Synchronous motor, type AMS

Chapter 7 Maintenance

Chapter 7 Maintenance

7.1 Preventive maintenance

A motor often forms an important part of a larger installation and if it is supervised and
maintained properly it will be much more reliable in operation.
The border between supervision and maintenance is rather diffuse. Normal supervision of
operation includes logging of operating data such as load, temperatures etc., and the comments
made are used as a basis for maintenance and service.
After commissioning or maintenance supervision should be intensive. Temperature of bearing
and winding, load, current, cooling, lubrication and vibration shall be checked frequently.
Local condition has to be considered when decision of maintenance interval and level.
It is the ABB customer responsibility to make sure that installations/components that is not
ABB scope of supply but connected/mounted to the machine are serviced according to a
maintenance schedule.

7.2 Before all maintenance work

Safety precaution
Read and follow the information in the following sections:
• Section 1.2, safety precautions.
• Section 1.4, prerequisites.

WARNING - Risk of personal injury

Before any maintenance or tests is performed the following must be done:
1. Make sure before maintenance work, together with factory electrical responsibility
manager, that the machine is electrical dead, grounded and mechanical blocked.
2. Before working on any electrical equipment, general electrical safety precautions are to be
taken and local regulation has to be respected, according to instructions of the customers
personnel in charge of security, in order to prevent personnel accidents.
3. Employees who perform maintenance on electrical equipment and installations shall be
qualified persons as required, and shall be trained in and familiar with the specific
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

maintenance procedures, and the tests required.

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 Synchronous motor, type AMS
Chapter 7 Maintenance

Preparation and preplanning of maintenance

Preparation and preplanning is recommended before all maintenance, special level 3 and 4.
Requirements of:
• Tools including rotor removal at level 4.
• Manpower and needed competence.
• Spare parts and other overhaul kit (replacement and consumables).
• Lifting capacity, according to table below:

Maintenance
Level 1 (L1) Level 2 (L2) Level 3 (L3) Level 4 (L4)
program
Weight capacity
N/A N/A 1 500 kg *
required

* The required weight to lift the rotor = rotor weight on outline drawing + 600 kg.

7.3 After all maintenance work

After completed maintenance work all removed covers, protections etc. must be mounted before
the machine is put into operation.
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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4 Recommended maintenance program

Maintenance
Level 1 (L1) Level 2 (L2) Level 3 (L3) Level 4 (L4)
program
max. 10 000h (equivalent max. 20 000h (equivalent max 40 000h (equivalent max 80 000h (equivalent
Interval hours) of operation hours) of operation hours) of operation hours) of operation
or yearly or max. 3 years or max. 6 years or max. 12 years

Preparation for Open inspection covers. Open inspection covers. Open bearings. Open bearings.
inspection Open water coolers. Removal rotor
and exciter.
Open water coolers.
Instrument/ Megger, stator. Megger, stator Megger, stator.
Tools Megger, rotor. Megger, rotor Megger, rotor.
Fibre-optic or video Rotor removal equipment.
borescope. Torque wrench.
Oscilloscope/Test Oscilloscope/Test
equipment. equipment.

Parts/ Bearing shell, Acc. to L1 and suggestion Acc. to L2 and suggestion Acc. to L3 and suggestion
Spare parts Shaft seals, from inspection L1. from inspection L1 and from inspection L1, L2
Airlock filter (bearing), Silicon tape. L2. and L3.
Control pulse unit, Water cooler. Rotor kit.
Thyristors, Diodes. Rectifier kit.
Other order specific Bearing kit.
parts. Gaskets.

Expected Approx. 1 day. Approx. 2 days. Approx. 5 days. Approx. 10 days.

downtime

Option: Diagnostic insulation test of the stator winding.

Equivalent hours = Total operation hours + No of starts x 20

Example of maintenance schedule:

Interval 10 20 30 40 50 60 70 80
Hours x 1000

Program L1 L2 L1 L3 L1 L2 L1 L4
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Timing of the inspection and overhauls are largely determined by the number of operating hours, the mode of operation and
the number of starts of the motor. Local condition has to be considered.
The maintenance intervals shall be co-ordinated for the motor, in a suitable way.

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4.1 Motor
Location L1 L2 L3 L4 Activity Approved

1. Motor X X X X 1. Look through all logged or recorded data available;

load, temperature, vibrations etc. Fill in the report. If
values deviate from time of commissioning or earlier
inspection please contact the supplier.
X X X X 2. Inspect exterior of motor for rust, leaks or other defects.
X X X X 3. Visual inspection of all external fastenings.
X X X X 4. Replace air filter, if necessary.
X X X X 5. Ensure ventilation ducts are clean and free of obstruction
if connected to external air.
X X 6. Check of quality on sealing gaskets and sealing
compound. Replace sealing gaskets and sealing
compound, if necessary.
2 Foundation X X 1. Inspect grouting and anchored bolts. Check for excessive
clearances and correct as required. Inspect for cracks in
the foundation.
3 Service/Repair X X 1. Replacing, cleaning and modification acc to
recommendation in earlier inspections and suppliers
service bulletin.

General cross-section
AMS machine (actual
design acc. to outline
included in binder
“Users Manual”).

Ventilation duct

Inspection covers
on both ND- and
D-end sides.
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Ventilation duct
Figure 7-1

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4.2 Stator
Location L1 L2 L3 L4 Activity Approved

1. Stator winding X X X X 1. Inspect winding connections.

X X X X 2. Inspect winding and bracing rope.
X X 3. Inspection for cleanliness, discoloration, condition of
insulation, looseness, movement and wear.
Clean if necessary.
X X X 4. Measure and record insulation resistance. Refer to
instruction “Commissioning” section “Electrical checks”,
included in the binder “Users Manual”.
X X X 5. Measure Polarization Index. Refer to instruction
“Commissioning” section “Electrical checks”, included
in the binder “Users Manual”.
2 Air cover X X X X 1. Visual inspection of sealing.
3 RTDs X X X X 1. Verify function of all RTDs.
4 Heaters X X 1. Function check.

Air cover

Sealing Air cover

Stator coils

Bracing rope
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Figure 7-2

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4.3 Stator terminal

Location L1 L2 L3 L4 Activity Approved

Terminal box X X X X 1. Visual inspection of all line- and neutral connections and
stator bushings.
X X X X 2. Visual inspection of general condition.
X X X X 3. Inspection of pressure relief hatch.
X X X X 4. Visual inspection of insulators.
X X 5. Check tightening torque at all connections and insulation
behind the terminals.
X X 6. Test e.g. Current transformers (CT), etc. if applicable.
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Chapter 7 Maintenance

7.4.4 Rotor
Location L1 L2 L3 L4 Activity Approved

1. Rotor X X 1. Check all brazed connections for cracks.

X X X 2. Measure field circuit insulation resistance, 500V DC
megger. Refer to section 5.3.
2 Rotor coils X X X X 1. Check turn insulation, discoloration etc.
X X 2. Check interconnections.
X X 3. Check turn insulation (voltage drop test).
Refer to section 7.5.
3 Rotor coil X X X X 1. Inspect coil supports, screws, washers and insulation.
support
X X 2. Check upper coil support insulation plate, Max.
movement, 10mm radially out of original position.

Brazed connection Rotor coils

Connection rotor and
exciter rotor Interconnection Lower coil support
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Upper coil support

Insulation plate

Figure 7-3

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 Synchronous motor, type AMS
Chapter 7 Maintenance

Location L1 L2 L3 L4 Activity Approved

4 Pole shoes X X X X 1. Check pole shoes for discoloration.

5 Pole bolts X 1. Inspect by knocking on bolt head.
If pole bolts are loose or corroded, ABB has to be
contacted.
6 Fan X X 1. Inspect fan blades and weldings.
7 Balancing X X 1. Inspect balancing weights and fastening details.
8 Air gap X 1. Check air gap after assembling of machine.

Fan
Balancing weights
Pole bolts
Pole shoes
Figure 7-4
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Chapter 7 Maintenance

7.4.5 Bearings
Location L1 L2 L3 L4 Activity Approved

1. Bearing X X 1. Open bearings.

inspection
2 Bearing X X X X 1. Inspect for leaks.
housing and
X X X X 2. Inspect all bolted joints.
support
X X X X 3. Inspect guide support.
3a. Shaft seals X X X X 1. Check for leaks. If leaks are found, check for wearing and
damages.
X X 2. Clean drain holes in the shaft seals.
3b. Sealing in air
lock cover X X 3. Check for leaks. If leaks are found, check the sealing.
4 Shaft surface X X 1. Verify that the sealing surface is free from corrosion and
wearing.
5 Bearing X X 1. Measure insulation resistance. Refer to section 5.3.
insulation
6 Oil ring X X 1. Check for wearing or damages.
7 Oil piping X X X X 1. Inspect for leaks.
8 Measuring X X X X 1. Verify function of all measuring instrument.
instrument
9 Lube oil X X 1. Analyse oil for contamination and replace oil and clean
the system if necessary. Refer to section 7.6.3.
X X 2. Check for water in each bearing and remove if necessary.
10 Air filter X X X X 1. If necessary replace filter for air intake to the airlock
seals, located on bearing pedestals.
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 Synchronous motor, type AMS
Chapter 7 Maintenance

Oilring Airlock cover

Fore bearing seal Sealing in airlock cover

Bearing shell

Rear bearing seal

Bearing housing

Baffle or
Tightening cover

Figure 7-5
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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4.6 Exciter and Rectifier

Location L1 L2 L3 L4 Activity Approved

1. Exciter Rotor X X X X 1. Visual inspection.

X X X 2. Measure insulation resistance, 500V DC megger. Refer to
section 5.3.
2 Diodes, X X 1. General cleaning.
thyristors
X X 2. Check all bolts fastening.
X X 3. Inverse voltage test. Refer to section 7.6.1.
3 Control pulse X X 1. Check wiring to and from the unit.
unit (Rectifier)
X X 2. Check firing level. Refer to section 7.6.1.
4 Rotor X X 1. Check all connections to the exciter.
terminals
5 Exciter stator X X X X 1. Visual inspection.
X X X 1. Measure insulation resistance, 500V DC megger. Refer to
section 5.3.
6 Air gap X X 1. Check air gap.
7 Heaters X X 1. Function check.

Exciter stator
Exciter rotor
Rectifier

Connection rotor and

exciter rotor
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Figure 7-6

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.4.7 Cooling system

Location L1 L2 L3 L4 Activity Approved

1. Coolers X X X X 1. Visual inspection.

X*) X*) X X 2. Check for cleanliness, corrosion and erosion of air and
Refer to the
water sides.
manufacturer
instruction X*) X*) X X 3. Clean air and water sides.
included in
binder “Users X X 4. Inspect protection anodes (placed in tube sheet) for
manual”. proper activity and replace if necessary.
X*) X*) X X 5. Pressure test.
X X X X 6. Function check of casing water leakage detector.

*) If bad efficiency; clean the heat exchanger by using a brush or chemical rinsing.

Tube

Tube plate

Water box

Gasket

Figure 7-7
If temperature detectors show normal temperature, usually no additional maintenance to
supervision inspection is required for the cooling system. If the coolers have to be cleaned, find
instructions included in the binder “Users Manual”.
If temperature detectors show an abnormal temperature, or close to alarm level in winding or
cooling air, a check of the cooling system has to be made. If the coolers have to be cleaned, find
instructions included in the binder “Users Manual”.
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Water leakage detector

To empty the water leakage detector of water, open the ball valve at the bottom of leakage
detector, see drawing included in the binder “User Manual”.

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.5 Main rotor coil turn insulation (voltage drop test)

WARNING - Electricity 230 V or 400 V 50 Hz / 208 V or 480 V 60 Hz

During the voltage drop test there is a AC-voltage over the field windings. Be careful so no
personal injury occur.
1. Connect all measuring cables before start of measurement.
2. Connect an earth current circuit breaker as protection.

Disconnect main rotor field winding from exciter rotor.

The test is carried out by applying an AC-voltage over the entire field winding and measuring
the current and the voltage drop across the total winding as well as each single coil, see figure
7-8.
The applied voltage should be 230 V or 400 V 50 Hz / 208 V or 480 V 60 Hz depending on the
rated frequency of the machine.
+ U1
The voltage over a single coil (U) should
U

not differ more than ±3% from U/4.

2

U
U

U4
3

-
Figure 7-8

7.6 Fault finding

The motor is protected with alarms and trips for most kinds of abnormal running conditions,
both electrical and mechanical. Some of these protections can be reset and the motor restarted
directly as the fault is known or easy to locate.
Examples of protections that if they give an alarm or trip, may need further investigations to be
located are:
• Diode fault protection.
• High temperature in bearing.
• High temperature in winding or in cooling air.
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

• Vibration protection.

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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.6.1 Diode fault

In case any of the diodes or thyristors in the rotating rectifier should fail, the “diode fault”
protection will pick up and trip the motor. To determine and locate a faulty diode, open the
cover of the rotating rectifier and measure with an ohm-meter over one of the diodes or
thyristors. If a faulty diode or thyristor is detected, disconnect all diodes and test them
separately to locate the faulty diode.

NOTE: If a faulty diode or thyristor the recommendation is to replace all diodes,

thyristors and control pulse unit.
Refer to the instruction “Replacement of diodes and thyristors” included in the binder “Users
Manual”.
To test the thyristors, firing unit and diodes the following method can be used:
• Open the cover of the rotating rectifier.
• Disconnect the rotor winding from the rectifier.
• Apply alternating voltage to the plus and minus bars of the diode bridge according to
figure 7-9. A 600 ohm resistor shall be connected to limit the current flow as shown in
figure 7-9.
Note: An equipment specially made for this test is possible to buy from ABB AB, Machines.

Test equipment - Rectifier unit

Supply
Exciter
voltage osc side
Uac

600
+

Figure 7-9
• Increase the voltage and check with an oscilloscope the triggering voltage level of the
firing unit and the thyristors as shown in figure 7-10 chart 2 and 3.
• Decrease the voltage to a level under the firing units trigger level, see figure 7-10 chart 1
and measure over each diode separately. A shorted diode will show zero (0) volt on the
oscilloscope.
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Chapter 7 Maintenance

Test result for healthy rectifier

1. Û< Triggering voltage level Ûac < UT

Triggering voltage UT
level
Test Voltage
Ûac
2. Û = Triggering voltage level Ûac = UT
UT

Ûac
3. Û > Triggering voltage level Ûac > UT
UT

Ûac

Figure 7-10
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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.6.2 Altering the firing voltage

To alter the firing level on the control pulse unit, the cable have to be connected to the terminal
corresponding to the new firing level.

NOTE: Before altering the firing level, write down the original connections for firing
level, thyristors, etc.

Thyristor B Thyristor A

K K-G K K-G +
150V
225V
300V
450V
600V
750V
900V
1.1kV
1.3kV
1.5kV

x Drawing number
x
Seriel number

Connect to right firing level

Figure 7-11
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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.6.3 Lubrication
The motors are provided with sleeve bearings with an almost unlimited service life provided
that the lubrication functions continuously and that the oil is changed at suitable intervals.

Temperature
To enable the bearing temperature to stabilize at a normal level, the correct amount or flow of
oil is required. The normal bearing temperature is 65 - 85 oC.

NOTE: The oil may be warm.

Characteristic properties of the oil qualities listed are:

The oil is a lubricant based on paraffin having high viscosity coefficient (VI>90) and a
particularly low fluid temperature. It includes the following additives:
• oxidation inhibitor
• anti-foaming
• mild EP action, anti-wear additive
• rust inhibitor

Condition of the lubricant

Check the oil with respect to colour, smell, turbidity and deposits in a test bottle.
The following requirements shall be fulfilled:
• The oil should be clear or negligibly turbid. The turbidity may not be caused by water.
• Strong acid or burnt smell is not acceptable.
• The quantity of metal impurities may not exceed 0.05% by weight.
• The original viscosity must be maintained within a tolerance of ±10-15%.
• The original acid number should not be exceeded by more than 1 mg KOH per gram oil.
An oil check should be performed a few days after the first test run of the motor and
subsequently as required. If the oil is changed just after the commissioning, it can be used again
after removing wear particles by filtering or centrifuging.
In doubtful cases an oil sample may be sent to the laboratory to determine viscosity, acid
number, foaming tendency, etc.
A duty period of 3-8 years before an oil change is necessary is not unusual.
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 Synchronous motor, type AMS
Chapter 7 Maintenance

Oil qualities
Unless otherwise stated on ABB AB, Machines drawing “Technical specification” included in
the binder “Users Manual”, the bearings are designed for any of the following oil qualities:

Oil 7 1201-301 (Oil 7061)

ISO VG 32
Viscosity 32 cSt at 40C (20 at 50C)
Pour point max. -30C.
BP: Energol HLP 32
Castrol: Hyspin AWS 32
Esso: Nuto HP 32
Gulf: Harmony 32 AW
Klüber: Lamora 32
Mobil: D. T. E. 24
Optimol: Ultra 5025
Shell: Tellus Oil 32
Texaco: Rando Oil HD A 32

Oil 7 1201-302 (Oil 7071)

ISO VG 46
Viscosity 46 cSt at 40C (28 at 50C)
Pour point max. -30C.
BP: Energol HLP 46
Castrol: Hyspin AWS 46
Esso: Nuto HP 46
Gulf: Harmony 46 AW
Klüber: Lamora 46
Mobil: D. T. E. 25
Optimol: Ultra 5035
Shell: Tellus Oil 46
Texaco: Rando Oil HD B 46
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 Synchronous motor, type AMS
Chapter 7 Maintenance

7.6.4 High temperature in bearing

7.6.4.1 Trouble shooting 1

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no : .......................................................................................................................................

Insufficient section 7.6.4.2

lubrication

Oil temperature Faulty oil cooler Replace the

too high cooler

High axial forces Faulty coupling

Faulty assembled Has bearing been Open and adjust

bearing disassembled?

Damaged part of Impurities in the Change oil

babbits oil?

Inductive bearing Repair bearing

currents? insulation

Complete seizure Repair bearing

of bearing journal
Replace
bearingshell
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Faulty
instrument?

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Chapter 7 Maintenance

7.6.4.2 Trouble shooting 2

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no : .......................................................................................................................................

Oil pump not motor protection Fault finding

reliable? trips? and action

Low Oil filter Check main-

oil flow clogged? tenance status Replace filter

Reduction valve Latest

Adjust flow
shut? adjustment?

Too low oil Faulty oil Fault finding

temperature heater and action

Check with
Unsuitable oil Change oil
ABB AB,
quality Machines´s quality
recommendation

Oil Check status of

worn out oil change Replace the oil
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Chapter 7 Maintenance

7.6.4.3 Trouble shooting 3

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no : .......................................................................................................................................

Oil worn out Replace the oil

Unstable bearing
temperature
Impurities in the
Replace the oil
oil

Damaged shaft
Repair the seals
seals

Airlock seal out Repair/replace

of action the airlock cover

Oil leaks
Too high oil
flow Correct oil flow

Incorrect
Problem in oil
inclination of
flow return
the return pipe?

Check for fault

in external oil
supply system
Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Check for
under/over
pressure in Check that
bearing under pressure
is well below
surrounding
outside the
bearing housing

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Chapter 7 Maintenance

7.6.5 High winding and/or air temperature

7.6.5.1 Trouble shooting

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no :.......................................................................................................................................

Faulty
Faulty sensor
instrument

Check fan motor if

Low cooling
included/ Repair or
water flow
replace if necessary

Cooling water Check fan motor if

temperature to included/ Repair or
high replace if necessary
High winding and/or
air temperature
Dirty or plugged
Clean the cooler
cooler

Replace the
Leaking cooler cooler

Air inside the Bleed the cooler

cooler

Overload Process control

Skeleton No. 3BSM903654, EN, Rev. B, (2014-09-17)

Dirty stator Clean the stator

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Chapter 7 Maintenance

7.6.6 Water leakage detector

7.6.6.1 Trouble shooting

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no :.......................................................................................................................................

Check if Verify running

condensation parameters
water

Signal from water

leakage detector
Replace the
Leaking cooler cooler or gasket

Broken detector/ Broken detector/

cable breakdown cable breakdown
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