Baldor-Reliance Above NEMA Duty Master AC Motors Owner's Manual

PDF Download

Document

Above NEMA Duty Master AC Motors

Frames: 8040, 9240, 10840,

Enclosures: Open and Totally Enclosed

Mounting: Horizontal

06/16

Installation & Operating Manual

MN428

Any trademarks used in this manual are the property of their respective owners.

Important:

Be sure to check www.baldor.com to download the latest version of this manual in Adobe Acrobat PDF format.

MN428

Section 1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1−1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−4

Section 2

Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2−1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

Horizontal Mounted Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−2

Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−2

Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−3

Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−3

Coupling Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−3

Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−5

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−5

Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−7

First Time Uncoupled Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−7

Coupled Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−8

Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−10

Section 3

Maintenance & Troubleshooting - Horizontal Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3−1

Horizontal Shaft Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

Replacement Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3

Winding Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6

Auxiliary Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8

Section 4

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4−1

Winding Resistence Temperature Detector (RTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

Winding Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

Winding Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2

Winding Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2

Bearing Reistence Temerpature Detector (RTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2

Bearing Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3

Bearing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4

Bearing Dial Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4

Space Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4

Oil Circulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4

Constant Level Oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4

Differential Air Pressure Switch for WPII Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5

Differential Air Pressure Gauge for WPII Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5

Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6

Lightning Arrestors and Surge Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6

Vibration Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7

Tachometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7 i

Section 5

Cross Sectional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5−1

8040 Frame Cross Section - Anti-Friction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

8040 Frame Cross Section - Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−2

9240 Frame Cross Section - Anti-Friction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−3

9240 Frame Cross Section - Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−4

10840 Frame Cross Section - Anti-Friction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−5

10840 Frame Cross Section - Anti-Friction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−6 ii MN428

Section 1 General Information

Overview

Baldor•Reliance Duty Master motors provide industry leading value largely because of their 100+ year heritage of exceeding customer expectations. This includes providing Above NEMA Motors to customers for more than 50 years and in doing so, gaining a deep understanding of a broad range of industries and critical applications, The Baldor•Reliance product legacy extends from a wide range of general purpose motors to motors designed for the most hazardous and critical application extremes. In addition to Baldor being the most preferred supplier of industrial motors in North America, Baldor•Reliance is also the most specified motor in the Petrochemical industry and is the first motor to be certified under the API 547 monogram program.

Nobody knows more about their process than the customer. That is why Baldor employs dedicated Industry teams whose sole purpose is working directly with Industry users, consultants and OEMs. These experienced

Baldor engineers are dedicated to understanding the customer’s specific performance requirements and translating this into solutions and products that exceed customer expectations.

This manual contains general procedures that apply to Baldor “Above NEMA” Motor products. Be sure to read and understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform maintenance procedures until you understand the Warning and Caution statements.

Warning

statement indicates a possible unsafe condition that can cause harm to personnel.

Caution

statement indicates a condition that can cause damage to equipment.

The following pages contain the information that you need to get the most out of your Duty Master Motor.

Please read it carefully and thoroughly before unpacking and installing motor.

Safety Notice:

This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment.

Be sure that you are completely familiar with NEMA publication MG-2, safety standards for construction and guide for selection, installation and use of electric motors and generators, the National Electrical Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury.

Only qualified personnel should attempt the installation, operation and maintenance of this equipment.

WARNING:

Do not touch electrical connections before you first ensure that power has been disconnected .

Electrical shock can cause serious or fatal injury . Only qualified personnel should attempt the installation, operation and maintenance of this equipment .

Be sure the system is properly grounded before applying power . Do not apply AC power before you ensure that all grounding instructions have been followed . Electrical shock can cause serious or fatal injury . National Electrical Code and Local codes must be carefully followed .

Avoid extended exposure to machinery with high noise levels . Be sure to wear ear protective devices to reduce harmful effects to your hearing .

This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment . Improper use can cause serious or fatal injury . Only qualified personnel should attempt to install operate or maintain this equipment .

Do not by-pass or disable protective devices or safety guards . Safety features are designed to prevent damage to personnel or equipment . These devices can only provide protection if they remain operative .

WARNING:

Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment .

Be sure the load is properly coupled to the motor shaft before applying power . The shaft key must be fully captive by the load device . Improper coupling can cause harm to personnel or equipment if the load decouples from the shaft during operation .

Use proper care and procedures that are safe during handling, lifting, installing, operating and maintaining operations . Improper methods may result in bodily injury .

Before performing any motor maintenance procedure, be sure that the equipment connected to the motor shaft cannot cause shaft rotation . If the load can cause shaft rotation, disconnect the load from the motor shaft before maintenance is performed . Unexpected mechanical rotation of the motor parts can cause injury or motor damage .

Disconnect all electrical power from the motor windings and accessory devices before disassembly of the motor . Electrical shock can cause serious or fatal injury .

WARNING:

Do not use non UL/CSA listed explosion proof motors in the presence of flammable or combustible vapors or dust . These motors are not designed for atmospheric conditions that require explosion proof operation .

Motors that are to be used in flammable and/or explosive atmospheres must display appropriate hazardous location markings including zone/division, class group and temperature codes . Specific service conditions for these motors are defined in NFPA 70 (NEC) Article 500 .

Continued on next page.

MN428 General Information 1-1

Safety Notice

Continued

WARNING:

UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere .

This equipment is at line voltage when AC power is connected . Disconnect and lockout all ungrounded conductors of the ac power line before proceeding . Failure to observe these precautions could result in severe bodily injury or loss of life .

WARNING:

Rotating parts can cause serious or fatal injury . If relubrication is performed with the motor running, to avoid injury do not contact any rotating parts .

Solvents can be toxic and/or flammable . Follow manufacturer’s safety procedures and directions .

Failure to observe this precaution could result in bodily injury .

Use of an air jet may cause flying debris and generate particulate matter . Wear suitable skin, eye and respiratory protection . Failure to observe this precaution may result in bodily injury .

WARNING:

Caution:

Space Heaters operate at line voltage . Disconnect power to space heaters before performing maintenance work on motor . Failure to observe this precaution could result in severe bodily injury or loss of life .

Thermostat contacts automatically reset when the motor has slightly cooled down .

To prevent injury or damage, the control circuit should be designed so that automatic starting of the motor is not possible when the thermostat resets .

High Voltage may be present even when the machine is not rotating .

Ensure that power has been disconnected before touching the motor or any of its components .

Electrical shock can cause serious or fatal injury .

Do not lift the motor and its driven load by the motor lifting hardware . The motor lifting hardware is adequate for lifting only the motor . Disconnect the load from the motor shaft before moving the motor .

If eye bolts are used for lifting a motor, be sure they are securely tightened . The lifting direction should not exceed a 20° angle from the shank of the eye bolt or lifting lug . Excessive lifting angles can cause damage .

Caution:

For motors built with an external circulating oil system (flood lube), refer to the motor nameplate for the appropriate orifice, pressure and flow rates for the oil .

To avoid damage to the windings do not use air pressures greater than 30 psi (200 kPa) .

Avoid directing the air in such a way that the dirt will be blown into inner crevices .

To prevent premature equipment failure or damage, only qualified maintenance personnel should perform maintenance .

Do not over−lubricate motor as this may cause premature bearing failure .

Over−lubricating can cause excessive bearing temperatures, premature lubrication breakdown and bearing failure .

To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate .

If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in NEMA MG1 and MG2 standards to avoid equipment damage .

To avoid damage to motor bearings, grease must be kept free of dirt . For an extremely dirty environment, contact your Baldor distributor or an authorized Baldor District Office for additional information .

Caution:

Do not use solvents containing trichloroethane to clean interior or exterior of motor .

Damage may occur to paint and insulation systems .

The Shaft Block must be removed before the shaft may be rotated .

The shaft block must be installed prior to moving or lifting the motor to prevent motor damage .

When driven equipment may be damaged by incorrect rotation direction, uncouple the motor form load and check motor rotation direction during initial start and be sure rotation is correct .

Continued on next page.

1-2 General Information MN428

Safety Notice

Continued

Caution:

Motors with oil lubricated bearings (such as sleeve bearings) are shipped without oil . As soon as the motor is received, the bearing oil reservoir should be filled to the indicated level with the proper lubrication oil (see Section 5 “Constant Level Oiler”) . To avoid motor damage, do not rotate the shaft until you have filled the oil reservoirs to the proper level with recommended lubricant .

Repeated starts and/or jogs can greatly reduce the life of an induction motor . If you have any questions or are uncertain about any statement or procedure, or if you require additional information please contact your Baldor District Office .

Receiving

Each motor is thoroughly tested at the factory and carefully packaged for shipment.

When you receive your motor, there are several things you should do immediately.

Do not unpack until ready for use.

1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your motor.

2. Verify that the part number of the motor you received is the same as the part number listed on your purchase order.

Unpacking

Each Baldor motor is packaged for ease of handling and to prevent entry of contaminants.

1. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.

(Room temperature is the temperature of the room in which it will be installed).

The packing provides insulation from temperature changes during transportation.

2. When the motor has reached room temperature, carefully remove the motor from packaging. Retain all packing materials if the motor will be placed into storage after operation. If this is the case, the thrust bearing lubricant cooling coils must be completely drained (if so equipped). To assure that the coils are water free, the coils should be purged with compressed air after the water supply line has been disconnected. (This will prevent damage to the coils in sub−freezing environments.)

Lifting means are provided as Lifting Lugs or holes in weldment that are part of the motor enclosure or as eyebolts on top of the motor. Place a lifting hook in each of the lifting means provided and carefully lift the motor from its packing, see Figure 1-1. Use a hoist with adequate capacity. Use spreader bars as required to ensure that lift chains/cables do not pull at an angle and prevent damage to lifting eyes or motor hoods.

Handling

The motor should be lifted using the lifting lugs or eye bolts provided.

1. Eyebolts or lifting lugs are intended for lifting only the motor with the standard factory installed accessories such as tachometer, etc., the lifting means on the motor must not be used to lift the motor plus additional equipment such as gears, pumps, compressors, or other driven equipment. The lifting means on the motor cannot be used to lift assemblies of motor and other equipment mounted on a common base.

2. In all cases, care should be taken to assure lifting in the direction intended in the design of the lifting means. Lift using all lugs provided using a hoist with adequate capacity.

Be sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over. If the shipping pallet is intact, use a fork lift to move the motor. If the shipping pallet is not used, lift using all lugs provided. Likewise, precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or shock forces. Angle of lift with rope or chain never to be less than 45° from horizontal.

Figure 1-1 Lifting Motor

MN428 General Information 1-3

Storage

Caution:

Do not unpack until ready for use.

If the motor is not put into service immediately, the motor must be stored in a clean, dry and warm location.

Several precautionary steps must be performed to avoid motor damage during storage.

For short term storage (less than 6 months) use the following procedures.

Oil lubricated motors are shipped without oil . As soon as the motor is received, the bearing oil reservoir should be filled to the indicated level with the proper lubrication oil (see Section 5 “Constant Level

Oiler”) . To avoid motor damage, do not rotate the shaft until you have filled the oil reservoirs to the proper level with recommended lubricant .

1. Oil lubricated motors − As soon as the motor has been received, the bearing oil reservoir should be filled to the required oil level and with the proper oil lubrication. (See Section 3 Bearing Lubrication for proper type).

2. Grease lubricated bearings − Do not lubricate bearings during storage. Duty Master anti−friction bearing motors are shipped with the proper amount of grease in each bearing.

3. The motor should be inspected periodically and the insulation resistance checked and recorded monthly

(see Checking Insulation Resistance in Section 3). If there is a significant change in insulation resistance, it should be investigated and corrective action should be taken.

Consult your local Baldor District office for additional data.

4. Motors with A/F Bearings - At 30 day intervals, remove only enough packing to expose the shaft and remove the shaft shipping brace, rotate the shaft (by hand) 10 to 15 revolutions. This distributes the grease or oil, preventing bearing corrosion due to condensation, or to the presence of contaminating gases near the motor. After rotating the shaft replace protective packing and shaft shipping brace.

5. Horizontal Motors with Sleeve Bearings - Once per month the shaft blocking must be removed and the shaft rotated 10-15 revolutions to redistribute the lubricant and prevent corrosion of interior surfaces.

Prior to rotating the shaft, 4 to 6 ounces of oil should be poured onto the bearing liner.

6. If the storage location is cold, damp or humid, the motor windings must be protected from moisture.

This can be done by applying power to the motors’ space heater (if installed) while the motor is in storage.

If space heaters are not installed, the motor can be kept warm by placing several 100 or 150 watt electric lamps inside the enclosure and connect them to a power source.

7. For grease lubricated bearings, if the motor is stored and directly exposed to weather conditions, it is important that the bearing cavity be inspected for the presence of water at the grease drain. If the cavity is contaminated with water, the motor must be disassembled, grease removed from the bearing(s) and housing(s) and bearing(s) inspected for corrosion. If corrosion is present, the bearing(s) must be replaced.

If there is no corrosion, repack the bearing(s) / housing(s) with grease as instructed in Section 3.

8. Duty Master motors with oil lubricated sleeve bearings are filled at the factory with an oil containing a rust inhibitor. This additive protects the bearings and associated structural parts from rust and corrosion.

Prior to shipment the oil is drained. A thin film of oil remains on the vital parts providing short term temporary rust protection.

Storage periods greater than 6 months

Refer to MN439 for storage procedures that exceed 6 months in duration.

Contact your Baldor District office for any additional storage procedures that may be required for your motor.

1-4 General Information MN428

Section 2 Installation & Operation

Overview

Location

Before installing the motor, be sure you read Section 1 and become familiar with the Warnings and Cautions to prevent damage to the motor and prevent injury to personnel. This is extremely important for a good installation and to ensure trouble free operation.

Installation should conform to the National Electrical Code as well as local codes and practices. When other devices are coupled to the motor shaft, be sure to install protective devices to prevent future accidents. Some protective devices include, coupling guard, belt guard, chain guard, shaft covers etc.

These protect against accidental contact with moving parts. Machinery that is accessible to personnel should provide further protection in the form of guard rails, screening, warning signs etc.

1. If the motor has been in storage for an extended period or had been subjected to adverse moisture conditions, check the insulation resistance of the stator winding (see Checking Insulation Resistance in section 3).

2. Examine the motor nameplate data to make sure it agrees with the power circuit to which it will be connected. The motor is guaranteed to operate successfully at line frequency not more than 5%, and line voltage not more than 10%, above or below the nameplate ratings, or a combined variation of voltage and frequency of not more than 10% above or below nameplate ratings. Efficiency, power factor and current may vary from nameplate data.

3. Check to make sure that direction of motor rotation is correct for the intended application.

It is important that motors be installed in locations that are compatible with motor enclosure and ambient conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced operating life of the motor. The motor must be located in an environment that satisfies local codes and National Board of

Fire and Underwriter’s regulations. For locations outside the USA., compliance with IEC requirements and other regulatory agencies are required. The following additional considerations should also govern its location:

For open and protected motors the installation should be in a location that provides adequate space for air circulation of the external cooling fan. Exposure to high ambient temperatures, humidity and atmospheric contamination should be avoided. Acids, alkalis and gases also have detrimental effects on electrical machinery. The location of installation should be accessible for routine maintenance and inspection.

If the room is not large enough to have natural ventilation, some external source of forced and filtered air will be necessary. The room should be such that the heat developed during operation can escape and will not be recirculated over the equipment.

Permanent handling equipment to facilitate major service and repair without complete disassembly of the individual units should be considered.

If the motor must be moved or additional handling or shipment of motor be required, be certain to block the shaft as it was blocked for shipment by the factory. Blocking the shaft, limits the rotor movement both axially and radially which prevents damage to the bearings.

Horizontal Mounted Motor

These procedures are for Horizontal mounting of motors only.

Foundation

The dimensions for mounting are shown on the outline drawing supplied with the motor software and should be referred to prior to planning of the foundation.

Large motors require a concrete foundation. The foundation should consist preferably of solid concrete walls or piers and should be carried down far enough to rest on a solid sub base. This base should be sufficient stiffness to prevent vibration and to insure long, trouble free operation. If necessary, a consulting engineer, who is familiar with foundation design, should design and supervise its construction.

If the foundation is to be steel girders instead of concrete, the girders should be well braced and supported by adequate columns to prevent vibration due to resonance. The natural frequencies of the motor and supporting structure must be at least 20% away from the speed of rotation and twice the speed of rotation and multiples of the power line frequency.

The size of the foundation is determined by the weight, size and speed of the equipment and by the type and condition of the underlying soil. The width and length of the foundation are usually made to extend at least

6 inches (150mm) beyond the equipment on all sides of the base. Increased width and weight are necessary for operation at higher speeds and for foundations that project above the floor level to give stability against rocking and resonant vibration.

Large motors are not rigid or self supporting, and should be uniformly supported. Therefore, when set on the foundation or base, adequate support should be provided by leveling plates and shims between the frame and the foundation, at points of loading; i.e., under the frame feet, and intersection points of the beams as well as under long, unsupported sections of the base. The number of shims should be kept to a minimum. A few thick ones are preferred over many thin ones.

A 1 inch (25mm) space should be allowed between the base and foundation for grouting. The concrete surface should be roughed to provide a good bonding surface. The lateral clearance for positioning the base can be

MN428 Installation & Operation 2-1

made by providing a space around the hold down bolts, that are secured head down to an anchoring washer,

Figure 2-1. A sleeve may be used to form the hole when poring the foundation around the bolt for the length between the anchoring washer and the top surface of the concrete foundation.

The size and depth of the hole will depend upon the size of the motor and accuracy of the hole location.

A template can be used to locate the hold down bolts. The bolts can be locked in place later, by filling the clearance hole with grout.

Figure 2-1 Suggested Foundation Bolt Installation

Foundation

Bolt

Pipe

Washer

Pre Installation Checks

The assurance of successful start−up depends upon the use of good handling, inspection, and installation practices.

Before shipment, every motor is given a running test to check operation. Although complete factory tests have been made, motors should be checked for any change resulting from improper handling during shipment, storage, installation or by an unsatisfactory foundation. Failure to check or do the necessary work as mentioned above, could cause misalignment resulting in vibration and premature bearing failure.

Before the motor is checked for alignment, remove all shipping blocks and supports installed at the factory.

The shaft should turn over freely. The degree of accuracy required in the alignment depends on the rated speed of the machine. The greater the speed, the greater the care and accuracy necessary in the alignment.

The motor must be level to maintain the proper oil level. Check the driven equipment to make sure that the motor will be coupled to a level shaft. If necessary, level it up before coupling.

Doweling & Bolting

After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation.

This will maintain the correct motor position should motor removal be required.

(Baldor motors are designed for doweling.)

1. Drill dowel holes in drive end motor feet in the locations provided.

2. Drill corresponding holes in the foundation.

3. Ream all holes.

4. Install proper fitting dowels.

5. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be used as an alternative to washers.

Soft foot is a condition in which one or more of the motor feet do not rest squarely on the base. This condition causes distortion of the motor frame once the mounting bolts are tightened and can lead to elevated vibration levels. Prior to alignment, the following procedure should be followed to minimize the effects of soft foot.

a. With the motor mounted on the base use a dial indicator to measure the soft foot deflection at each mounting location.

b. With all feet firmly torqued to 120 ft−lbs loosen and tighten each foot measuring the total foot deflection. The total foot deflection should not exceed 2.00 mils.

c. If the foot deflection exceeds 2.00 mils shim foot as necessary to reduce deflection”.

6. Tighten all motor mounting bolts to the identical recommended initial torque value.

7. Place a dial indicator to read vertical displacement on the top of a motor foot.

8. Loosen the mounting bolt in that foot and record the amount of deflection shown by the dial indicator.

9. Foot deflection should be limited to 0.001”−0.002”. If deflection exceeds this level, proceed to step10.

If it does not, proceed to step 11.

10. Place an amount of shims that corresponds to the measured deflection under the foot.

11. Retighten the bolt and repeat the procedure on the remaining motor feet.

2-2 Installation & Operation MN428

Coupling

1. In preparation for making the coupling alignment, wash off the rust protective slushing compound on the motor shaft and factory installed couplings with solvent. On sleeve bearing motors remove the rust preventative from the shaft to expose the magnetic center and rotor float scribe lines.

Fill oil sumps with proper oil to the proper level.

2. The couplings should be heated for proper mounting. Do not press or drive it onto the shaft.

Use the shaft extension key provided with the motor.

Figure 2-2 Indicator on API Motors

3. Motors supplied with sleeve bearings. The drive end shaft Extension is scribed with three lines indicating the magnetic center line and rotor end float limits. A single scribe line, magnetic center only is used in cases where the float extreme scribe lines would interfere with a shaft shoulder or extension key way,

Figure 2-2. The magnetic center scribe line is filled with light colored paint and covered with masking tape prior to coating with rust protection. The distance from the magnetic center scribe line to the reference surface is indicated on a name plate attached to the motor frame. The magnetic center is within +0.06 in.

(+1.5 mm) of the rotor float mechanical center. Rotor end float is 0.50 inch (12.7 mm) minimum. Sleeve bearing motors are not designed to withstand external axial thrust. A limited axial float coupling should be used. Total end float of the coupling should not exceed 0.19 inch (4.8 mm) ( +.09 inch. +2.3 mm). The motor axial placement should be established by locating the shaft on its magnetic center and spaced from the driven equipment as recommended by the coupling manufacturer.

4. After the motor is properly positioned for axial end play and with the hold down bolts snug but not tightened prepare for the coupling alignment. Mount the coupling hubs, but do not engage the coupling.

Coupling Alignment

There are a number of procedures to properly align the motor to the driven equipment. The end result depends upon the accuracy of the parts in roundness, flatness, run out of the reference surfaces, rigidity of the mounting and the skill of the setup man. The motor base surfaces must be flat and parallel to the shafts. Make allowance for inserting shims under the motor to make the elevation adjustment.

The shims size should be the full length of the motor foot pad, they should be flat, and free from burrs. Insert the shims carefully to maintain the foot plane and to avoid bending or twisting the motor frame. For a poor mounting surface, it may be necessary to machine a shim to compensate for the slope or surface irregularity.

To minimize soft stacking, use the thickest shim stock combination with the fewest shims.

A preliminary line up can be made with feeler gauge by measuring at top, bottom and sides between faces of the hubs. Angular alignment is satisfactory when there is no more than .002 in. (0.05 mm) difference between all sides of the hubs. Parallel alignment check can be made with a straight edge, or dial indicator, to determine if both hubs are parallel within 0.002 in. (0.05 mm). During shimming use shims that are as thick as possible to avoid a sponginess of an excessive number of layers.

Coupling Alignment Procedure

For more accurate alignment, refer to the manual for the driven equipment. When alignment is complete, tighten the motor and driven equipment hold down bolts and recheck alignment. The feet must be tightened uniformly. Ensure the feet are on the same plane by measuring the feet spring back when a bolt is loosened. It should not exceed 0.002 inch (0.050 mm) at any foot as the others remain tight. Repeat with two adjacent bolts loose. The shaft spring back should not exceed 0.001 inch (0.025 mm).

In some cases it may be necessary to make a hot alignment check to compensate for thermal expansion.

A compensating offset alignment should be made cold. The unit may run rough until the equipment temperatures stabilize. If for any reason alignment does not fall within limits, contact your local Baldor District

Office.

MN428 Installation & Operation 2-3

Grouting

Grout should be used, but should not be applied until all alignment and leveling have been completed, and the set is running satisfactorily - from the bearing noise, temperature and vibration standpoint - after the 4 hour run in test. A good quality commercial non shrinking type of grouting compound should be used. A cement/ sand ratio of 1:1 is recommended. Grout should be used with a minimum quantity of water to give a stiff mix.

The roughened concrete surface should be washed to remove the dust and loose particles. Grouting should be applied to a wet surface but to assure a good bond, there must be no puddles of water or contamination from oil or grease. Prepare only the amount that can be handled within set time and without adding water to the original mix. The grouting should be done quickly and continuously.

Tamp in place and vent the pockets to assure a solid casting, it is suggested that the motor remain idle while the grout is hardening.

At least 48 hours curing time is desirable for the grout to develop adequate strength before operating this set, or any nearby large equipment which could create a vibration.

2-4 Installation & Operation MN428

Lubrication

The lubrication system should be checked in preparation for rotating the shaft during the alignment operation.

Anti Friction Bearings (Grease Lubricated)

Bearing chambers are packed with grease during assembly, and do not normally need additional grease at time of installation, unless the unit has been in storage and installation for 6 months or longer. Lubricant must be added per Section 3, Maintenance.

Sleeve Bearing (Oil Lubricated)

Caution: Oil lubricated motors are shipped without oil . As soon as the motor is received, the bearing oil reservoir should be filled to the indicated level with the proper lubrication oil (see Section 5 “constant level

Oiler”) . To avoid motor damage, do not rotate the shaft until you have filled the oil reservoirs to the proper level with recommended lubricant .

Lubricating oils for sleeve bearing motors should be selected as follows:

1. Viscosity in SUS (centistokes) at 100° F. (37.8°C):

Table 2-1

Ambient Temperature Range**

to 120

F* (–18

C to 50

C*)

–20

to 50

F (–30

C to 10

900 RPM or Less

300 (68 cSt)

150 (32 cSt)

* For higher temperatures, oil coolers should be used.

** For lower temperatures, heaters should be used to assure adequately high starting temperature.

2. Pour Point: Below minimum starting temperature.

Speed

Greater than 900 RPM

150 SUS (32 cSt)

90 SUS (18cSt)

Caution: For motors equipped with circulating oil pump and adjustable needle valve, valve must be adjusted or flooding of oil sump may occur . Disconnect valve and adjust flow rate for 0 .10 GPM flow (or as specified on data sheet) .

3. Quality: Use a good grade of turbine type oil with rust, foam and oxidation inhibitors.

Avoid automotive oils or additives other than those specifically recommended by the oil manufacturer.

To fill sleeve bearing motor oil reservoirs on motors not equipped with constant level oilers, be sure that drain plugs are in place and secure and fill through filler cap until oil level shows at top line marked on oil gauge. Oil level must never be below bottom line marked on oil gauge. For motors with constant level oilers, refer to the instructions. See Accessories Section 5.

Electrical Connection

WARNING: Be sure the system is properly grounded before applying power . Do not apply AC power before you ensure that all grounding instructions have been followed . Electrical shock can cause serious or fatal injury . National Electrical Code and Local codes must be carefully followed .

The user must select a motor starter and overcurrent protection suitable for this motor and its application.

Consult motor starter application data as well as the National Electric Code and/or other applicable local codes.

A conduit box may be provided for the power lines to the stator and other conduit boxes for all other electrical connections. Tapped holes are provided for grounding.

Grounding

Failure to properly ground the motor may cause electrical shock hazard to personnel. Do not attach ground lead to motor foot bolt.

All large motors should be grounded with the grounding conductor equipped with a brazed copper terminal, or with a suitable solderless terminal fastened to the motor. Soldered terminals should not be used. A washer should be used between bolt head and terminal lug. The other end should be fastened with suitable clamps or terminals to rigid metallic conduit or to the nearest available ground.

Ground conductor size should be in accordance with the National Electrical Code Table 250−95 or Table 16

Part 1 of Canadian Electrical Code. (Table 2−2 in this section).

Attachment to the motor should not be made under a flange mounting bolt.

MN428 Installation & Operation 2-5

Be sure that the motor leads are connected as shown on the connection nameplate (when supplied on the motor) and that the power supply corresponds with the motor nameplate data (voltage, frequency and number of phases). The motor will operate, but with modified characteristics when the line voltage is within plus or minus 10%; the frequency within plus or minus 5% of the nameplate value; or combination of voltage and frequency within +10% of nameplate.

Table 2-2 Size of Equipment Ground Conductor

“Rating or Setting of Automatic Overcurrent

Device in Circuit Ahead of Equipment,

Conduit, etc., Not Exceeding (Amperes)”

500

600

800

1000

1200

100

200

300

400

1600

2000

2500

3000

4000

5000

6000

Copper Wire No.

2/0

3/0

4/0

250MCM

350MCM

400MCM

500MCM

700MCM

800MCM

Size

“Aluminum or Copper Clad Aluminum Wire No.*”

1/0

2/0

3/0

4/0

250MCM

350MCM

400MCM

600MCM

800MCM

1200MCM

* See installation restrictions in NEC Section 250−92(a).

2-6 Installation & Operation MN428

WARNING: This equipment is at line voltage when AC power is connected . Disconnect and lockout all ungrounded conductors of the AC power line before proceeding . Failure to observe these precautions could result in severe bodily injury or loss of life .

Pre−Operation Check

Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the motor shaft.

1. Verify that Hold Down bolts are tightened to the proper torque.

2. If the motor has been idle for a long period of time after installation, check insulation resistance.

3. Check the incoming power to be sure that line voltage, frequency and phase are correct for the motor

(refer to the motor nameplate).

4. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity.

5. Be sure all shipping materials and braces (if used) are removed from motor shaft.

6. Ensure alignment is correct and motor is properly lubricated.

a. On machines supplied with oil lubricated bearings inspect lubrication system to insure that oil reservoirs have been filled to the proper level with correct oil. Do not overfill oil reservoirs.

b. Motors operating with a forced lubrication system must have the forced lubrication system operating before starting the motor.

7. Manually rotate the motor shaft to ensure that it rotates freely.

Caution: When driven equipment may be damaged by incorrect rotation direction, uncouple the motor from the load and check motor rotation direction during initial start and be sure rotation is correct .

8. When the driven machine is likely to be damaged by the wrong direction of rotation, it is best to uncouple the motor from its load during the check for rotation and/or during the initial start.

Some motors are designed for a single direction of rotation as indicated by nameplates. Running those units in the wrong direction will reduce airflow causing overheating. Check to see that both the motor and driven equipment are operating in the correct direction of rotation. If it is necessary to change rotation, disconnect and lockout all input power and interchange any two input power phases.

9. Replace all panels and covers.

10. Check to see that coupling guards and other protective enclosures are not blocking the ventilating air into the motor and exhaust openings.

First Time Uncoupled Start−Up

Read each of the steps in the following procedure over thoroughly, so that each is fully understood, before attempting to start the motor.

1. Make the initial start by following the regular sequence of starting operations in the control instructions.

2. After starting, check that the motor is running smoothly. If the motor has excessive vibration, shut down immediately and investigate. Check for coupling and key unbalance, rusty bearing, lack of lubrication, foot planarity, structural resonance.

3. Check bearing temperatures frequently. Bearing temperature should not exceed 185°F (85°C). Likewise the rate of temperature rise should not be excessive. At initial start, the bearing temperature rate−of−rise is more indicative of trouble than overall temperature for a minimum of two hours, if at any time the rate of rise curve appears too steep, stop the motor immediately and re−check its alignment.

4. Ensure that the protective controls are functioning properly before any prolonged operation.

5. Run the motor for at least two hours.

MN428 Installation & Operation 2-7

Coupled Start−up

This procedure assumes a coupled start up. Also, that the first time start up procedure was successful.

Read and fully understand each of the steps in the following procedure before attempting to start the motor.

1. Disconnect and lockout the power source. Ensure no power is applied to the motor.

2. After a successful uncoupled start, assemble the coupling and lubricate with the manufacturer’s recommended lubricant. Check to see that the coupling is not binding.

3. Verify the motor shaft is on its magnetic center.

4. Verify coupling axial movement is within the bearing float limit.

5. Check to see that coupling guards and other protective enclosures are not blocking the ventilating air over the motor and exhaust openings.

6. Try no load coupled start−up, repeating steps 1 to 5 of the “First Time Uncoupled Start−up” procedure.

7. Verify the driven equipment is not transmitting vibration back to the motor through the coupling or base.

8. Inspect the motor carefully. Make the initial start by following the regular sequence of starting operations in the control instructions.

9. After starting, check that the motor is running smoothly. If the motor shows excessive vibration, shut down immediately and investigate. Check for coupling and key unbalance, lack of lubrication, foot planarity and structural resonance.

10. Check vibration at the bearing housing. Motor vibration must not exceed the limits given in Table 2−3.

Vibration severity and conversion of the above limits to velocity or acceleration can be determined by using the vibration nomograph in Figure 2-3. Nomograph shows accepted industry vibration levels.

11. Verify all panels and covers are securely in place.

12. Verify that coupling guards are properly installed and protective enclosures are not blocking the ventilating air into the motor and exhaust openings.

13. In addition, observe the following before attempted start−up of Belted, C−Face/D Flange and Sleeve bearing motors: a. For belted duty, ensure motor is intended for belted service and that the belted application data has been verified. Also be aware that some belted duty motors are built with bearings that are not suited for non−belted applications.

b. Due to their size, above NEMA C−Face and D−Flange motors are supplied with mounting feet and are not designed to be supported by the C−Face or D−Flange alone.

c. Sleeve bearing motors are intended for horizontal mounting only.

Contact your local Baldor District Office for any questions concerning this installation before power is applied to the motor.

Jogging and Repeated Starts

Caution: Repeated starts and/or jogs can greatly reduce the life of an induction motor .

Repeated starts and/or jogs can greatly reduce the life of an induction motor. If it is necessary to repeatedly start or jog a motor, check the application with your local Baldor District office.

At ambient temperature, the motor is normally capable of making two starts in succession and coasting to rest between starts.

The motor is also capable of making one start at its rated load operation temperature. For cooling time required before additional starts can be made consult your local Baldor District office or the motor starting nameplate if one is provided.

If more starts than defined above are attempted within the stated period of time, severe damage to the motor electrical windings and rotor may result.

The starting conditions listed above apply only if the inertia of the connected load, the load torque during acceleration, the applied voltage, and the starting method are those for which the motor was designed.

For starting situations not covered here, consult your local Baldor District office before proceeding.

Refer also to the motor nameplate which may list starting conditions.

2-8 Installation & Operation MN428

RPM

3000−4000 Incl.

1500−2999 Incl.

1000−1499 Incl.

999 or less

Table 2-3 Maximum Vibration Limits

On Bearing Housing

(Displacement mils Pk−Pk)

0.001

0.0015

0.002

0.0025

(Velocity in/sec., Pk)

0.19

0.14

0.13

0.12

Figure 2-3 Vibration Nomograph

Displacement - Inches

“On Shaft

(Displacement mils Pk−Pk)”

1.75

2.0

10.00

0.10

0.09

0.08

0.07

0.06

0.05

0.04

0.03

0.02

0.01

100

1.00

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

2 3 4 5 6 7 8 9

1,000

2 3 4 5 6 7 8 9

10,000

RPM (Divide by 60 for Hz)

2 3 4 5 6 7 8 9

100,000

Rough,

Needs Attention

Fair

Acceptable

MN428 Installation & Operation 2-9

Operation

Due to the inherent characteristics of insulation materials, abnormally high temperatures shorten the operating life of electrical apparatus. The total temperature, not the temperature rise, should be the measure of safe operation. Care must be taken not to overload the motor. Motor current and speed are good indicators of this.

Aging of insulation occurs at an accelerated rate at abnormally high temperatures.

The class of insulation determines the maximum safe operating temperature. A general rule for gauging the effect of excessive heat is that for each 10 º C rise in temperature above the maximum limit for the insulation, the life of the insulation is reduced by half.

Unbalanced voltage or single−phased operation of poly phase machines may cause excessive heating and ultimate failure. It requires only a slight unbalance of voltage applied to a poly phase motor to cause large unbalance current and resultant overheating.

Periodic checks of phase voltage, frequency and power consumption of a motor while in operation are recommended; such checks yield an indication of the load offered by the apparatus which the motor drives.

Comparisons of this data with previous no−load and full−load power demands will give an indication of the performance of the complete machine. Any serious deviations should be investigated and corrected.

Stator troubles can usually be traced to one of the following causes:

Worn bearings Operating single phase Moisture

Poor insulation Overloading Oil and dirt

Dust and dirt are usually contributing factors. Some forms of dust are highly conductive and contribute materially to insulation breakdown. The effect of dust on the motor temperature through restriction of ventilation is a principal reason for keeping the windings clean.

Squirrel cage rotors are rugged and in general, give little trouble. The first symptom of a defective rotor is lack of torque. This may cause a slowing down in speed accompanied by a growling noise or perhaps failure to start the load. This may be caused by an open or high resistance joint in the rotor bar circuit.

Such a condition can generally be detected by looking for evidence of localized heating.

Repairs for these type problems should only be performed by an authorized Baldor repair facility.

2-10 Installation & Operation MN428

Section 3 Maintenance & Troubleshooting - Horizontal Shaft

WARNING:

Caution:

High Voltage may be present even when the machine is not rotating . Ensure that power has been disconnected before touching the motor or any of its components . Electrical shock can cause serious or fatal injury .

Solvents can be toxic and/or flammable . Follow manufacturer’s safety procedures and directions .

Failure to observe this precaution could result in bodily injury .

Do not use solvents containing trichloroethane to clean interior or exterior of motor . Damage may occur to paint and insulation systems .

Horizontal Shaft Motors

There are two inspection periods which are important to the proper operation and maintenance of your Baldor motor. These occur every 3 months (or 500 operating hours - which ever comes first) and every six months, respectively, in addition, the following should always be observed.

• Provide adequate ventilation.

• Keep air and exhaust openings clean and free of obstructions.

• Avoid sharp blows and excessive axial thrust loads on the output shaft.

• Maintain proper lubricant level (check weekly on oil lubricated units).

Duty Master Large AC Motors when properly applied, are very easy to maintain. Since clearances and fits are precisely machined, there are no periodic mechanical adjustments to make. Like any precision machine, periodic inspection and simple routine maintenance will prolong your motor’s life and help locate potentially damaging conditions before they become problems. The minimal time spent performing these simple procedures cannot begin to compare with the cost of lost productivity and time consuming major repairs incurred through neglect of routine inspection and maintenance.

Periodic Inspection

Inspections are important to the proper operation and maintenance of a motor.

Quarterly − 3 months (or 500 operating hours whichever comes first).

1. Listen for any abnormal noises and check cause immediately.

2. Check for any vibration and check cause immediately if excessive vibration is found.

3. Check voltage and frequency variations. Unbalanced voltage or single phase operation of poly phase motors will cause excessive heating and ultimately failure. Only a slight unbalance of voltage applied to a poly phase motor will cause large unbalance currents and result in overheating.

4. Check power supply total harmonic distortion to avoid overheating.

5. Periodic checks of phase, voltage, frequency, and power consumption of an operating motor are recommended. These checks can also provide an excellent indication of the load from the driven equipment. Comparisons of this data with previous no load and full load power demands will give an indication of the performance of the driven machine.

6. Check to see that air filters, when used, are in place and clean.

7. Check all air passages and ensure that they are not blocked or clogged.

8. Check for proper lubrication. For sleeve bearing motors check oil level. The oil level must be at the midpoint of sight gauge when the motor is at rest and in operation.

9. When provided, check that constant level oilers have oil in them.

10. Check that cap on oiler is screwed on tightly. Make sure the oil is clean.

11. Check bearing temperature rise.

12. Disconnect and lockout the power source. Ensure no power is applied to the motor.

13. Check all electrical connectors to be sure that they are tight and corrosion free.

14. Check for frayed interconnecting wires, especially at points where it contacts the motor frame.

15. Verify that all covers and guards are in place and fasteners are properly torqued.

These checks can also provide an excellent indication of the load from the driven equipment.

Semi−Annual Maintenance − 6 months

1. Perform all quarterly inspections.

2. Inspect and clean rotor ends, windings and fan blades (Open Motors only).

3. Check electrical connections for tightness and absence of corrosion.

Bearing Lubrication

Depending on the application and rating, the horizontal motor is equipped with either anti−friction or sleeve type bearings. When properly cared for (ie., inspection and lubrication) bearings will provide years of uninterrupted service. Use one of the following lubrication procedures, depending on the type of bearings with which your motor is equipped.

MN428 Maintenance & Troubleshooting - Horizontal Shaft 3-1

Anti−Friction Bearing (Grease Lubricated)

This motor has been properly lubricated at the time of manufacture and it is not necessary to lubricate at time of installation. When the motor has been in storage for a period of six months or more, lubricate before starting.

Lubrication of anti−friction bearings should be done as a part of a planned maintenance schedule. The

Recommended Lubrication Interval should be used as a guide to establish this schedule.

Cleanliness is important in lubrication. Any grease used to lubricate anti−friction bearings should be fresh and free from contamination. Similarly, care should be taken to properly clean the grease inlet area of the motor to prevent grease contamination.

Relubrication intervals and volumes are listed on the main motor nameplate. This lubrication schedule is based on standard conditions. Modify intervals by using Tables 3-1 and 3-2. The relubrication periods shown in Table

3-2 are offered as a guide for different speeds, bearing types, operating time and service conditions (Table 3-1).

Recommended Lubricant

Refer to motor nameplate for recommended lubricant. If none is shown, the recommended lubricant is

Mobil Polyrex EM. The following is a list of alternate lubricants.

Operating TEMP. -25º C (−15º F) to 50º C (120º F)

Chevron Oil SRI

Shell Oil Co. STAMINA RL2

Use only clean, fresh grease from clean containers.

Do not mix greases unless compatibility has been checked and verified.

Contact your Baldor District Office if you have compatibility questions.

For motors operating in ambient temperatures shown below, use the following lubricant or its equal:

Minimum Starting Temperature −76º C (-105º F)

Shell Oil Co. AEROSHELL #7

Procedure

1. Select service conditions from Table 3-1.

2. Select lubrication frequency (Table 3-2).

Table 3-1 Service Conditions

Standard Conditions

Severe Conditions

Extreme Conditions

Eight hours per day, normal or light loading, clean ambient air at 40

C (100

F) maximum

Twenty four hours per day operation or shock loading, vibration, ambient air containing dirt or dust at 40-50 º C (104-122 º F)

Heavy shock or vibration, ambient air containing dust, dirt or high humidity and temperature in excess of 40 º C (104 º F)

Speed (RPM)

3600

1800, 1200

900, 600

1800

Table 3-2 Relubrication Intervals

Standard Conditions

6 months

Severe Conditions

3 months

6 months

3 months

Roller Bearing

3 months 1.5 months

Extreme Conditions

1 month

2 months

1 month

3-2 Maintenance & Troubleshooting - Horizontal Shaft MN428

Lubrication Procedure

Anti

− friction bearings may be lubricated with the motor running or stationary. (Stationary with the motor warm is recommended.)

1. Relubrication with the shaft stationary and a warm motor is recommended. If lubrication must be done with motor running, stay clear of rotating parts and electrical circuits.

2. Locate the grease inlet, clean the area and replace the pipe plug with a grease fitting, if the motor is not equipped with grease fittings.

3. Remove relief plug. If grease is caked around the plug, clean with a wooden stick or suitable tool, if severe caking appears at the plug, run the motor until the bearing housing is warm, permitting a free flow of grease through the housing.

4. Locate the motor nameplate. Find the lubricant recommended type and volume.

5. Add the recommended volume of the recommended lubricant using a hand operated grease gun.

6. Run the motor for 1/2 hour with relief plug removed.

7. Replace the pipe plugs and wipe off excess grease.

Replacement Bearings

Your maintenance program will not be complete without including spare bearings.

Remember that the bearing is a wearable component and therefore must eventually be replaced.

To ensure that you are able to maintain original operation we recommend the purchase of spares directly from

Baldor.

All bearings used in Baldor Reliance motors are subject to exact specifications.

Markings on the bearing do not indicate complete specifications.

Anti−Friction Bearing (Oil Mist Lubricated)

The following applies to anti−friction bearing motors built with provisions for oil mist lubrication. At the time of shipment, the bearings are packed with a minimal amount of corrosion inhibiting grease. This protects the bearings during temporary storage. However, if extended storage (greater than 3 months) or outdoor storage is anticipated, the units should be connected to the oil mist system while in storage.

If this is not possible, an amount of grease indicated under standard conditions in the grease chart (Table 3-2) should be added, and the shaft should be rotated several times by hand. (See extended storage instructions in appropriate motor instruction manual.)

This grease will require removal and all lubrication channels must be cleaned at the time of connection to the oil mist system.

Oil Mist Installation

1. Remove all grease from bearings and clean all lubrication channels. This step is necessary on motors that are labeled “Provisions for oil mist lubrication” or motors built for “oil mist lubrication”, but filled with grease by user. This step is not required on motors built “For oil mist lubrication” as ’supplied by factory.

2. Remove inlet and outlet pipe plugs from bearing brackets (or extension tubes) on each end of motor.

3. Install appropriate reclassifier in top opening.

4. Connect oil recovery trap to bottom opening or leave open to act as relief.

5. Refer to main motor nameplate for additional information. Consult factory for further information.

Sleeve Bearings (Oil Lubricated)

Oil should be changed periodically (at least every 6 months), or immediately if discolored or contaminated.

Follow the schedule on the motor nameplate, or if not known use the Table 3-8 schedule.

Table 3-3 Lubrication Schedule

Speed − RPM

All speeds

Service Conditions

Standard

Change Oil (Hours)

Every 4400 hrs.

All speeds Severe & Extreme Every 3 months (2200 hrs.)

MN428 Maintenance & Troubleshooting - Horizontal Shaft 3-3

Table 3-4

Ambient Temperature

0 to120º F (−18 to 50 º C)*

900 or less

300 SUS (68 cST)

Speed − RPM

Greater than 900

150 SUS (32 cST)

−20 to 50 º F (−30 to 10 º C)** 150 SUS (32 cST) 90 SUS (18 cST)

* For greater temperatures, oil coolers should be used.

** For reduced temperatures, heaters should be used to assure adequate starting temperatures.

Lubricating oil for sleeve bearing motors should be selected as follows:

1. Viscosity in SUS (centistokes) at 100 º F (37.8 º C).

2. Pour point: Below minimum starting temperature.

3. Quality: Use a good grade turbine type oil (rust, foam and oxidation inhibited). Avoid automotive oils or additives other than those specifically recommended by the oil manufacturer.

The procedure for changing oil is as follows:

1. De-energize the motor, preferably by opening the manual disconnect switches.

2. Remove drain plug and drain oil.

3. If oil appears to be contaminated, Flush out the housing by filling with fresh oil and drain again.

4. Replace plug and fill through filler cap until oil level is at proper level indicated on sights gauge.

5. Tighten caps and plugs, fill constant level oiler if provided.

6. Start unit and observe to be assured of no oil leakage.

Sleeve Bearing Replacement

RENK Sleeve Bearing Removal

Note: This procedure refers to the RENK type sleeve bearing.

1. Disconnect and lockout the power source. Ensure no power is applied to the motor.

2. Remove the frame end cover/trunk and accessories that are assembled to the end shield and bearing housing.

3. Remove drain plug at bottom of bearing housing and drain oil from the reservoir. Remove any forced lubrication plumbing.

4. Loosen and remove the bolts at the split line of the bearing housing.

5. A machined seal may be assembled outboard of the bearing housing. The seal must be dissembled from the bearing housing before removing the top half of the bearing housing. The seal is insulated from the bearing housing with a non−split gasket. The bearing housing top half can not be removed unless the seal and gasket are disassembled from the bearing housing.

6. Using the lifting eye bolts, lift the bearing housing top half straight up and pull forward away from the bearing area to clear the end shield. Insure that the bearing and seals are cleared before moving the bearing housing top half forward.

7. Lift the upper half of the bearing liner and remove from bearing housing.

8. Loosen and remove the bolts at the split line of the oil ring.

9. Remove oil ring.

10. Disassemble the garter springs that encircle the labyrinth seals (inboard and outboard).

11. Lift and remove the upper half of each seal. Rotate the lower half out of the seal carrier.

Note: The labyrinth seals must be assembled so that the locking tabs will be in the 12:00 position. The drain back holes in the seal face must face towards the oil sump and be located in the 6:00 position.

12. Disconnect and remove RTD’s from the lower half of the bearing liner.

13. Use hoist, jack or a non−metallic sling around the shaft to lift the shaft off the lower half of the bearing liner. Only lift the shaft enough to take the weight off the liner. Roll the lower half of the bearing liner out of the bearing housing.

3-4 Maintenance & Troubleshooting - Horizontal Shaft MN428

14. Loosen and remove the bolts securing the bottom half of the bearing housing to the end shield.

Use eye bolts and hoist to remove the bottom half of housing. Shims for axial location of the shaft are located between the lower bearing housing and end cap machined fits. Note their location for reassembly.

In some cases it may be necessary to remove the end shield with the housing due to limited clearance between the shaft shoulders and the seal carriers.

15. The inboard machined seal, outboard seal carrier, and bolt on baffle are still attached to the bearing housing. These parts can be removed by loosening all bolts and disassembling.

16. For reassembly perform the above listed steps in reverse order. Assemble both the bottom and top half of the seals. Press up on the bottom half of the outboard seal and baffle so that there is no clearance between the seal and shaft at the bottom. Make sure that the clearance from side to side is symmetric.

17. All machined split line surfaces of the bearing housing and seals must be coated with a sealing compound

(Curil T or Permatex #3). Also apply seal compound to the flange of the machined seals and seal carrier.

RENK Sleeve Bearing Replacement

1. The sleeve bearing may be replaced without disturbing the setup and uncoupling from the driven equipment. Remove the top and bottom bearing liners at stated in “RENK Sleeve Bearing Removal

Instructions”.

2. Make sure that the shaft bearing shoulders and journal are free of nicks and burrs before replacing bearing. Dress shaft with emery cloth or stone as necessary. Clean the shaft and oil sump thoroughly.

3. Apply a coating of oil to the bearing journal.

4. Inspect the replacement bearing for nicks and damage. The bearing may be packed in a waxy rust inhibiting compound. Remove all wax from bearing surfaces using solvent. Dry bearing before assembling in housing. The bearings are spherical self seating. Apply a coat of oil to the outside diameter of the bearing liner and also to the bearing housing bore.

Do not scrape the bearing Babbitt surface for seating .

5. Reassemble the motor. Apply sealant to the split line of bearing housing seals.

6. Fill oil reservoir so that oil is at the midway point in the sight gauge.

7. Slowly rotate the shaft to ensure the bearings and seals are seated properly.

Sleeve/Anti−Friction Bearing Bracket Removal

1. For anti−friction bearing motors the cartridge to end shield bolts must be removed before removing the end shield.

2. For sleeve bearing motors the bearing cartridge must be removed before disassembly of the end shield.

(See Sleeve Bearing Removal).

3. Ensure the shaft is supported by a hoist or jack before proceeding.

4. Remove all bolts that secure the end shield to the frame.

5. Using a hoist, support the bracket.

Anti−Friction Bearing Removal/Replacement

1. Remove the end shield (see Sleeve/Anti−Friction Bearing Bracket Removal).

2. The bearing can now be removed by using a conventional bearing puller with the puller arms located behind the bearing race. Protect the shaft center by using a spacer block of bass or some other soft material between the shaft and bearing puller.

3. Clean and inspect all parts. Remove all old grease.

4. All shaft bearing shoulders and journals should be free of nicks before replacing bearing.

Dress shaft with emery cloth or stone as necessary.

5. Heat bearing to 250º F (120º C) for at least 30 minutes.

6. Place bearing onto shaft. Make certain that the bearing is contacting the locating shoulder on shaft.

Do not use impact force on bearing.

7. Let the bearing cool. Grease the outboard side cavity of the bearing 100%. Grease inner caps and bracket bearing housing to 60% full.

8. Assemble end shield in reverse order. (See Sleeve/Anti−Friction Bearing Bracket Removal).

Rotor And Stator Removal

Consult your local Baldor District office for proper removal procedures.

MN428 Maintenance & Troubleshooting - Horizontal Shaft 3-5

Winding Maintenance

WARNING: Solvents can be toxic and/or flammable . Follow manufacturer’s safety procedures and directions .

Failure to observe this precaution could result in bodily injury .

Caution: Do not use solvents containing trichloroethane to clean interior or exterior of motor . Damage may occur to paint and insulation systems .

1. Disconnect and lockout the power source. Ensure no power is applied to the motor.

2. Remove the end cover from the motor. Inspection of the winding ends and outside surfaces provides a good indication of their general condition. To thoroughly inspect the windings, the rotor may have to be removed.

There are numerous methods for cleanings windings. The following methods are most commonly used, in order of preference.

Note: Before cleaning the windings check for loose blockings, evidence of damage to insulation, distortion or movement of coils, etc. If any of these conditions exist, contact your local Baldor District office for recommendations.

Dry Wiping

This method is satisfactory when the surfaces to be cleaned are accessible and when only dry dirt is to be removed. Use a clean dry, lint free cloth. The lint will adhere to the insulation and increase dirt collection. Lint is particularly objectionable on high voltage insulation systems as it tends to concentrate corona discharge.

Brushing and Suction Cleaning

Remove the dry dust and dirt by brushing with a bristle brush, followed by a vacuum suction cleaning.

Do Not Use Wire Brushes

Blowing

WARNING:

Caution:

Use of an air jet may cause flying debris and generate particulate matter . Wear suitable skin, eye and respiratory protection . Failure to observe this precaution may result in bodily injury .

To avoid damage to the windings do not use air pressures greater than 30 psi (200 kPa) . Avoid directing the air in such a way that the dirt will be blown into inner crevices .

Dry dirt and dust can be removed from inaccessible crevices by using a jet of low pressure compressed air.

Solvent Cleaning

WARNING: Be sure to follow all precautions and warnings stated by solvent manufacturer .

Caution: Avoid inhaling fumes .

Caution: Avoid using flammable solvents and fluids .

Caution: Do not use solvents containing trichloroethane to clean interior or exterior of motor . Damage may occur to paint and insulation systems .

Oil, grease, tar and wax can be removed by cloth wetted with solvent, followed by wiping with a dry cloth.

Typical solvents are: Atlantic Safety Solvent, Graymills Solvent, De−Greaseall, Zep and Stoddard Solvent.

Cleaning with Water and Detergent

Windings can be cleaned by hose washing or by pressure spray from a low pressure steam generator or shop steam line.

Oil, grease, tar and wax can be removed by adding a non conductive detergent to the wash water. After washing, it is necessary to dry the windings in an oven. See Checking Insulation Resistance.

Reconditioning (Revarnishing) Windings

If after cleaning with solvent or water and detergent, the insulation shows signs of dryness, etc., it may be necessary to revarnish the windings. Contact your local Baldor District Office for type and proper method of revarnishing.

Checking Insulation Resistance

If the motor has been in storage for an extensive period or has been subjected to adverse moisture conditions, check the insulation resistance of the stator winding with an insulation resistance meter.

The minimum insulation resistance (RM) can be determined from the following formula:

RM = KV + 1

Where

RM = Minimum insulation resistance in mega ohms at 40º C of the entire machine winding.

KV = Rating machine potential, in kilo volts.

3-6 Maintenance & Troubleshooting - Horizontal Shaft MN428

For machines in good condition, insulation and resistance readings of 10 to 100 times RM are common.

If the insulation resistance is less than that calculated from the formula, the windings should be dried out as follows:

1. Bake in an oven (preferably a circulating air oven) at a temperature not to exceed 90º C until insulation resistance remains constant. Do not exceed this temperature.

2. With the rotor locked, apply low voltage and gradually increase current through winding (do not exceed 50% full load amps) until winding temperature, measured with thermometer, reaches 90º C.

Do not exceed this temperature.

Auxiliary Cooling

Motors supplied with separately powered cooling fans (blowers), pipe in− pipe out flanges, or water cooling connections require proper connection and operation of these features for proper motor cooling.

Refer to the motor nameplate(s) or other unit−specific supplied documentation regarding the proper connections, air flow or water flow requirements. Operation of the motor without these auxiliary cooling features engaged will result in motor overheating and premature motor failure.

Renewal Parts

A detailed parts list, which gives Baldor’s recommendations for spare parts that should be stocked for your equipment, can be ordered from the nearest Baldor District Office.

Be sure to include complete nameplate data - purchase order number, serial number, model number, rating, etc., - for your equipment when ordering the spare parts list.

MN428 Maintenance & Troubleshooting - Horizontal Shaft 3-7

PROBLEM

Motor will not start

Motor noisy

Excessive Bearing

Temperature

(anti-friction bearing)

Excessive Bearing Temperature

(sleeve bearing)

(Vertical Shaft)

Excessive

Temperature

Oil Leak

(sleeve bearing units)

Oil Leak (Flood

Lubrication System)

Excessive Vibration

Water in Sump oil

Oil Leak or excess oil usage

Excess oil foaming

POSSIBLE CAUSE

Motor improperly connected Incorrect Line

Voltage Overload relay tripped

Fuses blown or defective

Open circuit in stator or rotor

Short circuit in stator

Grounded Winding

Winding single phased

Loose mounting

Noisy bearing

Coupling halves loose

Vibration

Uneven air gap

Table 3-5 Troubleshooting Guide

Inadequate lubrication

Coupling misalignment

Inadequate ventilation

Excessive amount of grease

Excess lubricant

Inadequate oil supply

Excessive end thrust

Contaminated oil

Tight clearance

Oil rings not functioning

Bearing material torn

Rough shaft or corrosion

Bearing Misalignment

Coupling misalignment

Shaft current

Oil level too high or low

Insufficient water flow (cooling coil)

Excessive water temperature to cooling coil

Overload

Restricted ventilation

Electrical

Overfilled

Seals not secured properly

Pipe fittings loose

Bearing air pressure equalizer vent clogged

Wrong sealing compound on bearing cap surface

To much oil flow in pressure lube system

Air pressure unbalanced

Coupling misalignment

Coupling , Coupling key or Rotor Unbalance

Foundation resonance/structure improper

Worn bearing

Coupled equipment

Shaft Straightness

Cooling coil leak

Water leak at cover

High oil level

Moisture in oil”

Improper oil High oil level Moisture in oil

CORRECTIVE ACTION

Check motor connection and control connections

Check nameplate for required voltage

Correct and reset

Replace fuses

Check for open circuit

Check for short circuit

Check for ground

If winding is single phased, unit will not start.

Stop unit and try to reset

Check and correct

Check and replace

Inspect alignment and tighten

Check alignment with driver connected

Check feet planarity

Correct balance of motor if necessary

Check key unbalance on coupling.

Check gap, correct problem.

Add lubricant per nameplate instructions

Realign unit

Clean filters, check to see if louvers are blocked

Clean out old grease

Clean reservoir & add correct lubricant volume

Refer to nameplate requirements and correct

Check for proper lubrication, oil level, leaks

Check alignment and coupling float

Drain and refill, change filters in flood lube system

Inspect for source of contamination

Check bearing bore and shaft O.D for proper clearance.

Check for damage, check roundness and for burrs - repair or replace if necessary

Dress, scrape and refit.

Dress and polish shaft

Realign bearing or reseat bearing

Realign motor

Insulate bearing and isolate shaft from ground

Reduce or add to proper level (sight gauge)

Increase water flow

Decrease inlet water temperature

Reduce load to nameplate rating or replace with larger unit

Check openings and duct work for obstructions and correct

Check for grounded or shorted coils and unbalanced voltages between phases

Drain to proper level or adjust oiler elevation

Tighten

Tighten or replace worn threaded parts

Clear out passage

Use Permatex Aviation type No. 3 or other non-hardening gasket sealer

Reduce flow to recommended level on nameplate

Clean venting pipes

Realign to operating condition

Rebalance

Make adjustments to foundation

Replace bearing if oversize

Check motor vibration uncoupled, if necessary rebalance equipment

Replace shaft

Test cooling coil & repair as required

Replace dome gasket and or seal with silicone gasket sealer

Use non-foaming oil. Reduce or add to proper level (sight gauge) Clean & replace oil

Use non-foaming oil.

Reduce or add to proper level (sight gauge)

Clean & replace oil

3-8 Maintenance & Troubleshooting - Horizontal Shaft MN428

Section 4 Accessories

The owner is responsible for conformance to national electric code and all other applicable local codes and practices. Refer to Safety Notice in Section 1 of this manual.

Note: Motor is equipped with the following accessories only if ordered with the motor.

Winding Resistance Temperature Detector RTD

Purpose

To measure or monitor winding temperature during operation.

Principle of Operation

The RTD uses a wire wound in a flat ribbon coil. It is wound so that it is a non−inductive device. Its mode of operation is that of a linear change in resistance with temperature.

Installation

Baldor typically installs two (2) RTD’s per phase, six (6) in total. Each RTD is located between the top and bottom coils in the slot.

Customer Interconnect

RTD leads are typically supplied in a separate conduit box. Leads are tagged and connected to a terminal block. One side of the customer’s bridge circuit must be grounded. This can be done either at the motor terminal box or at the instrumentation end of the circuit. Voltages that might appear on the circuit will then be passed to ground.

Types Available

Baldor standard is 100 ohms @ 0º C. The wire element is platinum.

Standard options available are either 120 ohms Nickel @0º C or 10 ohms Copper @ 25º C.

Dual element RTD’s are available on special order.

Remarks

1. Can provide either continuous temperature measuring or temperature monitoring.

2. Needs a separately mounted control and power source to read temperature or to provide a means for relay operation (for either alarm or motor shut down features. )

3. Temperature can be monitored using an ohm meter or a resistance bridge and converting the resistance to temperature.

4. Will respond thermally to normal load and temperature changes, but not fast enough to provide locked rotor protection.

Winding Thermostat

Purpose

To indicate1 the winding temperature has exceeded normal operating temperatures.

Principle of Operation

The thermostat uses a bi−metal snap action disc to operate a set of contacts. The operating temperature is factory selected and non−adjustable. The contacts can be wired directly to a relay to provide either alarm indication or motor shut down features. Means of temperature measuring or monitoring cannot be provided with this device. Refer to lead tags tor voltage and current limitations of contacts.

Installation

Baldor typically installs one thermostat per phase in motor coil head.

Customer Interconnect

Leads terminate in a separate conduit box. Leads are tagged.

Remarks

1. Cannot be used to measure or monitor temperatures.

2. Can be directly wired to motor starter hold in coil relay to provide motor shut down due to excessive temperature.

3. Can be wired directly to an alarm circuit without the use of a separate relay.

4. Can be used for AC or DC operation.

5. The thermostat provides a thermally automatic reset feature. The snap action automatic reset feature can cause difficulty in troubleshooting unless it is connected to a manual reset relay.

6. Will respond thermally to normal load / temperature changes; however will not respond fast enough to provide locked rotor protection.

MN428 Accessories 4-1

Winding Thermocouple − T/ C

Purpose

To measure or monitor winding temperature.

Principle of Operation

The T/C uses a junction of two dissimilar metals to generate a voltage which varies with change in junction temperature.

Installation

Baldor typically installs one T/C per phase. Form wound motors have the bi−metal junction located between the top and bottom coil sides in the slot.

Customer Interconnect

Using same type of T/C wire, connect to leads supplied in separate conduit box. Leads are tagged.

Remarks

1. Can provide either continuous temperature measuring or temperature monitoring.

2. Can measure temperature by using a potentiometer and converting from voltage to temperature by using proper conversion tables.

3. Needs separately mounted control and power source to read temperature or to provide a means of relay operation for either alarm or motor shutdown features.

4. Will respond thermally to normal load / temperature changes; however will not respond fast enough to provide locked rotor protection.

Winding Thermistors

Purpose

To indicate the winding temperature has exceeded normal operating temperatures.

Principle of Operation

Device is a semiconductor that changes its resistance abruptly at a certain temperature. The change is used to trigger a switching action in an external control which provides an alarm or shutdown signal.

Installation

Thermistors can be installed in either the coil head or slot between top and bottom coil sides. Baldor standard is to install three: in the slot on form wound stators and three in the coil heads on random wound stators. A controller, included in thermistor package is mounted in an accessory conduit box.

Customer Interconnect

Thermistor leads are brought to a terminal strip located on the coil head. Separate leads continue to controller, located in the accessory conduit box, where customer connections are made.

Remarks

Cannot be used to measure or monitor winding temperatures. Similar to thermostat providing a switching action to alarm or shutdown. Will not provide locked rotor protection.

Bearing Resistance Temperature Detector − RTD

Purpose

To measure or monitor bearing temperature during operation.

Principle of Operation

The RTD uses a wire wound in a coil. It is wound so that it is a non−inductive device. Its mode of operation is that of a linear change in resistance with temperature.

Installation

Baldor typically installs one RTD per bearing. The tip of the RTD is either in contact with or in close proximity to the bearing. The small gauge RTD leads are protected with a metal armored sheath and are terminated to a terminal strip inside a separate conduit box.

Customer Interconnect

A terminal strip is supplied inside a conduit box. Leads are tagged.

Remarks

1. Can provide either continuous temperature measuring or temperature monitoring.

2. Needs a separately mounted control and power source to read temperatures or to provide a means of relay operation for either alarm or motor shut down features.

4-2 Accessories MN428

3. Temperature can be monitored using an ohm meter or a resistance bridge and converting the resistance

(after subtracting lead resistance) to temperature by using the appropriate conversion tables for the element.

Suggested Bearing and Winding RTD Setting Guidelines

Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B

(80º C) temperature rise at rated load and are built with a Class F winding insulation system. Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be used as a starting point.

The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding RTD alarm and trip settings should be selected based on these tables unless otherwise specified for specific applications.

If the driven load is found to operate well below the initial temperature settings under normal conditions, the alarm and trip settings may be reduced so that an abnormal machine load will be identified.

The temperature limits are based on the installation of the winding RTDs imbedded in the winding as specified by NEMA. Bearing RTDs should be installed so they are in close proximity to the outer race on ball or roller bearings or in direct contact with the sleeve bearing shell.

Table 4-1 Winding RTDs − Temperature Limit In º C (40º C Maximum Ambient)

Class B Temp Rise ≤ 80º C (Typical Design)

Alarm Trip

Class F Temp Rise ≤ 105º C

Alarm Trip

135 145 160 170

- Winding RTDs are factory production installed.

- When Class H temperatures are used, consider bearing temperatures and relubrication requirements.

- Refer to performance data for motor specific limits.

Table 4-2 Bearing RTDs − Temperature Limit In C (40 C Maximum Ambient)

Type

Alarm

Anti−Friction

Trip

Bearing * 85 90

Alarm

Sleeve

Trip

Bearing Lube ** 75 80 70

* Bearing temperature limits are for standard design motors operating at class B temperature rise.

** High temperature lubricants include some synthetic oils and greases.

Bearing Thermocouple − T/C

Purpose

To measure or monitor bearing temperature during operation.

Principle of Operation

The TIC uses a junction of two dissimilar metals to generate a voltage, which varies linearly with change in junction temperature.

Installation

Baldor installs one T/C per bearing. The tip (bi−metal junction) is in close proximity to the outer race of the bearing. The small gauge T/C wires are protected with metal armored sheath and are terminated at a terminal strip inside a separate conduit box.

Customer Interconnect

Using the same type of T/C wire, connect to terminal strip posts in separate conduit box. Leads are tagged.

Remarks

1. Can provide continuous temperature measuring or temperature monitoring.

2. Can also measure temperature by using a potentiometer and converting voltage to temperature by use of the proper conversion tables.

3. Needs separately mounted control and power source to read temperature or to provide a means of relay operation for either alarm of motor shut down features.

MN428 Accessories 4-3

Bearing Thermostat

(Also called Bearing Temperature Relay or Gas Bulb Switch)

Purpose

To indicate the bearing temperature has exceeded normal operating temperatures.

Principle of Operation

The device operates due to expansion of gas sealed within a sealed gas bulb element which is placed in contact with the bearing or oil in the bearing sump. As the temperature of the bearing or oil increases, the gas in the element expands and deflects a diaphragm in the switch. The movement of the diaphragm activates the switch contacts. The contacts can be wired directly to a relay to provide either alarm indication or motor shutdown.

Construction

The thermostat consists of a set of normally closed or normally open contacts operated by a diaphragm which is connected to a gas bulb through a capillary tube.

Installation

The gas bulb must be mounted horizontally or vertically pointing downward. The gas bulb must be in contact with the bearing housing (anti−friction bearing) or submersed in the oil (sleeve bearing) for proper operation.

Bearing Dial Thermometer

Purpose

To measure and display the temperature of the oil in the bearing sump or of the bearing outer race.

Principle of operation

Bi-metal operation with large easy to read dial. Tip sensitive design.

Installation

Thermometer is installed in either the oil sump or in close proximity to the bearing.

Space Heater

WARNING: Space Heaters operate at line voltage . Disconnect power to space heaters before performing maintenance work on motor . Failure to observe this precaution could result in severe bodily injury or loss of life .

Purpose

Space heaters are used to prevent condensation of moisture within the motor enclosure during shutdown or storage periods.

Mounting

Space heaters are selected, unless otherwise ordered, using the following parameters.

1. Sheath temperature 392º F (200º C) nominal maximum as standard. Lower Sheath temperatures are available.

2. Temperature rise inside of motor raised approximately 10º F (6º C) above ambient.

3. Assume ambient maximum of 40º C

Space heaters are mounted and terminated at an accessory conduit box. Leads are tagged.

Oil Circulation System

Purpose

To provide a source of cool, clean oil to the bearings.

Description

The oil lubrication system consists of provision for supplying oil to the bearing and removing excess oil from the resevoir. The system will resist flooding and also provides oil rings to pick up oil in the event the source of oil is lost. An orifice is normally provided in the oil inlet piping to control oil flow.

Requirement

The need for a lubrication system may exist on some ratings due to temperature requirements versus journal size and speed of the shaft. In those cases the unit would be supplied with inlet and outlet provisions as standard for connection to a customer provided source of oil.

4-4 Accessories MN428

Constant Level Oiler

Description

Constant level oilers are used as small supplementary oil sumps which provide an additional source of oil to replenish small amounts of oil lost by long term leakage. They provide this feature without changing the oil level in the sump.

Operation

The device is mounted on the side of a unit and is interconnected to the bearing housing. As oil in the bearing sump is lowered, the constant level device adds oil to a predetermined level. This level is set at the factory and should not require additional adjustments. If the oiler is to be replaced or its operation checked, the following procedure should be followed:

A. TRICO OILER

The oiler is to maintain the oil level in the bearing sump oil level gage between the “Max” and “Min” levels.

1. Adjust the oiler by loosening the 3 set screws on the oiler housing.

2. Raise or lower the oiler bottle to raise or lower the oil level in the bearing sump level gauge.

3. When the oil level in the bearing sump level gage is between the “Max” and “Min” levels, tighten the 3 set screws.

4. The oiler must be adjusted with the motor running.

B. OIL RITE OILER

The oiler is to maintain the oil level in the bearing sump oil level gage between the “Max” and “Min” levels.

1. The oil level groove on the oiler body, below the oilers bottle, must be located at the midpoint between the

“Max” and “Min” level scribe lines on the bearing sump oil level gauge.

2. The position of the oiler is adjusted by changing the length of the pipe nipple threaded into the bottom of the oiler body.

3. The fill cap on the oiler must be closed tightly for the oiler to operate properly.

Features

The device has the following features:

1. Auxiliary source to replenish oil due to leakage.

2. Provides an indication of rate of oil leakage by the change in oil level in the constant level oiler.

3. Gives a “quick look” assurance that oil is in the bearing without the need to get close to the housing or shaft.

Figure 4-1 Constant Level Oiler Installation

Oil Level

Differential Air Pressure Switch For WPII Motors

Purpose

The differential air pressure switch is used to indicate dirty or clogged air filters.

Principle of Operation

The switch is connected through tubing or hoses to static pressure probes located on the inlet and exhaust sides of the air filters. As the air filters become clogged during operation the static pressure drop across the filters will increase and the air flow through the motor will be reduced. The static pressure probes sense the change in static pressure drop across the filter and, as a result of this pressure imbalance, a diaphragm in the switch body is deflected. The switch diaphragm deflection will actuate the switch contacts.

Remarks

1. Can provide an indication of reduced air flow (increased static air pressure drop) through the air filters but cannot be used to measure actual air flow rates.

MN428 Accessories 4-5

2. Primary function is as a maintenance aid to alert the user of the filter condition. since the switch can be utilized to activate an alarm or signal a potential shut down condition.

3. Switch contacts are preset to actuate at a static pressure differential of 0.5” W.G. This value indicates clogged filters.

Differential Air Pressure Gauge For WPII Motors

Purpose

The differential air pressure gauge is used to measure the static air pressure drop across the air filters which is an indication of the degree of blockage of the filter.

Principle of Operation

The gauge is connected through tubing or hoses to static pressure probes located on the inlet and exhaust sides of the air filters. As the air filters become clogged during operation the static pressure drop across the filters will increase and the air flow through the motor will be reduced. The static pressure probes sense the change in static pressure drop across the filter and, as a result of this pressure imbalance, a diaphragm in the gauge body is deflected. This deflection translates to the indicator movement on the gauge.

Remarks

1. Can provide a continuous indication of static air pressure drop across the air filters (I.e. reduced air flow volume) but cannot be used to measure actual air flow rates.

2. Primary function is as a maintenance aid to alert the user of the filter condition.

Current Transformers

Description

Current transformers are a means of measuring or sensing current flow through the input leads of AC motors.

Application

Applications involve use of current transformers either for differential protection or metering line phase current.

Installation

The current transformers can be supplied and mounted in an oversize main motor conduit box. The current transformers will be identified by ratio on the current transformers nameplate and will include screw type terminals on the secondary terminals.

Selection

The selection of the current transformers is based upon the ratio that the user requires for matching his meters or related instrumentation.

Lightning Arrestors And Surge Capacitors

Description

Lightning arrestors serve to limit the crest value of incoming voltage curves. Surge capacitors lengthen the rise time of the surge wave thus reducing its effects on the stator winding.

Installation

Arrestors and/or capacitors can be mounted in an oversize main conduit box. They are connected from line leads to ground, generally as near as possible to the motor.

Selection

Standard capacitance value for surge capacitors is 1.0 mfd − 460, 575 volts, .50 µ f for 2300−7000 volts and

.25 µ f above 7000 volts.

They are suitable for 25, 40, 50, or 60 Hz systems. Arrestors are selected according to the maximum RMS

Line−To−Ground voltage.

Air Filters

Filters will handle high velocity air speeds up to 600 FPM (3 m/s) net face velocity.

Resistance to air flow of a clean filter should not exceed 0.15” W.G. (37 N/m

gauge).

Baldor recommends that the filters be cleaned or replaced when the static air pressure drop across the filters reaches .50” W.G. (123.3 N/m2 gauge). Baldor furnishes permanent, cleanable all metal filters as standard.

Disposable filters can be furnished by special order.

4-6 Accessories MN428

Vibration Probes

Purpose

To measure shaft vibration

Principle of operation

Eddie current probes are placed in close proximity to properly prepared areas on the shaft. The distance between the shaft and the probe is a function of the voltage produced by the sensing electronics. This signal is translated into a linear distance and can be tracked over time to provide valuable shaft vibration data.

Installation

Baldor typically installs 2 probes per bearing located 90° from each other in a radial plane relative to the shaft centre line. Probes are pre-wired to proximitors in a junction box on the side of the motor.

Customer Interconnect

Customer connects to the proximitors in the junction box. This signal is then fed back to the customer’s analyzer.

Remarks

1. Can provide continuous monitoring of shaft vibration

2. Requires a separate customer supplied analyzer

3. Data can be used for trending alarm and/or shutdown safety measures

Tachometers

Purpose

To measure shaft rotational speed.

Principle of operation

The standard Baldor Tachometer measures shaft rotational speed via a magnetic pickup. The tachometer has a steel rotor with a various number of poles. By varying the number of poles it is possible to change the pulses per revolution (PPR). Tachometers can also provide information on direction of rotation.

Installation

Baldor typically installs the tachometer on the ODE of the motor. It is fixed to a stub shaft and is held in place with a torque arm.

Customer Interconnect

There are a wide variety of connection styles available for customer hook-up. Contacts can either be supplied on the Tachometer itself or be pre-wired to a junction box on the side of the motor.

Remarks

1. Numerous configurations are available. For further assistance with your particular model please contact the factory.

MN428 Accessories 4-7

4-8 Accessories MN428

Section 5 Cross Sectional Drawings

8040 Frame Cross Section - Anti-Friction Bearings

8040 FRAME - WPII WITH ANTI-FRICTION BEARINGS

AIR INTAKE AIR INTAKE

BEARING CROSS-SECTION

DETAIL

OPPOSITE DRIVE END

MN428

AIR EXHAUST

MOTOR CROSS-SECTION

AIR EXHAUST

ITEM

NO.

ODE BEARING

DE BEARING

STATOR CORE

ROTOR CORE

WPII HOOD

SHAFT

FRAME

DESCRIPTION

INNER CAP

OUTBOARD SEAL

BEARING CARTRIDGE

OUTER CAP

LEAD ENTRY PLATE

MAIN CONDUIT BOX

SHAFT EXTENSION KEY

FILTER

FILTER COVER

MOTOR LIFTING LUG

ODE TRUNK

DE TRUNK

ODE BAFFLE

DE BAFFLE

ODE FAN

DE FAN

ODE BRACKET

DE BRACKET

Cross Sectional Drawings 5-1

8040 Frame Cross Section - Sleeve Bearings

8040 FRAME - WPII WITH SLEEVE BEARINGS

AIR INTAKE

BEARING CROSS-SECTION

DETAIL

OPPOSITE DRIVE END

AIR EXHAUST

5-2 Cross Sectional Drawings

MOTOR CROSS-SECTION

AIR EXHAUST

AIR SEAL

INBOARD OIL SEAL

OUTBOARD OIL SEAL

OIL RING

BEARING LINER

ODE FAN

DE FAN

ODE BRACKET

DE BRACKET

ODE BEARING

DE BEARING

STATOR CORE

ROTOR CORE

WPII HOOD

SHAFT

FRAME

BEARING RTD TERMINAL HEAD

LEAD ENTRY PLATE

MAIN CONDUIT BOX

SHAFT EXTENSION KEY

FILTER

FILTER COVER

MOTOR LIFTING LUG

ODE TRUNK

DE TRUNK

ODE BAFFLE

DE BAFFLE

DESCRIPTION

ITEM

NO.

MN428

9240 Frame Cross Section - Anti-Friction Bearings

9240 FRAME - WPII WITH ANTI-FRICTION BEARINGS

MN428

AIR INTAKE

AIR EXHAUST

OPPOSITE DRIVE END

MOTOR CROSS-SECTION

AIR INTAKE

BEARING CROSS-SECTION

DETAIL

AIR EXHAUST

INNER CAP

OUTBOARD SEAL

BEARING CARTRIDGE

OUTER CAP

21 LEAD ENTRY PLATE

MAIN CONDUIT BOX

SHAFT EXTENSION KEY

FILTER

FILTER COVER

MOTOR LIFTING LUG

ODE END COVER

DE END COVER

ODE BAFFLE

DE BAFFLE

ODE FAN

DE FAN

ODE BRACKET

DE BRACKET

ODE BEARING

DE BEARING

STATOR CORE

ROTOR CORE

WPII HOOD

SHAFT

ITEM

NO.

FRAME

DESCRIPTION

Cross Sectional Drawings 5-3

9240 Frame Cross Section - Sleeve Bearings

9240 FRAME - WPII WITH SLEEVE BEARINGS

BEARING CROSS-SECTION

DETAIL

AIR INTAKE

OPPOSITE DRIVE END

AIR EXHAUST

5-4 Cross Sectional Drawings

MOTOR CROSS-SECTION

AIR EXHAUST

27 AIR SEAL

26 INBOARD OIL SEAL

25 OUTBOARD OIL SEAL

24 OIL RING

23 BEARING LINER

22 BEARING RTD TERMINAL HEAD

21 LEAD ENTRY PLATE

20 MAIN CONDUIT BOX

19 SHAFT EXTENSION KEY

18 FILTER

17 FILTER COVER

16 MOTOR LIFTING LUG

15 ODE END COVER

14 DE END COVER

13 ODE BAFFLE

12 DE BAFFLE

11 ODE FAN

10 DE FAN

9 ODE BRACKET

8 DE BRACKET

7 ODE BEARING

6 DE BEARING

5 STATOR CORE

4 ROTOR CORE

3 WPII HOOD

2 SHAFT

1 FRAME

ITEM

NO.

DESCRIPTION

MN428

10840 Frame - Anti-Friction Bearings

10840 FRAME - WPII WITH ANTI-FRICTION BEARINGS

MN428

AIR EXHAUST

AIR INTAKE

OPPOSITE DRIVE END

MOTOR CROSS-SECTION

AIR INTAKE

BEARING CROSS-SECTION

DETAIL

AIR EXHAUST

ODE TRUNK

DE TRUNK

ODE BAFFLE

DE BAFFLE

ODE FAN

DE FAN

ODE BRACKET

DE BRACKET

ODE BEARING

DE BEARING

STATOR CORE

ROTOR CORE

WPII HOOD

SHAFT

FRAME

INNER CAP

OUTBOARD SEAL

BEARING CARTRIDGE

OUTER CAP

LEAD ENTRY PLATE

MAIN CONDUIT BOX

SHAFT EXTENSION KEY

FILTER

FILTER COVER

MOTOR LIFTING LUG

ITEM

NO.

DESCRIPTION

Cross Sectional Drawings 5-5

10840 Frame - Sleeve Bearings

10840 FRAME - WPII WITH SLEEVE BEARINGS

AIR INTAKE AIR INTAKE

AIR EXHAUST

5-6 Cross Sectional Drawings

OPPOSITE DRIVE END

MOTOR CROSS-SECTION

AIR EXHAUST

AIR SEAL

INBOARD OIL SEAL

OUTBOARD OIL SEAL

OIL RING

BEARING LINER

22 BEARING RTD TERMINAL HEAD

21 LEAD ENTRY PLATE

MAIN CONDUIT BOX

SHAFT EXTENSION KEY

FILTER

FILTER COVER

MOTOR LIFTING LUG

ODE TRUNK

DE TRUNK

ODE BAFFLE

DE BAFFLE

ODE FAN

DE FAN

ODE BRACKET

ITEM

NO.

DE BRACKET

ODE BEARING

DE BEARING

STATOR CORE

ROTOR CORE

WPII HOOD

SHAFT

FRAME

DESCRIPTION

MN428

MN428-0616

Baldor Electric Company

P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895

www.baldor.com

MN428

06/16

Hello! I am an AI chatbot specifically trained to assist you with the Baldor-Reliance Above NEMA Duty Master AC Motors Owner's Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

Assistant typing

Assistant terminated

Above NEMA Duty Master AC Motors

Frames: 8040, 9240, 10840,

Enclosures: Open and Totally Enclosed

Mounting: Horizontal

06/16

Installation & Operating Manual

MN428

Any trademarks used in this manual are the property of their respective owners.

Important:

Be sure to check www.baldor.com to download the latest version of this manual in Adobe Acrobat PDF format.

Table of Contents

Section 1

General Information

Overview

Safety Notice:

Receiving

Unpacking

Handling

Storage

Storage periods greater than 6 months

Section 2

Installation & Operation

Overview

Location

Horizontal Mounted Motor

Lubrication

Electrical Connection

Pre−Operation Check

First Time Uncoupled Start−Up

Coupled Start−up

Jogging and Repeated Starts

Displacement - Inches

RPM (Divide by 60 for Hz)

Operation

Section 3

Maintenance & Troubleshooting - Horizontal Shaft

Horizontal Shaft Motors

Periodic Inspection

Bearing Lubrication

Anti−Friction Bearing (Grease Lubricated)

Anti−Friction Bearing (Oil Mist Lubricated)

Sleeve Bearings (Oil Lubricated)

Sleeve Bearing Replacement

Sleeve/Anti−Friction Bearing Bracket Removal

Anti−Friction Bearing Removal/Replacement

Rotor And Stator Removal

Winding Maintenance

Auxiliary Cooling

Renewal Parts

Section 4

Accessories

Winding Resistance Temperature Detector RTD

Winding Thermostat

Winding Thermocouple − T/ C

Winding Thermistors

Bearing Resistance Temperature Detector − RTD

Suggested Bearing and Winding RTD Setting Guidelines

Bearing Thermocouple − T/C

Bearing Thermostat

Bearing Dial Thermometer

Space Heater

Oil Circulation System

Constant Level Oiler

Oil Level

Differential Air Pressure Switch For WPII Motors

Differential Air Pressure Gauge For WPII Motors

Current Transformers

Lightning Arrestors And Surge Capacitors

Air Filters

Vibration Probes

Tachometers

Section 5

Cross Sectional Drawings

8040 Frame Cross Section - Anti-Friction Bearings

8040 FRAME - WPII WITH ANTI-FRICTION BEARINGS

8040 Frame Cross Section - Sleeve Bearings

8040 FRAME - WPII WITH SLEEVE BEARINGS

9240 Frame Cross Section - Anti-Friction Bearings

9240 FRAME - WPII WITH ANTI-FRICTION BEARINGS

9240 Frame Cross Section - Sleeve Bearings