Installation and Maintenance Manual

Horizontal and Vertical Mounted

Three Phase Squirrel Cage
Induction Machines Type

AMA 400-500

Machine type AMA ______________________________

Machine no

______________________________

Factory order no

______________________________

This manual has been checked. However, if any errors are found, we ask the user to notify us as
soon as possible.
The specified data is only a description of this product and should not be interpreted as binding
characteristics. In the interest of our customers we continually improve our product to the latest
technical development. Deviations between products and product descriptions or these operating
instructions can, therefore, occur.
We reserve all rights in this manual and in the information contained therein. Reproduction, use or
disclosure to third parties without express authority is strictly forbidden.

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THE MOST IMPORTANT IN GENERAL .....................................................................................4

1.1 Safety.................................................................................................................................4
1.2 Documentation ..................................................................................................................4
1.2.1 How to use this manual ........................................................................................4
1.2.2 Documentation of the machine.............................................................................4
1.2.3 Documentation of the starting, speed control and other equipment........................4
1.2.4 About this manual .................................................................................................4
1.3 Machine .............................................................................................................................5
1.3.1 Serial number of the machine...............................................................................5
1.3.2 Rating plate...........................................................................................................5
1.3.3 Mounting ...............................................................................................................5
1.3.4 Direction of rotation...............................................................................................5
1.3.5 Machine ends .......................................................................................................5
1.3.6 AMA machines type..............................................................................................5
1.3.7 Tools for the machine ...........................................................................................6
1.3.8 Normal operating conditions .................................................................................6
1.4 Safety instructions .............................................................................................................6
1.4.1 Low-voltage machines ..........................................................................................6
1.4.2 High-voltage machines .........................................................................................8
1.5 Limitation of liability..........................................................................................................10
1.6 Measuring unit conversion...............................................................................................11

TRANSPORT AND STORAGE .................................................................................................12

2.1 Protective measures prior to transport ............................................................................12
2.2 Packing and lifting ...........................................................................................................12
2.2.1 Machine on pallet................................................................................................12
2.2.2 Ocean freight package .......................................................................................12
2.2.3 Unpacked machine.............................................................................................12
2.3 Checks.............................................................................................................................13
2.3.1 Check on arrival..................................................................................................13
2.3.2 Check on unpacking ...........................................................................................13
2.4 Storage ............................................................................................................................13
2.4.1 Prior to installation ..............................................................................................13
2.4.2 Storage ...............................................................................................................13
2.4.3 Regular checking during storage ........................................................................15
2.4.4 Care after installation..........................................................................................15

PREPARATION FOR INSTALLATION......................................................................................16

3.1 General............................................................................................................................16
3.2 Check of foundation.........................................................................................................16
3.3 Disassembly of the transport locking device ...................................................................17
3.4 Assembly of the coupling halves .....................................................................................17
3.5 Drain plugs ......................................................................................................................17

INSTALLATION .........................................................................................................................18
4.1 General............................................................................................................................18
4.2 Preparations for installation of feet mounted machines ..................................................18
4.3 Anchorage to the foundation ...........................................................................................18
4.3.1 Grouting holes and machine supports ................................................................18
4.3.2 Shims and foundation studs ...............................................................................18
4.3.3 Erection onto the foundation...............................................................................19
4.3.4 Grouting ..............................................................................................................19
4.3.5 Final installation ..................................................................................................19
4.4 Alignment.........................................................................................................................19
4.4.1 Correction for thermal growth .............................................................................19
4.4.2 Levelling and adjusting equipment ........................................................................20
4.4.3 Rough levelling of the machine after erection.....................................................20
4.4.4 Rough axial alignment ........................................................................................20
4.4.5 Alignment check .................................................................................................21
4.4.6 Final inspection...................................................................................................21
4.4.7 Final installation ..................................................................................................22
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4.5
4.6
4.7
4.8

Installation of flange mounted machines ........................................................................ 22

Alignment analyzers........................................................................................................ 23
Laser optical alignment................................................................................................... 23
Belt drive......................................................................................................................... 23

COMMISSIONING .................................................................................................................... 24
5.1 Earth connection............................................................................................................. 24
5.2 Insulation resistance ....................................................................................................... 24
5.2.1 Checking the insulation resistance ....................................................................... 24
5.2.2 Measuring value................................................................................................. 25
5.3 Drying the windings......................................................................................................... 25
5.4 Protections...................................................................................................................... 25
5.5 Alarm and trip limits of the control equipment ................................................................ 25
5.5.1 Winding.............................................................................................................. 25
5.5.2 Bearings............................................................................................................. 26
5.6 Mechanical connections ................................................................................................. 26
5.7 Electrical connection....................................................................................................... 26
5.7.1 EMC requirements ............................................................................................. 27
5.7.2 Main terminal box............................................................................................... 27
5.7.3 Standard auxiliary terminal boxes...................................................................... 28
5.7.4 Connection of the external blower motors ......................................................... 28
5.8 Direction of rotation......................................................................................................... 29
5.9 Balancing of the rotor and the coupling .......................................................................... 29
5.9.1 Preliminary inspection........................................................................................ 29
5.9.2 Fitting instructions .............................................................................................. 29
5.9.3 Locking on vertical machines............................................................................. 29

STARTING OF OPERATION ................................................................................................... 30

6.1 Test start......................................................................................................................... 30
6.2 The first start................................................................................................................... 30
6.3 Supervision and maintenance during the first start ........................................................ 30
6.3.1 Machines with antifriction bearings ....................................................................... 30
6.3.2 Horizontal machines with sleeve bearings......................................................... 30
6.3.3 Vibrations ........................................................................................................... 31
6.3.4 Heat exchangers................................................................................................ 31

SUPERVISION OF THE OPERATION..................................................................................... 32

7.1 General ........................................................................................................................... 32
7.2 Number of starts ............................................................................................................. 32
7.3 Supervision ..................................................................................................................... 32
7.4 Follow-up ........................................................................................................................ 32

MAINTENANCE OF THE MACHINE ........................................................................................ 33

8.1 Bearings and lubrication ................................................................................................. 33
8.1.1 Antifriction bearings ........................................................................................... 33
8.1.2 Sleeve bearings ................................................................................................. 37
8.2 Heat exchangers............................................................................................................. 39
8.3 Filters of an upper cover ................................................................................................. 40
8.4 Maintenance of external blower motors.......................................................................... 40
8.5 Overhaul ......................................................................................................................... 40
8.6 Cleaning.......................................................................................................................... 40
8.7 Windings......................................................................................................................... 41
8.8 Maintenance painting...................................................................................................... 41
8.8.1 General .............................................................................................................. 41
8.8.2 Touch-up painting .............................................................................................. 41
8.8.3 Repainting.......................................................................................................... 42
8.8.4 Standards of the painting system and surface preparation ............................... 42

MAINTENANCE OF ELECTRICAL MACHINE WINDINGS ..................................................... 43

9.1 Need and scope of maintenance.................................................................................... 43
9.2 The maintenance program ............................................................................................. 43
9.3 Exterior inspection .......................................................................................................... 43
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9.4

Maintenance tests ...........................................................................................................44

9.4.1 Insulation Resistance Test..................................................................................44
9.4.2 Voltage Test........................................................................................................45
9.4.3 Tan delta-measurements....................................................................................45
9.5 Inspection ........................................................................................................................46
9.5.1 Observations.......................................................................................................46
9.5.2 Conclusions of the actions..................................................................................46
9.6 Cleaning the windings......................................................................................................47
9.6.1 Cleaning methods...............................................................................................47
9.6.2 Cleaning agents ..................................................................................................48
9.6.3 Drying..................................................................................................................48
9.7 Varnishing of the windings...............................................................................................49
9.8 Other maintenance operations ........................................................................................50
9.9 Maintenance of old windings ...........................................................................................50
9.10 Work safety principles with winding maintenance ...............................................................51
10

DISMANTLING AND REASSEMBLING THE MACHINE ..........................................................54

10.1. General............................................................................................................................54
10.2 Dismantling......................................................................................................................54
10.3 Reassembly.....................................................................................................................57

11

TROUBLE-SHOOTING GUIDE.................................................................................................60
11.1 General............................................................................................................................60
11.2 Electrical problem ............................................................................................................60
11.3 Bearing problem ..............................................................................................................60
11.3.1 Detection and identification of failures ................................................................60
11.3.2 How to detect the beginning of failures...............................................................60
11.3.3 Methods of failure identification ..........................................................................62

12

SPARE PARTS..........................................................................................................................63

13

REPORT SYSTEM AND CHECK SHEETS ..............................................................................64

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This chapter presents the basic concepts,

that you need to know about AMA squirrel
cage machines.


Besides the main dimensions, each machine

is supplied with a final dimension drawing
showing information on the following (as
applicable):

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Machine information

Checking systems

Appendices

Weight of machine

Instrumentation

Oil requirements for bearings having oil

lubrication

Load on foundation

Electrical connection diagrams for main and

auxiliary connections are also supplied with
each machine.

The checking systems presents check lists

and trouble shooting sheets, which help you
for inspection and for trouble shooting. The
check lists should be kept for reference
during maintenance work, trouble shooting
and repairs. The lists are not to be sent to
ABB.
The appendices presents drawings of machines
for example, foundation instruction, bearing
construction, etc.
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This manual does not include any information

about starting or speed control equipment
(e.g., liquid coupling, frequency converter
drive) connection diagram, cable blocks,
maintenance, etc. This information is
performed according to equipment manual.


The machine information presents the main

points of the machine construction and tasks
for the machine.



Mounting dimensions



This manual should be used with all others

machine documentation. This combination
gives accurate information of your machine.
The over all manual shall be read through.
The manual can be split in three different
parts:
-

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This general manual applies to squirrel cage

machines of the type AMA (400-500) made
by ABB. The manual covers both horizontal
and vertical mounted machines.
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Some customer specific items may

not be included in this manual.
Additional documentation should be
requested.

Careful study of this manual is essential to

ensure a long life time of the machines. The
manual is intented for AMA users of all
experience levels. The measuring units are
presented according to SI system and US
system. Unit conversion is found in chapter
1.6 when needed.

We recommend careful study off all machine

documentation before taking any action. The
instruction manual will be sent with each
machine, and it is located in a plastic cover
on the side of the machine.
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The direction of the rotation is shown with an

arrow plate located at the frame.

Machine is identified with a serial number. It

has always been stamped on the rating plate
(see chapter 1.3.2) and also on the frame. In
horizontal mounting machine it is located in
D-end of the frame beside the left lifting point,
and in vertical mounting machine it is on
mounting flange on the side of the terminal
box.




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In this manual the machine ends are

presented as follows (figure 3).
D-end (DE)
N-end (NDE)

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=
=

drive end
non-drive end
(opposite drive end)

A rating plate shows the machine type and

the most important data. It is located on the
machine frame. A standard rating plate is
shown in figure 1.

Fig. 3.

1
3
5
7
9
11
13
15
17
19

Serial number
Duty
Type of connection
Machine weight in kg
Type of cooling
D-end bearing type
Stator voltage
Rotating speed
Power factor (cos)
Direction of rotation

2
4
6
8
10
12
14
16
18

Year of manufacture
Type designation
Insulation class
Degree of protection
Mounting arrangement
Output in kW
Frequency
Stator current
N-end bearing type

only if bidirectional

Fig. 1.


Standard rating plate.

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In this manual mounting arrangements are

presented as in figure 2.

IM 1001
horizontal foot mounting
mounting

Fig. 2.

Machine ends.
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AMA machines are based on modular

construction. They have the output range
from 160 to 2500 kW at 50 Hz and from 250
to 4000 HP at 60 Hz with synchronous speed
from 500 to 3000 rpm at 50 Hz and from 600
to 3600 rpm at 60 Hz, as well as adjustable
frequencies are available. Voltage range
cover from 380 to 11500 V (AC). AMA
machines can be mounted horizontally or
vertically and the standard shaft heights are
400, 450 and 500 mm (16, 18 and 20 inch).
They are weather protected (IP23 / WPI,
IPW24 / WP II) or totally enclosed equipped
with air-to-air (IC611, TEAAC), or with air-towater (IC81W, TEWAC) heat exchanger
(figures 4, 5 and 6).

IM 4011
vertical flange

Fig. 4.

Weather protected AMA machine

IC01 IP23 / WPI, IPW24 / WP II.

Mounting arrangements.
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Fig. 5.

Air-to-water cooled AMA machine

IC81W IP54 / TEWAC.

Fig. 6.

Air-to-air cooled AMA

IC611 IP54 / TEAAC.

machine

The type designation of AMA machine is

established. The single symbols of the
designation are explained below.
Example:

Indication of special construction

E = Exe
T = separate ventilation
X = electrically special
N = Exn
F = frequency converter drive
Y = mechanically special
P = Exp
M = marine application
Z = special material specs

Origin, i.e., location of manufacture

C = Champagne (France)
H = Helsinki (Finland)
M = Vittuone (Italy)
O = Osasco (Brazil)



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It should be checked to see that the

necessary tools and erection equipment are
at hand in the plant, and whether they should
be procured. All tools and equipment should
be stored for future use.


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Normal operating temperature according to

IEC standard.

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Maximum operating height of

machine is 1000 m from sea level.

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Indicates $lternating Current 0achines

Indicates the type of machine, A =

Squirrel Cage Induction Machine



Shaft height in mm

/

Frame length, S = small, M = medium,

L = long

Number of poles

IC/IM combination,
D = IC01 / IP23 [WP I]
L = IC81W / IP54 (55) [TEWAC]
W = IC01 / IPW24 [WP II]
A = IC611 / IP54 (55) [TEAAC]
P = IC11, 21, 31 / IP23, 54, (55)
T = IC511 / IP54 (55)
R = IC411 / IP54 (55)

See chapter 1.5.

Mounting arrangement,
B = IM1001 (1002) horizontal
V = IM4011 vertical

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Bearing type,
A = antifriction
S = sleeve

standard

Surrounding air shall be free of dust, salt and

corrosive gases.
Each machine is individually designed and
manufactured to operate in normal or
abnormal operation conditions according to
customer specification.
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ABB s warranty is not valid, if

operation conditions will be changed
during machines lifetime.



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Low-voltage machines have dangerous live

and rotating parts and may have hot surfaces.
All operations serving transport, connection,
commissioning and maintenance are to be
carried out by responsible skilled personnel
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(in conformity with prEN 50110-1 / VDE 0105

/ IEC 364). Improper handling may cause
serious personal injury and damage to
property. Danger!

values 1 k per volt of rated voltage, dry

winding. Follow manufacturer's information.

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Make sure of even supporting surface, solid

foot or flange mounting and exact alignment
in case of direct coupling. Avoid resonances
with rotational frequency and double main
frequency as a result of assembly. Turn rotor,
listen for abnormal slipping noises. Check
direction of rotationin uncoupled state (mind
section electrical connection).

These low-voltage machines are intended for

industrial and commercial installations. They
comply with the harmonized series of
standards EN 60034 (VDE 0530). Their use
in hazardous areas is prohibited unless they
are expressly intended for such use (follow
additional instructions).
On noaccount use degrees of protection IP
23 outdoors. Air-cooled models are rated for
ambient temperatures of - 20C to + 40C
and altitudes of 1000 m above sea level.
Ambient temperature for air-/water-cooled
models should be not less than +5C (for
sleeve-bearing machines, see manufacturer's
documentation). Strictly observe different
instructions on the rating plate. Conditions on
site must conform to all rating plate markings.
1RWH

Low-voltage machines are components

for installation in machinery as
defined in the Machinery Safety
Directive 89/392/EEC. Commissioning
is prohibited until conformity of the
end product with this directive has
been established (follow particular
local safety and installation rules as
e.g. EN 60204).

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Follow manufacturers instructions when

mounting or removing couplings or other
drive elements and cover them with touch
guard. Avoid excessive radial and axial
bearing
loads
(note
manufacturer's
documentation).
The balance of the low-voltage machine is
indicated on the shaft end face or on the
rating plate (H = half, F = full key). In case of
half-key design, the coupling, too, must be
half-key balanced. In case of protruding,
visible part of key, establish mechanical
balance.
Make necessary ventilating pipe connections, if
any. Models with shaft end pointing upward
are to be provided with a cover by the
customer to prevent foreign objects from
falling into the ventilator. The ventilation must
not be obstructed and the exhaust air, also of
neighbouring sets, not taken in directly.
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Immediately report damage established after

delivery to transport company. Stop
commissioning,
if
necessary.
Tighten
screwed-in ring bolts before transport. They
are designed for the weight of the low-voltage
machine,
do not apply extra loads. If
necessary,
use
suitable,
adequately
dimensioned means of transport (e.g. rope
guides). Remove shipping brace (e.g.
antifriction or sleeve bearing locks, vibration
dampers) before commissioning. Reuse it for
further transports.
When low-voltage machines are stored,
make sure of dry, dust-free, low-vibration
(Vrms 0.2 mm/s) environment (danger of
bearing damage at rest). Before commissioning,
measure insulation resistance. In case of

All operations may be carried out only by

skilledtechnical personnel on the low-voltage
machine at rest. Before starting work, the
following safety rules must be strictly applied:
-

De-energize!

Provide safeguard against reclosing!

Verify safe isolation from supply!

Connect to earth and short!

Cover or provide barriers

neighbouring live parts!

De-energize auxiliary circuits (e.g. anticondensation heating)!

against

Exceeding of the tolerances specified in EN

60034-1(VDE 0530, Teil1), i.e. voltage 5%,

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frequency 2%, waveform, symmetry, leads

to elevated temperatures and affects the
electromagnetic compatibility. Take account
of rating plate markings and of connection
diagram in terminal box.
The connection must be so made as to
maintain a permanent safe electrical
connection (no loose wire ends). Use
appropriate cable terminals. Establish and
maintain safe protective conductor connection.
Minimum clearances between uninsulated
live parts and between such parts and earth
must not be below the following values: 8 mm
at UN 550 V, 10 mm at UN 725 V, 14 mm
at UN 1000 V.
No presence of foreign objects, dirt or
moisture is allowed in the terminal box. Close
unused cable entrance holes and the box
itself in a dust- and watertight manner.
For trial run without output elements, lock
fitting key For low-voltage machines with
accessories, checksatisfactory functioning of
thesebefore commissioning.
The proper installation (e.g. segregation of
signal and power lines, screened cables etc.)
lies within the installer's responsibility.
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Vibration severities in the "satisfactory" range
(Vrms 4.5 mm/s) according to ISO 3945 are
acceptable in coupled-mode operation. In
case of deviations from normal operation - e.g.
elevated temperature, noises, vibrations disconnect machine, if in doubt. Establish
cause, consult manufacturer, if necessary.
Do not defeat protective devices, not even in
a trial run. In case of heavy dirt deposits,
clean cooling system at regular intervals.
From time to time, open closed condensate
drain holes, if any.

oil supply system make sure the system is

working.
Refer to manufacturer's documentation for
sound power level and information about the
use of appropriate sound-reducing measures.
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Follow manufacturer's operating instructions.
1RWH

For further details, see our

comprehensive operating manual.
Preserve these safety instructions!



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High-voltage machines rated at more than 1

kV have dangerous live and rotating parts
and may have hot surfaces. All operations
serving transport, connection, commissioning
and maintenance are to be carried out by
responsible skilled personnel (in conformity
with prEN 50110-1 / DIN VDE 0105 / IEC
364). Improper handling may cause serious
personal injury and damage to property.
Danger!
,QWHQGHGXVH
These high-voltage machines are intended
for industrial and commercial installations.
They comply with the harmonized series of
standards EN 60034 / DIN VDE 0530. Their
use in hazardous areas is prohibited unless
they are expressly designed for such use
(follow additional instructions).
On no account, use degrees of protection IP
23 outdoors. Air-cooled models are rated for
ambient temperatures of -20C up to 40C
and altitudes of 1000 m above sea level.
Ambient temperature for air-/water-cooled
models should be not less than +5C (for
sleeve-bearing machines, see manufacturer's
documentation). Strictly observe different
instructions on the rating plate. Conditions on
site must conform to all rating plate markings.

Regrease antifriction bearings while the lowvoltage machine is running. Use right kind of
grease. Follow instructions on lubricating
plate. The possible grease collector box
should be emptied every third time.
In case of sleeve-bearing machines, observe
time-limit for oil-change and if equipped with
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1RWH

High-voltage machines are components

for installation in machinery as
defined in the Machinery Safety
Directive 89/392/EEC. Commissioning
is prohibited until conformity of the
end product with this directive has
been established (follow particular
local safety and installation rules as
e.g. EN 60204).

7UDQVSRUWVWRUDJH

visible part of key, establish mechanical

balance.
Make necessary ventilating pipe connections, if
any. Models with shaft end pointing upward
are to be provided with a cover by the
customer to prevent foreign objects from
falling into the ventilator. The ventilation must
not be obstructed and the exhaust air, also of
neighbouring sets, not taken in directly.
(OHFWULFDOFRQQHFWLRQ

Immediately report damage established after

delivery to transport company. Stop
commissioning,
if
necessary.
Tighten
screwed-in ring bolts before transport. They
are designed for the weight of the highvoltage machine, do not apply extra loads. If
necessary,
use
suitable,
adequately
dimensioned means of transport (e.g. rope
guides). Remove shipping brace (e.g.
antifriction or sleeve bearing locks, vibration
dampers) before commissioning. Reuse it for
further transports.
When high-voltage machines are stored,
make sure of dry, dust-free, low-vibration
(Vrms 0.2 mm/s) environment (danger of
bearing damage at rest). Before commissioning,
measure insulation resistance. In case of
values 1 k per volt of rated voltage, dry
winding. Follow manufacturers information.
,QVWDOODWLRQ
Make sure of even supporting surface, solid
foot or flange mounting and exact alignment
in case of direct coupling. Avoid resonances
with rotational frequency and double main
frequency as a result of assembly. Turn rotor,
listen for abnormal slipping noises. Check
direction of rotationin uncoupled state (mind
section electrical connection).
Follow manufacturers instructions when
mounting or removing couplings or other
drive elements and cover them with touch
guard. Avoid excessive radial and axial
bearing
loads
(note
manufacturer's
documentation).
The balance of the high-voltage machine is
indicated on the shaft end face or on the
rating plate (H = half, F = full key). In case of
half-key design, the coupling, too, must be
half-key balanced. In case of protruding,

All operations may be carried out only by

skilled technical personnel on the highvoltage machine at rest. Before starting work,
the following safety rules must be strictly
applied:
-

De-energize!

Provide safeguard against reclosing!

Verify safe isolation from supply!

Connect to earth and short!

Cover or provide barriers

neighbouring live parts!

De-energize auxiliary circuits (e.g. anticondensation heating)!

against

Exceeding of the tolerances specified in EN

60034-1 (VDE 0530, Teil1), i.e. voltage 5%,
frequency 2%, waveform, symmetry, leads
to elevated temperatures and affects the
electromagnetic compatibility. Take account
of rating plate markings and of connection
diagram in terminal box.
The connection must be so made as to
maintain a permanent safe electrical
connection (no loose wire ends). Use
appropriate cable terminals. Establish and
maintain safe protective conductor connection.
Minimum clearances between uninsulated,
live parts and between such parts and earth
must not be below the following values: 36
mm at UN 3.3 kV, 60 mm at UN 6.6 kV,
100 mm at UN 11 kV.
No presence of foreign objects, dirt or
moisture is allowed in the terminal box. Close
unused cable entrance holes and the box
itself in a dust- and watertight manner.

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For trial run without output elements, lock

fitting key For high-voltage machines with
accessories, checksatisfactory functioning of
thesebefore commissioning.



/LPLWDWLRQRIOLDELOLW\

The proper installation (e.g. segregation of

signal and power lines, screened cables etc.)
lies within the installers responsibility.

General conditions according to Orgalime

S92. ABB s warranty covers manufacturing or
material defect, it does not cover the damage
caused by improper storage conditions,
incorrect installation, operating and using
against specifications.

2SHUDWLRQ

1RWH

Vibration severities in the "satisfactory" range

(Vrms 4.5 mm/s) according to ISO 3945 are
acceptable in coupled-mode operation. In
case of deviations from normal operation - e.g.
elevated temperature, noises, vibrations disconnect machine, if in doubt. Establish
cause, consult manufacturer, if necessary.
Do not defeat protective devices, not even in
a trial run. In case of heavy dirt deposits,
clean cooling system at regular intervals.
From time to time, open closed condensate
drain holes, if any.
Regrease antifriction bearings while the highvoltage machine is running. Use right kind of
grease. Follow instructions on lubricating
plate. The possible grease collector box
should be emptied every third time.
In case of sleeve-bearing machines, observe
time-limit for oil-change and if equipped with
oil supply system make sure the system is
working.

Warranty will remain valid only if:

before making any changes in the
construction or repair work to the
machine, you have received approval
from the ABB office / factory who has
supplied you with machine.

If operation conditions, supply or load will be

changed during machines lifetime, ABB s
warranty is not valid.
Local ABB office may hold different
guarantee details, which are specified in the
sales terms, conditions, or guarantee terms.
If you have any questions, please contact
your local ABB representative or the factory:
ABB Industry Oy
Induction Machines
Hiomotie 13
00380 Helsinki
FINLAND
Tel +358 10 222 2000
Fax +358 10 222 3565

Refer to manufacturers documentation for

sound power level and information about the
use of appropriate sound-reducing measures.
0DLQWHQDQFHDQGVHUYLFLQJ

Follow manufacturers operating instructions.

1RWH

For
further
details,
see
our
comprehensive operating manual.
Preserve these safety instructions!

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0HDVXULQJXQLWFRQYHUVLRQ

In this manual units of measure are based on the SI (metric) system and the US system. If
somewhere in these documents the units are presented in only a single system, the conversion can
be performed using the following formulas. Some precalculated temperature conversions are
presented in table 1. A few useful conversion factors are presented in table 2.

C =

Temperature conversions F = 1,8 C + 32

F - 32
1,8

K = C + 273,2

Table 1. Precalculated temperature conversions.

C

10

20

30

40

50

60

70

80

90

100

110

32

50

68

86

104

122

140

158

176

194

212

230

PkW
0,746

Power conversions

Php =

Formulas for torque

TkNm =

PkW = Php 0,746

601/s PkW
2 n r/min

TNm =

9550 PkW
nr/min

Tlbf ft =

5250 Php
n r/min

Table 2. A few useful conversion factors

from US unit

to SI unit

81,7

from SI unit

to US unit

1 foot

0,3048 m

length

1 meter

3,280 ft.

1 inch

25,4 mm (0.0254 m)

"

1 mm = 0,001 m

0,039 in.

1 mil = 10-3 inch

0,0254 mm

"

1 square foot

929 cm2= 9,3x10-2 m2

1 square meter (m2)

10,76 sq.ft.

1 square inch

6,4516 cm2

"

1 square mil

6,4516 x 10-4 mm2

"

1 cubic foot

28,317 x 10 -3 m3

volume

1 cubic meter (m3)

35,30 cb.ft.

1 cubic inch

16,387 cm3

"

1 US gallon

3,785 dm3

"

1 liter = 1 dm3

0,264 gallons

1 pound

0,4536 kg

weight

1 kg

2.205 Ib.

1 US short ton

907 kg

1 pound / sq.ft.

4,8824 kg / m 2

1 pound/cubic foot

16,02 kg/m3

density

1 pound force-ft

1,356 Nm

torque

1 Nm

0,737 Ibf-ft

1 pound-sq. foot

0,04214 J

inertia

1 J = kgm2

23,73 Ib-ft2

1 pound force

4,448 N

force

1 N = kgm / s2

0,225 Ibf.

1 pound per sq.in

6,895 kPa

1 kPa

0,145 psi

area

"
pressure

pressure

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WR

To protect the bearings against damage

during transport, machines with cylindrical
roller or sleeve bearings are provided with
bearing locking device, irrespective of the
method of transport or distance.



2FHDQIUHLJKWSDFNDJH

When the machine is delivered in a wooden

box (figure 8), the lifting should be done by
using a forklift or a crane due to rigid
construction of the box. Normally the box has
been made of wood, but in special cases of
impregnated wood. The box is covered inside
with lamina paper.

The antifriction bearings are normally greased

with ESSO/EXXON UNIREX at the factory.
Sleeve bearings are bathed in oil during the
test before delivery. This gives sufficient
protection against corrosion for even the
longest transport distances.
Machined metal surfaces, such as shaft
extensions, are protected with an anti-corrosive coating before delivery.
To protect the machine properly against
water, salt spray, moisture, rust and vibration
during loading, sea transport and unloading
of the machine, it should be delivered in a
seaworthy packing box.


3DFNLQJDQGOLIWLQJ

Suitable hoisting equipment should be

available. The weight of the machine is
shown on the rating plate. It can also be
found from the dimension drawing or the
packing list.


Fig. 8.


Ocean freight package.

8QSDFNHGPDFKLQH

Lifting the machine should always be done

using the lifting eyes that are located on the
frame of the machine (figure 9). The machine
should never be lifted with a forklift from the
bottom. A lifting beam should be used to
avoid damaging the upper cover and the
main terminal box.

0DFKLQHRQSDOOHW

When the machine is delivered on a pallet,

the lifting can be done by crane from the
lifting eye(s) on the machine itself or by using
a forklift. The machine is fixed to the pallet
with bolts. Lifting possibilities are shown in
figure 7.

Fig. 7.

Lifting possibilities.

Fig. 9. The lifting eyes of the machines.

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The lifting of machines should be done as

shown in figures 10 and 11.



&KHFNRQXQSDFNLQJ

When the package has been removed, it

should be checked that the machine is not
damaged and that all accessories are
included. Report immediately to the supplier,
if there is any damage, suspect of damage or
if components are missing.
Use check list 3 and possibly 2 (chapter 13).

Fig. 10. Lifting of the horizontal mounting

machine.
Vertical mounting machine equipped with air
to air heat exchanger should be always lifted
with a lifting beam.



6WRUDJH



3ULRUWRLQVWDOODWLRQ

A machine that is not installed immediately,

e.g. a spare machine, should not be left
without supervision or protective precautions.
If the storage period is 6 months or more,
take special precautions. In this case, use
check list 4 (chapter 13).
If the machine is temporarily left outdoors or
in an open hall, it should be covered with a
tarpaulin. Do not lay the tarpaulins on the
cases; keep them about 30 cm (12 inch) from
the latter by draping them on laths or a
wooden frame, thus leaving space for
ventilation. The cases should be also
protected against ground damp by placing
them on battens or boards.


Fig. 11. Lifting of the vertical mounting

machine.


&KHFNV



&KHFNRQDUULYDO

When the transport company delivers the

machine to the customer, the responsibility
for the handling passes to the customer or
other party.
All damage, including damage in the
transportation box should be photographed.
Any transport damage must be reported
within one week after arrival, if the transport
insurance is to be claimed. It is therefore
important that evidence of careless handling
is checked and reported immediately to the
transport company and the supplier.
Use check list 1 and possibly 2 (chapter 13).

6WRUDJH

Machines with their associated control

enclosures are stored in their original
containers in a clean and dry warehouse. An
ideal warehouse for storage of electrical
machines maintains control of temperature,
dew point, dust, shock and vibration. The
surrounding air should be free of corrosive
gases. The machine should be also protected
against insects and vermin such as termites,
rodents, etc.
The storage area should be clean, dry and
ventilated and free of corrosive gases,
extreme indoor temperatures and high
relative humidity. The ideal storage
temperature range is from 10C to 50C
(from 50F to 120F) with a maximum relative
humidity of 75 %. If the relative humidity is
higher, the space heater should be turned on
to keep the machine 5C (9F) above the dew
point of the ambient air to prevent
condensation of moisture. This applies also
for high relative humidity. Check periodically
that the space heater is operating. If anticondensation heater is not fitted, an

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alternative method of heating must be applied.

Instead of heating, the machine can be
protected from humidity by using moisture
absorbing material, such as Silica-Gel.
The floor under the machine should be free
from excessive vibrations. If vibration is
present or may occur later, the machine
should be isolated by placing rubber blocks
(fit for the purpose) under the feet.
The anti-corrosive coating on blank metal
surfaces should also be checked. Any
corrosion on blank metal surfaces must be
removed with a fine emery cloth.
When the machine is stored in a wooden box,
small ventilation openings should be made as
shown in figure 12.

appropriately. The screws should be

tightened to the degree that the locking
requires. The tightening torque for the fixing
screw of the transport locking device is max.
10 Nm (7 Ibf-ft). A too tight fixing can damage
the bearing.
6OHHYHEHDULQJV
Horizontal mounting machines with sleeve
bearings are delivered without lubrication.
The inside of the bearings should be checked
for protective oil layer. Tectyl 511 or other
corresponding substance should be sprayed
into the bearing through the filling hole, if the
storing period is longer than one month. The
same procedure is required before sea
transportation. The Tectyl treatment is
repeated every six months for a period of two
years. If the storing period is longer than two
years, the bearing has to be taken apart and
treated separately. If the environment is
humid, a package of Silica-Gel can be placed in
the bearing case.
After storage it is recommendable that the
bearings are opened according to the
dismantling notes, and that the bearing
journal and lining are inspected before
commissioning. Any corrosion must be
removed with a fine emery cloth. If the shaft
has left imprints on the lower liner-half, it
must be replaced with a new one.
See check list 4 (chapter 13).

Fig. 12. Ventilation holes.

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The coolers and the piping within the

machine are to be cleaned and dried before
packing. The drying is made by blowing warm
air throug the pipes.

Antifriction bearings should be well lubricated

during the storage. If the storing period is
long, the amount of lubricating grease must
be monitored and added if necessary. Fully
penetrating lubricant grease for an operating
temperature range of -30C to +100C (-22F
to 230F) should be used. Good grease types
are presented in chapter 8.1.1.
To keep the antifriction bearings of the
machine in good condition, the rotor is turned
10 revolutions every two months. The end of
the shaft of the machine has been treated with
rust-proofing material. Rust-proofing must be
checked and performed again if needed.
Horizontal mounting machines with sleeve
bearings or roller bearings are equipped with
a locking system to be used during
transportation. Locking has to be checked

2SHQLQJV
If there are any openings where cables are
not connected up to terminal boxes, or piping
to flanges etc., these are to be temporarily
sealed up.
,QVSHFWLRQVUHFRUGV
The conservation methods are to be given a
final check and recorded together with the
date of the beginning of the conservation
period.

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5HJXODUFKHFNLQJGXULQJVWRUDJH

Check the following items every 6 months:

1

Check the following items every 3 months:

1

Insulation resistance:
The lowest rated value for insulation
resistance test at 40C (104F) is 40 M
[megaohms] (according to IEEE 43-1974
standard, IEEE recommended practice
for Testing Insulation Resistance of
Rotating Machines).

Check the temperature of the winding

(Pt-100).

Check that there is no rust on the

surfaces. If any rust is observed,
measures should be taken to remove
the rust and protect against it.

Check that the anti-corrosion agent has

not cracked on blank metal surfaces.

Dismount the upper cover of sleeve

bearing housing and check the anticorrosion protection of the shaft and the
bearing housing.



&DUHDIWHULQVWDOODWLRQ

If the machine is not in operation for a long

time after installation, the measures described
earlier in paragraph 2.4.2 apply. If high
external vibration is present, the shaft
coupling should be opened and suitable
rubber blocks should be placed under the
feet of the machine.

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Calculation and design of the foundation is

not included in the ABB undertaking and the
customer or the third party is therefore
responsible for it. Furthermore, the grouting
operation is also normally outside ABB
undertaking and responsibility.
The installation should be planned as early as
possible. The installation of the equipment
must be considered already at the project and
design stage of a plant. Also sufficient free
space should be left around the machine to
ensure easy access for maintenance and
monitoring. The cooling air should flow to and
away from the machine without obstruction.
If the machine has an open construction or is
equipped with an air-to-air cooling system,
care has to be taken that the machines near
the machine do not heat the machine s
cooling air. The incoming cooling air of the
machine must have the same temperature as
the surrounding air.
When a machine is purchased, available
lifting capacity, lifting height, roads for
transport, spare parts, installation tools etc.
should be checked.


The vertical machine is equipped with

mounting flange according to IEC-standard
publ. 72 (figure 13).

Fig. 13. Mounting flange of vertical machine.

The stress imposed on the foundation for
horizontal mounted machine can be
calculated with the aid of the following
formula and figure 14:
SI:

F = 0 .5 g m

where

= stress on foundation per side

= acceleration due to gravity

= weight of the machine

= max. torque of the machine

= distance between mounting holes [m]

&KHFNRIIRXQGDWLRQ

The foundation must be both strong and rigid

to avoid vibrations. Concrete foundation is
preferred, however, a correctly designed steel
construction is also acceptable. Provision of
air, water, and cable channels as well as
holes for the mounting feet should be
considered prior to construction.

4T
A

US:

F = 0 .5 W

4T
A

[N]
2

[m/s ]
[kg]
[Nm]

where

= stress on foundation per side

[lbf]

= weight of the machine

[lbf]

= max. torque of the machine

= distance between mounting holes

The foundation should be able to withstand a

sudden mechanical torque, which occurs
when starting the machine or at short circuit.
The short circuit force is a gradually damped
sine wave type vibration that changes
direction. The machine has to be tightly
bolted to the foundation, in order for the
machine to be as vibration free as possible
when in operation. The possibility of the
resonance with the foundation has to be
checked. The fixing bolts must be adequately
dimensioned to withstand short circuit forces.
Fig. 14. Dimension A.
3$0$HQ

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Before lifting the machine onto the foundation

following checks should be made:
1

Clean the foundation carefully.

The four machine feet are plain parallel

within 0.1 mm (4,0 mil) or better.

The foundation shall be flat and

adequately free from external vibration.

Check that the position of the grouting

holes and the height of the foundation
agree with corresponding measurements
on the drawing provided.

Attach a steel wire on the foundation to

indicate the centre line of the machine.
Mark also the axial position of the
machine.

Check that the drain holes in the bottom

of the machine are open.



Every time the machine is removed,

transported to another location or
stored, the transport locking device
must be fitted to the machine to avoid
bearing damage.

For machines with sleeve or cylindrical roller

bearings, the transport locking device is
made of steel bar attached to both the
bearing shield on the D-end and to the end of
the shaft. The locking system has to be
removed prior installation. The locking device
may be stored for future use.


As a standard the rotors are balanced with

half key. The way of balancing is stated on a
tape glued on the bearing cover in the D-end
and also stamped to the shaft end as follows:

$VVHPEO\RIWKHFRXSOLQJKDOYHV

half-key

full-key

When assembling the coupling halves, the

following instructions should be taken into
account:
1

Clean the shaft extension from anticorrosive coating and check measurements
of extension and coupling against the
drawings provided.

Prepare the assembly by checking

necessary tools and lifting arrangements.
Follow the coupling suppliers assembly
instructions.

'LVDVVHPEO\ RI WKH WUDQVSRUW

ORFNLQJGHYLFH

To avoid damage to the bearings caused by

vibration during the transportation, the
machine is equipped with a transport locking
device.
1RWH

bearings the driven equipment must be

axially locked to prevent axial forces against
the machine.

1RWH

No additional forces should be caused

to the bearings when assembling the
coupling half.



'UDLQSOXJV

The location of the drain plugs for AMA

machines are in the lowest part of the
machine.
For horizontal machines both drain plugs are
fitted at both ends of the machine.
For vertical machines two drain plugs are
fitted to the lower end shield.
There is also one plug in the bottom of the
main terminal box.
The drain plugs should always be open (half
of the plug inside and half outside).

When the machine is equipped with antifriction

bearings, it must be connected to the driven
equipment with flexible couplings (pin
couplings, gear couplings). In case of sleeve

The drain plug is constructed in such a way

that it keeps the dust outside the machine
and lets the condensation water to drain out.

3$0$HQ



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,167$//$7,21



*HQHUDO

of a replacement machine that has a different

height compared to the original machine.

The whole installation project should be

planned before machine delivery. It will
guarantee time saving and appropriate
installation. Safe running conditions with
maximum accessibility are assured. To avoid
resonance vibrations the foundation shall be
designed so that the natural frequency of
foundation together with machine is not within
20% range of running speed frequency.


3UHSDUDWLRQVIRULQVWDOODWLRQRIIHHW
PRXQWHGPDFKLQHV

When preparing for installation of the

machine, it is necessary to take following
aspects into account:
1

It is necessary to have at site sheet steel

material for shimming under the feet of
the machine. Possible adjustments require
shim thickness of 1, 0.5, 0.2, 0.1 and
0.05 mm (40, 20, 8, 4 and 2 mil). Shims
are normally not included in ABB
delivery.
Jacking screws for vertical positioning of
the horizontal mounted machine and
adjusting screws or hydraulic jacks for
axial and horizontal adjustment are
necessary to have at site. Jacking
screws for vertical positioning are
included in the ABB delivery.

Appropriate dial indicator gauges to

achieve accurate and precise alignment
within the tolerances specified must be
at site. Attachments should also be
made for these.

Before the rotor can be turned, oil has to

be filled into the sleeve bearings through
oil filling holes that are located on top of
the bearing housing. A simple lever arm
is needed for turning the rotor.



Foundation studs or base plates are used

when the machine is anchored to a concrete
foundation. If the order includes a foundation
stud set, each set consists four foundation
studs, four bolts for fixing the machine, four
shim plates 2 mm (0.8 inch) and two taper
dowels.


*URXWLQJ
VXSSRUWV

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PDFKLQH

The upper part of the foundation has to be

swept or vacuum cleaned. The grouting holes
are washed and rinsed.
Walls of the grouting holes must have rough
surfaces to give a good grip. For the same
reason they must be free from pollution. Oil
or grease must be removed by chipping away
slices of the concrete surfaces.


6KLPVDQGIRXQGDWLRQVWXGV

If the shims and the foundation studs are part

of the order, they will be delivered as loose
items. The assembly of these will be made at
site. When the assembly is done and the
machine is still suspended above the floor,
machine feet, sides and bottom surfaces of
the foundation plates as well as anchor bolts
are cleaned. To ensure that the foundation
studs are satisfactorily attached to the
concrete, they must be unpainted.
The foundation studs are assembled as
follows (see appendix 1 for the construction):
1

Screw greased levelling screw (5) to the

foundation plate (1).

Wrap a layer of tape around the upper

part of the anchor bolts (2) (shorter
threaded end) to the length shown in
appendix 1. The tape prevents this part
of the bolts from getting stuck in the
concrete.

Fit the anchor bolts (2) in the foundation

plate (1) so that the top of the anchor

When the machine is installed, sun and

rain protection must be provided to
eliminate measuring errors.

Shim plates 2 mm (0.8 inch) should always

be used between the machine feet and the
foundation (studs) to facilitate the installation

$QFKRUDJHWRWKHIRXQGDWLRQ

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bolts is 1...2 mm (40...80 mil) above the

upper surface of the nuts (3).
4

Fit the anchor flange (3) and the lower

nuts (4) to the anchor bolts (2). Bridge
the anchor flange (3) to the bolts by
welding and tighten the nuts. If the
bridging cannot be done, lock the anchor
flange between two nuts.
Center the fixing screw (6) at the first
mounting in the hole of the machine by
wrapping e.g. paper, cardboard or tape
around the upper part of the fixing
screw.

Place the shim (7) between the foot and

the foundation plate (1). Fasten the
foundation plate tightly against the foot
with a fixing screw.

Place the steel plate (under the levelling

plate) and levelling plate (8) in the
recess under the levelling screw (5). It is
easier to move the machine sideways
and in axial direction because of the
steel plate.

Check that the space between the

foundation plate (1) and the anchor bolts
(2) is tight. If concrete penetrates
through this interstice up to the nuts, the
retightening cannot be done.

1RWH

The tape and the steel plate are not

included in the delivery of the
foundation studs.

When the anchor bolts are tightened, the

machine is ready to be placed onto the
foundation.
During these working phases, general rules
as well as local instructions regarding safety
at work must be followed.


(UHFWLRQRQWRWKHIRXQGDWLRQ

The machine is lifted and placed onto the

foundation. A rough alignment is made with
the aid of the previously installed steel wire
and the marking of the axial location.
Required positioning accuracy is within 2 mm
(80 mil).



*URXWLQJ

Grouting of the machine into the foundation is

a very important part of the installation.
Problems can arise if materials are of poor
quality, which may show up early or after
several months of operation.
After the settings and alignment checks, the
foundation studs are grouted into the
concrete. The grouting instructions of the
supplier must be followed. Cracks in the
grouting compound or a poor attachment to
the concrete foundation cannot be accepted.


)LQDOLQVWDOODWLRQ

Retighten nuts (4) after the concrete has set.

Lock the nuts by bridging or hitting sufficiently
hard with a center punch.
Check the alignment so that the machine is
running within the permissible vibration. If
necessary, make the adjustment with shims,
and then complete the doweling according to
the holes in the feet at the machine D-end.
Store alignment and assembly accessories
together with the transport locking devices for
future use.
A test-run is made for the electrical machine
before the machine (coupling halves) is
connected, see chapter 6.1.


$OLJQPHQW

The following text refers both to installation

on a concrete foundation and a steel
construction. In case of concrete foundation,
shimming is not necessary.
This step must be performed with great
caution because alignment errors can easily
lead to bearing damages.


&RUUHFWLRQIRUWKHUPDOJURZWK

Temperatures have a considerable influence

and should therefore be considered during
the alignment. The machine temperature is
lower during erection than under operating
conditions. For this reason the shaft center is
going to lie higher during operating conditions. It
may be necessary to use compensating
alignment. This depends on the coupling type,
the distance between the machines, operating
temperature of the driven machine etc.

3$0$HQ



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The thermal growth of the electrical machine

(upwards) can be approximately calculated
according to following formula:
H = T H

Place the bracket plate against the foundation

edge and tie down the bracket by using an
expansion bolt.

where

H= thermal growth [mm]

-6

-1

= 10 10 K
T = 40 K

H = shaft height [mm]



/HYHOOLQJDQGDGMXVWLQJHTXLSPHQW

To facilitate the alignment in the vertical

plane, type M16 adjusting screws are fitted to
the feet of the horizontal machine and to the
counter flange of the vertical machine (figure
15). During the alignment, the coupling halves
must be loosely bolted together in order to
move freely when being rotated. When a
machine is aligned with another machine, the
cateral as well as the angular deviation
between the two shafts have to be minimized.

Fig. 17. Mounting the bracket plate.



5RXJK OHYHOOLQJ RI WKH PDFKLQH

DIWHUHUHFWLRQ

Check that the machine is vertically,

horizontally and axially in level by using for
example a spirit level. Make adjustments
accordingly by placing shims under the four
feet. The machine must stand on all four feet.


5RXJKD[LDODOLJQPHQW

The expected thermal growth of the rotor in

proportion to the stator frame, in case of fixed
bearing in the N-end, can be approximately
calculated according to the formula:
Fig. 15. Vertical positioning.
Possible adjustments require shim thickness
of 1, 0.5, 0.2, 0.1 and 0.05 mm (39, 20, 8, 4
and 2 mil).
Place the bracket plates, with adjusting
screws for horizontal and axial positioning of
the machine, at corners, as shown in figures
16 and 17.

L = T L

where

L = thermal growth [mm]

-6

-1

= 12 10 K
T = 50 K

L = frame length [mm]

When the rotor has axial float, check the
mechanical center position of the rotor.
As standard machines with sleeve bearing
are equipped with a pointer for magnetic
center. There are also grooves on shaft for
rotor end float limits. The pointer must always
be within the limits (figure 18).
The running center is not necessarily the
same as magnetic center.
The max. end float is 8 mm (0.315 inch).

Fig. 16. Positioning of bracket plates.

3$0$HQ

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mount the gauge to the coupling flanges by
means of suitable fastening devices.
It is practical to adjust the dial gauge in such
way that approximately half of the scale is
available in either direction.

Fig. 18. Rotor float center positioning pointer

(mounted on the outer seal of the
sleeve bearing).

All readings for radial and axial misalignment

are determined in the gauge positions: top,
bottom right and left, i.e. every 90, while both
shafts are simultaneously turned (figure 19).
Readings are recorded in table 1 and 2 of the
machine alignment sheet (check list 5,
chapter 13).

When there is axial float, the machine can not

withstand any axial force from the driven
machine. All axial force must be carried by
the driven machine. The coupling must be of
limited axial float type.
Move the machine at offset positioning by
using the four axial adjusting screws until the
desired distance between the coupling halves is
reached.

Radial misalignment
Gap (angular displacement) b
Axial displacement
a

Make sure that continuous free axial movement

is possible between the coupling halves
(excluding rigid couplings) in order to permit
thermal expansion of the machine shaft
without damaging the bearings.

Fig. 19. Alignment check.

Tighten the horizontal adjusting screws only

lightly when the machine is moved axially.

Maximum permissible radial misalignment

and axial displacement:

When the machine stands axially in its right

position, leave all adjusting screws only lightly
tightened.

r, a



$OLJQPHQWFKHFN

Every alignment check must be preceded by

a run-out measurement at the coupling
flanges. Record the results always in a log.
Check the run-out of each coupling half in
respect to the bearing housing by means of a
dial gauge.



)LQDOLQVSHFWLRQ

Rigid flange coupling r 0.02 mm (0.8 mil)

r 0.05 mm (2 mil)
Gear coupling
r 0.10 mm (4 mil)
Flexible coupling
b (coupling flange diameter 100...250 mm)
Rigid flange coupling b 0.01 mm (0.4 mil)
b 0.03 mm (1 mil)
Gear coupling
b 0.05 mm (2 mil)
Flexible coupling
b (coupling flange diameter 250...500 mm)

Admissible run-out error:

Rigid flange coupling b 0.02 mm (0.8 mil)

Gear coupling
b 0.05 mm (2 mil)
Flexible coupling
b 0.10 mm (4 mil)

0.02 mm (0.8 mil).

This measurement will show possible alignment
or installation inaccuracies.
If the run-out measurements verify that the
coupling flanges are in acceptable condition,

The normal accepted misalignments are as

above. A definite tolerance is impossible to
state because too many factors have an
influence.

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Do not use the tolerances given by the

coupling manufacturer for judgement of how
accurate the alignment should be, because
these tolerances indicate what the coupling
can survive. Too large tolerances will cause
vibration, bearing damage etc. and therefore
it is recommended to aim at as narrow
tolerances as recommended.
Check the rigidity of the gauge brackets to
eliminate the possibility of sag. Finally check
the axial distance between the two coupling
halves.
Draw up a record for future checks (check list
5, Alignment).


)LQDOLQVWDOODWLRQ

Tighten the fixing screws of the machine.

Check the alignment and that the machine is
running within the permissible vibration. If
necessary, make adjustment with shims and
then complete the doweling according to the
holes in the feet at the D-end of the machine.

r, a
Rigid flange coupling r 0.02 mm (0.8 mil)
r 0.05 mm (2 mil)
Gear coupling
r 0.10 mm (4 mil)
Flexible coupling
b (coupling flange diameter 100...250 mm)
Rigid flange coupling b 0.01 mm (0.4 mil)
b 0.03 mm (1 mil)
Gear coupling
b 0.05 mm (2 mil)
Flexible coupling
b (coupling flange diameter 250...500 mm)
Rigid flange coupling b 0.02 mm (0.8 mil)
b 0.05 mm (2 mil)
Gear coupling
b 0.10 mm (4 mil)
Flexible coupling
The normal accepted misalignments are as
above. A definite tolerance is impossible to
state because too many factors have an
influence.

Store alignment and assembly accessories

together with the transport locking devices for
future use.
Before the machines (coupling halves) are
connected, make a test-run for the electrical
machine (see chapter 6.1).


,QVWDOODWLRQ RI IODQJH PRXQWHG

PDFKLQHV

Vertical mounting machine will always be

mounted to the opposite flange which shall be
designed according to IEC standard. When
using mounting adapter coupling connection
and inspection during operation to make are
easy (figure 20). An adapter is not included in
the ABB delivery.

Fig. 20. Mounting adapter.

Check the misalignment after the machine
has been installed and coupled to the driven
machine (figure 21). Maximum permissible
radial misalignment and axial displacement:

Fig. 21. Checking the misalignment of the

flange mounted machine.
Because the tolerances given by the coupling
manufacturers indicate what the coupling can
survive, do not use them for judgement of
how accurate the alignment should be. Too
large tolerances will cause vibration, bearing
damage etc. and therefore it is recommended
to aim at as narrow tolerances as
recommended.
Check the rigidity of the gauge brackets to
eliminate the possibility of sag. Finally check
the axial distance between the two coupling
halves.
Draw up a record for future checks (check list
5, Alignment).

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It is practical to use a Machinery Alignment

Analyzer. The dial gauge measurements are
directly fed into the analyzer, which can be
connected to a personal computer.
Consequently, the measurements can be
printed out as they are taken.


%HOWGULYH

Machines for belt drives are always equipped

with cylindrical roller bearing in the D-end.
1RWH

Do not exceed the radial force

specified at the time when ordering
the machine.

/DVHURSWLFDODOLJQPHQW

Laser optical alignment is the most exact

shaft aligning method (figure 22). It comprises
the transmitter-localizer and the prism. The
transmitter is a laser diode. The transmitter is
mounted on one side of the coupling and the
prism is mounted on the other side. The laser
beam emitted by the laser diode is reflected
by the prism to the localizer. The offset can
be detected by rotating the shaft. This
aligning method is particularly useful when
the distance between the machines is long.

If a belt drive is used, make sure that the

driving and the driven pulleys are correctly
aligned.

Fig. 22. Laser optical alignment.

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&ULWHULDIRUKXPDQVDIHW\

Connect the machine frame, the terminal box

and the associated equipment to the earth
with suitable cable blocks. Earth connection
and the power supply have to be such that
harmful or dangerous potential can not be
created to the machine frame. Voltage of 250
mV between the shaft and the frame does
typically not cause any harm to the product
e.g. bearings. Mark the machine and terminal
boxes with earth symbol according to relevant
national standards.
1RWH

Warranty is not valid if bearing is

destroyed due to wrong earthing or
cabling.

Terminals of auxiliary equipment, which are

normally under voltage when the machine is
switched off (e.g. space heaters), are
correspondingly labelled.
1RWH

Circuit may be live.



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&KHFNLQJWKHLQVXODWLRQUHVLVWDQFH

Before a squirrel cage machine is started up

for the first time or after a long period of
standstill, the windings insulation shall be
checked.
Check the insulation resistance against earth
and
between
the
phases
before
commissioning, after longer idle periods or
within the scope of general maintenance
work.
The insulation resistance measurements
provide information about the humidity and
dirtiness of the insulation. Consequently,
necessary measures for cleaning and drying
can be determined. New machines and
machines with new windings have normally
very high resistance insulation. However,
unsuitable transportation or storage conditions
might subject the machine to such extremely
moist conditions that the insulation resistance
becomes far too low.

For safe (human safe) starting of the

machine, minimum acceptable insulation
resistance of the stator winding at temperature
40C (104F) can be determined by using the
following formula:
R40C = 1 + UN

where

R40C = insulation resistance [megaohms, M]

UN = rated supply voltage of the machine [kV]
&ULWHULDIRUGU\ZLQGLQJ
To judge if a winding has got moist higher
insulation resistance limits than those
defining the safe starting conditions (human
safety) must be considered. For a clean and
dry winding the insulation resistance value is
typically very high - in the order of thousands
of M. Depending on the winding type, the
insulation resistance value may be very
sensitive to moisture inside the machine. As
a thumb rule 1000 M is recommended to be
applied as the minimum accepted insulation
resistance value prior starting a machine.
In general, if a machine is suspected to have
got moist it shall be dried carefully
independent on the measured insulation
resistance value.
The insulation resistance value will decrease
when the winding temperature rises. The
resistance is halved for every 10 ... 15 K
temperature rise.
Usually the star point connection or delta
connection of high voltage machines can not
be opened. The insulation resistance must be
measured against the ground. If the phase
windings are not connected, each phase
must be measured separately, but if they are
connected, one measurement suffices (figure
23).
If it is possible to open the star point
connection, each phase must be measured
separately, with the other phases grounded
(figure 24).

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one decade or more lower than the value
measured in the factory, check the winding
for excess moisture or dirt, as well as the
calibration of the measuring device. The test
report contains the insulation resistance value
measured in the factory.



Fig. 23. Measuring the insulation resistance

of the whole winding.

'U\LQJWKHZLQGLQJV

If the windings have been affected by damp

to an extent that the insulation resistance is
too low, dry the windings. For drying the
winding see chapter 9 "Winding maintenance
for electrical machines".


3URWHFWLRQV

The machine has to be protected against

various disturbances that might damage it.
Protections must be in accordance with the
instructions and regulations for each country.

M
Fig. 24. Measuring the insulation resistance
of an individual phase.
Disconnect the power supply cables before
measuring the insulation resistance. To meet
safety requirements, the frame and the
windings not being tested shall be earthed
during the insulation resistance test.
Required notes and measures:
-

All resistance temperature detectors

(RTD) must be grounded.

Measurement device is checked.

All other groundings are done or checked.

Winding temperatures are measured.

Measuring values should be compared

with value which has been given in the
test report.

1RWH

After measurement the winding must

be grounded for discharging the
winding.



0HDVXULQJYDOXH

The insulation resistance of new machine is

normally very high. As a thumb rule it can
be taken that if the measured value is

Protective relays are used to protect the

equipment from different disturbances and
stresses, e.g. overloading in operation, or in
starting (like too long or too many consecutive
or stall startings), supply disturbances or
faults, switching errors, and insulation faults
like earth faults. The scope of relay protection in
practice depends on the actual application
characteristics, local network and other
protective means, which may be necessary.
The motor parameter values for relay settings
are informed in the document Performance
data of motor, which is delivered after order.
1RWH

ABB is not responsible for relay

settings at site.



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HTXLSPHQW



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5HVLVWDQFHWHPSHUDWXUHGHWHFWRUV57'
With Pt-100 and other corresponding elements,
alarm and trip temperatures should be set as
low as possible based on the test results and
operating temperature of the machine. Alarm
temperature can be set e.g., 10 K and trip
temperature 20 K higher than the operating
temperature of the machine at max load and
ambient temperature.
The maximum recommended values for
alarm and trip temperatures are:

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1 function:

trip

2 function:

alarm 160C (320F)

trip

160C (320F)

2 function:

trip

180C (355F)

Usually alarm and trip temperatures are set to:

1 function:

trip

2 function:

alarm 120-140C (250-285F)

trip

120-140C (250-285F)

130-150C (265-300F)

7KHUPLVWRUV37&
Based on the order the machine is equipped
with three or six thermistors. If the machine is
equipped with three thermistors, the
operating temperature of the thermistors is
150C (300F). Operating function can be
chosen to be alarm or trip signal. If the machine
is equipped with six thermistors, the operating
temperatures are 150C (300F) and 170C
(340F). In that case both alarm and trip
signals can be used.
In case of tripping, the reason must be found
out and eliminated before the machine is
restarted. Use trouble shooting 2 for finding
out the reason.


%HDULQJV

With Pt-100 and other corresponding

elements, alarm and trip temperatures can be
set as low as possible based on the test
results and operating conditions of the
machine. The maximum alarm and trip values
recommended for normal operating with
standard lubricants are:
$QWLIULFWLRQEHDULQJV
1 function:

trip

2 function:

alarm 85C (185F)

trip

alarm 85C (185F)

90C (195F)

90C (195F)

In case of tripping, find out the reason and

eliminate it before the machine is restarted.
Use trouble shooting 3 for finding out the
reason.


0HFKDQLFDOFRQQHFWLRQV

Machines equipped with an air-to-water heat

exchanger have flanges specified in standards
DIN 633 or ANSI B 16,5. Prior to starting the
machine, water has to be turned on. A check
for possible leaks must be performed.
Install all necessary oil pipes and connect the
oil circulating units in horizontal machines
equipped with sleeve bearings with forced
lubrication. Initially, clean all oil pipes and
rinse them with rinsing oil. A pressure gauge
and a flow indicator is often provided at the oil
inlet. These are normally already fitted before
delivery.
Install the outlet pipes at a minimum angle of
10 which corresponds to 160 to 170 mm/m
(2 - 2 in/ft). The oil level will increase if the
oil is flowing too slowly from the bearing
base. This can result in oil leaks or
disturbances in the flow.
The type of oil must be correct and the
amount of oil used sufficient. There is enough
oil in the bearing if half of the oil sight gauge
is covered. The class ISO VG is shown in the
dimension drawing of the machine. Correct
oil types are listed in chapter 8.1.2.
Install the oil circulating unit near the machine
in equal distance from each bearing. The
outlet oil pipes have to be at a minimum
angle of 10 which corresponds to 160 to 170
mm/m (2 - 2 in/ft). Test the oil circulating
unit by using rinsing oil before connecting the
tubes. After this, remove the oil filter and
clean it. Connect the pipes and fill the oil
circulating unit with oil after testing.

90C (195F)
For mechanical installation use check list 5.

The limits can be set 20C (70F) higher,

when high temperature grease is used.

6OHHYHEHDULQJV
1 function:

trip

(OHFWULFDOFRQQHFWLRQ

The whole electrical installation should be

planned before taking any action.
90C (195F)
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If making any installation of an

equipment on the frame, do not drill
the hole trough the frame.

used for the 360 high frequency earthing of

the cable screens at the cable entries.

(0&UHTXLUHPHQWV

Connection diagrams are delivered with the

machine has to be studied before starting the
installation work. It is important to verify that
the supply voltage and the frequency are the
same as the values indicated on the rating
plate on the machine.

Compliance with the EMC directive

(89/336/EEC, as amended by 93/68/EEC)
requires that the AC machine fed with
frequency converter is installed with screened
cables specified below. For information on
other equivalent cables, please contact your
local ABB representative.
0DLQFDEOHV
The main cable installed between the
machine and the frequency converter must
be a symmetrical three conductor screened
cable in order to fulfil the radiated emission
requirements stated in the generic emission
standard for industrial environment EN
50081-2. The cable types MCCMK and
AMCCMK from NOKIA KAAPELI and VUSO
and VO-YMvK-as from DRAKA KABEL have
been tested and approved by ABB Industry
Oy for low voltage (<1 kV) frequency
converter applications. Equivalent cables
from other manufacturers that fulfil the
requirements can be used in the installation
as well.



0DLQWHUPLQDOER[

The size of input cables have to be adequate

for the maximum load current and in
accordance with local standards. The cable
terminations have to be of appropriate type
and of correct size. The connection of all
devices, such as temperature probes, has to
be checked.
1RWH

Prior to installation work, it is

important to check that the incoming
cables are separated properly. The
cables should be grounded.

The stator terminal is marked with letters U, V

and W according to IEC 34-8 and with T1, T2
and T3 according to NEMA MG-1. A neutral
terminal is marked with N in IEC and with T0
in NEMA.

(DUWKLQJRIPDLQFDEOHV
The compliance with the EMC directive
requires high frequency earthing of main
cable. This is achieved by a 360 earthing of
the cable screens at the cable entries both in
the machine and in the converter. The
earthing at the machine is implemented for
example by means of the EMC ROX
SYSTEM cable transits for shielded
installations.
1RWH

360 high frequency earthing of cable

entries is done in order to suppress
electromagnetic disturbances. In
addition, cable screens have to be
connected to protective earth (PE) in
order to meet safety regulations.

Fig. 25. Main terminal boxes.

When the supply cables are connected U, V
and W and the phase sequence is L1, L2 and
L3, the machine will rotate in clockwise
direction when viewed from the D-end.
Main terminal boxes can be turned in 90
degrees steps. Before turning, check that the
length of the cables is sufficient.

$X[LOLDU\FDEOHV
The auxiliary cables must as well be
screened to meet the requirements of the
EMC directive. Special cable glands must be
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Fig. 29. Attachment of auxiliary terminal

box.
Fig. 26. Low voltage terminal box.

Auxiliary terminal boxes are equipped with

terminal blocks and cable glands (figure 30).
The size of the cables is limited to max 4
mm2, 750 V. Cable glands are in accordance
with DIN 46320 Teil 1.

Fig. 27. Medium voltage terminal box of the

IEC standard.

Fig 30.


Auxiliary terminal box.

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PRWRUV

The external blower motor is normally three

phase motor (figure 31). The motor rating
plate shows the voltage and frequency. The
rotation direction is indicated by an arrow on
the plate of the flange.
1RWH

Checking of the direction rotation

should be done before start the
machine.

Fig. 28. Medium voltage terminal box of the

NEMA standard.
For electrical installation use check list 6.


6WDQGDUGDX[LOLDU\WHUPLQDOER[HV

The auxiliary terminal boxes are attached to

the cover plates on both sides of the frame.
The plates protect the cables against
damages (figure 29).

Fig. 31. External blower motor.

If the motor is running in wrong direction, the
phase sequence should be changed.

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The direction of the rotation is shown with an

arrow plate located at the frame. The
machine may only be operated in the
specified direction of rotation.
Machines suitable for reversing operation are
labelled on the rating plate as well as the
direction of rotating plate with a doubleheaded arrow.


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FRXSOLQJ

A rotor is dynamically balanced at the factory.

A half key is used in the shaft extension
keyway unless otherwise agreed. The rotor,
i.e. the coupling half, shall be balanced with a
half key in the keyway. The end of the shaft is
marked with H (half key) or F (full key)
depending on which balancing has been
performed.


)LWWLQJLQVWUXFWLRQV

Thoroughly clean and dry all mating surfaces.

Never coat such surfaces with molybdenum
diosulphide (Molykote) or similar products. A
thin coating of oil on the shaft extension and
hub bore is recommended. In general the
coupling manufacturers instructions are valid
for mounting and removing the coupling
hubs. The weight of the coupling hub can be
considerable, therefore suitable lifting gear
must be available.


/RFNLQJRQYHUWLFDOPDFKLQHV

On vertical machines, the couplings are to be

locked against slipping in the axial direction
e.g. by a lock plate on the end of the shaft.

3UHOLPLQDU\LQVSHFWLRQ

Inspection of all functional parts is essential

before fitting a coupling for the first time. The
hub bore and shaft extension should be
checked against the dimensions specified in
the dimension drawing. It should be also
ensured that the keyways in the coupling and
the shaft extension are truly parallel.

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Test start is a standard procedure after all

devices, except the couplings, have been
connected. The squirrel cage unit should be
checked before starting.
1RWH

For sleeve bearing machines the oil

reservoir must be filled with
recommended oil to correct level.

The first start should last only about one

second. During that time check the direction
of the rotation and ensure that there are no
obstacles deterring free running of the
machine. In case of sleeve bearings, check
that stationary parts do not touch the rotating
parts.
After the initial test, the machine can be run
for a longer time. Check the temperature of
the winding and the temperature and
lubrication of the bearings. Check the oil level
or the oil pressure if the machine has sleeve
bearings.

Record all maintenance and service performed

on the maintenance card or in a computer
file. The temperature readings given by the
probes, placed in the windings and possibly in
the bearings, need to be checked to ensure
that they remain below the maximum limits.
Compare the load current with the value given
on the rating plate of the machine to check
the operating conditions of the machine.


0DFKLQHVZLWKDQWLIULFWLRQEHDULQJV

In case of a newly installed machine or a

machine which has been out of service for a
longer time, inject new grease immediately
after the start-up. When the machine is
running, make sure that the old grease and
the excess new grease are discharged
through the opening in the bottom of the
bearing housing.
The temperature of the bearing will initially
increase because of the excess grease. After
few hours the excess grease will be
discharged through the lubrication valve and
the temperature of the bearing will return to
normal.

Test run 1 and 2: check list 7-8 (chapter 13).



Measure the SPM-values from the SPMnipples and record them for future use as
reference values.

7KHILUVWVWDUW

When all procedures described in previous

chapters have been made, connect the
coupling and start the machine.
The first start is a normal start. Check the
temperatures of the windings and bearings
frequently and the squirrel cage unit. If the
operation seems normal, the machine can be
left running.
1RWH



When RTDs or equivalent are not

available surface temperature at
bearing area shall be measured if
possible. Bearing temperature is
approximately surface temperature
+10C (50F).
6XSHUYLVLRQ DQG
GXULQJWKHILUVWVWDUW

PDLQWHQDQFH

Factors essential for the operation of the

machine need to be checked regularly. These
factors include machine load, cooling and
operation of the bearings.



+RUL]RQWDO PDFKLQHV ZLWK VOHHYH

EHDULQJV

After the start-up, check that the stationary

parts do not rub against the rotating parts.
Pay also attention to the oil tightness of all
connections. A bearing inspection after
running on load for some hours during
commissioning or after changing shells or
segments still represents the best measure to
prevent damage.
The rotation of the lubrication ring is verified
through the inspection window on top of the
bearing. Check the temperature and the oil
level continuously in the beginning.
1RWH

When RTDs or equivalent are not

available surface temperature at
bearing area shall be measured if
possible. Bearing temperature is
approximately surface temperature
+10C (50F).

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In machines with circulating oil lubrication, the

oil pressure inside the bearing can be
adjusted if required. The normal oil pressure
is 125 kPa 25 kPa (18 psi 4 psi). The
gauge for adjusting the oil pressure is inside
the oil pipe. The rate of oil flow is given in the
dimension drawing (see appendix 10).


9LEUDWLRQV

If noticeable vibration is detected, measure

the vibration from the bearing cover or the
end shield from both ends. Compare the
measurements to the values written in the

commissioning report or in the prescribed

standard. It is useful to analyse the different
frequencies of the vibration, speed and twice
the net frequency.
For measuring vibration see chapter 8.1


+HDWH[FKDQJHUV

Prior to start, check that the connections are

tight and there are no leakage in the system.
After the start-up, the cooling system must be
checked.

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1RWH

A machine must be looked after and carefully

supervised to ensure trouble free running.


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The cooling air must be clean and

free corrosive materials.

If the cooling air contains dust, clean the

cooling surfaces of the unit regularly using
compressed air and a brush.

Check always before starting that no shutdown means have been forgotten and that
the lubrication and cooling are functioning.

3 Miscellaneous

The recommended maximum number of

start-ups is 1000 a year. Depending on the
machine
characteristics
and
starting
conditions, even higher values are allowed.
Abnormally high temperatures and stresses
can otherwise occur. Too many and too
frequent starts can accelerate ageing and
result in abnormally short life time.

For further information about these inspections

see next chapter.



6XSHUYLVLRQ

The operating personnel shall inspect the

machine frequently. The purpose of the
inspection is to thoroughly familiarize
personnel with the equipment. This is
imperative if abnormal occurrences are to be
detected and remedied in time.
It is vital that the inspections cover the
following points:
1 Bearings
-

- noise
- vibration level
- alarms and fault indications

Use check list 9 (chapter 13).



The border between supervision and

maintenance is rather diffused. Normal
supervision of operation includes logging of
operating data such as load, temperature etc.
The comments are used as a basis for
maintenance.
During the first period of operation (24 hours)
supervision should be intensive. Read the
temperature of winding and bearings every
hour. Check also load, current, cooling,
lubrication and vibration.
1RWH

check the bearing temperature

measure the SPM-values
feel the bearing
check the oil level or flow
check that there is no oil leakage
vibration

2 Cooling
- check the temperature of the stator
winding
- observe if the flow of cooling air is
normal
- feel the machine

)ROORZXS

When RTDs or equivalent are not

available surface temperature at
bearing area shall be measured if
possible. Bearing temperature is
approximately surface temperature
+10C (50F).

During the next period of operation (first

week) supervision should be done every 24
hours.
During normal use machine checking must
be done in conjunction with the regular
inspections, the maintenance of the driven
machine or during the relubrication.

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$QWLIULFWLRQEHDULQJV

The bearing in the N-end is axially fixed

downwards for vertical machines. In this case
the thermal growth will happen in the D-end.
This should be considered when adjusting the
coupling and moving the machine.

%HDULQJVROXWLRQV
The bearing constructions for different
bearing solutions are shown in appendices 26. Deep groove ball bearings both in the Dend the N-end is the standard solution. When
great radial forces appear, for example in belt
drives, a cylindrical roller bearing can be fitted
in the D-end. The complete bearing types are
stamped on the rating plate.
The bearing in the D-end is axially fixed for
horizontal machines when ball bearings are
used in both ends. This means that the
thermal growth will happen towards the Nend.
The bearing in the N-end is axially fixed for
horizontal machines, when a cylindrical roller
bearing is used in the D-end. In this case the
thermal growth will happen towards the Dend. This should be considered when
adjusting the coupling.

/XEULFDWLRQ
The lubricating system of the machine is
shown in appendices 2-5. Grease is injected
to the inner side of the bearing through the
grease passage. After filling the free space in
the bearing, excessive grease will be
discharged out from the bearing passing the
grease valve. The excessive grease comes
out through the opening in the bottom of the
bearing construction.
The machines are equipped with a greasing
nipple in both ends for lubricating the
bearings. The grease nipples are located on
side of the machine in both ends. The
amount of grease and the interval of greasing
are stamped on the relubrication plate. These
can also be read from tables 3 and 4.

Table 3. Relubrication intervals and amount of grease for horizontally mounted machines.
Bearing

Amount

Lubrication intervals in running hours at different speeds [rpm]

of
type

grease [g]

3600

3000

1800-1500

1200-1000

900-750

600-500

6317
6319
6322
6324
6326
6330
NU317
NU319
NU322
NU324
NU326
NU330

35
45
60
70
80
100
35
45
60
70
80
100

800
400

2200
1600

400

1100

8800
6600
6600
4400
4400
3300
4400
3300
3300
2200
2200
2200

8800
8800
8800
8800
8800
6600
8800
6600
6600
6600
6600
3300

8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
6600

8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800

3$0$HQ



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Table 4. Relubrication intervals and amount of grease for vertically mounted machines.
Bearing

Amount

Lubrication intervals in running hours at different speeds [rpm]

of
type

grease [g]

3600

3000

1800 - 1500

1200 -1000

900 -750

600 -500

6317
6319
6322
6324
6326
6330
7317
7319
7322
7324
7326
7330
NU317
NU319
NU322
NU324
NU326
NU330

35
45
60
70
80
100
35
45
60
70
80
100
35
45
60
70
80
100

400

1100
800

4400
3300
3300
2200
2200
1100
4400
3300
3300
2200
2200
2200
2200
1600
1600
1100
1100
1100

4400
4400
4400
4400
4400
3300
4400
4400
4400
4400
4400
3300
4400
3300
3300
3300
3300
1600

6600
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
3300

6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
4400
4400
4400
4400
4400
4400

1100
800

400

The lubrication interval stamped on the

relubrication plate is based on the bearing
temperature of 70C (158F). The size and
type of bearings, the speed and mounting
arrangement of the machine have also been
taken in consideration when fixing the
lubrication data. The lubrication interval
should be halved for every 15 K increase in
the bearing temperature.
If the temperature is noticeably under 70C
(158F), the lubrication interval can be
lengthened
to
some
extent.
Other
environmental conditions need also to be
taken into consideration.
Clean the grease nipples well before use to
prevent dirt from entering the bearings. Fill up
the grease pump gun used for lubrication
completely, leaving no air bubbles in the
grease. The grease shall be free from
impurities and water.

the bearings are lubricated at the

manufacturers work (ESSO UNIREX N2),
relubricate new bearings after few days of
use to ensure a long life time. The
recommended types of standard lubricants
are listed in table 5.
If lubrication intervals are very short due to
high bearing temperature (over 85C [185F]),
high temperature grease should be used.
Recommended types of high temperature
greases are listed in table 6.
1RWH

High viscosity grease (over 130 cSt)

for two-pole machines should not be
used due to high bearing temperature
at start.

If the ambient temperature may stay below

-25C (-13F), low temperature grease should
be used.

Carry out the lubrication of the bearings while

the machine is running normally. Although

3$0$HQ

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Table 5. Recommended standard lubricants.

Manufacturer

Quality

Thickener

Base oil

Temperature range
[C]

Kinematic
viscosity of
base oil
[mm2/s, cSt
at 40C]

Kinematic
viscosity of
base oil
[mm2/s, cSt
at 100C]

Consistency
[NLGI
scale]

ESSO

UNIREX N2

Li

Mineral

-30 to +165

115

12.2

ESSO

UNIREX N3

Li

Mineral

-30 to +165

115

12.2

ESSO

BEACON 2

Li

Mineral

-40 to +120

100

9.5

SKF

LGMT 2

Li

Mineral

-30 to +120

92

9.6

MOBIL OIL

Mobilux 2

Li

Mineral

-30 to +120

100

10.0

SHELL

Alvania Grease G2

Li/Ca

Mineral

-25 to +140

100

11

SHELL

Alvania Grease G3

Li/Ca

Mineral

-20 to +150

100

11

TEBOIL

Multi-Purpose
Grease

Li

Mineral

-30 to +110

110

10.5

BP

Energrease LS 2

Li

Mineral

-30 to +110

92

9.5

STATOIL

Uniway Li 42

Li

Mineral

-30 to +120

100

12.0

1RWH

AMA machines are lubricated in the factory with ESSO UNIREX N2, if nothing else is
specified.

Table 6. Recommended high temperature greases.

Manufacturer

Quality

Thickener

Base oil

Temperature range
[C]

Kinematic
viscosity of
base oil
[mm2/s, cSt
at 40C]

Kinematic
viscosity of
base oil
[mm2/s, cSt
at 100C]

Consistency
[NLGI
scale]

ESSO

UNIREX N3

Li-comp.

Mineral

-30 to +165

115

12.2

SKF

LGHT 3

Li-comp.

Mineral

-30 to +150

110

13.0

MOBIL OIL

Mobiltemp SHC 100

Inorga.

Synthetic

-40 to +200

100

12.5

SHELL

Syntix 100

Li-comp.

Synthetic

-40 to +150

100

21.0

TEBOIL

Syntex Grease

Li-comp.

Synthetic

-40 to +140

150

20.0

STATOIL

Uniway LiX 42 PA

Li-comp.

Polyalfa

-35 to +150

100

18.0

CHEVRON

SRI 2

Polyr.

Mineral

-30 to +150

115

14.0

NESTE

Rasva 606

Li-comp.

Synthetic

-40 to +150

150

20.0

0L[LQJSURSUHUWLHV
It is important to consider the miscibility of
greases if it is necessary to change from one
grease to another. If incompatible greases
are mixed, the consistency can change
dramatically and the maximum operating
temperature of the grease mix can be so low
compared to the original grease, that bearing
damage cannot be ruled out.
Greases having the same thickener and
similar base oils can generally be mixed
without any detrimental consequences, e.g. a
lithium base grease can be mixed with another

lithium base grease. Calcium and lithium

base greases are generally miscible with
each other but not with sodium base greases.
However, mixtures of compatible greases
may have a consistency which is less than
either of the component greases, although
the lubricating properties are not necessarily
impaired.
&RQWURORIWKHEHDULQJVZKHQUXQQLQJ
One way of detecting bearing damages is to
measure the shock pulse generated by
impacts as damaged surfaces are overrolled.
Measuring devices for this kind of measuring

3$0$HQ



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register the rapid sequence of minor shock

pulses caused by small irregularities. The
curve and shock pulse diagrams represent
bearing damage development and how it can
be followed with a shock pulse measuring
device.
Material fatigue is not the only possible cause
for deterioration of a bearing condition and
high shock pulse value readings. Bearing
condition and life time are largely affected by
installation, speed, load, lubrication and other
external factors, which also determine the
shock pulse value of a bearing.
After commissioning, and when the machine
is smoothly running on-load, register the
"initial shock values" (SV) of the bearings
using a shock pulse tester (e.g. SPMinstrument type T30) or a similar device. Fit
the measuring probe to the nipple provided
on the end shield. After a certain running-in
period, the SV measurement could decrease,
i.e. the bearing condition can improve.
Therefore, the initial SV measurement should
be taken as a reference value for further
measurements. Measurements should be
taken periodically with same speed, load,
measuring points and lubrication conditions,
never directly after relubrication.
6WDQGDUG630PHDVXULQJQLSSOHV
Measuring nipples are bolts that are installed
in threaded holes that have a cone-shape
ends in the bearing housings. They are
compatible with the quick connectors. The
material is zinc-coated steel. The external
dimensions are shown in figure 32.

the measuring results, a slide rule has been

included in the SPM instrument.
0RQLWRULQJUXQQLQJTXDOLW\
Another possibility to detect bearing failure by
vibration monitoring is to determine typical
defect frequencies. Every time a defect is
overrolled it causes a peak in the vibration
signal. The repetition of these peaks depends
on the position of the bearing defect (inner or
outer ring or a rolling element, etc.) and the
bearing geometry and speed.
The bearing defect frequency peaks generally
appear in the lower part of the frequency
spectrum (0-2 kHz), usually with harmonics.
The frequency depends on the bearing
speed, only for rotation speeds lower than
6000 r/min.
The decisive quantity is the rms value of the
vibration velocity measured on the bearing
housing. Measuring point arrangement in
accordance with ISO 3945.
ALARM

V = 7.1 mm/s

SHUTDOWN

V = 11.2 mm/s

RMS

RMS

In order to have a comparison with the

measured values, the vibration amplitude S
can be calculated as follows (supposing that
vibration is sinusoidal):

9
2 9rms
9
6$ = 2 rms =

0. 225 rms
2
I
I

where

6 = vibration amplitude [mm]

I = speed frequency [Hz]
A conversion nomograph with limit values is
shown in figure 33:

Fig. 32. SPM nipple.

Compare the new readings with the previously
measured values to see if there is any reason
to replace the bearing soon. For evaluation of
3$0$HQ

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the bearing plate of the bearing itself. The
bearings are rigidly mounted to the end
shields of the machine. The bearing in the Dend is usually the locating bearing (code B in
the type designation). This means that the
thermal growth will happen towards the Nend.
The bearing in the N-end is insulated. This
means that the inside spherical housing
surfaces are lined with nonconducting PTFE
film in order to avoid bearing currents (figure
35).

Fig. 33. Conversion nomograph with limit

values.
The bearing defect frequencies are in the
same range as the low frequency vibrations
caused by normal operation of the machine.
This is why it is often hard to distinguish
these peaks from normal machinery noise.
Use check list 10 (chapter 13).


6OHHYHEHDULQJV

%HDULQJVROXWLRQV
The sleeve bearing type used in AMA
machines is a side flange bearing. Middle
flange sleeve bearings can be used too
(figure 34).

Fig. 34. Middle flange sleeve bearing.

The bearings can be self or force lubricated.
The complete bearing types are stamped on

Fig. 35. Insulation films of the sleeve bearing.

The retention stopper in housing, which
prevents the bearing shell from dislocating, is
surrounded by a nonconducting sleeve. The
shaft seals and as well as the temperature
sensor
connection
are
made
of
nonconducting material. Measure insulation
resistance between the insulated parts of
bearing end shield or bearing pedestals and
the steel foundation every 3 months by using
a 500 V or max 625 V megger.
/XEULFDWLRQ
1RWH

Machines with sleeve bearings are

delivered without oil. The oil reservoir
must be filled with recommended oil
before startup. There is enough oil in
the bearing if half of the oil sight glass
is covered.

The oil level can be checked through a sight

glass located in the upper part of the housing.
Connections are provided for oil feed and
drain, thermometer and oil level checking on
both sides of the bearing. Oil is filled in
through the sight glass opening on top of the
bearing housing. The drain screw is located
in the bottom part of the housing.

3$0$HQ



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The oil used in the bearings must have a

viscosity value as defined in ISO 3448 class
or SSU. When rotation speed is greater than
1800 rpm, a lubricant defined in the standard
ISO VG 32 or 150 SSU/100F is usually
used. When rotation speed is between 1200
rpm and 1800 rpm, a lubricant defined in the
standard ISO VG 46 or 214 SSU/100F is
usually used. When rotation speed is 1200
rpm or less ISO VG 68 or 315 SSU/100F is
usually used. The type of oil that has to be
used for lubricating the bearing is given on
the lubrication plate of the machine.
1RWH

Permission to use the synthetic oil

should be asked from machine
manufacturer.

Table 7. Recommended lubricants.

1RWH

Manufacturer

Quality

EXXON

Terresso

GULF

Harmony

MOBIL

DTE

SHELL

Tellus Oil

TEBOIL

Larita Oil

NESTE

Paine

influences. The general condition of the oil

will provide information in this respect.
The housing is drained through the oil drain
hole (III) which is located centrally in the
bottom of the bearing. Filling is effected
through the bore of the sight glass (8) which
can be removed using an adjustable face
spanner. See figure 42.
When changing out the oil, special care
should be taken to rinse out contamination
and to remove oil sump residues (if possible,
the oil should be drained while the bearing is
still warm). If unusual alterations of the oil or
extra-ordinary residues are noted, it is
paramount to investigate and, if possible, to
remove the causes for this before putting the
bearing into operation again. If chemical
detergents are used they have to be
completely removed when the cleaning
process is finished.
For filling and re-filling use the same quality
of oil as specified for the application. The
dimension drawing should be referred for the
relevant indications.

The class ISO VG is shown in the

dimensions drawing of the machine.

To check the quality of oil, oil analyses should

be performed regularly. An oil analysis
performed by mineral oil companies may
form the basis for decisions as to whether the
oil in the bearing is still suitable for use.
&RQWURORIWKHEHDULQJVZKHQUXQQLQJ

0DLQWHQDQFH

Do the following:

Bearing housings has to be kept clean on the

outside, since the radiation of heat is reduced by
deposits of dust or dirt.
During the first 24 operating hours, the oil
flow, possible leaks and the level of vibration
are inspected every hour. Changing of a
possible oil filter must be done after 1000,
2000 and 3000 operating hours. Changing of
oil and cleaning of an oil filter must be
performed after 8000 operating hours.
In case of sleeve bearings with separate oil
supply system, oil is changed every 20000
operating hours.
Shorter intervals are required in case of
frequent starts and stops, high oil temperature
or excessive contamination due to external

Check the oil level and tightness of the

bearing.
Check the equipment regularly for
unusual noise.
Check the bearing temperature.

Vibration.

0RQLWRULQJUXQQLQJTXDOLW\
A possibility to detect bearing failure by
vibration monitoring is to determine the
typical defect frequencies.
The decisive quantity is the rms value of the
vibration velocity measured on the bearing
housing. Measuring point arrangement in
accordance with ISO 3945.

3$0$HQ

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ALARM

V = 7.1 mm/s

,QVSHFWLRQV

SHUTDOWN

V = 11.2 mm/s

Inspections are carried out as a part of the

preventive maintenance work. Inspections
are also necessary if the temperature
increases clearly by several degrees or if the
lubricating oil alters strikingly.

RMS

RMS

In order to have a comparison with the

measured values, the vibration amplitude S
can be calculated as follows (supposing that
vibration is sinusoidal):

9
2 9rms
9
6$ = 2 rms =

0. 225 rms
2
I
I

For an inspection it is sufficient to remove the

top part of the bearing while the bottom part
may be left on the machine. The bearing and
the work place are cleaned thoroughly before
disassembling.

where

Use check list 10 (chapter 13).

6 = vibration amplitude [mm]



I = speed frequency [Hz]

Machine of type IP54 IC611 IEC/BS or

TEAAC NEMA are equipped with air-to-air
heat exchangers (figure 37).

A conversion nomograph with limit values is

shown in figure 36:

+HDWH[FKDQJHUV

Noise damper

Air guide

Fig. 37. AMA machine with air-to-air heat

exchanger.
The tube type heat exchanger, which is
placed on top of the machine, does not have
to be dismantled for cleaning. Noise damper
and air guide must be removed before
cleaning. Dust and dirt can be removed using
a soft round brass wire brush, which is
pushed through each tube. Steel wire
brushes should not be used, because they
are too hard and can damage the tubes.
Machine of type IP54 IC81W IEC/BS or
TEWAC NEMA are equipped with air-towater heat exchangers (figure 38).

Fig. 36. Limit values.

Bearing defect frequencies are in the same
range as low frequency vibrations caused by
normal operation of the machine. This is why
it is often hard to distinguish these peaks
from normal machinery noise.

Fig. 38. AMA machine with air-to-water heat

exchanger.

3$0$HQ



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During the initial period of operation, the

cooling coil should be inspected frequently.
Prior to commissioning, the bolts at the ends
of the water cooler should be tightened. Other
than checking the water flow through the
cooler and the tightness of the connection
flanges.
Even if water filter is used, some fouling of
the cooling surface and the tube wall will
occure. This fouling reduces the cooling
capacity. The cooling coil should therefore be
cleaned at reqular intervals, depending on the
property of the water. Measures should be
taken to repair any damage, due to corrosion,
that may have occurred in the tubes or the
water chambers.
Fig. 39. Filters of an upper cover.
1RWH

Stop the machine and water before

cooler cleaning.



0DLQWHQDQFH RI H[WHUQDO EORZHU

PRWRUV

Drain the coil thoroughly. Remove the cooler

from the upper cover. Remove heading,
chambers and mark up the location of the
chamber to secure a correct mounting. Clean
the inside of the tubes by using the brush and
flush with water. Remove the old gasket and
clean the inside of the chamber.

The external blower motors are maintenance

free units, e.g. the bearings of external blower
motors are greased for life. A spare external
blower motor is recommended. The
maintenance of the blower motor is performed
according to motor s manual.





)LOWHUVRIDQXSSHUFRYHU

2YHUKDXO

Upper cover of the standard weather

protected machine WP / IP23 or WP /
IPW24, can be delivered with or without filters
according to customers specification (figure
39). By special order, the upper cover is
equipped with a differential pressure switch
for monitoring the condition of the filters. The
filter should be changed immediately after
alarm. It is also higly recommended that the
operating personnel manually inspect the
filters frequently.

When carried out at set intervals, every 2-4

years are recommended, overhauls allow
supervision of wear, early recognition of any
sign of damage and replacement of defective
parts in time. The extent of overhaul will be
mostly determined by the observations made
during operation. All inspection and dismantling
/reassembly work is to be performed by
suitably trained personnel. The first overhaul
should be performed after 500 starts or 8000
hours of operation whichever occurs first, but
not later than 2 years of operation.

How often the filters are changed depends

upon the cleanliness of the air in the
surrounding environment. If surrounding air is
sufficiently clean, the filters can be changed
during operation.



1RWH

Remove the filter from machine

before cleaning them.

The filters are washable. A stream of water or

cleaning solution can easily reach and flush
out collected dirt.

&OHDQLQJ

Before beginning the cleaning work, the

machine should be partially dismantled (as
far as practical). Components of austenic
steel can be destroyed by stress corrosion if
halogenous cleaning solvents are employed.
Therefore, electrical machines should only be
cleaned with non-halogenous solvents.
Mechanical dry cleaning should be used first,
"to get the worst off". Wet cleaning methods
should only be used for the main cleaning,
after thorough application of a mechanical
cleaning method. Standard cleaning agent,

3$0$HQ

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industrial benzene, should be used for

ordinary dirt and xylene may be required with
very gummy oil.


Before starting the maintenance

procedures
for
the
windings,
disconnect the machine from the
electric power source.



0DLQWHQDQFHSDLQWLQJ



*HQHUDO

SSPC-Vis 1-82

SFS-ISO 8501-1:1994 (SS 05 59 00)

St 2, Sa 1

SSPC = Steel Structures Painting Council

ISO = International Standards Organisation
SFS = Finnish Standards Association
If the entire surface has to be overcoated,
abrade the old topcoat to a rough finish.
Remove all dust and other cleaning residues.
$SSOLFDWLRQFRQGLWLRQV

Touch-up
painting
is
sufficient
for
maintenance when the rusted area is less
than 8% of the painted surface that means
that the rust grade is Ri1 Ri3 (ISO 4628 and
SFS 3762). Damages caused by transport or
installation may also be repaired by touch-up
painting.
Repainting is necessary for maintenance
when the rusted area is 8% or more (the rust
grade is Ri4 or Ri5).


:LQGLQJV

Maintenance of the windings is performed

according to the instruction "Maintenance of
Electrical Machine Windings", described in
chapter 9.
1RWH

The surface preparation is in accordance with

the following standards:

7RXFKXSSDLQWLQJ

If it is not possible to blast clean steel

surfaces to Sa 2.5 (SFS-ISO 8501-1) in
accordance with the original paint system, it
is recommended to use the following paint
system.
6XUIDFHSUHSDUDWLRQ
Remove any solid impurities. Remove watersoluble salts, grease and oil using an alkaline
solution or emulsions. Wash the surfaces
thoroughly with water.
Remove all loose paint. Remove rust by
power tool or wirebrush cleaning to minimum
St 2 - the best result is achieved by blast
cleaning. (SFS-ISO 8501-1). Level off the
edges between the old paint film and cleaned
up areas. When using blast cleaning, be sure
that there are no cracks in the remaining
paint film and do not cause damage for the
sealings.

Surface must be dry. The temperature of the

ambient air, surface or paint should not fall
below +10C / 50F during application and
drying. Relative humidity should not exceed
80%. The surface temperature of the steel
should remain at least 3C / 5F above the
dew point.
$SSOLFDWLRQ
Touch-up painting should be done by brush
or airless spray. Mix first the base and the
hardener separately before mixing the
components together. Total film thickness
should be the same as for the original paint
system. If the film thickness exceed 200 m,
application should be done with 2 layer and
both layers should have the same thickness.
The topcoat is not necessity but it can be
used if outward appearance is important. The
standard colour is blue (RALASEA C, TVT
B-062, Munsell 8B 4,5 / 3,25, NSC 4822B05G).
Surface treatment:
2-component high-solids, modified epoxy
aluminium paint (e.g. TEMASTIC ST 200)
100 200 m
2-component high-solids, modified epoxy
aluminium paint (e.g. TEMASTIC ST 200)
(only if necessary)
100 200 m
2-component epoxy or polyurethane topcoat
(not necessity)

3$0$HQ




$%%
5HSDLQWLQJ
Parts made of cold rolled sheet or light metal:

When the rusted area exceed 8 %, the entire

coating must be renewed. Remove the old
paint film and blast clean to Sa 2.5.
Recoating in accordance with the original
paint system.


6WDQGDUGV RI WKH SDLQWLQJ V\VWHP

DQGVXUIDFHSUHSDUDWLRQ

TP26 - EPUR 180/ 2 - Fe St2

Steel, cast iron and parts made of hot-rolled
steel:
SFS 4596: E 180-320/ 1-2 - Fe St2

SFS 4962: E 180-320/ 1-2 - Fe St2

SFS 4962: EPUR 320/ 2-3 - Fe St2
-

EPUR
320:
epoxy
undercoating,
polyurethane
finish
nominal
film
thickness 320 m

Fe: surface material

St2: wire brushing to the degree 2

Sa2.5: sand blasting to the degree 2.5

ISO 12944-5 / paint system 5.13 and 7.03.

SFS 4596: EPUR 180-320/ 2-3 - Fe St2

3$0$HQ

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0$,17(1$1&(2)(/(&75,&$/0$&+,1(:,1',1*6



1HHGDQGVFRSHRIPDLQWHQDQFH

The windings of rotating electrical machines

are subject to electrical, mechanical and
thermal stresses. The windings and insulation
gradually age and deteriorate due to these
stresses. Therefore, the service life of the
machine often depends on the insulation
durability.
Many processes leading to damages can be
prevented or at least slowed down with
appropriate maintenance. Windings in small
AC-machines usually require only minor
maintenance. The guidelines and instructions
in this section of the manual are valid for the
maintenance of windings in all large ACmachines.


7KHPDLQWHQDQFHSURJUDP

Principles:
-

Maintenance of the windings should be

arranged according to other machine
maintenance.

Maintenance only when necessary.

An important machine should be serviced

more often than a less important one. This
also applies to windings that become
contaminated rapidly, and to heavy drives.
Table 8 is an example of a simple maintenance
scheme. Users should, however, plan the
maintenance program according to their
machines, conditions, and processes.


([WHULRULQVSHFWLRQ

The correct temperature of the windings is

ensured by keeping the exterior surfaces of
the machine clean and by monitoring the
temperature of the cooling agent. If the
cooling agent is too cold, water may
condensate on the cold water - radiator, and
the mixture of cold and warm air might
produce mist. This can wet the winding and
deteriorate the insulation resistance. The
operating temperatures must be monitored
with resistance temperature detectors.
Significant temperature differences among
the detectors could be a sign of a damage in
the windings. Make sure that the changes are
not caused by the drifting of the measuring
channel.

Table 8. Maintenance scheme.

Type of machine

Inspection interval

Maintenance

1 Heavy drives

Periodic bearing inspection.

Check the temperatures and

vibration. Clean the outer surface
if necessary.

Once a year.

Open, inspect, clean, tighten

supports, re-varnish if necessary.

Every third bearing

inspection.

Check the temperatures and

vibration. Clean the outer surface
if necessary.

Every three to five years

(when changing the
bearings).

Open, inspect, clean, tighten

supports, re-varnish if necessary.

2 Form wound LV and HV

machines

3$0$HQ




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0DLQWHQDQFHWHVWV

7KH 3RODUL]DWLRQ ,QGH[ (PI) is given by the

relation:

ABB Service in many countries offers a

complete service package with several tests.


PI =

,QVXODWLRQ5HVLVWDQFH7HVW

51min
5
RU ( 10 min )
515V
51min

(IIHFW RI 7HPSHUDWXUH: The insulation

resistance usually decreases sharply due to
the temperature rise. This is shown by the
coefficient Kt in figure 40. By measuring the
winding temperature, one can determine the
coefficient Kt from the graph below. By
multiplying this coefficient Kt with the
measured insulation resistance of the winding
Rm, the corresponding insulation resistance
at a standard 40C, R40C, is determined:

3XUSRVH: The insulation resistance values

supply information on wetness and degrees
of contamination in the insulation. With this
information, one can prepare the necessary
cleaning and drying actions.
0HWKRG: When the nominal voltage of the
tested machine is less than or equal to 3 kV,
the test voltage is usually between 500 and
1000 V DC. If the nominal voltage of the
tested machine is higher than 3 kV, the test
voltage is usually between 1000 and 2500 V
DC. The insulation resistance values are
noted at fifteen seconds and one minute or at
one minute and ten minutes.

R40C = Kt Rm

(1)

100

10

0.1

0.01
0

10

20

30

40

50

60

70

80

90

100

110

Winding temperature,
Degrees Celsius C

Fig. 40. Correlation between the insulation resistance and the temperature.
Table 9. Temperature values in degrees Celsius (C) and degrees Fahrenheit (F).
C

10

20

30

40

50

60

70

80

90

100

110

32

50

68

86

104

122

140

158

176

194

212

230

3$0$HQ

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The polarization index is less dependent on

the temperature than the insulation
resistance. When the winding temperature is
below 50C (122F), it may be considered
independent of temperature. High temperatures
can cause unpredictable changes in the
polarization index, so it should not be used
above 50C (122F).
(IIHFWV RI GLUW DQG KXPLGLW\: The dirt and
humidity accumulating in the winding normally
reduce the insulation resistance and the
polarization index as well as their
dependence on temperature. Thus, the line
from Figure 40 becomes less steep.
Windings with open creepage distances (e.g.
from squirrel cage) are very sensitive to the
effects of dirt and humidity.
$FFHSWDEOH YDOXHV: There are several rules
of thumb for determining the lowest insulation
resistance value with which the machine can
be safely started. The probability of insulation
failure increases as the insulation resistance
deteriorates, but an absolutely safe value of
insulation resistance does not exist. Although
the insulation resistance value may be high,
conducting dirt collecting on one spot of the
creepage surface risks failure. In the US. [1],
the following equation is used for determining
the minimum acceptable insulation resistance at
40C:
(2)

R40C = 1 + U

where PI =

51min
.
515V

The PI is seldom used anymore because it

occasionally gives misleading values. For
instance, some very low PI values have been
measured
with
modern
epoxy-mica
insulations although the windings have been
dry and the insulation resistance high
(thousands of M). When estimating a
machines ability to start after a standstill, the
insulation resistance is more important than
the polarization index.


9ROWDJH7HVW

A voltage test is used to check for electrically

weak spots in the windings that may lead to
insulation failure during servicing. It is carried
out with greater maintenance work and
repairs. DC or AC voltage is used for the over
voltage test. DC voltage tests, although
seldom performed, use 1,6 times the rootmean-square value of the AC voltage. AC
voltage tests use the following test voltages:
-

for service and repair

1,2 U + 400

for periodical tests

1,5 U

[M]

[V]

[V]

where U = main voltage [kV]

where U = main voltage (V).

This value is compared with that determined

from Eq (1) and insulation measurements.
Insulation resistance values for machines
serviced at ABB Service are determined
using a standard temperature of 80C instead
of 40C as shown in the following equation:

1RWH

The higher voltage test is always

used
for
modern
epoxy-mica
insulations.



7DQGHOWDPHDVXUHPHQWV

(3)

R80C = 1 + U

[M]

where U = main voltage [kV]

The polarization index values usually range
between 1 and 4. When the windings are
humid and dirty, the PI is approximately 1.
As a thumb rule the following minimum
values may be applied to the PI:
-

for class A machines

PI = 1,5

for class B-F machines

PI = 2,5

Tan delta, representing the dielectric and

discharge energy losses, is measured in
steps of 0.2 U up to the main voltage U.
The rate of rise of tan delta as a function of
voltage describes the average partial
discharge level both inside and on the
surface of the insulation. This makes it
difficult to determine the condition inside the
insulation. It is emphasized that tan delta
measurements can not estimate the age or
predict failure of the insulation.

3$0$HQ



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,QVSHFWLRQ



2EVHUYDWLRQV

Hair cracks and fractures in metal parts such

as supporting bolts and squirrel cage
windings are also signs of deterioration, but
they take longer to develop a failure.

Winding inspections reveal information about:

-

the rate of contamination; presence of

dirt and humidity
radiator condensation and leakage
stability of bracings, vibration marks, and
cracking
marks of overheating.

All inspections should be recorded on the

enclosed maintenance form.
When examining WKH FRQWDPLQDWLRQ,
particular attention should be paid to the open
creepage surfaces, as the insulation
resistance is easily affected by the dirt
accumulating there.
Accumulating dirt blocking coil gaps and air
ducts diminishes the cooling capacity of the
machine. As a result, the winding temperature
increases, and the ageing may speed up
considerably.
Mechanical strain, vibration, and shocks may
produce cracks on the edges of the supports,
tyings, and around slot ends. Loose supports
and slot wedges are signs of further
deterioration. Abrasion marks and powder
near the supports, tyings, and at the slot
ends, must be checked. Complete loosening
of the slot wedges and bent coils are serious
problems that must be rectified immediately.

+XPLGLW\ in the winding is often shown by the

marks it leaves behind: rust on iron, drop
marks, dripping, and wetting marks on dirt
layers. Bush-like patterns, often charred and
left behind by the tracking currents, warn of
an approaching failure. In rare cases,
conductors are corroded.
Marks of the HOHFWULFDO HIIHFWV (apart from
tracking current marks), are usually hidden
inside the slot and conductor insulations.
6KRUW SHULRG RYHUWHPSHUDWXUHV can leave
marks all over the machine. Copper in the
squirrel-cage
windings
grows
darker
(darkening may also be due to the gases in
the environment), and it oxidizes. &RUH
ODPLQDWLRQV of the rotor become blue (over
350C [662F]) if the temperature rises due to
a jam or an exceedingly heavy start.
3URORQJHGSHULRGRYHUWHPSHUDWXUHV cause
premature ageing. The insulating materials
become brittle and darken in the early stages,
especially varnishes containing cellulose. As
a result, the windings split, disintegrate, and
fracture.


&RQFOXVLRQVRIWKHDFWLRQV

According to the observations the following

conclusions can be drawn for necessary
actions (table 10):

3$0$HQ

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Table 10. Observations and actions.

2EVHUYDWLRQ

$FWLRQ

Degree of contamination

a lot of dirt, cooling ducts about to be

plugged
conductive dirt, low insulation resistance
humidity, low insulation resistance

cleaning, and drying, if necessary

cleaning, and drying, if necessary

drying

cleaning and re-varnishing

remove old varnish and re-varnish

tightening *)
tightening, strengthen and re-varnish *)
strengthen or redo winding *)

cleaning and re-varnishing

redo windings

Finishing varnish

mat, worn, cracked

coming off

Supporting parts

loose slot wedges

vibration marks
bent coils

Ageing

darkening, slight embrittlement

embrittlement, loose insulation layer

*)



&OHDQLQJWKHZLQGLQJV

Accumulating dirt in the open creepage

surfaces should be removed. This is
especially important when re-varnishing the
windings because a new varnish coat will trap
any existing dirt beneath the new coat.


&OHDQLQJPHWKRGV

%ORZLQJDQGYDFXXPLQJ
Blowing and vacuuming are used if the dirt is
dry and can be removed easily. Vacuuming is
recommended, since blowing tends to
redistribute the dirt or move it deeper
between the insulation layers.
:LSLQJ
Wiping is used when spray-wash is not
possible. Surfaces easily reached are wiped
clean with a cloth dampened with detergent.
In cramped areas of the windings, a special
brush may be more effective.
6SUD\ZDVK
A spray wash is carried out with an airless
high-pressure spray or a conventional spray.
The high-pressure spray is more effective in

A statement from an expert is needed.

removing dirt. The detergent used should

remove the dirt without softening or
damaging the insulation. Use excessive
amounts of the cleaning agent.
'LSZDVK
A dip wash can be used if the detergent does
not soften or damage the insulation. Since
the dirt is not removed mechanically in this
method, a very effective cleaning and
scouring agent is needed. A long dipping time
may be required.
:DWHUZDVK
A water wash involves rinsing with water to
prevent the detergents from penetrating into
places where they can not be removed. A
water wash is done if needed following the
instructions given above for wiping, dip wash,
or spray wash. The detergents used are
described in Section 9.6.2.
After washing, the windings are rinsed with
pure water several times. It is recommended
to use distilled or deionized water for the last
rinse.
Drying after the water wash is necessary (see
Section 9.6.3).

3$0$HQ




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&OHDQLQJDJHQWV

Some features of the

described in table 11.


detergents

are

Before any cleaning agent is used, its

damaging effect on the old winding surface
should be checked. A suitable test can be
performed as follows:
Using a cloth wet with the cleaning agent, rub
the surface to be tested for five minutes.
Make sure that the surface remains
completely wet during this time. After rubbing,
try to remove the finishing varnish by thumb
nail. For comparison, do the same thing to a
dry part of the surface. If the surface layer is
soft or removed easily, the cleaning agent is
too strong.
For minimal environmental loading, water or
water-detergent mixtures should be used
when possible. If the dirt contains water
soluble agents, water PXVWbe used.
Substances that improve the cleaning power
should be added to the water to dissolve
grease-containing dirt. These detergents
should not leave electrically conductive
residues on the surfaces.
Water soluble solvents such as acetone and
isopropyl alcohol can also be used to improve
the cleaning effect. Note that such solvents
increase the flammability of the mixture.
If organic solvents must be used, cleaning
agents based on DOLSKDWLF K\GURFDUERQV
are recommended. Several manufacturers of
cleaning solvent mixtures are presently
developing such halogen-free cleaning
agents to replace the chlorinated solvent
mixtures used in the past.
:KLWH VSLULW is the most common organic
solvent. It is a good solvent for greases but
quite inefficient for pitch-like dirt on the
windings (produced by coal and burning
residues of diesel oil and humidity). White
spirit is also flammable (flash point 30...40C
[86...104F]). The cleaning capacity of white
spirit can be improved by adding 1.1.1trichlorethane to the solvent, however, the
use of chlorinated solvents is QR ORQJHU
UHFRPPHQGHG.

'U\LQJ

The windings must be dried after a wash

(especially a water wash and rinse) or if they
have become humid in use or during a
standstill.
The rate of temperature rise of the winding
should not exceed 5 K (9F) per hour, and
the final temperature should not exceed
105C (220F). A sudden temperature rise or
a too high final temperature can cause steam
to be formed in the cavities of the windings,
which in turn can destroy the windings.
During the drying process, the temperature
should be monitored periodically, and the
insulation resistance should be measured at
regular intervals.
A very wet machine should be dismantled
and the winding dried in the oven. Every part
should be checked. If the machine is not very
wet, the winding can be dried by passing a
current through it.
If the winding is dried by passing current
through it, the source of electricity could be a
welding generator or a similar device.
1RWH

When an electric current is used for

drying the windings, the rotor must be
first removed from the machine.
Direct current or alternate current can
be used.&XUUHQWFDQQRWH[FHHG
 RI WKH YDOXH RI WKH QRPLQDO
FXUUHQW, which is indicated on the
rating plate on the machine.

When drying in an oven, the temperature rise

and the maximum temperature should be
monitored carefully. The oven temperature
should be 90C (194F) for 12 to 16 hours
and then 105C (220F) for six to eight hours.
Effective drying is achieved with the proper
balance of heat and ventilation. The air inside
the machine should be circulated in the most
effective way.
Drying in an oven with good ventilation is the
most effective technique. Unfortunately, this
is not usually possible at the machine's
operating site. Therefore, either hot-air-blow
or heating the windings with current should
be used. Adequate fresh-air exchange is
essential, whatever heating method is used.
The drying of the windings should be followed
by insulation resistance tests. At the

3$0$HQ

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beginning of the drying treatment, the

insulation resistance decreases due to the
temperature rise. As the drying continues,
however, the insulation resistance increases
until it reaches a stable value.


9DUQLVKLQJRIWKHZLQGLQJV

A finishing varnish is a varnish or a resin coat

that is sprayed or brushed on the insulation. It
is a protective layer that seals the windings,
improves tracking resistance somewhat and
makes cleaning easier. In new machines
finishing varnish treatment is made optionally.
The finishing varnish may after long operating
time crack or peel off to certain extent. This
can be corrected by giving the ZLQGLQJV a
new coat of finishing varnish. Re-varnishing is
necessary when:
-

the old finishing varnish flakes, cracks or

peels off,

the surface of the winding is rough (dirt

sticks to it easily)

the materials on the surface of the

insulation or tyings have moved.

The windings should be cleaned with utmost

care before a new coat of varnish is given so
that no dirt will be left under this new coat of
varnish. Old finishing varnish that can come
off easily should be removed.
Varnish is usually applied with a spray (one or
two coats suffices). If the windings are still
warm after drying, the temperature should be
less than 40C (104F). One should try to
apply the varnish between the coils and other
parts that are not easily reached. Thick coats
of varnish should be avoided as they dry
slowly. Rotating parts should be left to dry at
least 24 hours at room temperature before
bringing them into use. Solvent fumes from
the varnishes are generally poisonous and
flammable, so safety at work should be taken
into account (see Section 9.10).

3$0$HQ



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Table 11. Features of the detergents for the winding.

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or become soft when tested with a fingernail,

the solvent may be used.

Some examples of repair maintenance are:

-

impregnation
tightening of the slot wedges
tightening of the supporting parts.

Determine from the manufacturer if these

operations are necessary. If they are, obtain
a detailed plan to carry them out.


0DLQWHQDQFHRIROGZLQGLQJV

The old finishing varnish type may be

unknown. When choosing the cleaning
solvent, make sure not to damage the old
coat of varnish (see Section 9.5.2). Test:
Rub the surface with a cloth moistened with
the solvent for a couple of minutes. If the
varnish does not dissolve, stick to the fabric,

Finishing varnish and surface materials may

be brittle and the insulations at the coil
overhangs may be soft and fragile, so avoid
hard pressing or rubbing when cleaning.
Finishing varnish that comes off on its own
should be removed. Re-varnishing is then
generally needed.
When re-tightening the slot wedges, make
sure that they are not too tight as the old
insulation might get damged. It is best to fix
the slot wedges with an adhesive resin.
When re-varnishing, ask the manufacturer
about the impregnation process and the
choice of finishing varnish. The type of
finishing varnish can be determined by testing
a small sample on the old surface and
checking the adhesion and quality. For
example, epoxy finishing varnish usually

3$0$HQ

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adheres well to old bitumen varnish,

increasing the resistance of the surface to oil
and solvents. Sometimes, it is best to use the
original finishing varnish when re-varnishing.
When drying, the construction of winding
insulation should be taken into account so
that the insulation does not get damaged.
Insulations consisting of cellulose and
micafolium should be dried slowly. The water
vapour should be allowed to escape without
causing a high pressure on the insulation,
making it swell or break; the highest drying
temperature range is 100C-110C (212F230F).


:RUNVDIHW\SULQFLSOHV ZLWK ZLQGLQJ

PDLQWHQDQFH

There are special instructions for handling

dangerous substances during maintenance
work. Important handling instructions can
also be found on warning labels of the
packing.
Some general safety measures are as
follows:
-

Avoid breathing air fumes; ensure proper

air circulation at the work site or use
respiration masks.

Wear gloves and suitable protective

clothing to protect the skin. One should
always use protective creams.

Spray-varnish equipment, the frame of

the machine, and the windings should be
earthed during spray-varnishing.

Winding maintenance involves:

-

handling hazardous solvents, varnishes,

and resins,

Do not smoke, eat, or drink at the work

site.

dealing with flammable solvents and

varnishes,

Take necessary precautions when

working in pits and cramped places.

testing at high voltage (HV).

Only people trained to do high voltage

work can carry out a voltage test.

Some dangerous substances are:

/,7(5$785(

white spirit:

solvent

1.1.1-trichloroethane: solvent

finishing varnish:

solvent and resin

adhesive resin:

epoxy resin

1)

IEEE Std. 43-1974, IEEE Recommended

Practice for Testing Insulation Resistance
of Rotating Machines

2)

IEEE Std. 432-1976, IEEE Guide for

Insulation Maintenance for Rotating
Electrical Machinery

3$0$HQ



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TEST RECORD

Machine, type

..............................

No:

..............................

..............................

No:

..............................
..............................

Annual inspection

Use

Inspection every 4 years

Voltage/output ..............................

Random inspection

Running hours ..............................

kW

Distribution ................................................ Date/inspected by ........................./..........................

1. Seals

OK o

Observations:

........................................................

2. Fixing air guiding plates etc.

OK o

Observations:

........................................................

3. Contamination

Stator
windings

Rotor
windings

Air
ducts

Cooling
radiators

Explanations

End
D

Total amount of dirt

Grease, oil
Dry dirt,dust
Dampness, rust

OK

Observations

4. Windings
4.1 AC stator
Support
Coils
Connecting cables
Core laminations
4.2 Asynchr. rotor
Ends of squir. cage windings
Keys of squir. cage ring
Core laminations

5. Fan
6. Cooling system
Visible radiator parts
Inner radiator parts
Flow-switch

7.Elect. connections
Main connection
Control gear

3$0$HQ

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8. Electrical test
Insulation resistance to earth

R 15 = .................. M R60 = .................. M

Winding temperature ...................

Voltage test 1 min o

Test voltage ................................

Operation test of protection o Voltage ...................... kV, DC voltage o AC voltage o

QUANTITY ESTIMATION
0 = clean
1 = slight
2 = plentiful (ducts about to plug)
3 = very plentiful (ducts plugged)

ESTIMATION BASIS
1 = dropping

12 = risen bars

2 = loosening

13 = battered

3 = cracking

14 = knocking: doubtful

4 = breaking

15 = corrosion

5 = dust, caused by vibration

16 = leakages

6 = swelling

17 = condensation

7 = darkening

18 = loose ribs

8 = embrittlement

19 = abrasion

9 = water marks

20 = noise from the bearing

10 = tracking

21 = another noise. What kind of ?

11 = hair cracks

22 = other flaws. What sort of?

3$0$HQ



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',60$17/,1*$1'5($66(0%/,1*7+(0$&+,1(



*HQHUDO

Before any attempt is made to remove covers

and end shields, disconnect the machine
reliably from the electrical supply.
1RWH

6)

Place the lifting hooks to the lifting

points of the machine frame.

7)

Remove the mounting screws of the

machine and lift it up.

8)

Turning the machine is done with one

hoist for lifting and another for tilting.

Mark each cable and wire before

disconnecting them.

Disconnect auxiliary cables for reassembly.

All necessary safety precautions should be
taken according to the regulations governing
the work.
Remember also:
-

Remove any top-mounted attachments.

Uncouple the machine.

Remove the hold-down bolts and dowel

pins.



,WHPV  IRU YHUWLFDO PDFKLQHV RQO\ VHH

DSSHQGL[

'LVPDQWOLQJ

,WHPVIRUPDFKLQHVHTXLSSHGZLWKDLU
WRDLUKHDWH[FKDQJHU
9)

Remove the end plate of the outer fan

cover.

10)

Remove the air guide of the outer fan.

11)

Remove the circlip of the outer fan and

remove outer fan by using the holes in
the fan hub. Remove also the key of
the fan.

12)

Place the lifting hooks to the lifting

points of the outer fan cover.

13)

Remove the mounting nuts of the outer

fan cover and lift it away.

,WHPVIRUPDFKLQHVHTXLSSHGZLWKDLU
WRDLU KHDW H[FKDQJHU RQO\ VHH DSSHQGLFHV
DQG
1)

2)

Place the lifting hooks to the lifting

points of the air guide cover (between
the upper cover and the outer fan
cover).
Remove the mountig screws of the air
guide cover and lift it up.

,WHPVIRUPDFKLQHVHTXLSSHGZLWKKHDW
H[FKDQJHUXSSHUFRYHU
3)

Place the lifting hooks to the lifting

points of the heat exchanger (upper
cover).

4)

Remove possible pipes, hoses,

instrument cables and/or earthing
cables between upper cover and
machine frame.

5)

Remove the mounting screws of the

heat exchanger (upper cover) and lift it
up.

,WHPV  IRU PDFKLQHV HTXLSSHG ZLWK

DQWLIULFWLRQEHDULQJV
When dismantling and reassembling the
machine, pay attention to the bearing
insulation at the N-end. AMA machines with
shaft heigts 400, 450 and 500 have insulated
bearing in N-end as option and in converter
supplied machines as a standard. The
purpose is to stop possible shaft currents
flowing trough the bearings. The bearing
housing at the N-end is insulated from the
end shield. The grease tubing is also
insulated. The insulation is shown in figure
41.

3$0$HQ

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1RWH

The bearing must be protected from

dust and moisture by wrapping it up
in e.g. waxed paper if the bearing is
going to be reused. Reusing is not
recommended.

,WHPV  IRU PDFKLQHV HTXLSSHG ZLWK

VOHHYH EHDULQJV VHH ILJXUH  DQG
DSSHQGL[
Fig 41.

The insulation of the antifriction

bearing.

Clean the bearing and the working place

thoroughly before disassembly.

Dismantle first the axially free bearing.

Different bearing constructions are shown in
appendices 2-5.

Dismantle first the D-end bearing.

23)

Drain off the bearing oil.

Horizontal machines:
- N-end bearing is axially free

24)

Vertical machines:
- D-end bearing is axially free

Disconnect possible oil pipe connections

and remove possible Pt-100 or
thermocouple and vibration probe of
the bearing.

25)

Remove the seal carrier (11).

14)

Remove the grease filling tube and

possible Pt-100, thermocouple or
vibration probe of the bearing.

26)

Remove the fastening screws of the

machine seal (14). This item for
bearing size EFZL_ 9 only.

15)

Remove the circlip of the grease valve.

27)

16)

Remove the grease valve. Use M12

threads for pulling out the grease
valve.

Unscrew the flange bolts of the top part

of the housing (2) on the machine end
shield (15) and the bottom part (1).

28)

Raise the top part of the housing

carefully just enough for the housing
joint to open evenly, then swing it out of
the machine end shield and lift it off.

29)

Mark the assembly position of the

upper bearing shell (4) and take it off
carefully.

30)

Unscrew the bolts of the oil ring (6) and

handle the two halves carefully in a
way not to affect their true geometric
shape.

17)

Loosen the outer bearing cover and

pull it away.

18)

Raise the shaft end by only a few

tenths of a mm by using a jack.

19)

Remove the end shield (the end shield

is drawn out by gently tapping the rim
of the shield). Use the threaded holes
to pull out the shield.

20)

Let down the rotor and remove the

jack.

31)

21)

Pull out the bearing. Use an adequate

bearing withdrawal tool set which will
apply pressure only on the inner
bearing ring.

Open the garter springs of the shaft

seals (9 and 10) by turning left on the
lock and remove the shaft seals.

32)

Raise the shaft end by only a few

tenths of a mm just enough to relieve
the lower bearing shell (3). Use a jack.

33)

Swing the lower bearing shell (3) up

and lift it up.

34)

Remove the housing bottom part (1).

After that remove the end shield (15)

22)

Remove the springs which preload the

bearing (axially free bearings only). Pull
away the inner cover.

3$0$HQ



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with the machine seal (14). Use the
threaded holes to pull out the shield.

35)

36)

Dismantling the N-end bearing.

37)

Drain off the bearing oil.

This item for bearing size EFZL_ 11

and EFZL_ 14 only.

38)

Remove the end shield (15) and with

the housing bottom part (1). After that
remove the machine seal (14). Use the
threaded holes to pull out the shield.

Disconnect possible oil pipe connections

and remove possible Pt-100 or
thermocouple and vibration probe of
the bearing.

39)

Remove the seal carrier (11) or the

end plate of the bearing

This item for bearing size EFZL_ 9

only.

40)

Repeat items 26-36.

Let down the rotor and remove the

jack.

II

Housing bottom part

Joint bolt

12

Oil level gauge

for temperature control

Housing top part

Oil ring sight glass

13

Retention pin

II

for temperature control

Lower shell

Inboard shaft seal

14

Machine seal

Upper shell

10

Outboard shaft seal

15

Machine shield

Loose oil ring

11

Seal carrier

16

Oil outlet

Fig 42.

Sleeve bearing.

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III

for oil outlet

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The Non-drive end:

Prior to reassembly, check that the surface of

the shaft and the parts of the bearings are
clean. Worn out parts must be replaced.

51)

Perform the same procedures as

described in points 43 to 45 for the
drive end.

If a new antifriction bearings must be fitted,

its type designation must be exactly the same
as on the rating plate of the machine.

,WHPIRUKRUL]RQWDOPDFKLQHVRQO\
52)

Place a new O-ring onto the end shield.

A layer of molybdenic sulphide grease
is needed between the end shield and
the bearing.

53)

Attach the end shield.

54)

Fit and attach the outer bearing cover.

55)

Install the grease valve.

56)

Attach the circlip.

,WHPVIRUDQWLIULFWLRQEHDULQJVRQO\
The Drive end:
41)

Attach the air guide.

42)

Install the fan on the shaft using

appropriate tools.

43)

44)

Place the inner bearing covers in

position. Axially free bearings are
equipped with springs, which must be
attached at this point.
Heat up the bearings to 110C (221F)
by using the induction heater (figure
43).

,WHPVIRUVOHHYHEHDULQJVRQO\
The drive end:
57)

Attach the air guide.

58)

Install the fan on the shaft using

appropriate tools.

59)

Attach the bottom part of the bearing

housing to the end shield (figure 44).

Fig. 43. Induction heater.

45)

Fit the bearings on the shaft. Then

place a new layer of grease on them.

,WHPIRUYHUWLFDOPDFKLQHVRQO\

Fig. 44. Attaching the bearing housing.

46)

60)

Place the machinery seal on the shaft.

61)

Set the lubrication ring and the springs

holding shaft seals hanging on the
shaft in appropriate places (see figure
45).

Place a new O-ring onto the end

shield. A layer of molybdenic sulphide
grease is needed between the end
shield and the bearing.

47)

Attach the end shield.

48)

Fit and attach the outer bearing cover.

49)

Install the grease valve.

50)

Attach the circlip.

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The Non-drive end:
71)

Perform the same procedures as

described in items 62 to 70 for the
drive end.

,WHPVIRUDLUWRDLUFRROHGPDFKLQHV
RQO\
72)

Put the cover of the external fan on

place.

73)

Put the key of fan on place.

74)

Attach the fan.

75)

Attach the circlip.

76)

Change the seal of the upper cover.

Lift the upper cover on its place and
attach it.

77)

Place the auxiliary devices in their

positions, and connect their cables.

78)

Measure the space around the machine

for free air flow. The recommended
space is defined in the commissioning
report.

Fig. 45. Prepairing for attaching the shield.

62)

Lift the rotor as much as the air gap

allows.

63)

Lift the bearing shield on its position

and attach it.

64)

Put the bottom bearing shell on its

place.

65)

Install the shaft seals.

66)

Put the upper bearing shell on its

place.

67)

Apply luting agent on the bottom part of

the bearing housing (see figure 46).

Fig. 46. Applying luting agent.

68)

Attach the upper part of the bearing

housing.

69)

Attach the dust seal.

70)

Lubricate the bearing.

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Table 12.


Schedule for regular checkings.

PERIOD

SCHEDULE FOR REGULAR CHECKINGS

DAILY

MONTHLY

YEARLY

SUBJECT
Power
Current
P.F.
Excitation current
Winding temperatures
Bearing temperatures
Cooling air temperatures
Oil pressures
Bearing vibration
Heat exchangers
Contamination
Cleanliness of inner parts of the machine
Cleanliness of diodes and diode bridges
Condition and support of windings, lockings
Possible shifting of the slot wedges
Condition of the winding insulation and finishing
varnish
Possible shifting or loosening of the field windings
Insulating resistances of the windings
Condition of the fan(s)
Lockings in connection with the rotating parts
Painting and protection against corrosion
Checking the seals preventing the ingress of dirt
Checking the performances of control and regulation
equipment as well as protective relays
Checking the solderings and possible broken bars of
the rotor cage
Bearings and bearing seals

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DURING
THE
COMPLETE
OVERHAUL

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X



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Mounting conditions

1RWH

Disconnect always the machine from

the power source before investigating
a fault or performing any work on the
machine.

1.

Improper tools and mounting procedures.

2.

Dirty mounting conditions.

3.

Mounting shock loads.

4.

Improper manufacturing of components

surrounding the bearing: out of tolerance
shafts and housing, inadequate lubricant
supply, misalignment.

Any abnormal machine behaviour during

commissioning or subsequent operation must
be identified and remedied immediately. By
following this precaution major damage can
generally be prevented. The following tables
offer information on the most common faults,
their causes and remedies. In cases where a
fault cannot be traced, it is advisable to
contact ABB.


(OHFWULFDOSUREOHP

Use trouble shooting list 1 for starting

problems and list 2 for temperature problems
of the machine.


%HDULQJSUREOHP

Operating conditions
1.

Over-loading.

2.

Vibrations in an operating or static

bearing.

3.

Over-speed.

4.

Shaft deflection (bowing).

Environmental conditions

 'HWHFWLRQ DQG LGHQWLILFDWLRQ RI

IDLOXUHV

1.

Too low or too high ambient temperature

&ODVVLILFDWLRQRIEHDULQJIDLOXUHFDXVHV

2.

Electric arcing.

3.

Contamination
from
water,
chemical product, textiledebris ...

Failures can be classified in 3 major categories:

1.

2.

3.

Failures due to environmental factors:

improper or negligent mounting, dirty
working conditions, inadequate lubrication,
over-loading, vibrations, over-speeding,
over-heating, pollution...

dust,

Lubrication conditions
1.

Improper lubricant.

Failures due to a misapplication:

inadequate size or type of bearing or
improper mounting design.

2.

Inadequate supply of lubricant.

3.

Relubrication interval.

Failures due to quality of the bearing

itself:
material
quality,
structure,
composition of steel, bearing design and
manufacturing (internal geometry, cage
or seal quality).

The chart in the fold-over sums up the basic

failures with their corresponding causes and
will guide the user in identifying the probable
origin of failures.

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RI

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The following causes are the most common.

Bearing failures usually stem from many
reasons but all causes can be classified in 4
basic categories.

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IDLOXUHV
The main concern for the user is to detect the
beginning of a failure before the machine
breaks down.

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Preventive maintenance is certainly the best

remedy but is only economically achievable in
certain cases (time consuming and high
expenses are involved to reach the bearing).
In a few cases preventive maintenance is a
"must" (air craft industry, mine ventilation...).
More frequently the bearing damage will have
to be identified from an external indication.

frequency with the extent of the damage.

Conversely the damage due to unbalance
loads is generally inaudible since their
frequency is identical to the rotating
assembly frequency.
3.

Any operating bearing is subject to a

temperature rise above the ambient.
This rise depends on many factors and
reaches a certain level considered as
normal, for a particular mounting. Any
rise beyond that normal level is an
indication of failure.

The amount of fatigue in a bearing might be

difficult to evaluate from external indications.
Generally the bearing is close to the end of its
useful life when the external indications are
detectable.
([WHUQDOLQGLFDWLRQVRIGDPDJH

4.

Exact levels will vary as they are dependent

on several factors: load, speed, lubrication,
type of bearing...

Generally, an increase of the rotation

torque generates a temperature rise.
,QWHUSUHWDWLRQRIH[WHUQDOLQGLFDWLRQV
1.

2.
These signals are:
Vibrations

Noise

3.

Temperature rise
Excess or lack of lubrication
Elimination of the internal clearance
Thrust overloading due to improper
mounting

Some abnormal noises can be heard

immediately, such as those due to rolling
element
indentations
because
of
improper
mounting;
others
are
progressive.
Noise is usually an indication of incipient
failure and varies in intensity and

Noise
Rolling element indentations
Spalling
False brinelling (indentations caused by
vibrations)
Foreign particles
Corrosion
Elimination of the internal clearance due
to excessive press fit
Cage or rolling element failure

These can be detected by hand or with

electronic equipment (frequency or
amplitude analyzer). This type of
equipment can be used to alert the
operator or to stop the machine.
2.

Vibrations
Spalling
Abrasive wear - foreign particles
Corrosion
Unbalanced loads due to bearing wear
Excessive clearance
Under-tightening of a ring

Deviations from the "norms" established

under your operating conditions should signal
the need for implementation of your
preventive maintenance program or at least a
close check to determine the cause of the
deviation.

1.

Increase of the rotation torque

Any rotation system (rotor, shaft, wheel,
pulley) presents a resistant torque, even
when mounted on bearings. Any torque
increase is indicative of an alteration in
the bearing.

A bearing rotating under functional conditions

will exhibit certain "normal" operating levels of
temperature, noise and vibrations.

These levels should be considered as signals

or warnings when they exceed those
established for the "normal" or steady state
conditions.

Temperature rise

4.

Abnormal running torque

Cage distortion

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Lubrication deterioration
Seal damage or displacement

5.

Torque

6.

Evolution of deterioration

7.

Orientation
assembly.

3UHYHQWLYHFRQWUROSURFHGXUHVDQGPHDQV
Frequency of control
It essentially depends upon the expected
reliability, on the material usage and on many
other factors specific to each user. Sampling
controls based on the bearing life expectancy
could be regularly performed.
External control means
These means are very limited. However,
some control instruments detecting unusual
vibrations are available. "Sonic meters"
measuring the bearing noise level can also
be used. In any case, a reference level
should be determined in order to measure the
difference.

1.

Record significant facts noticeable on

the bearing.

2.

Record any noticeable symptoms on

components surrounding the bearing.

3.

Identify all probable failure causes.

4.

Among these possible causes select

those matching the majority of the signs.

1.

Dirt

2.

Temperature

3.

Loss of lubricant

4.

Noise

bearing

in

the

Do not clean a bearing before examination.

Doing so would prevent the research and
identification of foreign particles as well as
the review of the condition and quality of the
lubricant.
1.

Note the condition of cages and rolling

elements.

2.

Check the presence of particles by

washing the bearing and filtering the
washing liquid.

3.

Keep lubricant, selas and shields for

examination.

4.

Keep track of bearing and ring mounting

5.

Check shaft and housing fits.

6.

Check the shoulders - out of squareness

- presence of debris, rust due to metalto-metal contact etc.

Use trouble shooting list 3 for bearing

problem.
/,7(5$785(
1)

SKF,
SKF
Handbook

2)

SKF, Bearing failures and their causes

3)

SNR, SNR Technical Leaflet 010:

Causes of premature bearing failures

4)

FAG, Rolling Bearings in Electric

Machines: Publ. No. WL 01 200 EA

5)

FAG, Rolling Bearing Damages: Publ.

No. WL 82 102/2 EA

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Before removal:

the

After removal

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Failure identification is not always easy. The
following steps should be considered:

of

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Maintenance

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63$5(3$576

it is recommended that spare parts listed

below are always kept in stock. This modest
investment can often prevent minor faults
from developing into serious trouble.

Orders for spare parts should always include

the following information and be forwarded to
the responsible ABB representative:
1.

Serial number according to the rating

plate.

Recommended spare parts:

-

Set of antifriction bearings.

2.

Type designation of the AMA-machine.

Set of bearing shell and sealings in the

case of sleeve bearings.

3.

Quantity and designation of the desired

spare parts.

Where a machine for a single but extremely

important drive is involved or if several
identical machines are operating in the same
plant, the following parts are also
recommended:
-

Spare machine.

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5(32576<67(0$1'&+(&.6+((76

The check sheets included in this instruction

manual shall be used upon arrival of the
machine, at assembly and at commissioning.
They shall also be used for the regularly
recurring maintenance work.
It is vital, both for the customer and for ABB,
that installation and maintenance are carried
out carefully. Maximum availability is obtained
with a minimum of disturbances in operation.

Follow the recommendations given in this

manual and give ABB a chance to follow up,
by sending copies of the maintenance
reports. If a problem occurs, the discussion
can be concentrated on solving a technical
matter, without time consuming investigations.
The copies of the check lists should be sent
to the local ABB representative.

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*HQHUDO

&KHFN/LVW

Customer
Machine type AMA
Machine serial no.

Arrival date of the machine

Signature of
the consignee
DATE

Transport damage to motor and/or accessories

(use check list 2)
Missing parts at delivery
(use check list 3)
Machine storage period longer than 6 months
(use check list 4)
Check list 5 for mechanical installation

SIGNATURE

o Yes o No
o Yes o No
o Yes o No

Check list 6 for electical installation

Check list 7 for test run 1
Check list 8 test run 2
Check list 9 Inspection
Check list 10 maintenance

Comments:

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Register no.

Continues on page



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'DPDJHV

&KHFNOLVW

Customer
Machine type AMA
Machine serial no.

Arrival date of the machine

Damage(s):
o Machine

Signature of
the consignee

o Accessories

o Package
o Other...............................................
Dispatched by:

Action(s) taken in response to damage(s):

o Photographed
o Registered
o Reported to
supplierinsurance

o Reported to
company

To carrier

o Railway
o Lorry/Truck
o Airfreight
o Post/Mail
o Shipped by the m/s ..................................
o Other.........................................................

Damages found during customer inspection:

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Register no.

Continues on page

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8QSDFNLQJ

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Customer
Machine type AMA
Motor serial no.

Motor arrival date

Signature of
the consignee

Missing parts or comments:

Check the list of parts while unpacking the machine.

All damages, including those to the transportation box, should be photographed. Damages or missing
parts should be reported immediately to the forwarding agent, the insurance company and ABB.
After unpacking, store spare parts and installation tools for future use.
If no parts are missing at delivery, mark it on Check List 1.
For files
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6WRUDJHWLPHORQJHUWKDQPRQWKV

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Customer
Machine type AMA
Machine serial no.

Storage date

Person responsible
for storage

Storage:

o Outdoors

o Indoors

o In packing case

o Protected by
waterproof cover

o Warm

Measures taken during storage:

o Case is provided with
ventilation openigs
o Bearings are lubricated
o Rotor is turned 10 revolutions every
two months (antifriction bearings only)

o Cool

o External heating
is used
o Shaft end rust-proofing
material is checked
o Storage place is vibration-free
o Documentations are protected

o Space heaters
are used
o Absorbing
material is used
o Air is free of
corrosive gases

In case the standstill period is longer than year:

- Repeat the preservation procedures
- Put a new bag of dessicant into the bearing
In case the standstill period lasts more than a year:
- Dismantle the bearing shells
- Preserve and store the bearing parts

Comments:

Protective measures must be taken before operating the motor if it is stored for a long period.
The customer is responsible for the storage and the required protective measures.
The motor must be stored on a level surface in a vibration-free area. If storage is outdoors, the motor
must be protected against environmental effects.
If long-time storage under humid conditions is anticipated, connection of space heaters, efficient
coverage, and other protective measures must be arranged.
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Customer
Machine type AMA
Machine serial no.

Measures:
o Foundation according to drawing................................................................
o Alignment checked according to instructions.
o Foundation bolts tightened with torque wrench.
o Assembly of coupling half checked.
o Bearings filled with lubricant - type..............................................................
o Bearings filled with lubricant - quantity........................................................
o Assembly of oil and coolant pipes checked, flanges tightened.
o Cooling water test run. Check for leakage.
o Stator terminal box mounted correctly.
o Rotor rotates without scrapings/sound (transport locking device dismantled).
Comments:

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0HFKDQLFDO,QVWDOODWLRQ

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Customer
Machine type AMA
Machine serial no.
5DGLDOPLVDOLJQPHQW

a1, b1, c1 and d1 are readings from the dial indicator "R" at the points a = top, b = bottom, c = right, d = left (4 turns, each of 90 angle).
The readings are entered in the formula to obtain the values of radial misalignment (table 1).
Table 1
Measuring points

1st measurement

2nd measurement

Example

9HUWLFDO

Top
Bottom
Difference
Vertical
misalignment
+
-

a1
b1
a1-b1

a2
b2
a2-b2

25
31
-6

28
28
0

D E


D E


-3

Left-hand coupling is higher than the right-hand one

Left-hand coupling is lower than the right-hand one

Left hand coupling

raised by 0,03 mm.

+RUL]RQWDO

Right
Left
Difference
Vertical
misalignment
+
-

c1
d1
c1-d1

c2
d2
c2-d2

38
18
20

28
28
0

F1 G1
2

F2 G 2
2

10

Left-hand coupling displaced to right of right-hand coupling

Left-hand coupling displaced to left of right-hand coupling

  

D + E
D + E
= = 
F + G
F + G 

Check
for
measuring error

Left hand coupling

moved to left by 0.1
mm.

38 + 18

= =

  
  

Schematic for table 1

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The axial gap is determined by taking readings from the two dial indicators AI and AII, whereby the first reading from the top indicator AI is
designated by e1 and that from the bottom indicator AII by h1. The values for vertical and horizontal misalignment can be determined as shown in
table 2; axial displacement (in example 0.2 mm) during the measurement does not effect the results. Use a feeler gauge in case the gap is too
small to use a dial gauge.
Table 2
Measuring points

Dial AI

Dial AII

Example

9HUWLFDOJDS

Top
Bottom
Gap
+
-

e1
f1

g1
h1

(I1 H1 ) (J 1 K1 )
2
The gap is greater at the top
The gap is greater at the bottom

50
62

42
50

(62 50) (42 50)

2

The gap is greater by

0.1 mm at the top.

+RUL]RQWDOJDS

Left
Right

i1
k1

40
48

36
40

( 48 40 ) ( 36 40 )
2

(N 1 L 1 ) ( O 1 P 1 )
2

Gap
+
-

l1
m1

The gap is greater at the left

The gap is greater at the right

The gap is greater by

0.06 mm at the left.

Schematic for table 2

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Customer
Machine type AMA
Machine serial no.
Safety:
o7KHLQFRPLQJFDEOHVDUHVHSDUDWHGIURPWKHHOHFWULFSRZHUQHWZRUN
o7KHFDEOHVDUHJURXQGHG
Electrical data:
Machine

Electric power network

Voltage.............................................V/VAC

Voltage.............................................V/VAC

Frequency........................................Hz

Frequency........................................Hz

o Space heater:.........................................V/VAC,
o External blower motor.............................V/VAC,
Insulation test:

...................W
...................W/HP

o Automatic stop connection

Stator winding meggered with....................... V/VDC,

Winding temperature.............................C/F

Insulation value (after 1 min)......................... M,

R (40C/104F) = .................................. M

Insulation value (after 10 min)....................... M,

R (40C/104F) = .................................. M

(See chapter - Winding Maintenance for Electrical Machines)

Main protection settings:
Overcurrent level..................................................

Overload level................................................

Differential protection level...................................

Ground fault level...........................................

Negative sequence level......................................

Acceleration time............................................

Other protection level(s).......................................

The supply network is provided with:
Under voltage protection, set at..............................................................................................................
Current transformers, ratio......................................................................................................................
Voltage transformers, ratio......................................................................................................................
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Monitoring equipment
Temperature monitoring
In stator winding

Alarm (C/F)

Trip (C/F)

Alarm

Trip

In bearing
In.......................................................

Flow or pressure monitoring:

(m3/s or Pa)
(ft3/s or psi)

Lubricating oil

min

Lubricating oil

max

Cooling water
Filter guard
Vibration:

Comments:

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7HVWUXQ

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Customer
Machine type AMA
Machine serial no.

Date

Name of
supervisor

Connections:
o The supply cables have been connected

o The auxiliary devices have been connected.

First start
Direction of rotation:
o clockwise
o counter-clockwise (as seen from drive-end)
Noise:
o normal
o abnormal
Second start (to full speed)
Run:
o normal
o abnormal
Noise:
o normal
o abnormal
Vibration:
o normal
o abnormal
o Run OK
o operation stops (why ?).......................................................................
..................................................................................................................................................................
..................................................................................................................................................................
Time
Bearing
Temp.
Oil
Comments:
Stator
D-end
N-end
Temp.
(run, noise, vibration, etc.)
Current
Power
(C/F)
(C/F)
(C/F)
(A)
factor

Comments:

For files
To

From

Issued by

3$0$HQ

Date

Page

Register no.

Continues on page



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Customer
Machine type AMA
Machine serial no.

o Coupling is connected

o Load applied

Acceleration time:

o Coupling is disconnected

o No load applied

....................................

Time
or
Date

Bearing temp.
D-end
N-end
(C/F) (C/F)

Winding temperature
U / T1
V / T2
W / T3
(C/F) (C/F) (C/F)

Stator
Curr.
(A)

Power
factor

Vibr. (mm/s, m)
(in/sec,mil)
D-end
N-end

Load
(W)
(HP)

Comments:

For files
To

From

Issued by

3$0$HQ

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Page

Register no.

Continues on page

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Customer
Machine type AMA
Machine serial no.

Number of starts during week....................................................................................................................

Operating hours during week.....................................................................................................................

Comments:

Loggings of operational data and remarks should be kept for reference during maintenance work,
trouble shooting, and repairs. Copies of loggings are not to be sent to ABB.
Year............. , Week.............
Point of inspection
Date
Load power
(W/HP)
Load current
(A)
Fault indication
(Yes/No)
Bearing temperature DE
(C/F)
Bearing temperature NDE (C/F)
Oil level
(Normal/Abnormal)
Oil leakage
(Yes/No)
Winding temperature U/T1 (C/F)
Winding temperature V/T2 (C/F)
Winding temperature W/T3 (C/F)
Coolant flow
(m3/h/Gpm)
Water leakage
(Yes/No)
Vibration level
(Normal/Abnormal)
Noise
(Normal/Abnormal)

Mon

Tues

Wed

Thurs

Fri

Sat

Sun

For files
To

From

Issued by

3$0$HQ

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Page

Register no.

Continues on page



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Customer
Machine type AMA
Machine serial no.

Maintenance interval...........h,
Operating hours ............,
Number of starts......................
Bearings:
o Lubricant change
Lubricant type.................................
Quantity...........................................
o Oil filter change
Oil filter type....................................
o Flanges and pipes checked
Comments:

Cooling:

o Water cooler bled

o Flanges and pipes checked
o Air filter checked
o Air cooler checked

o Cleaned
o Cleaned
o Cleaned

Comments:

Electr. part:

o Connection of high-voltage cables checked

o Connection of control cables checked
o Space heater checked
o Machine opened and inspected

Comments:

Mech. part:

o Couplings checked
o Foundation bolts checked
o Foundation checked
o Machine in general checked
o Machine opened and checked
o Bearings opened and checked

Comments:

For files
To

From

Issued by

3$0$HQ

Date

Page

Register no.

Continues on page

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Customer
Machine type AMA
Machine serial no

MACHINE
DOES NOT
START

One phase is
missing

The fuse has

blown

Check, why the fuse has blown and

repair the fault. Change the fuse.

The momentary overcurrent protection

relay has tripped

The setting of the momentary

overcurrent tripping is not
correct

The thermal overload

relay has tripped

Starting time has

been too long

Voltage drop
is too high

Load inertia is
too high

The maximum momentary value of the

starting current may be as high as 2.5
times the indicated r.m.s value

Check, that the load inertia

is same which has been
reported to ABB Company 1)

If possible, use some

means to reduce starting
current 2)

Check the supply

transformer

Load torque
is too high

Check the starting

method of the
driven machine 3)

1) If the load inertia is larger than has been reported, please contact ABB Company.
2) Starter can be star-delta connection, starting reactor or auto transformer. When the starter is used the
machine torque decreases and starting time increases. This must be noticed.
3) Driven machines may have different starting method. Many of them can be started without load. For
example compressors and blowers can be started with closed suction vanes. In refiners the pulp feeding
can be started after starting the motor. It is possible that the motor does not start loaded, if it has been
designed to start without load. The machine can be damaged when starting with load if it has been
designed for no load start.
3$0$HQ



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Customer
Machine type AMA
Machine serial no

HIGH MOTOR TEMPERATURE

Cooling air
is too hot

Air duct is
blocked

Ambient temperature

Cooling-water circulation

is too hot

is not working

Another machine
is too near

Water-pipes are

Air in the

blocked

water-pipes

Open and

Cooling circuits should not

Open and

Bleed air from

adjust

disturb each another

adjust

the water-pipes

Cooling-water temperature
is too hot

Cooling-water pump
is not working

Repair the fault

through bleeder
screw
Adjust sufficient ventilation
Adjust sufficient

for the motor 1)

condensation for
cooling-water

One phase is
Overload

Check voltage and

current, eliminate
overload

missing

External blowers
is not working

External blowers

The motor fan

rotating in the

rotating in the

wrong direction

wrong direction

Change direction

The fan must

of rotation

be changed

The fuse has

blown
Stop the running

Blower motors
protection has
tripped

and check, why the

fuse has blown

Repair the fault

Repair the fault

1) For example machines can be partitioned off, or if the room temperature is too high an air-conditioning
must be improved.

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Customer
Machine type AMA
Machine serial no
COMMON SYMPTOMS
A
B
C
D

Overheated bearing
Noisy bearing
Replacements are too frequent
Vibration

Unsatisfactory equipment performance

Bearing is loose on the shaft
Shaft is difficult to turn

Typical conditions

Reason for condition

Practical solution

Inadequate lubrication

Grease or oil is breaking

down because it is the
wrong type for operating
conditions.

Consult lubricant manufacturer to

determine proper type of lubricant.
Check miscibility if grease or oil has
been changed from one type to another.

Insufficient lubrication

Insufficient grease in the

housing.

Fill housing 1/3 to 1/2 with grease.

Low oil level. Lubricant is

being lost through the seal.

Oil level should be just below the center

of the lowest rolling element in the
bearing.

E
F
G

Excessive lubrication

Housing is fully packed with

grease or the oil level is too
high. This causes excessive
lubricant
churing,
high
operating temperature or oil
leakage.

Purge bearing until the housing is 1/2

filled with grease. For oil lubricated
bearings, reduce the oil level to just
below the center of the lowest rolling
element.

Insufficient
clearance

Bearing has inadequate

internal
clearance
for
conditions where external
heat is conducted through
the shaft. This causes the
inner
ring
to
expand
excessively.

Check weather overheated bearing had

clearance according to the rating plate
of the machine. If so, then change to
bearing with increased radial clearance.
If not, order according to rating plate.

bearing

Check with bearing manufacturer if the

bearing designation has
become
illegible.

Foreign matter acting as

an abrasive.

Dirt, sand, carbon or other

contaminants are entering
the bearing housing.

Clean the bearing housing. Replace

worn seals or improve the seal design to
obtain adequate bearing protection.

Foreign matter acting as

a corrosive.

Water, acids, paints or other

corrosives are entering the
bearing housing.

Install a protective shield and/or flinger

to guard against foreign matter. Improve
seals.

Foreign
matter
bearing housing.

Chips, dirt etc. were not

removed
from
housing
before
assembling
the
bearing unit.

Carefully clean and install lubricant.

Preloaded bearings

"Two locating bearings" on

one shaft. Insufficient axial
float in bearing construction
caused by excessive shaft
expansion.

Improve the
expansion by
bearing cover .

Unbalanced load.

Rebalance the machine.

Outer ring
housing

in

spins

in

3$0$HQ

possibility
machining

of
the

shaft
outer



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Customer
Machine type
Machine serial no

Noisy bearing

Flat spot on rolling element

due to skidding.

Visually check the rolling elements and

replace the bearing if a rolling element
has flat spot. Make sure that the
requisite minimum load is applied to the
bearing.

Linear or/and angular

misalignment of shaft.

Incorrect linear or angular

alignment of two or more
coupled shafts with two or
more bearings.

Correct alignment by shimming the

electrical machine. Ensure that the
shafts are coupled in a straight line. Be
sure to use full support shims.

Rolling
dented.

Incorrect mounting method.

Hammer blows on bearing.

Replace the bearing with a new one.

Newer hammer any part of a bearing
when mounting. Always heat up the
bearing before mounting.

Vibrations

Excessive clearance in the

bearing causing vibration.

Use a bearing with

internal clearance.

Vibrations

Equipment is vibrating.

Check the balance of the rotating parts.

Rebalance the equipment.

element

is

recommended

Check the stiffness of the foundation.

Stiffen the foundation.

Bearing is discolored.

Distortion of the shaft and

other bearing assembly
components, probably due
to heat.

Use a torch to remove a bearing only

under extreme circumstances. Avoid
high heat concentration at any one point
to avoid distortion. Replace discolored
bearings.

Bearing noisy

Bearing is exposed to
vibration while the machine
is idle.

Carefully examine the bearing for wear

spots corresponding to the spacing of
rolling elements. For standby equipment
ball bearings are better suited than roller
bearings to withstand vibration.

REFERENCE: SKF, Maintenance Handbook

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Customer
Machine type AMA
Machine serial no

HIGH BEARING TEMPERATURE

Lubrication
insufficient

Continued to
page 2

Faulty oil
cooler

Oil temperature
too high

Faulty
coupling

High axial
forces

Faulty assembled
bearing

Damaged
linings

Repair the cooler

Has bearing been

disassembled

Impurities in
the oil?

Inductive bearing
currents?

Complete seizure
of bearing

Faulty
instrument?

3$0$HQ

Open and
adjust

Change oil

Repair bearing
insulation

Repair bearing journal

Replace lining
Renewed commissioning



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Customer
Machine type AMA
Machine serial no

Continuing
from page 1

Low oil
level

Check maintenance
status

Oil pump not

reliable?

Low oil
flow

Oil filter
clogged

Reduction valve
shut?

Oil leaks ?

Motor protection
trips?

Check maintenance
status

Latest
adjustment?

Fault finding
and action

Too low oil

temperature

Faulty oil
heater

Unsuitable
oil quality

Check with
ABB Drives
recommendation

Change oil
quality

Check status of
oil change

Replace the oil

Oil worn out

Oil ring working

unreliable

Previous bearing
disassembly

Oil worn out

Low oil level

Disassemble and
adjust

Replace the oil

Add oil

UNSTABLE BEARING
TEMPERATURE
Oil ring working
unreliable

Open bearing
and adjust

Impurities in
the oil

Replace the oil

Damaged
shaft seals

OIL LEAKS

Air-lock seals
out of action

Too high oil level

Problem in oil
flow return

Replace the seals

Repair and clean

Correct oil level

Incorrect inclination
of the return pipe?

3$0$HQ

Add oil

Fault finding
and action

Replace filter

Adjust flow

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LINE

TYPE

AL

AM

AN

AP

BH

CL

DD

DE

DF

ZBHE 301

300

160

200

385

30

ZBHE 362

440

205

160

200

200

500

36

150

84

SUITABLE FOR MACHINE TYPES

WEIGHT kg

AMA 400

30

AMA 450, 500

60

Name of the parts

Name of the parts

Foundation plate

Fixing screw

Anchor bolt

Shim

Flange

Levelling plate

Nut

Conical cotter

Levelling screw

a) Foundation bolt to be mounted in the machine foundation.

b) Foundation bolt to be mounted through the machine foundation.

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GROOVE BALL BEARING

OUTER BEARING COVER

INNER BEARING COVER

CIRCLIP

GREASE VALVE

HEXAGON SCREW

a) Screws are locked with Loctite (item no. 6).

b) Seal the surface between parts with sealing compound.

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CIRCLIP

INNER BEARING COVER

HEXAGON SCREW

GREASE VALVE

SPRING

OUTER BEARING COVER

O-RING

a) The inner surface of bearing housing to be smeared with molybdensulphide.

b) Screws are locked with Loctite (item no. 6).
c) Seal the surface between parts with sealing compound.

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CYLIND.
BEARING

2
3

ROLLER

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CIRCLIP

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HEXAGON SCREW

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INNER BEARING COVER

CIRCLIP

GREASE VALVE

HEXAGON SCREW

a) Screws are locked with Loctite (item no. 6).

b) Seal the surface between parts with sealing compound.

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AXIALLY LOCATING BEARING

AXIALLY FREE BEARING

BEARING HOUSING

OIL SIGHT GLASS

BEARING SHELL

OIL RING SIGHT GLASS / OIL FILL

PLUG

OIL RING

OIL DRAIN PLUG

LABYRINTH SEAL

THERMOMETER BORE POSITION

MACHINERY SEAL

10

INSULATED SHELL

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ROTOR

N-END SHIELD

STATOR LOCKING PIN

FAN

INNER FAN

O-RING

AIR GUIDE

FAN COVER

D-END SHIELD

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STATOR

D-END SHIELD

ROTOR

N-END SHIELD

END SHIELD STATOR LOCKING PIN

FAN

AIR GUIDE

FAN COVER

INNER FAN

10

O-RING

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!"" 7ORLDWIDE 3ERVICE

In the event that service is needed ABBs service is always on hand to solve any problems locally.

P34 AMA 05 en 9812

For more detailed information, please contact your local ABB representative
ABB Industry Oy
Induction Machines
P.O. Box 186
00381 Helsinki FINLAND
Tel +358 10 22 2000
Fax +358 10 22 23565
www.abb.fi