C.F.R.

srl
Via Raimondo dalla Costa 625 - 41122 Modena (MO) - Italy
Tel: +39 059 250837 - Fax: +39 059 281655 / 2861223 e-mail:
[email protected] www.cfritaly.com

 Reproduction or translation of any part of this manual without the writen permission of the owner is forbidden. The information and illustrations
contained in these instruction are indicative only. C.F.R. srl reserves the right to make changes to its products without prior notice.
Electric motors
Ed. 01 May 2014
 GENERAL INDEX

Heading Description Page

1 Introduction 3
1.1 Symbols adopted 3
1.2 General information 3
1.3 General safety warnings 4
1.4 Residual risks 5
1.5 Intended use 5
1.6 Prohibited uses 6
1.7 Identification of operators 6
1.8 Warranty conditions 6
1.9 Declaration of conformity 7
2 DC motors 8
2.1 Design 8
2.2 Motor identification and data plate 12
2.3 Nominal operating characteristics 13
2.4 Types of duty 13
3 Handling and transport 15
3.1 Preliminary warnings 15
3.2 Handling of motors 16
4 Installation and commissioning 17
4.1 Acceptance and storage 17
4.2 Installation and commissioning 17
4.2.1 Preliminary warnings 17
4.2.2 Keying 20
4.2.3 Electrical connections 21
4.2.4 Connections for different types of winding 23
4.2.5 Accessories 25
4.2.6 Connection of an external encoder 27
4.3 Reminders on incorporation procedures 28
5 Maintenance 29
5.1 General maintenance 30
5.2 Major servicing 33
5.3 Decommissioning 35
6 Troubleshooting 36

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 1 INTRODUCTION
1.1 SYMBOLS ADOPTED

IMPORTANT:
Read the highlighted information with care, and follow instructions to the letter.

CAUTION
This symbol warns the reader to pay maximum attention to the highlighted
information. Failure to follow instructions can result in serious damage to persons or
to the product.

FORBIDDEN
Pay careful attention to the highlighted instructions.

1.2 GENERAL INFORMATION

It is important that all the precautions indicated in the manual are strictly observed. In the event
that the expected conditions of use or technical data are not covered by this document, contact
C.F.R. so that the application can be evaluated.
The purpose of this document is to provide the user with all the information needed to ensure
correct selection and proper use of the products described.

Products must be used according to the methods described in this

document, by persons who are properly trained for the purpose.

Customers are responsible for ensuring correct selection and use of the
product on the basis of their industrial and/or business needs.
With the state of the art constantly evolving, C.F.R. reserves the right to
update and improve the content of this literature at any time, making
changes which however cannot be regarded as binding.
Responsibility for the selection of the product lies ultimately with the
Customer, unless otherwise agreed in writing between the parties.

DC electric motors Page 3 of 38

 1.3 GENERAL SAFETY WARNINGS

DC electric motors contain dangerous parts and carry various types of risk;
consequently, it is essential to observe all the safety warnings indicated.
The electric motor must be used only after proper training has been given and the
following instructions have been read.
Technicians entrusted with installation, commissioning, inspection, maintenance
and repair operations must be suitably qualified and familiar with general safety
regulations both in the country of origin and in the country where the product will be
installed. They must also have received specific technical training that will enable
them to identify and avoid every potential danger. In particular, maximum caution
must be exercised in respect of live components, rotating parts and hot surfaces.
The electric motor must not be operated in hostile environmental conditions. Be
certain to abide by the parameters indicated in this manual.
Important:
 do not deactivate or tamper with protection devices; if safety systems are
tampered with or by-passed, C.F.R. will acknowledge no liability for any
damage that could occur as a result;
 if an electric motor develops a fault and/or is not running smoothly, withdraw
it from use and label it officially out of service. If repairs are required, contact
C.F.R. Technical Assistance.
An electric motor must not be installed in areas where potentially explosive
atmospheres can be created or where there is a high fire risk.
Commissioning of the motor must not proceed if the driven machine is found to be
at variance with the pertinent directive.

Always use appropriate items of personal protective equipment, e.g. gloves,

safety eyewear, etc...

Do not run the motor if it has become damaged during transport or assembly; in
this instance contact C.F.R. for instructions on how to proceed.
Use only original replacement parts or accessories, or in any event those
authorized by C.F.R srl. If this condition is ignored, claims for repairs or damages
will not be recognized.
Avoid swallowing oil, grease or other material from the electric motor, and do not
dispose of these items irresponsibly.
Do not clean or wash the motor with solvents or pressurized water jets. These are
actions that could damage the product. Do not clean the electric motor using
flammable substances, and never use cleaning compounds that are corrosive or
harmful to health.
Do not apply paint to the electric motor.

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 1.4 RESIDUAL RISKS

Danger from moving parts

Take particular care to avoid any kind of physical contact with moving parts.
Install control components that will allow the motor to be started and stopped both
under normal operating conditions and in an emergency.
Be careful to stop the motor and wait a few minutes before commencing
maintenance operations, making certain that all moving parts have slowed to a
complete standstill.

Danger from explosion and fire

Do not install the motor outdoors or in hostile environments without first checking the
level of protection specified.
A DC motor can continue to carry voltage even after the stop control has been
operated: after testing the earth system, for example, certain parts may present
residual risks of explosion. Make certain live parts are completely safe before
working on the motor.

Waterless fire extinguishers only

In the event of fire, put out flames only with extinguishers using powder or CO2.

Danger of burns through contact with motor surfaces

Remember always to wait a few minutes after shutting down the machine before
working on the motor, as some hot parts may not cool down immediately.
Before starting up the motor, ensure that parts made of plastic or temperature-
sensitive materials are shielded from sources of excessive heat.

1.5 INTENDED USE

C.F.R. electric motors are intended for incorporation into machines, generally for professional use,
secured to fixed mountings such as the machine frame or baseplate and designed to cover the
widest imaginable range of applications.

Electric motors are not normally designed for use in conditions exposed directly to the elements. If
electric motors are to operate in hostile environments with notable levels of dirt, water splash, heat
or humidity, they must be equipped with special guards. For applications requiring electric motors
equipped with special protective enclosures, contact the C.F.R. sales office to ensure these are
ordered correctly.

DC electric motors Page 5 of 38

 1.6 PROHIBITED USES

The intended use for C.F.R. electric motors is as described above. Any other uses not specifically
indicated are prohibited.

The following are severely prohibited:

 Tampering with parts of the motor or fitting replacements not supplied by C.F.R.
 Use in environments where potentially explosive atmospheres can be expected.
 Connection to power sources and use in conditions other than those described in the
technical specifications

The electric motor must absolutely not be used in an improper manner and/or
operated before it has been definitively installed in and interfaced with the driven
machine.

Where electric motors are used for unsuitable or unspecified applications,

warranty is automatically invalidated and C.F.R. will decline liability for any
damage that may be caused to persons or property.

1.7 IDENTIFICATION OF OPERATORS

Given that certain activities essential to the use of electric motors involve the exposure of operators
to specific risks (e.g. connections at installation), persons entrusted with the operations described
in this document, from installation through to maintenance, must be properly trained in accordance
with current statutory regulations.

1.8 WARRANTY CONDITIONS

The motors referred to in these instructions are guaranteed for 12 months from the date of
consignment by C.F.R. Any warranty arrangements of a different nature or duration must be
negotiated with C.F.R. and included in the agreed contractual conditions.
The warranty cover is limited strictly to cases of malfunction deriving from defects of manufacture,
in accordance with the indications given in this document. C.F.R. acknowledges no liability for
damage caused to machinery or systems in which the motor is installed. Warranty covers the
repair or replacement only of defective motor parts. Warranty does not cover any defect
attributable to installation, maintenance, cleaning or parts replacement procedures that have been
performed incorrectly or ineffectively.
If a claim under warranty is acknowledged by C.F.R., the defective component will be replaced or
repaired by the company's own staff. Warranty does not cover parts subject to normal wear and
tear. Warranty claims will not be acknowledged in cases of incorrect installation or maintenance,
tampering with the product, improper use, or damage sustained during transport, handling and
storage. All transport costs incurred in returning the product to C.F.R. and restoring it subsequently
to the customer are excluded from the warranty.

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 1.9 DECLARATION OF CONFORMITY AND INCORPORATION

The manufacturer:
C.F.R. srl, with registered office at Via Raimondo dalla Costa, 625, 41122 – Modena (MO) –
Italy, in the person of its Legal Representative Mr Luciano Cottafavi

Declares under its own responsibility that products manufactured by the company under the
name:

DC electric motors - type CA, MP.

to which this declaration relates, are in conformity where applicable with the following directives:

 2006/95 (low voltage),

 2004/108 (electromagnetic compatibility),
 2006/42/CE (machinery), insofar as they meet applicable safety requirements and are
capable of being incorporated into a machine

The electric motors are also in conformity with the following technical standards:

EN 60034-1
EN 60034-5
EN 60034-7

Furthermore:

 The technical file is held by C.F.R. srl with registered office at Via Raimondo dalla Costa 625,
41122 – Modena (MO) – Italy, in the person of its legal representative,
 C.F.R. undertakes to transmit information regarding its products, in response to any
reasonable request from the national authorities. This undertaking is given in respect of the
method of transmission and without prejudice to the intellectual property rights retained by the
manufacturer of the product,
 Electric motors must not be commissioned until the system or the machine into which
they will be incorporated have been declared as being in conformity with the
requirements of applicable directives.

Modena, 05/05/2014

Signed

…………………………
Luciano Cottafavi
(Legal Representative of C.F.R. srl)

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 2 DC MOTORS
2.1 DESIGN

These are electric motors operating off a low voltage d.c. power supply, designed for general use
in industrial applications.

MOTOR TYPE MP
Ref Description Ref Description
01 CASE 06 BRUSH
02 ROTOR 08 BRUSH-HOLDER CASTING
03 BEARING 09 FRONT END COVER
04 BEARING 12 CLIP
05 BRUSH-HOLDER

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 MOTOR TYPE CA
Ref Description Ref Description
01 CASE 08 BRUSH-HOLDER CASTING
02 ROTOR 09 FRONT END COVER
03 BEARING 10 FAN
05 BRUSH-HOLDER 13 TERMINAL BLOCK
06 BRUSH

Main parts of the motor:

 Case: steel, protected externally by zinc coating or paint finish.

 Flanges and end covers: can be made of aluminium, cast iron or steel.

 Motor shaft: always steel, with both male and female output configurations at the coupling
end and at the end opposite. Special shafts can be supplied if requested by the customer.

DC electric motors Page 9 of 38

  Bearings: these are double-shielded, grease lubricated low clearance radial ball bearings
designed specifically for electric motors. Efficient lubrication is guaranteed at operating
temperatures up to 100 °C maximum.

 Brushes: these can be carbon or metal-graphite, depending on the technical specifications

of the motor. The brushes are positioned for ease of access and can be replaced quickly
and simply if necessary. Motors can be supplied with 2, 4, 8, 12 brushes; selection between
the models is required in order to avoid exceeding a given current density at the single
brushes.

 Types of ventilation: motors can be designated

o NV: non ventilated motor, generally with ingress protection IP 44 or higher.

o VA: front end — the fan is located at the coupled end of the motor shaft. This
configuration is generally adopted when the rear end of the motor shaft is fitted with
an electromagnetic brake or other accessory.

o VP: rear end — the fan is positioned at the rear end of the motor, behind the
brushes.

o VF: forced ventilation — the motor is equipped with an external fan unit and a
special ducting arrangement. This type of ventilation is recommended when the
motor may be operated at low running speeds or used for particularly heavy work
cycles (continuous duty S1).

NV VA

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 VP VF

 Insulation: both the armature and field windings are assembled with round or flat copper
wire, insulated to class H, and the rotor is also impregnated with epoxy resins and
varnished to withstand temperatures up to 155 °C.

 Motor enclosure rating: ingress protection from IP 00 to IP 66, on request.

 Terminal box enclosure rating: motors can be supplied with

terminal box or exit cables having ingress protection from IP 00 to
IP 66.

 Type of winding: in the case of wound field designs, C.F.R. can supply:

o Series excited motors

o Compound excited motors
o Shunt excited motors
o Separately excited motors

DC motors will generally operate with electronic controls. Before commissioning the motor,
check for compatibility between the type of winding and the control that will be utilized.

DC electric motors Page 11 of 38

In addition, if requested, C.F.R. can supply:

 Electromagnetic brakes: The electromagnetic brakes supplied are generally negative

acting: when the circuit is powered up, the brake releases; when powered off, the brake is
applied

 Bimetal thermal sensors: normally closed or normally open, with temperature thresholds
of 90 °C, 110 °C, 140 °C. Used to protect the motor from excessively high temperatures.
Items supplied on request when ordering

 Mounting feet: fixing feet can be supplied for certain types of motor

 Painting: motors can be supplied with special paint finishes, if requested

 Brush wear indicators: brushes are available with wear indicators, if requested

 Starting contactors

 Encoders or dynamos

2.2 MOTOR IDENTIFICATION AND DATA PLATE

All motors made by the company are identified by a data plate, as illustrated below:

Power Duty cycle

Voltage Insulation class
Current Ingress protection
Speed Form factor
Torque Testing date
Bar code
Type Motor designation
code
Serial number Notes

Many items of technical data on the plate are self-explanatory. For further
information, refer to drawings supplied with the accompanying
documentation, or contact C.F.R. direct

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 2.3 NOMINAL OPERATING CHARACTERISTICS

Unless otherwise indicated, the operating characteristics refer to:

 duty cycle S2 60 min;
 ambient temperature: 0 °C – +40°C;
 maximum altitude 1000 m above sea level;
 power input at nominal voltage and frequency; maximum permissible voltage fluctuation
±5%. For maximum and minimum power input values, assume a further ±5% (e.g. a motor
rated 48 V is suitable for nominal mains voltages from 45 V to 50 V).

The efficiency of a motor may be reduced if input voltages deviate from the
nominal rated values.

2.4 TYPES OF DUTY

Duty cycles are explained in the following summary of the reference standards and the definitions
adopted.

 Load: the combined values of electrical and mechanical quantities that characterize the
requirements placed on a rotating machine by an electrical circuit or by a mechanical
device, at a given moment.
 Duty: the definition of the load, or loads, to which the machine is subject, which include (if
applicable) starting, electric braking, no-load and idle periods, as well as their duration and
their sequence over time.
EN 60034-1 standards define different types of duty. Those of interest for C.F.R. products are:

Continuous Duty – S1
Operation at constant load for a duration sufficient to
reach thermal equilibrium.

P = Load
Pv = Electric losses
T = Temperature
t = Time
Tcc = Time period of operation at constant load
Tmax = Maximum temperature recorded

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 Short time duty – S2
Operation at constant load for a given period of time
less than that required to reach thermal equilibrium,
followed by an idle period of duration sufficient to re-
establish equality between the temperature of the
machine and the temperature of the cooling fluid,
with a tolerance of 2°K.
Example: S2-60 min
The motor operates continuously under nominal
rated conditions for 60 min, then remains idle for a
duration sufficient to return to ambient temperature.
P = Load
Pv = Electric losses
T = Temperature
t = Time
Tcc = Time period of operation at constant load
Tmax = Maximum temperature recorded

Intermittent periodic duty – S3

Sequence of identical operating cycles, each
comprising a period of operation at constant load
and an idle period.
Duration of cycle 10 minutes.
In this duty cycle, the sequence is such that the
starting current has no significant effect on
temperature rise. The nature of periodic duty dictates
that thermal equilibrium is never reached during the
on-load period.
Example: S3-70%
The motor runs for 7 minutes and remains idle for 3
minutes

P = Load
Pv = Electric losses
T = Temperature
t = Time
Dc = Duration of single cycle
Tcc = Time period of operation at constant load
Tr = Idle period
Tmax = Maximum temperature recorded
Intermittent ratio = Tcc / (Tcc+Tr)
* 100%

DC electric motors Page 14 of 38

 3 HANDLING AND TRANSPORT
3.1 PRELIMINARY WARNINGS

All C.F.R. products are prepared for shipment packed in wooden crates or steel containers, or
boxed on pallets, as appropriate for the weight and dimensions of the particular item. Special
packing can be provided on request; in this instance, contact the sales department when placing
the order.

In the case of models that cannot be handled manually, the choice of suitable
lifting gear (straps, slings, chains, eyebolts) will depend primarily on the weight of
the electric motor.
Handling, transport and installation procedures must be carried out by persons
properly trained and instructed for the purpose, in accordance with current
regulations on health and safety in the workplace.

If any pack received from a carrier has been seriously damaged, the best policy is
to indicate PROVISIONAL ACCEPTANCE, check immediately that the actual
product has not been damaged, photographing it if necessary, then provide a
written account of the situation and the condition of the product. The product must
not be used until written authorization is received from C.F.R.
If any parts or components are found to be defective or damaged, contact the
Engineering - Sales Department.
Should the data plate be damaged, a duplicate must be requested in writing from
the Engineering department.
Make certain that there are no parts of the packing such as fragments of
cardboard, staples etc., occluding or obstructing motor ventilation holes.
If electric motors are not going to be used immediately, they must be stored in
clean, dry, temperate surroundings, protected from vibration, sheltered from the
weather, and preferably covered in such a way that the case cannot be penetrated
by dust and debris.
Before using a motor, check that all parts are in serviceable condition, especially
the shaft, bearings and flanges, and all electrical contacts.
Test the insulation of the winding, or windings, using the appropriate instrument.
Do not touch the terminals either during tests or immediately afterwards, as they
can remain live for a certain duration.

The materials in which electric motors and relative components are packed must
be suitably disposed of at authorized collection sites.

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 3.2 HANDLING OF MOTORS

Small motors can be handled manually, without lifting gear. Motors that cannot be man-handled
are provided with a threaded hole into which an eyebolt of suitable capacity can be screwed.

If necessary, the motor can be cradled using straps or slings of suitable capacity looped around the
case at the appropriate points; in any event, be sure to observe current accident prevention
regulations.

Do not added further loads to the motor when lifting.

Do not lift a motor by its output shaft or fan cowl, or by plastic parts, terminals or
power cables.

DC electric motors Page 16 of 38

 4 INSTALLATION AND COMMISSIONING

4.1 ACCEPTANCE AND STORAGE

Check that the motor is exactly as ordered, and has not been damaged during
transport.
Eyebolts that may already be fitted to the case must be used only for lifting the motor
itself.
If the required operating parameters are different to those indicated in the technical
specifications, contact the C.F.R. engineering department before proceeding.

4.2 INSTALLATION AND COMMISSIONING

4.2.1 PRELIMINARY WARNINGS

When installing the motor, the machine must be at a standstill, and disconnected from
the electrical power supply.

Motors can be installed in any of the mounting positions covered by EN/IEC 60034-7.
The mounting position of the motor must be selected in such a way that:
- The motor can be properly secured, with all threaded fasteners properly tightened.
- In the case of a ventilated motor, there is sufficient clearance between the fan and the frame
of the machine to allow a free flow of air.
- All power cables of the motor, electromagnetic brakes and any other components
(accessories) supplied with the motor can be fastened securely between nuts and lock nuts
or with connectors. In addition, power cables must not be pressed or pinched against other
parts (machine frame, flanges, etc...) and must be long enough to ensure they can be
connected without difficulty, in other words free of any tensile stress that could place strain
on terminals and connections.

When tightening cables to the relative terminals, always use two wrenches as illustrated. Hold
the bottom nut stationary to prevent the terminal from turning, then, with the cable termination lug
in position on the post, tighten the top nut to obtain a secure and durable contact.

DC electric motors Page 17 of 38

 Do not install near heat sources.
Bearing in mind the required ingress protection, install the motor in such a way that
foreign matter cannot penetrate the frame, or obstruct the ventilation holes if any.
Make certain that water or other liquids cannot infiltrate the motor.
Make sure the motor cannot be damaged when the machine is moved for whatever
reason.
Check that the data plate remains clearly visible once the motor is installed.

If the case includes drain holes, check that these are correctly positioned in such a
way that condensate can run off freely.

During the installation procedure, ensure that fixing screws or bolts do not
penetrate internally of the motor, as these could damage the electrical windings.

Once in position on the driven machine, all motors must be connected mechanically to the
machine pivot so that rotation can be transmitted.
The connections most frequently used are:

- Direct coupling to another component (gear unit, differential, pump...).

- Indirect coupling, by way of pulleys, drive couplings or pinions.

Before coupling the motor, clean and lubricate contact surfaces to prevent any risk of seizing.
If the motor is bolted to a bed or baseplate, ensure that the mounting surface is sufficiently thick,
with a flatness tolerance of less than 0.03 mm.

DC electric motors Page 18 of 38

 It is always important to check that the fit tolerances of coupled components are correct
and compatible with those of the motor components. In particular, for both direct and
indirect coupling arrangements, the rectangularity tolerance between the motor shaft
and output flange and the components to be coupled must be less than 0.03 mm.

When making the connection, avoid axial or radial loads that could damage the
bearings and other components of the motor.

Use the appropriate special tools for

assembly purposes.

To find out the permissible axial or radial loads, always ask for and refer to literature
originated by C.F.R.

Correct Incorrect

Avoid mounting components in such a

way as to create overhung loads, and
ensure that chains or belts are not
tensioned to the point of affecting
bearing life, or even causing failure of
the motor shaft (see illustration
alongside)

a: hub
F: Force

DC electric motors Page 19 of 38

 Make certain there is no way that elements coupled to the motor can cause damage to
parts of the machine or injury to persons.

Ensure that parts of the motor likely to reach high temperatures are suitably protected
against possible bodily contact.

The coupling component and the type of transmission are selected and designed to
suit the particular operating conditions. Selection and design are the responsibility of
the customer: the responsibility of C.F.R. srl is limited to the reliability of such technical
data as the company can be expected to provide to the customer, on request.

The recommended tightening torques for threaded fasteners are:

Tightening torque for typical rated strengths

Bolt size 8.8 10.9 12.9
[Nm] [Nm] [Nm]
M4 3 4 5
M5 6 9 10
M6 10 15 18
M8 25 35 41
M10 50 70 85
M12 90 120 145
M16 210 295 355
M20 450 580 690
M24 750 1,000 1,200
A tolerance of +/- 8% is permissible on the above values

4.2.2 KEYING

C.F.R. motors are always balanced with a half-key fitted to the shaft (unless specified otherwise
when ordering). Accordingly, transmission components must also be balanced using a half-key.
For special keying requirements, refer to the detailed instructions provided by the supplier of the
component and by C.F.R.

DC electric motors Page 20 of 38

 Example of transmission
component keyed cold to the
motor, using the threaded hole
in the end of the shaft.
a) Motor
b) Transmission component
c) Assembly tool

If the end face of the shaft end and/or the hole in the hub are damaged, the defect
must be rectified BEFORE proceeding with assembly.

4.2.3 ELECTRICAL CONNECTIONS

C.F.R. srl can supply different types of motors, consequently it is important that each one should
be wired according to the instructions provided. If the motor is operated by an electronic control
or other device, compatibility between the motor winding and the control must be verified.

Before making the electrical connection, make certain that the power supply
matches the values indicated on the data plate.

Make the electrical connections to the motor and to auxiliary items when the
machine is idle, with the motor isolated from the mains power supply.

Use cables of section large enough to prevent overheating and/or excessive

voltage drop at the motor terminals. Remove the key from the keyway
before starting the motor with the shaft uncoupled, otherwise it could be
flung out with considerable force.

Be careful, when connecting the motor and the electronic control, to proceed
strictly in accordance with the wiring diagram illustrated below.

Motors can turn in either direction of rotation, left or right: if the direction is not
as required, consult C:F:R. for information on how to select the correct
direction.
In addition, always consult the connection-related information provided by the
maker of the electronic control device.

DC electric motors Page 21 of 38

Example of connection between d.c. motor with accessories, and electronic control.

Electronic control for DC motors

Contactor Fuse

BATTERY

Thermocouple

DC
MOTOR

Electromagnetic brake

DC electric motors Page 22 of 38

 4.2.4 CONNECTIONS FOR DIFFERENT TYPES OF WINDING

SERIES excited motors

Series-wound motor with 2 terminals: this motor can have one

direction of rotation only. Important: the required direction of
rotation must be specified when ordering.

2 Terminals

Series-wound motor with 3 terminals: this motor can have two

directions of rotation.

3 Terminals

Series-wound motor with 4 terminals: this motor can have two

directions of rotation.

4 Terminals

Series-wound motor with 5 terminals: this motor can have two

directions of rotation and two speeds.

5 Terminals

COMPOUND excited motors

Compound-wound motor with 2 terminals: this motor can

have one direction of rotation only. Important: the required
direction of rotation must be specified when ordering.

2 Terminals

DC electric motors Page 23 of 38

 SHUNT excited motors

Shunt-wound motor with 2 terminals: this motor can have one

direction of rotation only. Important: the required direction of
rotation must be specified when ordering.

2 Terminals

Shunt-wound motor with 4 terminals: this motor can have two

directions of rotation.

4 Terminals

SEPARATELY excited motors

Separately-wound motor with 4 terminals: this motor can have

two directions of rotation.

4 Terminals

PERMANENT MAGNET motors

Permanent magnet motor with 2 terminals: this motor can

have two directions of rotation and two speeds.

2 Terminals

The code for the type of winding is indicated on the motor data plate.

DC electric motors Page 24 of 38

 4.2.5 ACCESSORIES

Various accessories requiring an electrical connection can be installed on the motor, if requested.

Thermal overload protections

Motors used for heavy duty applications can be protected against excessive overheating by means
of a bimetal thermal sensor. This protection device must be specified when ordering the motor.
C.F.R. supplies 3 different thermal overload sensors with temperature thresholds of: 90 °C, 110 °C
and 140 °C (+/- 8 °C); different thresholds are available on request.

The thermal sensor is generally embedded in the winding, with two relative wires emerging from
the motor; these must be connected as indicated in the wiring diagram.

THERMOCOUPLE TYPE S 01 WITH AUTOMATIC RESET AND CONNECTING CABLE

Switching method breaker contact
Switching temperature threshold 90 °C, 110 °C, 140 °C
Tolerance +/- 5 °K
Measurement current / n° cycles 2.5 A / 10 000, 5 A / 3000
Standard connection Cable of 0.25 mm2 section

DC electric motors Page 25 of 38

Connection of electromagnetic brake

If the motor is equipped with an

electromagnetic brake, this must also
be connected to the electrical circuit.

The electromagnetic brakes we supply

are generally negative acting: when
the circuit is powered up, the brake
releases; when powered off, the brake
is applied.

All brakes are supplied calibrated and

mounted with 3 screws, normally at
the rear end of the motor.

The middle screw can provide a

torque rise of ±10%.
Torque, power requirement and
maximum air gap values are indicated
in the following table:

Nominal braking
Size Power at 20 °C Smax
torque
[Nm] [W] [mm]
06 4 20 0.3
08 8 25 0.3
10 16 30 0.3
12 32 40 0.5
14 60 50 0.5
16 80 60 0.5

Smax indicates the maximum permissible air gap, beyond which the brake
must be recalibrated and, if necessary, the brake disc replaced.

DC electric motors Page 26 of 38

 4.2.6 CONNECTION OF AN EXTERNAL ENCODER

Connection of an external encoder

An external encoder can be fitted to the motor, if requested by the customer.

The external encoder is not essential for control of the actual motor, but will be used to increase
the resolution of speed and position signals utilized in monitoring the performance of the driven
machine.
If requested by the customer, C.F.R. will prepare the motor shaft to accept the installation of any
encoder selected and installed subsequently by the customer.

An external encoder must not be connected to the electronic control governing

the motor, but to the electronic control governing the driven machine as a whole.

All wiring operations must be entrusted to an expert installation/service

technician and undertaken with maximum care.
C.F.R. recommends users to procure the proper connectorization tools for the
various cables.

DC electric motors Page 27 of 38

 4.3 REMINDERS ON INCORPORATION PROCEDURES

During the process of installing the motor in the driven machine, all of the various controls must be
included: start, stop, emergency stop devices if applicable, and machine safety devices. The motor
must be protected permanently against unacceptable power input or loading situations, and
against malfunction or breakdown. C.F.R. srl can assist in identifying the most suitable protection
systems for particular cases. Where the requisite protection systems are omitted or incorrectly
calibrated or found to be ineffective, C.F.R. srl will decline all liability in respect of faults or failures.

Electrical protections
Motors are not supplied with any kind of electrical protection installed (e.g. fuses,
thermal-magnetic breakers...); it is the responsibility of the user to ensure that
protections against short-circuit and overvoltage are provided.

Mechanical protections
Before machines are commissioned, the user must make certain that all moving
parts are suitably protected; in particular, the machine must not be commissioned
if:
 The motor has not been suitably fixed.
 The cover of the terminal box, if specified, has not been properly fitted and
secured with its screws, to prevent accidental contact with live parts.
 Power cables have not been suitably connected and protected against
accidental contact with live parts.
 The cowl of the cooling fan, if specified, has not been correctly fitted.
 Motors presenting accessible moving parts have not been properly protected.
In addition to mechanical protections associated specifically with motors, the user
must also make certain that all components connected to the driven machine and
set in motion (couplings, pulleys, driver belts, etc.) are suitably protected against
accidental contact.

Protections against thermal risk

The outer surfaces of motors can reach particularly high temperatures.
The user must deploy suitable guards that will prevent operators from coming into
contact with hot parts, whether intentionally or unintentionally.

DC electric motors Page 28 of 38

 5 MAINTENANCE
All maintenance operations must be carried out by skilled service
technicians.

If in doubt, or in need of any information on the use of electric motors,

always contact C.F.R. technical assistance.

Any maintenance operation on the motor must be carried out with the
machine at standstill and disconnected from the power supply (including
auxiliary circuits). Irregularities or abnormalities discovered during an
inspection must be remedied without delay.

Do not carry out maintenance work when the electric motor is running or
connected to the power supply. Make certain that the motor has been
disconnected from the power supply and always wait a few minutes after it
has been shut down, as there are parts that may still be hot.

When work is completed, replace guards and protections that have been
removed.
Take every precaution during maintenance operations to ensure that the
motor cannot be started up by unauthorized persons.

If the electric motor needs to be painted, contact C.F.R. srl for instructions.
To ensure maintenance is performed correctly, it is always advisable
that the electric motor should be removed from the machine in which it
is installed.

During maintenance work, wear suitable items of personal protective

equipment; wait for a few minutes until the electric motor has cooled down
sufficiently and come to a complete standstill.

Do not release or dispose of residual matter into the surrounding environment

when carrying out maintenance. Always observe statutory regulations on
waste disposal.

The frequency of inspections will depend mainly on the number of hours the motor has been
running and on ambient conditions; in any event, current regulations on the servicing of machinery
must be observed.

DC electric motors Page 29 of 38

 5.1 GENERAL MAINTENANCE

As electrical appliances with parts engaged in sliding contact (brushes on commutator), DC motors
require periodic maintenance. It is therefore important that the motor should be serviced at regular
intervals, to ensure smooth operation and long service life.

Checks to be carried out at installation and at least once a year

 Check that there are no traces of debris, oil or water on the motor, and that these have
caused no damage to any parts of the motor, especially wiring components. Clean all
components if necessary, and before reassembly, test the insulation of the stator and the
rotor.
 Check that the entire cooling circuit (case, fan cowl air inlet vents, motorized fan unit if any)
is free of dust, oil and any process waste, in order to ensure that the motor will not overheat
due to the normal flow of cooling air being impeded.
 Check that all connections — whether cables secured to terminals or connectorized cables
— are clean, neatly arranged and properly tightened. If connections are damaged, they
must be renewed or replaced.
 Check that the motor runs free of vibration and without abnormal noise. If vibrations are
detected, check that the motor is fastened securely and that the driven machine is properly
balanced.
 Where drive belts are in use, check that these are correctly tensioned, as a belt that is too
tight can significantly reduce the life of motor bearings and even cause failure of the shaft
extension.
 Where O-rings, seals and other protection devices are installed, check their condition and
replace if necessary with identical components.
 Check that all additional components fitted to the motor, such as contactors, thermal
sensors or external fan units, are operating as they should and calibrated as per
specification.
 Check that the insulation between phase and earth is greater than 2 mOhm.
 Check that the springs on the brush-holder ring have not been damaged by excessive
heating, and are still applying sufficient force to hold the brushes against the commutator.
 Check that the surface of the commutator is clean and even, presenting no grooves or
scorch marks.

DC electric motors Page 30 of 38

 Inspection of bearings: at least once a year

All bearings used by C.F.R. are designed specifically for electric motors, with double seals and
grease lubrication, and do not require any special maintenance; all the same, it is good policy to
check on a regular basis that they are functioning correctly when in operation.
Bearing life can vary to a considerable extent depending on the nature of the loads applied to the
motor and the starting cycles adopted, also on temperature and humidity levels in the operating
environment. Excessive bearing noise will generally indicate the need for replacement.
If the motor has been commissioned only recently, the first area to check is the coupling (rectify
any possible misalignment or check the tension of drive belts, if in use; see also heading 4.2). If
bearing noise persists after remedial action has been taken, this means the bearings are already
impaired and must be replaced.

Inspection and replacement of brushes

In DC motors, current is fed to the rotor by way of brushes that require periodic maintenance.

The brushes should be inspected at least once a year (or every 500 hours in the case of heavy
duty applications). In particular, assess how far the brushes have been lowered from their original
height, and check that there is sufficient pressure from the springs. The brushes must be replaced
when worn beyond a certain point. To find out the reduction in height at which replacement
becomes necessary, contact the C.F.R. engineering department. Whenever the brushes are
replaced, the commutator must also be ground smooth and the mica segments undercut.

Generally speaking, the diameter of the commutator can be reduced by turning on a lathe,
removing up to 2 mm approx of material (for further details regarding this procedure, contact the
C.F.R. engineering department); to ensure the operation is performed correctly, take care not to
damage the soldering on the collar of the commutator. Thereafter, the mica segments between the
DC electric motors Page 31 of 38
commutator bars must be undercut to a depth of no more than 0.4 mm; finally, the outer surface of
the commutator is ground with a diamond tool to restore the finish. This done, it is advisable to test
the insulation of the rotor. The rotor should also be rebalanced following these operations.

When replacing the brushes, follow the steps indicated below, referring to the illustration:

1) Disconnect the motor from the power supply.

2) Remove the clip and the protective grilles, if fitted.
3) Lift the spring retaining the brush in position on the commutator, and remove the brush from its
holder.
4) Undo the screw and remove the brush from the motor.
5) Clean the brush-holder thoroughly, then fit the new brushes and secure with the relative screws
in such a way as to ensure an efficient electrical contact; finally, check that the brushes slide
smoothly in their seats. Reposition the springs on the brushes.
6) Take care throughout this procedure that no foreign matter finds its way into the motor.
It is important that brushes are replaced with identical parts, or in any event, with parts
approved by C.F.R.
Never use brushes having a different chemical composition or of dissimilar size; this could
result in damage to the motor.
7) Reassemble the various components by repeating the above steps in reverse order.

DC electric motors Page 32 of 38

 5.2 MAJOR SERVICING

Replacement of bearings
Always remove bearings with the aid of a puller, taking care not to deface or damage the motor
shaft.

Removal of bearing
turning
the handle
of the puller

Before bearings are fitted, make certain the relative seats have been thoroughly cleaned. Bearings
should be fitted using a press, taking care not to damage the ball races. Check that the bearing
rings are correctly abutted against the shoulders of the shaft and of the relative flanges, also that
the replacement bearings are of the same type as the original components, or equivalent. Where
shaft seals are fitted, these should always be renewed throughout.

When removing and replacing motor components installed with protective

mastic and/or silicone sealant, make certain that the same level of protection
is reinstated following reassembly.

Replacement of motor:
All operations must be entrusted to expert service technicians and carried out
in accordance with current regulations, using the requisite items of Personal
Protective Equipment.
Before commencing any removal steps, the motor and any accessories
installed should be disconnected completely from the power supply.

It is always preferable, where possible, to remove the motor from the machine and position it on a
work bench.
Proceed to strip down the motor, following the steps described:
 If the motor has a fan, remove the fan cowl, and the propeller,
 Disconnect the cables from the terminals,

DC electric motors Page 33 of 38

  The motor shaft (rotor) is always retained at one of the two flanges by a circlip preventing
axial movement; remove the circlip, proceed to remove the two flanges, and the rotor can
then be separated from the case.

Take care not to damage the rotor or the stator winding when separating one
from the other.

 Proceed to remove the bearings, which may be force fitted to the motor shaft or to the flanges;
in either case, use the appropriate pulling tools or drivers, being careful not to damage the
seats.
C.F.R. will undertake the overhaul and repair of motors at its own premises. In any event, the
work must be entrusted only to expert service technicians who are able to guarantee that the
motor will be returned to its faultless original condition.
When carrying out an overhaul or repair, always use original replacement parts, or at least parts
approved in writing by C.F.R.
To obtain correct information on the product, indicate

 Motor designation code

 serial number
 date of manufacture

In the case of maintenance, it always advisable that bearings and shaft seals should all be
replaced.
Following the removal steps, conduct a visual inspection to verify the mechanical integrity and
functional efficiency of all components, replacing any that are found to be defective or worn (e.g.
shaft). Measure the insulation resistance of the stator and the rotor applying a test voltage of at
least 1000 V, and if correct, the serviced or repaired motor can be reassembled.

Before installing the reassembled motor on the machine:

- test the insulation again between phase and earth;
- secure the motor to the bench and, before connecting to the power supply,
check that there are no parts incorrectly or insufficiently tightened, liable to
injure the operator or damage the motor, or parts connected to the motor;
- connect the motor and any accessories (e.g. electromagnetic brake) to the
power supply, following the relative instructions;
- supply the correct voltage to the motor and to components (e.g. brake),
checking that the shaft rotates in the required direction and there is no
vibration or noise;
- check that the current draw is correct, on the basis of data plate values.
This done, the motor can be installed on the machine.

DC electric motors Page 34 of 38

 5.3 DECOMMISSIONING

With regard to the correct handling of Waste Electrical and Electronic Equipment,
remember that:
1. waste electrical material must not be disposed of as household refuse, but
properly sorted in accordance with local regulations;
2. this item of equipment may contain hazardous substances: improper use or
incorrect disposal could have negative effects on human health and on the
environment.
Incorrect disposal of WEEE materials is punishable by law.

DC electric motors Page 35 of 38

 6 TROUBLESHOOTING
The following table shows a list of abnormal situations that could arise, together with possible
remedies and an indication of the person authorized to remedy them.
If a given problem does not appear in the table, contact the C.F.R. engineering department.

Problem Causes Remedy Competency

Check that the power supply is
correct and reaching the
Routine
No electrical power contactor or the electronic
maintenance
reaching the motor control (if installed) and that
technician
voltage is registering at the
motor
Routine
Incorrect electrical
Restore the correct connection maintenance
connection
technician

Check that the control is working

and correctly configured
Electronic control Routine
(if installed) Check whether or not there are maintenance
alarms tripped; if so, remove the technician
cause to restore normal
operation of the electronic control

Electric motor does Check that the electronic

not start. control or the dedicated brake
Routine
Electromagnetic brake (if control device are working
maintenance
installed) not releasing correctly and able to release the
technician
brake. Check that the brake is
correctly calibrated

Contact the C.F.R. engineering C.F.R. approved

Motor damaged
department service technician

Routine
Input voltage too high or maintenance
Check the power supply
too low technician

Routine
Disconnect the drive coupling
maintenance
Resisting torque too high and test the motor under no-
technician
load conditions

DC electric motors Page 36 of 38

 Problem Causes Remedy Competency
Check that there is no foreign
matter inside the motor
Check that the brushes are all
correctly positioned and in Routine
motor malfunctioning contact with the commutator, maintenance
and that there is no excessive technician
sparking
Check that the motor shaft
bearings are not damaged
Check that all components are Routine
Motor emits Misalignment and/or securely and firmly fastened maintenance
vibration or noise incorrect assembly and there are no bolts loose technician
when tested under
no-load conditions. C.F.R. approved
Rotor and stator touching Contact C.F.R.
service technician

Routine
Damaged, defective or
Replace the bearings maintenance
worn bearings
technician

Fan touching the cowl or Routine

Locate the point of contact and
other fixed parts of the maintenance
eliminate
motor technician
Check that the motor is not
damaged

Check that the brake (if Routine

Possible motor fault installed) is fully released maintenance
technician
Excessive power Check that there is no
consumption mechanical component of the
motor seized or damaged, or
that there is no misalignment
Check that the load factor for Routine
Workload too high the machine is the same as maintenance
used for selection of the motor technician
size.
Fan cowl or ventilation Routine
holes occluded or Clean thoroughly to restore maintenance
obstructed cooling air flow technician
Motor overheating
Routine
Input voltage too high or Check the voltage against the maintenance
too low data plate technician

DC electric motors Page 37 of 38

 The manual cannot possibly inform the user as to every potential danger situation
that might arise during the operation or maintenance of these electric motors.
Accordingly, a sound technical knowledge of the product and of the precautions
indicated in this manual — and careful observance of the basic rules regarding
safety — can certainly help in anticipating and resolving many danger situations.
Our aim is to help the user adopt and develop safe working procedures, and put
them into practice.
Remember: safety is in your interests, and is your responsibility.

DC electric motors Page 38 of 38