WEG Synchronous Motor Brushless

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Synchronous Motors S line - Brushless - Horizontals
Installation, Operation and Maintenance Manual
11866576 - Brushless synchronous motors - Horizontals
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Installation, Operation and Maintenance Manual

Document Number: 11866576 Models: SEA, SED, SET, SEV, SEF, SER, SEI, SEW, SEL, SFA, SFD, SFT, SFV, SFF, SFR, SFI, SFW and SFL Language: English Review: 1 February 2012
11866576 - Brushless synchronous motors - Horizontals | 3
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Dear Customer,
Thanks for purchasing a WEG motor. It is a product developed with quality and efficiency levels which ensure an outstanding performance. Since the electric motor plays an important role in the comfort and well being of mankind, it must be identified and treated as a driving machine, whose characteristics involve certain care, such as proper storage, installation and maintenance. All efforts have been made to ensure that the information contained in this manual is faithful to the configurations and application of the motor. Therefore, we recommend that you read this manual carefully before proceeding with the installation, operation or maintenance of the motor in order to ensure the safe and continuous operation of the motor and also the safety of your installations. If you need any further information, please, contact WEG. Keep this manual always close to the motor, so it can be referred to when needed.
ATTENTION
1. It is imperative to observe the procedures contained in this manual for the warranty to be valid; 2. The motor installation, operation and maintenance procedures must be performed by qualified personnel only.
NOTES
1. Reproduction of the information contained in this manual, in whole or in parts, is allowed since the source is mentioned; 2. In case this manual is lost, the electronic file in PDF format is available at www.weg.net or another printed copy may be requested.
WEG EQUIPAMENTOS ELTRICOS S.A.
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INDEX
INTRODUCTION .................................................................................................11
1.1 1.2 NOMENCLATURE...........................................................................................................................11 SAFETY WARNINGS IN THIS MANUAL ..........................................................................................11
GENERAL INSTRUCTIONS .................................................................................12

2.1 2.2 2.3 2.4 2.5 2.6 2.7 QUALIFIED PERSONNEL ................................................................................................................12 SAFETY INSTRUCTIONS ................................................................................................................12 MOTORS APPLIED IN AREAS OF RISK ..........................................................................................12
2.3.1 2.3.2 General care .......................................................................................................................................13 Additional care....................................................................................................................................13
STANDARDS...................................................................................................................................13 CHARACTERISTICS OF THE ENVIRONMENT ................................................................................13 OPERATING CONDITIONS .............................................................................................................13 VOLTAGE AND FREQUENCY .........................................................................................................13
RECEIVING, STORAGE AND HANDLING .............................................................14

3.1 3.2 3.3 RECEIVING .....................................................................................................................................14 HANDLING......................................................................................................................................14 STORAGE .......................................................................................................................................14
3.3.1 3.3.2 3.3.3 Indoor storage ....................................................................................................................................14 Outdoor storage .................................................................................................................................14 Extended storage ...............................................................................................................................15 3.3.3.1 Storage location ..................................................................................................................15 3.3.3.1.1 Indoor storage ................................................................................................15 3.3.3.1.2 Outdoor storage .............................................................................................15 3.3.3.2 Separate parts ....................................................................................................................15 3.3.3.3 Space heater.......................................................................................................................15 3.3.3.4 Insulation resistance ............................................................................................................15 3.3.3.5 Exposed machined surfaces................................................................................................15 3.3.3.6 Bearings..............................................................................................................................16 3.3.3.6.1 Sleeve bearing ................................................................................................16 3.3.3.6.2 Oil-lubricated rolling bearing............................................................................16 3.3.3.6.3 Grease-lubricated rolling bearing.....................................................................16 3.3.3.7 Terminal box .......................................................................................................................16 3.3.3.8 Radiator ..............................................................................................................................16 3.3.3.9 Inspections and records during storage ...............................................................................17 3.3.3.10 Preparation for commissioning ............................................................................................17 3.3.3.10.1 Cleaning .........................................................................................................17 3.3.3.10.2 Bearing lubrication ..........................................................................................17 3.3.3.10.3 Checking the insulation resistance ..................................................................17 3.3.3.10.4 Others ............................................................................................................17 3.3.3.11 Maintenance plan during storage.........................................................................................18
INSTALLATION ...................................................................................................19
4.1 4.2 4.3 4.4 LOCAL OF INSTALLATION .............................................................................................................19 SHAFT PROTECTION .....................................................................................................................19 DIRECTION OF ROTATION .............................................................................................................19 INSULATION RESISTANCE.............................................................................................................19
4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 Safety instructions ..............................................................................................................................19 General considerations .......................................................................................................................19 Measuring stator windings ..................................................................................................................19 Measurement on the windings ............................................................................................................20 Polarization index................................................................................................................................20 Conversion of measured values ..........................................................................................................21 Minimum insulation resistance.............................................................................................................21 Thermal protections ............................................................................................................................21 4.5.1.1 Temperature sensors ..........................................................................................................21 4.5.1.2 Temperature limits for the windings .....................................................................................22 11866576 - Brushless synchronous motors - Horizontals | 7
4.5
PROTECTIONS ...............................................................................................................................21
4.5.1
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4.5.2 4.5.3
4.5.1.3 Alarm and tripping temperatures......................................................................................... 22 4.5.1.4 Temperature and ohm resistance of the PT100................................................................... 23 Space heater ..................................................................................................................................... 23 Water leak sensor .............................................................................................................................. 23 Water radiators .................................................................................................................................. 23 4.6.1.1 Radiators for application with seawater............................................................................... 24 Independent ventilation ...................................................................................................................... 24 Electric connections ........................................................................................................................... 24 4.7.1.1 Main connection ................................................................................................................. 24 4.7.1.2 Grounding .......................................................................................................................... 24 4.7.1.3 Power supply and control of the field .................................................................................. 25 Connection diagram........................................................................................................................... 25
4.6
COOLING ....................................................................................................................................... 23
4.6.1 4.6.2
4.7
ELECTRICAL CHARACTERISTICS ................................................................................................. 24

4.7.1
4.7.2
4.8
MECHANICAL CHARACTERISTICS ............................................................................................... 25

4.8.1 4.8.2 4.8.3 Foundations ....................................................................................................................................... 25 Forces on the foundations.................................................................................................................. 25 Base types......................................................................................................................................... 25 4.8.3.1 Concrete base.................................................................................................................... 25 4.8.3.2 Metal base.......................................................................................................................... 25 4.8.4 Motor mounting ................................................................................................................................. 25 4.8.5 Anchoring plate set ............................................................................................................................ 25 4.8.6 Natural frequency of the base............................................................................................................. 26 4.8.7 Inspection of pedestal bearings .......................................................................................................... 26 4.8.8 Alignment of the motor with the driven machine ................................................................................. 27 4.8.9 Motor leveling..................................................................................................................................... 28 4.8.10 Couplings........................................................................................................................................... 28 4.8.10.1 Direct coupling ................................................................................................................... 28 4.8.10.2 Coupling by gears .............................................................................................................. 28 4.8.10.3 Coupling of motors equipped with sleeve bearings ............................................................. 28
4.9 4.10
BRAKE ........................................................................................................................................... 29 HYDRAULIC UNIT .......................................................................................................................... 29
START ............................................................................................................... 30
5.1 DIRECT START .............................................................................................................................. 30
5.1.1 5.1.2 5.1.3 5.1.4 Direct start with discharge resistor...................................................................................................... 30 Direct start without discharge resistor................................................................................................. 30 Direct start frequency ......................................................................................................................... 30 Locked rotor current (Ip/In) ................................................................................................................. 30 Start with reactor ............................................................................................................................... 31 Start with autotransformer.................................................................................................................. 31 Start with frequency inverter ............................................................................................................... 31 Start with soft-starter.......................................................................................................................... 31 Excitation circuit with voltage control (Random) .................................................................................. 32 Excitation circuit with frequency control .............................................................................................. 33 Excitation circuit for AC exciter ........................................................................................................... 34
5.2
OTHER START METHODS............................................................................................................. 31

5.2.1 5.2.2 5.2.3 5.2.4
5.3
EXCITATION CIRCUITS .................................................................................................................. 32

5.3.1 5.3.2 5.3.3
COMMISSIONING .............................................................................................. 35
6.1 6.2 6.3 PRELIMINARY INSPECTION .......................................................................................................... 35 INITIAL START-UP (UNCOUPLED) ................................................................................................. 35 OPERATION ................................................................................................................................... 36
6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 Resynchronization.............................................................................................................................. 36 Data record........................................................................................................................................ 36 Temperatures..................................................................................................................................... 36 Bearings ............................................................................................................................................ 36 6.3.4.1 High-pressure oil injection system....................................................................................... 36 Radiators ........................................................................................................................................... 37 6.3.5.1 Inspection of the performance of the radiator ...................................................................... 37 Vibration ............................................................................................................................................ 37
6.4
STOP.............................................................................................................................................. 37
MAINTENANCE .................................................................................................. 38
7.1 GENERAL....................................................................................................................................... 38
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7.2 7.3 7.4
GENERAL CLEANING .....................................................................................................................38 INSPECTIONS IN THE WINDINGS ..................................................................................................38 WINDING CLEANING ......................................................................................................................38
7.4.1 7.4.2 7.4.3 Inspections .........................................................................................................................................38 Re-impregnation .................................................................................................................................39 Insulation resistance............................................................................................................................39 Maintenance of radiators.....................................................................................................................39
7.5 7.6 7.7 7.8
MAINTENANCE OF THE COOLING SYSTEM..................................................................................39

7.5.1
VIBRATION .....................................................................................................................................39 SHAFT GROUNDING DEVICE .........................................................................................................39 MAINTENANCE THE EXCITER........................................................................................................39

7.8.1 7.8.2 7.8.3 Exciter ................................................................................................................................................39 Diode test ...........................................................................................................................................40 7.8.2.1 Diode replacement ..............................................................................................................40 Thyristor test SCR...............................................................................................................................40 7.8.3.1 Thyristors replacement ........................................................................................................40 Sleeve bearings ..................................................................................................................................41 7.9.1.1 Bearing data........................................................................................................................41 7.9.1.2 Bearing installation and operation ........................................................................................41 7.9.1.3 Protection adjustments........................................................................................................41 7.9.1.4 Cooling by water circulation.................................................................................................41 7.9.1.5 Oil change...........................................................................................................................41 7.9.1.6 Seals...................................................................................................................................42 Oil rolling bearing ................................................................................................................................42 7.9.2.1 Lubrication instruction .........................................................................................................42 7.9.2.2 Oil type................................................................................................................................42 7.9.2.3 Oil change...........................................................................................................................42 7.9.2.4 Protection adjustments........................................................................................................43 7.9.2.5 Bearing assembly and disassembly .....................................................................................44 Grease rolling bearings .......................................................................................................................45 7.9.3.1 Lubrication instructions........................................................................................................45 7.9.3.2 Procedure to lubricate the rolling bearings ...........................................................................45 7.9.3.3 Bearing lubrication with spring device to remove the grease ................................................45 7.9.3.4 Grease type and quantity ....................................................................................................45 7.9.3.5 Protection adjustments........................................................................................................45 7.9.3.6 Bearing assembly and disassembly .....................................................................................46 7.9.3.7 Grease quality and quantity .................................................................................................47 7.9.3.8 Compatibility .......................................................................................................................47 Disassembly and assembly of the bearing Pt100.................................................................................47
7.9
BEARING MAINTENANCE ..............................................................................................................41

7.9.1
7.9.2
7.9.3
7.9.4
MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................48

8.1 8.2 8.3 8.4 8.5 DISASSEMBLY ...............................................................................................................................48 ASSEMBLY .....................................................................................................................................48 MEASUREMENT OF THE AIR-GAP.................................................................................................48 GENERAL RECOMMENDATIONS...................................................................................................48 SPARE PARTS ................................................................................................................................48
MAINTENANCE PLAN.........................................................................................49
10 ABNORMALITIES, CAUSES AND SOLUTIONS .....................................................50 11 WARRANTY TERMS ...........................................................................................52
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1 INTRODUCTION
The motors are supplied with specific documents (dimension drawing, connection diagram, etc.). Those documents together with this manual must be thoroughly studied before proceeding with installation, operation or maintenance of the motor. All procedures and standards contained in this manual must be observed in order to ensure the proper operation of the motor and safety of the personnel involved in its operation. Following these procedures is also important to ensure the validity of the motor warranty. Thus, we recommend the careful reading of this manual before installing and operating the motor. If any questions remain, please, contact WEG.
1.1
NOMENCLATURE
S
MOTOR LINE S Engineered Synchronous Machine EXCITATION CHARACTERISTIC E Brushless synchronous motor without auxiliary exciter F Brushless synchronous motor with auxiliary exciter COOLING SYSTEM
800
A Open, self-ventilated D Self-ventilated by ducts, air inlet and outlet T Forced ventilation, air inlet and outlet by ducts V Forced ventilation, ventilation on the motor F Self-cooled with air-air heat exchanger on the motor R Self-ventilated with air-air heat exchanger around the stator I Forced ventilation in the internal and external air circuit, air-air heat exchanger W Air-water heat exchanger L Air-water heat exchanger, forced ventilation in the internal air circuit IEC FRAME ABNT/IEC 355 to 3.150
1.2
SAFETY WARNINGS IN THIS MANUAL
In this manual, the following safety warnings are used:
DANGER
The not following of the procedures recommended in this warning can lead to death, serious injuries and considerable material damages.
ATTENTION
The not following of the procedures recommended in this warning can lead to material damages.
NOTE
The text aims at providing important information for the full understanding and proper operation of the product.
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2 GENERAL INSTRUCTIONS
All personnel working in the assembly, operation or maintenance of electrical installations must be permanently informed and updated on the safety standards and instructions and are advised to strictly comply with them. Before beginning any job, the person in charge must make sure that all points have been duly observed and warn the respective personnel about the danger inherent to the task to be performed. When inappropriately applied or lacking adequate maintenance, or also when handled by people lacking qualification, such motors may cause serious personal injuries and/or material damages. Therefore, it is highly recommended that services be always performed by qualified personnel.
2.1
QUALIFIED PERSONNEL
The term qualified personnel represents those who, due to their training, experience, education level, knowledge of applicable standards, safety standards, accident prevention and knowledge of operating conditions, have been authorized by those in charge to execute all necessary tasks, and to recognize and avoid any possible danger. Such qualified personnel must also know first aid procedures and must be able to provide such services, if necessary. All operation, maintenance, and repair tasks are to be exclusively performed by qualified personnel.
2.2
SAFETY INSTRUCTIONS
DANGER
During operation, this equipment features exposed energized or spinning parts which may present high voltages or high temperatures. Thus, the operation with open terminal boxes, unguarded couplings, or improper handling, failing to comply with the operating standards, may cause severe personal and material damages.
All qualified personnel must also observe: All technical data regarding the applications allowed (operating conditions, connections and installation environment), provided in the purchase order documents, operating instructions, manuals, and other documentation; The specific determinations and conditions for local installation; The use of appropriate tools and equipment for handling and transportation; That the protection devices of the individual component parts are removed just before the installation. Individual parts must be stored in vibration-free environments, avoiding falls and ensuring their protection against aggressive agents and/or that they do not present risks to the safety of personnel.
2.3
MOTORS APPLIED IN AREAS OF RISK
The personnel in charge of the installation safety must ensure that: Only qualified personnel perform the installation and operation of the equipment; Such personnel must have immediate access to this manual and other documents provided with the motor as well as perform tasks in strict compliance to the service instructions, relevant standards, and specific product documentation.
ATTENTION
Failure to comply with the installation and safety standards will void the product warranty. Firefighting equipment and first aid notices must be available in visible and easilyaccessible locations within the work site.
The motors specified to operate in areas of risk have additional safety features, which are defined in specific standards for each kind of area of risk, according to their classification. The general requirements for equipment that operate in areas of risk are described in the following Brazilian and international standards: IEC 60034-1 - Rotating Electrical Machines - Part 1: Rating and Performance IEC 60079-0 - Electrical Apparatus for Explosive Gas Atmospheres - Part 0: General Requirements ABNT NBR IEC 60079-0 - Atmosferas Explosivas - Parte 0: Equipamentos - Requisitos Gerais IEC 60079- 1 - Explosive Atmospheres - Part 1: Equipment Protection by Flameproof Enclosures 'd' ABNT NBR IEC 60079-1 - Atmosferas Explosivas - Parte 1 - Proteo de Equipamento por Invlucro Prova de Exploso d IEC 60079-15 - Explosive Atmospheres - Part 15 Protection by Type of Protection n ABNT NBR IEC 60079-15 - Equipamentos Eltricos para Atmosferas Explosivas - Parte 15: Construo, Ensaio e Marcao de Equipamentos Eltricos com Tipo de Proteo n ABNT IEC 60079- 7 - Electrical Apparatus for Explosive Gas Atmospheres - Part 7: Increased Safety 'e' ABNT NBR IEC 60079-7:2008 - Atmosferas Explosivas Parte 7: Proteo de Equipamentos por segurana Aumentada "e" IEC 60079- 2 - Electrical Apparatus for Explosive Gas Atmospheres. Part 2: Pressurized Enclosures 'p' ABNT NBR IEC 60079-2 - Atmosferas Explosivas - Parte 2: Proteo de Equipamento por Invlucro Pressurizado p IEC 60079-17 - Explosive Atmospheres - Part 17: Electrical Installations Inspection and Maintenance ABNT NBR IEC 60079-17 - Atmosferas Explosivas - Parte 17: Inspeo e Manuteno de Instalaes Eltricas
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2.3.1
General care
2.5
Before installing, operating or servicing electric motors for areas of risk, the following safety procedures must be taken: Study and understand the standard according to the degree of protection of the motor mentioned in the item Motors applied in areas of risk; All the requirements established by the applicable standards must be met.
CHARACTERISTICS OF THE ENVIRONMENT
The motors were designed according to specific environment characteristics for your application and they are described on the nameplate and on the specific datasheet of the motor.
2.6
OPERATING CONDITIONS
2.3.2
Additional care
Shut down the motor and wait until it is completely stopped before performing any maintenance, inspection or repair. All the existing protections must be installed and properly adjusted before putting the motor into operation. Make sure the motors are properly grounded; The terminals must be properly connected so as to prevent any kind of poor contact that may cause heating or spark.
In order for the product warranty to remain valid, the motor must be operated in compliance with the rated data indicated on the nameplate, observing all applicable standards and codes, as well as the information provided in this manual.
2.7
VOLTAGE AND FREQUENCY
NOTE
Observe all other instructions regarding storage, handling, installation and maintenance contained in this manual and applicable to the relevant motor type.
2.4
STANDARDS
The motor must be able to perform its main function continuously in Zone A, but it does not have to fully meet its performance characteristics at rated voltage and frequency (see rated characteristics point in Figure 2.1), and it may present some deviations. The temperature rises may be above those at rated voltage and frequency. The motor must be able to perform its main function in Zone B, but it may present greater deviations of its performance at rated voltage and frequency than in Zone A. The temperature rises may be higher than those observed at rated voltage and frequency and, very likely, will be higher than those in Zone A. Prolonged operation in the periphery of Zone B is not recommended. Voltage p.
The motors are normally specified, designed, manufactured and tested according to the standards described in Table 2.1. The applicable standards are specified in the commercial contract that, in turn, depending on the application or installation local, may indicate other national or international standards.
Table 2.1: Examples of applicable standards STANDARDS Specification Tests Degrees of protection Cooling Mountings Noise IEC60034.1 NBR5117 IEC60034.4 NBR5052 IEC60034.5 NBR IEC 60034-5 IEC60034.6 NBR5110 IEC60034.7 NBR5031 IEC60034.9 NBR7565 ISO10816-1 ISO10816-3 ISO10816-5 ISO7919-1 ISO7919-3 ISO7919-5 ISO286 NBR6158 ISO1940 NBR8008
Zone A
Rated characteristics point Frequency p.
Mechanical vibration
Zone B (exterior to zona A)

Figure 2.1: Voltage and frequency variation limits (IEC60034-1)
Mechanical tolerances Balancing
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3 RECEIVING, STORAGE AND HANDLING

3.1 RECEIVING
NOTES
Observe the weight informed. Do not lift the motor jolting or place it on the ground suddenly in order to prevent bearing damage; In order to lift the motor, use only the eyebolts present on its frame. In order to make the transportation of the motor easier, WEG recommends the use of a rocker arm; The eyes on the heat exchanger, covers, bearings, radiator, terminal box, base, etc., are designed to handle these components separately only; Never use the shaft to lift the motor by means of cables, etc; To move the motor, the shaft must be locked with the shaft locking device supplied with the motor. Steel wire ropes, clevises and the lifting equipment must be able to stand the motor weight.
All the motors are tested and supplied in perfect operating conditions. All machined surfaces are protected against corrosion. The package must be checked upon receipt for occasional damages during transportation.
ATTENTION
All damages must be immediately photographed, documented, and reported to the transportation company, to the insurance company and to WEG. Failure to comply with such procedures will void the product warranty.
ATTENTION
Parts supplied in additional packages must be checked upon receipt.
When lifting a package (or container), the correct hoisting points, the weight indicated in the package or on the nameplate, and the operating capacity of the hoisting devices must be observed. Motors packed in wooden crates must always be lifted by their own eyebolts/lifting lugs or by a proper forklift, and must never be lifted by its wooden parts; The package must never be tumbled. Carefully place it on the floor (without impact) to avoid bearing damage; Do not remove the grease-based corrosion protection from the shaft end, nor the closing plugs or rubber parts in terminal box holes; These protections must remain in place until the final assembly. A complete visual inspection of the motor must be performed after removing the package; The shaft locking device must only be removed shortly before installing and stored in a safe location for future transportation of the motor.
ATTENTION
For handling and assembling motors supplied disassembled, refer to the handling and assembly manual supplied with the motor.
3.3
STORAGE
Any damage to the painting or corrosion protection of the machined parts must be corrected.
3.3.1
Indoor storage
3.2
HANDLING
If the motor is not installed immediately after reception, it must remain inside the package and stored in a location protected against humidity, vapors, fast heat variations, rodents, and insects. The motor must be stored in vibration-free locations in order to avoid bearing damage.
3.3.2
Outdoor storage
The motor must be stored in a dry location, free of flooding and vibrations. Repair all damages to the packaging occasionally occurred during transportation before storing the motor, which is necessary to ensure proper storage conditions. Place the motor on platforms or foundations which ensure protection against land humidity and keep it from sinking into the soil. Free air circulation underneath the motor must be assured. The cover or canvas used to protect the motor against the weather must not be in contact with its surfaces. In order to ensure free air circulation between the motor and such covers, place wooden blocks as spacers.
Figure 3.1: Handling of the motor
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3.3.3
Extended storage
3.3.3.1.2 Outdoor storage ATTENTION

Outdoor storage is not recommended
When the motor is stored for a long period of time before being operated, it is exposed to external agents, such as temperature fluctuations, moisture, aggressive agents, etc. Empty spaces inside the motor, such as bearing, terminal box, and windings, are exposed to air humidity, which may condensate and, depending on the type and degree of air contamination, aggressive substances may also penetrate these empty spaces. Consequently, after long storage periods, the winding insulation resistance may drop below acceptable values. Internal components, such as roller bearings, may oxidize, and the lubricant power of the lubricant agent in the bearings may be adversely affected. All of these influences increase the risk of damages before starting up the motor.
ATTENTION
All preventive measures described in this manual, such as constructive aspects, maintenance, packaging, storage, and periodical inspections, must be followed and recorded, in order to maintain the product warranty. The following instructions are valid for motors stored for long periods of time and/or idle for two or more months before being operated.
In case outdoor storage is unavoidable, the motor must be packed in a specific packaging for such condition, as follows: For outdoor storage, besides the packaging recommended for internal storage, the package must be covered with a protection against dust, moisture and other foreign materials, using a resistant canvas or plastic. The package must be placed on gratings or foundations, ensuring protection against dirt and moisture and keeping the motor from sinking into the soil; After the motor is covered, a shelter must be constructed in order to protect it against direct rain, snow and excessive sun heat.
ATTENTION
In case the motor remains stored for long periods of time, it is recommended to inspect it regularly as specified in item Maintenance plan during storage of this manual.
3.3.3.2 3.3.3.1 Storage location

In order to ensure the best storage conditions for the motor during long periods of time, the chosen location must strictly meet the criteria described below.
Separate parts
3.3.3.1.1 Indoor storage

The storage room must be closed and covered; The location must be protected against moisture, vapors, aggressive agents, rodents, and insects; The location must be free of corrosive gases, such as chlorine, sulphur dioxide, or acids; The storage room must be free of vibration; The environment must present an air-filtered ventilation system; Ambient temperature between 5C and 60C, and must not be subject to sudden temperature variations; Relative humidity <50%; Protection against dirt and dust accumulation; It must feature a fire detection system. In case the storage location does not meet any of these requirements, WEG recommends that additional protections are incorporated to the motor packaging during the storage period, as follows: Closed wooden crate or similar with proper electrical installation, providing power to the space heaters. If there is risk of infestation and fungus growth, the package must be protected on the site by spraying or painting it with proper chemical agents; Package preparation must be carefully executed by experienced personnel.
In case separate parts have been supplied (terminal boxes, covers, etc.), these must be packed as specified in items Indoor Storage and Outdoor Storage of this manual; Air relative humidity inside package must not exceed 50%.
3.3.3.3
Space heater ATTENTION

The motor space heaters must remain powered during storage to avoid moisture condensation inside the motor and ensure that the winding insulation resistance remains within acceptable levels.
3.3.3.4
Insulation resistance
During the storage period, the motor winding insulation resistance must be measured and recorded quarterly, before the motor is installed. Any eventual insulation resistance reduction must be investigated.
3.3.3.5
Exposed machined surfaces
All exposed machined surfaces (e.g. shaft end and flanges) are factory-protected with a temporary rust inhibitor. This protection film must be reapplied at least twice a year or when removed and/or damaged.
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Recommended Products: Name: Dasco Guard 400 TX AZ, Manufacturer: D.A. Stuart Ltda Name: TARP, Manufacturer: Castrol.
ATTENTION
During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the oil circulate and keep the bearing in good operating conditions. After 6 months of storage and before starting the operation of the motor, the bearings must be relubricated. If the motor remains stored for a period over two years, the bearings must be disassembled, washed, inspected and relubricated.
3.3.3.6
Bearings
3.3.3.6.1 Sleeve bearing

Depending on the mounting position and lubrication type, the motor can be transported with or without oil in the bearings and must be stored in the original operation position with oil in the bearings when specified; The oil level must be observed, remaining in the middle of the sight glass.
3.3.3.6.3 Grease-lubricated rolling bearing

The roller bearings are lubricated at the factory to perform the tests on the motor;
ATTENTION
During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the oil circulate and keep the bearing in good operating conditions. If not possible to turn the motor shaft, the following procedure must be carried out in order to protect the bearing inside and the contact surfaces against corrosion: Drain all the oil from the bearing; Disassemble the bearing; Clean the bearing; Apply an anti-corrosion product (such as: TECTIL 511, Valvoline or Dasco Guard 400TXAZ) on the upper and lower halves of the bearing sleeve and on the contact surface on the motor shaft; Assemble the bearing; Close all the threaded holes with plugs; Seal the interstices between the shaft and the bearing seal on the shaft by applying water-proof adhesive tape; All the flanges (e.g.: oil inlet and outlet) must be protected with blank covers; Remove the upper sight glass from the bearing and apply the anticorrosive spray inside the bearing; Put some dehumidifier bags (silica gel) inside the bearing. The dehumidifier absorbs the humidity and prevents condensation inside the bearing; Close the bearing with the upper sight glass. If the storage period exceeds 6 months. Repeat the procedure described above; Put new dehumidifier bags (silica gel) inside the bearing. If the storage period exceeds 2 years. Disassemble the bearing; Preserve and store the bearing component parts.
ATTENTION
During storage period, every two months the shaft locking device must be removed and it must be turned at 30 rpm in order to make the grease circulate inside the roller bearing and keep the bearing in good operating conditions. After 6 months of storage and before starting the operation of the motor, the bearings must be relubricated. If the motor remains stored for a period over two years, the bearings must be disassembled, washed, inspected and relubricated.
3.3.3.7
Terminal box
When the insulation resistance in the motor windings is measured, the main junction box and the other terminal boxes must also be inspected, especially considering the following aspects: The inner part must be dry, clean, and free of any dust accumulation; The contact elements cannot be corroded; The sealing must remain under appropriate conditions; The cable inlets must be correctly sealed.
ATTENTION
If any of these items is not correct, the parts must be cleaned or replaced.
3.3.3.8
Radiator
3.3.3.6.2 Oil-lubricated rolling bearing

Depending on the assembly position, the motor can be transported with or without oil in the bearings; The motor must be stored in its original operation position and with oil in the bearings, except when specific documentation of the machine determines another transportation and/or storage method; The oil level must be observed, remaining in the middle of the sight glass;
When the radiator remains for a long period out of operation, it must be drained and dried. The drying may be done with pre-heated compressed air. During the winter, in case there is risk of freezing, all the water must be drained from the radiator, even if the motor remains out of operation just for a short period so as to prevent deformation of the pipes or damages to the seals.
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NOTE
During short stoppages, it is recommended to keep the water circulation at low speeds instead of interrupting its circulation through the heat exchanger without its draining, ensuring that harmful products, such as ammonia compounds and hydrogen sulfide, will be taken out of the radiator and will not settle inside.
3.3.3.10.3 Checking the insulation resistance

Before operating the motor, the insulation resistance must be measured according to the item Insulation resistance of this manual.
3.3.3.10.4 Others
Follow the other procedures described in the item Commissioning of this manual before operating the motor.
3.3.3.9
Inspections and records during storage
Stored motors must be periodically inspected and inspection records must be filed. The following points must be inspected: 1. Physical damages; 2. Cleanliness; 3. Signs of water condensation; 4. Protective coating conditions; 5. Paint conditions; 6. Signs of aggressive agents; 7. Satisfactory operation of space heaters. It is recommended that a signaling system or alarm be installed in the location in order to detect power interruption in the space heaters; 8. Record ambient temperature and air relative humidity around the machine, winding temperature (using RTDs), insulation resistance and polarization index; 9. The storage location must also be inspected to assert its compliance with the criteria described in the item Storage location.
3.3.3.10
Preparation for commissioning
3.3.3.10.1 Cleaning
Motor inner and outer parts must be free of oil, water, dust, and dirt. Remove the rust inhibitor from the exposed surfaces with a cloth damped in a petroleum-based solvent; Make sure the bearings and cavities used for lubrication are free of dirt and the cavity plugs are correctly sealed and tightened. Oxidation and marks on bearing seats and on the shaft must be carefully removed.
3.3.3.10.2 Bearing lubrication

Only use the specified lubricant to lubricate the bearings. Information on bearings and lubricants are indicated on the bearing nameplate, and lubrication must be performed as described in the item Bearing maintenance of this manual, always considering the relevant type of bearing.
NOTE
Sleeve bearings containing anticorrosive products and dehumidifier bags must be disassembled and washed, and the dehumidifier bags removed. Assemble the bearings again and lubricate.
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3.3.3.11
Maintenance plan during storage
During the storage period, the motor maintenance must be performed and recorded in accordance with the plan described in Table 3.1.
Table 3.1: Storage plan Monthly Storage location Inspect cleanliness conditions Inspect humidity and temperature conditions Check signs of insects Measure vibration level Package Inspect physical damages Inspect relative humidity inside the motor Replace the dehumidifier in the package (if applicable) Space heater Check operating conditions Whole motor Clean external part Check paint conditions Check oxidation inhibitor in the exposed machined parts Reapply oxidation inhibitor Windings Measure insulation resistance Measure polarization index Terminal box and grounding terminals Clean the inner part of the boxes Inspect the seals Grease or oil rolling bearing Spin the shaft Relubricate the bearing Disassemble and clean the bearing Sleeve bearings Spin the shaft Apply anticorrosive and dehumidifier Clean the bearings and relubricate them Disassemble and store the parts X X X If the storage period exceeds 2 years X X X X X X X X X X X X X X X X X X X X When necessary X X X X X X Every 2 months Every 6 months Every 2 years Before starting operation Note
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4 INSTALLATION
4.1 LOCAL OF INSTALLATION 4.4
4.4.1
INSULATION RESISTANCE
Safety instructions DANGER
In order to measure the insulation resistance, the motor must be shutdown. The winding being tested must be connected to the frame and grounded until all residual electrostatic charges are removed. Also ground the capacitors (if applicable) before disconnecting and separating the terminals and measure with the megohmmeter the insulation resistance. Noncompliance with these procedures may result in personnel injuries.
The motors must be installed in easily accessible places, allowing periodic inspections, local maintenance and, if necessary, removal for external services. The following environment characteristics must be ensured: Clean and well-ventilated location; Other equipment or building must not block the motor ventilation; The area around and above the motor must be sufficient for its maintenance or handling; The environment must be in accordance with the motor protection level.
4.2
SHAFT PROTECTION
The motor leaves the factory with a lock on the shaft to prevent damages to the bearings during transportation. This lock must be removed before installing the motor.
4.4.2
General considerations
ATTENTION
The shaft locking device must be installed whenever the motor is removed from its base (uncoupled) in order to prevent damages to the bearings during transportation. The shaft end is covered by anticorrosion protection grease. During the installation of the motor, remove this grease from the area of the track where the shaft grounding brush (if applicable) makes contact.
4.3
DIRECTION OF ROTATION
When motor is not immediately operated, it must be protected against moisture, high temperatures and dirt, thus avoiding impacts to the insulation resistance. Winding insulation resistance must be measured before operating the motor. If the environment is too humid, the insulation resistance must be measured periodically during storage. It is difficult to establish fixed rules for the actual value of a motor insulation resistance, as it varies according to the environmental conditions (temperature, humidity), machine cleanliness conditions (dust, oil, grease, dirt), and quality and condition of the insulating material used. Evaluating periodical follow-up records is useful to conclude whether the motor is able to operate.
The direction of rotation of the motor is indicated by a plate fixed to the drive end of the motor as described in the specific documentation of the motor.
4.4.3
Measuring stator windings
ATTENTION
Motors supplied with a single direction of rotation must not operate in the opposite direction. In order to operate the motor in the opposite direction, please contact WEG.
The insulation resistance must be measured with a megohmmeter. The test voltage for the motor windings must be in accordance with Table 4.1 and the IEEE43 standard.
Table 4.1: Voltage for the winding Insulation resistance test *Winding rated voltage (V) < 1000 1000 - 2500 2501 - 5000 5001 - 12000 > 12000
* Phase-phase rated voltage
Insulation resistance test continuous voltage (V) 500 500 - 1000 1000 - 2500 2500 - 5000 5000 - 10000
Before measuring the stator winding insulation resistance, check that: The connection cables are disconnected from the insulating bushings; The CT secondary connections (if applicable) are not open; All power cables are disconnected; The motor frame is grounded; The winding temperature was measured; All temperature sensors are grounded.
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The measurement of the stator windings insulation resistance must be carried out in the main junction box. The instrument (megohmmeter) must be connected between the motor frame and the winding. The frame must be grounded and the three phases of the stator winding must remain connected to the neutral point, as shown in Figure 4.1.
4.4.4
Measurement on the windings
Figure 4.1: Connection of the megohmmeter to the stator winding
When possible, each phase must be insulated and tested separately. The separate test allows comparing the phases. When a phase is tested, the other two phases must be grounded to the same ground of the frame, as shown in Figure 4.2.
Measurement on the rotor winding: Disconnect the rotor cables from the diode cluster and from the load resistor (when applicable); Connect the device to measure the insulation resistance (megohmmeter) between the rotor winding and the motor shaft. The measuring current must not pass through the bearings. Measurement of the main exciter stator winding Disconnect the exciter power cables; Connect the device to measure the insulation resistance (megohmmeter) between the exciter stator winding (terminals I and K) and the motor frame. Measurement on the main exciter rotor winding: Disconnect the exciter rotor cables from the diode cluster; Connect the device to measure the insulation resistance (megohmmeter) between the exciter rotor winding and the motor shaft. The measuring current must not pass through the bearings. Measurement of the auxiliary exciter stator winding (PMG) motors model SP--_: Disconnect the cables that connect the auxiliary exciter to the voltage regulator; Connect the device to measure the insulation resistance (megohmmeter) between the auxiliary exciter stator winding (terminals 13, 14 and 15) and the motor frame.
ATTENTION
Figure 4.2: Connection of the megohmmeter to separate phases
If the total winding measurement presents a value below recommended, the neutral connections must be opened and the insulation resistance of each phase must be separately measured.
After measuring the insulation resistance, ground the tested winding in order to discharge it. The test voltage for the rotor, main exciter, auxiliary exciter and space heater must be 500 Vdc and for the other accessories 100 Vdc. It is not recommended to measure the insulation resistance of thermal protectors.
ATTENTION
Much higher values may be frequently obtained in motors being operated for a long period of time. Comparison with values obtained in previous tests in the same motor, under similar load, temperature, and humidity conditions, may be an excellent parameter to evaluate the winding insulation conditions, instead of exclusively using the value obtained in a single test as the basis. Significant or abrupt reductions are considered suspicious.
Table 4.2: Insulation resistance referential limits in electric machines Insulation resistance value 2M or less < 50M 50...100M 100...500M 500...1000M > 1000M Insulation evaluation Unacceptable Dangerous Regular Good Very Good Excellent
4.4.5
Polarization index
The polarization index is traditionally defined by the relation between the insulation resistance measured for 10 min and the insulation resistance measured for 1 min. This measurement procedure is always carried out at relatively constant temperatures. The polarization index allows the evaluation of the motor insulation conditions according to Table 4.3.
Table 4.3: Polarization index (relation between 10 minutes and 1 minute) Polarization index 1 or less < 1.5 1.5 to 2.0 2.0 to 3.0 3.0 to 4.0 > 4.0 Insulation evaluation Unacceptable Dangerous Regular Good Very Good Excellent
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DANGER
In order to prevent accidents, the motor winding must be grounded immediately after measuring the insulation resistance.
4.4.7
Minimum insulation resistance
If the measured insulation resistance is below 100M at 40C, before putting the motor into operation, contact WEG.
4.4.6
Conversion of measured values
4.5
PROTECTIONS
The insulation resistance must be kept at 40C. If the measurement is performed at a different temperature, it will be necessary to correct the reading to 40C by using an insulation resistance variation curve according to the temperature obtained from the motor itself. If this curve is not available, the approximate correction provided by the curve in Figure 4.3, according to the NBR 5383 / IEEE43 standard, may be employed.
The motors used in continuous duty must be protected against overloads by means of a motor integral device, generally a thermal relay with rated or adjusted current equal to or below the value obtained by multiplying the motor supply rated current at full load by: 1.25 for motors with duty factor equal to or above 1.15; 1.15 for motors with duty factor equal to 1.0. The motors also feature temperature sensors to be used as protection devices against excessive temperature rise (in case of overloads, motor stuck, low voltage, lack of ventilation of the motor).
4.5.1
Thermal protections
Insulation resistance variation coefficient Kt40C
The temperature sensors are installed on the main stator, bearings and other component parts that require temperature monitoring and thermal protection. The terminals of the temperature sensors are available in the accessory box. Those sensors must be connected to an external temperature monitoring and protection system.
4.5.1.1
Temperature sensors
Thermostats - Bimetallic thermal detectors with normally closed silver contacts. They open at a certain temperature. The thermostats are connected in series or independently according to the wiring diagram. Thermistors (PTC or NTC) - Thermal detectors composed of semiconductors that vary their resistance sharply when they reach a certain temperature. Thermistors are connected in series or independently according to the wiring diagram.
NOTE
The thermostats and thermistors must be connected to a control unit which will interrupt the supply of the motor or will activate a signaling device. Pt100 - Calibrated resistance element. Its operation is based on the principle that the electric resistance of a metallic conductor varies linearly with the temperature. The detector terminals must be connected to a control panel, which includes a thermometer.
To convert the measured insulation resistance (Rt) to 40C multiply by the temperature coefficient (Kt)
Winding temperature C R40C = Rt x Kt40C

Figure 4.3: Insulation resistance variation coefficient according to the temperature
NOTE
The RTD thermistors provide monitoring by means of the absolute temperature informed by its instant resistance value. With this information, the relay can perform the reading of the temperature, as well as the parameterization for alarm and tripping according to the preset temperatures.
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4.5.1.2
Temperature limits for the windings
ATTENTION
The alarm and tripping values may be determined as a result of experience, but cannot exceed the values indicated in Table 4.5 and Table 4.6.
The temperature of the winding hottest spot must be kept below the insulation thermal class limit. The total temperature is composed by the ambient temperature plus temperature elevation (T), plus the difference between the average winding temperature and the winding hottest spot temperature. The ambient temperature, according to the standards, is up to 40C. Above this value, the operating conditions are considered special and the specific documentation of the motor must be referred to. The numeric values and the composition of the acceptable temperature at the winding hottest spot are indicated in Table 4.4.
Table 4.4: Insulation class Insulation class Ambient temperature T = temperature rise (temperature measurement method by resistance variation) Difference between the hottest spot and the average temperature Total: hottest spot temperature C C C C F 40 H 40
ATTENTION
The motor protection devices are listed in drawing WEG - Motor connection diagram. The not using of those devices is fully responsibility of the user and, in case of damages to the motor, it will void the warranty.
105 125 10 15
155 180
ATTENTION
In case the motor operates with temperatures in the windings above the limit values of the insulation thermal class, the lifespan of the insulation and, consequently, of the motor, will be significantly reduced or it may even cause the burnout of the motor.
4.5.1.3
Alarm and tripping temperatures
The temperature level for alarm and tripping must be set as low as possible. This level can be determined based on test results or through the motor operating temperature. The alarm temperature can be set for 10C above the machine operating temperature at full load, always considering the highest local temperature. The temperature values set for tripping must not exceed the maximum acceptable temperatures for the stator winding insulation class and for the bearings (according to the lubrication system).
Table 4.5: Stator maximum temperature Maximum temperature set for protections (C) Alarm Tripping 130 155 155 180
F H
Table 4.6: Maximum temperature of the bearings Maximum temperature set for protections (C) Alarm Tripping 110 120
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4.5.1.4
Temperature and ohm resistance of the PT100
Table 4.7 shows the temperature values as a function of the ohm resistance measured for thermistors PT100 type. Formula: - 100 = C 0,386
Table 4.7: Temperature X Resistance (Pt100) C 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 0 100.00 103.90 107.79 111.67 115.54 119.40 123.24 127.07 130.89 134.70 138.50 142.29 146.06 149.82 153.58 157.31 1 100.39 104.29 108.18 112.06 115.93 119.78 123.62 127.45 131.27 135.08 138.88 142.66 146.44 150.20 153.95 157.69 2 100.78 104.68 108.57 112.45 116.31 120.16 124.01 127.84 131.66 135.46 139.26 143.04 146.81 150.57 154.32 158.06 3 101.17 105.07 108.96 112.83 116.70 120.55 124.39 128.22 132.04 135.84 139.64 143.42 147.19 150.95 154.70 158.43 4 101.56 105.46 109.35 113.22 117.08 120.93 124.77 128.60 132.42 136.22 140.02 143.80 147.57 151.33 155.07 158.81 5 101.95 105.95 109.73 113.61 117.47 121.32 125.16 128.98 132.80 136.60 140.39 144.17 147.94 151.70 155.45 159.18 6 102.34 106.24 110.12 113.99 117.85 121.70 125.54 129.37 133.18 136.98 140.77 144.55 148.32 152.08 155.82 159.55 7 102.73 106.63 110.51 114.38 118.24 122.09 125.92 129.75 133.56 137.36 141.15 144.93 148.70 152.45 156.19 159.93 8 103.12 107.02 110.90 114.77 118.62 122.47 126.31 130.13 133.94 137.74 141.53 145.31 149.07 152.83 156.57 160.30 9 103.51 107.40 111.28 115.15 119.01 122.86 126.69 130.51 134.32 138.12 141.91 145.68 149.45 153.20 156.94 160.67
4.5.2
Space heater
ATTENTION
The protection devices of the cooling system must be monitored periodically; The water inlets and outlets must not be blocked, since that could cause overheating and even the burnout of the motor. For further details, refer to the motor dimensional drawing.
When the motor is equipped with space heaters to prevent water from condensing inside during long periods out of operation, you must ensure they are powered on right after the motor is shut down and that they are powered down before the motor goes into operation. The motor wiring diagram and a specific nameplate fixed to the motor specify the power supply and power rating of the space heaters.
4.5.3
Water leak sensor
4.6.1
Water radiators
Motors with air-water heat exchanger feature a water leak sensor intended to detect water leaks from the radiator into the motor. This sensor must be connected to the control panel, according to the wiring diagram of the motor. The signal of this sensor must be used for alarm. When this protection goes off, the heat exchanger must be inspected and, if any water leak is detected, the motor must be shut down and the problem corrected.
4.6
COOLING
The cooling type of the motor may vary according to the application and is identified by the third letter of the nomenclature, as indicated in the item Nomenclature. Only the proper installation of the motor and of the cooling system can ensure its continuous operation without overheating.
The water radiator is a surface heat transmitter designed to dissipate heat of electrical equipment or others in an indirect way, that is, air in closed circuit is cooled by the radiator after removing the heat generated by the equipment that must be cooled. Clean water, with the characteristics below, must be used as coolant: PH: 6 to 9; Chlorides: maximum 25.0 mg/l; Sulphates: maximum 3.0 mg/l; Manganese: maximum 0.5 mg/l; Suspended solids: maximum 30.0 mg/l; Ammonia: no traces
ATTENTION
The data of the radiators that compose the air-water heat exchanger are described on the nameplate and dimension drawing of the motor. This data must be observed for the proper operation of the motor cooling system and, thus, prevent overheating. 11866576 - Brushless synchronous motors - Horizontals | 23
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4.6.1.1
Radiators for application with seawater ATTENTION

In case of radiators to work with seawater, in order to avoid corrosion, the materials in contact with water (pipes and flush plates) must be resistant to corrosion. Besides, the radiators may feature sacrificial anodes (for instance: Zinc or Manganese) according to Figure 4.4, which are corroded during operation of the heat exchanger, protecting the exchanger heads. In order to keep the integrity of the heads, these anodes must be periodically replaced, according to the corrosion degree presented.
4.7
4.7.1
ELECTRICAL CHARACTERISTICS
Electric connections ATTENTION
Study carefully the wiring diagram supplied with the motor before starting the power, grounding and accessory cable connection. For the electric connection of the auxiliary equipment, refer to the specific manual of this equipment.
4.7.1.1
Main connection
Sacrificial anodes
Depending on the motor mounting, the motor stator terminals are fixed to insulators or by means of copper terminals in the main terminal box. The location of the power terminal box is identified in the specific dimension drawing of each motor. The identification of the power terminal and connections to the terminals must be done according to the specific wiring diagram for each motor. Make sure the section and insulation of the connection cables is suitable for the motor current and voltage. The motor must spin in the direction of rotation specified on the nameplate and/or plate fixed to the drive end of the motor.
Figure 4.4: Radiator with sacrificial anodes
NOTE NOTE
The type, quantity and position of the sacrificial anodes may vary according to the application. The direction of rotation is determined looking at the shaft end from the drive end of the motor. Motors with a single direction of rotation must only spin in the indicated direction, since the fans and other devices are unidirectional. In order to operate the motor in the direction of rotation opposite the specified, contact WEG.
4.6.2
Independent ventilation
The independent fans are generally driven by threephase asynchronous motors. The terminal box of the independent ventilation fan motor is generally assembled on the frame of the motor. The motor characteristic data (frequency, voltage, etc.) is specified on the nameplate of this motor and its direction of rotation is indicated by a plate fixed to the exhaustion box or fan cover of the fan motor.
ATTENTION
Before making the connections between the motor and the electric energy, it is necessary to measure carefully the winding insulation resistance. In order to connect the main power supply cables of the motor, unscrew the stator terminal box cover, cut the sealing rings (standard motors without cable gland) according to the cable diameters to be used and insert the cables in the sealing rings. Cut the power supply cables to the necessary length, strip the ends and mount the terminals to be used.
NOTE
Check the direction of rotation of the independent fan before turning on the motor. If the fan is turning in the opposite the specified direction, invert the connection of two phases of the fan motor. The air filters (if applicable) which prevent the passage of dirt to the inner part of the motor must be regularly inspected. The filters must be in perfect conditions to ensure the proper operation of the cooling system and continuous protection of the sensitive internal parts of the motor.
4.7.1.2
Grounding
The motor frame and the main terminal box must be grounded before connecting the motor to the power supply system. Connect the metal cover of the cables (if applicable) to the common grounding conductor. Cut the grounding conductor to the proper length and connect it to the
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connector in the terminal box and/or frame. Fasten all connections firmly.
ATTENTION
Use shims of different thicknesses (total thickness of approximately 2 mm) between the motor feet and the foundation surfaces so that later you can make a precise vertical alignment.
ATTENTION
Do not use steel washers or another low electric conductivity material to fasten the terminals.
4.7.1.3
Power supply and control of the field
NOTE
The user is responsible for dimensioning and building the foundation where the motor will be installed.
The power supply and control of the field must be connected and adjusted according to the wiring diagram of the motor and the specific manual of the excitation panel.
4.8.2 4.7.2 Connection diagram

Together with the motor documentation, the stator, rotor and accessory connection diagram is also supplied. Figure 4.5 shows the single line connection diagram of a brushless motor.
Forces on the foundations
The forces on the foundation are informed in the motor documentation.
4.8.3 4.8.3.1
Base types Concrete base
Power factor regulator
The concrete bases are the most widely used for the installation of these motors. The type and size of the foundation, bolts and anchoring plates depend on the motor size and type.
4.8.3.2
Transformers Motor Rectifiers Sstator Field Figure 4.5: General connection diagram (brushless motor) Exciter stator
Metal base
Exciter rotor
4.8
4.8.1
MECHANICAL CHARACTERISTICS
Foundations
The motor feet must be settled evenly on the metal base so as to prevent deformations of the frame. Occasional height errors of the motor foot rest surface can be corrected with shims (a maximum height of 2 mm is recommended). Do not remove the machines from the common base to align them. The base must be leveled on the foundation itself by using leveling devices. When a metal base is used to adjust the height of the motor shaft end to the driving machine shaft end, it must be leveled on the concrete base. After the base is leveled, the anchors tightened and the couplings checked, the metal base and the anchors are cemented.
4.8.4
Motor mounting ATTENTION

Mount and align the motor properly. The inadequate mounting can generate excessive vibration, causing early wear of the bearings and even the break of the shaft.
The foundation or structure where the motor will be installed must be properly strong and flat, free of external vibration and capable to stand the mechanical forces it will undergo during the start or short circuit of the motor; If the dimensioning of the foundation is not carefully done, serious vibration problems may affect the foundation set, motor and driving machine; The structure dimensioning of the foundation must be done based on the dimension drawing, on the information regarding the mechanical forces on the foundations, and on the form of fixing the motor.
4.8.5
Anchoring plate set
The anchoring plate set is composed of the anchoring plate, leveling bolts, leveling shims, alignment bolts and anchors.
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NOTE
The user is responsible for the procedure to mount, level and grout the anchor plates for motors (except when specific agreement establishes otherwise). The anchors must be fastened according to Table 4.8.
Table 4.8: Tightening torque of the anchors Type Tightening torque (*) N.m M30 550 M36 960 M42 1460 M48 2200 * using lubricant paste for the bolts (Molykote P37)
4.8.7
Inspection of pedestal bearings ATTENTION

Pedestal bearings must be inspected and, if necessary, realigned according to the instructions below:
Bearing upper half
Bearing lower half
After the positioning of the motor, perform the final leveling by using the vertical leveling bolts and the leveling shims.
Figure 4.6: Pedestal bearing
4.8.6
Natural frequency of the base
In order to ensure a safe operation, the motor must be precisely aligned with the coupled equipment and both must be properly balanced. As a requirement, the motor installation base must be flat and meet the requirements of DIN standard 4024-1. In order to check if the criteria of the standard are being met, the following potential frequencies of vibration excitation generated by the motor and coupled machine must be checked: The motor rotation frequency; The double of the rotation frequency; The double of the electric frequency of the motor supply. According to DIN standard 4024-1, the natural frequencies of the base or foundation must keep a distance from these potential frequencies of excitation, as specified below: The first natural frequency of the base or foundation (natural frequency of first order of the base) must be out of the range from 0.8 to 1.25 times any of the potential frequencies of excitation above; The other natural frequencies of the base or foundation must be out of the range from 0.9 to 1.1 times any of the potential frequencies of excitation above;
Drive end bearing alignment 1. Loosen the fixing bolts of the two halves of the drive end bearing housing; 2. Lift the upper half of the bearing housing; 3. Loosen the fixing bolts of the two halves of the bearing shell and lift the upper half; 4. Lubricate the shaft sliding surface and the sliding surface of the upper half of the bearing shell, if necessary, with the same kind of oil of the bearing using a piece of soft and absorbent paper or a clean cloth that will not release lint; 5. Check if the face of the split part of the lower half of the bearing shell is aligned with the face of the split part of the lower half of the bearing housing by using a perfectly parallel bar. 6. Using a feeler gauge, check the clearances between the lower half of the bearing shell and the shaft in four points (right, left, front and back side of the bearing shell); 7. In case the measured clearances are different, or the faces of the split parts of the bearing shell are misaligned with the faces of the split part of the bearing housing, the bearing shell must be aligned with the shaft, as follows: 8. Loosen the fixing bolts of the two halves of the nondrive end bearing housing before lifting the bearing; 9. Lift the drive end of the motor shaft just enough for the rotor weight not to rest on the bearing shell and it can be adjusted in the spherical seat of the lower half of the bearing housing;
NOTE
Use some material softer than the shaft material between the shaft and the lifting device so as to prevent damages (copper or bronze, for instance). 10. Align the bearing shell making the measurements according to items 5 and 6; 11. Lower the shaft until it touches the lower bearing shell; 12. Mount the upper half of the bearing shell and tighten the fixing bolts of the upper half of the bearing shell with the lower half of the bearing shell observing the torque specified in Table 4.9;
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13. Apply a sealing layer of CURIL T on the machined faces of the lower half of the lower bearing housing; 14. Using a hoist, mount the upper half of the bearing housing on the lower half; 15. Tighten the bolts observing the torque specified in Table 4.10; 16. After the proper tightening of the bolts, apply seal paint between the bolts and bearing housing. Non-Drive end bearing alignment Use the same procedure to align the drive end bearing.
ATTENTION
The two pedestal bearings must be perfectly aligned.
dial gauge measurement in the 90 and 270 points represents the horizontal coaxial error. This measurement indicates when it is necessary to lift or lower the motor, or move it to the right or to the left on the driven side in order to eliminate the coaxial failure. Half the difference of the dial indicator maximum measurement in a complete turn represents the maximum found run out. The misalignment in a complete turn of the shaft cannot exceed 0.03 When flexible couplings are used, values that are greater than those indicated above are acceptable, provided that they do not exceed the acceptable value provided by the coupling manufacturer. Maintaining a safety margin for these values is recommended. Angular misalignment Axial measurement
Table 4.9: Bearing shell torque Pedestal bearing size 14 18 22 28 35 45 Table 4.10: Bering house torque Pedestal bearing size 14 18 22 28 35 45 Torque (N.m) 170 330 580 1160 1150 2010 Torque (N.m) 20 69 170 330
Figure 4.8: Angular alignment
4.8.8
Alignment of the motor with the driven machine
The motor must be perfectly aligned with the driving machine, especially when direct coupling is used. The alignment must be carried out according to the directions of the coupling manufacturer. The alignment must be performed observing the maximum acceptable values. Especially in direct couplings, the motor and driven machine shafts must be aligned in the axial and radial directions, as shown in Figure 4.7 and Figure 4.8. Parallel misalignment Radial measurement
Figure 4.7: Parallel alignment
Figure 4.7 shows the parallel misalignment of the two shaft ends and a practical form to measure it by using proper dial gauges. Measurement is performed in four points with a 90 displacement from each other and with the two halfcouplings spinning together in order to eliminate the effects of irregularities on the support surface on the tip of the dial gauge. Choosing a vertical point greater than 0, half the difference of the dial gauge measurement in the 0 and 180 points represents the vertical coaxial error. In case of deviation, it must be properly corrected, adding or removing assembly shims. Half the difference of the
Figure 4.8 shows the angular misalignment and a practical form to measure it. Measurement is performed in four points with a 90 displacement from each other and with the two halfcouplings spinning together in order to eliminate the effects of irregularities on the support surface on the tip of the dial gauge. Choosing a vertical point greater than 0, half the difference of the dial indicator measurement in the 0 and 180 points represents a vertical misalignment. In case of deviation, it must be properly corrected, adding or removing assembly shims from the motor feet. Half of the dial indicator measurement difference in the 90 and 270 points represents a horizontal misalignment, which must be adequately corrected by displacing the motor in the lateral/angular direction. Half the difference of the dial indicator maximum measurement in a complete turn represents the maximum angular misalignment found. The misalignment in a complete turn of the rigid or semiflexible coupling cannot exceed 0.03 mm. When flexible couplings are used, values that are greater than those indicated above are acceptable, provided that they do not exceed the acceptable value provided by the coupling manufacturer. Maintaining a safety margin for these values is recommended. In the alignment/leveling, the influence of temperature on the motor and driven machine must be taken into account. Different dilatations of the component parts may change the alignment/leveling conditions during operation. After aligning the set and having assured a perfect alignment (both, hot and cold), the motor must be fixed on the anchor plate or on the base, as shown in Figure 4.9.
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ATTENTION
Carefully align the shaft ends, and, whenever possible, use flexible coupling, leaving a minimum clearance of 3 mm between the couplings. Weld in 4 points
Figure 4.9: Motor fixation
4.8.9
Motor leveling
The motor must be supported by the four feet (bolts) on a surface with flatness of up to 0.08 mm/m. If this flatness is not reached, the motor frame will be twisted or bent, which may cause damages to the bearings or other parts. Check if the motor is perfectly leveled in the vertical, horizontal and axial planes. Make the proper adjustments by putting shims under the four feet of the motor. The machine horizontal leveling must be checked with proper equipment.
Axial clearance Figure 4.10: Axial clearance
4.8.10.2
Coupling by gears
4.8.10
Couplings
Only proper couplings must be used, which convey only torque, without generating transversal forces. The centers of the motor and driven machine shafts must be in a single line for elastic and rigid couplings as well. Elastic couplings aim at mitigating the residual misalignment effects and preventing vibration transmission between the coupled machines, which does not happen when you use rigid couplings. The coupling must be assembled or removed with the aid of proper devices and never by means of rudimentary tools, such as hammers, mallets, etc.
Coupling by gears poorly aligned generate vibration in the gears and motor. Therefore, the shafts must be perfectly aligned, precisely parallel in the case of straight gears and in the precise angle in the case of helical or bevel gears. The perfect gear alignment can be controlled by inserting a paper strip which will show the trace of all the teeth after a complete turn of the gear.
4.8.10.3
Coupling of motors equipped with sleeve bearings

Axial clearance
Axial clearance
ATTENTION
Pins, nuts, washers and leveling shims may be supplied with the motor when requested by the customer in the purchase order.
Shaft Shell
NOTES
The user is responsible for the motor installation (except when specified by commercial agreement). WEG is not liable for damages to the motor, associated equipment and installation, occurred due to: Excessive vibration transmission; Poor installations; Faulty alignment; Improper storage conditions; Noncompliance with the instructions before commissioning; Incorrect electric connections.
Figure 4.11: Sleeve bearing
ATTENTION
Motors equipped with sleeve bearings must operate with direct coupling to the driving machine or by means of a gear box. This kind of bearing does not allow coupling by pulleys and belts. Motors equipped with sleeve bearings have three marks on the shaft end, seeing that the central mark (painted red) is the indication of the magnetic center, and the two external marks indicate the limits of axial movement of the rotor.
4.8.10.1
Direct coupling
Because of costs, space, absence of belt sliding and greater safety against accidents, direct coupling must be used whenever possible. Also in case of using reduction gearing, direct coupling is recommended.
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4.9
Axial clearance
BRAKE
For further information on installation, operation and maintenance of the brake (if applicable), refer to the dimension drawing of the motor and specific manual of this equipment.
4.10 HYDRAULIC UNIT

Figure 4.12: Magnetic center mark
For the motor coupling, the following factors must be taken into account: Bearing axial clearance; Axial displacement of the driving machine (if applicable); The maximum axial clearance allowed by the coupling.
For further information on installation, operation and maintenance of the hydraulic unit (if applicable), refer to the dimension drawing of the motor and specific manual of this equipment.
ATTENTION
Move the shaft fully forward and then properly measure the axial clearance; Carefully align the shaft ends, and, whenever possible, use flexible coupling, leaving a minimum clearance of 3 to 4 mm between the couplings.
NOTE
If it is not possible to move the shaft, you must consider the shaft position, the travel of the shaft forward (according to the marks on the shaft) and the axial clearance recommended for the coupling. Before starting operation, you must check if the motor shaft allows free axial movement within the clearance conditions aforementioned; In operation, the arrow must be positioned on the central mark (red), which indicates that the rotor is in its magnetic center; During the start, or even in operation, the motor may move freely between the two external limit marks.
ATTENTION
The sleeve bearings used in this motor were not designed to stand constant axial loads; therefore, under no circumstances can the motor continuously operate under axial load on the bearings. The motor can only continuously operate under axial and/or radial loads on the bearing if the criteria informed in the machine documentation are observed.
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5 START
The kind of start used for synchronous motors is specified during the project and depends on the following factors: Short circuit capacity of the power supply; Acceptable voltage drop (maximum current with minimum starting voltage); Resistive torque and load inertia; Starting time; Starting duty. The number of successive starts depends on the starting procedure used.
5.1
DIRECT START
5.1.2
Direct start without discharge resistor
It is the simplest and most economically feasible method; however, it must be used only when the starting current will not affect the power grid. Bear in mind that the starting current of motors may reach six to seven times the value of the rated current. Therefore, it must be ensured that this current (Ip) will not affect the supply of other consumers because of the greater voltage drop in the power grid. This requirement is met by one of three conditions: a) When the power grid is "strong enough and the motor current is negligible in relation to the grid capacity. b) The motor start is always done without load, which reduces the starting time and, in turn, the duration of the starting current, and the momentary voltage drop, which is acceptable for some consumers of the grid; c) When the start is properly authorized by the local electric energy utility company. When the motor starting current is high, the following problems may happen: a) The great voltage drop of the power supply system of the grid may cause interference in equipment installed in this system; b) The protection system (cables, contactors) must be over dimensioned, increasing the installation costs.
In order to start the motor, the exciter field must not be energized by the dc supply of the excitation panel; The circuit breaker of the main circuit of the machine is activated and, through the cage (generally called damper winding), enough torque is developed to accelerate the rotor close to the synchronism rotation. When the rotor has reached enough speed for synchronization, then the exciter field must be energized to synchronize the motor, which will start spinning at the rotation of the revolving field of the main stator (synchronous rotation). Any unbalance or vibration must be investigated.
5.1.3
Direct start frequency
NOTE
In some cases, the electric energy utility companies limit the voltage drop of the grid.
5.1.1
Direct start with discharge resistor
In order to start the motor, the exciter field must be energized by the dc supply of the excitation panel. When the circuit breaker of the main circuit of the machine is activated, the main field winding supply is blocked by the triggering circuit located in the brushless exciter, which also connects the starting resistor in series with the motor main field winding. Through the cage (generally called damper winding), enough torque is developed to accelerate the rotor close to the synchronism rotation; When the rotor has reached enough speed for synchronization, then the triggering circuit disconnects the starting resistor and applies direct current to the motor field winding, which will start spinning at the rotation of the revolving field of the main stator (synchronous rotation); Any unbalance or vibration must be investigated.
As induction motors have high starting current, the time spent to accelerate loads with great inertia results in a quick rise of the motor temperature. If the interval between successive starts is too short, that will lead to a quick and excessive temperature rise of the windings, reducing their useful life or even causing their burnout. The standards establish a minimum starting duty that the motors must be able to perform: a) Two successive starts, seeing that the first one with the motor cold, that is, with its windings at ambient temperature, and the second one right afterwards, but after the motor have come to a full stop; b) A start with the motor hot, that is, with the windings at duty temperature. The first condition simulates the case in which the first motor start is aborted, for instance, because of cut-off by the motor protection, when a second motor start must be permitted soon afterwards. The second condition simulates the case of an accidental shutting down of the motor in normal operation, for example, by power outage, allowing returning to operation right after the power is reestablished.
NOTE
Special start conditions must be checked in the specific documentation of the motor before starting the procedure.
5.1.4
Locked rotor current (Ip/In)
According to NBR 7094 standard, the value of IP/In, which is the relation between the locked rotor current and the rated current, is indicated on the motor nameplate.
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5.2
OTHER START METHODS
If direct start is not possible, an indirect start system can be used to reduce the motor starting current. The most used systems are: Reactor Autotransformer Frequency Inverter Soft-starter
ATTENTION
The selection of the start method depends on a previous evaluation of the performance of the machine to validate the procedure.
5.2.1
Start with reactor
In the soft start with reactor, impedance in the form of a reactor is introduced in series with the main terminals of the motor, reducing the motor terminal voltage, resulting in a reduction of the starting current. Being a function of the current that passes by the reactor, the impedance gradually reduces the motor acceleration, and when the motor reaches 95% of the rated speed, the reactor is short circuited and then the motor is synchronized and starts working at full voltage. Ensure enough acceleration torque to start the motor, since in this start method there is a considerable reduction of the starting torque.
5.2.2
Start with autotransformer
The effect of the start with autotransformer is similar to the start with reactor. The use of a transformer to limit the voltage reduces the starting current and the torque. The starting torque is reduced proportionally to the line current. The start of the motor with autotransformer consists of a voltage transformer with taps that allows the operation with reduced voltage until reaching the full voltage. The taps may be modified during the start until reaching the synchronization rotation and torque.
5.2.3
Start with frequency inverter
For start and operation of the motor with frequency inverter, refer to the equipment manual.
5.2.4
Start with soft-starter
The starting procedure with soft-starter is similar to direct start, except for the time to accelerate the load up to the rotation for synchronization, which is longer. During the starting process, the soft-starter progressively increases the motor voltage from zero, allowing the motor to accelerate the load up to the rated speed without causing current or torque peaks. The soft-starter can also be used to control the motor stop.
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5.3
EXCITATION CIRCUITS
The type of excitation circuit used in the asynchronous start of the brushless motor depends on the application, and it may be identified in its specific documentation.
5.3.1
Excitation circuit with voltage control (Random)
The circuit shown in Figure 5.1 works as follows: During normal operation of the motor, the exciter rotor and the diodes D1-D6 generate rectified DC voltage to supply field current to the motor according to the exciter field current supplied by an external controlled source; During normal operation, the thyristors SCR1 and SCR2 are not conducting; During the motor start, the revolving field generated by the motor stator induces a very high alternate voltage in the motor field winding which is proportional to the relation between the number of turns of the stator and the slip; In order to prevent damages to the insulation system and to the other component parts of the rotor, the exciter rectifier offers a low impedance path for the current that reduces the induced voltage to acceptable levels preventing the current from circulating through the exciter armature winding; When the field induced current is in the positive direction, the diode bridge will deviate the induced field current with a small voltage drop; When the induced field current is in the negative direction, the alternate voltage of the field winding is positive by means of the thyristors SCR1, SCR2 and in the triggering circuits; The circuit is arranged so that the triggering circuits identify the full voltage. As the alternate voltage increases, the triggering circuits make the SCRs conduct; The voltage level of the triggering circuits is specified to be enough above the normal operation field voltage; When the motor gets close to the synchronous rotation, the induced field voltage value and the frequency of this voltage get close to zero; The exciter field voltage, which until this moment remained not applied by the voltage supply and external control, can now be applied, increasing the exciter DC voltage to the operation levels; If the thyristors SCR1 and SCR2 are conducting when the exciter is at a significant voltage, the connection between the crossing of SCR1 and SCR2 and the exciter AC phase will allow the tripping of the thyristors when the motor induced field current is no longer negative.
Revolving circuit
Motor field
Triggering circuit 1
Exciter rotor
Triggering circuit 2
Static circuit Motor Stator
Exciter Stator TC Power supply and field control of the exciter
TP
AC three-phase supply Figure 5.1: Triggering circuit with voltage control
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5.3.2
Excitation circuit with frequency control
The circuit shown in Figure 5.2 works as follows: During normal operation, the exciter rotor and the diodes D1-D6 generate rectified DC voltage to supply field current to the motor according to the exciter field current supplied by an external controlled source; During the motor start, the revolving field generated by the motor stator induces a very high alternate voltage in the motor field winding which is proportional to the relation between the number of turns of the stator and the slip; The exciter field must be energized during the motor start as soon as the motor circuit breaker is closed. That allows the exciter output voltage to increase with the increase of the motor speed. SCR2 is not conducting; When the induced field current is in the positive direction, the current circulates through the starting resistor and diode D7; When the induced field current is in the negative direction, the thyristors SCR1 is initially locked. The voltage increases quickly until the controller activates the SCR1, and, at this moment, the current of negative direction circulates through the SCR1 and the starting resistor; Close to the synchronous rotation, the thyristors SCR2 is continuously activated, so that the field voltage is applied, even if the motor is with light load and the acceleration up to the rated speed occurs before the control can react during a positive semi-cycle; The thyristors SCR3 supplies a tripping circuit for SCR1 in case a transient interference activates the starting resistor during normal operation. The motor control notices a continuous voltage in the starting resistor and activates the SCR3. SCR3 provides an alternate temporary path for the current, deviating from SCR1, allowing SCR1 to be turned off. When the phase of the exciter connected to the SCR3 is no longer supplying current to the starting resistor, SCR3 returns to its normal lock state.
Revolving circuit
Triggering circuit Motor field Start resistor
Exciter rotor
Static circuit Motor stator Exciter stator TC Exciter power supply and Field control
TP
AC three-phase supply Figure 5.2: Triggering circuit with frequency control
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5.3.3
Excitation circuit for AC exciter
The circuit shown in Figure 5.3 is used in brushless synchronous motors with AC exciter for frequency inverter drive works as follows: During normal operation, the exciter rotor and the diodes D1-D6, which are fixed to the motor shaft, generate a rectified DC voltage to supply field current to the motor according to the exciter field current supplied separately by an exciter drive in alternate current. During the motor operation, the revolving field of the exciter stator induces an alternate voltage in the exciter rotor, even when the motor is completely stopped. The field excitation is controlled by the exciter drive by means of voltage amplitude; The AC exciter phase sequence makes the slip increase from one to normally three at maximum speed. Thats why the revolving field applied to the exciter stator must turn in the opposite direction of the motor direction; If the revolving field has the same direction of rotation as the motor and they have the same speed, then the voltage and the induced current in the exciter rotor will be zero; This kind of rectifier configuration is not used for direct start. Only drive this motor by using frequency inverter.
Motor field
Exciter rotor
Motor stator
Exciter rotor
Exciter AC power supply and Field control
AC three-phase supply Figure 5.3: Triggering circuit for AC exciter.
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6 COMMISSIONING
When the motor is started for the first time or after longs periods out of operation or large repairs, several aspects must be considered besides the regular operation procedures.
ATTENTION
Avoid any contact with electric circuits; Even low-voltage circuits may put life at risk; In any electromagnetic circuit, overvoltage may occur under certain operating conditions; Do not open the electromagnetic circuit suddenly, because the presence of an inductive discharge voltage may break the insulation or injure the operator; In order to open those circuits, driving switches or circuit breakers must be used.
6.1
PRELIMINARY INSPECTION
19. When spinning the motor, check if it there are no strange noises.
Before the initial start-up of a motor or after long periods out of operation, the following items must be inspected: 1. Check if the motor is properly aligned; 2. Check if the motor feet were fixed with the torque recommend in this manual. The motor must be fixed to the base; 3. Check if the motor is clean and if all the objects that will no longer be used have been removed from the operation area, such as: packages, tools, measuring instruments and alignment devices; 4. Check if the motor is properly grounded; 5. Measure the insulation resistance of the windings, making sure they are within the specified value; 6. Check if coupling connecting components are in perfect operating conditions, duly tightened and greased, where necessary; 7. Check if the bearings are not damaged, if they are properly fixed and aligned; 8. Check if the bearings are properly lubricated. The lubricant must be of the type specified on the nameplate. Check the oil level in the motors with oillubricated bearings. Bearings with forced lubrication must have the oil pressure and flow as specified in their nameplate; 9. Check if the field control and the excitation system are properly connected according to the instruction in the specific installation manual; 10. Check if the protection relay is parameterized and operating according to the selectivity study; 11. Check if the power grid cables are properly connected to the motor main terminals and ensure they are properly tightened and no short circuit possibility exists; 12. Inspect the cooling system. In motors with water cooling, inspect the operation of the radiator water supply system. In motors with forced ventilation, check the direction of rotation of the fans; 13. The motor air inlets and outlets must be clear; 14. The movable parts of the motor must be protected to prevent accidents; 15. The terminal box covers must be properly fastened; 16. Test the high-pressure oil injection system (if applicable), ensuring its proper operation; 17. Check if the brake is properly fixed and adjusted (if applicable). Check the operation of the brake control panel; 18. Test the hydraulic unit (if applicable), ensuring its proper operation;
6.2
INITIAL START-UP (UNCOUPLED)
After all the inspections described above have been made, the following procedures must be followed to perform the motor initial start-up: 1. Turn off the space heater; 2. Adjust the protection in the motor protection/excitation panel; 3. Switch on the hydraulic unit (if applicable); 4. Switch on the oil circulation system of the bearings (if applicable); Check the oil level, flow and pressure, ensuring they comply with the data on the nameplate; 5. The feedback signal of the pressure or flow of the oil circulation system in the bearings must be waited for, ensuring the oil has reached the bearings; 6. Start the cooling industrial water system and check the required flow and pressure (motors with air-water heat exchanger); 7. Turn on the fans (motors with forced ventilation); 8. Switch on the high-pressure oil injection system (if applicable), keeping it on as informed in the motor technical documentation, until the bearings can get lubricated by self-pumping; 9. Release the brake (if applicable); 10. Check the motor direction of rotation;
ATTENTION
In order to invert the direction of rotation of motors with single direction, it is necessary to contact WEG. 11. Start the motor as described in item Start; 12. Keep the motor turning at the rated speed and record the bearing temperatures at 1-minute intervals until they become constant. Any sudden or continuous increase in bearing temperature indicates lubrication or friction surface issues; 13. Check the motor vibration levels. In case excessive vibration is observed, investigate possible causes and solve the problems. 14. When the bearing temperatures become constant, the start-up with load and normal operation of the motor can be executed.
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ATTENTION
The noncompliance with the procedures described above may jeopardize the motor performance, cause damages and even lead to a burnout, voiding the warranty.
At the start of operation, the values must be checked every 15 minutes. After some hours of operation, check those values every hour. After some time, those intervals may be progressively increased, but those values must be recorded daily for a period of five to six weeks.
6.3.3
Temperatures
6.3
OPERATION
After the first successful test of start with no load, couple the motor to the load driven and then perform the start and operation as follows: Activate the motor coupled to the load until its temperature stabilizes and observe unusual noises and vibrations or excessive heating. In case of significant variations in the vibration of the set after the temperature stabilizes, it is necessary to check the alignment and leveling; Measure and compare the consumed electric current to the value indicated on the nameplate. In continuous duty, without load oscillation, the value of the current measured must not exceed the value indicated on the motor identification multiplied by the duty factor; All measurement and control instruments and devices must be permanently monitored to detect occasional alterations, determine the causes and make the proper corrections.
The temperature of the bearings, stator winding and ventilation air (if applicable) must be monitored while the motor is running. The temperature of the bearings and stator winding must stabilize in a period of four to eight hours of operation; The stator winding temperature depends on the motor load condition. Therefore, its operation data (voltages, currents, frequency) must be monitored during the motor operation.
6.3.4
Bearings
6.3.1
Resynchronization
If the motor loses synchronism, the excitation circuit will present a field current above the normal value of the motor supplied by the exciter before this operating condition. To put the motor back to synchronism, it is necessary to turn off the field supply for a period of two to three seconds after the loss of synchronism. If the motor control system is adjusted for resynchronization after the loss of synchronism, the following criteria must be observed: 1. Shut down the field supply for at least two seconds in order to allow the motor induced field current to activate the discharge circuit and/or the insertion of the discharge resistor and, thus, reduce the transient torques during resynchronization. 2. The resynchronization time must not exceed the motor normal start sequence time. 3. Normally, the removal of the excitation is necessary for a successful resynchronization; 4. The motor control panel must distinguish start failure from loss of synchronism, so that an attempt of resynchronization will not occur immediately after a start failure; 5. The quantity and the time of the attempts of resynchronization must be limited according to each motor project.
The system start must be monitored carefully, as well as the first hours of operation. Before starting the motor operation: Check if the high-pressure oil injection system (if applicable) is ON; Check if the external lubrication system (if applicable) is ON; Check if the lubricant used corresponds to that specified on the motor nameplate; Analyze the lubricant characteristics; Check the oil level (oil-lubricated bearings); Check the alarm and shutdown temperatures set for the bearing; During the first start-up, it is important to inspect for unusual vibrations or noises; If the bearing is not running silently and smoothly, the motor must be immediately shutdown; The motor must operate for several hours until bearing temperatures stabilize within the previously specified limits; In case of over temperature, the motor must be immediately shutdown, bearings and temperature sensors must be inspected and the causes corrected; After the bearing temperatures stabilize, check if there are no leaks through the plugs, gaskets or shaft end.
6.3.4.1
High-pressure oil injection system
In bearings which feature the option of shaft lifting at start or stop by means of oil pressure, the drive of this system is done by means of an external oil pump and the following procedure must be observed:
ATTENTION
The oil injection system under high pressure must be switched on before putting the motor into operation and during the stop procedure, as informed in the motor technical documentation.
6.3.2
Data record
The following data must be collected and recorded periodically during the motor operation: Temperature of the bearings; Oil level of the bearings; Stator winding temperature; Air inlet and outlet temperature; Motor vibration level; Field stator voltage and current. 36 l 11866576 - Brushless synchronous motors - Horizontals
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6.3.5
Radiators
ATTENTION
Operating the motor with vibration levels above the values provided above may jeopardize its useful life and/or performance.
For motors with air-water heat exchanger, it is important: To control the temperature at the radiator inlet and outlet and, if necessary correct the water flow; Set the water pressure just the necessary to overcome the resistance imposed by the pipes and radiator; In order to control the motor operation, it is recommended to install thermometers at the radiator air and water inlet and outlet and record those temperatures at certain time intervals; When installing the thermometers, you may also install recording or signaling instruments (siren, light bulbs) in certain places.
6.4
STOP
6.3.5.1
Inspection of the performance of the radiator
In order to control the operation, it is recommended to measure the temperatures at the radiator water and air inlet and outlet and record them periodically. The radiator performance is expressed by the temperature difference between the cold water and cold air during normal operation. This difference must be periodically controlled. If an increase in this difference is observed after a long period of normal operation, probably the radiator must be cleaned. A reduction of performance or damage to the radiator may also occur by air accumulation inside it. In this case, removing the air from the radiator and pipes may correct the problem; The pressure difference on the water side may be considered an indicator of the need of cleaning the radiator; We also recommend measuring and recording the pressure difference of the water before and after the radiator. Periodically, the new values measured are compared to the original value, and an increase of the pressure difference indicates the need of cleaning the radiator.
In order to stop the motor, proceed as follows: 1. Switch off excitation; 2. Open the main stator circuit breaker; 3. Switch off the voltage regulator; 4. Switch on the high-pressure oil injection system (if applicable); 5. Apply the brakes as informed in the motor technical documentation; After the motor fully stops: 6. Switch off the high-pressure oil injection system (if applicable); 7. Shut down the oil circulation system of the bearings (if applicable); 8. Switch off the hydraulic unit (if applicable); 9. Switch off the industrial water system (if applicable); 10. Switch off the forced ventilation system (if applicable). 11. Switch on the space heaters. They must be kept ON until the next operation of the motor.
DANGER
Even after the de-excitation, there might be voltage present in the motor terminals. Therefore, any job can only be performed after the full stop of the equipment. Noncompliance with the aforementioned may cause serious injuries or death.
6.3.6
Vibration
The acceptable vibration levels must be directly obtained in the standard referring to the motor.
Table 6.1: Standards to evaluate the vibration in coupled motors Application Motor (reciprocating and rotary screw compressor) Motor (centrifugal compressor) Motor (pump) Measurement in non-rotating parts ISO 10816-1 ISO 10816-3 ISO 10816-5 Measurement in rotating parts ISO 7919-1 ISO 7919-3 ISO 7919-5
Common causes of vibration are: Misalignment between the motor and equipment; Inadequate fixation of the motor to the base, with loose shims under one or more of the motor feet, and loose fixation bolts; Inadequate or not sufficiently strong base; External vibrations from other devices.
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7 MAINTENANCE
7.1 GENERAL 7.3 INSPECTIONS IN THE WINDINGS
A proper motor maintenance plan, when properly executed, includes the following recommendations: Keep the motor and all related equipment clean; Periodically measure the insulation resistance; Routinely measure the temperature of windings, bearings and ventilation system; Inspect wear, operation of the lubrication system and useful life of the bearings; Check the ventilation system to ensure air is flowing correctly; Inspect the heat exchanger; Measure the machine vibration levels; Inspect related equipment; Check all of the motor accessories, protections and connections, ensuring that they are operating properly; The frame must be kept clean, without oil or dust built up on its external part in order to make the heat exchange with the ambient easier.
The motor winding insulation resistance must be measured at regular intervals, especially during damp weather or after long periods out of operation. The windings must undergo a careful visual inspection at frequent intervals, recording and fixing any damages. Low values or sudden variations in the insulation resistance must be carefully investigated. At points where the insulation resistance may be low (due to an excess of dust or moisture), it may be increased back to the required values by removing the dust and drying up humidity on the windings.
7.4
WINDING CLEANING
ATTENTION
Noncompliance with the recommendations aforementioned may cause undesired stops of the equipment. The frequency with which such inspections are performed depends on local application conditions. Whenever necessary to transport the motor, the shaft must be properly locked to prevent damages to the bearings. Use the device supplied with the motor to lock the shaft. If the motor requires reconditioning or replacement of any damaged part, please contact WEG.
For satisfactory operation and longer useful life of insulated winding, it is recommended to keep them free of dirt, oil, metallic dust, contaminants, etc. In order to do so, it is necessary that the winding be periodically inspected and cleaned and that it operate in clean air. If re-impregnation is necessary, contact WEG. The winding may be cleaned with industrial vacuum cleaner with a non-metallic thin tip or just a dry cloth. For extremely dirty conditions, there might be the need of cleaning with a proper liquid solvent. This procedure must be quick to prevent prolonged exposure of the windings to solvent effects. After being cleaned with solvents, the winding must be completely dried. Measure the insulation resistance and the polarization index to ensure the winding is completely dry. Winding drying time after cleaning varies depending on weather conditions, such as temperature, humidity, etc.
DANGER
7.2
GENERAL CLEANING
The frame must be kept clean, without oil or dust built up on its external part in order to make the heat exchange with the ambient easier; The interior of the motor must also be kept clean, and free from dust, debris and oils; For cleaning, use brushes or clean cotton cloths. If the dust is not abrasive, an industrial vacuum cleaner must be used to remove the dirt from the fan cover and the excess of dust on fan blades and on the frame; The grounding brush compartment must be kept clean and without dust accumulation (if applicable); Debris impregnated with oil or moisture may be removed with a cloth soaked in appropriate solvents; Cleaning the terminal boxes is also recommended. Terminals and connectors must be kept clean, rust-free and in perfect operating conditions. Avoid contact between connecting parts and grease or verdigris.
Most solvents currently used are highly toxic and/or flammable. The solvents must not be used in the straight parts of the coils of high-voltage motors, because the protection against corona effect may be affected.
7.4.1
Inspections
The following inspections must be performed after the winding is carefully cleaned: Check the connections and winding insulation; Check if spacers, bindings, groove wedges, bandages and supports are fixed correctly; Check if there were no breaks, if there are no faulty welds, short circuit between turns and against the mass in the coils and connections. In case any fault is detected, contact WEG. Ensure that all cables are properly connected and that terminal fixation components are duly tightened. If necessary, retighten them.
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7.4.2
Re-impregnation
If any layer of resin on the windings is damaged during cleaning or inspection, such parts must be corrected with adequate material (in this case, please contact WEG).
7.4.3
Insulation resistance
Insulation resistance must be measured after all maintenance procedures have been performed.
ATTENTION
Before putting the motor into operation, in case it remained out of operation for some time, it is essential to measure the insulation resistance of the windings and ensure that the values meet the specifications.
Instructions for removing and maintaining the radiator In order to remove the heat exchanger for maintenance, follow the steps below: 1. Close all the water inlet and outlet valves after stopping the ventilation; 2. Drain the radiator water through the drain plugs; 3. Loosen the heads and keep the bolts, nuts and washers and gaskets together in a safe place; 4. Carefully brush the pipes inside with nylon brushes to remove the residue. If during the cleaning operation, damages to the radiator pipes are observed, they must be repaired; 5. Reassemble the heads, replacing the gaskets if necessary.
7.6
VIBRATION
Any sign of increase in unbalance or vibration of the machine must be immediately investigated.
7.5
MAINTENANCE OF THE COOLING SYSTEM
7.7
SHAFT GROUNDING DEVICE
The air-air heat exchangers must be kept clean and unblocked in order to ensure a perfect heat exchange. In order to clean the pipes, a round brush may be used to remove the dirt; The pipes and radiator of air-water heat exchangers must be periodically cleaned in order to prevent the built up of incrustations.
In some motors, depending on application, a brush is used to ground the shaft. This device prevents the circulation of electric current through the bearings, which is highly harmful to their operation. The brush is put in contact with the shaft and connected by a cable to the motor frame, which must be grounded. Make sure the fixation of the brush holder and its connection to the frame have been done properly.
NOTE
If the motor features filters in the air inlets

and/or outlets, they must be cleaned by using compressed air. If the dust is difficult to remove, wash them in cold water with mild detergent and dry them in the horizontal position; In case the filter is impregnated with dust containing grease, it is necessary to wash it with gasoline, kerosene or another petroleum solvent or hot water with P3 additive; All the filters must be dried after the cleaning. Do not twist them; Change the filter if necessary.
Shaft Figure 7.1: Brush for grounding the shaft
In order not to damage the motor shaft during transportation, it is protected with drying oil. In order to ensure the proper operation of the grounding brush, this oil, as well as any residue between the shaft and the brush, must be removed before starting the motor. The brush must be constantly observed during the operation and, at the end of its useful life, it must be replaced by another one of the same quality (granulation).
7.8
7.8.1
MAINTENANCE THE EXCITER

Exciter
7.5.1
Maintenance of radiators
Using clean water, the radiator may remain in operation for several years, without having to be cleaned. With dirty water, it is necessary to clean it every 12 months. The level of dirt in the radiator may be detected by the air temperatures increase in the outlet. When the temperature of the cold air, in the same operating conditions, exceeds the specified value, you can assume the pipes are dirty. If corrosion is observed, it is necessary to provide a proper protection against corrosion (for instance, zinc anodes, cover with plastic, epoxy or other similar protection products) in order to prevent greater damages to the affected parts. The external surface of all parts of the radiator must be always kept in good conditions.
In order to have a good performance of its components, the motor exciter compartment must be kept clean. Clean it regularly, following the procedures described in this manual. Windings Check the main exciter and auxiliary exciter winding insulation resistance regularly so as to determine their insulation conditions, following the procedures described in this manual.
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7.8.2
Diode test
NOTE
The diode polarity is indicated by an arrow on its frame. When replacing the diodes, make sure they are installed in each part of the heatsink disk with the correct polarity.
The diodes have a long useful life and do not require frequent inspections. If the motor presents any defects which indicate diode failure through the voltage regulator or an increase in the field current for the same load condition, the diodes must then be tested as per the procedure below:
NOTE
When testing diodes, the polarity of the test terminals in relation to diode polarity must be observed.
The current conduction must occur only in the anodecathode direction, that is, in the direct polarization condition.
7.8.3
1. 2. Loosen the flexible cables of the 6 diodes; With an ohmmeter, measure the resistance of each diode in both directions.
Thyristor test SCR
The diode is good when it presents low resistance (up to 100) in its direct direction and high resistance (approximately 1M) in the opposite direction. Defective diodes will have a resistance of 0 or greater than 1M in both directions. In most cases, the method with ohmmeter to test the diodes is enough to identify the failures in the diodes. However, in some extreme cases, it may be necessary to apply the rated locked voltage and/or current circulation to detect failure in the diodes. In view of all the work required to perform those tests, in case of doubt, it is recommended to replace the diodes.
Disconnect the controlled rectifiers (SCR) to be tested from the circuit by disconnecting the flexible braid and the gate and cathode terminals. The SCR in good conditions has high resistance in both directions. When defective, normally the reading is close to zero in both directions. The triggering circuit of the thyristor must present low resistance (25 100 ohms) in both directions.
ATTENTION
The application of more than 10V in the thyristors trigger may damage the triggering circuit. The noncompliance with this instruction may damage the equipment. In most cases, the test procedure by the ohmmeter test is enough to identify failures in the thyristors. The comparison of the readings in more than one reliable device is convenient.
7.8.2.1
Diode replacement
In order to replace any of the diodes, WEG recommends that the following recommendations be followed: 1. Replace the damaged diodes by new diodes identical to the original ones, observing the position of each anode diode and each cathode diode. 2. The diodes are already supplied with insulated flexible connection braid and connection terminal; 3. Clean the heatsink disk completely around the diode mounting hole. 4. Check if the diode thread is clean and free of burs; 5. Apply heatsink compound on the contacts; 6. Install the diode in its correct position using a torque wrench, observing the torques recommended in Table 7.1.
Table 7.1: Diode tightening torque Diode thread (mm) M12 M16 M24 Torque wrench (mm) 24 32 41 Tightening torque (Nm) 10 30 60
7.8.3.1
Thyristors replacement
With flexible braid: In order to replace any of the thyristor, WEG recommends that the following recommendations be followed: 1. Replace the damaged thyristors by thyristors identical to the original ones, observing the position of each anode thyristor and cathode thyristor; 2. The thyristors are already supplied with insulated flexible connection braid and connection terminal; 3. Clean the heatsink disk completely around the thyristor mounting hole. 4. Check if the thyristor thread is clean and free of burs; 5. Apply heatsink compound on the contacts; 6. Install the thyristor in its correct position using a torque wrench, observing the torques recommended in Table 7.2.
Table 7.2: Thyristor tightening torque
ATTENTION
It is essential that the tightening torque be observed so as to prevent damages to the diodes during assembly. 7. After fixing the diodes, connect the diode flexible braids.
Thyristor thread (mm) M12 M16 M24
Torque wrench (mm) 24 32 41
Tightening torque (Nm) 10 30 60
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ATTENTION
It is essential that the tightening torque be observed so as to prevent damages to the thyristors during assembly 7. After fixing the thyristors, make the thyristor flexible braid connection.
7.9
7.9.1
BEARING MAINTENANCE
Sleeve bearings Bearing data
7.9.1.1
NOTE
The diode polarity is indicated by an arrow on its frame. When replacing the thyristors, make sure they are installed in each part of the heatsink disk with the correct polarity.
The characteristic data, such as oil flow, quantity and type are indicated on the bearing nameplate and must be strictly observed; otherwise, overheating and damages to the bearings may occur. Hydraulic installation (for bearings with forced lubrication) and oil supply for the motor bearings are responsibility of the user.
7.9.1.2
Bearing installation and operation
In order to obtain the part list, assembling and disassembling instructions and maintenance details, refer to the specific installation and operation manual of the bearings.
7.9.1.3
Protection adjustments
With heatsink: In order to replace any of the thyristor, WEG recommends that the following recommendations be followed: 1. Replace the damaged thyristors by thyristors identical to the original ones, observing the position of each thyristor and the correct position of the anode and cathode; 2. Clean the heatsink completely around the contact spot; 3. Apply heatsink compound on the contacts; 4. The thyristor must be assembled on the support and the gate terminal wires must be welded and insulated with shrink tubing; 5. Apply tightening torque of 10Nm.
Each bearing is equipped with temperature detectors. Those devices must be connected to a control panel in order to indicate overheating and protect the bearings from damages due to operation with high temperatures.
ATTENTION
The following temperatures must be adjusted on the bearing protection system: ALARM 110C SHUTTING DOWN 120C The alarm temperature must be adjusted 10C above the working duty temperature, not exceeding the limit of 110C.
7.9.1.4
Cooling by water circulation
ATTENTION
It is essential that the tightening torque be observed so as to prevent damages to the thyristors during assembly
NOTE
The diode polarity is indicated by an arrow on its frame. When replacing the thyristors, make sure they are installed in each part of the heatsink disk with the correct polarity.
The sleeve bearings with cooling by water circulation feature a serpentine inside the oil tank where the water circulates. The water must present, at the bearing inlet, a temperature below or equal to the ambient temperature in order to perform the cooling. The water pressure must be 0.1 bar and the flow equal to 0.7 l/s. The pH must be neutral.
NOTE
Under no circumstances can water leak into the oil tank, which would cause the contamination of the lubricant.
7.9.1.5
Oil change
Self-lubricated bearings The oil change of the bearings must be carried out observing the intervals indicated below, according to the bearing operating temperature: Below 75C = 20,000 hours; Between 75 and 80C = 16,000 hours; Between 80 and 85C = 12,000 hours; Between 85 and 90C = 8,000 hours; Between 90 and 95C = 6,000 hours; 11866576 - Brushless synchronous motors - Horizontals | 41
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Between 95 and 100C = 4,000 hours. Bearings with (external) oil circulation The oil of the bearings must be changed every 20,000 hours of operation or whenever the lubricant presents modifications in its characteristics. The oil viscosity and pH must be checked regularly.
7.9.2
Oil rolling bearing 1- Oil inlet 2- Sight glass 3- Oil outlet
NOTE
The oil level must be monitored daily and kept approximately in the middle of the sight glass.
The bearings must be lubricated with the specified oil, observing the flow values informed on their nameplate; All threaded holes that are not used must be closed with plugs and no connections can present leak; The oil level is reached when the lubricant can be seen approximately in the middle of the sight glass. The use of a larger amount of oil will not damage the bearing, still it can cause leaks through the shaft seals.
Figure 7.2: Oil rolling bearing
7.9.2.1
Lubrication instruction
Oil drainage: When it is necessary to change the bearing oil, remove the oil outlet plug (3) and drain the oil completely. To put oil in the bearing: Close the oil outlet with the plug (3); Remove the oil inlet cap (1); Fill with the specified oil up to the level indicated in the oil sight glass.
ATTENTION
The care with the lubrication will determine the useful life of the bearings and the safety during the motor operation. Therefore, the following recommendations must be observed: The selected oil must be the one with proper viscosity for the working temperature of the bearings; That must be observed in an occasional oil change or in periodical maintenances; Never use or mix hydraulic oil with the lubricant oil of the bearings; Lack of lubricant, due to incomplete filling or the not monitoring of the level, can damage the bearing shells; The minimum oil level is reached when the lubricant can be seen touching the lower part of the sight glass with the motor out of operation.
NOTES
1. All threaded holes that are not used must be closed with plugs and no connections can present leak; 2. The oil level is reached when the lubricant can be seen approximately in the middle of the sight glass; 3. The use of a larger amount of oil will not damage the bearing, still it can cause leaks through the shaft seals; 4. Do not use or mix hydraulic oil with the lubricant oil of the bearings;
7.9.2.2 7.9.1.6 Seals

In case of maintenance of the bearings, when adjusting them again, the two halves of the taconite seal must be joined by a garter spring. This spring must be inserted in the ring seat in such way that the locking pin fits into its fillister in the upper half of the frame. Improper installation destroys the seal. Before assembling the seals, clean the surfaces that touch the ring and its seat carefully, and cover them with a nonhardening sealing component. The drain holes located in the lower half of the ring must be cleaned and cleared. When installing this half of the sealing ring, press it slightly against the shaft lower part.
Oil type
The type and quantity of the lubricant oil to be used are specified on the nameplate fixed onto the motor.
7.9.2.3
Oil change
The oil change of the bearings must be carried out observing the intervals indicated below, according to the bearing operating temperature: Below 75C = 20,000 hours; Between 75 and 80C = 16,000 hours; Between 80 and 85C = 12,000 hours; Between 85 and 90C = 8,000 hours; Between 90 and 95C = 6,000 hours; Between 95 and 100C = 4,000 hours. The lifespan of the bearings depends on their operating conditions, on the motor operating conditions and on the procedures observed by the maintenance personnel. The following recommendation must be observed: The oil selected for the application must have the proper viscosity for the bearing operating temperature.
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The type of oil recommended by WEG already considers those criteria; Insufficient quantity of oil may damage the bearing; The minimum oil level recommended is reached when the lubricant can be seen in the lower part of the oil sight glass with the motor stopped.
ATTENTION
The oil level must be inspected daily and must remain in the middle of the oil sight glass.
7.9.2.4
Protection adjustments
The temperature sensors installed on the bearings must be connected to a control panel in order to indicate overheating and protect the bearings from damages due to operation with high temperatures.
ATTENTION
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7.9.2.5
Bearing assembly and disassembly
1. External oil tank 2. Internal oil tank 3. External bearing cap 4. Oil centrifuge 5. Bolt 6. Internal bearing cap 7. Rolling bearing 8. Taconite seal 9. Bolt 10. Vent 11. External tank fastening bolt 12. Internal tank fastening bolt 13. Cover fastening bolt 14. Bearing protection cover
Figure 7.3: Parts of the oil rolling bearing
In order to disassemble the bearing, follow the instructions below: Before disassembling Clean all the external part of the bearing; Drain all the oil from the bearing; Remove the temperature sensor from the bearing; Remove the grounding brush (if applicable); Provide a support for the shaft in order to hold the rotor during the disassembly. Disassembly: Take special care to prevent damages to the balls, rollers and surface of the shaft. Keep the disassembled parts in a safe and clean place. In order to disassemble the bearing, follow the instructions below: 1. Remove the bolt (9) that fixes the taconite seal (8); 2. Remove the taconite seal (8); 3. Remove the bolts (11) that fix the bearing protection cover (14); 4. Remove the protection cover (14); 5. Remove the bolts (5) that fix the oil centrifuge (4) and remove it; 6. Remove the bolts that fix the external bearing cap (3) and remove it; 7. Loosen the bolts (12 and 13); 8. Remove the external oil tank (1); 9. Remove the bearing (7); 10. If complete disassembly of the bearing is necessary, remove the internal bearing cap (6) and the internal oil tank (2). Assembly: Clean the rolling bearing and the oil tanks thoroughly, and inspect all the parts before the bearing assembly. Make sure the rolling bearing contact surfaces are smooth and free of signs of scratches or corrosion; Before inserting the rolling bearing on the shaft, heat it to a temperature from 50 to 100C; For the full assembly of the bearing, follow the instructions for disassembly in the reverse order.
ATTENTION
The oil level must be inspected daily and must remain in the middle of the oil sight glass.
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7.9.3
Grease rolling bearings

Grease inlet
7.9.3.2
Procedure to lubricate the rolling bearings
Grease outlet Figure 7.4: Grease rolling bearings
7.9.3.1
Lubrication instructions
1. Remove the drain cover; 2. Clean with a cotton cloth the area around the grease nipple; 3. With the rotor operating, inject the grease with a manual grease gun until grease starts coming out from the drain or until the proper amount of grease is injected. 4. Leave the motor running long enough for the grease excess to drain; 5. Inspect the bearing temperature to make sure there was no significant change; 6. Put the drain plug back on.
The lubrication system was projected so that during the lubrication of the bearings, all the old grease is removed from the bearing tracks and expelled through a drain which allows it to come out, but prevents the income of dust or other harmful contaminants into the bearing. This drain also prevents damages to the bearings due to excessive lubrication. It is recommended to make the lubrication with the motor in operation, ensuring the renewal of grease in the bearing enclosure. If that is not possible due to the presence of rotating parts near the grease nipple (pulleys, etc.) which may put the operator at risk, follow the procedures below: With the motor stopped, inject approximately half the total estimated amount of grease and put the motor into operation for about one minute at rated speed; Stop the motor and inject the rest of the grease. The injection of all the grease with the motor stopped may lead to the penetration of part of the lubricant into the motor through the internal seal of the bearing case.
7.9.3.3
Bearing lubrication with spring device to remove the grease
ATTENTION
It is important to clean the grease nipples before lubrication in order to prevent foreign material from coming into the bearing. For lubrication, use manual grease gun only.
In order to lubricate the bearings, the removal of the old grease is done by the spring device installed in each bearing. Procedures for lubrication: 1. Before beginning the bearing lubrication procedure, clean the grease nipple with a cotton cloth; 2. Remove the rod with spring to remove the old grease, clean the spring and put the rod back; 3. With the motor running, inject the amount of grease specified on the bearing nameplate by means of a manual grease gun; 4. The grease excess comes out through the lower drain of the bearing and settles on the spring; 5. Leave the motor running long enough for the grease excess to drain; 6. That grease must be removed pulling the rod of the spring and cleaning the spring. This procedure must be repeated as many times as necessary until the spring will not hold grease; 7. Inspect the bearing temperature to make sure there was no significant change.
7.9.3.4
Grease type and quantity
The bearing lubrication must always be done with the original grease specified on the bearing nameplate.
NOTE
The bearing data, amount and type of grease and lubrication intervals are informed on a nameplate fixed onto the motor. Check this information before making the lubrication.
ATTENTION
WEG does not recommend the use of grease different from the original one.
7.9.3.5
Protection adjustments ATTENTION

The lubrication intervals informed on the plate refer to bearing operating temperature of 70C; Based on the operating temperature ranges listed below, apply the following ratio-corrector factors for the bearing lubrication intervals: Operating temperature lower than 60C: 1.59; Operating temperature of 70C to 80C: 0.63; Operating temperature of 80C to 90C: 0.40; Operating temperature of 90C to 100C: 0.25; Operating temperature of 100C to 110C: 0.16.
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7.9.3.6
Bearing assembly and disassembly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Internal bearing cap White felt Ring fastening bolt Disk fastening bolt External bearing cap Taconite seal Centrifuge fastening bolt Grease centrifuge Grease outlet compartment Rolling bearing Thermal protector External closing disk
Figure 7.5: Parts of the grease rolling bearing
Before disassembling: Remove the extension tubes form the grease inlet and outlet; Clean carefully the external part of the bearing; Remove the grounding brush (if applicable); Remove the bearing temperature sensors and provide a support for the shaft to prevent damages to the rolling bearing. Disassembly Take special care to prevent damages to the balls, rollers and surface of the shaft. Keep the disassembled parts in a safe and clean place. In order to disassemble the bearing, follow the instructions below: 1. Remove the bolts (4) that fix the closing cap (13); 2. Remove the taconite seal (6); 3. Remove the bolts (3 ) that fix the fixation caps (1 and 5); 4. Remove external bearing cap (5); 5. Remove the bolt (7) that fixes the grease centrifuge (8); 6. Remove the grease centrifuge (8); 7. Remove the D-endshield; 8. Remove the bearing (10); 9. Remove the internal bearing cap (1) if necessary. Assembly Clean the bearings completely and inspect the disassembled parts and the inside of the bearing caps; Make sure the bearing, shaft and bearing cap surfaces are perfectly smooth; Fill with the recommended grease up to of the internal and external fixation cap deposit (Figure 7.6) and lubricate the rolling bearing with grease enough before assembling it; Before assembling the bearing on the shaft, heat it to a temperature between 50C and 100C; For the full assembly of the bearing, follow the instructions for disassembly in the reverse order.
Figure 7.6: External bearing cap
GENERAL NOTES: 1. In case the bearing is open, inject new grease through the grease nipple to expel the old grease that is in the grease inlet tube and apply the new grease to the bearing, to the internal ring and external ring, filling 3/4 of the empty spaces. In case of double bearings (ball + roller), also fill 3/4 of the empty spaces between the intermediate rings; 2. Never clean the bearing with cotton cloths, because they may release lint as solid particles; 3. It is important to perform a correct lubrication, that is, apply the correct grease and in the proper quantity, because both an insufficient lubrication and an excessive lubrication damage the bearings; 4. Excessive lubrication makes the temperature rise due to the great resistance against the movement of the revolving parts and especially due to the beating of the grease, which eventually completely loses its lubrication properties.
NOTE
WEG is not responsible for changing the grease, or even for occasional damages caused by the change.
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7.9.3.7
Grease quality and quantity
7.9.4
Disassembly and assembly of the bearing Pt100

Pt-100 Pt-100
It is important to perform a correct lubrication, that is, apply the correct grease and in the proper quantity, because both an insufficient lubrication and an excessive lubrication damage the bearings. Excessive lubrication makes the temperature rise due to the great resistance against the movement of the revolving parts and especially due to the beating of the grease, which eventually completely loses its lubrication properties.
Condute
ATTENTION
Greases with different types of base must never be mixed. Example: Lithium-based greases must never be mixed with others with sodium or calcium base.
Noninsulated bearing Figure 7.7: Pt100 on the bearings
Insulated bearing
7.9.3.8
Compatibility
Instructions for disassembly: If necessary to remove the Pt100 for bearing maintenance, the following procedures must be adopted: Remove the Pt100 with care, lock the locknut (3) and unscrew just the Pt100 from the bulb adjustment (4); The parts (2) and (3) must not be disassembled. Instructions for assembly: Before performing the assembly of the Pt100 on the bearing, check if it does not contain dents or any other damage that may compromise its operation. Insert the Pt100 on the bearing; Lock the locknut (3) with a wrench; Screw the bulb (4), adjusting it so that the end of the Pt100 touch the bearing sleeve or the external surface of the rolling bearing.
The compatibility of different types of grease may cause a problem. You can say the greases are compatible when the properties of the mixture lie within the property ranges of the greases individually. In general, greases with the same type of soap are compatible with each other, but depending on the proportion of the mixture, there might be incompatibility. Therefore, it is not recommended the mixture of different types of grease without consulting the grease supplier or WEG. Some thickeners and basic oils cannot be mixed with each other, because they do not form a homogeneous mixture. In this case, you cannot disregard the possibility of hardening or, on the other hand, softening of the grease or fall of the dropping point of the resulting mixture.
NOTES
The assembly of the Pt100 on the noninsulated bearings must be done directly on the bearing, without the insulating fitting (2); The tightening torque to assemble the Pt100 and the adapters must not be exceed 10Nm.
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8 MOTOR DISASSEMBLY AND ASSEMBLY

All the services referring to repairs, disassembly and assembly must be executed by duly qualified and trained personnel. The disassembly and assembly sequence depends on the mounting characteristics of the motor.
8.1
DISASSEMBLY
NOTE
The strength class is usually indicated on the head of the hexagonal bolt; When there is no marking on the bolt, it indicates that the strength class of the bolt is 4.6; Allen-type hexagon socket cap bolts have strength class 12.9.
Below are some cares to be observed when the motor is disassembled: 1. Always use proper tools and devices to disassemble the motor; 2. Before disassembling the motor, disconnect the lubrication and cooling water pipes (if applicable); 3. Disconnect the electrical and accessory connections; 4. Remove the heat exchanger and noise suppressor (if applicable); 5. Remove the temperature sensors from the bearings and grounding brush; 6. In order to prevent damages to the rotor, provide a support to hold the shaft on the front and back sides; 7. To disassemble the bearings, follow the procedures described in this manual; 8. The removal of the rotor from inside the motor must be done with a proper device and with extreme care for the rotor not to scrape the stator core or the coil heads, preventing damages.
8.3
MEASUREMENT OF THE AIR-GAP
After disassembling and assembling the motor, it is necessary to measure the air gap in order to check the concentricity between rotor and stator. The difference between the air gap measures in two points diametrically opposed must be less than 10% of the average air gap.
8.4
GENERAL RECOMMENDATIONS
ATTENTION
All services described herein must be performed by specialized and experienced personnel; otherwise, personal injuries or damages to the equipment may occur. If you have any questions, contact WEG.
8.2
ASSEMBLY
NOTA
When the motor is supplied disassembled, an assembly manual is provided with it, describing the procedures to assemble the motor at the installation site.
8.5
Below are some cares to be observed when the motor is assembled: 1. Always use proper tools and devices to assemble the motor; 2. To assemble the motor, use the disassembly procedure in the reverse order; 3. Any damaged part (cracks, dents on machined parts, faulty threads) must be replaced, always avoiding restorations. Table 8.1 shows the recommended tightening torques of the bolts for the assembly of the motor or its parts:
Table 8.1: Bolt tightening torque Strength class Diameter M6 M8 M10 M12 M16 M20 M24 4.6 5.8 8.8 12.9
SPARE PARTS
Tightening torque (Nm) tolerance 10% 1.9 3.2 5.1 8.7 4.6 7.7 12.5 21 9.1 15 25 41 16 27 42 70 40 65 100 175 75 125 200 340 130 220 350 590
WEG recommends keeping in stock the following spare parts: DE bearing and NDE bearing (motor with rolling bearings); Bearing shell for DE bearing and NDE bearing (motor with sleeve bearings); Temperature sensor for each bearing; Space heater; Filter felts (if applicable); Diode set; Varistor set; Lubricant for the bearings; Brake pad (if applicable); Grounding brush (if applicable); The spare parts must be stored in clean, dry, wellventilated environments and, if possible, at constant temperature.
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9 MAINTENANCE PLAN
The maintenance plan described in Table 9.1 is only referential, considering that the intervals between each maintenance intervention may vary according to the motor location and operating conditions.
Table 9.1: Maintenance plan EQUIPMENT STATOR Stator visual inspection Cleaning control Groove wedges inspection Stator terminal control Measure the winding insulation resistance ROTOR Cleaning control Visual inspection Shaft inspection (wear, incrustations) EXCITER Cleaning control Test diodes, thyristors and varistors Inspect the windings Inspect connections and operation of triggering circuit BEARINGS Noise, vibration, oil flow, leak and temperature control Lubricant quality control Inspect the bearing shell and shaft track (sleeve bearing) Change the lubricant AIR-WATER HEAT EXCHANGER Inspection of the radiators Clean the radiators Change the gaskets of the radiator heads AIR-AIR HEAT EXCHANGER Clean the ventilation pipes Inspect the ventilation AIR FILTER(S) Inspect and replace if necessary TERMINAL BOX AND GROUNDING TERMINALS Clean the inside of the terminal boxes Retighten the screws PROTECTION AND CONTROL EQUIPMENT Test operation Record values Disassemble and test its operation COUPLING Inspect alignment Inspect fixation WHOLE MOTOR Inspect noise and vibration Drain condensate Retighten the bolts Clean terminal boxes Refasten electric and grounding connections BRAKE Wear of the pads Operating control Weekly Monthly 3 6 3 annually months months years x x x x x x x x x x x x Note
x x x According to period indicated on the bearing nameplate x x x x x Perform procedure every two months x x x x x x x x x x x x According to the equipment manual Check after first week of operation
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10 ABNORMALITIES, CAUSES AND SOLUTIONS

NOTE
The instructions of Table 10.1 present only a basic list of abnormalities, causes and corrective actions. If you have any questions, contact WEG.
Table 10.1: Basic list of abnormalities, causes and corrective actions ABNORMALITY POSSIBLE CAUSES At least two power cables are interrupted, without voltage Rotor is locked Motor will neither start coupled Damaged bearing nor uncoupled Excessive load at start Stator circuit is open Diode in short circuit or open thyristor Power supply voltage is too low Motor starts with no load, but Sharp voltage drop in the power cables fails when load is applied It starts very slowly and will not Rotor bars (damper winding) are damaged or reach the rated speed interrupted A power cable was interrupted after the start Current without load is too high Failure in excitation (power factor too low out of step) Short circuit among turns Heating spots in the stator winding Interruption of the parallel wires or phases of the Rewind the stator winding stator winding Defective electrical connections Fans operating in the wrong direction Faulty cooling due to dirt in the heat exchanger (if applicable) Overload Excessive number of starts or load inertia excessively high Supply voltage too high, increasing the iron loss Stator winding overheats under Supply voltage is too low, making the current load too high Interruption in a power cable or in a winding phase Rotor scratches against the stator The operating condition does not correspond to the data on the nameplate Unbalance in the power supply (fuse burnout, wrong command) Ventilation blocked (air inlet or outlet) Make connections again Correct the direction of rotation of the fans Clean the pipes of the heat exchanger Measure the stator voltage, reduce load, check the motor application Reduce the number of starts Do not exceed 110% of the rated voltage, except otherwise specified on the nameplate Check the supply voltage and the voltage drop in the motor Measure the current in all the phases and correct Check the air gap, operating conditions (vibration...), bearing conditions Keep the operating condition according to the motor nameplate or reduce the load Check if there is voltage unbalance or operation with two phases and correct Unblock the air inlet and outlet CORRECTION Check the control panel, the power cables, the terminals Unlock the rotor Repair or replace the bearing Check the load characteristics at start Measure and compare the stator phase resistance Replace the defective rectifier Measure the power supply voltage, adjust the correct value Check the section of the power cables Check and repair the rotor bars (cage). Check the connection of the power cables Check the power factor and correct the failure in the excitation
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ABNORMALITY Heating spots in the rotor Heating in the damper winding (rotor) Abnormal noise during operation with load
POSSIBLE CAUSES Interruptions or failure in the insulation of the rotor winding Motor over-excited High negative sequence current Mechanical causes: The noise normally decreases when the speed reduces; see also: noisy operation when uncoupled Electrical causes: The noise ceases when the motor is shut down Contact the manufacturer Failure in the drive or driven machine Failure in the gear drive
CORRECTION Repair the rotor winding or replace it Check and correct exciting current Correct voltage unbalance; Check the harmonic line (correct); Check mechanical causes (balancing, alignment, coupling, bearings...) Perform electrical and magnetic analysis Check the power drive, the coupling and the alignment Align the drive, check the position of the gear box Align the motor and the driven machine Repair the foundation Perform new balancing Check the supply voltage and the current with no load Invert the connection of two phases Perform new balancing Measure the current input of all connecting cables Refasten and lock the bolts Balance the coupling Adjust the foundation Check flatness of the base Correct or replace the shaft Check the rotor balancing and eccentricity Check shaft warpage or bearing wear Adjust the load to the motor characteristics or dimension a new motor for the application Check cause of vibration and correct it
When coupled, there is noise; uncoupled, the noise disappears
Defect in the coupling Problems in the foundation Faulty balancing of the components or driven machine Power supply voltage is too high Wrong direction of rotation of the motor Unbalance Noise remains during deceleration after powering down the voltage Interruption in one phase of the stator winding Fastening bolts are loose
Noisy operation when uncoupled
The rotor balancing conditions become worse after the assembly of the coupling Resonance in the foundation Motor frame is deformed Crooked shaft Air gap is not even Overload
Sparking Excessive vibration
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11 WARRANTY TERMS
These products, when operated under the conditions stipulated by WEG in the operating manual for such product, are warranted against defects in workmanship and materials for twelve (12) months from start-up date or eighteen (18) months from manufacturer shipment date, whichever occurs first. However, this warranty does not apply to any product which has been subject to misuse, misapplication, neglect (including without limitation, inadequate maintenance, accident, improper installation, modification, adjustment, repair or any other cases originated from inadequate applications). The company will neither be responsible for any expenses incurred in installation, removal from service, consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation expenses of a technician when this is requested by the customer. The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do not give Warranty extension, unless otherwise expressed in writing by WEG. This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed or implied, written or oral. There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale. No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG nor to assume for WEG any other liability in connection with any of its products. In case this happens without WEG's authorization, Warranty is automatically cancelled.
LIABILITY Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any claims for consequential damages or labor costs, by reason of any breach of the express warranty described therein. The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action (other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or repair of any product described in this quotation and sold or furnished by the company to the purchaser.
WEG Equipamentos Eltricos S.A. International Division Av. Prefeito Waldemar Grubba, 3000 89256-900 - Jaragu do Sul - SC - Brazil Phone: 55 (47) 3276-4002 Fax: 55 (47) 3276-4060 www.weg.net
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ANOTAES
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WEG Equipamentos Eltricos S.A. Internation Division AV. Prefeito Waldemar Grubba, 3000 89256-900 - Jaragu do Sul - SC - Brasil Phone: 55 (47) 3276-4002 Fax: 55(47) 3276-4060 www.weg.net
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WEG Synchronous Motor Brushless

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Motors | Automation | Energy | Transmission & Distribution | Coatings

Synchronous Motors S line - Brushless - Horizontals

Installation, Operation and Maintenance Manual

11866576 - Brushless synchronous motors - Horizontals

11866576 - Brushless synchronous motors - Horizontals

Installation, Operation and Maintenance Manual

11866576 - Brushless synchronous motors - Horizontals

WEG EQUIPAMENTOS ELTRICOS S.A.

11866576 - Brushless synchronous motors - Horizontals

11866576 - Brushless synchronous motors - Horizontals

GENERAL INSTRUCTIONS .................................................................................12

RECEIVING, STORAGE AND HANDLING .............................................................14

ELECTRICAL CHARACTERISTICS ................................................................................................. 24

MECHANICAL CHARACTERISTICS ............................................................................................... 25

BRAKE ........................................................................................................................................... 29 HYDRAULIC UNIT .......................................................................................................................... 29

OTHER START METHODS............................................................................................................. 31

EXCITATION CIRCUITS .................................................................................................................. 32

7.2 7.3 7.4

7.5 7.6 7.7 7.8

MAINTENANCE OF THE COOLING SYSTEM..................................................................................39

BEARING MAINTENANCE ..............................................................................................................41

MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................48

10 ABNORMALITIES, CAUSES AND SOLUTIONS .....................................................50 11 WARRANTY TERMS ...........................................................................................52

11866576 - Brushless synchronous motors - Horizontals

11866576 - Brushless synchronous motors - Horizontals

SAFETY WARNINGS IN THIS MANUAL

In this manual, the following safety warnings are used:

11866576 - Brushless synchronous motors - Horizontals

MOTORS APPLIED IN AREAS OF RISK

11866576 - Brushless synchronous motors - Horizontals

CHARACTERISTICS OF THE ENVIRONMENT

VOLTAGE AND FREQUENCY

Rated characteristics point Frequency p.

Zone B (exterior to zona A)

Mechanical tolerances Balancing

11866576 - Brushless synchronous motors - Horizontals

3 RECEIVING, STORAGE AND HANDLING

11866576 - Brushless synchronous motors - Horizontals

3.3.3.1.2 Outdoor storage ATTENTION

3.3.3.2 3.3.3.1 Storage location

3.3.3.1.1 Indoor storage

Space heater ATTENTION

Exposed machined surfaces

11866576 - Brushless synchronous motors - Horizontals

3.3.3.6.1 Sleeve bearing

3.3.3.6.3 Grease-lubricated rolling bearing

3.3.3.6.2 Oil-lubricated rolling bearing

11866576 - Brushless synchronous motors - Horizontals

3.3.3.10.3 Checking the insulation resistance

Inspections and records during storage

Preparation for commissioning

3.3.3.10.2 Bearing lubrication

11866576 - Brushless synchronous motors - Horizontals

Maintenance plan during storage

11866576 - Brushless synchronous motors - Horizontals

Measuring stator windings

11866576 - Brushless synchronous motors - Horizontals

Measurement on the windings

Figure 4.1: Connection of the megohmmeter to the stator winding

11866576 - Brushless synchronous motors - Horizontals

Minimum insulation resistance

Conversion of measured values