Cat BM25 22kW 2 pole 3.3kV Scrubber Fan Drive Operating & Instruction Manual – PDF DOWNLOAD

BI619169

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BUCYRUS R

Technical Manual

BI619169

Morley Electric Motors Ltd. Operating and Instruction Manual For BM25 22kW 2 pole 3.3kV Scrubber Fan Drive AC 3 Phase Induction TEFC Motor

DBT Australia Pty Ltd North Goonyella Longwall Project Motor Reference: 050158 Manufactured By

Morley Electric Motors Ltd., Bradford Road, Leeds, LS28 6QA, United Kingdom.

Telephone: (0113) 2571734. Fax: (0113) 2570751.

Morley Electric Motors Australia Pty Ltd. 8 Wiltshire Court Cherrybrook NSW 2126 Telephone 61 2 9980 9590 Fax 61 2 9980 8591 Email gjm@mema.com.au Page 1 of 25

BI619169

TABLE OF CONTENTS SAFETY INFORMATION .................................................................................................................................................... 3 1.1 1.1.2 1.2 1.3 2

PURPOSE AND PLANNING INFORMATION............................................................................................................. 4 INTRODUCTION ....................................................................................................................................................... 4 CAPABILITIES AND PERFORMANCE ............................................................................................................................ 4 OPERATING ENVIRONMENT ...................................................................................................................................... 4

2.1 2.3 2.4 3

MAJOR COMPONENT DESCRIPTION ...................................................................................................................... 5 STATOR FRAME ...................................................................................................................................................... 5 ROTOR .................................................................................................................................................................. 5 BEARINGS.............................................................................................................................................................. 5 VENTILATION / COOLING .......................................................................................................................................... 5 STATOR WINDING TEMPERATURE DETECTORS (IF FITTED).......................................................................................... 5 BEARING TEMPERATURE DETECTORS (IF FITTED) ...................................................................................................... 5

3.1 3.2 3.3 3.4 3.5 3.6 4

HANDLING, TRANSIT, STORAGE AND INSTALLATION ......................................................................................... 6 HANDLING AND TRANSIT .......................................................................................................................................... 6 STORAGE .............................................................................................................................................................. 6 INSTALLATION ........................................................................................................................................................ 7

4.1 4.2 4.3 5

COMMISSIONING AND FIRST STARTING................................................................................................................ 9 INSULATION RESISTANCE MEASUREMENT ................................................................................................................. 9 DRYING OUT .......................................................................................................................................................... 9 STARTING ............................................................................................................................................................ 10

5.1 5.2 5.3 6

OPERATING INSTRUCTIONS.................................................................................................................................. 11

6.1 6.2 6.2.1 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 9

EXPLANATION OF SYMBOLS AND NOTES.................................................................................................................... 3 Warnings...................................................................................................................................................... 3 HEALTH AND SAFETY .............................................................................................................................................. 3 DISPOSAL .............................................................................................................................................................. 3

OPERATION ......................................................................................................................................................... 11 OPERATING ENVIRONMENT .................................................................................................................................... 11 Cooling....................................................................................................................................................... 11

MAINTENANCE SCHEDULES ................................................................................................................................. 12 MAINTENANCE...................................................................................................................................................... 12 INSPECTION SCHEDULE FOR EX ‘D’ EQUIPMENT ....................................................................................................... 12 INSPECTION SCHEDULE TABLE ...............................................................................................................................13 MAINTENANCE INSTRUCTIONS ............................................................................................................................ 13 BEARING REPLACEMENT ....................................................................................................................................... 14 RE-GREASING BEARINGS ...................................................................................................................................... 14 TORQUE WRENCH SETTINGS FOR METRIC SCREWS ................................................................................................ 15 FLAMEPROOF JOINTS ............................................................................................................................................ 15 ASSEMBLY AND DISASSEMBLY PROCEDURE.................................................................................................... 16

9.1 DISASSEMBLY ...................................................................................................................................................... 16 9.2 INSPECTION AND RENEWAL ................................................................................................................................... 18 General.......................................................................................................................................................................... 18 9.3 WINDINGS............................................................................................................................................................ 18 9.4 BALL AND ROLLER BEARINGS ................................................................................................................................ 18 9.5 REPAIRS .............................................................................................................................................................. 19 9.6 ASSEMBLING PROCEDURES ................................................................................................................................... 19 9.7 MOTOR ASSEMBLY ............................................................................................................................................... 19 10

FAULT FINDING ....................................................................................................................................................... 22

11

MACHINE MAINTENANCE HISTORY...................................................................................................................... 23

12

SPARES AND SERVICE BACKUP .......................................................................................................................... 23

13

SPECIAL FEATURES - COMMISSIONING SERVICE & MAINTENANCE............................................................... 24 Page 2 of 25

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SAFETY INFORMATION 1.1

Explanation of Symbols and Notes Please read and follow the instructions with special care. Always pass on instructions for safety to other users.

1.1.2 Warnings

! WARNING !

This word “Warning” marks those parts of the text which must be followed in order to ensure that instructions, regulations, notes and correct sequences are adhered to, and avoid damage to, or destruction of, the machine, and/or other parts of the system.

1.2

Health and Safety During operation, this machine has dangerously exposed rotating parts. Therefore, if essential protective covers are improperly removed or if the machinery is improperly used, incorrectly operated or inadequately serviced, serious damage to health or to the machinery can result.

Electrical installations in hazardous areas possess features specially designed to render them suitable for operations in such atmospheres. It is essential for reasons of safety in those areas that, throughout the life of such installations, the integrity of those special features is preserved; they therefore require initial inspection and either: a). b).

regular periodic inspections thereafter; or continuous supervision by skilled personnel and, when necessary, maintenance.

These instructions should be read thoroughly before the motor is installed and run for the first time. Afterwards they should be kept handy for reference purposes.

If any of these instructions differ from the site safety instructions, local regulations and specific requirements of the system, then the site safety officer must be consulted on the procedure to be adopted. Where safety regulations do not exist or are not clearly defined for the tasks to be performed, then the person performing the tasks must maintain vigilance and avoid injury to himself and/or other people. No part of these instructions may be taken as an instruction to perform tasks which even given due vigilance, could result in injury and whilst every care is taken in the preparation of these instructions, every detail cannot be covered, therefore Morley Electric Motors Limited cannot accept liability for direct or consequential damage or injury that may arise from the non observance of good practices.

In the United Kingdom, the Health and Safety At Work Act 1974 requires designers, manufacturers and suppliers of articles and substances, which are used by persons at work, to provide information regarding their safe use. Warnings of Hazards to personnel in this manual are identified by the use of capital letters.

At all times care must be taken when carrying out the instructions contained in this manual. Only recognised potential hazards have been identified as described in the previous paragraph, it must NEVER be assumed that these are the only hazards that can be encountered.

1.3

Disposal When changing lubricating grease, used material must be properly disposed of in accordance with local and relevant environmental regulations.

Contamination of soil, sewage and water systems must be avoided.

No materials contained in the construction of this product will cause a harmful effect on the environment providing that the local environmental regulations for disposal are enforced.

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! SAFETY !

The inspection and maintenance of this machine shall be performed only by authorised personnel, whose training has included instruction on various types of protection and installation practices, the relevant rules and regulations, and on the general principles of area classification.

These persons MUST KEEP the operating instructions provided, and other relevant documents available when carrying out the operations to which they refer and to follow that documentation.

2

Purpose and Planning Information

2.1

Introduction This machine is an asynchronous running, cage rotor induction motor, for use on three phase, alternating current supplies, and is suitable for use in Group I explosive atmospheres (mines).

The motor is a Totally Enclosed Air Cooled (T.E.F.C.) squirrel cage induction type and is designed in accordance with relevant principle IEC Standards IEC 60079-0:2004 and IEC 60079-1:2003 The area classification for which the equipment is certified to be used is EEx d I

! Important Notes !

This equipment must only be used in conjunction with a suitably certified cable adaptor / gland arrangement that has been certified by a Notified Body.

If at any time there is a change in the area classification or the apparatus is moved from one classified area to another, a check must be made to ensure that the type of protection, apparatus group and temperature class are suitable for the revised conditions.

2.3

Capabilities and Performance This machine has been designed, manufactured and constructed under high standards and has been tested and certified to suit the conditions described in the introduction above. However, the voltage and performance details given on the main motor rating plate MUST NOT under any circumstances be exceeded.

2.4

Operating Environment This induction motor is designed to be robust and suitable for use in operating applications as specified. The motor is not intended for use in harsh operating environments where excessive voltages, water ingress, and mechanical abuse may be present.

Deposits of dust and coal can block the air passageways of the stator frame and create a potential hazard. ENSURE THAT COOLING RIBS ARE REGULARLY CLEANED AND ANY BLOCKAGES REMOVED.

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3

Major Component Description

3.1

Stator Frame The stator frame is manufactured from fabricated steel that supports the stator core that is an interference fit in the frame. The stator winding core is assembled from separately insulated sheet steel laminations.

The stator winding slots are insulated with a liner material of a composite type. The coils are manufactured from insulated strip and laid directly into the liner material in the stator core-pack slots.

After winding, the core-pack is heated and vacuum impregnated to expel air from voids in the winding. The whole unit is then impregnated with varnish and baked for several hours to fully cure.

This provides a high resistance to moisture and damage from vibration.

3.2

Rotor Produced from laminated insulated, high grade, low loss silicone steel with substantial laser cut steel fingered tooth pressure plates fitted at each end. The core is positioned on the shaft against a shoulder at one end and keywayed along the full length of the rotor core. A tab washer secures the core and castellated nut to ensure no axial movement occurs.

The rotor is of a cage pinned bar sash type with hard drawn copper bars and short circuit rings pool brazed together. The rotor is dynamically balanced in the process of manufacture to ensure that it will run with the minimum of vibration in service. The rotor is supported at each end by grease lubricated bearings.

3.3

Bearings The rotor is supported at the drive and non-drive end by rolling element bearings as indicated on the motor rating plate. The bearings are grease lubricated, as specified on the motor rating plate, and are directly mounted into cartridge bearing housings with separate outer covers to seal against the ingress of dirt and moisture.

3.4

Ventilation / Cooling The stator is cooled by a fan at the non-drive end that ensures a circulating flow of cooling air around the stator frame. The internal air volume of the stator frame is self-ventilated by fans fitted to the rotor shaft providing circulating air through the windings and rotor cage.

3.5

Stator Winding Temperature Detectors (If fitted) PTC and RTD thermistors are fitted into the stator windings. Settings are to be found in the Technical Data section. The leads terminate in a terminal box mounted on the stator frame body.

3.6

Bearing Temperature Detectors (If fitted) Both the drive end and non-drive end bearings are fitted with temperature censoring devices.

The detectors are mounted in each bearing cover that is in contact with the bearing faces. Settings are to be found in the Technical Data section. The detector device leads terminate in a terminal box mounted on the stator frame body.

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4

Handling, Transit, Storage and Installation

4.1

Handling and Transit

! WARNING !

This equipment must be lifted at the appropriate lifting points attached to the stator.

The lifting gear must be suitable and have the carrying capacity of the full machine weight that is stamped on the main motor rating plate.

Immediately the machine is received on site, visually examine it for damage. If damage is apparent, immediately inform the transport company involved, and Morley Electric Motors Limited.

It is assumed that delivery into the construction programme is such that site storage does not occur, however if circumstances are such that site storage is desired, the following procedure should be adopted.

Precautionary measures should be taken in transit to protect them against vibration and temperature variations exceeding 20 K per hour (not only in the event of minus temperatures), otherwise initial damage, destruction of components and condensation are to be expected.

Transit clamps may be fitted to prevent the motor shaft moving axially or radially, within the bearing clearances, during transit or storage to combat stationary vibration damage to the rolling element bearings and raceways.

Where motors are delivered to driven machine manufacturers for lining up, necessitating transit clamp removal, then the whole unit transported to site, the transit clamps must be refitted, or if not possible, coupling, clamping or another means must be used to produce the same affect as the transit clamp.

4.2

Storage During storage in driven machine manufacturers works, or later on site, the following instructions must be followed.

The salient features of these motors are robust design and long life. To maintain these positive features, the following measures should be taken for storage :a).

The machines should be stored in a clean, dry, dust free and warm place wherever possible.

b).

Sufficient heating should be provided to keep the atmosphere and the machines well above the dew point.

c).

There should be no perceptible vibrations in the area where the machines are stored during the standstill / storage period.

d).

Should transit clamps be fitted, they must be removed to allow the following procedure.

During a standstill / storage period, at equally spaced intervals (every 4 to 8 weeks), the motor bearings should be rotated as fast as possible by hand.

Alternatively, the bearings and rotor must be locked to stop rotation and vibrations causing brinelling to the bearing element raceways.

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! SAFETY !

Great care must be taken when turning the rotor shaft by hand as rotating components will be exposed.

A reduction in lubricating grease quality is not expected within less than 2 years.

It is also not necessary to check the bearing elements before commissioning the motor for a storage period of less than 2 years.

0 Should the motor experience storage in conditions of extreme sub-zero temperatures (-40 C) the atmosphere must be carefully monitored to ensure MOISTURE AND CONDENSATION DOES NOT OCCUR within the motor enclosure.

Prior to commissioning, it is advised to rotate the shaft a couple of times to check the seals are still in good working order and there are no signs of rust or corrosion evident.

If there is corrosion evident then the parts must be checked. e).

4.3

Prior to start up after storage, the insulation resistance of the windings must be measured and if it is low steps must be taken to rectify this by thoroughly drying out the windings, as detailed in our Installation Instructions. See “5 Commissioning and First Starting”, for recommended minimum insulation resistance.

Installation

!! IMPORTANT NOTES !!

Before putting this machine into first use it is essential that checks are made to ensure that the machine is suitable for use in the operating area classification.

This equipment must only be used in conjunction with a suitably certified cable adaptor / gland arrangement that has been certified by a Notified Body as meeting the requirements of Directive 94/9/EC. Always use the lifting attachments provided.

The mating surfaces of the motor mounting should be clean, except for a protecting film of clean lubricant.

Where storage of the motor has taken place in sub-zero temperatures, the motor must be brought up to room temperature (200C) at a rate of no more than 50C per hour before operation, or for temperatures below minus -10oC a minimum period of 12 hours should be allowed for stabilisation.

Before any rotation of the shaft, including that for the alignment, any transit protection or clamps must be removed and the bearings checked for being correctly lubricated.

If the motor has been in storage for a period of more than 2 years, check the quality of grease.

Grease that is soft with oil apparent is satisfactory (although it may have discoloured to a grey colour).

Bearings where the grease is soft but without oil apparent should have as much grease removed as accessible and replaced with new grease; bearings where the grease is hard, like wax, must be cleared out and repacked.

For the correct grade of lubricating grease, see the motor rating plate.

When repacking the bearings, fill the voids in the rolling bearing elements and half fill the end caps.

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To achieve rotation, connect the phases to the terminals in the main terminal box in the sequence given on the terminal connection diagram.

If this has been lost, apply to Morley Electric Motors Limited Sales Department for information, quoting the motor serial number in all communications.

Connect any protection devices to their appropriate circuits.

The stator frame must be earthed using its earthing point.

If commissioning does not immediately follow erection the machine shafts should be rotated through two and a half revolutions at least once per day.

!! IMPORTANT NOTE !!

During the Installation process it is important that the recommended number of starts is not exceeded as this can seriously damage the insulation system of the motor windings and cause harmful transient over voltages.

Cage rotor machines are suitable for continuous rating, with 20 starts per hour, continuous operation between starts and with no more than two starts in rapid succession (coasting to a rest between starts).

Covers which prevent contact with 'LIVE' parts must not be opened during operation.

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5

Commissioning and First Starting

5.1

Insulation Resistance Measurement Before the motor is started, it’s windings must be known to be unaffected by moisture, therefore review the history of the machine and if there is any doubt, check the value of the insulation resistance.

This is temperature dependent but because the motor has not yet been run, the temperature of the windings can be taken as being the ambient temperature.

The recommended minimum values are given below. For intermediate ambient temperature use the next above.

RECOMMENDED INSTRUMENT TERMINAL VOLTAGE

MOTOR SUPPLY VOLTS Over 110v 3.3kV

Upto & Including

1100v 6.6kV

500v 1000v

RECOMMENDED MINIMUM INSULATION RESISTANCE IN MEGOHMS AT WINDING TEMPERATURE OF 10oC 15oC 20oC 25oC 30oC 40oC 16 11 8 6 4 2 40 28 20 14 10 5

As a further safeguard it is strongly recommended that the polarisation index of the insulation system be measured.

To obtain the Polarisation Index a mains or battery powered D.C. insulation resistance tester (Megger) must be used.

Measure the Insulation Resistance after 1 minute and again after 10 minutes.

P.I. = 10 Minute Reading 1 Minute Reading

TEST PARAMETERS MOTOR VOLTAGE 1100 1101-3300 above 3300

5.2

INSTRUMENT TEST VOLTAGE 500 1000 2000

MINIMUM ACCEPTABLE P.I. 2.0 3.0 3.0

Drying Out The only way that moisture can be removed from the windings is by the application of heat, it is necessary that all moisture be evaporated from the insulation before it is subjected to the stress of normal voltage.

The winding temperature should be raised to at least 75oC but MUST NOT EXCEED 100oC by the use of hot air blowers can be used to circulate warm air through the machine windings.

!! CAUTION !!

Irrespective of the method of drying, it is essential that the temperature of the windings be brought up slowly, as any rapid heating may result in damage to the insulation layers due to expanding air and moisture being unable to escape quickly enough.

NOTE !

Grease lubricated bearings should be inspected after drying out to ensure that the grease has not melted. If so, clean out and re-charge with grease.

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5.3

Starting

! WARNINGS !

COVERS WHICH PREVENT CONTACT WITH aLIVEa PARTS MUST NOT BE OPENED DURING OPERATION LETHAL VOLTAGES, IMPOSE FULL SAFETY PRECAUTIONS PARTICULARLY;ENSURE COOLING AIR INTAKE OF THE MOTOR IS NOT IN A POSITION THAT COULD INHIBIT THE FLOW OF COOLING AIR IE. TOO NEAR TO A WALL OR ENCLOSURE. CHECK THAT THE SUPPLY IS DISCONNECTED AND CANNOT BE RE-CONNECTED WITHOUT YOUR CONSENT ENSURE THE FRAME AND THE SHAFT ARE SOLIDLY EARTHED EARTH ANY WINDINGS NOT BEING TESTED A WINDING CAN HOLD A CHARGE FOR A LONG PERIOD, TAKE CARE WHEN EARTHING IT AFTER TESTING. If the measured insulation resistance is still reading lower than the recommended value, contact Morley Electric Motors Limited, Sales Department requesting advice.

Also, before the motor is started, check the switchgear for correct operation; check the rating of the fuses; check the overload protection device to operate full load current declared on the nameplate, check the function of all protection devices.

During the commissioning programme, do not exceed the starting frequency limit. (20 starts per hour, continuous operation between starts and with no more than two starts in rapid succession (coasting to a rest between starts)).

The motor should be uncoupled when it is first started.

During the initial start, check that the direction of rotation corresponds to that required by the driven machine, also be aware of any unusual noise or vibration. Investigate and remedy the cause of any vibration and/or unusual noise.

If the rotation is incorrect according to the requirements of the driven machine, refer to Morley Electric Motors Engineering Dept.

When the machines are started up for the first time they should be run for a short period to allow any surplus grease to be ejected.

Alignment of the machines must be checked when the machines are cold and again when hot.

After the machines have been commissioned they must be regularly maintained and greased in accordance with instructions given on the machine nameplate and/or “Special Features”.

!! WARNINGS !!

LETHAL VOLTAGES :- ENSURE THE ELECTRICITY IS ‘OFF’ BEFORE WORKING AT THE TERMINALS AND THAT IT CANNOT BE INADVERTENTLY RESTORED. After the driven machine has been commissioned check the overload protection devices.

After approximately two hours running, re-check the alignment, and when it is known that this is acceptable, locate the motor.

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6

Operating Instructions

6.1

Operation Cage rotor motors are suitable for continuous rating, with 20 starts per hour, with continuous operation between starts and with no more than two starts in rapid succession (coasting to a rest between starts).

The motor is designed to work without constant supervision, but a periodic check on its performance is advocated.

The normal reading of the ammeter, or if load varies, it’s fluctuation limits, should be known and if it deviates from the normal, the motor should be stopped and investigated as soon as it’s operational requirements permit, and the fault investigated and remedied.

When the motor is working the carcass can get warm, even reaching a condition when prolonged contact is uncomfortable, but correctly connected, effective thermal protection devices will adequately protect any motor to which they are fitted.

When bearings are equipped with RTD’s the bearings will be seen to operate at a temperature that is normally between 30°K and 50°K above the ambient temperature.

Any bearing that attains a temperature (note that this is NOT a differential above ambient) of 90°C must be stopped as soon as possible and investigated. When the combination of high ambient temperature and working differential cause the working temperature to exceed 90°C, consult Morley Electric Motors Limited regarding the suitability of the bearing arrangement for operation at this temperature.

6.2

Operating Environment This induction motor is designed to be robust and suitable for use in normal operating applications in the area environments previously specified.

The motor is not intended for use in harsh operating environments where excessive voltages, vibration, humidity, temperature, moisture, chemical or solvent erosion, oil or grease, likelihood of water ingress, and mechanical abuse may be present.

6.2.1

Cooling The motor must be provided with a sufficient air cooling supply.

Deposits of dust and coal can block the air passageways of the stator frame and create a potential hazard. The surface of the motor must be cleaned regularly to ensure that the cooling ribs do not become blocked.

! WARNING !

ENSURE THAT COOLING RIBS ARE REGULARLY CLEANED AND ANY BLOCKAGES REMOVED.

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7

Maintenance Schedules !! Important Note !!

The inspection and maintenance of this machine shall be performed only by experienced personnel, whose training has included instruction on various types of protection and installation practices, the relevant rules and regulations, and on the general principles of area classification.

7.1

Maintenance The ‘X’ indicates the recommended service period for average conditions. If operating experience shows that these require to be modified, delete the ‘X’ and insert a replacement at the desired intersection.

These revisions should occur within the length of the leader lines, these lines must NOT be extended.

The lubricant change period is based upon contamination from normal industrial atmospheres and an operating temperature of 80°C, but if atmospheric conditions are unusually polluted this period should be revised; also the life of the lubricant should be halved for each increment of 10° rise above 80°C but it must not be extended when the running temperature is less than 80°C. THE FOLLOWING TO BE CARRIED OUT WHEN FITTED / APPLICABLE Period Task

1 Day

Read Instruments Verify Coolant Flow (Air) Examine Cables Replenish Lubricant Clean Exterior Check Winding Insulation Check Thermistor Circuits Check Security of Terminals

X

Motor Condition MOTOR RUNNING MOTOR STOPPED

7.2

1 Week

2 Week

1 Month

3 Month

6 Month

1 Year

2 Years

X X SEE MOTOR RATING PLATE / BEARING LIFE X X X X

Inspection Schedule for Ex ‘d’ Equipment Definitions of Inspection Schedule Visual Inspection :-

Weekly Close Inspection :-

Monthly

Detailed Inspection :-

6 Monthly

An inspection which identifies, without the use of accessing equipment or tools, those defects, such as missing bolts or components, which are apparent to the eye.

An inspection which encompasses those aspects covered by visual inspection and, in addition, identifies those defects, such as loose bolts, which will be apparent only by the use of equipment or tools. Close inspections do not normally require the equipment to be opened or de-energised.

An inspection which encompasses those aspects covered by close inspection and, in addition, identifies those defects, such as loose terminations, which will only be apparent by opening the enclosure.

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7.3

Inspection Schedule Table Check that

APPARATUS Apparatus is appropriate to area classification Apparatus group is correct Apparatus temperature is correct Enclosure, sealing gaskets and/or compounds are satisfactory There are no unauthorised modifications There are no visible unauthorised modifications Bolts, cable entry devices, and blanking elements are of the correct type and are complete and tight • physical check • visual check Flange faces are clean, undamaged and are satisfactory Flange gap dimensions are within the values permitted INSTALLATION Type of cable is appropriate There is no obvious damage to cables Boxes and cable entry boxes, as applicable, are completely filled Earthing connections are satisfactory, • physical check • visual check Insulation resistance is correct Automatic electrical protective devices, as applicable, operate within permitted limits Special conditions of use are, as applicable, are complied with Cables not in use are correctly terminated Obstructions adjacent to flameproof flanged joints are in accordance with IEC 79-14 ENVIRONMENT Apparatus is protected against corrosion, weather, and vibration No undue accumulation of dust and dirt Electrical insulation is clean and dry

Grade of Inspection Detailed Close Visual

9 9 9 9 9

9

9 9 9 9

9

9

9

9

9 9

9 9 9 9 9

9

9

9

9

9

9

9

9

9 9 9

9 9

9 9

9 9 9 9 9

If apparatus is dismantled during the course of an inspection, precautions must be taken during reassembly to ensure that the integrity of the type of protection is not impaired.

8

Maintenance Instructions !! Important Note !!

The inspection and maintenance of this machine shall be performed by experienced personnel, whose training has included instruction on various types of protection and installation practices, the relevant rules and regulations, and on the general principles of area classification.

This machine is intended for use in Explosive Atmospheres, Group I, and as such we recommend that for any overhaul or repair work the machine is returned to Morley Electric Motors Ltd to ensure that the flameproof protection concept to the applicable standards is maintained.

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Should any previous overhauls, repair work or modifications have occurred by a third party on this equipment, then it is imperative that the complete machine history is communicated when returned.

!! WARNING !! !! ELECTRICITY CAN KILL! ALL WORK ON ELECTRICAL INSTALLATIONS, SHOULD BE CLOSELY CONTROLLED AND A ‘PERMIT TO WORK’ SYSTEM IS RECOMMENDED.

!! WARNING !!

DO NOT TOUCH THE CABLES UNLESS IT IS KNOWN TO BE SAFE.

!! WARNING !!

BEWARE OF THE ROTATING SHAFT : REMOVE OR SECURE LOOSE CLOTHING Etc.

!! WARNING !!

DO NOT USE SOLVENTS FOR CLEANING PURPOSES IN CONFINED SPACES

8.1

Bearing Replacement For selection of the rolling element bearings, sufficient data (bearing number designation) is marked on the main motor nameplate.

The rated bearing life interval for replacing rolling element bearings is also given on the main motor nameplate.

!! Important Note !!

It is important that rolling element bearings are replaced within the recommended life period stated on the motor nameplate.

Failure to do so will increase the probability of a bearing failure, leading to the creation of a possible ignition hazard.

Remove bearing elements by means of an extraction device. Never use a hammer to remove old bearings as this could damage the rotor shaft.

Before installing new bearings, make sure that the bearing seatings on the rotor shaft are clean and free from burrs or sharp edges.

Use extreme care and ensure that there are clean working conditions during the installation and assembly of bearing elements.

8.2

Re-Greasing Bearings For the correct grade of lubricant, re-greasing quantity and lubrication interval, see the motor rating plate.

When re-packing the bearings, work the new grease into the cavities of the rolling bearing elements, and fill the bearing end caps to half of their capacity, ensuring that the grease port is filled also.

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8.3

Torque Wrench Settings For Metric Screws Socket Head (cap) Screws Screw Size Torque Lbs.ft Torque NM Torque kgf/m

M3 1.4 1.9 0.2

M4 4.2 5.7 0.6

M5 6.3 8.5 0.8

M6 11.5 15.5 1.6

M8 26 35 3.5

M10 50 70 7.1

M12 100 130 13.2

M16 230 315 32.1

M20 430 580 59.1

M24 700 950 96.8

M10 40 56 5.7

M12 70 98 10

M16 180 250 25.4

M20 350 480 48.9

M24 600 820 83.6

Hexagon Head Screws Screw Size Torque Lbs.ft Torque NM Torque kgf/m

M3 -

M4 -

M5 5.1 6.9 0.7

M6 8.6 11.7 1.2

M8 20 28 2.8

The above torque figures represent 75% of yield point stress.

The torque figures assume that screws turn freely in the thread and with minimum lubricant.

The above recommended tightening torque’s apply to metal-to metal joints only. No recommended torque’s can be given for the following but care must be taken to avoid damage to the various components due to over-tightening. a)

Slotted screws, e.g. small terminal blocks, etc.

b)

Non-ferrous fasteners, e.g. brass terminal nuts.

Torque Settings For Terminal Mouldings Screw / Nut Size M10 M12 M16

Securing Torque 16 N/m 25 N/m 50 N/m

The figures in the above table are taken from EN 50014 for clamping forces applied to terminal bushings.

8.4

Flameproof Joints After any examination of flameproof joints and when reassembling flameproof enclosures, all joints shall be thoroughly cleaned and lightly smeared with a suitable grease to prevent corrosion and to assist weather proofing. Blind bolt holes must be kept clear of grease.

When overhauling, check that the motor still complies with flameproof certification and protection concept requirements.

Should any doubt arise concerning the fitness of any flameproof components it is recommended that Morley Electric Motors is contacted.

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9

Assembly and Disassembly Procedure

Refer to spare part list in the Technical Section of this manual.

9.1

Disassembly

1).

At the non-drive-end, remove the hexagon headed screws (31) from the outside of the fan cowl.

2).

Remove the cowl by pulling it from its location on the bearing endshield.

SAFETY !

Should a lifting point be provided on the fan cowl then use appropriate lifting tackle to support the cowl when removing, as the cowl may be heavy.

3).

Remove the 4 Hex. screws (29) securing the fan to the fan hub. Remove the fan.

4).

Find the location of the locking tab that has been bent over into one of the castellation of the locknut (27) and straighten the tab to enable the lock nut to be unscrewed and removed with an appropriate 'C' spanner.

5).

Withdraw the fan hub (24) from the rotor shaft (2).

6).

Unscrew and remove socket head cap screws in the bearing cover (19) and withdraw the bearing cover from its location in the bearing endshield (7).

7).

Unscrew and remove the socket head cap screws (14) in the bearing endshield that secure the bearing housing to the bearing endshield.

8).

Unscrew and remove the top two bearing endshield securing screws (8) and insert two lengths of threaded rod, approx. 200mm long. This will support the bearing endshield as it is being removed from its location in the stator frame (1).

9).

Remove the rest of the securing screws (8) and re-insert an appropriate number of screws into their jacking off holes in the bearing endshield (7).

10).

Using the jacking off holes and screws, withdraw bearing endshield (7) from its location inside the stator frame (1).

NOTE !

The bearing elements will now be exposed therefore care must be taken not to allow any contamination or damage to the bearings, suitably cover the bearing assembly.

11).

Should bearing thermistor or RTD protection circuits be provided at the bearing housing (13), carefully remove the connections from the housing and store safely until re-assembly.

12).

At the drive-end of the motor, remove the labyrinth (30) and 'V' seal (28), Inpro seal (20) as appropriate.

13).

Unscrew and remove the securing screws (19) for the bearing cover, withdraw the cover from its location in the bearing endshield (4).

14).

Unscrew and remove the socket head cap screws (14) for the bearing housing (12) to bearing endshield (4) location.

15).

Unscrew and remove the top two bearing endshield securing screws (5) and insert two lengths of threaded rod, approx. 200mm long. This will support the bearing endshield as it is being removed from its location in the stator frame (1).

16).

Remove the rest of the securing screws (5) and re-insert an appropriate number of screws into their jacking off holes in the bearing endshield (4).

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17).

Using the jacking off holes and screws, withdraw bearing endshield (4) from its location inside the stator frame (1).

NOTE !

The bearing elements will now be exposed therefore care must be taken not to allow any contamination or damage to the bearings, suitably cover the bearing assembly.

18).

Should bearing thermistor or RTD protection circuits be provided at the bearing housing (12), carefully remove the connections from the housing and store safely until re-assembly.

19).

The rotor assembly may then be removed from the stator assembly, by the use of a suitable lifting beam, or a tube over the rotor shaft. Examples are provided below (bearing assemblies removed for clarity).

20).

Lift the rotor assembly to a suitable clean workbench, where removal of the bearing assemblies can commence, by use of bearing puller or hydraulic ram and plate. Ensure bearing circlip is removed (22) before attempting to remove bearings.

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21).

Store bearing elements and housings on a clean workbench to protect from contamination and damage.

22).

Label components with motor serial number for ease of identification when re-assembling motor after checks or repairs have been undertaken.

9.2

Inspection and Renewal

General ALWAYS REPLACE USED 'O' RING SEALS, 'V' SEALS AND INPRO SEALS WITH NEW. ALWAYS REPLACE SECURING SCREWS THAT MAINTAIN THE ENCLOSURES PROTECTION CONCEPT WITH NEW. Check for signs of moisture, check whether any moisture has accumulated in the bottom of the stator frame.

Investigate the cause of any traces of moisture as this could influence the insulation readings.

Remove any dust from the windings and interior of the motor with dry compressed air. Remove any traces of grease from the windings with a cleaning agent formulated for cleaning electrical machine windings : Genklene.

Keys must be a good fit in their keyways. They must be flat, parallel and free from burrs. Worn or damaged keys must be renewed.

Examine and clean the grease lubrication points, and tubes to ensure that they are not contaminated with dirty grease, and cannot contaminate the free grease ways of the bearing assembly.

Examine all studs, nuts and bolts for damage or deterioration. Renew as necessary.

Examine the internal fan for loose, cracked or broken blades.

9.3

Windings

Wipe all insulation with a clean dry cloth. Inspect the windings for signs of brittleness. Serious deterioration in the condition of the winding insulation may make the re-winding of the motor a necessity.

Check the insulation resistance, if the winding insulation resistance is less than that specified then the windings should be dried out.

Check the surfaces of the windings for evidence of the need for re-coating with insulation varnish. The windings must be thoroughly cleaned before varnishing.

9.4

Ball and Roller Bearings

IT IS RECOMMENDED GOOD ENGINEERING PRACTICE TO NEVER RE-USE A BEARING ELEMENT THAT HAS BEEN REMOVED FROM A ROTOR SHAFT, AS DAMAGE MAY HAVE TAKEN PLACE DURING WITHDRAWAL. Before fitting, thoroughly examine the bearing elements for damage, erosion, pitting or transit damage.

NOTE :- A good bearing should revolve freely in either direction under very light pressure applied with the fingers. If the bearing feels rough when revolved, or if it is rusty or stained, it must be discarded. Compressed air must NOT be used to spin the bearing.

Care must be taken to ensure cleanliness of the bearings before they are fitted onto the rotor shaft. The bearings must be thoroughly dried, coated with a thin covering of grease to prevent rust, and then wrapped in oiled paper and stored in a clean dry place until required for installation.

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9.5

Repairs

If repairs or alterations are undertaken, that influence the explosion protection concept, Morley Electric Motors must be consulted before the repair work is undertaken, as the repair could invalidate the requirements of the protection concept standard and certification.

9.6

Assembling Procedures

NOTE :-

When assembling the motor, reference should be made to Table 1, below for recommended retaining screw tightening torques.

TABLE 1 TORQUE WRENCH SETTINGS FOR METRIC SCREWS Socket Head (cap) Screws to BS 4169

Screw Size Torque Lbs.ft Torque NM Torque kgf/m

M3 1.4 1.9 0.2

M4 4.2 5.7 0.6

M5 6.3 8.5 0.8

M6 11.5 15.5 1.6

M8 26 35 3.5

M10 50 70 7.1

M12 100 130 13.2

M16 230 315 32.1

M20 430 580 59.1

M24 700 950 96.8

M12 70 98 10

M16 180 250 25.4

M20 350 480 48.9

M24 600 820 83.6

Hexagon Head Screws to BS 3692 Screw Size Torque Lbs.ft Torque NM Torque kgf/m

M3 -

M4 -

M5 5.1 6.9 0.7

M6 8.6 11.7 1.2

M8 20 28 2.8

M10 40 56 5.7

The above torque figures represent 75% of yield point stress.

The torque figures assume that screws turn freely in the thread and with minimum lubricant.

The above recommended tightening torques apply to metal-to metal joints only. No recommended torques can be given for the following but care must be taken to avoid damage to the various components due to overtightening.

Slotted screws, e.g. small terminal blocks, etc.

Non-ferrous fasteners, e.g. brass terminal nuts.

9.7

Motor Assembly

1).

Check the rotor shaft and shaft shoulders for damage. A burr on the shaft shoulder can cause bearing misalignment.

2).

At the end of the motor where the ball bearing is located, lightly oil the bearing seating of the rotor shaft.

CAUTION -

NEVER HEAT A BEARING USING AN OPEN FLAME. USE CLEAN PROTECTIVE GLOVES TO HOLD HOT BEARING ELEMENTS AND ASSEMBLIES.

3).

Using a bearing induction heater or oil bath, thermally expand the bearing housing to a o o temperature of 100 C to 120 C and drop the ball bearing elements into the bearing housing bore.

4).

Re-heat the bearing assembly, ensuring the thermometer probe is in contact with the inner bearing race, to a temperature of 100oC, up to a maximum of 120oC. Page 19 of 25

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5).

Immediately temperature is reached, offer the expanded bearing elements and assembly up to the rotor shaft and locate on it’s seating and up to the bearing seating shoulder. The inner race of the bearing element must be held up against the location shoulder until the inner race grips the rotor shaft. Fit the bearing locking circlip.

6).

The bearing assembly must then be covered to prevent contamination, and allowed to cool to room temperature before any more assembly work can continue.

7).

At the end of the motor where the roller bearing is located, lightly oil the bearing seating of the rotor shaft.

8).

Using a bearing induction heater or oil bath, thermally expand the bearing housing to a o o temperature of 100 C to 120 C and drop the outer race of the roller bearing element into the bearing housing bore. Insert the rolling elements into the bearing housing.

9).

Re-heat the bearing assembly, ensuring the thermometer probe is in contact with the inner bearing race, to a temperature of 100oC, up to a maximum of 120oC.

10).

Immediately temperature is reached, offer the expanded bearing elements and assembly up to the shaft and locate on it’s seating and up to the bearing seating diameter shoulder. The inner race of the bearing element must be held up against the bearing location shoulder until the inner race grips the rotor shaft.

11).

The bearing assembly must then be covered to prevent contamination, and allowed to cool to room temperature before any more assembly work can continue.

12).

Suitably sling the rotor and lift the rotor into the drive end of the stator frame.

13).

Slide the extension tube onto the end of the rotor shaft.

CAUTION :-

The following procedure requires GREAT CARE to be taken whilst inserting the rotor so that damage does not occur to the stator core or the windings. Ensure that the rotor core remains central to the stator core and the windings at all times. A layer of insulating material can be used to protect the winding overhangs during the rotor threading operation.

14).

Carefully insert the rotor into the drive end of the stator core until it is in position.

15).

Support the rotor at both ends and re-position the slings to each end of the rotor.

16).

Continue to insert the rotor into the stator core, avoiding contact between the cores, and winding until the stator and rotor cores coincide axially. Rest the rotor on the stator core and remove the extension tube.

17).

Attach any bearing thermistors or RTD's removed during stripdown to the bearing housings.

18).

Uncover the bearing assemblies at both ends of the rotor shaft and grease the spaces between the rolling elements of the bearing with grease detailed on the main motor rating plate.

19).

At the end of the motor where the ball bearing is located, insert two lengths of screwed rod, approx. 200mm lg., into the top holes of the stator frame where the bearing endshield is secured, and insert two lengths of screwed rod approx. 200mm lg. into the securing holes of the bearing housing, to aid location of the bearing endshield.

20).

Mount the bearing endplate (using the locating studs for alignment) over the bearing housing assembly and into the stator frame register. The rotor shaft may have to be lifted to allow engagement of the bearing endplate registers into the spigots of the stator frame.

21).

Using the securing screws, fasten the bearing housing to the bearing endshield and then the bearing endshield to the stator frame, replacing the locating screwed rod with the appropriate fastening screw.

22).

To attach the INPRO seal into the bearing cover at the drive end, lightly lubricate the bore of the bearing cover and the outside of the Inpro seal. Using a hand press, ensuring that the Inpro seal is Page 20 of 25

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square to the bore of the bearing cover, press the Inpro seal into the bore of the bearing cover.

There may be a slight shearing of 'O' ring sealing material, if so this will ensure a secure fit is achieved.

23).

Fill half the free space volume of the bearing cover with grease as detailed on the main motor rating plate. Smear a small quantity of grease onto the bore of the Inpro seal, so that it freely slides along the rotor shaft.

24).

Secure the bearing cover to the bearing housing using the appropriate screws.

25).

Where the cover is fitted with a labyrinth and 'V' seal arrangement, fit the 'V' seal onto the labyrinth, lubricate 'V' seal with bearing grease and push the labyrinth assembly onto the rotor shaft, until it is engaged with the bearing cover to form an adequate seal.

26).

At the end of the motor where the roller bearing is located, insert two lengths of screwed rod, approx. 200mm lg., into the top holes of the stator frame where the bearing endshield is secured, and insert two lengths of screwed rod approx. 200mm lg. into the securing holes of the bearing housing, to aid location of the bearing endshield.

27).

Mount the bearing endplate (using the locating studs for alignment) over the bearing housing assembly and into the stator frame register. The rotor shaft may have to be lifted to allow engagement of the bearing endplate registers into the spigots of the stator frame.

28).

Using the securing screws, fasten the bearing housing to the bearing endshield and then the bearing endshield to the stator frame, replacing the locating screwed rod with the appropriate fastening screw.

29).

At the bearing cover half fill the free volume space with grease as detailed on the main motor rating plate, fit to the bearing housing and secure.

30).

Mount the fan hub onto the rotor shaft, and secure using the locknut and locking tab washer.

Ensure that a locking tab is beat into a castellation of the locknut.

31).

Rotate the rotor shaft by hand to ensure that there is freedom of movement and the bearings are located correctly.

32).

Secure the cooling fan to the fan hub.

33).

Secure the fan cowl to the locating positions on the bearing endshield / stator frame.

34).

Rotate the rotor shaft by hand to ensure that the cooling fan is not catching the fan cowl.

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10

Fault Finding Should any faults be found with the machine, then a record of the malfunctioning component must be made so that appropriate evaluation and investigation into the failure can take place.

Recording of any abnormal symptoms, indications, performance measurements, alarms or trips must be made so that a complete history of the machines performance can be assessed should a major failure occur.

FAULT Fails to start coupled or uncoupled with no noise emitted.

POSSIBLE CAUSE Two or more leads open circuited.

One lead open circuited

Fails to start coupled or uncoupled, Hums.

Rotor locked

Fails to start under load.

Starts too slowly under load.

Bearing seized up.

Load torque too high.

Supply voltage too low.

Load speed too low.

Excessive voltage drop in supply leads.

Starts unloaded but fails to accelerate.

Magnetic load.

Stator current fluctuates at double slip frequency.

Current swing increases with load.

No load current too high.

Rotor winding open circuited in several places.

One supply lead broken after starting.

Rotor winding open circuited.

Stator winding heats up quickly and hums during running.

Stator winding heats up quickly Under no-load conditions.

Excessive stator winding heating on load.

Rotor winding open circuited.

Supply voltage too high.

Stator winding parallel connections or phase winding open circuited.

Supply voltage too high.

Inadequate cooling caused by clogged water passages.

Motor rotates wrong way.

Inadequate cooling caused by clogged air passages.

Motor rotates wrong way, too slow.

Load excessive.

Excessive number of consecutive starts.

Voltage too high causing high iron losses.

Voltage too low therefore current too high.

Fractured lead or open circuit in one phase.

Rotor rubs against stator.

Stator winding temperatures Increase.

Hot spots in stator winding.

Hot spots on rotor.

Duty differs from nameplate data.

Winding contaminated, air passages clogged.

Interturn short circuits.

Open circuit in winding parallel connections or phase of stator winding.

Open circuit in rotor winding.

RECTIFICATION Check supply ie. Transformer, breaker, fuses, leads & terminals.

Check supply ie. Transformer, breaker, fuses, leads & terminals.

Check bearing alignment and air gap for obstructions Replace bearing and dress shaft.

Un load driven machine during start-up Measure supply voltage and adjust to correct value.

Check cross sectional area of supply leads Check rotor winding and repair / replace Check supply leads.

Check rotor winding and repair / replace Check rotor winding and repair / replace Measure supply voltage and adjust to correct value.

Measure resistance of phase winding and replace winding as necessary.

Check supply voltage and no-load current.

Clean out air passages.

Changeover two motor supply leads.

Clean out air passages.

Changeover two motor supply leads.

Measure stator current and reduce load.

Reduce number of starts and include adequate period of cooling.

Adjust voltage. DO NOT EXCEED RATED VOLTAGE unless nameplate indicates otherwise.

Check supply voltage and voltage drop in supply leads.

Check currents in all phases.

Check air gap, Check bearings, Check concentricity of rotor.

Adhere to duty or reduce load.

Clean.

Replace scorched coils as necessary.

Measure resistance of all phase winding, replace as required.

Repair rotor cage.

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11

Machine Maintenance History The following is a proposed style for ‘machine history’. A machine history should record all work from monthly maintenance to bi-annual maintenance and the replacement of bearings etc.

PARTICULARLY NOTE !

When entering the history notes compare the serial number of the machine that has been serviced with that at the top of the table.

MOTOR SERIAL No. :DATE

12

ACTION TAKEN

Spares And Service Backup

When in difficulty, contact Morley Electric Motors Australia Pty Ltd., or alternatively contact the Morley Service Representative. G & D Donnelly Pty Ltd at the numbers below.

This equipment is intended for use in Explosive Atmospheres (Group I), and as such we recommend that for any overhaul or repair work the machine be returned to G & D Donnelly Pty Ltd to ensure that the flameproof protection concept to the applicable standards is maintained.

Should any previous overhauls, repair work or modifications have occurred by a third party on this equipment, then it is imperative that the complete motor history be communicated when returned.

Morley Electric Motors Australia Pty Ltd. Telephone Number :02 9980 9590 Fax Number :02 9980 9591 E-mail :gjm@mema.com.au Web Site :www.morleymotors.com G & D Donnelly Pty Ltd 12 Young Street East Maitland 2323 Telephone Number

02 4933 8033 (Business Hours) 02 4966 3120 (After Hours)

Facsimile Number 02 4933 1089 E-mail admin@gddonnelly.com.au WHEN REQUIRING ASSISTANCE OR ORDERING SPARES, PLEASE QUOTE THE MOTOR SERIAL NUMBER !

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13

Special Features - Commissioning Service & Maintenance This equipment is intended for use in Explosive Atmospheres (Group I), and as such we recommend that for any overhaul or repair work the machine be returned to Morley Electric Motors Ltd., to ensure that the flameproof protection concept to the applicable standards is maintained.

Should any previous overhauls, repair work or modifications have occurred by a third party on this equipment, then it is imperative that the complete motor history be communicated when returned.

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Appendix 1 Drawings, Diagrams and Spare Parts List

Page 25 of 25