BALDOR: Installation, Operation and Maintenance Manual

BALDOR: Installation, Operation and Maintenance Manual
Integral Horsepower
AC Induction Motors
ODP, WPI Enclosures
TENV, TEAO, TEFC Enclosure
Explosion Proof
Installation & Operating Manual
8/12
MN408
Any trademarks used in this manual are the property of their respective owners.
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Marking for IEC Certified Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair of Motors used in Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaker Duty Motors only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested bearing and winding RTD setting guidelines for Non−Hazardous Locations ONLY . . . . . . . . . . . .
MN408
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Table of Contents i
Section 1
General Information
ii Table of Contents
MN408
Section 1
General Information
Overview
Important:
This manual contains general procedures that apply to Baldor 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.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S
NEMA Publication MG-2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S
IEC 34−1 Electrical and IEC72−1 Mechanical specifications
S
ANSI C51.5, the National Electrical Code (NEC) and local codes and practices.
Limited Warranty
www.baldor.com/support/warranty_standard.asp
Safety Notice:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
MN408
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.
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.
Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
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.
Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
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.
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.
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.
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.
General Information 1−1
Section 1
General Information
Safety Notice Continued
WARNING:
Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
WARNING:
Pacemaker danger − Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING:
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.
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.
WARNING:
Motors that are to be used in flammable and/or explosive atmospheres must display the UL label
on the nameplate along with CSA listed logo. Specific service conditions for these motors are
defined in NFPA 70 (NEC) Article 500.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Caution:
To prevent premature equipment failure or damage, only qualified maintenance personnel should
perform maintenance.
Caution:
Do not over tension belts. Excess tension may damage the motor or driven equipment.
Caution:
Do not over−lubricate motor as this may cause premature bearing failure.
Caution:
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 (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution:
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:
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.
Caution:
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.
Caution:
The space heaters are designed to operate at or below the maximum surface temperature stated
on the nameplate. If the marked ambient and/or voltage are exceeded this maximum surface
temperature can be exceeded and can damage the motor windings. If applied in a division 2 or
zone 2 environment this excessive temperature may cause ignition of hazardous materials.
Caution:
Shaker Duty motors must be properly lubricated prior to Start Up to prevent damage.
See Section 3.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor distributor or an Authorized Baldor Service Center.
Receiving
Each Baldor Electric 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.
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.
Handling
The motor should be lifted using the lifting lugs or eye bolts provided.
Caution:
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 (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift
only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor.
1−2 General Information
MN408
Storage
2. 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.
3. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into
holes on top of the cooling hood. These lugs are to be used for hood removal only.
A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.
4. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc.,
it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling
around the mounting base. The entire assembly can be lifted as an assembly for installation.
Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to
lift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slings
or other means must be used to prevent tipping. In any event, the load must be secure before lifting.
If the load is unbalanced (as with couplings or additional attachments) additional slings or other
means must be used to prevent tipping. In any event, the load must be secure before lifting.
Storage requirements for motors and generators that will not be placed in service for at least six months
from date of shipment.
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does
not experience regular usage while being exposed to normally humid atmospheric conditions is likely to
develop rust in the bearings or rust particles from surrounding surfaces may contaminate the bearings.
The electrical insulation may absorb an excessive amount of moisture leading to the motor winding
failure.
A wooden crate “shell” should be constructed to secure the motor during storage. This is similar to an
export box but the sides & top must be secured to the wooden base with lag bolts (not nailed as export
boxes are) to allow opening and reclosing many times without damage to the “shell”.
Minimum resistance of motor winding insulation is 5 Meg ohms or the calculated minimum, which ever is
greater. Minimum resistance is calculated as follows: Rm = kV + 1
where: (Rm is minimum resistance to ground in Meg−Ohms and
kV is rated nameplate voltage defined as Kilo−Volts.)
Example: For a 480VAC rated motor Rm =1.48 meg−ohms (use 5 M).
For a 4160VAC rated motor Rm = 5.16 meg−ohms.
Preparation for Storage
1. 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. The brace must be
reinstalled to hold the shaft firmly in place against the bearing before the motor is moved.
2. Store in a clean, dry, protected warehouse where control is maintained as follows:
a. Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from
brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used.
b. Storage temperatures of 10C (50F) to 49C (120F) must be maintained.
c. Relative humidity must not exceed 60%.
d. Motor space heaters (when present) are to be connected and energized whenever there is a
possibility that the storage ambient conditions will reach the dew point. Space heaters are optional.
Note: Remove motor from containers when heaters are energized, reprotect if necessary.
3. Measure and record the resistance of the winding insulation (dielectric withstand) every 30 days of
storage.
a. If motor insulation resistance decreases below the minimum resistance, contact your Baldor
District office.
b. Place new desiccant inside the vapor bag and re−seal by taping it closed.
c. If a zipper−closing type bag is used instead of the heat−sealed type bag, zip the bag closed
instead of taping it. Be sure to place new desiccant inside bag after each monthly inspection.
d. Place the shell over the motor and secure with lag bolts.
4. Where motors are mounted to machinery, the mounting must be such that the drains and breathers
are fully operable and are at the lowest point of the motor. Vertical motors must be stored in the
vertical position. Storage environment must be maintained as stated in step 2.
MN408
General Information 1−3
5. Motors with anti−friction bearings are to be greased at the time of going into extended storage with
periodic service as follows:
a. Motors marked “Do Not Lubricate” on the nameplate do not need to be greased before or during
storage.
b. Ball and roller bearing (anti−friction) motor shafts are to be rotated manually every 3 months and
greased every 6 months in accordance with the Maintenance section of this manual.
c. Sleeve bearing (oil lube) motors are drained of oil prior to shipment.
The oil reservoirs must be refilled to the indicated level with the specified lubricant, (see
Maintenance). The shaft should be rotated monthly by hand at least 10 to 15 revolutions to
distribute oil to bearing surfaces.
d. “Provisions for oil mist lubrication” – These motors are packed with grease. Storage procedures
are the same as paragraph 5b.
e. “Oil Mist Lubricated” – These bearings are protected for temporary storage by a corrosion
inhibitor. If stored for greater than 3 months or outdoor storage is anticipated, connected to the oil
mist system while in storage. If this is not possible, add the amount of grease indicated under
“Standard Condition” in Section 3, then rotate the shaft 15 times by hand.
6. All breather drains are to be fully operable while in storage (drain plugs removed). The motors must
be stored so that the drain is at the lowest point. All breathers and automatic “T” drains must be
operable to allow breathing and draining at points other than through the bearings around the shaft.
Vertical motors should be stored in a safe stable vertical position.
7. Coat all external machined surfaces with a rust preventing material.
An acceptable product for this purpose is Exxon Rust Ban # 392.
8. Carbon brushes should be lifted and held in place in the holders, above the commutator, by the brush
holder fingers. The commutator should be wrapped with a suitable material such as cardboard paper
as a mechanical protection against damage.
Non−Regreaseable Motors
Non−regreasable motors with “Do Not Lubricate” on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types
Before storage, the following procedure must be performed.
1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket
prior to lubricating the motor.
2. The motor with regreasable bearing must be greased as instructed in Section 3 of this manual.
3. Replace the grease drain plug after greasing.
4. The motor shaft must be rotated a minimum of 15 times after greasing.
5. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months (see Section 3) to each bearing.
6. Bearings are to be greased at the time of removal from storage.
Removal From Storage
1. Remove all packing material.
2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into
service. If resistance is low, contact your Baldor District office.
3. Regrease the bearings as instructed in Section 3 of this manual.
4. Reinstall the original shipping brace if motor is to be moved. This will hold the shaft firmly against the
bearing and prevent damage during movement.
1−4 General Information
MN408
Equipment Marking for IEC Certified Product
IEC certified products have special markings that identify the protection concept and environment
requirements. An example is shown in Figure 3-1.
Figure 3-1 IEC Certified Product Markings
Temperature Class
Gas Group (IIC)
Ex Protection Concept (ExnA)
Ambient Range
ExnA MOTOR
ATEX Specific
Marking of
Explosion Protection
ExnA IIC
Gc Tamb
C to
MFG. BY BALDOR ELECTRIC FORT SMITH, AR 72901
ATEX Equipment Group and Category (II3)
Type of Atmosphere: G-Gas, D-Dust (G)
C
II 3 G IP______
Sira__________________
IECEx__________________
USA
European Conformity Mark
Place of Manufacture
Specific Conditions of Use:
If the motor certificate number is followed by the symbol “X”, this indicates that the motor has specific
conditions of use which are indicated on the certificate. It is necessary to review the product certification
certificate in conjunction with this instruction manual.
Operation On Frequency Converters:
If the motor is evaluated for operation with an adjustable speed drive, the type of converter (for example
PWM for Pulse Width Modulated) and safe speed ranges (for example 0−120Hz) will be specified in the
certification documents or on motor nameplates. It is necessary to consult the adjustable speed drive
manual for proper set up. IECEx Certificates are available online at www.iecex.com
MN408
General Information 1−5
1−6 General Information
MN408
Section 2
Installation & Operation
Overview
Location
Mounting
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, 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.
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.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.
1. Open Drip−Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry,
well ventilated and non−corrosive.
2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in
outdoor locations.
Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with high
corrosion or excessive moisture conditions. These motors should not be placed into an environment
where there is the presence of flammable or combustible vapors, dust or any combustible material, unless
specifically designed for this type of service.
IEEE841 motors are suitable for application in Class I Division 2 and Class I Zone 2 areas on sine wave
power in accordance with the applicable codes and standards.
Hazardous Locations are those where there is a risk of ignition or explosion due to the presence of
combustible gases, vapors, dust, fibers, or flyings. Facilities requiring special equipment for hazardous
locations are typically classified in accordance with local requirements. In the US market, guidance is
provided by the National Electric Code.
EMC Compliance Statement for European Union
The motors described in this instruction manual are designed to comply 2004/108/EC . These motors are
commercial in design and not intended for residential use.
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:
Table 2−1 Enclosure Clearance
TEFC / TENV ( IC0141 ) Enclosures
Fan Cover Air Intake
180 − 210T Frame 1  25mm)
Fan Cover Air Intake
250 − 449T Frame 4  100mm)
IEC 112 − 132 1  25mm)
IEC 160 − 280 4  100mm)
Exhaust
Envelope equal to the P Dimension on the motor
dimension sheet
OPEN/Protected Enclosures
Bracket Intake
Same as TEFC
Frame Exhaust
Exhaust out the sides envelope
A minimum of the P dimension plus 2 (50mm)
Exhaust out the end same as intake.
The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may
cause vibration, misalignment and bearing damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
When installation is complete and accurate alignment of the motor and load is accomplished, the base
should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center
for further information.
MN408
Installation & Operation 2−1
Frame Mounting Holes
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 2-2 indicates the proper mounting holes to use.
Figure 2-2 6 & 8 Hole Motor Frame Mounting
For short frame designations 182, 213,
254, 284, 324, 364, 404, 444 (NEMA)
Top View
Allows F-1 to F-2 Conversion on 8 hole
frames.
Not present on 6 hole frames.
Not used on 8 hole frames.
Shaft
For long frame designations 184, 215,
256, 286, 326, 365, 405, 445 (NEMA)
(IEC) 112M, 132M, 160L, 200L, 225M,
250M, 280M
Caution:
Alignment
Caution:
Always use these holes, closer to the
shaft 112S, 132S, 160M, 180M,
200M, 225S, 250S, 280S, (IEC)
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 (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
In the case of assemblies on a common base, any lifting means provided on the motor should not be
used to lift the assembly and base but, rather, the assembly should be lifted by a sling around the base or
by other lifting means provided on the base. Assure lifting in the direction intended in the design of the
lifting means. Likewise, precautions should be taken to prevent hazardous overloads due to deceleration,
acceleration or shock forces.
Accurate alignment of the motor with the driven equipment is extremely important. The pulley, sprocket,
or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible. It is
recommended to heat the pulley, sprocket, or gear before installing on the motor shaft. Forcibly driving a
unit on the motor shaft will damage the bearings.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for
more information. Mechanical vibration and roughness during operation may indicate poor alignment.
Use dial indicators to check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
2. End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The standard
motor bearings are not designed for excessive external axial thrust loads. Improper adjustment will
cause failure.
3. Pulley Ratio
The best practice is to not exceed an 8:1 pulley ratio.
Do not over tension belts. Excess tension may damage the motor or driven equipment.
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt
tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage
may occur during starting.
2−2 Installation & Operation
MN408
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.
(BaldorSReliance motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite 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.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Guarding Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key
ways or set screws. Some satisfactory methods of guarding are:
1. Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate
guarding during normal service.
Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding should
conform to the National Electrical Code and local codes and practices.
For ExnA hazardous location motors, it is a specific condition of use that all terminations in a conduit box
be fully insulated. Fully insulated and lugged terminations must be bolted and provided with lock washer
to prevent rotation. Flying leads must be insulated with two full wraps of electrical grade insulating tape or
heat shrink tubing.
Grounding In the USA consult the National Electrical Code, Article 430 for information on grounding of motors and
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 non−USA locations
consult the appropriate national or local code applicable.
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 over current 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.
Select a motor starter and over current 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.
For motors installed in compliance with IEC requirements, the following minimum cross sectional area of
the protective conductors should be used:
Cross­sectional area of phase
conductors, S
mm2
S< 16
16 < S 35
S>35
Minimum cross­sectional area of the corresponding
protective conductor, Sp
mm2
S
16
0,5 S
Equipotential bonding connection shall made using a conductor with a cross-sectional area of
at least 4 mm2.
MN408
Installation & Operation 2−3
Conduit Box For ease of making connections, an oversize conduit box is provided. Most conduit boxes can be
rotated 360 in 90 increments. Auxiliary conduit boxes are provided on some motors for accessories
such as space heaters, RTD’s etc.
AC Power
Motors with flying lead construction must be properly terminated and insulated.
Connect the motor leads as shown on the connection diagram located on the name plate or inside the
cover on the conduit box. Be sure the following guidelines are met:
1. AC power is within 10% of rated voltage with rated frequency. (See motor name plate for ratings).
OR
2. AC power is within 5% of rated frequency with rated voltage.
OR
3. A combined variation in voltage and frequency of 10% (sum of absolute values) of rated values,
provided the frequency variation does not exceed 5% of rated frequency.
Performance within these voltage and frequency variations are shown in Figure 2-4.
Figure 2-3 Accessory Connections
One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).
TD1
TD2
Three thermistors are installed in windings and tied in series.
Leads are labeled TD1 & TD2.
Winding RTDs are installed in windings (2) per phase.
Each set of leads is labeled 1TD1, 1TD2, 1TD3, 2TD1, 2TD2, 2TD3 etc.
* One bearing RTD is installed in Drive endplate (PUEP), leads
are labeled RTDDE.
* One bearing RTD is installed in Opposite Drive endplate (FREP), leads
are labeled RTDODE.
* Note RTD may have 2−Red/1−White leads; or 2−White/1−Red Lead.
Rotation
All three phase motors are reversible. To reverse the direction of rotation, disconnect and lock out power
and interchange any two of the three line leads for three phase motors. For single phase motors, check
the connection diagram to determine if the motor is reversible and follow the connection instructions for
lead numbers to be interchanged. Not all single phase motors are reversible.
Adjustable Frequency Power Inverters used to supply adjustable frequency power to induction motors
produce wave forms with lower order harmonics with voltage spikes superimposed. Turn−to−turn,
phase−to−phase, and ground insulation of stator windings are subject to the resulting dielectric stresses.
Suitable precautions should be taken in the design of these drive systems to minimize the magnitude of
these voltage spikes. Consult the drive instructions for maximum acceptable motor lead lengths, and
proper grounding.
2−4 Installation & Operation
MN408
Caution:
Note: Main power leads for CE Marked Motors may be marked U,V,W – for standard configurations,
please consult connection diagrams.
The space heaters are designed to operate at or below the maximum surface temperature stated
on the nameplate. If the marked ambient and/or voltage are exceeded this maximum surface
temperature can be exceeded and can damage the motor windings. If applied in a division 2 or
zone 2 environment this excessive temperature may cause ignition of hazardous materials.
Connection Diagrams
MN408
Installation & Operation 2−5
Connection Diagrams Continued
2−6 Installation & Operation
MN408
+20
Changes in Motor Performance (%)
+15
Figure 2-4 Typical Motor Performance VS Voltage Variations
Maximum
Torque
Full -Load
Current
+10
+5
Full -Load
Current
Power
Factor
0
−5
Efficiency
Efficiency
−10
−15
−20
Power
Factor
Maximum
Torque
−15
−10
−5
0
+5
+10
+15
Voltage Variations (%)
Initial Lubrication BaldorSReliance 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. When motors are equipped for oil mist
lubrication refer to the instruction manual for installation, operation, and maintenance of oil mist lubrication
systems.
Caution:
Shaker Duty motors must be properly lubricated prior to Start Up to prevent damage.
See Section 3.
First Time Start Up 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. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc.
2. If motor has been in storage or idle for some time, check winding insulation integrity.
3. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical
continuity.
4. Be sure all shipping materials and braces (if used) are removed from motor shaft.
5. Manually rotate the motor shaft to ensure that it rotates freely.
6. Replace all panels and covers that were removed during installation.
7. Momentarily apply power and check the direction of rotation of the motor shaft.
8. If motor rotation is wrong, be sure power is off and change the motor lead connections.
Verify rotation direction before you continue.
9. Start the motor and ensure operation is smooth without excessive vibration or noise.
If so, run the motor for 1 hour with no load connected.
10. After 1 hour of operation, disconnect power and connect the load to the motor shaft.
Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.
11. 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.
MN408
Installation & Operation 2−7
This procedure assumes a coupled start up. Also, that the first time start up procedure was successful.
Check the coupling and ensure that all guards and protective devices are installed.
Check that the coupling is properly aligned and not binding.
The first coupled start up should be with no load. Apply power and verify that the load is not
transmitting excessive vibration back to the motor though the coupling or the foundation. Vibration
should be at an acceptable level.
4. Run for approximately 1 hour with the driven equipment in an unloaded condition.
The equipment can now be loaded and operated within specified limits. Do not exceed the name plate
ratings for amperes for steady continuous loads.
Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or jog than by the
same motor under full load. If it is necessary to repeatedly start or jog the motor, it is advisable to check
the application with your local Baldor distributor or Baldor Service Center.
Heating - Duty rating and maximum ambient temperature are stated on the motor name plate.
Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor
distributor or Baldor Service Center.
Coupled Start Up
1.
2.
3.
Hazardous Locations
Hazardous locations are those where there is a risk of ignition or explosion due to the presence of
combustible gases, vapors, dust, fibers or flyings.
Selection Facilities requiring special equipment for hazardous locations are typically classified in accordance with
local requirements. In the US market, guidance is provided by the National Electric Code. In
international hazardous location areas, guidance for gas / vapor / mist classification is given in
IEC60079−14, or for dust in IEC61241−14. This classification process lets the installer know what
equipment is suitable for installation in that environment, and identifies what the maximum safe
temperature or temperature class is required. It is the customer or users responsibility to determine the
area classification and select proper equipment.
Areas are classified with respect to risk and exposure to the hazard. In the US market, areas are
typically classified as follows Class, Division, Group and Temperature Class. In some newer installations
in the US and in most international markets, areas are classified in Zones.
Protection Concepts
Class I Division 1 / Zone 1 [Equipment Group I (mining) or II (surface), Equipment Protection Level
(EPL) Gb, Mb ]
Baldor offers a range of motors suitable for installation in a Division 1 or Zone 1 environment. These
motors are known as explosion proof or flameproof.
Motors that are explosion proof or flameproof use specially machined flameproof joints between the end
bell or bracket and the frame, as well as along the rotating shaft and at connection box covers and
entries. The fit of these flameproof joints are designed to contain the combustion or quench the flame of
an explosive gas atmosphere prior to it exiting the motor. These flameproof joints have lengths and
widths selected and tested based on the gas group present in the atmosphere. BaldorSReliance motors
are typically designed to meet Class I (Division 1) Group C and D (explosion proof) or Ex d IIB
(flameproof).
An application note regarding equipment applied in accordance with the US National Electric Code (NFPA
70−2008) − according to Article 500.8(C) Marking, sub clause (2) in the fine print note, it is noted that
Equipment not marked to indicate a division is suitable for both Division 1 and Division 2 locations. These
motors are not gas tight. To the contrary, this protection concept assumes that due to the normal heating
and cooling cycle of motor operation that any gas present will be drawn into the motor. Since flameproof
or explosion proof motors are designed to contain the combustion and extinguish any flame transmission,
for this protection concept, only external surface temperatures are of concern. Thermal limiting devices
such as thermostats, thermistors or RTDs may be provided on these motors to limit the external surface
temperature during overload conditions.
If thermostats are provided as a condition of certification, it is the installer’s responsibility to make sure
that these devices are properly connected to a suitable switching device. The ATEX directive requires
that motor shutdown on thermal trip be accomplished without an intermediate software command. Where
intermediate circuitry is involved the circuit shall fall within the scope of a safety, controlling and regulating
device as defined in article 1(2) of European Directive 94/9/EC, and shall be covered by an appropriate
EC Type Examination Certificate.
2−8 Installation & Operation
MN408
Flameproof motors, internationally referred to as Ex d use a protection concept similar to that used in
Class I Division 1 motors, with minor differences in the flameproof joints and cable entry designs.
Flameproof and explosion proof motors are both type tested. Representative motors are connected to a
reference gas and ignited in laboratory conditions to verify that the flame is not transmitted outside the
motor enclosure and to determine the maximum internal pressure encountered.
Explosion proof and Flame proof motors shipped without a conduit box require use of a certified box of
suitable dimensions and that is appropriate for the classification. Openings in connection boxes must be
closed with suitably certified and dimensioned device.
Class I Division 2 / Zone 2 Ex nA, [Equipment Protection Level (EPL) Gc ]
This protection concept relies on having no sources of ignition present such as arcing parts or hot
surfaces. For this protection concept, internal temperatures as well as external temperatures are
considered. In many cases, the internal temperatures are higher than the external temperatures and
therefore become the limiting factor in determination of temperature code designation. In these
applications, it is very important to use a motor that has been evaluated thermally for use with an inverter
or converter, if variable speed operation is desired. Thermostats used for Class I Division 2 and Ex nA
motors are used to protect the motor only. For motors using flying lead construction, it is important to use
connection lugs and insulate with heat shrink tubing or a double wrap of insulation grade electrical tape to
avoid the risk of spark or ignition.
Class II Division 1 / Zone 21 [Equipment Group III, Equipment Protection Level (EPL) Db ]
This area classification is one where the risk of ignitable concentrations of dust is present at all or some of
the time. The protection concepts used for Class II Division 1 is similar to flamepath, except with
additional dust exclusion paths designed for the rotating shaft. In the international designations, this
concept is referred to as dust ignition proof or Ex tD. External surface temperature remains the limiting
factor. Thermal limiting devices such as thermostats, thermistors or RTDs may be provided on these
motors to limit the external surface temperature during overload conditions. If thermostats are provided
as a condition of certification, it is the installer’s responsibility to make sure that these devices are
properly connected to a suitable switching device.
Note: In the North American area classification system, Class III exists for fibers and flyings.
In the IEC designation, both dusts and flyings are absorbed into Group III.
Class II Division 2 / Zone 22 [Equipment Group III, Equipment Protection Level (EPL) Dc ]
This area classification is one where the risk of exposure to ignitable concentrations of dust are not likely
to occur under normal operating conditions and relies heavily on the housekeeping practices within the
installation.
Sine Wave Power Operation for Division 1 or 2 and Zone 1 or 2 and Zone 21 or 22 Hazardous
Location.
These motors are designed to operate at or below the maximum surface temperature (or T−Code) stated
on the nameplate. Failure to operate the motor properly can cause this maximum surface temperature to
be exceeded. If applied in a Division 1 or 2 / Zone 1 or 2 and Zone 21 or 22 environment, this excessive
temperature may cause ignition of hazardous materials. Operating the motor at any of the following
conditions can cause the marked surface temperature to be exceeded.
1. Motor load exceeding service factor nameplate value
2. Ambient temperatures above nameplate value
3. Voltages above or below nameplate value
4. Unbalanced voltages
5. Loss of proper ventilation
6. Altitude above 3300 feet / 1000 meters
7. Severe duty cycles of repeated starts
8. Motor stall
9. Motor reversing
10. Single phase operation of polyphase equipment
11. Variable frequency operation
Variable Frequency Power Operation for Division 1 or 2 and Zone 1 or 2 and Zone 21 or 22
Hazardous Location (motors with maximum surface temperature listed on the nameplate).
Only motors with nameplates marked for use on inverter (variable frequency) power, and labeled for
specific hazardous areas may be used in those hazardous areas on inverter power. The motor is
designed to operate at or below the maximum surface temperature (or T−Code) stated on the nameplate.
Failure to operate the motor properly can cause this maximum surface temperature to be exceeded.
MN408
Installation & Operation 2−9
If applied in a Division 1 or 2 / Zone 1 or 2 and Zone 21 or 22 environment, this excessive temperature
may cause ignition of hazardous materials. Operating the motor at any of the following conditions can
cause the marked surface temperature to be exceeded.
1. Motor load exceeding service factor nameplate value
2. Ambient temperature above nameplate value
3. Voltage (at each operating frequency) above or below rated nameplate value
4. Unbalanced voltages
5. Loss of proper ventilation
6. Operation outside of the nameplate speed / frequency range
7. Altitudes above 3300 feet / 1000 meters
8. Single phase operation of polyphase equipment
9. Unstable current wave forms
10. Lower than name plate minimum carrier frequency
Thermal Limiting
Thermal limiting devices are temperature sensing control components installed inside the motor to limit
the internal temperature of the motor frame by interrupting the circuit of the holding coil of the magnetic
switch or contactor. They are required for most Division 1 and Zone 1 applications. For Division 2 or
Zone 2 applications, motors should be selected that preclude running temperatures from exceeding the
ignition temperatures for the designated hazardous material. In Division 2 or Zone 2 classified locations,
thermal limiting devices should only be used for winding protection and not considered for limiting all
internal motor temperatures to specific ignition temperatures.
Equipotential Bonding and Shaft Current Reduction
Larger motors (ie WP construction) may require proper bonding between motor enclosures and covers to
avoid the risk of stray currents during start up. Fastening methods and bonding straps must not be modified.
Bearing currents can exist in some motors for both line−fed and inverter−fed applications. Larger line−fed
motors may require at least one insulated bearing to prevent a flow of current through the bearings. Do not
defeat such insulation whether the motor is line−fed or inverter−fed applications. Inverter−fed motors may
require additional bearing insulation or even a shaft brush. Do not defeat such features. When the motor and
the coupled load are not on a common conductive baseplate, it may also be necessary to electrically bond
together the stationary parts of the motor and the coupled equipment.
Repair of Motors used in Hazardous Locations
Repair of hazardous certified motors requires additional information, skill, and care. It is the customer’s
responsibility to select service shops with proper qualifications to repair hazardous location motors.
Contact the manufacture for additional repair details. Use only original manufacturer’s parts.
Repair of Explosion Proof or Flame Proof Motors Class I Division 1 and Zone 1
In the North American market, recertification programs are offered by Underwriters Laboratories and
Canadian Standards Association which allow authorized service shops to mark the rebuilt motors as
certified. In the international markets using IEC based requirements, repair should be undertaken only
after consulting IEC60079−19 Explosive Atmospheres−Part 19 Equipment repair, overhaul and
reclamation. If use of a certified repair facility is desired, consult the IECEX Repair Scheme at
http://www.iecex.com/service_facilities.htm
Explosion proof and flameproof motors achieve their safety based on the mechanical construction −
flameproof joints and bearing clearance, and the electrical design including any thermal limiting devices. If
it is necessary to repair a flameproof or explosion proof motor, it is critical that the mechanical flameproof
joints be maintained. Consult Baldor Electric Company for flameproof joint construction details. Use only
BaldorSReliance supplied parts. Baldor does not recommend reclamation of parts. Since this protection
method also relies on temperature being maintained, make sure that any rewinding uses the original
electrical designs, including any thermal protection that may be present.
Repair of Dust Ignition Proof Motors − Class II Division 1 and 2, Zone 21 and 22.
For Dust Ignition Proof, proper sealing is required. Do not modify the motor construction to add any
additional opening, and ensure that proper sealing is maintained in the connection box and at the shaft
seal. Since this protection method also relies on temperature being maintained, make sure that any
rewinding uses the original electrical designs, including any thermal protection that may be present
Repair of Class I Division 2 and Zone 2 motors
For Division 2 and Zone 2, the internal and external temperatures are of concern. Since this protection
method also relies on temperature being maintained, make sure that any rewinding uses the original
electrical designs, including any thermal protection that may be present. Use only Baldor replacement
thermostats, if provided.
2−10 Installation & Operation
MN408
Section 3
Maintenance & Troubleshooting
WARNING:
UL and EX Listed motors must only be serviced by UL or EX Approved Authorized Baldor Service
Centers if these motors are to be returned to a hazardous and/or explosive atmosphere.
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3
months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following
steps should be performed at each inspection:
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.
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil,
grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor
ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor
failure.
2. Perform a dielectric with stand test periodically to ensure that the integrity of the winding insulation
has been maintained. Record the readings. Immediately investigate any significant decrease in
insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings
Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating
ability of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed
at which the bearing operates and the severity of the operating conditions. Good results can be obtained
if the following recommendations are used in your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Baldor motors are pregreased,
normally with Polyrex EM (Exxon Mobil) or as stated on the nameplate.
Do not mix greases unless compatibility has been checked and verified.
MN408
Maintenance & Troubleshooting 3−1
Relubrication Intervals Recommended relubrication intervals are shown in Table 3-2. It is important to realize that
the recommended intervals of Table 3-2 are based on average use.
Refer to additional information contained in Tables 3-3, 3-4 and 3-5.
Table 3-2 Relubrication Intervals *
NEMA / (IEC) Frame Size
Up to 210 incl. (132)
Over 210 to 280 incl. (180)
Over 280 to 360 incl. (225)
Over 360 to 449 incl. (315)
10000
**
6000
2700 Hrs.
**
**
**
Rated Speed - RPM
3600
1800
5500 Hrs.
12000 Hrs.
3600 Hrs.
9500 Hrs.
* 2200 Hrs. 7400 Hrs.
*2200 Hrs.
3500 Hrs.
1200
18000 Hrs.
15000 Hrs.
12000 Hrs.
7400 Hrs.
900
22000 Hrs.
18000 Hrs.
15000 Hrs.
10500 Hrs.
*
Relubrication intervals are for ball bearings.
For vertically mounted motors and roller bearings, divide the relubrication interval by 2.
**
For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.
Table 3-3 Service Conditions
Severity of Service
Standard
Severe
Extreme
Hours per day
of Operation
8
16 Plus
16 Plus
Low Temperature
Ambient Temperature
Maximum
40 C
50 C
>50 C* or
Class H Insulation
<−29 C **
Atmospheric
Contamination
Clean, Little Corrosion
Moderate dirt, Corrosion
Severe dirt, Abrasive dust, Corrosion, Heavy
Shock or Vibration
*
Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does
not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.
**
Special low temperature grease is recommended (Aeroshell 7).
Table 3-4 Relubrication Interval Multiplier
Severity of Service
Standard
Severe
Extreme
Low Temperature
Multiplier
1.0
0.5
0.1
1.0
Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate.
In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use the
appropriate amount of grease for each bearing size (not the same for both).
3−2 Maintenance & Troubleshooting
MN408
Table 3-5 Bearings Sizes and Types
Frame Size
NEMA (IEC)
56 to 140 (90)
140 (90)
180 (100−112)
210 (132)
250 (160)
280 (180)
320 (200)
360 (225)
400 (250)
440 (280)
440 (280)
5000 to 5800 (315−355)
5000 to 5800 (315−355)
360 to 449 (225−280)
AC Induction Servo
76 Frame 180 (112)
77 Frame 210 (132)
80 Frame 250(160)
*
Bearing Description
(These are the “Large” bearings (Shaft End) in each frame size)
Volume of grease
Weight of Grease to
to be added
Bearing
add *
in3
teaspoon
oz (Grams)
6203
0.08 (2.4)
0.15
0.5
6205
0.15 (3.9)
0.2
0.8
6206
0.19 (5.0)
0.3
1.0
6307
0.30 (8.4)
0.6
2.0
6309
0.47 (12.5)
0.7
2.5
6311
0.61 (17)
1.2
3.9
6312
0.76 (20.1)
1.2
4.0
6313
0.81 (23)
1.5
5.2
6316
1.25 (33)
2.0
6.6
6318
1.52(40)
2.5
8.2
6319
2.12 (60)
4.1
13.4
6328
4.70 (130)
9.2
30.0
NU328
4.70 (130)
9.2
30.0
NU319
2.12 (60)
4.1
13.4
6207
6210
6213
0.22 (6.1)
0.32 (9.0)
0.49 (14.0)
0.44
0.64
0.99
1.4
2.1
3.3
Weight in grams = .005 DB of grease to be added
Note: Not all bearing sizes are listed.
For intermediate bearing sizes, use the grease volume for the next larger size bearing.
Caution: 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 Service Center for
additional information.
Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already
in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the
recommended type is to be used.
Caution: Do not over−lubricate motor as this may cause premature bearing failure.
Caution:
With Grease Outlet Plug
1. With the motor stopped, clean all grease fittings with a clean cloth.
2. Remove grease outlet plug.
Over−lubricating can cause excessive bearing temperatures, premature lubrication breakdown
and bearing failure.
3. Add the recommended amount of grease.
4. Operate the motor for 15 minutes with grease plug removed.
This allows excess grease to purge.
5. Re-install grease outlet plug.
Without Grease Provisions
Note: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL/CSA
listed explosion proof motor to maintain it’s UL/CSA listing.
1. Disassemble the motor.
2. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3
full of grease and outboard bearing cavity should be about 1/2 full of grease.)
3. Assemble the motor.
MN408
Maintenance & Troubleshooting 3−3
Sample Relubrication Determination
Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of
43 C and the atmosphere is moderately corrosive.
1. Table 3-2 list 9500 hours for standard conditions.
2. Table 3-3 classifies severity of service as “Severe”.
3. Table 3-5 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.
Shaker Duty Motors only
Caution:
Shaker Duty motors must be properly lubricated prior to Start Up to prevent damage.
See Table 3-6.
Lubrication should be performed before Start Up and at regular maintenance intervals. Follow these
recommendations to ensure proper lubrication.
Recommended Lubricant
For ambient temperatures between −15F to 120F the following lubricants are recommended:
Mobil PolyrexEM, Texaco Premium RB, Exxon Unirex N−2.
Do not mix greases unless compatibility has been checked and verified.
NEMA Frame Size
184TY
215TY
256TY
286TY
Table 3-6 Lubrication Volume
Volume in Cubic Inches
Normal Duty
Severe Duty
Start Up
Relub
Start Up
Relub
1.4
0.5
1.4
0.5
1.6
0.5
1.6
0.5
7
1
9
1
Extreme Duty
Start Up
Relub
2.7
0.5
4.5
1
11
2
15
3
Lubrication Frequency
Normal Duty 8 hours per day (16 hours per day in a clean environment). Lubricate every 2 months.
Severe Duty 16 hours per day or more in a dirty environment (corrosive atmosphere, chemical fumes,
acids, alkalies or extreme high humidity). Lubricate every month or 700 hours of operation.
Extreme Duty operation in extremely dirty or dusty environments and high ambient temperatures
exceeding 104F (40C). Lubricate twice a month or 350 hours of operation.
Lubrication Procedure
1.
2.
3.
4.
5.
Locate the grease inlet and outlet. Clean the areas.
Remove the plug(s) and install a grease fitting in the inlet if grease fitting is not already installed.
Add the recommended amount of lubricant.
Run the motor for two hours with the outlet plug removed.
Install outlet plug.
Note: To loosen hardened grease it may be necessary to insert a rod or wire into the grease inlet and
outlet holes.
3−4 Maintenance & Troubleshooting
MN408
Section 1
General Information
Table 3-7 Troubleshooting Chart
Symptom
Motor will not start
Excessive humming
Motor Over Heating
Possible Causes
Usually caused by line trouble, such
as, single phasing at the starter.
High Voltage.
Eccentric air gap.
Overload. Compare actual amps
(measured) with nameplate rating.
Single Phasing.
Improper ventilation.
Unbalanced voltage.
Rotor rubbing on stator.
Over voltage or under voltage.
Open stator winding.
Grounded winding.
Improper connections.
Bearing Over Heating
Misalignment.
Excessive belt tension.
Excessive end thrust.
Excessive grease in bearing.
Insufficient grease in bearing.
Dirt in bearing.
Vibration
Misalignment.
Rubbing between rotating parts and
stationary parts.
Rotor out of balance.
Resonance.
Noise
Growling or whining
MN408
Foreign material in air gap or
ventilation openings.
Bad bearing.
Possible Solutions
Check source of power. Check overloads, fuses,
controls, etc.
Check input line connections.
Have motor serviced at local Baldor service center.
Locate and remove source of excessive friction in
motor or load.
Reduce load or replace with motor of greater capacity.
Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build-up on motor. Clean motor.
Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Check air gap clearance and bearings.
Tighten “Thru Bolts”.
Check input voltage at each phase to motor.
Check stator resistance at all three phases for
balance.
Perform dielectric test and repair as required.
Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Check and align motor and driven equipment.
Reduce belt tension to proper point for load.
Reduce the end thrust from driven machine.
Remove grease until cavity is approximately 3/4 filled.
Add grease until cavity is approximately 3/4 filled.
Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Check and align motor and driven equipment.
Isolate and eliminate cause of rubbing.
Have rotor balance checked are repaired at your
Baldor Service Center.
Tune system or contact your Baldor Service Center
for assistance.
Remove rotor and foreign material. Reinstall rotor.
Check insulation integrity. Clean ventilation openings.
Replace bearing. Clean all grease from cavity and
new bearing. Repack with correct grease until cavity
is approximately 3/4 filled.
Maintenance & Troubleshooting 3−5
Suggested bearing and winding RTD setting guidelines for Non−Hazardous Locations ONLY
Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B
(80C) temperature rise at rated load and are built with a Class H 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. Some motors with 1.0 service factor have Class F temperature rise.
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 contact with the outer race on ball
or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs − Temperature Limit In 5C (405C Maximum Ambient)
Class B Temp Rise 3 80C
(Typical Design)
Alarm
Trip
130
140
140
150
Motor Load
3 Rated Load
Rated Load
to 1.15 S.F.
Class F Temp Rise 3 105C
Alarm
155
160
Trip
165
165
Class H Temp Rise 3 125C
Alarm
175
180
Trip
185
185
Note: S Winding RTDs are factory production installed, not from Mod−Express.
S When Class H temperatures are used, consider bearing temperatures and relubrication requirements.
Bearing RTDs − Temperature Limit In 5C (405C Maximum Ambient)
Anti−Friction
Sleeve
Alarm
Trip
Alarm
Trip
95
100
85
95
110
115
105
110
Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise.
** High temperature lubricants include some special synthetic oils and greases.
Greases that may be substituted that are compatible with Polyrex EM (but considered as “standard” lubricants)
include the following:
− Texaco Polystar
− Rykon Premium #2
− Chevron SRI #2
− Mobilith SHC−100
− Pennzoil Pennzlube EM−2
− Chevron Black Pearl
− Darmex 707
− Darmex 711
− Petro−Canada Peerless LLG
Bearing Type
Oil or Grease
Standard*
High Temperature**
See the motor nameplate for replacement grease or oil recommendation.
Contact Baldor application engineering for special lubricants or further clarifications.
3−6 Maintenance & Troubleshooting
MN408
Baldor District Offices
BALDOR ELECTRIC COMPANY
World Headquarters
P.O. Box 2400 Fort Smith, AR 72901−2400
(479) 646−4711 Fax (479) 648−5792
www.baldor.com
 2009 Baldor Electric Company
MN408
All rights reserved. Printed in USA
8/12
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