inst & maint motors gb
TRANSCRIPT
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MSIMMA 982 ind. b
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""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""
MANUAL FOR SAFETY,
INSTALLATION AND MAINTENANCE
FL - F3 - N3 SERIES
INDUCTION MOTORS
""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""
Rev. a .01 Rev. b 23.01.02
ALSTOM Moteurs 4,rue de la Rompure - B.P.90 - 54250 Champigneulles France - Tel. (33) 03.83.38.40.00 - Fax (33) 03.83.38.42.99
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MSIMMA 982 ind. b
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WARNING
Users must follow the instructions and read the information contained in this manual. Anyone working on the equipment supplied MUST fully under-stand the instructions and information contained in this manual.
The personnel installing, commissioning and servicing the equipment MUST be both qualified and experienced in these fields and satisfy all relevant legal obligations, including all health and safety rules and recommenda-tions applicable in the country where the equipment is to be installed.
Safety note
.........................................................................
Before working on the motor, always :
Check that the electric power to the motor is cut.
Check that the motor cannot rotate.
Ensure that electric power cannot intentionally or accidentally be restored through-out the work, and that the motor cannot rotate
Take all necessary steps to ensure personal safety and prevent damage to equipment.
This manual contains the general safety, installation and maintenance in-structions for the Flowpak 2, F3 & N3 series motors. The term motor in this manual covers induction motors and generators.
For motors located in hazardous areas (e.g. potentially explosive atmos-pheres), the instructions in paragraph 11.2 must be observed.
It is therefore essential to read this manual carefully, and consult the draw-ings, connection diagrams and data sheets.
Before the motor enters full service after installation, the installation report must be completed, a specimen copy of which is to be found at the end of this manual. This report will need to be produced for any intervention during and the warranty period.
The "Warning or Caution" symbol is used to draw the user's attentionto important points.
CAUTION
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MSIMMA 982 ind. b
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CONTENTS
Page
WARNING 1
Contents 2
1 - Definition of main graphical symbols ..3-4
2 - Abbreviations and direction of rotation5
3 - Shipping ..6
4 - Acceptance procedure ..7
5 - Handling (motor in crate) .................................................................. 8
6 Handling (handling diagrams) ......................................................... 9 to 11
7 - Storage.................................................................................................. 12
8 - Installation ............................................................................................ 13 to 16
9 - Stator insulation measurement ......................................................... 17
10 - Machine drying ................................................................................. 18-19
11 - Checks prior to start-up .................................................................... 20-21
12 - Start-up................................................................................................ 22
13 - Troubleshooting procedure ............................................................. 23
14 - Maintenance ..................................................................................... 24 to 39
15 - After sales service.............................................................................. 40 to 42
Acceptance report (1 page)
Installation report (7 page)
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MSIMMA 982 ind. b
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1 - DEFINITION OF MAIN GRAPHICAL SYMBOLS
Symbols concerning packaging and handling.
Key Symbol Meaning Fragile Handle with care
iso 7000/n 0621
Indicates : a) That the contents of the package are fragile; b) That the package should be handled with care.
Do not use hooks
iso 7000/n 0622
Indicates that the pack-age is not to be handled using hooks.
This way up
iso 7000/n 0623
Indicates the correct up-right position of the pack-age.
Store away from heat
iso 7000/n 0624
Indicates that the pack-age is to be stored away from heat.
Store away from heat and radioactive materi-als.
iso 7000/n 0615
Indicates that the con-tents of the package may be damaged or rendered useless by exposure to high temperatures or ra-dioactivity.
Lifting point
iso 7000/n 0625
Indicates the fixing points for the slings used to lift the package.
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MSIMMA 982 ind. b
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DEFINITION OF MAIN GRAPHICAL SYMBOLS
Key Symbol Meaning Keep dry
iso 7000/n 0626
Indicates that the pack-age must be kept dry.
Centre of gravity
iso 7000/n 0627
Indicates the centre of gravity of the package.
Do not roll
iso 7000/n 0628
Indicates that the pack-age must not be rolled.
No sack trucks on this side.
iso 7000/n 0629
Indicates the points where sack and pallet trucks must not be placed.
Stack height
iso 7000/n 0630
Indicates the stacking height for the package.
Lateral clamping points
iso 7000/n 0631
Indicates the clamping points on the package.
Temperature limits
iso 7000/n 0632
Indicates the maximum and minimum tempera-tures between which the package must be main-tained and handled.
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MSIMMA 982 ind. b
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2 - ABBREVIATIONS AND DIRECTION OF ROTATION
CS : Coupling side OSC : Opposite side from coupling
DIRECTION OF ROTATION
The direction of rotation is always given for an observer looking at the motor from the coupling side (CS) and identified by a single arrow-head for a single direction of rotation, and by two arrow-heads for motors turning in both di-rections.
The motor can only be operated in the direction of rotation forwhich it was built.
FClockwiseAnti - clockwise
F
OSCCS
OSC
CS
F
Anti - clockwise ClockwiseF
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MSIMMA 982 ind. b
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3 - SHIPPING
Motors in seaworthy packaging
When shipped by sea, or where the motor is likely to be exposed to adverse weather conditions, we recommend it is packaged in accordance with offi-cial standard SEI 4 c (standard seaworthy packaging).
Except where specifically written in the contract, we recommend following the procedure below when the equipment is delivered :
Remove the crate lid
Remove the thermowelded cover
Check the quality of the equipment supplied
Replace the crate lid
Place the equipment and crate in storage (see storage page).
4 - RECEIPT PROCEDURE
Check that all packaging is perfect condition, indicating that the equipment has not been damaged in transit.
Check the various items against the shipping documents and inspect the equipment and accessories visually.
In the event of anomaly :
Any signs of impact or damage must be indicated.
All official reservations should be made to the shippers within 24 hours and to ourselves by fax within 24 hours and by registered mail.
All necessary steps should be taken to keep the equipment safe and in good condition.
Ideally, a legal damage report should be drawn up, and in all cases photo-graphs clearly showing the damage are to be taken.
Check that appropriate handling equipment for the equipment, weightsand sizes is available on-site.
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MSIMMA 982 ind. b
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5 - HANDLING
Crated motors
Note the position of centre of gravity carefully, as it may not lie at the centre of the crate.
Where crates have to be moved using a fork-lift truck, they should be care-fully centred on the forks, taking into account their dimensions and centre of gravity.
Under no circumstances should crates be overturned or carried on their sides.
Crates should be properly lashed to, prevent impacts and overturning.
Do not stack crates, to avoid damaging them.
Slings are to be fitted as indicated by the markings on the packaging.
TOP
BOTTOM
CUSTOMERWEIGHT
Example centre ofgravity
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MSIMMA 982 ind. b
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6 - HANDLING
The motor is supplied fully assembled.
Weight : see name plate on the motor.
Fragile equipment. Handle with care.
Use a lifting beam * or adjustable slings.
Fit hoisting shackles into the holes on the lifting lugs.
When handling the entire motor, use the lugs on the upper part of the frame
Always check that the rotor, locking device is fixed before moving the motor.
(*) Lifting beam, slings and hoisting shackles not supplied.
Example handling diagrams
Flowpak 2 horizontal motor.
Adjustable slings
Refer to the enclosed dimensional drawings before moving the motor.The drawings show the weight, centre of gravity and overall dimensions.
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MSIMMA 982 ind. b
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F3 horizontal motor
N3 horizontal motor
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MSIMMA 982 ind. b
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Flowpak 2 vertical motor
F3 vertical motor N3 vertical motor
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MSIMMA 982 ind. b
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7 - STORAGE
7.1 Storage instructions
The equipment is to be stored in a clean, dry and adequately ventilated place.
The equipment is to be stored at a temperature above -20C, except where expressly written into the contract.
The equipment is not to be placed directly on the ground, but on wooden beams, in order to prevent damage from below and to allow air to circulate freely around the equipment.
The storage area should be free from vibrations, which might otherwise dam-age the equipment.
The storage area should as far as possible be protected against potential hazards such as flooding, animal infestations, etc.
The equipment is not to be stored in a saline or corrosive atmosphere, except where expressly written into the contract.
7.2 - Equipment protection
All bearings are protected against corrosion for at least 2 years from leaving the factory, and require no on-site maintenance.
All our motors are fitted with an external, red silicone packing seal at the join between the bearing and shaft (bearing baffle). This seal serves no purpose when operating the motor. This seal may break away from its mounting when the motor is commissioned, and does not affect motor operation.
Note 1 ; The rotor locking device is to remain fixed.
Note 2 : Where different, specific storage conditions have been agreed in the contract, they are to take precedence over those described above.
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MSIMMA 982 ind. b
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8 - INSTALLATION
8.1 - Motor positioning
The rotor locking device is to remain fixed while the motor is handled, moved and positioned next to the machine to be driven.
The rotor locking device should be dismantled :
before adjusting the shaft alignment on horizontal machines ;
before placing a vertical motor against the shaft of the driven machine.
Note : Two diagonally opposite 10 mm holes must be drilled into the base-plate or frame to allow the motor to be pinned. This procedure is to be per-formed prior to positioning the motor, in accordance with the floor plan for the vertical holes, and after final tightening for the oblique holes (with the motor acting as a template).
8.2 - Supply of base-plates and anchor rods
The shaft heights of the two machines can be aligned by placing adjusting shims between the base-plates and motor feet.
The upper surface of the base-plates must be adjusted as shown in the diagram below:
Add : shims must be positioned as close as possible of lightning screws
Shims with excessive lengths cun generale the important bendings.
Driven machineMotor foot
MotoDriven machineshaft axis
Base plate
X + 1
mm
X = motor shaft height
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MSIMMA 982 ind. b
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8.3 - Machine adjustments
8.3.1 - Introduction
The parallelism (axial alignment) and concentricity (radial alignment) of the coupling sleeves on the driving and driven machines must be set correctly. Use the jack-bolts and adjusting shims supplied with the machine for this pur-pose.
8.3.2 - Special cases : machnes with axiall free rotors
The correct "X" or "Y" dimension is indicated on a plate fixed over the bearing
and in the test re-port.
With axially free rotors, the rotor must be correctly centred in themotor with the correct X or Y dimension, as shown below
Y = mm
X = mm
With coupling sleeve
With coupling flange
Shaft shoulder on coupling side
Bearing seal
Collar rigide
Collar rigide
Radial misalignment
Axial misalignment
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MSIMMA 982 ind. b
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8.3.3 Tolerances
We cannot the alignment tolrances specified by coupling manufacturers. The high prcision of our bearings allows the following tolrances.:
. 0.03 mm (0.0012) in all directions for coupling sleeves of external diameter 200 mm ( 8 ). . 0.05 mm (0.0012) in all directions for coupling sleeves of external diameter < 200 mm (8) .
8.4 - Instructions
The motor should be aligned and vertically adjusted in accordance with the
manufacturer of the driven machine's instructions.
With semi-flexible couplings, refer to the tolerances given above.
With rigid couplings of all sizes, a single tolerance of 0.03 mm axe to axe (
0.0012 ) is to be taken into account.
Importance of instructions
The failure to respect the instructions and tolerances stated above will result
in :
Excessive vibration ;
Bearing overheating ;
Premature wear of bearing components.
PRECAUTIONS
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MSIMMA 982 ind. b
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8.5 Machine mounting screw torque settings
The torque settings given in the chart below must be respected in to prevent screw fatigue or thread stripping, or damage to the motor caused by vibra-tion.
Screw diameter(mm) Torque (N.m)
20 310
22 420
24 540
27 800
30 1000
33 1450
39 2450
42 3000
48 4550
52 5200
8.6 Motor pinning
Pin the motor.
8.7 Connection of forced oil lubricated sleeve bearings to the lubrication system
Refer to paragraph headed "Forced oil lubrication".
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MSIMMA 982 ind. b
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9 STATOR INSULATION MEASUREMENT
Moisture is particularly detrimental to the proper operation of electric motors.
Before switching on the power, check the insulation resistance of the stator windings with respect to the earth.
- Stator voltage 2500 Volts
A 2500 Volt megohmmeter (at least) should be to make these measure-ments.
The insulation resistance must at least equal :
R=3 (1+U)
R=insulation resistance in megohms
U=rated voltage in Kv.
- Stator voltage < 2500 Volts
Use a 500 Volt megohmmeter.
The insulation resistance must be 10 megohms.
If the readings are lower than those started above, dry the motrorbefore starting it.
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MSIMMA 982 ind. b
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10 MACHINE DRYING
10.1 - Drying
Connect the stator to a three-phase power supply of at most 10% of rated voltage.
During the drying procedure, use stator temperature probes or a thermome-ter to monitor the heating of the stator windings. The temperature is not to exceed 80C.
Once drying is complete, disconnect the power supply and allow the motor to cool to room temperature. Check the resistance values again, and if the measured value is correct, the normal power supply may be connected ready for start-up. If the value is not correct repent the procedure and check again.
10.2 Insulation resistance levels
Insulation measurements are to be made at three-hours intervals. Readings are taken after disconnecting the power supply from the stator and following the procedure described in the paragraph headed "Stator insulation meas-urements".
At the stator of the procedure, the insulation resistance will decrease, before gradually rising.
The drying procedure should be stopped two or three hours after the insula-tion resistance reaches the required value.
The drying process may be quite slow (up to 48 hours).
It should be noted that the insulation resistance reading measured after the machine has cooled may be higher than the value obtained with the ma-chine hot at the time when drying was stopped.
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MSIMMA 982 ind. b
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10.3 Heating elements
The heaters should not be left energized while the motor is running.
The purpose of the heating elements is to keep the motor warm enough to prevent internal condensation.
Refer to the electrical connection diagram enclosed with the motor when wiring the heating elements.
Note : The heaters should also not be left energized while the alignement period.
The thermal equilibrium in the motor may be upset by leaving the heatingelements switched on while the motor is running.
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MSIMMA 982 ind. b
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11 CHECKS PRIOR TO START-UP
The coupling used is to be fitted with axial play limitation device (0.5mm) During motor installation on site, it is mandatory to place/rotor to get right size X(or Y) according to special label fitted on motor and as indicated in work-shoptest report.
11.1 General electric motor start-up conditions for every electric motor
The driving and driven machines are correctly coupled and fixed to-gether.
The safety covers on moving parts are fitted, in position and fixed to the floor or a fixed object.
Nobody is working on either the driving or driven machine.
There are no loose objects in or on the driving or driven machine.
The complete installation is suitable for the starting of the electric motor.
The frame is correctly earthed, offering proper protection for workers.
The electrical power and instrument connections comply with the wiring diagram.
The insulted bearing (s) is (are) correctly insulated.
The power cables are correctly fitted to the motor terminals.
All the protection devices (thermal, electrical, etc.) are operational and correctly calibrated.
The fluid systems have been connected and tested, and are fully op-erational.
The diaphragms for every forced oil bearings have been correctly drilled and fitted, and oil circulates efficiently.
Water circulates in the water coolers and bearing cooling coils (sleeve bearings cooled by water coils).
Covers and inspection hatches are closed.
Bearing oil tanks are filled in accordance with oil level instructions (oil bath sleeve bearings).
The protection degree and the certification level of the electrical motor and all accompanying equipment is suitable for the risks and condi-tions of the area in which it is to operate.
Rotor is unlocked in axial direction (No thrust bearing)
Before starting the motor, check that :
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MSIMMA 982 ind. b
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toris
atio
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11.2 Equipment located in hazardous areas
11.2.1 - General remarks
These motors may under certain circumstances produce sparks while starting.
Motors must always be scavenged before starting the motor, even after brief accidental stoppages.
Where Alstom has fitted a scavenging or pressurisation monitoring system, the specific instructions contained in the appendix to this handbook must be fol-lowed.
11.2.2 - Safety equipment - EEx "e"; Ex "N"; Ex "n"; Cl1 div.2 (IEC area 2 NEC Class1 division 2)
These motors must be scavenged in accordance with the figures listed in the table below and on the marking plate fixed to the motor frame.
It is essential to check that scavenging proceeds correctly. Such checks should form part of the motor start-up logic. This logic is to be checked prior to all scavenging procedures.
Motor Scavenging flow (m3/h) Scavenging (min)
FL 30 15
F3 60 30
N3 630 60 30
N3 > 630 140 30
11.2.3 - Safety equipment - equipment - EEx "p" (area 1 or 2 )
The scavenging and pressurisation criteria indicated on the classification certificate and the marking plate fixed to the motor frame must be re-spected
The motor must always be stopped immediately in the event of a pressuri-sation fault.
It is essential to check that scavenging proceeds correctly. Such checks should form part of the motor start-up logic. This logic is to be checked prior to all scavenging procedures.
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MSIMMA 982 ind. b
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toris
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12 - START-UP
12.1 Checks during start-up
Once all the criteria described in the section headed "Checks prior to start-up " have been met, the motor can be started.
As the motor begins to turn, check that.
The motor is turning in the right direction;
There are no abnormal vibrations on the bearings : immediately after start-up, after 1 hour and after 4 hours running.
There are no abnormal temperature on the bearings or housing bearings.
There are no abnormal noises.
Check the bearing temperatures after, 1, 2, 4, 8, 12, and 24 hours operation, and log these temperatures on the installation report.
In the event of an anomaly, refer to the section headed "Troubleshooting procedure".
12.2 Ongoing checks
The readings given by the safety devices (temperature, vibration and speed sensors, etc.) must remain within the set limits, in accordance with the wiring diagrams appended to this handbook.
The service and safety settings appear on these wiring diagrams.
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MSIMMA 982 ind. b
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fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
13 GENERAL TROUBLESHOOTING PROCEDURE
PROBLEM DIAGNOSIS SOLUTION
Motor does not turn. No power. Check fuses, power ca-ble and especially ter-minals.
Motor does not start under load ; high magnetic noise lev-els.
a) Too much resistance ; drive machine jammed ; binding rotor;
Disengage motor and run it under no load.
b) Voltage too low ; possibly less magnetic noise.
Measure supply voltage as motor is started.
a) Noisy bearing. Grease bearing and check alignment.
Motor starts but makes abnormal noise.
b) Excessive bearing vibra-tions.
Grease bearing, check alignment and check shaft line balance.
c) Moving part rubbing on static part.
Check dimension "X" and check that fan is not binding on air guide.
a) Wrong direction of rota-tion.
Check phase sequence direction.
Motor overheats dur-ing no - load opera-tion.
b) Air inlets blocked. Free air ducts.
c) Water system incorrectly connected.
Restore adequate wa-ter flow.
a) Motor overloaded. Reduce load. Motor overheats un-der load.
b) Inadequate cooling. Check cooling system.
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MSIMMA 982 ind. b
23
Ce do
cum
ent,
pro
pri
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xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
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Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14 - MAINTENANCE
It is important to draw up a routine maintenance schedule so as to ensure the correct running of the motor. All work undertaken is to be logged in a maintenance record ; this record will be useful not only to be customer, but also to the manufacturer.
Except where otherwise specified in the contract, a full inspection is be car-ried out at least twice a year. (or after 4,000 service hours).
14.1 - Criteria for proper machine operation
Air inlets to be kept clear ;
Correct fluid flows (air, water & oil);
Motor is to be frost - proofed (cooling system water, bearing oil);
Bearing housings to be kept clean;
Cooling air circuits to be kept clean;
Filters in good condition;
Safety devices operating correctly;
All criteria set out in contract to be respected.
14.2 - Anti - friction bearing lubrication
A plate indicating greasing intervals and grease quantities and qualities is fixed to each bearing (figures may vary between bearings).
These instructions must be respected.
We recommend using the grease specified on the plate or any equivalent, miscible grease.
The recommended lubricants and equivalencies are valid for ambient temperatures of -20C a +40C. For temperatures outside this range, refer to specific information in contract.
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MSIMMA 982 ind. b
24
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treSo
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, e
st s
trict
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con
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Il ne
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t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.2.1 - Equivalency chart
Mobil Oil : Mobilux n 2 or 3
Esso Standard : Esso Beacon n 2 or 3
Roller Grease 2
Esso : Unirex N3
Caltex : Caltex Rgal Starfack Special
Hougton : Cossolube n 2
Antar : Antar RT 33
BP : BP Energrease LS 2 or 3
ELF : Rolexa 2 or 3
Total : Multis EP 1 or EP 2
Shell : Albida RL 2
Alvania G3
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MSIMMA 982 ind. b
25
Ce do
cum
ent,
pro
pri
t e
xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.2.2 - Greasing instructions
14.2.2.1 - Importance of correct greasing
Anti - friction bearings must be greased progressively, if possible at low speed, over a period of several minutes, for a better initial distribution of the grease.
The following list points out the risks associated with over - hasty, excessive or poorly implemented greasing procedures :
Grease leaks past baffles due to excessive grease pressure within the bear-ing (over - hasty greasing or excessive grease).
Bearing temperature increases of 10 to 25C (or more) over normal operat-ing temperatures, until the excess grease is expelled.
Surplus grease may produce a braking effect in the ball races, which might cause moving parts (ball and rollers) to shift from their raceway, leading to heating, intermittent noises and bearing wear (scaling, micro - seizures), as well as loss of grease performance (shearing in the lubricant film and localised excessive grease temperatures in the affected area, or grease pollution caused by metal particles breaking away from the unlu-bricated area).
Seizing of the bearing within a few minutes following lubrication, especially at rotation speeds above 3000 rpm.
Grease is injected too quickly (continuous injection);
There is little internal radial play within the bearing (small ball bearings);
The motor operates at high speed (3000-3600 rpm).
14.2.2.2 - Bearing commissioning and servicing
When the motor is commissioned, inject two "doses" of grease at five minute intervals. The quantity of greases is indicated on the marking plates on the bearing, unless bearing noises typical of insufficient initial greasing can be heard, do not re-grease for 24 hours. Several hours are required for the disc to expel all the excess grease (especially from the bearings on vertical shaft motors).
These risks are aggravated where :
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MSIMMA 982 ind. b
26
Ce do
cum
ent,
pro
pri
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xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
24 hours later, inject one further dose of the recommended grease. After two weeks in service, inject one dose of the recommended grease, followed by a second dose 24 hours later.
Thereafter, follow the normal servicing plan indicated on the plates on the bearings (grease quantities & intervals). Under severe operating conditions, e.g. bearing temperatures above 80C, the greasing intervals can be halved.
14.2.2.3 - Greasing instructions
a) Calculating the number of pump strokes per dose of grease.
So as to inject the exact quantity of grease specified on the marking plates, carefully check and calibrate the quantity of grease injected by the grease-gun. For example, weigh the results of 10 pump strokes :
W = Weight of 10 pump strokes of grease
Q = Specified quantity of grease (dose)
n = number of pump strokes for one dose (Q)
n = ( 10xQ ) / W )
b) Greasing procedure
The grease nozzle should be cleaned in order to avoid injecting dirt or for-eign particles into the bearing lubrication circuit. Similarly, both the grease-gun and grease should be clean.
The general conditions required for a good greasing operation are as follows :
leave at least 5 seconds between every gram or cm3 of grease injected, where the motor speed is less than 3000 rpm.
e.g. 1 pump stroke = 4 g. Therefore 4 g x 5 sec = 20 second gap between pump strokes.
leave at least 30 seconds between every gram or cm3 of grease injected, where the motor speed is around 3000 rpm or higher, with no more than 5 g of grease injected at a time.
These general greasing instructions may, however, be refined for specific mo-tor types :
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MSIMMA 982 ind. b
27
Ce do
cum
ent,
pro
pri
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xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
c) Continuous operation constant speed motors
If there is no means of varying the motor speed, nor halting production (con-tinuous operation), the following criteria MUST be respected :
Leave at least 5 seconds between every gram or cm3 of grease injected, where the motor speed is less than 3000 rpm.
Leave at least 30 seconds between every gram or cm3 of grease injected, where the motor speed is around 3000 rpm or higher, with no more than 5 g of grease injected at a time.
We emphasise that by failing to respect these conditions when greasing at 3000 or 36000 rpm, there is a serious risk of bearing damage (rapid heating, seizing, etc). It is therefore very important to respect the set pauses be-tween each injection of grease, and the limit of 5 g or 5 cm3 per stroke.
d) Constant speed motors with short post-shutdown stopping times
Where motors cannot be greased at low speed (constant speed motors which stop too quickly after power is switched off), they should be greased just prior to shutting down the motor. By this means, the additional heat in the bearing caused by the greasing procedure will be dissipated while the motor is stopped, thus avoiding damage to the bearings.
Constant speed motors running at less than 3000 rpm
Respect the following recommendations :
Leave at least 3 seconds interval per gram or cm3 of grease injected.
Wherever possible, minimise the time (< 1 min) between greasing each bearing.
After greasing the last bearing, wait 2 minutes before shutting down the motor, to allow the grease to be distributed within the last bearing.
Wait 45 minutes before restarting the motor, in order to allow the addi-tional heat due to the greasing of the bearings to be dissipated.
Constant speed motors running at around 3000 rpm or more
Respect the following recommendations :
Leave at least 5 seconds gap per gram or cm3 of grease injected.
Wherever possible, minimise the time (
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MSIMMA 982 ind. b
28
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pro
pri
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xclu
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no
treSo
cit
, e
st s
trict
eme
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con
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Il ne
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t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
After greasing the last bearing, wait 30 seconds before shutting down the motor, to allow the grease to be distributed within the last bearing, but not more than 30 seconds, owing to the additional heat generated in the greased bearings.
Wait 1 h 15 minutes before restarting the motor, in order to allow the addi-tional heat due to the greasing of the bearings to be dissipated.
e) Variable speed and slow stopping motors
Where the rated motor speed is less than 3000 rpm, the greasing proce-dure should be carried out at between 30 and 60% of rated speed.
Where the rated motor speed is around 3000 rpm or more, the greasing procedure should be carried out at between 10 and 40% of rated speed.
This is possible on variable speed motors and slow-stopping motors as they fall into the recommended speed range specified above when shutting down. During greasing, at least 3 seconds pause per gram or cm3 of grease should be left between strokes.
Variable speed motors
After greasing the last bearing, wait 10 minutes at low speed (as specified above) to allow the grease to be properly distributed, before increasing speed gradually. Where the rated speed is around 3000 rpm or more, wait 20 minutes at the corresponding low speed before gradually increasing speed.
Constant speed motors operating at less than 3000 rpm
After greasing the last bearing, wait 30 minutes before restarting the motor, in order to dissipate the additional heating of the bearings due to the greasing procedure.
Constant speed motors operating at around 3000 rpm or more
After greasing the last bearing, wait 1 hour before restarting the motor, in or-der to dissipate the additional heating of the bearings due to the greasing procedure.
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MSIMMA 982 ind. b
29
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treSo
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Il ne
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com
mun
iqu
, co
pi
ou re
prod
uit
sans
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au
toris
atio
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rite.
14.3 - Sleeve bearings lubrication
14.3.1 - Bearing identification
Key to reading the plate located on the side of the bearing.
Example : E F Z L K 14 - 125
1 2 3 4 5 6
1 Type E
2 Bearing housing F = Flanged with fins
3 Heat dissipation
N = Natural cooling
Z = Constant flow externally cooled oil lubrication
W = Water cooled (oil cooling coil)
U = Forced oil circulation pump plus natural cooling
T = Forced water circulation pump plus water cooling
4 Bore type and lubrication mode
L = Cylindrical bore with free oil ring
5 Thrust bearing B = Smooth shouldered guide bearing with oil baths
(no thrust)
K = Bracket bearing (do not exceed thrust specified in contract)
Q = No thrust
6 Bearing size and shaft diameter
14.3.2 - Self-lubrication by free oil ring
Motors are supplied without oil in the bearings. Bearings must be filled with the motor stopped.
14.3.2.1 - Filling
The oil should match the grade specified on the marking plates fixed to the motor and the equivalency chart below.
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MSIMMA 982 ind. b
30
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Il ne
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, co
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ou re
prod
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sans
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au
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Bearing are filled via the hole in the oil ring inspection glass, which is located at the top of the bearing (see cross-sectional diagram of motor).
The inspection glass should be removed with care, possibly using an adjust-able pin spanner.
Fill with new oil.
To avoid adversely affecting the quality of the new oil filling the bearings, which could result in premature bearing wear, take all necessary precautions to prevent foreign matter (dust, grit, sand, water, grease, rags, paper, etc) from entering the bearing.
Check that the oil level lies in the middle of the oil gauge. The oil gauge is fit-ted on one side of the bearing. This check should be made with the motor stopped.
Replace and correctly tighten the filler plug.
14.3.2.2 - Oil change
Do not throw used oil in nature.
Follow the oil manufacturer's instructions as to how to dispose of used oil.
Use a large enough container to allow all the oil to be drained.
Remove the sump plug at the bottom of the bearing (see cross-sectional dia-gram).
Replace the sump plug with a new seal, and tighten to the torque settings given in the table below :
Bearing size 9 11 14 18 22 28
Torque setting in Nm 30 30 30 40 60 60
Drain oil while hot, in order to prevent oil deposits in the tank.
First oil change after 150 service hours.
Oil change interval : every 8,000 service hours.
ENVIRONMENTAL HAZARD
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MSIMMA 982 ind. b
31
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Il ne
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t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.3 - Forced oil lubrication
The oil should comply with the grade specified on the marking plates fixed to the motor and the equivalence chart below.
14.3.3.1 - Oil supply
To avoid running the bearings dry, the lubricating system should be designed to provide an adequate safety margin by operating for a long enough pe-riod before and after starting and stopping the motor.
The oil pumping system must deliver the recommended normal flow of oil.
14.3.3.2 - Diaphragm
A stainless steel diaphragm supplied with the motor is located at the oil inlet pipe flange on each bearing (see diagram below).
There is a punch mark at the centre of the diaphragm. The diaphragm should be drilled and carefully de-burred during installation. The diameter of the hole depends on the pressure upstream, and should be as indicated in the table below.
The figures in the table were calculated on the basis of the following factors :
Bearing size,
Sleeve diameters,
Rotation speed,
Pressure upstream from diaphragm.
Once installed, the recommended flow MUST be checked.
A half-moon plate fitted into the pipework at the oil outlet ensures aminimum safe oil level. Under no circumstances should thispipework be removed.
Oil inlet
Diaphragm
BearingOil level
15%
Oil outlet
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MSIMMA 982 ind. b
32
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Il ne
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mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.3.3 - Oil inlet diaphragm diameters selection table
For bearings size 9 diameter 80 to bearings size 11 diameter 125.
Diaphragm diameters for bearings EF "Z" LB or LQ... Bearing size 9
diam. = 80
bearing size 9
diam. = 90
bearing size 9
diam. =100
bearing size 11
diam. = 110
bearing size 11
diam. = 125
maxi flow
(l/mn.)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
1.5 1.5 2 2.2 2.1 3
2.5 1 1.5 1.9 1.8 2.5 3600
3.5
1
1
1.6
1.5
2.1
2
1.9
1.5
3.3
2.2
1.5 1.7 2 2 2.5
2.5 1.5 1.8 1.8 2.5 3000
3.5
1.2
1
1.8
1.5
1.7
1.5
2.9
2
1.5 1.7 2.2
2.5 1.5 1.9 1800
3.5
1.2
1
2.1
2
1.5 1.8
2.5 1.5 1500
3.5
1.3
1
1.5
2.5 1200
3.5
1.5
2.5 1000
3.5
1.5
2.5 900
3.5
1.5
2.5 750
3.5
Suitable for oil ISO VG 32 and ISO VG 46
Oil filtered at 25 maxi.
Minimum diameter drilling 1 mm (risk of obstruction)
Pression up-stream form diaphragm
(bars)
Rotation speed (rpm)
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MSIMMA 982 ind. b
33
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pri
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, co
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ou re
prod
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sans
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au
toris
atio
n c
rite.
Oil inlet diaphragm diameters selection table
For bearings size 14 diameter 140 to bearings size 18 diameter 225.
Diaphragm diameters for bearings EF "Z" LB or LQ... Bearing size 14
diam. = 140
bearing size 14
diam. = 160
bearing size 14
diam. =160
bearing size 18
diam. = 200
bearing size 18
diam. = 225
maxi flow
(l/mn.)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
maxi flow
(l/mn)
drilling diam. (mm)
1.5 3
2.5 3 3600
3.5
4.5
2.5
1.5 2.5
2.5 2.5 3000
3.5
3.1
2
1.5 3 3.5 4
2.5 2.5 3 3.5 1800
3.5
3.8
2.5
5.2
2.5
6.7
3
1.5 3 3.3 4
2.5 2.5 2.5 3 1500
3.5
3.3
2
4.4
2.5
5.9
3
1.5 1.7 2.5 3 3.5 4
2.5 1.5 2 2.5 3 3.5 1200
3.5
1.2
1
2.8
2
3.7
2
5
2.5
6.6
3
1.5 1.5 2 2.5 3 4
2.5 1 1.8 2 2.5 3 1000
3.5
1
1
1.8
1.5
2.4
2
4.4
2.5
5.8
3
1.5
2.5 900
3.5
1.5
2.5 750
3.5
Suitable for oil ISO VG 32 and ISO VG 46
Oil filtered at 25 maxi.
Minimum diameter drilling 1 mm (risk of obstruction)
Pression up-stream form diaphragm
(bars)
Rotation speed (rpm)
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MSIMMA 982 ind. b
34
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pri
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trict
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con
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Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.3.4 - Oil return
The oil drain pipework leading from the bearings to the lubrication systems must not retain oil in the circuit.
The pipe should have a gradient of at least 15 %. Any obstacles in the circuit may cause a rise in the oil level within the bearings and to oil leaks.
14.3.3.5 - Oil change
Do not throw used oil in nature.
The lubrication system is to be entirely drained every 20,000 hours in accor-dance with the manufacturer's instructions.
Follow the oil manufacturer's instructions as to how to dispose of used oil.
Draining both bearings
Use a large enough container to allow all the oil to be drained.
Remove the sump plug at the bottom of the bearing (see cross-sectional dia-gram).
Replace the sump plug with a new seal, and tighten to the torque settings given in the table below :
Bearing size 9 11 14 18 22 28
Torque setting in Nm 30 30 30 40 60 60
Always run the lubrication system before starting the motor, in order to restore a satisfactory oil level in the bearings (see paragraph headed "Oil supply").
ENVIRONMENTAL HAZARD
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MSIMMA 982 ind. b
35
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con
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Il ne
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t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.4 - Lubricant oil equivalency chart
14.3.4.1 - Oil grade : ISO VG 32
Kinematic viscosity in centiStokes at :
Dynamic viscosity in centiPoises at :
40C 50C 60C 50C 60C
AGIP Ote 32
30 14.8 12.8
ARAL Motanol GM 32
32 22 19.3
B.P. Energol CS 32
32.6 21.9 15 18.7 12.7
CASTROL Perfecto T 32
32 15 12.6
CHEVRON Mechanism LPS 32
32 16 14
ELF Elfolna 32
32 14.9 13
ESSO Teresso 32
30 23 14.4 19.8 12.4
FINA Cirkan 32
31 21 18.3
MOBIL DTE Oil Light
29.6 20.2 14.3 17.1 12.4
SHELL Turbo T 32
Tellus oil C 32
32 32
22 15.3
18.7 13.3
TEXACO Regal R et O 32
Rando oil 32
32.5 32
21 14.5
17.8 12.2
TOTAL Azolla ZS 32
32 16 13.5
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MSIMMA 982 ind. b
36
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pro
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treSo
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trict
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con
fiden
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Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.4.2 - Oil grade : ISO VG 46
Kinematic viscosity in centiStokes at :
Dynamic viscosity in centiPoises at :
40C 50C 60C 50C 60C
AGIP Ote 46
44 20 17.4
ARAL Motanol HK 46
46 30 26.5
B.P. Energol CS 46
47 30.7 20.5 26.3 17.4
CASTROL Perfecto T 46
46 20.4 17.2
CHEVRON Mechanism LPS 46
46 22 19
ELF Elfolna 46
46 20 17.5
ESSO Teresso 46
44.7 30 19.6 26 17
FINA Cirkan 46
46 30 26.3
MOBIL DTE Oil Medium
46 28.7 19 24.4 16.6
SHELL Turbo T 46
Tellus oil C 46
46 46
30
20.1
21.9
17.6
TEXACO Regal R et O 46
Rando oil 46
47.6 46
29
21.2
25
18
TOTAL Azolla ZS 46
46 22 18.7
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MSIMMA 982 ind. b
37
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pri
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treSo
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trict
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nt
con
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Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.4.3 - Oil grade : ISO VG 68
Kinematic viscosity in centiStokes at :
Dynamic viscosity in centiPoises at :
40C 50C 60C 50C 60C
AGIP Ote 68
64 27 23.6
ARAL Motanol HK 68
68 43 38
B.P. Energol CS 68
68 42.6 28 36.0 23
CASTROL Perfecto T 68
64 27 22.8
CHEVRON Mechanism LPS 68
68 29 25
ELF Elfolna 68
68 28.9 25
ESSO Teresso 68
64 43 26.7 37 23.2
FINA Cirkan 68
69 44 33
MOBIL DTE Oil Medium
63.9 41 27.2 35.1 23.8
SHELL Turbo T 68
Tellus oil C 68
68 68
43
23.4
28.7
24.9
TEXACO Regal R et O 68
Rando oil 68
67.3 68
41
28.5
35.3
24.2
TOTAL Azolla ZS 68
68 29 24.9
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MSIMMA 982 ind. b
38
Ce do
cum
ent,
pro
pri
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xclu
sive de
no
treSo
cit
, e
st s
trict
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nt
con
fiden
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Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
14.3.4.4 - Oil grade : ISO VG 100
Kinematic viscosity in centiStokes at :
Dynamic viscosity in centiPoises at :
40C 50C 60C 50C 60C
AGIP Ote 100
100 40 35.4
ARAL Motanol HK 100
100 61 54
B.P. Energol CS 100
96 67.6 38.55 59 33
CASTROL Perfecto T 100
96 38.3 32.3
CHEVRON Mechanism LPS 100
100 41 36
ELF Elfolna 100
105 40.5 35.8
ESSO Teresso 100 Nuray 100
154 100
59
56
53
50
FINA Cirkan 100
107 65 58
MOBIL DTE 27
DTE Vactra Oil Heavy
100 94
48
53
50
47.2
SHELL Turbo T 100
Tellus oil C 100
100 100
62
40
53.3
35
TEXACO Regal R et O 100
Rando oil 100
99.5 100
62
39.39
54.1
33.6
TOTAL Azolla ZS 100
100 39 33.5
-
MSIMMA 982 ind. b
39
Ce do
cum
ent,
pro
pri
t e
xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
15 - AFTER SALES SERVICE
We provide the following services :
Supply of replacement parts which are fully compliant with our technical specifications. Only ALSTOM can guarantee that parts are fully inter-changeable and easily fitted using the technical, quality or specific in-structions supplied with the parts.
We draw the customer's attention to the serious risks caused by not knowing about or not following these instructions, especially where motors are to be located in hazardous areas (zone 1 or 2).
List of wearing and replacement parts, pages 39 and 40.
Supervision of installation procedures for our equipment.
Commissioning of our equipment.
Servicing and repairs, on-site or at our workshops, as appropriate.
After sales service fax no : (+33) (0)3 83 38 42 95
-
MSIMMA 982 ind. b
40
Ce do
cum
ent,
pro
pri
t e
xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
Wearing and replacement part list (see cross-sectional diagram)
Group Sub-group Marking Consumable Approximate service life Replacement (emergency
stock)
110
115
116
117
Air inlet silencer
Air outlet silencer
Slip ring compartment filter unit
10 Years
1 Year
120 122 Filter unit (WPII) 2 Years
130 133 Slip ring compartment filter unit (watercooler)
1 Year
142 Complete internal air venti-
lation motor fan 140
146 Complete external air ven-
tilation motor fan
100 (Ventilation)
150 152
Complete slip ring assem-bly ventilation motor fan
211 Bearing 40000 hours
212 Compressing ring 40000 hours
214 Ejector disk
215 Circlips 40000 hours
216 V ring seal
210
(Antifriction bear-ing)
217
Grease nipple
251 Sleeve
252 Oil ring
253a Full external sealing as-sembly
254 Floating internal seal
255 Type 12 special seal
256a Filler plug
256b Sump plug
200 (Bearing on CS)
250
(Sleeve bearing)
256c
Oil gauge
311 Bearing 40000 hours
312 Compressing ring 40000 hours
314 Ejector disk
315 Circlips 40000 hours
316a V ring seal
310
(Antifriction bear-ing)
317
Grease nipple
351 Sleeve
352 Oil ring
353a Full external sealing as-sembling
354 Floating internal seal
355 Type 12 special seal
356a Filler plug
356b Sump plug
300 (Bearing on OSC)
350
(Sleeve bearing)
356c
Oil gauge
-
MSIMMA 982 ind. b
41
Ce do
cum
ent,
pro
pri
t e
xclu
sive de
no
treSo
cit
, e
st s
trict
eme
nt
con
fiden
tiel.
Il ne
peu
t tre
com
mun
iqu
, co
pi
ou re
prod
uit
sans
son
au
toris
atio
n c
rite.
Wearing and replacement part list (see cross-sectional diagram)
Group Sub-group Marking Consumable Approximate service life Replacement (emergency
stock)
411 Insulators 410
(main box) 412
Connection bar
421 Insulators
422 Connection bar 420
(Neutral) 423
Connection bar
400 (Terminal boxes)
450
(Auxiliary) 457 Auxiliary terminal box
511 Bearing probe on CS
512 Bearing probe on OSC
515 Internal air probe
516 External air probe
517 Water inlet T probe
510
(Temperature
sensor)
518
Water outlet T probe
530
(Heating ele-ment)
531 Space heater
540
(Water leak
sensor)
541 Complete leakage detec-
tor
551 Complete control box 550
(Pressurisation sensor) 552
Valve
561 Brushes 1 year
500 (Instruments)
560
(Rotor insulation
sensor) 562 Brush holder
610
(Slip ring
compartment)
611 Complete slip ring assem-
bly
621 Contact
622 Power socket
623 Yoke and bearings
620
(Slip rings short-circuiting device)
624
Gear reduction unit + nut
651 Set of brushes
(permanent contact) 1 year
651 Set of brushes
(brushes lifting device)
653 Set of brush holders
600 (Bush compart-
ment)
650
(Brush holder
system)
654
Solenoids