO 14001
Certificate Registration No.
12 100 4269
12 104 4269
Operation instructions
Doc. PBPNU5999001 Pag. 195/458
Multi-turn actuators SA 07.1 SA 30.1 / SAR 07.1 SAR 30.1
with actuator controls AUMA MATIC AM 01.1 / AM 02.1 Operation instructions
Scope of these instructions: These instructions are valid for multi-turn actuators of the type range SA(R)
07.1 SA(R) 30.1 with the controls AM 01.1 / AM 02.1. These operation
instructions are only valid for clockwise closing, i.e. driven shaft turns
clockwise to the valve.
Page
17. Closing the switch compartment 25
18. Actuator controls AM 01.1/AM 02.1 26
18.1 Functions of the diagnosis LEDs on the interface board (standard version) 26
18.2 Programming the logic board 27
18.3 EMERGENCY OPEN and EMERGENCY CLOSE signal (option) 28
19. Electronic positioner (option) 29
19.1 Technical data 29
19.2 Programming 29
19.2.1 Setting the type of signal 30
19.2.2 Setting actuator behaviour on loss of signal 31
19.3 Positioner adjustment end position CLOSED (standard version) 32
19.4 Positioner adjustment end position OPEN (standard version) 33
19.5 Setting of the sensitivity 33
19.6 Positioner adjustment end position OPEN (inverse operation) 35
19.7 Positioner adjustment end position CLOSED (inverse operation) 36
19.8 Positioner in Split Range version (option) 37
19.8.1 Split Range: description of functions 37
19.8.2 Programming 37
19.8.3 Positioner adjustment for Split Range 37
20. Timer (option) 39
20.1 Functions of the diagnosis LEDs (timer) 39
20.2 Setting start and end of stepping mode via DUO limit switching (option) 40
20.3 Setting ON and OFF times 41
21. Fuses 42
22. Enclosure protection IP 68 (option) 43
23. Applications in Ex Zone 22 (option) 44
24. Maintenance 45
25. Lubrication 45
26. Disposal and recycling 45
27. Service 45
28. Spare parts list multi-turn actuator SA(R) 07.1 - SA(R) 16.1 46
29. Spare parts list controls AM 01.1/AM 02.1 48
30. Declaration of Conformity and Declaration of Incorporation 50
Index 51
Addresses of AUMA offices and representatives 52
1. Safety instructions
1.1 Range of application AUMA actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves and ball valves. For other
applications, please consult us. The manufacturer is not liable for any
possible damage resulting from use in other than the designated
applications. Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the
controls/ actuators designated use.
1.2 Commissioning During electrical operation, certain parts inevitably carry lethal voltages.
(electrical connection) Work on the electrical system or equipment must only be carried out by a
skilled electrician himself or by specially instructed personnel under the
control and supervision of such an electrician and in accordance with the
applicable electrical engineering rules.
1.3 Maintenance The maintenance instructions (refer to page 45) must be observed,
otherwise a safe operation of the actuator is no longer guaranteed.
1.4 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries or
damage. Qualified personnel must be thoroughly familiar with all warnings
and notes in these operation instructions.
Correct transport, proper storage, mounting, and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe
operation.
During operation, the multi-turn actuator warms up and surface
temperatures > 60 C may occur. Check the surface temperature prior to
contact in order to avoid burns.
2. Short description AUMA multi-turn actuators type SA(R) 07.1 SA(R) 30.1 have a modular
design. The actuators are driven by an electric motor and operated with the
controls AM 01.1/AM 02.1, which are included in the scope of supply. The
limitation of travel is realised via limit switches in both end positions. Torque
seating is also possible in both end positions. The type of seating is
determined by the valve manufacturer.
3. Technical data
Table 1: Multi-turn actuator with actuator controls AUMA MATIC AM 01.1/AM 02.1
Features and functions
Type of duty 1) Standard: SA Short time duty S2 15 min
SAR Intermittent duty S4 25 %
Option: SA Short time duty S2 30 min
SAR Intermittent duty S4 50 %
Intermittent duty S5 - 25 %
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34
Option: Special motors
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking yes (for output speeds from 4 to 90 rpm)
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke)
Standard: Single switch (1 NC and 1 NO) for each end position:
Options: Tandem switch (2 NC and 2 NO) for each end position, switches galvanically isolated
Triple switch (3 NC and 3 NO) for each end position, switches galvanically isolated
Intermediate position switch (DUO limit switching)
Torque switching Adjustable torque switching for direction OPEN and CLOSE
Standard: Single switch (1 NC and 1 NO) for each direction
Options: Tandem switch (2 NC and 2 NO) for each direction, switches galvanically isolated
Position feedback signal, Potentiometer or 0/4 20 mA
analogue (options) For further details see separate data sheet
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
Running indication Blinker transmitter (for SA standard, for SAR option)
Heater in switch compartment Standard: Resistance type heater, 5 W, 24 V DC
Option: Self-regulating PTC heater, 5 20 W
110 250 V DC/AC or 24 48 V DC/AC
Motor heater (option) SA(R) 07.1 10.1: 12.5 W
SA(R) 14.1 16.1: 25 W
SA(R) 25.1 30.1: 50 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during
electrical operation.
Option: Handwheel lockable
Connection to controls AUMA plug/ socket connector with screw type connection
Output drive types A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3
1) Based on 20 C ambient temperature and at an average load with running torque according to Technical data SA or SAR.
2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles are to be expected, thyristor units with
virtually unlimited lifetime should be used.
Service conditions
Enclosure protection according Standard: IP 67
to EN 60 5295) Options: IP 68
IP 67-DS (Double Sealed)
IP 68-DS (Double Sealed)
(Double Sealed = terminal compartment additionally sealed against interior)
Corrosion protection Standard: KN suitable for installation in industrial units,
in water or power plants with a low pollutant concentration
Options: KS suitable for installation in occasionally or permanently aggressive
atmosphere with a moderate pollutant concentration
(e.g. in wastewater treatment plants, chemical industry)
KX suitable for installation in extremely aggressive atmosphere with
high humidity and high pollutant concentration
KX-G same as KX, however aluminium-free version (outer parts)
Finish coating Standard: two-component iron-mica combination.
Colour Standard: silver-grey (DB 701, similar to RAL 9007)
Option: Other colours are possible on request
Ambient temperature Standard: SA 25 C to + 70 C
SAR 25 C to + 60 C
Options: SA 40 C to + 60 C (low temperature)
SAR 40 C to + 60 C (low temperature)
Vibration resistance6) 1 g, from 10 Hz to 200 Hz
according to EN 60068-2-6
Lifetime7) Type Operating cycles (OPENCLOSEOPEN)
with 30 turns per stroke
SA 07.1 SA 10.1 20,000
SA 14.1 SA 16.1 15,000
SA 25.1 SA 30.1 10,000
5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure
protection IP 68, we recommend to use the double sealed terminal compartment DS.
For special motors, the enclosure protection according to the name plate applies.
6) For standard version SA(R) 07.1 SA(R) 16.1 in combination with the actuator controls AM 01.1
7) The lifetime in operation hours (h) depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To
reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process.
8) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an
RWG has to be used within the actuator.
Information B: The type of seating in the end positions is determined by the valve
manufacturer. The setting is done at the programming switches S1 2 and
S3 2 (see page 27). The tripping of a torque switch in an intermediate
position switches off the actuator and gives a fault signal.
The limit switches are used for signalisation when switching off by torque
seating. They need to be set so that the appropriate switch is tripped shortly
before reaching the end position. If the torque switch trips before the limit
switch, the actuator is switched off and a fault signal is generated.
For further programming possibilities, e.g. self-retaining in operation mode
REMOTE, see table 7, page 27.
Information D: The following faults are registered and can be transmitted to the control
room as a potential-free collective fault signal:
- Power failure
- Phase failure
- Motor protection tripped
- Torque switch tripped in mid-travel.
This signal can be switched off on the logic board, see table 7, page 27.
Information G: Potential-free contacts are available for signals. The internal control voltage
(XK 11 / + 24 V and XK 5 / 24V) must not be used for external lamps,
relays etc.
. hoist.
If multi-turn actuator is mounted on valve, attach ropes or hooks for the
purpose of lifting by hoist to valve and not to multi-turn actuator.
Fitting the handwheel: For transport purposes, handwheels from a diameter of 400 mm are
supplied separately.
.. Slip handwheel over the red change-over lever on shaft (figure A-2).
Secure handwheel using the circlip supplied.
Figure A-1 Figure A-2
85
.. a wooden pallet.
Cover to protect against dust and dirt.
Apply suitable corrosion protection agent to bright surfaces.
If multi-turn actuators are to be stored for a long time (more than 6 months),
the following points must be observed additionally:
. Prior to storage: Protect bright surfaces, in particular the output drive parts
5.3 Packaging Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can
easily be separated and recycled.
We use the following packaging materials: wood, cardboard, paper and PE
foil. For the disposal of the packaging material, we recommend recycling
and collection centres.
6. Mounting to valve/ gearbox . Prior to mounting, the multi-turn actuator must be checked
for damage. Damaged parts must be replaced by original
. spare parts.
After mounting, check multi-turn actuator for damage to
paint finish. If damage to paint-finish have occurred after
mounting, they have to be touched up to avoid corrosion.
Mounting is most easily done with the valve shaft/ gearbox shaft pointing
vertically upward. But mounting is also possible in any other position.
The multi-turn actuator leaves the factory in position CLOSED (limit switch
CLOSED operated).
The output drive types B1, B2, B3, or B4 (figure A-3) are delivered with bore
and keyway (usually according to ISO 5210).
Figure A-3
Output drive type B1/ B2 Output drive type B3/ B4
Plug sleeve Bore with keyway
For output drive type A (figure B-1), the internal thread of the stem nut must
match the thread of the valve stem. If not ordered explicitly with thread, the
stem nut is unbored or with pilot bore when delivered. For finish machining
..
of stem nut refer to next page.
Check whether bore and keyway match the input shaft of valve/ gearbox.
Thoroughly degrease mounting faces at multi-turn actuator and valve/
..
gearbox.
Apply a small quantity of grease to input shaft of valve/ gearbox.
Place actuator on valve/ gearbox and fasten. Fasten bolts (at least quality
8.8, refer to table 2) evenly crosswise.
80.3
80.01/80.02
80.2
The output drive flange does not have to be removed from the actuator.
.. When fixing in the chuck, make sure stem nut runs true!
Clean the machined stem nut.
Apply Lithium soap EP multi-purpose grease to thrust bearing and races,
.. that dogs are placed correctly in the slots of the hollow shaft.
Screw in spigot ring until it is firm against the shoulder.
Press Lithium soap EP multi-purpose grease on mineral oil base into the
grease nipple with a grease gun (for quantities, please refer to table):
.
Protection tube for rising valve stem
Protection tubes may be supplied loose. Seal thread with hemp, Teflon
7. Manual operation The actuator may be operated manually for purposes of setting and
commissioning, and in case of motor failure or power failure.
Manual operation is engaged by an internal change-over mechanism.
Engaging manual operation: . Lift up change-over lever in the centre of the handwheel to approx. 85,
while slightly turning the handwheel back and forth until manual operation
engages (figure C).
Figure C Figure D
. Release change-over lever (should snap back into initial position by spring
action, figure D), if necessary, push it back manually.
Figure E Figure F
Disengaging manual operation: Manual operation is automatically disengaged, when the motor is started
again. The handwheel does not rotate during motor operation.
In case the actuator controls are equipped with a fieldbus interface (Profibus
DP, Modbus, or DeviceNet), refer to the operation instructions of the
respective fieldbus for a description of the bus and electrical connection.
.
Electric power cables, in particular motor cables, are interference sources.
Lay cables being susceptible to interference or sources of interference at the
51.0
. Connect cables according to order-related wiring diagram.
The wiring diagram applicable to the actuator is attached to the
handwheel in a weather-proof bag, together with the operation
instructions. In case the wiring diagram is not available, it can be obtained
51.01 from AUMA (state commission no., refer to name plate) or downloaded
directly from the Internet (www.auma.com).
A special parking frame (figure G-2) for protection against touching the bare
contacts and against environmental influences is available.
Parking frame
.
wall bracket.
For the connection of actuator and AUMA MATIC on wall bracket, use
suitable flexible and screened connecting cables.
.max. of 100 m.
Versions with potentiometer in the actuator are not suitable. Instead of the
8.3 Heater AUMA multi-turn actuators have a heater installed as standard. Unless
ordered otherwise, the heater is internally supplied.
8.4 Motor protection In order to protect against overheating and impermissibly high temperatures
at the actuator, PTC thermistors or thermoswitches are embedded in the
motor winding. The thermoswitch is tripped as soon as the max. permissible
winding temperature has been reached.
8.5 Remote position transmitter For the connection of remote position transmitters (potentiometer, RWG)
screened cables must be used.
. Insert the socket carrier (51.0) into the plug cover (50.0) and fasten it with
.. screws (51.01).
Clean sealing faces at the plug cover and the housing.
. Replace plug cover (50.0) and fasten bolts (50.01) evenly crosswise.
Fasten cable glands with the specified torque to ensure the required
enclosure protection.
9. Opening the switch To be able to carry out the following settings (clauses 10. to 16.), the switch
compartment compartment must be opened and, if installed, the indicator disc must be
removed.
These settings are only valid for clockwise closing, i.e. driven shaft turns
clockwise to close the valve.
. Remove 4 bolts and take off the cover at the switch compartment
(figures H).
Figure H-1: Cover with indicator glass Figure H-2: Cover without indicator glass
Bolts
. If installed, pull off indicator disc (figure J). Open end wrench
(approx. 14 mm) may be used as lever.
RSD
RDW
Indicator disc
T P
B E
C F
A D
10.2 Setting end position OPEN (white section)
. approximately a turn.
Press down and turn setting spindle D (figure K-1) with screw driver
(5 mm) in direction of arrow, thereby observe pointer E.
While a ratchet is felt and heard, the pointer E moves 90 every time.
When pointer E is 90 from mark F, continue turning slowly. When pointer
E has reached the mark F, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer
has snapped), continue turning the setting spindle in the same direction
and repeat setting process.
10.3 Checking the limit switches The red test buttons T and P (figure K-1) are used for manual operation of
the limit switches.
.. Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED.
Turning P in direction of the arrow LSO (WL) triggers limit switch OPEN.
T P
C F
H L
G K
..
11.2 Setting the direction OPEN (white section)
Move valve to desired intermediate position.
Press down and turn setting spindle K (figure K-2) with screw driver
(5 mm) in direction of arrow, thereby observe pointer L.
While a ratchet is felt and heard, the pointer L moves 90 every time.
When pointer L is 90 from mark F, continue turning slowly. When pointer
L has reached the mark F, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer
has snapped), continue turning the setting spindle in the same direction
and repeat setting process.
11.3 Checking the DUO switches The red test buttons T and P (figure K-2) are used for manual operation of
.
the DUO limit switches.
Turning T in direction of the arrow LSC (WSR) triggers DUO limit switch
O P O P
. operation.
The torque switching acts as overload protection over full
travel, also when stopping in the end positions by limit
switching.
The red test buttons T and P (figure K-2) are used for manual operation of
the torque switches:
. Turning T in direction of the arrow TSC (DSR) triggers torque switch CLOSED.
S1/S2
Table 5:
Direction of rotation of the indicator disc:
counterclockwise correct
Direction of rotation of the hollow shaft:
clockwise correct
..
When limit switching is set correctly:
Set selector switch to local control (I)(figure M-3).
Perform test run at the local controls via push-buttons
OPEN STOP CLOSE.
13.3 Checking the type of seating The valve manufacturer states whether switching off in the end positions
.
should be by limit switch (limit seating) or torque switch (torque seating).
For checking the setting, refer to page 27, subclause 18.2.
.
If no other options (clauses 14. to 16.) require setting:
Close switch compartment (see page 25, clause 17.).
E2
The position transmitter board (figure P-1) is located under the cover plate
(figure P-2).
Cover plate
E2
.. This ensures that the signal remains above the dead and live zero point.
Move valve to end position OPEN.
..
15.2 Setting for 3-/ 4- wire system 4 20 mA
Connect voltage to electronic position transmitter.
..
Move valve to end position CLOSED.
If installed, pull off indicator disc.
Connect ammeter for 0 20 mA to measuring points (figure P-2).
Cover plate
E2
.. is reached.
Move valve to end position OPEN.
Indicator disc
Mark
Cover
Timer board
(option)
Cover plate
Interface board
Logic board
Positioner board
(option)
18.1 Functions of the diagnosis LEDs on the interface board (standard version)
The LEDs STOP, CLOSE, OPEN indicate the available control commands
(only in selector switch position REMOTE).
The type of seating - limit or torque seating - (switch S1-2 and switch S3-2,
figure R-3) must be determined by the valve manufacturer.
Position 2:
Torque seating
in end position OPEN
S3-2
S2-2
Position 1:
Limit seating
S1-2 in end position CLOSED
Position 2:
Torque seating
in end position CLOSED
Table 7
Self-retaining REMOTE
Self-retaining LOCAL
activated deactivated
Blinker transmitter (option)
Figure R-4: Cover plate for option EMERGENCY OPEN or EMERGENCY CLOSE
Links: B1(EMERGENCY CLOSE) LED for EMERGENCY
B2 (EMERGENCY OPEN) run command
B2
B1
19.2 Programming The positioner in the actuator controls AM 01.1/AM 02.1 is programmed
according to the purchase order details and is set together with the actuator
prior to delivery.
Due to peculiarities of the regulating system not known beforehand, a
readjustment may become necessary. Before adjusting the positioner, the
programming of the positioner should be checked.
. Take off cover plate (figure S1) and carry out required programming at
positioner board (figure S2) according to tables 9 and 10.
V10 (red)
P10
P8
V28
V27
Meas- V18
points: V10
E1{MP4()
MP3(+) P10
E2{
MP2(+)
MP1()
S1-7
19.2.1 Setting the type of signal The signal type (current/ voltage signal) of nominal value E1 and actual
value E2 is set in the factory and marked with a label on the cover plate of
the positioner (refer to figure S1).
If the setting is subject to a subsequent change, the marking also has to be
changed. Furthermore the wiring diagram indicated on the name plate of the
actuator controls also changes (see page 48).
Programming
Command signal Feedback via DIP switch S1-7
Nominal value E1 Actual value E21) (refer to figure S2)
4 20 mA 4 20 mA
0 20 mA 0 20 mA
4 20 mA
05V
0 20 mA
4 20 mA
05V
0 20 mA
05V 05V
4 20 mA
0 10 V
0 20 mA
0 10 V 05V
fail as is 4 20 mA 4 20 mA
4 20 mA 4 20 mA
fail close
0 20 mA
4 20 mA
05V
4 20 mA 4 20 mA
fail open
0 20 mA
4 20 mA
05V
4 20 mA
05V
0 20 mA
0 20 mA
0 20 mA
05V
05V
0 10 V
0 20 mA 4 20 mA
fail close fail as is
0 10 V 4 20 mA
1) During loss of signal, signals from 0 20 mA and 0 5 V may be misinterpreted since E1 or E2 (without any fault) can also be < 4 mA (end position CLOSED =
0 mA or 0 V), when working properly.
2) Signals for internal feedback:
0/4 20 mA from electronic positioner or 0 5 V from precision potentiometer 5 k
.. CLOSED.
Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
Turn potentiometer t-off (P10) counterclockwise to the stop
(figure S1).
. Connect voltmeter to measuring points MP3 and MP4 (figure S2) for
measuring the nominal value (0 5 V).
For a nominal value E1 of 0 mA the voltmeter shows 0 V.
For a nominal value E1 of 4 mA the voltmeter shows 1 V.
In case nominal value (0 V or 1 V) is not correct:
Table 11
V28
V27
Meas. V18
points: V10
{
MP4()
E1 MP3(+)
P10
{
MP2(+)
E2 MP1()
S1-7
.. positioner adjustment.
Connect max. command signal (nominal value E1) = 20 mA.
Connect voltmeter to measuring points MP3 and MP4 for measuring the
nominal value E1:
For a nominal value of 20 mA the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.
Table 12
19.5 Setting of the sensitivity .. Set selector switch at the local controls to position REMOTE.
Set command signal E1 according to label on cover plate
(see figure S1).
The sensitivity (E / dead band) is set to maximum value (2.5 %) in the
. factory.
With the potentiometer E (P9) the dead band can be increased by
turning clockwise. Left stop = small dead band (= high sensitivity). For a
precise setting of the dead band, a set point device with setting options in
V28 (green)
V27 (yellow)
V18 (red)
V10 (red)
P10
V28
V27
Meas. V18
points: V10
{
E1 MP4()
MP3(+) P10
{
E2 MP2(+)
MP1()
S1-7
.
operation to end position OPEN.
By switching the code switch S3-7 (figure S2) to position 1" an inversion