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Installation, Operation and Maintenance Manual Standard Industrial AC Induction Motors • 180-449 Frames (NEMA) • 112-280 Frames (IEC) 2 Standard Industrial AC Induction Motors ! Table of Contents ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this motor. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. Receiving and Handling Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Storage Conditions - Short Term . . . . . . . . . . . . . . . . . . . . . 3 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Storage for Extended Periods (greater than 18 months) . . . 5 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lifting Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test for General Condition . . . . . . . . . . . . . . . . . . . . . . . . . 11 Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operation Maintenance and Repair Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lubrication of Bearings Grease Lubricated Bearings . . . . . . . . . . . . . . . . . . . . . . . 15 Recommended Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replacement Bearings Total Service Programs Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cross Sectional and Parts Identification Drawing Standard Industrial AC Induction Motors Receiving and Handling 3 Acceptance Thoroughly inspect this equipment before accepting shipment from the transportation company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight or express agent at once and request him to make an inspection. We are willing to assist you in collecting claims for loss or damage in shipment; however, this willingness on our part does not remove the transportation company's responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the invoice, nor should payment of the invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe delivery. If considerable damage has been incurred and the situation is urgent, contact the nearest Allen-Bradley Sales Office for assistance. Please keep a written record of all such communications. Storage Conditions - Short Term Following are requirements for storage: 1. Motors must be kept in their original containers (or with equivalent protection). In addition, they must be stored in a warehouse free from extremes in temperature, humidity and corrosive atmosphere. 2. If unusual vibrations exist at the storage location, the motor should be protected with isolation pads. 3. All breathers and drains are to be operable while in storage and/or the moisture drain plugs should be removed. The motors must be stored so the drain is at the lowest point. Storage Preparation Improper storage of electric machines will result in seriously reduced reliability of that equipment. For example, the following items can occur to an electric motor that does not experience regular usage while exposed to normally humid atmospheric conditions: • Bearings may rust. • Rust particles from surrounding surfaces may contaminate the bearings. • The electrical insulation may absorb an excessive amount of moisture leading to the motor winding failing to ground. 4 Standard Industrial AC Induction Motors The following preparations should be followed: 1. Minimize condensation in and around the motor by use of desiccants or other humidity control methods. 2. Motor space heaters, when specified, must be energized when there is a possibility that the ambient storage conditions will reach the dew point. Space heaters are an option. 3. Coat all external machined surfaces with a material to prevent corrosion. An acceptable product for this purpose is Exxon Rust Ban #392 (or equivalent). 4. Measure and record the electrical resistance of the winding insulation with a megger or insulation resistance meter. Minimum accepted megohm level is the insulation kv rating + 1 megohm. If levels fall below this value, contact your Allen-Bradley Sales Office. The recorded data will be needed when the motor is removed from storage. 5. Some motors have a shipping brace attached to the shaft to prevent damage during transportation. The shipping brace, if provided, must be removed and stored for future use. Before the motor is moved, the brace must be reinstalled to hold the shaft firmly in place against the bearing. 6. When placing the motor into extended storage (greater than 3 months), the motors with regreasable bearings must be greased per Table A. The motor shaft must then be rotated a minimum of 15 times after greasing. Non-regreasable motors with a “Do Not Lubricate” nameplate should also be rotated 15 times to redistribute grease within the bearing. 7. Before lubricating the motor, remove the grease drain plug (opposite the grease fitting) on the bottom of each end bracket. Replace the plug after greasing. Table A Lubrication Volume (Storage) NEMA (IEC) Frame Size 182-215 (112-132) 254-286 (160-180) 324-365 (200-225) 404-449 (250-280) Volume in Cubic Inches (cm3) 0.5 (8) 1.0 (16) 1.5 (24) 2.5 (40) 8. When the motor is placed into extended storage, regreasable bearings must be greased (see Table A). Motor shafts are to be rotated 15 revolutions manually every 3 months and additional grease added every nine months to each bearing (see Table A). Bearings must be greased at the time of removal from storage. Shafts on non-regreasable motors should be rotated 15 revolutions every 3 months. 9. All breather drains should be fully operable while in storage. The motors must be stored so the drain is at the lowest point. All breathers and automatic “T” drains must be operable to allow breathing at points other than through the bearing fits. Standard Industrial AC Induction Motors 5 10. Space heaters, when specified, are to be connected and operable while in storage. 11. Windings must be meggered at the time equipment is put in storage (refer to step 4 on page 4). When the motor is removed from storage, the insulation resistance must not have dropped more than 50% from the initial reading. Any drop below this point necessitates electrical or mechanical drying. 12. When motors are not stored in the original containers, but are removed and mounted on other pieces of machinery, the mounting must be such that the drains/breathers and space heaters are fully operable. In this respect, the drains must be kept at the lowest point in the motor so that all condensation can automatically drain out. Storage for Extended Periods (greater than 18 months) All of the preceding requirements described in this document apply, with the following additional requirements. 1. Motor must be crated in a box similar to Export Boxing, but the “shell” (sides and top of box) will be lag-bolted to the wooden base (not nailed). This design will allow the box to be opened and closed many times without destroying the “shell.” 2. The motor will be sealed in an airtight vapor barrier bag with desiccant inside. This airtight bag will give added protection during shipment of motor to the permanent storage area. 3. After the first “inspection” (for megger reading, turing the shaft, etc.) it is recommended that the vapor bag be re-sealed with masking tape (or similar method). New desiccant should also be added inside the bag before closing. Once closed, place the shell over the motor and replace the lap bolts. 4. If a “zipper” type of bag is used (instead of a “heat-sealed” bag), then close the bag with the zipper (instead of taping). 5. New desiccant must be added inside the bag after each periodic inspection. 6. Minimize the accumulation of condensed water in and around the machine. Unpacking After unpacking and inspecting, turn the motor shaft by hand to assure that there are no obstructions to free rotation. Equipment which has been in storage for some time should be tested and relubricated (regreasable type) prior to being put into service. Refer to “Test General Condition” and “Lubrication” for procedure to be performed after extended storage. Equipment with roller bearings is shipped with a shaft block. After removing the shaft block, be sure to replace any bolts that are required in service and that were used to hold the shaft block in place during shipment. 6 Standard Industrial AC Induction Motors Installation Inspection After the motor is unpacked, examine the nameplate data to see that it agrees with the power circuit to which it is to be connected. The motor will operate with frequency not more than 5% and voltage not more than 10% above or below the nameplate data, or combined variation of voltage and frequency of not more than 10% above or be low nameplate data. Efficiency, power factor and current may vary from nameplate data. Performance within these voltage and frequency variations will not necessarily be in accordance with the standards established for operation at rated voltage and frequency. Location The motor should be installed in a location compatible with the motor enclosure and specific ambient. To allow adequate air flow, the following clearances must be maintained between the motor and any obstruction: TEFC (IC0141) Enclosures Fan Cover Air Intake Exhaust 180-210T Frame 25.4 mm (1.00 in.) 250-449T Frame 101.6 mm (4.00 in.) IEC 112 - 132 25.0 mm (0.98 in.) IEC 160 - 280 100.0 mm (3.94) Envelope equal to the “P” dimension on the motor dimension sheet Protected Enclosures Bracket Intake Same as TEFC Frame Exhaust Exhaust out the sides-envelope a minimum of the “P” dimension plus 50.0 mm (1.97 in.). Exhaust out the end-same as intake. Table B General Effect of Voltage & Frequency Variation on Induction-motor Characteristics Starting & Maximum Running Variation Torque Voltage Variation: 120% Increase voltage 44% Efficiency Sync Speed Slip % No change Decrease Increase 30% 1.5% 110% Increase voltage 21% Functions (voltage)2 of Voltage 90% Decrease Voltage 19% Frequency Variation: 105% Decrease frequency 10% No change Constant No change Decrease 17% 1 (voltage)2 Increase 23% Increase 5% Practically Increase no change 5% Function of frequency 95% frequency 1% phase unbalance Frequency Decrease 5% Slight decrease (sync speed slip) Practically Decrease Slight no change 5% decrease Slight 2% decrease decrease Slight decrease Slight decrease 1 (frequency)2 Increase 11% Slight decrease 2% phase Slight unbalance decrease Full Load Full-Load Speed Power Factor/COS 3/4 Load Decrease 6-0% 1/2-2 Decrease points (1-75 HP) 0-3% Increase (100-200 HP) Slight Practically decrease no change Increase 1% (sync speed slip) Decrease Decrease 1-1/2% 2 points Slight increase 1/2 Load Full Load 3/4 Load 1/2 Load Decrease Decrease Decrease Decrease 15-40 5-15 points 10-30 7-20 points points points Full Load Current Starting Current Increase Increase 12% 20% Decrease Decrease Decrease Decrease Increase Increase 1-2 points 5-10 points 5 points 5-6 points 2-4% 10-12% voltage Magnetic Temperature Maximum Noise Overload (no-load in Rise Capacity particular) (full load) Increase 5-6 degrees C. (1-75 HP) Decrease 3-4 degrees C. (100-200 HP) Increase 3-4 degrees C. Increase 44% Noticeable increase Increase Increase 21% slightly (voltage)2 Practically Increase Increase no change 1-2 points 5 points Increase Increase Increase Decrease Increase 6-7 2-3 points 4-5 points 11% 10-12% degrees C. Decrease Slight 19% decrease Slight increase Slight increase Slight decrease Slight decrease Increase slightly Increase slightly Slight decrease Slight increase Slight decrease 8% decrease NOTE: This table shows goneral effects, which will vary somewhat for specific ratings. Slight increase Slight decrease 5-6% decrease 7% decrease Slight increase Slight Slight decrease decrease Slight Decrease Slight decrease 5-6% decrease 1 frequency Slight Increase Increase increase 5-6% slightly 1-1/2% Slight 2% increase decrease increase 3% Slight 8% increase decrease increase Standard Industrial AC Induction Motors 7 Lifting Means ! ATTENTION: When lifting means are provided for handling the motor, it should not be used to lift the motor plus additional equipment such as gears, pumps, compressors or other driven equipment. Failure to observe this precaution could result in bodily injury. In the case of assemblies on a common base, any lifting means provided on the motor or generator should not be used to lift the assembly and base. The assembly should be lifted by a sling around the base or by other lifting means provided on the base. In all cases, care should be taken to assure lifting in the direction intended in the design of the lifting means. Precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or shock forces. Mounting Mount the motor on a foundation sufficiently rigid to prevent excessive vibration. Roller bearing and ball-bearing motors may be mounted with the shaft at any angle. Roller bearing motors are not suitable for coupled duty applications. After carefully aligning the motor with the driven unit, bolt securely in place. When motors, which are normally mounted with the shaft in a horizontal position, are mounted vertically, it may be necessary to provide additional guards to prevent foreign objects from falling into the motor openings and striking rotating parts. Such guards may be obtained at the time of purchase or from a local service repair center. Explosion proof motors are shipped from the factory with the conduit box mounted. If the conduit box is removed or rotated, a minimum of five (5) full threads of engagement on the motor pipe nipple must be maintained for explosion proof integrity of the conduit box. Some motors have standardized frames containing 6 or 8 mounting holes. 6 hole frames are not suitable for field reversal of mounting from F-1 to F-2, etc. Figure 1 indicates the proper mounting holes to use. 8 Standard Industrial AC Induction Motors Figure 1 Mounting of 6 & 8 Hole Motor Frames View from above Not present on "6-hole frame" and not used on "8-hole frame" (allows F-1 to F-2 conversion on 8-hole frames) Drive Shaft End Use these holes for short frame designations 182, 213, 254, 284, 324, 364, 404, 444 (NEMA) Always use these holes which are closer to shaft. 112S, 132S, 160M, 180M, 200M, 225S, 250S, 280S (IEC) Use these holes for long frame designations 184, 215, 256, 286, 326, 365, 405, 445 (NEMA) (IEC) 112M, 132M, 160L, 200L, 225M, 250M, 280M Drive The pulley, sprocket, or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible. Heat to install. Driving a unit on the shaft will damage the bearings. Belt Drive – Align the pulleys so that the belt will run true. Tighten the belt just enough to prevent slippage, any tighter will cause premature bearing failure. If possible, the lower side of the belt should be the driving side. Chain Drive – Mount the sprocket on the shaft as close to the bracket as possible. Align the sprockets so that the chain will run true. Avoid excessive chain tension. Gear Drive and Direct Connection – Accurate alignment is essential. Secure the motor and driven unit rigidly to the base. Rotating Parts ! ATTENTION: Rotating parts such as couplings, pulleys, external fans and unused shaft extensions must be permanently guarded against accidental contact with hands or clothing. This is particularly important where the parts have surface irregularities such as keys, keyways or set screws. Failure to observe this precaution could result in personal injury. Some Satisfactory Methods Of Guarding Are: • Covering the machine and associated rotating parts with structural or decorative parts of the driven equipment. • Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate guarding in normal service. Standard Industrial AC Induction Motors ! 9 ATTENTION: The user is responsible for conforming with the National Electrical code and other applicable local codes. Wiring practices, grounding disconnects and overcurrent protection are of particular importance. Failure to observe these precautions could result in personal injury or loss of life. Wiring ! ATTENTION: The following steps require rotating parts and/or electrical circuits to be exposed. Stay clear if unit must be running or disconnect and lockout power source if contact must be made. Connect the motor to the power supply according to the diagram on the motor nameplate. For most 230/460 volt motors, nine leads are brought out from the stator windings so that the motor may be connected for either 230 or 460 volts. Important: When motors are provided with thermal protection (typically thermostats), it is important to properly connect and apply the devices. This will ensure that the motor is properly protected from being operated if thermal limits are reached and/or exceeded. The control system must be configured to reduce the motor load and/or shut down the motor control system to allow the motor to cool to a level within acceptable operating ranges. If the motor is operated with the thermal protective devices tripped (indicating an over temperature condition), the motor insulation could be damaged and complete failure of the motor insulation is possible. In the event of motor failure due to an over temperature condition, Rockwell Automation requires that motor thermal protective devices (when supplied) be adequately monitored and incorporated into the motor control system to maintain warranty. Failure on the part of the individual installing this equipment to take these steps will result in the factory warranty being voided. Grounding In the USA consult the National Electrical Code, Article 430 for information on grounding of motors, Article 445 for grounding of generators, and Article 250 for general information on grounding. In making the ground connection, the installer should make certain that there is a solid and permanent metallic connection between the ground point, the motor or generator terminal housing, and the motor or generator frame. In other locations consult the appropriate national or local code applicable. 10 Standard Industrial AC Induction Motors Motors with resilient cushion rings usually must be provided with a bonding conductor across the resilient member. Some motors are supplied with the bonding conductor on the concealed side of the cushion ring to protect the bond from damage. Motors with bonded cushion rings should usually be grounded at the time of installation in accordance with the above recommendations for making ground connections. When motors with bonded cushion rings are used in multimotor installations employing group fusing or group protection, the bonding of the cushion ring should be checked to determine that it is adequate for the rating of the branch circuit overcurrent protective device being used. There are applications where grounding the exterior parts of a motor or generator may result in greater hazard by increasing the possibility of a person in the area simultaneously contacting ground and some other nearby live electrical parts of other ungrounded electrical equipment. In portable equipment it is difficult to be sure that a positive ground connection is maintained as the equipment is moved, and providing a grounding conductor may lead to a false sense of security. 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. ! ATTENTION: When careful consideration of the hazards involved in a particular application indicate the machine frames should not be grounded or when unusual operating conditions dictate that a grounded frame cannot be used, the installer should make sure the machine is permanently and effectively insulated from ground. In those installations where the machine frame is insulated from ground, it is recommended that appropriate warning labels or signs be placed on or in the area of the equipment by the installer. Failure to observe these precautions could result in severe bodily injury or loss of life. Starting ! ! ATTENTION: Before starting the motor, remove all unused shaft keys and loose rotating parts to prevent them from flying off. Failure to observe this precaution could result in bodily injury. ATTENTION: Check direction of motor rotation before coupling motor to load. Failure to observe this precaution could result in damage to or destruction of the equipment. Standard Industrial AC Induction Motors 11 Before starting the motor, check the following items: • The rotor should turn freely when disconnected from the load. • Driven machine should be unloaded when first starting the motor. The motor should run smoothly with little noise. If the motor fails to start and produces a decided hum, it may be that the load is too great for the motor or that it has been connected improperly. Shutdown immediately and investigate for trouble. Drain Plugs If motor is totally enclosed fan-cooled or non-ventilated, it is recommended that condensation drain plugs, if present, be removed. These are located in the lower portion of the end-shields. Totally enclosed fan-cooled “XT” motors are normally equipped with automatic drains which may be left in place as received. Rotation To reverse the direction of rotation, disconnect from power source and interchange any two of the three line leads for the three-phase motors. Test for General Condition If the motor has been in storage for an extensive period or has been subjected to adverse moisture conditions, it is best to check the insulation resistance of the stator winding with a megohmeter. If the resistance is lower than one megohm the windings should be dried in one of the two following ways: 1. Bake in an oven at a temperature not exceeding 90 degrees C (200 degrees F) until insulation resistance becomes constant. 2. With rotor locked, apply low voltage and gradually increase current through windings until temperature (measured with a thermometer) reaches 90 degrees C (200 degrees F). Do not exceed this temperature. Initial Lubrication Allen-Bradley motors are shipped from the factory with the bearings properly packed with grease and ready to operate. Where the unit has been subjected to extended storage (6 months or more) the bearings should be relubricated (regreasable type) prior to starting. 12 Standard Industrial AC Induction Motors Operation ! ATTENTION: Surface temperatures of the motor enclosure may reach temperatures which can cause discomfort or injury if contact is made with hot surfaces. When installing, protection must be provided by the user to protect against accidental contact with hot surfaces. Failure to observe this precaution could result in personal injury. Due to the inherent characteristics of insulating 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. The class of insulation determines the maximum safe operating temperature. Aging of insulation occurs at an accelerated rate at abnormally high temperatures. A general rule for gauging the effect of excessive heat is that for each 10 degrees C (50 degrees F) rise in temperature above the maximum limit for the insulation, the life of the insulation is halved. Unbalanced voltage or single-phase operation of polyphase machines may cause excessive heating and ultimate failure. It requires only a slight unbalance of voltage applied to a polyphase motor to cause large unbalance currents and resultant overheating. Periodic checks of phase voltage, frequency and power consumption of a motor while in operation are recommended. Such checks assure the correctness of frequency and voltage applied to the motor and 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 problems 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 is 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. Standard Industrial AC Induction Motors 13 Motors with maximum surface temperatures listed on the nameplates. ! ATTENTION: The motor is designed to operate at or below the maximum surface temperature stated on the nameplate. Failure to operate the motor properly can cause this maximum surface temperature to be exceeded. If applied in a Division 2 or Zone 2 environment, this excessive temperature may cause ignition of hazardous materials. Operating the motor under any of the following conditions can cause the marked temperature to be exceeded. • Motor load exceeding service factor value. • Ambient temperatures above nameplate value. • Voltages above or below nameplate value. • Unbalanced voltages. • Loss of proper ventilation. • Variable frequency operation. • Altitude above 1000 meters (3000 feet). • Severe duty cycles, repeated starts. • Motor stall. • Motor reversing. • Single-phase operation. 14 Standard Industrial AC Induction Motors Maintenance and Repair The fundamental principle of electrical maintenance is keep the apparatus clean and dry. This requires periodic inspection of the motor, the frequency depending upon the type of motor and the service. ! ATTENTION: To ensure that the driven equipment is not unexpectedly started, remove all power before proceeding. Failure to observe this precaution could result in personal injury or death. The following should be checked at regular intervals: • Windings should be dry and free of dust, grease, oil and dirt. Windings may be cleaned by suction cleaners or by wiping. Nozzles on suction type cleaners should be nonmetallic. Gummy deposits of dirt and grease may be removed by using a commercially available low volatile solvent. • Terminal connections, assembly screws, bolts and nuts should be tight. They may loosen if motor is not securely mounted and tend to vibrate. • Insulation resistance of motors in service should be checked periodically at approximately the same temperature and humidity conditions to determine possible deterioration of the insulation. When such measurements at regular intervals indicate a wide variation, the cause should be determined. Motor should be reconditioned if the motor has been subjected to excessive moisture by re-winding or re-insulating if necessary. Enclosed motors require very little attention. Ensure that the external air chamber of fan-cooled motors does not become clogged with foreign material which will restrict passage of air. Disassembly If it becomes necessary to disassemble the motor, care should be taken not to damage the stator windings as the insulation may be injured by improper or rough handling. Precautions to keep bearings clean should also be exercised. Before removing either end shield: 1. Disconnect motor from power source. Label the leads to assure proper reconnection. 2. Remove motor from mounting base. Remove fan cover and fan if present. 3. Mark end brackets relative to position on frame so they can be easily replaced. Standard Industrial AC Induction Motors 15 Removing Brackets and Rotor 1. Remove bearing cartridge nuts or screws (if used). 2. Remove opposite drive end bracket bolts. 3. Pull bracket. 4. Remove drive end bracket in same manner. 5. Remove rotor. Removing and Replacing Ball Bearings Bearings should not be removed unless they are to be replaced. When removal is necessary, use a bearing puller. A bearing puller may be rigged by using a metal plate with holes drilled to match the tapped holes in the inner cap. Use care to keep the pressure equal to prevent breaking the cap. To install a bearing, heat the bearing in an oven at 121 degrees C (250 degrees F). This will expand the inner race, allowing it to slip over the bearing seat. All bearings must be replaced with the identical part. In many cases special bearings are used which cannot be identified by markings on the bearing. In all cases, when replacing bearings, use markings on bearings and motor identification number to obtain correct replacement bearing. The majority of bearings used now have a C3 internal fit. Reassembly Follow reverse procedure as outlined above. Having marked the brackets in the original position, replace as marked. Lubrication of Bearings Motors covered by this Instruction Manual are equipped with several types of bearings. This description covers regreasable anti-friction bearings only. Non-regreasable ball bearings require no periodic maintenance. Grease Lubricated Bearings This motor has been properly lubricated at the time of manufacture. It is not necessary to lubricate at time of installation unless the motor has been in storage for a period of six months or more. 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 pre vent grease contamination. 16 Standard Industrial AC Induction Motors Recommended Lubricant For motors operating in ambient temperatures shown below, use the following lubricants or their equivalent: Ball Bearing Motors Operating Temperature: –25 to 50 degrees C (–15 to 120 degrees F) Minimum Starting Temperature –60 degrees C (–76 degrees F) Chevron Oil – SRI No. 2 Exxon – Unirex N2 Shell Oil Co. – Dolium R Texaco, Inc. – Premium RB Shell Oil Co. – Aeroshell 7 Roller Bearing Motors Operating Temperature: –25 to 50 degrees C (–15 to 120 degrees F) Chevron Oil – Black Pearl EP No. 2 Texaco, Inc. – Premium RB Lubrication Procedure Anti-friction bearings may be lubricated with the motor running or stationary. However, stationary with the motor warm is preferred. 1. 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). 2. If motor is equipped with grease drain plug, remove plug and loosen any hardened grease that may block drain. 3. Add the recommended volume of the lubricant using a hand operated grease gun. 4. Run the motor for two hours. 5. Replace the pipe plug in grease drain plug. 6. Grease may not relieve from drain. Use only volume shown in Table E. Lubrication Instructions 1. Select Service Condition from Table C. 2. Select Lubrication Frequency from Table D. 3. Select Lubrication Volume from Table E. 4. Lubricate the motor at the required frequency with the required lubricant volume in accordance with Lubrication Procedure above. Standard Industrial AC Induction Motors ! 17 ATTENTION: Mixing lubricants is not recommended due to possible incompatibility. If changing lubricant without motor disassembly is desired, follow lubrication instructions and repeat lubrication after 100 hours of service. Care must be taken to look for signs of lubricant incompatibility, such as extreme “soupiness” visible from the grease relief area. Failure to observe this precaution could result in damage to or destruction of the equipment. Table C Service Conditions Standard Conditions: Severe Conditions: Extreme Conditions: Eight hours per day; normal or light loading, clean, 40 degree C (100 degrees F) maximum ambient. Twenty-four hour per day operation or shock loading, vibration, or in dirt or dust at 40-50 degrees C (100-120 degrees F) ambient. Heavy shock or vibration, or dust. Table D Lubrication Frequency for Ball Bearings Speed 1800 RPM & slower 3600 RPM NEMA (IEC) Frame 182- 215 (112-132) 254-365 (160-200) 404-449 (225-280) All Condition Standard 3 Years 2 Years 1 Year 6 Months Severe 1 Year 6-12 Months 6 Months 3 Months Extreme 6 Months 3 Months 1-3 Months 1 Month Lubrication Frequency for Roller Bearings For Roller Bearings – divide the above times by 2. Table E Recommended Volume NEMA (IEC) Frame 182- 215 (112-132) 254-286 (160-180) 324-365 (200-225) 404-449 (250-280) Replacement Bearings Volume in Cubic Inches (cm3) 0.5 (8) 1.0 (16) 1.5 (24) 2.5 (40) Your maintenance program will not be complete without including spare bearings. It must be remembered 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 spare parts directly from Allen-Bradley. All bearings are subject to exact specifications and tests necessary to satisfy performance requirements. In this manner, it is possible to duplicate your present bearing. Markings on the bearing do not indicate complete specifications. 18 Standard Industrial AC Induction Motors Total Service Programs Allen-Bradley can provide a wide range of maintenance programs to help you reduce downtime, improve productivity and increase profits. Capabilities include: • Motor Start-up Service • Motor Electrical and Mechanical Preventive Maintenance • Vibration Analysis • Mobile Van Repair Service • Balancing and Alignment Service • Maintenance Service • 24-Hour Technical Support • Modernization Service For more information contact your local Allen-Bradley Sales Office. Renewal Parts Parts can be obtained from your nearest Allen-Bradley parts distributor, or directly from the factory. When ordering parts for which a part number is not available, give complete description of part and purchase order number, serial number, model number, etc., of the equipment on which the part is used. A detailed parts list, which gives recommendations for spare parts that should be stocked for your equipment, can also be ordered. Standard Industrial AC Induction Motors 19 Cross Sectional and Parts Identification Drawing Find No. 1 2 3 4 5 6 7 8 Part Description Frame Stator Rotor/internal Cooling Fan Backend Bracket Frontend Bracket Shaft Backend Ball Bearing Backend Inner Cap Find No. 9 10 11 12 13 14 15 16 Part Description Frontend Ball Bearing Frontend Inner Cap Wave Washer, Frontend Fan Cover Outer Cooling Fan Front End Bracket Bolts Fan Cover Bolts Eyebolt Find No. 17 18 19 20 21 22 23 24 Part Description Terminal Box Fan Clamp Grease Entry Condensation Drain Key Slinger Backend Cap Bolts Grease Drain NOTE: Bearings shown are regreasable type. Not all items shown may be present on motor. Not all items on motor may be shown on drawing. Drawing is for general reference purposes only. Online Documentation The latest motor information can be obtained from the Allen-Bradley Drives & Motors home page on the World Wide Web at: http://www.ab.com/drives/motors Publication 1329R-UM002A-EN-P Ð August, 2001 Supersedes 1329R-5.1 dated March, 1999 Copyright © 2001 Rockwell Automation. All rights reserved. Printed in USA. ">

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