Installation Maintenence
Installation Maintenence
Installation Maintenence
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about one third of the space within bearing covers is filled with grease. Over filling of grease is not recommended. While regreasing motors provided with regreasing arrangement, keep the grease outlet open and fill grease when the motor is running so that old grease/excess grease will flow out. Balmer Lawrie LL3 and Shell-MP 3 are recommended for use in motors. Mixing of grease should be avoided. When the motor is opened, protect bearings from foreign particles and dirt by wrapping them with clean paper or polythene sheet. During reassembly of motor ensure that wavy washer and brass washers are kept in their position and bearing covers are secured properly. These washers are specially designed to provide adequate preloading on the bearings. Clean the entire path of the cooling air on the motor at regular intervals. The temperature of the motor, judged by hand feeling, could be misleading. In the case of suspected overheating the actual temperature should be measured with thermometer and should be compared with the permissible temperature rise according to the temperature class of the motor. Overheating of the motor may be due to over loading of motor, too low or too high supply voltages, frequency fluctuations, over greasing of bearings, foreign material in the air gap between stator and rotor. Necessary corrective action is to be taken accordingly. When ordering spare parts state the motor type, machine number, type of construction as shown in the rating plate, part description given in the part list and number of units required.
Conduit entries are fitted with threaded plugs and are sealed. Open the plug and clean threads before fitting cable gland. Use double compression gland and seal the threads of glands with sealing cement. This will ensure IP55/IP56 Protection of the cable entry. After the cable connection fix the T. Box properly. Ensure that the rubber gasket provided is not dislocated or distorted and fixing screws are fully tightened. Wherever possible it is recommended to cover the motor from direct heating by the sun. Provide a canopy over the motor. The motor shaft is provided with oil seals/ v rings on both ends. Drain plugs are provided on front and back sides.(ref. fig 2.) During periodic inspection say once in 3 months open the drain plugs and drain out condensed water if any. While replacing oil seals make sure that oil seals are not distorted, the springs are in their position and the lip of the oil seal is free. Apply small amount of grease to the lip. V rings can be replaced by first removing the M.S. cap. the new v ring is to be fitted such that the lip just rests against the end shield face. (Excessive pressure will lead to premature failure of the v ring). Replace the M.S.cap. Whenever, the motor is opened and reassembled ensure that all joints faces are properly cleaned and gasket cement is applied properly at all joints.(ref. fig 2.) Recommended gasket cements : Anabond 681 of Anabond Ltd.
Electrical Connections :
While doing electrical connection ensure following points: Use appropriate size of cable for connecting the motor. The supply voltage should be same as given in the rating plate. Unless otherwise specified the tolerances is 10% of the rated voltage. Connect the motor in accordance with the connection (Star or Delta) given in the rated plate and connection diagram given inside the Terminal box cover. Connect earth terminal effectively for protection. This is very important to ensure safety. Local electrical code must be followed. Normally 3 phase motors upto 2 HP have their winding connected in Star (Y). These motors have three terminals and are meant for direct on line starting only. Motors above 2 HP have windings suitable for delta (D) connection. These motors can be started with a Y-D starter or Direct on Line starter using connecting links as shown in the connection diagram. While connecting the cables to motor terminals please ensure that the cable in properly secured and clamped and it does not exert any tension on terminal . A heavy load or tension by the cable can break the terminals. Motors must be installed as per the local electrical code/regulation by an authorised person. Motors must be protected against overload and short circuit conditions.
Maintenance :
During maintenance please note the following points : The bearings are prelubricated and maintenance free. Operating conditions permitting, unsealed bearings should be cleaned at intervals of about 10000 operating hours, with trichloroethylene or clean petrol. While lubricating please see that the bearings are well lubricated and
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Press out the back endshield in the case of MJ80 to MJ130 after removing the circlip on the inside of enshield bearing housing.. In other frame sizes back endshield can be removed from rotor after removing back outer B.B.cover. v Dismantling of the motor should be done carefully without damaging any of the joint faces components rotor, stator and windings. If any damage is noticed after dismantling, such component should be replaced by the new component. Rectification of damage by metal filling or adhesive filling is not permitted. v Assembly of the motor is to be done in reverse order of dismantling . v During rewinding take precautions given below. v Burning of old winding to remove coils from slot should not be done. v Cut overhang portion of winding with chisel. v Heat the body at 130o-140o C in the oven for 2 hrs. v With the help of copper rod and hammer, force out copper wire from the slots and clean slots by filing. v Stator body should be handled carefully to avoid damage on machined portion of the body. Any damage, burr will result in change of flame path gap. v Reassembled motor carefully as explained above. N.B.: 1) Burning of winding with flame will distort the body. After reassembly flame path gap may increase. 2) Carefull handling and correct reassembly shall ensure flame-proofness of the enclosure. 3) It is advisable to give rewinding work to an authorised rewinder of BBL.
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4:
METHOD :
Remove the fan cowl. In case of motors in frame size 71 & 80 remove the split pin (400) from the castlenut(ref.fig. 5). In case of motors in frame size 90 to 132, remove the screws (402) Remove the rubber cover 075).2). from the locknut (401) (ref. fig. Now rotate the castlenut/lockknut till the air gap is 0.3 mm. Use fillergauge to ensure proper air gap. Insert the split pin or fix the screws in the castlenut/locknut as the case may be. Replace the rubber cover in its place and fix the fan cowl. The brake is now adjusted and ready for operaation. It is recommended that the entire armature disk assembly is replaced when the liner has worn by 3 to 4 mm. (i.e. after 3 or 4 adjustments).
Where, R r In U Mn Ma
= = = = = =
external resistance per phase rotor resistance per phase rotor rated current rotor Voltage rated torque, kg-m required starting torque, kg-m
In most cases,the rotor resistance is neglected and R+r is assumed equal to the external starting resistance. Should it be necessary to allow rotor resistance, it can be determined with sufficient accuracy from the following equationr = U X In x 3 Ns - n Ns
It can be increased by upto 40% (max). by inserting washers under all the compression springs, after removing the castle nut/lock nut and fan. It can also be reduced by upto 50% (max). by removing some of the compression springs. Not more than half of them should be removed. the remaining springs must be distributed uniformly around the circumference of the magnet yoke. The brake should be then reassembled.
Where Ns n
As the speed picks up, the starter cuts-out the external resistance in steps.The various values for R+r are calculated by assigning different values to Ma while using the equation.
SPARES :
The list of spares which can be provided is given in fig, 5and 6. A manual release kit is available for incorporating manual release arrangement for motors in 90S onwards.
SPARES :
The following items are available as spares (in addition to items shown in fig. 3.) 1. Brush holder 2. Slip Ring 3. Carbon Brushes
N.B:
1.0 Brake unit with Manual Release arrangement cannot be replaced in old design for 132S/132M Frame Brake motors. 2.0 Brake unit with manual release arrangement can be replaced in old design of 90S/90L, 100L & 112M Frame.
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i) Fan rubbing against end shield ii) Fan rubbing against cowl, dented iii) Bearing failure iv) oil seal rubbing v) Rotor-Stator rubbing vi) Excess preloading of bearing
i) Rectify the defect ii) Replace cowl/rectify iii) Replace bearing iv) Apply few drops of oil to lip v) Rectify the defect vi) Reduce preloading
(b) Intermittent
i) Clean & regrease bearings (ref: 6-II) i) check & correct endshield fit/bearing ii) Re-balance rotor i) ii) iii) iv) v) vi) Verify & correct Correct * Vertify & correct 7) Shaft temp. is high
v) Broken ball/rough races i) Defective bearing ii) Oil sealing rubbing against shaft (in motors with oil seal) i) Rotor - stator rubbing ii) Wrong motor selection iii) Overloading iv) Ambient temp. is high v) Inherent design feature (B/F class) vi) Fan cooling is affected vii) High no. of start/stops viii) Motor dirty ix) Single phasing x) Voltage unbalanced
2) Magnetic noise
Wrong external connections Voltage high Frquency low Faulty installation Inherent design feature Stator - rotor misalignment
* Note : a) In case of small hp, special motors, Crane duty motors, the no Load current could be as high as Full Load current. b) No Load current specified in Test Certificate is at rated voltage i.e. generally 415 V 50 Hz. If No load current is high check for Voltage & Freq. variation. 4) Full Load current is high i) Voltage high/low ii) Motor selection is wrong iii) Overloading iv) Blowers/pumps operating out of specified range 5) No laod Current unbalance i) Wrong external Correction ii) Voltage unbalance i) Regulate supply ii) Select correct motor iii) Take coorective action iv) Operate in specified range i) Verify & Correct ii) Check for faulty leads connections and transformer iii) Rewind 10)Wrong direction rotation. 11)Motor runs and then stops 9) Speed is low
i) Frequency low ii) Defective rotor iii) Overloading i) Wrong sequence of phases i) Power failure/Single phasing iii) Overload
i) No supply voltage, one phase open or voltage too low ii) Starting torque of load too high
Note :
There could be current unbalance of 5% (15% for 2 pole) on No load running even with balanced volatge supply. The unbalance in current reduces when the motor is loaded. 1% unbalance in voltage can cause 6 to 10% u.balance in current iii)Control great defective
ii) Reduce load or study requirement. If sq. cage motor with autotransformer starting, change to a higher tap. If slipring, lower starting resistances. iii) Rectify (Check contacts)
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REMEDY i) Replace motor ii) Change the motor iii) i) Replace oil seal ii) Replace oil seal iii) Rectify i) Rectify
CAUSE i) Bearing preloading washer misplaced ii) Wrong application of motor iii) NDE End Shield bearing housing damaged. i) Overloading ii) Starting time is high iii) Defective rotor iv) Wrong selection of motor v) High voltage variation vi) Low Frequency vii) Wrong relay setting (Due to variation in voltage & frequency the current drawn will be higher. If relay setting is on full load current as per name plate relay may trip.)
REMEDY i) Replace preloading washer ii) Select the correct motor iii) Replace End Shield i) Take corrective action ii) Take corrective action iii) Replace motor iv) Change the motor v) Contact the manufacturer vi) Reduce loading if possible vii) Set relay at 1.15 times full load current
i) Oil seal defective ii) Improper mounting of oil seal iii) Poor joint sealing i) Flange fixing holes are not tightened/ sealed. i) Defective bearings ii) Rotor-rubbing iii) Motor misalignment iv) Loose fixing bolt v) Poor balancing of drive equipment vi) Coupling out of balance vii) B a l a n c i n g weights detached viii) Wound rotor coils replaced ix) Weak foundation x) Single phasing xi) Excessive end play add washer
15) Vibration
i) Replace bearings ii) Rectify iii) Re-alignment iv) Rectify v) Rebalance vi) Balance coupling vii) Rebalance rotor viii) Rebalance rotor ix) Strengthen base x) Check for single phasing xi) Replace bearing or add washer under D. E. bearing
i) Replace bearing
i) Design of motor not matching application ii) Wrong selection of thermistor for the application/motor
i) Excessive belt load ii) Bearing failure iii) Inner BBC loosely fitted
i) Reduce belt load ii) Re-assemble after rectifying damage iii) Fixing screws of Bearlng covers should be tightened properly during reassembly
i)
Defective bearings
ii) Voltage unbalance overheating iii) Loss of insulation of stators wdgs. iv) Overloading v) Ambient temp. is high vi) Winding failure (intertum short, failure of lead wire, insulation paper, etc)
ii) iii) Rewind-provide space heater if humidty is high. iv) Take corrective action v) Rewind with higher insulation class vi) Rewind. 23) Low Insulation i) Motor subject to water, rains, floods. i) Dismantle and clean parts. Then bake windings In oven at 90o C for 24hours or until resistance to ground is sufficient (>1 megaohm)
i) Defective bearings ii) Overloading (in the case of belt drive, use roller bearing) iii) Poor alignment iv) Poor/No lubrication v) Dried out greases
i) Replace bearing ii) Take corrective action iii) Correct misalignment iv) Lubricate v) Regrease i) Clean shaft/flange ii) Clean shaft/flange Note: 1) Also refer IS 900 - 1992. 2) In case of difficulty In locating the cause for a problem please contact nearest branch office of Bharat Bijlee Ltd.
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Note : 1) Where regreasing provision is given, regreasing should be done while the motor is running. Keep the grease outlet open. 2) The grease used by Bharat Bijlee is Balmer Lawrie LL3. Mixing of grease of other make/type should be avoided.
Weekly Maintenance :
Check belt tension. In cases where this is excessive, it should immediately be reduced . Blow out the motor surface of protected type motors situated in dusty locations. Examine starting equipment for burnt contacts where motor is started and stopped frequently.
Annual Maintenance :
Check all high speed bearings and renew, if necessary. Blow out all motor surface thoroughly with clean dry air. Make sure that the pressure is not so high as to damage the insulation. Clean and varnish dirty and oily windings. Overhaul motors which have been subjected to severe operating conditions. Renew switch and fuse contacts, if damaged. Renew oil in starters subjected to damp/corrosive and wiring. Check resistance of earth connections. Test the motor overload relays and breakers. elements. Check insulation resistance to earth and between phases of motor windings, control gear
Monthly Maintenance
Overhaul controllers. Inspect and clean oil circuit breakers. Wipe brush holders and check bedding of brushes of slip- ring motors.
Records :
Maintain a register giving one or more pages for each motor and record therein all important inspection and maintenance works carried out from time to time. These records should show past performance, normal insulation level, air gap measurements, nature of repairs and time between previous repairs and other important information which would be of help for good performance and maintenance.
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(FIG. 2)
2) Disc (M.S.)
(FIG. 1)
3) Nut (M.S.)
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8
Note : In Aluminium Pr. die cast body tie rods are In place of Hexhead Bolt for endshiels fixiing.
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T Box Cover
Flange ( B5 Construction)
T Box
Terminal Bushing
T Box Bottom Piece Fan Circlip (bearing locking) Bearing Inner Bearing Endshield ( BS) cover Rotor Stator
Note: All Flame proof Motors are with IP55 protection Flame Proof motors inFrame size 16FP/16LFP/MJ180/20LFP/60FP/MJ280 are with Oil seaal on both sides ( AS & BS ) for IP55 protection. Flame proof motors MJ80,MJ90,MJ130,MJ160,MJ200,MJ225,aqnd MJ250are provided with Rubber seal V ring and M.S.Cap on both sides ( AS & BS) for IP55 protection. Flame proof motors with B5 construction are provided with Oil seal on Driving side ( AS ) for O.T.S.
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: Registered Office :
Offices
REGION NORTH CITY NEW DELHI LUDHIANA INDORE EAST WEST KO L K ATA MUMBAI PUNE ADDRESS Milap Niketan, 4th floor 8A, Bahadur Shah Zafar Marg, New Delhi 110 002. 7, Gian Market, Opp. Ramgarhia Gurudwara, G. T. Road, Miller Ganj, Ludhiana - 141 003. C/o. Tirupati Engineering, 128, 3rd Floor, Dawa Bazar, RNT Marg, Indore 452 001. Flat No.8, 'Mansarowar', 2nd Floor, 3B Camac Street, Kolkata 700 016. Post Box No.100, Thane-Belapur Road, Thane 400 601. 9, Ketki Building, 2nd Floor, Next to Alka Theatre, Sadashiv Peth, Pune 411 630. 202, Arth, 8-Rashmi Society, Behind A. K.Patel House, Mithakhali, Cross Road, Ahmedabad - 380 009. 204-207, Ramanashree Chambers, 2nd Floor, No.37, Lady Curzon Road, Bangalore 560 001. C/o. Arpan Corporation, AVM Studios Compound, 38, Arcol Road, Vadapalani, Chennai 600 026. Krishna Mansion, 2nd Floor, Adjacent to Bible House, 134, Rashtrapati Road, Secunderabad 500 003. PHONE 2371 14 34 2331 96 94 /95/96 2531 663 2542 131 2704 474 2704 486 2217 23 82 2217 23 83/ 84 2760 58 34 2760 58 35 / 36 433 48 31 432 12 67 2642 76 67 2643 08 98 559 26 81 559 21 37 559 62 74 2372 85 79 2472 67 34 2753 45 12 FAX 011-2331 9413 0161-2533826 0731-2704390 033-2217 2467 022-2760 0430 020-433 9210
CHENNAI SECUNDERABAD
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