user manual

Fan Motor
I N STA L L AT I O N - O P E R AT I O N - M A I N T E N A N C E

Z0239042_B ISSUED 8/2017 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
 installation

Receiving — Storing
A motor should be inspected on receipt to make sure it was not damaged
during shipment. Turn the shaft by hand to see that it turns freely. Check motor
nameplate for correct horsepower, voltage, phase and speed.
If a motor is stored before installation, place it in a building in which air is kept
reasonably dry and with a minimum of temperature fluctuation to prevent moisture
condensing in the motor. Do not store directly on the floor, always block up.
Windings should be meggered at the time the motors are put in storage.
If the motors are fitted with space heaters, they must always be turned on
during the storage period or when the installed motor is out of operation.
Space heaters will prevent water condensation inside the motor and keep
the winding insulation resistance within acceptable levels. Store the motor in
such position that any condensed water can easily drain.
Remove units from containers when heaters are energized. Repro‑
Note tect if necessary.
If outdoor storage is necessary, protection should include a vapor barrier
beneath the motor. The motor should be blocked up to prevent flooding. All
external parts such as shafts, machined surfaces, and threaded holes should
be protected with a rust inhibitor coating.
Rotate motor shaft monthly to insure that the bearing surfaces are
Note protected with lubricant.

When a motor is removed from storage, the insulation and rotor movement
should be checked. The insulation should be checked by applying the potential
from a 500 volt megohmmeter between the windings and grounded frame for
10 minutes. Resistance readings should be taken at 1 and 10 minutes. Cor‑
rect the readings to 40°C as discussed on page 6 of this manual. Calculate
the winding polarization index by dividing the 10 minute reading by the one
minute reading. The recommended minimum value of polarization index for
alternating current machine is:
Class A insulation 1.5
Class B insulation 2.0
Class F insulation 2.0
A low polarization index indicates the insulation should be cleaned and dried
before the motor is placed in operation. It is possible to operate a motor with
a polarization value less than the minimum listed above but this is not consid‑
ered good practice.
The rotor movement is checked by rotating the shaft by hand. If shaft is not
free, contact the motor manufacturer’s authorized repair shop. Grease in the
motor bearings should be purged at the time of removal from storage. Refer
to Lubrication on pages 8 and 9.

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 installation

Installation
Check to see that the motor nameplate data agrees with the voltage and fre‑
quency of the power supply provided for the motor. All induction motors will
operate successfully when the frequency is not more than five percent above
or below the nameplate rating, the voltage is not more than ten percent above
or below the nameplate rating, and the combined variation in voltage and
frequency is not more than ten percent above or below the nameplate rating.
The power supply line for the motor should be of sufficient capacity to carry
125% of the motor’s full load current with a maximum voltage drop of three
percent on the line.
The power supply MUST conform with motor nameplate voltage. Mo‑
Caution tors rated 200 volts are for a 208 volt system. Motors rated 230/460
volts are for a 240 or 480 volt system. Do not use a 230 or 230/460
volt motor on a 208 volt system.

Unbalanced voltages in the power supply will greatly increase the internal
losses of the motor, reducing the safe load the motor can carry. Have the
power company correct any unbalanced voltage.

When motor power is supplied by overhead conductors, it is advisable to

provide a lightning arrestor on each ungrounded line.
Wire the motor to the power supply through a disconnect switch, short‑circuit
protection, and suitable magnetic starter with overload protection. All wiring
and fusing should be in accordance with the National Electrical Code and
local requirements. All motors should be connected as shown on the name‑
plate diagram.
The National Electrical Code requires a motor to be in sight of the control‑
ler unless the disconnecting means can be locked open or unless there is a
manually operated switch in sight of the motor which will disconnect the motor
from its electrical supply.
Overload protection should be installed in all three lines. Size overload heaters
in starters for nameplate service factor and amps. Overloads for 1.15 service
factor motors must kick out at no more than 125% of nameplate current.
Overloads for 1.0 service factor motors must kick out at no more than 115%
of nameplate current.
Overloads should be at the same ambient temperature as motor. Do not use
ambient compensated overloads.
If a two-speed motor is used, be sure control characteristics are compatible with
the motor. A two-speed single-winding motor requires a different starter than
a two-speed two-winding motor. Starters for two-speed motors must include
a minimum time delay of 20 seconds when switching from high to low speed.

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 installation

When a disconnect switch is installed between motor and starter for two speed
or part winding start single- speed motor, a 6‑pole disconnect must be used.
Use of two 3‑pole disconnects can result in one disconnect not be‑
Caution ing off and unexpected starts or motor damage.

If reverse operation of mechanical equipment is required, provide

Note minimum time delay of two minutes before energizing motor when
changing direction of rotation.

Check the wiring system for grounds and check the resistance
between all leads for open, bad or incorrect connections before
operating the motor.

The conduit system should be arranged so that trapped water will collect in a
sump equipped with suitable drain and will not go into the motor terminal box.
When the motor must be moved for coupling removal or belt adjustment, a
short section of flexible, watertight metallic conduit should be used in place
of rigid conduit to protect the leads to the motor.
Remove appropriate condensation drain plugs from totally-enclosed motors.
The proper drain plugs to remove are dependent on the orientation of the
motor during operation, and only the plugs located in the lowest part of the
installed motor should be removed so that gravity can help drain condensa‑
tion and prevent accumulation. Because of the inaccessibility of drain plugs
with motor installed on supports, it is sometimes necessary to remove plugs
before the motor is bolted in place.
The drain plugs on explosion-proof motors are automatic and must not be
removed.

Space Heaters:
Some motors, depending on manufacturer, include a standard internal space
heater which may not be customer-specified. It is common for cooling tower
motors to cycle on and off which increases the chance for condensation to
build up inside the motor. Moisture inside the motor weakens the insulation
properties of the motor windings, which potentially can lead to winding failures
and ground faults. The use of space heaters helps to keep the internal motor
temperature above the dew point, preventing condensation inside. If the motor
includes a space heater, refer to the space heater nameplate located on the
motor frame for heater wattage and voltage rating. Typically the space heater
is energized from a remote 120VAC source with ON and OFF operation co‑
ordinated through logic contacts within the VFD or motor starter.
Before switching ON the space heaters, check if the space heater
Note connections have been made according to the connection diagram
shown on the space heater nameplate.

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 operation

The space heaters should never be energized when the motor is

Caution in operation.

On larger motor frame sizes, multiple space heaters may be furnished which
need to be wired in parallel with each other, with only two power leads to the
voltage source. Failure to use the space heater may void the motor warranty
and cause moisture to form inside.
Even when the motor is off, dangerous voltages may be present
Warning inside the terminal box used for the space heater supply or winding
energization when the winding is used as heating element. Motor
capacitors will hold a charge even after the power has been cut
off. Do not touch the capacitors and/or motor terminals, before
discharging the capacitors completely.

After motor is installed, it should be run for three hours at least

Note once a month, even if the tower is not in operation. This serves to
dry out windings and relubricate bearing surfaces. If motors are
purchased with space heaters, they should be energized as soon
as possible. Use an auxiliary contact on the starter to turn heater
off when motor is running.

Operation
Sleeve bearing motors are usually shipped without oil and must be oiled before
operation. Ball bearing motors are lubricated for the initial operation by the
motor manufacturer; however, it is recommended that the grease and relief
plugs be removed and the motor bearing housing be examined for presence of
adequate grease before motor is placed in operation. Add grease if necessary.
See instructions on pages 8 and 9 for lubricating ball bearing or sleeve bearing
motors. Motors with sealed bearings do not require lubrication maintenance.
Turn the rotor by hand to see that it rotates freely. Motor shaft should be parallel
to driven shaft so that there are no stresses in motor frame.

Initial Starting:
The motor should bring the fan up to speed in less than 15 seconds. If it does
not, check connections, fuses, overloads and voltage at motor terminals dur‑
ing start‑up period. Run the motor to check the connections and direction of
rotation. If the rotation is incorrect, change any two of the three motor leads
for a three phase motor or interchange the connections of either the main or
start windings for single phase capacitor start motor.

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 operation

Excessive fan cycling may shorten the motor's expected service life.
Caution On fans 20 feet (6 meter) diameter and smaller allow for 4 to 5 starts
per hour. On larger fans, 2 or 3 starts per hour may be the limit. On
two speed motors each low speed start and each high speed start
count as one start.

If a two-speed motor is used, allow a time delay of a minimum of 20 seconds

after de‑energizing the high speed winding and before energizing the low
speed winding. Tremendous strains are placed on driven machinery and motor
unless the motor is allowed to slow to low speed rpm or less before the low
speed winding is energized.
When changing fan direction of rotation, allow a minimum of two minutes time
delay before energizing the fan motor.

Determine Load at Motor:

With design water rate and design heat load on the tower, test motor hp as
follows:
1. Run motor for 30 minutes. Record motor name plate data.
2. Measure voltage between all lines at motor terminals.
3. Measure amps in all three lines.
4. Average the measured volts and amps and calculate test horsepower us‑
ing the following equation:
Volts x Amps (average)
hp (test) = x hp (nameplate)
Volts x Amps (nameplate)

5. For a given fan pitch setting and RPM, horsepower will vary directly with
the air density which is a function of temperature and barometric pressure.
Because fans are generally pitched for summer weather horsepower, it is
expected that the motor nameplate horsepower will be exceeded during
winter operation. Assuming 100% heat load, the temperature rise in the mo‑
tor will be greater at the higher horsepower, but the operating temperature
of the motor will actually be lower due to the drop in ambient temperature.
Under these conditions, the higher horsepower should not be detrimental
to the motor.
If the horsepower measurement is taken during cold weather conditions,
the predicted horsepower which will result during summer operation may
be determined by applying the Factor from Figure 1. For a given location,
the barometric pressure will not normally vary enough to cause significant
error and for this reason, has not been included in the Factors.

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 maintenance
96

97

98

99

100

101

FACTOR
102

103

104

105

106 Figure 1

107
108
0 10 20 30 40 50 60 70 80 90 100

Example: The horsepower on an induced draft cooling tower* is 7.8 hp on a 40°F

ambient wet‑bulb day. What is the predicted hp on a 75°F ambient wet‑bulb day?
Factor (75°F) 100.8
hp (75°F) = hp (40°F) X = 7.8 x = 7.43
Factor (40°F) 105.9

If it is desired to correct for high or low test barometric pressure, multiply
the predicted horsepower by standard station barometric pressure and
divide by test station barometric pressure.
*Use ambient dry‑bulb temperatures if checking a forced draft cooling
tower.
Fan motor overloads sized for summer weather will handle the higher winter
horsepower without adjustment providing they are at the same ambient
temperature as the motor and there is ample heat load on tower.

Normal Operation:
Class B insulated motors are rated at a maximum total operating temperature
of 266°F (130°C). A thermometer in contact with the winding may indicate
a temperature up to 212°F (100°C). on a protected motor or up to 239°F
(115°C) on a totally enclosed motor without the motor being too hot. There‑
fore, a motor that appears to be hot is not necessarily overloaded. Check
with thermometers.
Normal operating temperatures of electric motors can be hot enough
Caution to cause burns. Avoid any unprotected contact with the surface of
an operating motor.

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 maintenance

Higher density of cold air at fan increases motor horsepower. If

Note motor overloads will not allow fan motor operation at high speed
in forward direction, one of the following might be done:

1. If overloads are adjustable, set at a higher value (+15%) for cold weather
operation. Readjust for summer operation.
2. Operate motor (fan) in reverse (reverse 2 loads).
3. Operate two‑speed motor at low speed.

Maintenance
When working on the fan or fan drive, make sure the electric motor
Warning cannot be started. See “Installation” section.

To obtain maximum motor life, establish a schedule of maintenance based on

the particular application of the motor and observe the following procedures
and precautions:
Remove any oil, dust or scale deposits from the motor. They can cause exces‑
sive insulation temperatures.

Lubrication:
Ball Bearing Motors: The following table may be used as a guide in determin‑
ing greasing periods for motors:

Duty 1 – 30 hp 40 – 250 hp

I n te rm itte n t 12 m on ths 12 m on th s

8 to 16 h ou rs pe r da y 12 m on th s 6 m on th s

Con tin u ou s 8 m on th s 4 m on th s

All greases will deteriorate in time depending upon bearing size, speed and
temperature. The grease used should be recommended by the motor manufac‑
turer. See instructions attached to motor for recommended lubricant. If these
instructions have been lost or misplaced, obtain information on lubricant to use
and local supply source from motor manufacturer’s nearest authorized service
facility or from the motor manufacturer. Give complete motor nameplate data
and state clearly that the motor is used on a water cooling tower. Chevron
SRI‑2 is recognized by many motor manufacturers as a suitable grease for
ball bearing motors for cooling tower service. In general, a polyurethane or
lithium base grease with rust and oxidation inhibitors is recommended. Use
a grease of NLGI No. 2 consistency. Do not mix greases which are of differ‑
ent types or specifications. If a change is desired, the motor bearing housing
grease reservoir should be completely cleaned of old grease before repacking
with new grease.

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 maintenance

The relief method of greasing motors tends to purge the bearing housing
reservoir of used grease by forcing out old grease with new grease. Use a
plunger type grease gun which will not fit the bearing grease fill hole too tightly.
Either an excess or insufficient amount of lubricant in the bearings can cause
overheating. To prevent this occurrence, use the following greasing procedure:
1. Stop motor.
2. Wipe grease plugs, outside of bearing housing, and relief plug, clean.
3. Remove grease and relief plugs and free relief hole of any hardened grease.
Use a thin piece of wire in opening.
4. Add grease with a hand operated pressure gun until new grease appears
at the relief hole. Take special care when greasing the fan end bearing of
TEFC motors. The long relief might be too small for the bearing to relieve
properly.
5. Run the motor for approximately one hour after greasing to permit rotating
parts of the bearing to expel excess grease. Take out some of the excess
grease with a thin piece of wire.
6. Replace plugs and wipe the outside of the bearing hous­ing clean.
Every few years the motor end brackets should be removed and the grease
reservoirs cleaned and repacked full with approved ball bearing grease. Open
bearings should be cleaned and repacked.
Bearings should be checked for "roughness" by turning the outer race slowly
with the fingers while holding the inner race. If the bearing feels rough or binds
in spots, it should be replaced.
Sleeve Bearing Motors: Check oil in sleeve bearings at least every three
months. When journal size is less than two inches, stop the motor to check
the oil level. Oil should be drained and replaced at least every year. Clean out
oil well if there is evidence of dirt and sludge.
Motor shaft must be stopped when motor is oiled.
Note
The oil used should be a good grade of mineral oil of light or medium viscos‑
ity (such as SAE No. 10). Turbine oil rather than automotive crankcase oil is
recommended.
Check bearing wear yearly by measuring the air gap with a feeler gauge. Mea‑
sure gap in at least four equally spaced positions at each end of the motor with
two of the places being the lowest point and the point subject to the load pull.
Sealed Bearing Motors: Sealed bearing motors do not require additional
lubrication maintenance.

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 maintenance

Insulation:
Check insulation resistance with a megohmmeter at the end of each shutdown
period. Apply the megohmmeter potential to the winding for one minute before
taking a reading. Correct the reading to 40°C by using the equation:

R40°C= Kt x Rt and the curve below

100

50
Insulation Resistance Temperature Coefficient Kt

10

1.0

0.5

0.1

To Convert Observed Insulation Resistance Rt to 40°C

0.05
Multiply by the Temperature Coefficient Kt , Rc – Rt x Kt

-10 0 10 20 30 40 50 60 70 80 90 100

Winding Temperature °C

Approximate Insulation Resistance Variation with

Temperature for Rotating machines.

A record of these corrected readings will show a trend in the insulation condi‑
tion. It is considered good practice to recondition a winding if the resistance,
having been high on previous readings, drops to near the recommended
minimum value as calculated by:

Megaohms = 1000 + Rated Voltage of Machine

1000

Motors in continuous operation will stay at a temperature sufficiently above

ambient temperature to prevent condensation of moisture on and about the
windings, even if the location is very humid. Idle motors, however, accumulate

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 maintenance

moisture readily which causes gradual deterioration of insulation. Where mo‑

tors are idle for a long time, single‑phase heating or space heaters may be
required to prevent water condensation.
Check insulation resistance at least once a year with the motor at normal
operating temperature. Comparison with several previous readings will give
an indication of improvement or deterioration of insulating value. Readings,
to have comparison value, should be taken under the same conditions (tem‑
perature, operating time since last shutdown, etc.).
Low or falling resistance readings indicate the need for maintenance. Contact
the nearest repair facility authorized by the motor manufacturer for repair service.

Vibration:
If vibration occurs, it should be corrected without delay. Use the following
procedure to determine source of trouble:
1. Check motor mounting to see that fasteners are tight.
2. Disconnect motor from load and run motor separately. If motor still vibrates,
rebalance rotor.
3. If vibration is in mechanical equipment*, check:
a. Alignment of motor with mechanical equipment.
b. Tightness of Geareducer, or belt driven components, mounting bolts.
c. Unbalance in drive shaft or fan.
*Refer to component user manual for operating and maintenance recom‑
mendations.

Seasonal Shutdown
If a motor is used only seasonally, it should be cleaned and lubricated at the
close of each season. Refer to motor manufacturer’s recommendations for
lubrication and maintenance instructions. At start of new season, make sure
bearings are adequately lubricated before returning motor to operation.
If the motors are fitted with space heaters, they must always be turned on
during the storage period or when the installed motor is out of operation.
Space heaters will prevent water condensation inside the motor and keep
the winding insulation resistance within acceptable levels.
When tower is not in operation, the motor should be run for three
Note hours at least once a month. This serves to dry out windings and
relubricate bearing surfaces.

Do not start motor without determining that there will be no interfer‑

Caution ence with free rotation of the fan drive.

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 Motor
U S E R M A N UA L

Motor Warranty
Motor manufacturers’ warranties run for 12 months in service but not to ex‑
ceed 18 months from date of manufacture. Motor manufacturers warrant their
products to be of the type and quality described, suitable for the service for
which they are supplied, and free of defects in materials and workmanship.
Failures from causes external to the motor (e.g., single phasing, operation
under prolonged or extensive overload, damage from handling, improper
maintenance, use on other than the service for which supplied, defect in wir‑
ing to power supply, or deficiency or defect in controls) are not covered by
the motor manufacturers’ warranties.
If a motor failure occurs within the warranty period because of defect
Note in material or workmanship, the motor manufacturer is liable and has
the right to remedy the failure by adjustment, repair, or supplying a
replacement motor F.O.B. motor factory or authorized repair facil‑
ity. In such event, the motor must be delivered to the nearest repair
facility authorized by the motor manufacturer with notification that
the motor is from a Marley product and that warranty consideration
is requested. Prompt notification of such failure should be directed
to a Marley sales representative.

Motor manufacturers will not accept warranty obligation for repair of motors
by other than their authorized repair facility nor warranty obligation for ma‑
terials or workmanship employed in making repairs. Repair shops, including
authorized repair facilities, generally warrant their material and workmanship
for a period of 12 months.
Motor manufacturers’ warranties do not cover cost of dismounting, transporta‑
tion to and from repair facilities, or remounting motors.

SPX COOLING TECHNOLOGIES, INC.

7401 WEST 129 STREET Z0239042_B | ISSUED 8/2017
OVERLAND PARK, KS 66213 USA COPYRIGHT © 2017 SPX CORPORATION
913 664 7400 | [email protected] In the interest of technological progress, all products are subject to design

spxcooling.com and/or material change without notice.