Rotating Electrical Machines Spare parts, installation and maintenance of ac motors 103-4E 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Contents Introduction Pre-installation requirements Warning Receipt Lifting Eyebolt/lifting lug bolt torques Motor weights Storage Environment Drain holes Bearings Grease Heaters Insulation resistance Wound rotors Installation General Location Mechanical installation Drain holes Alignment Noise levels Free rotation Slide rails Electrical connection Cable terminations Drying out procedures Supply Earthing Heater/thermistor continuity Auxilliary electrical items Control gear Connection diagrams Rotation Wound rotors Starting/running Motor modifications Endshield/foot fixing torques Maintenance On-going maintenance Periodic maintenance Wound rotor Hazardous area motors Enquiry and policy Spare parts, installation and maintenance Appendices Slide rail dimensions TEFV relubrication or replacement 2 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Installation and maintenance of ac electric induction motors Introduction Your Brook Crompton motor is designed for long life, and low running costs. Careful installation and maintenance will ensure that you achieve reliable operation and optimum efficiency. Pre-installation requirements WARNING Type Eyebolt dia Cast iron frames Eyebolt/lifting lug bolt torques Metric NEMA/ CSA 63 – – – – 71 – – – – 80 56 – – – 90S/L 143/145 – – – 100L – – – – 112M 182/184 M12† M12† – – – – – – – – Lifting lug bolt dia* Torque Nm Lbf.FT Handling and lifting of electric motors 132S/M 213/215 must only be undertaken by authorised 160M/L 254/256 personnel. Full product documentation and 180M/L 284/286 M12† M16† 200L 324 M10* 52 38 225S 326 M10* 52 38 225M 364 M10* 52 38 250S 365 M10* 52 38 250M 404 M16* 220 162 280S 405 M16* 220 162 280M 444 M16* 220 162 315S 445 M16* 220 162 315M 504 M20* 400 295 Packing materials may be damaged 315L 505 M20* 400 295 including sheeting and crate timbers. 355M/L 585/6/7 M20* 400 295 Handling operations may have damaged fan * W-DF design only. Lifting lugs secured with bolts and nuts. High tensile socket headed bolts and special square nuts must be used operating instructions must be available together with tools and equipment necessary for safe working practice. Receipt Before any motor is accepted on site it should be inspected carefully for damage or loss incurred during transit. cowls, terminal boxes or auxiliaries. Where an instance of droppage or loss is evident or suspected, it may be necessary to † The eyebolt should be firmly screwed down (without over tightening), to ensure that the collar is fully seated Cast iron construction Frames W-DF100L–W-DF355L Type Net weight Gross weight Cubage kg kg m3 W-DF100L 35. 38 .03 W-DF112M 45 48 0.05 W-DF132S/M 72.5 78.5 0.08 W-DF160M/L 133 145 0.15 W-DF180M/L 177.5 193.5 0.21 W-DF200L 255 270 0.30 W-DF225S 320 335 0.37 W-DF225M 375 390 0.37 W-DF250S 420 460 0.63 W-DF250M 570 610 0.70 W-DF280S 660 721 1.2 W-DF280M 800 871 1.2 W-DF315S 1000 1095 1.8 W-DF315M 1100 1195 1.8 W-DF315L 1300 1395 1.8 W-DF355S 2000 2120 2.3 W-DF355M 2300 2420 2.3 W-DF355L 2500 2620 2.3 Aluminium construction Frames DA63–DA180 Type Net weight Gross weight Cubage kg kg m3 DA63 5 5.4 0.010 unpack the goods to establish the full extent W-DA71 6 6.4 0.010 of the problem. W-DA80 9 10 0.020 W-DA90S 12.5 13.5 0.030 Where two eyebolts/lifting lugs are used with Wherever possible, damage should be inclined loading, the maximum safe working W-DA90L 14.5 15.5 0.030 recorded, photographed and witnessed. loads of BS 4278: 1984 should not be W-DA100L 19 21 0.038 exceeded (ISO 3266). W-DA112M 27 29 0.050 W-DA132S 38 41 0.071 W-DA132M 46 49 0.076 W-DA160M 80 95 0.125 W-DA160L 100 112 0.125 W-DA180M 140 165 0.253 W-DA180L 148 174 0.253 Report any damage to the carriers and Brook Crompton as soon as possible, quoting the motor number and consignment Tables of approximate weights note reference. The insurance company’s agents shown on the insurance certificate Cast iron construction Frames DF80–DF90L should also be advised. Type Lifting Net weight Gross weight Cubage kg kg m3 Eyebolts and/or lifting trunnions supplied DF80M 15 16.5 0.02 with the motor are designed to support only DF90S 19 20.5 0.03 the weight of the motor, not the weight of DF90L 22 23.5 0.03 the motor and any ancillary equipment Drip proof cast iron construction Frames K-CF225M–K-CF315M Type attached to it. Be absolutely sure that cranes, Net weight Gross weight Cubage kg kg m3 K-CF225M 378 411 0.37 K-CF250S 391 446 0.63 K-CF250M 444 499 0.70 K-CF280S 536 602 1.2 Where an eyebolt is provided with the K-CF280M 633 699 1.2 motor, this should be screwed down until its K-CF315S 801 885 1.8 shoulder is firmly against the face of the K-CF315M 916 1000 2.3 jacks, slings and lifting beams are capable of carrying the weight of equipment to be lifted. stator frame to be lifted. Eyebolts are normally designed for a vertical lift. For eyebolt/lifting lug torques, see opposite. 3 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Storage Shielded bearings have a storage life of five If motors have to be stored before years and a further two years operational life installation, precautions should be taken to following installation. prevent deterioration. contaminating solvent. Lightly pack the Depending on the site conditions it may bearings with grease applying a 33% fill be necessary to create a suitable stores area by volume into the bearing and housings Packing cases are not waterproof. b the approval certificate c codes of practice (BS 5345, IEC 79 Part * Wash all bearing parts with a non- Environment to hold the motor prior to installation. BS 5000 Part 16 14) All warning instructions and labels must be observed and retained with the motor Heaters Where space heaters are fitted, and the Health & Safety at Work etc Act 1974 Motors should be stored in a dry, vibration storage environment has wide humidity free and clean area at normal ambients and temperature variations, it is strongly (–20°C to 40°C), unless other arrangements recommended they be energised. It is essential equipment is installed, earthed and guarded in accordance with current legislation have been agreed with Brook Crompton. Where low temperature ambient storage is anticipated, special precautions should be taken with the type of grease, no plastic parts etc. to ensure trouble free start-up. Warnings should be placed on the Location motors to make operatives aware of Motors must be installed with adequate the live heaters access for routine maintenance. A minimum of 0.75m of working space around the motor Supplies are normally 220-240 volt is recommended. Adequate space around Motors must be stored away from corrosive single phase, from a 380-415 volt three the motor, particularly at the fan inlet or chemically damaging fumes. phase supply. See terminal box lid for (50mm), is also necessary to facilitate details. airflow. Before placing motors into storage, machined components should be carefully A low voltage DC supply could be used as Where several motors are installed in close inspected. Bearings and shafts are normally an alternative (see page 14). proximity, care must be taken to ensure that covered with a corrosion resistive barrier. If this coating is damaged it should be made good. The component should be cleaned and the protective coating reapplied. Under no circumstances should rust be merely covered over. Insulation resistance During extended storage a three monthly insulation test is recommended to avoid Mechanical Drain holes The insulation resistance between phases and between the windings and the frame should be checked. 200 and above. Position the drain holes at the lowest point. Bearings To avoid static indentation the storage area should be vibration free. If this is not possible it is strongly recommended that the motors be stood on thick blocks of rubber or other soft material. Shafts should be rotated by hand one quarter of a revolution weekly. When the application calls for direct the drying out methods recommended on coupling, the shafts must be correctly page 14 until an acceptable reading is aligned in all three planes. Bad alignment obtained. If heaters are fitted but not can be a major source of noise and energised, they should be used in future. vibration. See also note on page 14. Allowance must be made for shaft end-float Wound rotors and thermal expansion in both axial and Ideally, wound rotor motor brushes should vertical planes. It is preferable to use flexible not be in contact with the slip-rings during drive couplings. storage as there is a risk of corrosion. rings or stored separately. This may not be possible with small motors (up to frame bearings. Roller bearings may be fitted with W-DF180). a shaft locking device. This should be kept in years. If stored for a longer period, grease may need to be replaced.* Installation Work on hazardous area motors should only be carried out by Brook Crompton trained personnel or those trained to an equivalent standard Reference should be made to: a constructional standards EN50014, 4 into place after draining. Alignment position to avoid static indentation of the grease with a recommended shelf life of two integrity of all gaskets, sealants etc. should If a lower reading is measured, use one of Brushes should either be lifted off the slip- Factory fitted bearings use a lithium based if fitted. If any water has accumulated, the maintained above 10 megohm. unavoidable the shaft should be locked in Grease Prior to installation remove drain plugs be checked. Drain plugs should be put back The insulation resistance should be Where the exposure to some vibration is place during storage. level. installing. Use a 500 volt d.c. Megger. Motors provided with drain holes have drain to frame size 180, and fitted on frames size air. Foundations must be solid, rigid and possible lengthy drying out periods when Drain holes plugs provided loose in the terminal box up there is no recirculation of exhausted warm EN50018 (EEx d), EN50019 (EEx e), 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Installation and maintenance of ac electric induction motors Noise levels regulations. The equipment must be (see motor nameplate) without overheating The noise levels published in current Sales correctly fused and isolated. All covers must or excessive voltage drop under starting Specifications are equal to or less than the be in position prior to running. conditions. limiting values for rotating machines specified in European and International Standards BS EN 60034 and IEC 34-9. In most cases noise levels also meet limiting values for exposure to noise in the work place i.e. Guidance on regulations for Noise at Work issued by HMSO. WARNING Earthing Isolate power supply to motor before All motors are fitted with an earthing commencing any routine cleaning or terminal, in or adjacent to the terminal box, maintenance work. to enable connection to an effective earthing Drying out procedures It is preferable to dismantle the motor to the point where the rotor is removed. bond. The terminal is designed for connecting the correct size of copper earth connector. If a different material is to be used please refer to Brook Crompton. It is the responsibility of the purchaser to This is not essential but the drying out ensure that other overriding lower noise process will take longer in the assembled The motor must be earthed by connecting levels if required, eg Machinery Directive, state. the shortest possible length of cable to the are specified at the time of order, or that the installation incorporates noise attenuating measures. The temperature of the windings and the insulation resistance should be monitored at regular intervals. On initial application Free rotation of heat the insulation resistance will drop The rotor must be free to rotate within quickly and then start to rise slowly until its housing. Where uneven or bumpy level. On discontinuation of the drying rotation occurs the bearings should be process, a further rise in resistance will inspected to establish that they have not occur. been damaged during transportation or storage. Slide rails Slide rails are available for all motors in the Brook Crompton product range to provide adjustable mounting. Fabricated steel rails are the standard as they are suitable for all mounting arrangements. Alternative aluminium slide rails are available for floor mounting. There are several methods which can be used: 1 place the motor in a warm (typically 40°C), dry airstream (fan or convector heater) or in a warm oven with a temperature not exceeding 80°C. This method is preferred if the motor is dismantled 2 connect the motor to a low voltage* three phase supply and inject a current not exceeding 50% of the full load current into Installation 1 slide rails must be installed on a flat surface 2 rails must have a secure location 3 drive and driven shafts must be parallel Electrical connection The connection diagram is shown on the leaflet enclosed in the motor terminal box or the diagram inside the terminal box lid. The cables used should be capable of carrying the full load current of the motor (see motor name-plate) without overheating or undue voltage drop. Cable terminations All cable terminations should be tightly secured. Mains lead terminal lugs should be in face to face contact with the motor lead lugs and securing nuts and lockwashers of the line voltage). If this is carried out on an assembled motor, it is possible though unlikely that the motor will turn. If so the 3 connect two phases in parallel, and the and 35mm2 phase conductors, the earth should be a minimum of 16mm2. Above 35mm2 phase conductors, the earth conductor should be a minimum of half the phase conductor. Phase conductor mm2 Earth conductor mm2 up to 16 at least equal 16-35 16 minimum above 35 at least half An earthing bond should not be terminated under the motor fixture bolts or terminal cover screws. The earth lead could be over-looked on reconnection after maintenance Heater continuity Heaters should be checked for continuity prior to connection to the control circuitry. Thermistor continuity third in series. Apply a low voltage a.c. or If fitted, it is recommended that thermistors d.c. supply up to a maximum of 50% of be connected to the control circuit. full load current. The stator winding Thermistors provide good thermal overload temperature must not be allowed to protection. exceed 80°C. In practice the frame should not be hot to the touch, to guard against internal overheating and consequent damage to the insulation 4 where heaters are fitted these can be energised Auxiliary electrical items Where auxiliaries are fitted, the characteristics should be checked. Example: RTDs (Resistance Temperature Detectors) should have their resistances checked against manufacturer’s figures. Supply Do not megger across the thermistor. Do not It is important that a motor is operated apply more than 6V across the thermistor for within the limits of its design voltage and continuity check. frequency. Standard motors for the UK will operate without damage on any voltage in the range between the mains and motor lugs. 94% to 106% of the nameplate voltage. earthed in accordance with current up to 16mm2 phase conductors. Between 16 rotor should be locked in position should be no nuts or lockwashers fitted qualified electrician and equipment must be capacity at least that of the main connections the stator winding (*approximately 10% screwed firmly over the connection. There Wiring should be carried out or checked by a earth screws. The cable must have a The supply cables must be capable of carrying the full load current of the motor 5 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors 17 strip paint from the pads where the feet Control gear Some initial bearing noise may be present Ensure all control gear and associated during the running in period. This is normal are to be fitted and apply a thin film of metering/protection circuits have been because the grease has to settle down grease for corrosion protection on bare checked fully. within the bearing. The noise should surfaces disappear after a few hours of operation. It is imperative that any overload trips vertical nuts and bolts for location and emergency shutdown circuits are Check that the motor runs up smoothly and working correctly before the motor is within the permitted run-up time. Note that energised. All covers must be in repeated starting in quick succession may position lead to a thermal overload of the motor. Where a motor is fitted with a 18 slide first foot into position, using Motor modifications purposes. Lightly tighten to prevent foot from falling out of the slots in the frame 19 insert horizontal bolts 20 ensure the feet are fully in contact with the machined faces. Tighten all bolts to the torque given on page 17 separately driven fan unit, the W series interlocks and thermal overload Multimount modification 21 repeat stages 18 to 20 on the other foot protection circuits must be operative. Cast iron motors 22 prime and paint all machined surfaces Frames (200-355) Connection diagrams Refer to the connection diagram supplied SAFETY WARNING with the motor for supply details and the Do not work under suspended load required winding connection. and use correct lifting equipment. left exposed by the changes 23 refit fan cover with the greasing hole in the correct position Bearings, grease, bearing change Rotation Changing terminal box Grease Before coupling the motor to the drive, run 1 lift motor, using two lifting lugs provided Bearings are prepacked with a lithium or 2 slacken the two vertical foot fixing bolts lithium complex based grease. the motor briefly to check rotation. All covers must be in place on one foot 3 remove the two horizontal foot fixing Motors fitted with angular contact or bolts duplex bearings must be run in the correct 4 pull the foot away from the frame mounting position eg vertical. 5 repeat stages 2 to 4 on the other foot To reverse rotation interchange any two supply leads. The stator of a wound rotor motor is similar to a cage motor but the rotor circuit is connected to a starting resistance. Take care to ensure that the brushes are in contact with the slip rings and that the rotor resistances are connected in the ‘start’ position. consistency would be compatible. See Table 1 for some alternatives. Table 1 Alternative lithium complex greases 6 lower the motor onto two pieces of timber 7 remove both lifting lugs Wound rotors Other lithium based greases of a similar 8 rotate the motor until the terminal box is in the correct postion 9 refit the two lugs on the machined pads at the top of the motor on diagonally opposite corners. Ensure that lifting lugs are in contact with all machined faces and that the correct bolts and nuts are Grease Reference Manufacturer Energrease LC2 BP Castrol LMX Castrol Luplex M2 Century Unirex N2 Esso Sovereign LS Gulf Mobilgrease HP Mobil Liplex EP2 Shell Hytex EP2 Texaco Retinax LX Shell LGHT3 – SKF used. Tighten the bolts to the torque Starting Motors are rated by the output required, the number of starts per hour, the load curve/ inertia, and environmental considerations. shown on page 12 this will be indicated on the motor 11 remove the endshield bolts at both ends nameplate. of the motor 12 slacken drive end bearing cap or Operating outside the contractual clamping screws to allow endshield parameters may thermally overload the spigot to disengage motor eg too many starts per hour, or Regreasing Standard regreasing facilities, where provided, are situated on the periphery of the drive end and non drive endshields. 13 disengage both endshield spigots and mechanically stress components eg rotate the endshields through 90 Grease relief is via a: overspeeding. degrees until the grease nipples are at a diaphragm relief valve the top Refer to starter literature for method of start and safety precautions to be taken 14 refit endshield bolts and tighten to Running After one hour of running, check the general vibration levels. If these are excessive, check alignment (and belt tensioning if belt driven). b rotating grease relief flinger c plugged grease chute torque given on page 17 15 retighten the bearing cap screws at the 6 Where a special grease has been supplied 10 remove fan cover Standard regreasing facilities drive end, replacing the Nyltite washers Type under the bolt heads. Tighten screws to 63/180* on request the torque given on page 17 200/355 standard 16 lift motor, using hooks in the two lifting lugs Regreasing facility * Bearings are double shielded and prepacked with grease for life 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Installation and maintenance of ac electric induction motors An overgreased bearing will cause over- 4 fit flange ring onto spigot, positioning heating of the bearing with the possible fixing holes to provide either BS or DIN escape of the grease, loss of lubrication flange hole positions qualities, leading to ultimate bearing failure. Lubrication procedure The following procedure should be adopted. 5 bolt ring into position, using the same size socket head bolts as used on the feet. These are supplied with the flange ring kit 6 tighten the bolts to torque as given on 1 wipe clean the grease gun fitting and the regions around the motor grease fittings page 17, ensuring a progressive tightening sequence 2 remove the grease relief plug if fitted. hours of operation or 3 months, whichever is the sooner. Checklist • no visible damage ie fans cracked, fan cowls bent, foot cracked etc • no accumulation of dust or fibres on the frame or around the fan inlet • no significant corrosion of the lifting lugs/ eyebolts • no excessive vibration Some motors will have one way grease Change from ball/ball to roller/ball valves which should be left in place construction (refer to Brook Crompton • no loose fasteners for W-EF) • cables and earths are sound 3 add a small quantity of grease, approximately 4 to 10 shots depending on frame size 4 allow motor to run for about ten minutes in order that excess grease may be expelled before refitting the relief plug. 1 isolate motor before commencing work 2 remove fan cover and fan 3 remove bearing cap screws 4 remove endshield at both ends Bearings fitted with rotating grease relief 5 remove bearing circlips at both ends or through grease valves will relieve 6 remove preload washer at non-drive-end automatically 7 replace drive-end ball bearing with new 5 on initial start up or after relubrication, ‘bearing noise’ may result from the new grease moving around the bearing. This noise is normal and will disappear after a few hours of running Bearing change When fitting new bearings the parts should be lightly lubricated with grease. The bearing should be driven onto the shaft by pressure on the inner race only using a short length of tube placed over the motor shaft. On larger motors it is easier to raise the temperature of the bearing using an oil bath, oven, or induction heating. The temperature must be controlled to 120°C maximum. roller bearing and refit circlip 8 remove non-drive-end ball bearing and inner bearing cap 9 fit new non-drive-end inner bearing cap into place, ensuring that the bearing is in contact with the shaft shoulder. When cool, ensure that the bearing is clean and charge the bearing with the recommended quantity of grease. Bearings and housings should be one third full. • insulation resistance adequate, imperative this is checked after a prolonged shutdown • Note - Fumex smoke extraction motors should be rewound after 5 years of operation. See specification sheet 2215E • regrease required, particularly large output 2 pole motors • bearing condition Periodic maintenance Remove the cover and the fan which is drive-end inner bearing cap) keyed, clamped, pinned or knurl located to 10 examine existing non-drive-end ball bearing and either refit or replace the shaft extension. Loosen and remove bearing cover screws and endshield 11 refit non-drive-end bearing circlip bolts/studs. The endshields should then be 12 repack bearings with new grease in eased off their spigots. accordance with recommendations The rotor can now be carefully withdrawn 13 ensure the lip, on both oilseals, is greased from the stator, taking care not to damage 14 refit both endshields and check that:- the stator bore and both stator and rotor a spacer O/D is the same as the bearing windings. O/D b bearing spacer supplied is fitted into recess c slots in inner bearing caps are aligned with endshield grease chutes d correct location for bearing cap by the use of a stud e bolts are torqued up to recommended figures 15 refit bearing cap screws, ensuring correct torque to recommended figures Fitting Flange Adaptor good condition with shallow recess (identical to existing the non-drive-end endshield bearing The bearing should then be quickly slipped • sealing of the motor and gland plate in Having dismantled the motor, maintenance can be carried out to remove all dirt. For this purpose, the use of an air line supplying dry compressed air under comparatively low pressure is best, as a high velocity air-stream can force dirt into the spaces between the windings and insulation, etc. Greaseremoving solvents should only be used very sparingly to avoid damage to impregnating varnish or insulation. Motors should be re-assembled in the reverse order from dismantling, 16 refit fan and fan cover remembering to ease endshields onto 17 Turn shaft by hand to ensure free rotation bearings and spigots. Do not use force. Maintenance Before starting, check that the rotor revolves On-going maintenance freely. Ensure that the electrical connections Induction motors by their very nature require are correct and terminal nuts tight (see sec- spigot and remove all the plastic bolt-hole very little maintenance. However a regular tion – Electrical Connection). cover caps. Apply a film of Hylamar regime of inspection is recommended to jointing compound on bare machined ensure minor problems do not escalate to surfaces for sealing and corrosion breakdowns. Typical intervals would be 2000 1 if required, remove foot as detailed in terminal box position change 2 if required, reposition terminal box and lifting lugs 3 clean paint off the drive end endshield protection 7 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Hazardous area motors Endshield fixing bolt torques Type Metric Bolt dia NEMA/CSA W-DA Aluminium frames Torque Nm Lbf.FT DF & W-DF Cast iron frames Torque Nm Lbf.FT In addition to the conditions referred to, K-CF Torque Nm Lbf.FT special requirements apply to motor types Ex N, Ex nA, EEx e, EEx d, EEx de. Refer to – – – the approval certificate and appropriate – – – – codes of practice eg BS 5435. 5 3.7 – – 5 3.7 – – 5.9-7.4 20-24 14.7-17.7 – – 8-10 5.9-7.4 20-24 14.7-17.7 – – the motor serial number to ensure that the 8-10 5.9-7.4 28-32 20.5-23.6 – – correct spares will be supplied. M8 (taptite) 29 21 28-32 20.5-23.6 – – 284/286 M10 (taptite) 52 38 38-42 27.8-30.7 – – 200L 324 M10* 52 38 52 38 52 38 a fixing bolts, nuts, studs, screws, spacers or 225S 326 M10* 52 38 52 38 52 38 washers are not included with these parts 225M 364 M10* 52 38 52 38 52 38 and, if required, should be clearly specified 250S 365 M10* 52 38 52 38 52 38 250M 404 M16* 220 162 220 162 220 162 280S 405 M16* 220 162 220 162 220 162 280M 444 M16* 220 162 220 162 220 162 315S 445 M16* 220 162 220 162 220 162 315M 504 M20* 400 295 400 295 400 295 315L 505 M20* 400 295 400 295 400 295 b bearings ordered direct from bearing 585/6/7 M20* 400 295 400 295 400 295 manufacturers must be specified as 63 – M4 1.5 1.1 71 – M4 1.5 1.1 80 56 M5 5 3.7 90S/L 143/145 M5 5 3.7 100L – M6 (taptite) 8-10 112M 182/184 M6 (taptite) 132S/M 213/215 M6 (taptite) 160M/L 254/256 180M/L 355S/M/L – Spares and repairs When ordering spares it is important to state Notes on the order in addition to the part description number. The fixing duty and part description reference number for which they are required should also be clearly stated follows: * High tensile socket headed bolts and square nuts must be used 63-90 CN bearing 100-355 C3 bearing Foot fixing bolt torques Type Metric 63 Bolt dia NEMA/CSA M5 – W-DA Aluminium frames Torque Nm Lbf.FT 6-7 W-DF Cast iron frames Torque Nm Lbf.FT 4.5-5.2 – – Please contact Brook Crompton or its Agents for information on any aspects of the motor performance that need clarifying. 71 – M5 6-7 4.5-5.2 – – 80 56 M8 (taptite) 24-25 17.7-18.4 – – 143/145 M8 (taptite) 24-25 17.7-18.4 – – 100L – M8 (corflex) 32-35 23.6-25.8 – – Please quote the motor number in all such 112M 182/184 M8 (corflex) 32-35 23.6-25.8 – – cases with full details of the problem. 132S/M 213/215 M8 (corflex) 32-35 23.6-25.8 – – 160M/L 254/256 M10 68-72 50-53 – – Policy 180M/L 284/286 M10 68-72 50-53 – – Our policy is one of continuous improvement 200L 324 M10* – – 52 38 and we reserve the right to alter any detail of 225S 326 M10* – – 52 38 our products at any time without giving 225M 364 M10* – – 52 38 notice. 250S 365 M10* – – 52 38 250M 404 M16* – – 220 162 280M 405 M16* – – 220 162 280L 444 M16* – – 220 162 315S 445 M16* – – 220 162 315M 504 M20* – – 400 295 315L 505 M20* – – 400 295 585/6/7 M20* – – 400 295 90S/L 355S/M/L * High tensile socket headed bolts and square nuts must be used Wound rotor Inspection Brushes should be inspected every 1000 Replacement of brushes is recommended running hours or at three monthly intervals if when the brush is approximately a quarter of this is a shorter period of time. the way down the brush holder. On calliper type designs the brushes should be replaced The inspection should include checks for when 1/4” (5mm) of brush remains. brush wear and tensioning. Build up of 8 Enquiries carbon dust should be removed using a It is important that the correct grade of brush suitable dust extraction unit. be used as this significantly affects operation. If in doubt please refer to Brook Crompton. Contact must be made prior to any remedial action being taken under guarantee. 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Spare parts, installation & maintenance Aluminium construction - frame sizes DA63, W-DA71 to W-DA180* 17 13 29 1 15 16 10 30 11 9 20 19 12 14 23 24 25 26 18 27 2 28 4 7 5 6 21 22 8 3 Ref Part description 1 Aluminium flange endshield, frames 100132, cast iron flange frames 160-180 Endshield fixing bolt Drive end endshield Rotor assembly Flinger Drive end oil seal Preload washer Drive end bearing Stator assembly with or without feet Eyebolt (when fitted) Bearing retention circlip Non-drive end bearing Non-drive end endshield Endshield fixing bolt Bearing circlip Non-drive end oil seal Fan Fan circlip Fan cover Fan cover screw and washer Foot fixing bolts and washer Detachable feet Terminal board Terminal box to frame gasket Terminal box Internal earth terminal Terminal box lid gasket Terminal box lid Pad mounting bracket Face endshield 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 * This drawing typifies the range W-DA100–W-DA180 9 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Spare parts, installation & maintenance Cast iron construction - frame sizes W-DF112 to W-DF180 11 10 9 7 13 12 25 24 16 15 2 4 26 29 28 27 30 20 3 21 22 18 14 5 8 5 17 23 19 1 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 10 Part description Drive end endshield Drive end oil seal Drive end endshield fixing screws Pre-load washer Drive end bearing Fan cover Fan circlip Rotor assembly Flange endshield Face endshield Bolt on pad Earth terminal Eyebolt Stator assembly with or without feet Stator winding Rating plate Multi-mount foot Terminal block Terminal box gasket Terminal box Terminal box gasket Terminal box lid Terminal box lid fixing screw Inner bearing cap Non drive-end bearing Circlip Non-drive end oil seal Non-drive end endshield Non-drive end endshield fixing screws Fan 6 103-4E Issue 2 Spare parts, installation and maintenance of ac electric induction motors Spare parts, installation & maintenance Cast iron construction - frame sizes W-DF200 to W-DF355L 47 46 45 44 42 48 43 49 41 40 38 39 37 36 31 35 33 32 34 10 1 9 27 2 21 22 23 25 24 26 20 18 30 19 50 28 15 29 7 14 8 4 3 50 11 12 13 5 6 Alternative W-DF280M to W-DF355L terminal box arrangement 47A 46A 45A 43A 49A 38A 48A 39A 41A 35A 37A 36A 34A 16 17 Ref Part description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Flange adaptor (optional) Flange adaptor fixing bolt (optional) Endshield fixing bolt Drive end oil seal Drive end bearing cap fixing bolt and washer Plug Grease nipple Drive end endshield Stator frame assembly with or without feet Stator core pack Drive end bearing circlip Drive end bearing Drive end inner bearing cap Rotor assembly Non-drive end inner bearing cap Non-drive end bearing Non-drive end bearing circlip Preload washer Non-drive end endshield Endshield fixing bolt Non-drive end inner bearing cap fixing bolt and washer Non-drive end oil seal Fan Fan locking screw Fan cover fixing bolt and washer Fan cover Self adhesive nameplate Multi-mount foot Foot fixing bolt Foot fixing nut Lifting lug Lifting lug fixing bolt and washer Lifting lug nut Terminal box to frame gasket Terminal box Gland plate gasket Gland plate Gland plate fixing bolt and washer Main terminal block Auxiliary terminal bracket Clip-in auxiliary terminal block Main terminal retaining plug Main terminal block fixing bolt and washer Mains terminal cover (optional) Terminal box lid gasket Terminal box lid Main terminal box lid fixing bolt and washer Terminal lock nuts, spring washer and plain washer Terminal link Drain plug 22 23 24 25 26 27 28 29 30 31 32 33 34(A) 35(A) 36(A) 37(A) 38(A) 39(A) 40 41(A) 42 43(A) 44 45(A) 46(A) 47(A) 48(A) 49(A) 50 11 Rotating Electrical Machines Every care has been taken to ensure the accuracy of the information contained in this publication, but, due to a policy of continuous development and improvement the right is reserved to supply products which may differ slightly from those illustrated and described in this publication For the most recent version of any Brook Crompton catalogue/leaflet, please refer to www.brookcrompton.com Brook Crompton St Thomas’ Road Huddersfield West Yorkshire HD1 3LJ UK Tel: +44 (0) 1484 557200 Fax: +44 (0) 1484 557201 E-mail: email@example.com Internet: www.brookcrompton.com Printed in England dh0711/**/**/11/07 103-4E issue 2 © Copyright 2009. Brook Crompton. All rights reserved.