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CG Electric Systems Hungary Zrt.

1095 Budapest, Mrissy str.7.


T:+36-1-483-6600
www.cgglobal.com

THREE-PHASE
WOUND ROTOR INDUCTION MOTOR
111.174

FTA 500 Fs4

TECHNICAL DESCRIPTION
OPERATING AND MAINTENANCE INSTRUCTION

CG ELECTRIC SYSTEMS HUNGARY Zrt.

CONTENTS

CONTENTS

TECHNICAL DATA .............................................................................................. 4

BEARINGS........................................................................................................... 5

2.1

TYPE AND LUBRICATION ........................................................................... 5

2.2

BEARING SHIELDS...................................................................................... 5

TECHNICAL DESCRIPTION ............................................................................... 6


3.1

STATOR ....................................................................................................... 6

3.1.1

STATOR HOUSING............................................................................... 6

3.1.2

STATOR CORE ..................................................................................... 6

3.1.3

STATOR WINDING ............................................................................... 7

3.1.4

STATOR HEATING, SLIPRING SPACE HEATING............................... 8

3.1.5

LOCATION OF THE THERMOMETERS ............................................... 8

3.2

ROTOR ......................................................................................................... 9

3.2.1

SHAFT ................................................................................................... 9

3.2.2

LAMINATED ROTOR CORE ................................................................. 9

3.2.3

ROTOR WINDING ................................................................................. 9

3.2.4

SLIPRINGS............................................................................................ 9

3.2.5

BALANCING, VIBRATION, OVERSPEED TEST ................................ 10

3.3

TERMINALS ............................................................................................... 10

STATOR TERMINAL BOX ................................................................................. 10


3.3.1

ROTOR TERMINALS .......................................................................... 10

3.4

BRUSHGEAR ............................................................................................. 11

3.5

VENTILATION ............................................................................................ 12

3.5.1

INTERNAL VENTILATION CIRCUIT ................................................... 12

3.5.2

AIR TO AIR HEAT EXCANGER .......................................................... 12

3.5.3

VENTILATION OF THE SLIPRING SPACE ........................................ 12

3.5.4

CHANGING THE DIRECTION OF THE ROTATION ........................... 13

OPERATING AND MAINTENANCE INSTRUCTIONS....................................... 14


4.1

STORING, LIFTING .................................................................................... 14


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CONTENTS

4.2

INSTALLATION .......................................................................................... 14

4.3

COUPLING TO THE DRIVEN MACHINE ................................................... 15

4.4

ELECTRIC CONNECTION ......................................................................... 17

4.5

PUTTING INTO OPERATION..................................................................... 18

4.6

CHECKING OF THE BRUSH GEAR .......................................................... 18

4.7

STARTING.................................................................................................. 19

4.8

MAINTENANCE .......................................................................................... 19

4.9

PREVENTIVE MAINTENANCE PROGRAMME ......................................... 20

4.10

LENGTH OF BRUSHES ............................................................................. 21

4.11

CHANGE OF BRUSHES AND BRUSH HOLDERS .................................... 22

4.11.1

PRELIMINARY CHECK ON BRUSHES AND BRUSH HOLDERS ...... 22

4.11.2

PUTTING NEW BRUSHES IN THE HOLDERS .................................. 22

4.11.3

CHANGE OF BRUSH HOLDERS........................................................ 22

4.12

MAJOR OVERHAUL WITH REMOVING THE ROTOR FROM THE STATOR


.................................................................................................................... 23

4.12.1
4.13
5

WORK STAGES .................................................................................. 23

TROUBLE SHOOTING CHECK LISTS ...................................................... 24

DRAWINGS AND ACCESSORIES .................................................................... 26

CG ELECTRIC SYSTEMS HUNGARY Zrt.

TECHNICAL DATA

1 TECHNICAL DATA

Type ......................................................................................... FTA 500 Fs4


Serial number ........................................................................... 451184
Mounting arrangement ............................................................. IM B3
Relevant standard .................................................................... IEC 34-1
Cooling method ........................................................................ IC 611
Protection of motor / slipring compartment............................... IP55
Protection of the terminal box................................................... IP55
Output ...................................................................................... 1130 kW
Connection / number of terminals ........................................... Y/3
Rated voltage and its tolerance ................................................ 6300 V 5 %
Rated stator current.................................................................. 120 A
Frequency and its tolerance ..................................................... 60 Hz 2%
Rated rotor voltage and current1010 V 680 A
Power factor ............................................................................. 0.91
Efficiency .................................................................................. 94.9 %
Rated torque............................................................................. 6050 Nm
Maximum torque/rated torque .................................................. 2.6
Speed ....................................................................................... 1785 rpm
Sense of rotation ...................................................................... One (CW from DE)
Max. vibration velocity .............................................................. 2,8 mm/sec
Machine mass .......................................................................... 6950 kg
Rotor mass ............................................................................... 2000 kg
2
Rotor moment of inertia............................................................ 70 kgm
Insulation class......................................................................... F
Temperature rise ...................................................................... B=70 K
Max. slot temperature............................................................... 125 C
Max. bearing temperature ........................................................ 95 C
Max. ambient temperature ....................................................... 50 C
Stator heating ........................................................................... 1 kW, 440 V, 60 Hz
Slipring case heating ................................................................ 0,2 kW, 440 V, 60 Hz

CG ELECTRIC SYSTEMS HUNGARY Zrt.

TECHNICAL DESCRIPTION

2 BEARINGS

The machine is provided with grease lubricated antifriction bearings, located in the
shields. To prevent excessive lubrication the bearings are provided with a grease
control device. This device presses out the excessive grease -through the opening of
the external bearing cover -into a tank from where it can be removed at regular
intervals. Replenishment of the grease can be carried out by means of a ball greaser
with the aid of a lubricating press.
The lubricant is SHELL ALVANlA RL2 grease. The bearings on one side are fixed
while those of the other side are axially released to compensate for thermal dilatation.

2.1 TYPE AND LUBRICATION


Drive Side
Type of bearing

Drive Counter Side

6230 M/C3
NU 230 EMC/C3

Regrease

NU 230 EMC/C3

0,12 kg / 550 WHR

0,06 kg / 550 WHR

1 kg / 8700 WHR

1 kg / 8700 WHR

Grease change
Type of grease

Shell Alvania RL2

2.2 BEARING SHIELDS


Both the drive and the counter drive side bearing shields are steel structures.
Their fixation to the stator enclosure is ensured by bolts.

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TECHNICAL DESCRIPTION

TECHNICAL DESCRIPTION

3.1 STATOR

3.1.1 STATOR HOUSING


Its function is to hold the stator core and the winding, to protect the internal parts of
the machine against moisture, dust, penetration of foreign particles, and against
mechanical, thermical and other loads occurring in service.
Furthermore, this housing ensures support for other connecting parts, shield, cooler,
terminals, rotor, etc.
The stator housing is a welded construction.
Rigidity of the housing is ensured by the transversal main supports, the two end faces
and the longitudinal ribs holding together these formerly mentioned parts.
The cover is thin sheet. On the lower end of the housing a footplate can be found
with the holes of the fixing screws, threaded holes of the lifting bolts and taper holes
of the fitting studs on it.
The top of the housing is open, the cooler is connected here.
The shields are screwed on the fitting flanges of the end faces. The terminal
openings are on the two sides of the machine, in the middle. Below each of these
one respective earthing eye can be found. The auxiliary terminal box for RTD-s and
space heater is on the right side of the main terminal box.

3.1.2 STATOR CORE


The stator core is entirely laminated to minimize eddy current losses. Stator
laminations are made of insulated thin sheets of high-grade electrical steel. All stator
cores are manufactured as self-supporting components outside the motor frame. This
enables easy VPI treatment of the complete wound core. The core is fitted and
doweled to the frame.

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TECHNICAL DESCRIPTION

3.1.3 STATOR WINDING


MICASYSTEM, the Class F insulating system specially developed for stator windings
of AC motors and generators, is used for voltage ratings from 1200 to 15000 V.
This high-reliability, advanced insulating system is mainly based on the use of special
mica tapes and on the vacuum-pressure impregnation with a blend of solventless
epoxy resins. Due to the high mica content and the fully cured binder, the tape used
for ground insulation has exceptional dielectric strength. The VPI treatment improves
the dielectric properties of the insulating wall and helps to provide the thermal stability
necessary to satisfy the Class F requirements of the applicable Standards.
Due to the vacuum-pressure process, the resin fills all the voids in the insulation and
between the insulation and the stator core. This result in a significant improvement in
heat transfer between the winding and the core steel and prevents vibrations and
relative movements of the coils in the slots.
The coils are manufactured with rectangular copper wire, usually enameled and
covered with glass yarn or insulated with mica tape (selection based on machine
voltage and other functional parameters).
After winding the conductors in bobbin form, the design shape of the coils is obtained
by means of special forming machines. The ground insulation is applied by means of
programmable taping machines. The number of layers depends on motor rated
voltage. Armour tapes and corona suppressing materials are finally applied onto the
coils as required, depending on rated voltage.
Coils are then inserted into the stator slots and firmly held in place by means of glass
laminate wedges. After all connections between coils are completed, the coil ends
are tied together and braced by steel or polyester-fiberglass rings, using highresistance conformable materials.
After an oven drying process, the wound stators are impregnated under vacuum and
pressure. The number and duration of VPI cycle phases are selected on the basis of
the insulating wall thickness and the required degree of protection.
The impregnated stators are then cured in oven. During the oven treatment the
stators are rotated slowly by means of motor-driven rollers, to ensure a uniform
distribution of the resin within the insulation.

CG ELECTRIC SYSTEMS HUNGARY Zrt.

TECHNICAL DESCRIPTION

MICASYSTEM, which was developed through long-term research work and extensive
testing, provides excellent dielectric and mechanical properties and all the other
physical characteristics needed for the specific applications. The main features are:
o outstanding mechanical strength, which allows the insulation to withstand the
stresses which can occur during motor transient operation;
o high resistance to long-term thermal overload and thermal cycling endurance
evaluation results meet Class F requirements with ample margins;
o outstanding resistance against moisture, tropical and marine environments,
common chemical contaminants and polluting agents;
o high surge voltage withstand capability;
o high resistance against radioactive radiation.

3.1.4 STATOR HEATING, SLIPRING SPACE HEATING


The electric properties of the winding insulation, the laminated core and the other
active structural elements are impaired by the humidity condensed on them in cold
environment.
Therefore, the machine is provided with anticondensation heating. The heaters are
located in the lower part of the stator case. The heating can be operated both
manually and automatically. Its function is to keep a certain temperature within the
machine being out of operation preventing the condensation of the humidity
without overheating the individual structural part of the machine. This heating is not
suitable for heating out the machine. No operating automatics are supplied with it.

3.1.5 LOCATION OF THE THERMOMETERS


The thermal protection of the machines is ensured by slot RTD-s built in between the
two coil sides. Thus, in each phase there are two Pt 100 Ohm RTD-s. Further 1 Pt
100 thermometers measures the temperature of each bearing.
Further thermometers and other instruments according to the Outline drawing and
Wiring scheme.

CG ELECTRIC SYSTEMS HUNGARY Zrt.

TECHNICAL DESCRIPTION

3.2 ROTOR

3.2.1 SHAFT
The machine is manufactured with welded ribbed shafts. The shafts are made of
high-strength steel. There are longitudinal ribs and these are supported by
transversal ones. Before welding the shaft and the ribs should be checked for cracks
by ultrasonic tests and the quality of the seams should be checked by paint flowing
test.

3.2.2 LAMINATED ROTOR CORE


The rotor core is also fully laminated. The rotor consists of a stack of full-circle
laminations, which is shrunk onto the shaft.
The laminated core is manufactured in jig and it is pulled on the ribbed shaft in hot
state with overlapping. This shrinkage fit and a lock located in one of the
longitudinal ribs ensure perfect torque transmission.

3.2.3 ROTOR WINDING


Due to the half-closed slots the double-layer wavy type rotor winding is pushed-in.
The coils are fixed by plastic wedges. The insulation system complies with Class F
requirements. The coil ends are supported by the insulated coil holding rings.
The bars of the lower and upper layers of the winding are brazed together. Due to the
occurring centrifugal force the end windings are fixed with prestressed glass bandage
tape. The coil cross connections are formed on the counter drive side. The outlets
are connected to the pins of the sliprings by means of cross sections retained on the
shaft by glass bandage tape.

3.2.4 SLIPRINGS
The sliprings are made of steel. They are pulled on the insulated slipring hub in hot
state. The secure the position of the outlet pins the hub is prevented from swivelling
by means of a lock. The copper phase outlets are fixed with brazing.
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TECHNICAL DESCRIPTION

The outlet pins, between the rings are hermetically closed. The complete slipring unit
is impregnated in a vacuum oven.
After pulling onto the shaft, the surfaces of the sliprings are machined so as to ensure
coaxiality.

3.2.5 BALANCING, VIBRATION, OVERSPEED TEST


The finished rotor is dynamically balanced at rated speed without the coupling.
Rotors for keyed coupling are balanced with half-key inserted in the shaft extension.
After balancing the RMS value of the vibration velocity measured on bearings of the
machine corresponds to the grade "good" of VDI Standards. For 2 minutes the rotor
should be rotated at 1,2 times the rated speed.

3.3 TERMINALS

STATOR TERMINAL BOX

The main terminal box can be found on the stator casing. The main terminal box is of
welded steel on the aluminium terminal board on which there are the 3 main
terminals. Current buses are made of electrolytic copper. In the rear wall of the
terminal casing a lightened lobe is provided, which opens in case of incidental
exploding, thus protecting the staff and the terminals. The terminal lid is grounded to
the terminal casing and the terminal casing to the stator casing.

3.3.1 ROTOR TERMINALS


The rotor is similar to the stator terminal box.

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TECHNICAL DESCRIPTION

3.4 BRUSHGEAR
The brushgear is located in the slipring enclosure wich is connected to the stator
case at the counter drive side of the motor, and closed by the bearing shield at the
other end.
The brushgear is fixed onto the brush bridge. In the slipring enclosure the brush
bridges are retained by the brush holder pins. Insulated spacer rings are pulled on
the section of the pins falling between the brush bridges. The brushes are pressed
onto the surface of the sliprings by means of springs, the pressing force is:
(1.8 - 2)x104 N/m2.
The metal content of the brushes is approximately 70%, the brushes are designed to
withstand a normal operation period of half year, depending on the environmental
circumstances, like:
o ambient temperature;
o relative humidity content;
o vibration level of the complete drive;
o changing of the load.
The optimum current density on the brushes RC 87 is cca 18 A/cm2 (~180 A/brush).
In case of longer underloaded periods (installation period, reduced production
capacity) the number of brushes should be reduced in order to provide the optimum
brush current load.
On the four sides of the brushes there is a groove, running along, ensuring that no
brush powder should jam in the brush holder.

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TECHNICAL DESCRIPTION

3.5 VENTILATION

3.5.1 INTERNAL VENTILATION CIRCUIT


The inner ventilation of the motor is two-sided radial one. The hot air flowing upwards
in the middle of the machine gets into the heat exchanger. Here-passing between the
pipes- it cools down then gets back into the motor at the ends of the enclosure. The
path of the airflow is ensured by deflecting and closing plates located in the cooler
box

3.5.2 AIR TO AIR HEAT EXCANGER


On the drive counter side of the shaft there is an outer fan. This fan absorbs cold air
through the grid cover of the fan enclosure. This cold air directed by deflecting plates
is forced back into the air space through the pipes of the cooler. These pipes run
parallel with the longitudinal axis of the machine and they are rolled in the walls-at the
end of the cooler- by flanging. The cooling tubes made of aluminum.

3.5.3 VENTILATION OF THE SLIPRING SPACE


The slipring space is separated from the motor inner space. Its ventilation is provided
by a small or separate fan.

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TECHNICAL DESCRIPTION

3.5.4 CHANGING THE DIRECTION OF THE ROTATION


Normally the machine is equipped a back-step blade ventilator, with clockwise or
counter clockwise direction of rotation.
If you want to change the direction of rotation:

1, Remove the 6 pcs M8 [1] screws and washers


2, Remove the mesh and the air baffle [2]
3, Remove the 8 pcs M10 screws[3] and washers
4, Remove the ventilator [3], turn it over and assembly again.

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OPERATING AND MAINTENANCE INSTRUCTIONS

4 OPERATING AND MAINTENANCE INSTRUCTIONS

4.1 STORING, LIFTING


If, after delivery, the machine is not installed in its final place it can be expediently
stored in original factory packing. The temperature in the storeroom must not be
below +5 C and the atmosphere of the room must be dry, free of dust and chemical
vapours. The machine should be lifted by the lifting points formed on the stator
enclosure and the lifting should be free of jerks. If the manufacturer supplies a
separate lifting mechanism, it must be used. When selecting the proper lifting rope
the total weight indicated on the rating plate should be taken into consideration.
WARNING!
In case the motor is stored for a longer period place thin insulating plates
between the brushes and the slipring surface.

4.2 INSTALLATION
The architectural works have to be carried out as per the foundation drawing paying
special attention to the exact location of the fixing bolts. The requirement to start the
installation works is the proper machine foundation being true to size and loadable.
Before the works after alignment the beams should be carefully degreased because
the concrete will not set on a greasy or painted surface. After assigning the
centerline of the machine group with the aid of the spacers and wedges located on
the right and left sides of the fixing bolts the desired height level can be set as per
the drawing but close attention has to be paid to the dimensions of the driven unit.
It is very important that the base plate should not be distorted when tightening the
fixing bolts. Otherwise, the non-uniform positioning of the machine will result in
uneven running and vibration problems. When making the concrete structure great
care should be taken to avoid the existence of continuous voids because these are
liable to resonance. Prior to complete setting of the concrete it is strictly forbidden to
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OPERATING AND MAINTENANCE INSTRUCTIONS

load the base plate or to start the machine on it because owing to unavoidable
vibrations the concrete and the plate disjoin and this may result again in vibration
problems.

4.3 COUPLING TO THE DRIVEN MACHINE


The fine adjustment of the machine should be carried out by using the jacket on front
surface of the coupling halves. The accuracy is checked by dial gauge and a gap
gauge. If the manufacturer of the driven unit and the manufacturer of the coupling do
not give a stricter value, the accuracy of the adjustment of the half couplings may be
0.01-0.05 mm. The required corrections can be made by using insert plates.
Instructions for aligning couplings
The aim of the instructions given in the following is to attain proper alignment of the
shaft extension without angular or parallel mismatch.
This requirement can be fulfilled, as far as practically possible,by careful and
accurate workmanship. The alignment instructions are basically valid for all rigid and
flexible couplings and for all kinds of driven equipment. The manufacturers of the
machines to be coupled must advise by how much the shaft centre heights will
change under the influence of the operating and ambient temperatures. Based
on these values it must then be decided how much radial displacement is to be set
for the cold machine in order to have the ideal condition of zero misalignment at
those operating and ambient temperatures expected to be most predominant.
The relevant measurements require that the machine rotor can be turned.
In the case of vertical machines with plain bearings (Segmental thrust and guide
bearings) this can no longer be done manually above a certain machine size
because of the high bearing frictional torques involved. At the same time there is
also a danger that the bearing surfaces could be damaged by the slowly rotating
rotor. Therefore, all vertical plain bearing machines must be provided with a lifting
possibility at the top end of the shaft so that the rotor canbe suspended on the crane
or other lifting device. The kind of lifting possibility must be clarified before alignment
begins.
If for example, in the case of a vertical machine with plain

bearings, more exact

values are required by the coupling

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OPERATING AND MAINTENANCE INSTRUCTIONS

manufacturer because of the coupling type, the radial clearance of the bearing can
be reduced to a minimum by the employment of a special centering tool. Even with
this reduced bearing clearance it must still be possible to turn the rotor. The
employment of the afore- mentioned centering

tool

for erecting such vertical

machines is described in a separate chapter.


If a horizontal machine with plain bearings has been at standstill for a longer
period of time, then the oil film between the bearing shells and the shaft will have
been pressed out by the weight of the rotor i.e. the bearings will be dry. Therefore,
before turning the rotor, approximately 100 ... 200 cm3 of oil must be manually fed
into each bearing. This can be done through the openings in the top of the bearing
housing. The oil

should be poured in using a funnel. If the manufacturer has not

given details for setting radial displacement on the cold machine, then the rule is that
zero displacement should be set.
Alignment
The following must be observed when coupling two or more machines together:
The coupling halves must be exactly aligned to each other, following the
fundamental rule that the shaft train is to be exactly horizontal, or vertical for vertical
machines, at the main coupling location. The shafts being coupled must naturally be
exactly concentric to each other and the coupling end faces exactly parallel.

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OPERATING AND MAINTENANCE INSTRUCTIONS

4.4 ELECTRIC CONNECTION


When connecting up the HV cables care must be taken to follow the right sequence.
Have to reverse the sequence in case of counter clock wise (left) rotation direction.

WARNING!
The cooling fan must be rotated, if changing the
rotation direction of air-to-air cooled machines!
Inappropriate fan rotation direction cause overheating!

Connection to the heating and thermometer terminals should be made as per the
circuit diagram on the inner side of the cover. On both sides of the enclosure there is
one respective earthing eye for the purpose of earthing.
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OPERATING AND MAINTENANCE INSTRUCTIONS

4.5 PUTTING INTO OPERATION


In the course of the putting into operation the following checks and operations must
be carried out:
o Mechanical check. Mounting, alignment of coaxiality, checking of the rotor for
free motion with separated coupling.
o Checking of the electric connections. Checking of the correct phase sequence
of the HV cable connections and that of the thermometer terminals serving for
protection and indication purposes. The built-in thermometers should be
separately checked for breakage and body contact.
o Insulation resistance test. The stator winding can be considered dry if its
insulation resistance measured and evaluated as per IEEE 43 Standards is:
Rmin (Mom) = Urated (kV) + 1 at 40 C,
and the minimum polarisation index for Class F insulation is equal to 2, where the
polarisation index is:
R10 minutes / R1 minute
Machines provided with up-to-date insulation can comply with this requirement when
stored under proper circumstances. If the humidity in the machine deteriorates the
above value, heating out is required and it can be expediently carried out by the
machine's own winding at reduced voltage and at approximately 60% current
compared to the rated values. When checking the resistance continuously it can be
observed that at the beginning of the heating out the value of the resistance
decreases, then after reaching the minimum point it starts to increase again.
When the value calculated with the aid of the formula is reached, heating out can be
finished. In the case of heating out the phase coils with AC, their temperature must
not be checked by means of a mercury thermometer.
During heating out ventilation should be ensured so as to avoid overheating of
certain structural parts.

4.6 CHECKING OF THE BRUSH GEAR


Use 2-3 mm spacer to check the distance between the brush holder and the slipring.
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OPERATING AND MAINTENANCE INSTRUCTIONS

Check if the brushes and brush holder sliding part can move freely and easily.
Check the tightening of brush cable fixing screws.
Check the surface of the sliprings from the point of view of roughness and patina
layer.
Check the brushes edges that there is no chipping.
WARNING!
In case the motor is stored for more than two years, change the brushes,
because the cable tamping can be oxidised.

4.7 STARTING
The first starting must be carried out with disconnected coupling of the driving and
driven units. It is expedient to run the machine unloaded for approximately three
hours. If no irregularity is experienced, the linking of the coupling halves can be
performed.
At the first commissioning after a longer stoppage obviously the instructions of
Chapter Putting into operation should be followed.

4.8 MAINTENANCE
In addition to daily observation the overall condition and operation of the motors, it is
recommended that the machines be periodically and routinely checked for the
impending need of corrective maintenance.
A general maintenance program is given in the following table. Maintenance cycles
may be changed in relation to the specific customer experience.

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OPERATING AND MAINTENANCE INSTRUCTIONS

4.9 PREVENTIVE MAINTENANCE PROGRAMME


Periodicity
Weekly

Monthly
(On the base of
the operational
experiences of
the first period it
may be varied.)

Component

Maintenance required

General

Verify proper operation the motor, absence of evident


vibrations and noise, and overheating.

Brushgear

Visual inspection of the slipring compartment through


the inspection cover in rotating state. Check the
insulated parts particulary the insulated bolts of
brushgear if they are clean.

Bearing

Visual inspection

Brushes: a.) Length

a.) The wearing rate depends on the environmental


vibration and the speed, too). See figure Length of
brushes and chapter Change of brushes and brush
holders.

b.) Free motion in the


brush holder

b.) Check along the total length of the brushes.

c.) Cables

c.) Integrity of insulating tubes, tightness of the


connecting screws.

Slipring and brush


structure insulators

Clean with electric detergent and dry.*

Slipring surface

Check the patina (colour) of slipring running surface.


WARNING!
If the patina is damaged the following reasons can
initiate it.
- Captured brush in the brush holder and sparking
- Loose contacts
Find the reason and eliminate it.

Slipring compartment

If the compartment and the brushgear are not clean


enough then clean them before the next start. Use
vacuum cleaner, textile and even solvent if needed.

* WARNING!
REPAIRING OF THE SLIPRING COMPARTMENT AND THE BRUSH HOLDER STRUCTURE
In case of any flash over in the slipring compartment, even if the slipring assembly seems to be
uninjured, disconnect the slipring electrically from the rotor winding, and a voltage test should be
performed with reduced / 80%/ test voltage.
The same test should be done on the brush structure insulators.

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Periodicity
Semi-annually

OPERATING AND MAINTENANCE INSTRUCTIONS

Component

Maintenance required

Fixing

Ensure that all fixing bolts are secured.

Terminal box

Check conductors and clean the bushing insulators.


Ensure the connection terminals are tight.

Connections

Check all electrical connections and ensure they are


tight.

Annually

Cooler

Cleaning of the internal surface of the tubes of the


coolers with proper pipe brush and of the external
surface with compressed air.

Every 2 years

Windings: stator, rotor

Measure the insulation resistance. See chapter 0

5 years

Winding

Blowing out with pure compressed air, clean and dry if


necessary.

Bearings

See chapter Hiba! A hivatkozsi forrs nem tallhat.


Para 8.

4.10

LENGTH OF BRUSHES

Check the remaining length of brushes without removing them from the brush holder.

permitted distance 6mm


brush holder
brush
2-3mm

slipring

WARNING!

Change the brushes when the remaining length of them decreases to 36mm.
Do not remove the brushes from the holder unless it is needed.

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4.11

OPERATING AND MAINTENANCE INSTRUCTIONS

CHANGE OF BRUSHES AND BRUSH HOLDERS

4.11.1 PRELIMINARY CHECK ON BRUSHES AND BRUSH HOLDERS


Check the brushes before changing.
o type of brushes ( they should be RC87)
o cross section of brushes:
dimensions, tolerance: 3200,,24 x 32 00,,24
o see attached drawing
Check the brush holders before changing of the brushes in them
o check of cleanliness
o check if it moves well
o check the fixings
o check if the holder has loose or injured parts (spring, screw etc.)
If everything is OK. Leave as it is.
In other cases repair or change them. Before changing check the size of brush
holder dimensions (see the attached catalogue sheet).

4.11.2 PUTTING NEW BRUSHES IN THE HOLDERS


o Make the grinding and polishing of all the brushes
o Check the brushes then as follows:
If the running surface is min. 80 % then OK.
o Measure and record the length of brushes
o Make a map in order to identify the brushes
o Clean the slipring compartment as above mentioned
o Check the clearance between brush and brush holder (the right value is
0,2-0,25 mm on each side).

4.11.3 CHANGE OF BRUSH HOLDERS


Do not modify the adjustment of holders even do not change them only in case of
necessity (failure, damage, loosening etc.)
o Use 2 - 3 mm spacer to set the distance between the holder and the slipring.
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CG ELECTRIC SYSTEMS HUNGARY Zrt.

OPERATING AND MAINTENANCE INSTRUCTIONS

o Check the radiality visually. 2 - 3 difference can be recognised by visual


inspection. The setting by visual observation is sufficient.
o Check followings: fixing, proper moving.

4.12

MAJOR

OVERHAUL

WITH

REMOVING

THE

ROTOR FROM THE STATOR


When the overhaul includes disassembly of the machine for this purpose a proper
assembly room or at least a covered assembly place should be ensured. Its
atmosphere must be free of acid vapours, corrosive gases and dust and its relative
humidity must not exceed 60% while its temperature must not be below 10 C. The
assembly space should be clean and free of cuttings.

4.12.1 WORK STAGES


o Disconnection of the terminal leads mains supply cable, earthing and
thermometer terminals. Common marking of the terminals and connecting wire so
as to facilitate correct connecting up.
o Disconnection of the coupling.
o Removal of the base plate fixing bolts and taper pins.
o Taking the machine into the mounting space paying regard to the instructions for
lifting.
o Dismantling of the and shields and slide bearings, if applied , removal of the rotor
as per the assembly drawing.
o The following have to be checked:
clamping of the stator end windings
tightness of the slot closing wedges
mechanical state of the brush holders.
o Cleaning of the cooler is proposed only with mechanical method (pipe-brush).
See Installation, Operation and Maintenance Instruction.
o After checking and cleaning, the assembly of the machine is carried out obviously
in reversed sequence. Both on disassembling and on assembling care must be
taken to avoid damaging the matching surfaces.

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CG ELECTRIC SYSTEMS HUNGARY Zrt.

OPERATING AND MAINTENANCE INSTRUCTIONS

o After major overhaul, upon putting into operation the instructions of Putting into
operation should be followed.

4.13

TROUBLE SHOOTING CHECK LISTS

o If some operating difficulties occur, first of all make sure that:


o the rated voltage be actually present on the three stator phases;
o the supply voltage and frequency be consistent with the rated voltage and
frequency
o the protective devices be well-operating:
o the machine be not too overloaded (by comparing the absorbed current with the
specification one ).
Trouble
1.

2.

Motor vibrations

Motor at no-load, does


not start up (without
noise)

2.
3.

Motor at no load does


not start up (with
magnetic noise)

Possible trouble

Corrective action

1.a

Misalignment with the coupled 1.a


machine.

Verify and provide to align the


machine.

1.b

Unbalanced or settled
foundation, lose hold-down
bolts, uneven air gap
alignment.

1.b

Verify and provide as


required.

1.c

Wear bearings.

1.c

Replace the bearing shell.

2.a

Two phases of the power


supply line interrupted.

2.a

Verify and restore the


interrupted phases.

2.b

Power supply line without


voltage.

2.b

Verify and provide to cut-on


power supply line.

One phase interrupted. The


3.
motor can turn in no-load on
both directions in single phase.

Verify and restore the


interrupted phase.

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CG ELECTRIC SYSTEMS HUNGARY Zrt.

4.

4.a

Supply line voltage too low.

4.b

Resistant torque too high, as 4.b


consequence of locking of the
coupled machine or of the
rotor.

Disconnect the motor from


the driven machine, check
and remove the lock.

Motor starts at no load 5.a


but it produce low toque
when under load. The
5.b
stator current oscillates.

A phase is fell down after the


start.

Verify and restore the


interrupted phase.

One rotor phase is interrupted. 5.b

Verify, repair or replace the


rotor.

6.

Motor, at no-load heats. 6.a

Wrong connections between


stator winding and supply line
(i.e. delta instead of star
connect.).

6.a

Verify the compliance with the


connection data detailed.

6.

6.b

Supply line voltage too high.

6.b

Verify that supply line voltage


is in compliance with the
tolerance values

6.c

Improper or restricted
ventilation, obstructed air
passages.

6.c

Check air passage for


obstruction. Remove
obstruction.

7.a

Motor runs only in single phase 7.a


(supply line interrupted).

Check the supply line and


provide to restore the
interrupted phases.

7.b

Supply line voltage too high or 7.b


low.

Verify that supply line values


are in compliance with
specifications.

Local heat on the motor 8.a


with: noise, smoke,
spark, or flames.
8.b

Short circuit in the stator


winding.

Verify and replace the stator


winding.

The rotor rubs on the stator


8.b
during running, causing sparks
in the air gap.

Check the air gap and


eventually replace the
bearing shells.

Motor runs with


abnormal noise.

9.a

Irregular air gap.

9.a

Check the air gap and


eventually replace the
bearings.

9.

9.b

Not correct coupling.

9.b

Check the coupling of the


driven machine and provide
as consequence.

10. Abnormal bearing


temperature.

10.a Axial thrust too high.

10.a

Verify operation of the driven


machine.

10.b External shocks.

10.b

Verify and eliminate the


external cause.

10.c Poor bearing lubrication or


damaged bearing.

10.c

Check lubrication system or


replace the bearing shell.

5.

7.

8.

9.

Motor under load does


not start up (normal
magnetic noise)

OPERATING AND MAINTENANCE INSTRUCTIONS

Motor under load heats


too much.

4.a

5.a

8.a

10.d Direct external heat radiation 10.d


towards the bearing, by driven
machine, sunray.

Check that the supply voltage


is in compliance with the
tolerance values.

Verify and use shadowing


screen.

25

CG ELECTRIC SYSTEMS HUNGARY Zrt.

ANNEX

5 DRAWINGS AND ACCESSORIES

Outline drawings.......................................................................................... 1033288G


Instrumentation and wiring .......................................................................... 1033351C
Main terminal box assembly ...........................................................................1043180
Rotor terminal box assembly ..........................................................................1043170
Auxiliary terminal box .....................................................................................1033499
Heater terminal box ......................................................................................1108185F
Drive side bearing assembly ..........................................................................1110302
Drive counter side bearing assembly .............................................................1110306
Installation, operation and Maintenance Instruction for VC1100 C11
Datasheet for VS-069 vibration sensor

CG Electric Systems Hungary Co. Ltd.


H-1095 Budapest Mrissy street 7.
Registration Nr.: 01-10-044689
T:+36-1-483-6600
www.cgglobal.com

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