Operating & Maintenance Instructions for ATEX Conforming Motors

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AC Induction Motor

INDEX

1. Description ......................................................................................................................................... 2 2. Specific Conditions for Safe Use ..................................................................................... 2

3. Storage .................................................................................................................................................... 3

4. Installation & Commissioning ........................................................................................... 4

5. Thermal Protection ..................................................................................................................... 6

6. Heaters ................................................................................................................................................... 6

7. General Inspection & Maintenance ............................................................................. 6

8. Spare Parts ........................................................................................................................................... 8

9. Other Languages ........................................................................................................................... 8

10. Typical Construction Diagrams ...................................................................................... 9

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2. Specific Conditions for Safe Use (cont.)

Anti-Condensation Heaters w Anti-condensation heaters shall be de-energized before the motor is energized. Operating the heaters while

operating the motor may cause an over temperature fault.

TerminalsThe user/installer shall ensure all terminal connections meet the following conditions prior to energizing the motor:

w Not more than one stranded lead shall be connected into either side of any terminal.

w Any used or unused terminal screws shall be tightened down.

w Leads connected to the terminals shall be insulated for the appropriate voltage. This insulation shall be extended to within 1 mm of the metal of the terminal throat.

Applied Voltage w The applied rms voltages shall not be greater than 140% of maximum nameplate voltage.

w The applied peak voltages should not be greater than 200% of maximum nameplate voltage.

3. Storage

If motors are to be stored before installation, precautions must be taken to prevent damage or deterioration.

w Motors are to be driven by a converter of type and model indicated on nameplate.

w Motors should be stored in a dry condition, free from any and all rain and condensation. If damp storage cannot be avoided, the motor can be stored in a sealed shipping crate with a desiccant, or wrapped in plastic with a desiccant. When fitted with heaters, the motor heaters can be energized to prevent condensation in the motor. Adequate safety precautions must be taken as parts of the motor will be live.

w The motors should be protected from the ingress of dust, dirt, powders and similar. Concrete/cement dust is extremely damaging. When protecting motors from dust, care should be taken that the protection method does not generate condensation. If dust, dirt or similar are ingested contact the manufacturer.

w Motors must be stored away from corrosive or chemically damaging fumes. If liquid or gaseous chemicals are in the area, examine the chemical’s Safety Diamond and MSDS sheets for details. Acceptable materials

Instruction Manual for Ward Leonard ATEX CONFORMING MOTORS

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will have 0, 1, 2 in the Red Diamond; 0, 1 in the Yellow Diamond; 0 in the Blue Diamond, and nothing or “SA” in the White Diamond.

w During storage protect the motor from vibration (storage vibration shall be less than 0.01 Inch/second) to avoid fatigue aging to internal components such as to ball and/or roller bearings, leads, and conductors.

w Rotate the shaft a minimum of 10 turns by hand every four weeks to transport an oil film to all load bearing surfaces and to load the bearing elements at different places randomly to prevent damage.

w Inspect the motors at least every 6 months for impact damage (i.e., dents and scratched paint), damaged leads, wires and cables (i.e., scrapes, cuts, and animal bites), water and chemical exposure (i.e., rust, paint bubbling, corrosion on terminals, Insulation Resistance), material ingression (i.e., powder, mud, residue, sand, wood, metal, plastic pieces or similar on surfaces, in vents, or blower inlets).

w Inspect bearing grease before putting motor into operation and renew if it has deteriorated. See Grease Replacement Procedure within the General Inspection and Maintenance section.

w Check insulation resistance before putting motor into operation. Use an Insulation Measurement meter, not a multi-meter and follow the procedure described in the General Inspection and Maintenance section. If any value is less than 10 MΩ, perform the Drying Operation as detailed in the General Maintenance section below.

4. Installation & Commissioning

w If the motor is to be installed in a potentially explosive atmosphere, perform an ignition hazard assessment in accordance with EN 13463-5 (Non electrical equipment intended for use in potentially explosive atmospheres – Protection by constructional safety) and in accordance with IEC 60079-10 (Electrical Apparatus for Explosive Gas Atmospheres – Part 10 Classifications of Hazardous Areas).

w Inspect for damage that may have occurred during shipment upon receipt or from storage. If there is any evidence of damage to the packaging, the motor must be inspected and checked by qualified personnel before putting into service.

w The motor must be lifted using approved lift devices at specified points only identified on the outline drawing.

w Ensure that the motor rating plate data meets the requirements of the application. Operating the motor outside the stated design limits may cause a potential hazard to personnel and will invalidate the warranty.

w The installation must provide adequate guarding of rotating or heated parts. Where fitted, these guards must be in position and secured.

w Adjustments or measurements must not be made through ventilation or similar openings unless the motor has been disconnected from the power supply.

w Any cover provided for live electrical parts or connections must be secured in place before operating motor.

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4. Installation & Commissioning (cont.)

w Power cables connected to the motor must be sized appropriately for the applied current and rated voltage according to local electric code.

w Control cables for auxiliary circuits must be intrinsically safe (IEC 60079-11).

w The motor should be connected to an electrical supply system driven by a converter of type and model indicated on nameplate which has overload, over temperature and over speed protection systems. Overload protection shall be set above the nameplate full load. The over temperature system shall interface using the accessory leads of the embedded temperature devices in the motor according with the certification rating.

w The over speed protection shall use the line frequency or the accessory speed detection device and be set at the nameplate rated speed.

w The motor must be properly grounded in accordance with the site regulations and local electrical code. In special cases where it is a specific design requirement additional grounding maybe implemented.

w Cabling to the motor must be connected in accordance with the diagram supplied and in accordance with local electrical code.

w Read the nameplate minimum and maximum allowable ambient temperatures, and compare its value to the measured or known maximum ambient temperature for this location. If the location ambient temperature is lower than the motor maximum allowable ambient temperature, supply the motor with sufficient ventilation from the ambient air (maximum temperature noted on nameplate). If the ambient air is hotter, identify a source of air below the motor maximum allowable ambient temperature and plumb a channel twice the area of the inlet to the motor inlet. The controls for the forced ventilation system should operate in conjunction with the main motor drive system to ensure that ventilation is available from the time the motor starts. Without cooling air, the motor will overheat and cause an over temperature fault on the drive. Many of our motors come with an air pressure switch which indicates appropriate internal pressures when correct airflow is achieved. Connect the air pressure switch to the control panel to enable the control to de-energize the motor if there is inadequate air flow. All motors must be equipped with pressure switch.

w Ensure that ventilation openings are free from obstruction and nearby equipment surfaces and fans do not cause re-circulation of motor outlet air. If there are any concerns of outlet air-circulation, use flow indicators such as meters, light weight fibres or potentially small sources of smoke.

w Confirm the shaft is free to rotate before starting up the motor.

w The motor must run without excessive vibration. Preferred motor vibration levels are below 0.07 inches/ second rms (1.8 mm/second rms). Motor vibration shall be less than 0.11 inches/second rms (2.8 mm/second rms) measured at the bearing housing. If vibration levels exceed these values contact the manufacturer.

w Drain points must be open and free from obstruction.

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7. General Inspection & Maintenance (cont.)

w Isolate the motor from all power supplies if access covers are to be removed.

w Ensure the ventilation openings are not blocked or obstructed, including motor, heater and blower motor.

w Check the condition of the shaft seals and replace if necessary.

w Check the condition of bearings, and replace if necessary.

Measure Insulation Resistance

w Use an Insulation Measurement meter — not a multimeter. Follow all the safety and operating instructions for that specific equipment. Start at the 500 VDC setting and record the insulation resistance value. Without exceeding the motor’s nameplate voltage rating, increase the applied voltage to the next setting and record the resistance value. Continue increasing the applied voltage to the next setting and taking measurements; until the motors applied nameplate voltage rating.

w If any value is less than 10 MΩ, perform the Drying Operation as detailed in the General Maintenance section below.

MaintenanceBearing Inspection Check the condition of the bearing by listening for excessive noise, an inspection of used grease, observing/monitoring bearing temperatures, and/or measurement of vibration.

w Bearings should run quite. Note any noise, audio record it if distinctive.

w Grease should be smooth and glossy. Replace the grease if it appears dry, crumbly, dirty or contaminated.

w Bearing temperatures should be less than 120°C.

w Vibration shall be less than 0.11 inches/second rms (2.8 mm/second rms) measured at the bearing housing.

Grease Replacement Procedure The motor is fitted with re-greasable bearings. Zerk grease fittings are provided for both the drive and non-drive end bearings. The grease fitting for the drive end bearing is typically located behind the front guard at the top of the motor. Location varies with motor size/frame design. The grease fitting nipple is directed axially towards the NDE. The grease fitting for the NDE is located on the outside bearing cap. The bearings should be re-greased at least every 6 months. Use grease that is compatible with the grease originally installed.

Bearing Replacement Procedure

Please contact the manufacturer if you do not have a bearing replacement procedure and desire to replace the bearings. Contact information is located on the front page.

Instruction Manual for Ward Leonard ATEX CONFORMING MOTORS

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NOTES

Ward Leonard is a global industrial technology company that develops highly engineered motor, generator, control and MRO (maintenance, repair and overhaul) solutions for a diverse range of Energy, Heavy Industry

and Government customers worldwide.

For over 120 years, our products and services have harnessed power to solve complex, mission-critical infrastructure applications, and enabled our customers to achieve benchmark performance, productivity

and uptime in the world's most demanding environments.

We are dedicated to total customer support and satisfaction, and encourage you to learn more about our products and services, or to speak with a Ward Leonard engineer today.

www.wardleonard.com401 Watertown Road Thomaston, CT 06787

Tel: 860-283-5801 Fax: 860-283-5777

© 2015 Ward Leonard CT LLC. All rights reserved. 11/15

Operating & Maintenance Instructions for ATEX Conforming Motors