Beruflich Dokumente
Kultur Dokumente
AMA 400-500
______________________________
Factory order no
______________________________
This manual has been checked. However, if any errors are found, we ask the user to notify us as
soon as possible.
The specified data is only a description of this product and should not be interpreted as binding
characteristics. In the interest of our customers we continually improve our product to the latest
technical development. Deviations between products and product descriptions or these operating
instructions can, therefore, occur.
We reserve all rights in this manual and in the information contained therein. Reproduction, use or
disclosure to third parties without express authority is strictly forbidden.
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INSTALLATION .........................................................................................................................18
4.1 General............................................................................................................................18
4.2 Preparations for installation of feet mounted machines ..................................................18
4.3 Anchorage to the foundation ...........................................................................................18
4.3.1 Grouting holes and machine supports ................................................................18
4.3.2 Shims and foundation studs ...............................................................................18
4.3.3 Erection onto the foundation...............................................................................19
4.3.4 Grouting ..............................................................................................................19
4.3.5 Final installation ..................................................................................................19
4.4 Alignment.........................................................................................................................19
4.4.1 Correction for thermal growth .............................................................................19
4.4.2 Levelling and adjusting equipment ........................................................................20
4.4.3 Rough levelling of the machine after erection.....................................................20
4.4.4 Rough axial alignment ........................................................................................20
4.4.5 Alignment check .................................................................................................21
4.4.6 Final inspection...................................................................................................21
4.4.7 Final installation ..................................................................................................22
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4.5
4.6
4.7
4.8
COMMISSIONING .................................................................................................................... 24
5.1 Earth connection............................................................................................................. 24
5.2 Insulation resistance ....................................................................................................... 24
5.2.1 Checking the insulation resistance ....................................................................... 24
5.2.2 Measuring value................................................................................................. 25
5.3 Drying the windings......................................................................................................... 25
5.4 Protections...................................................................................................................... 25
5.5 Alarm and trip limits of the control equipment ................................................................ 25
5.5.1 Winding.............................................................................................................. 25
5.5.2 Bearings............................................................................................................. 26
5.6 Mechanical connections ................................................................................................. 26
5.7 Electrical connection....................................................................................................... 26
5.7.1 EMC requirements ............................................................................................. 27
5.7.2 Main terminal box............................................................................................... 27
5.7.3 Standard auxiliary terminal boxes...................................................................... 28
5.7.4 Connection of the external blower motors ......................................................... 28
5.8 Direction of rotation......................................................................................................... 29
5.9 Balancing of the rotor and the coupling .......................................................................... 29
5.9.1 Preliminary inspection........................................................................................ 29
5.9.2 Fitting instructions .............................................................................................. 29
5.9.3 Locking on vertical machines............................................................................. 29
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9.4
11
TROUBLE-SHOOTING GUIDE.................................................................................................60
11.1 General............................................................................................................................60
11.2 Electrical problem ............................................................................................................60
11.3 Bearing problem ..............................................................................................................60
11.3.1 Detection and identification of failures ................................................................60
11.3.2 How to detect the beginning of failures...............................................................60
11.3.3 Methods of failure identification ..........................................................................62
12
SPARE PARTS..........................................................................................................................63
13
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Machine information
Checking systems
Appendices
Weight of machine
Instrumentation
Load on foundation
Mounting dimensions
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=
=
drive end
non-drive end
(opposite drive end)
Fig. 3.
1
3
5
7
9
11
13
15
17
19
Serial number
Duty
Type of connection
Machine weight in kg
Type of cooling
D-end bearing type
Stator voltage
Rotating speed
Power factor (cos)
Direction of rotation
2
4
6
8
10
12
14
16
18
Year of manufacture
Type designation
Insulation class
Degree of protection
Mounting arrangement
Output in kW
Frequency
Stator current
N-end bearing type
only if bidirectional
Fig. 1.
IM 1001
horizontal foot mounting
mounting
Fig. 2.
Machine ends.
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IM 4011
vertical flange
Fig. 4.
Mounting arrangements.
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Fig. 5.
Fig. 6.
machine
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Shaft height in mm
/
Number of poles
IC/IM combination,
D = IC01 / IP23 [WP I]
L = IC81W / IP54 (55) [TEWAC]
W = IC01 / IPW24 [WP II]
A = IC611 / IP54 (55) [TEAAC]
P = IC11, 21, 31 / IP23, 54, (55)
T = IC511 / IP54 (55)
R = IC411 / IP54 (55)
Mounting arrangement,
B = IM1001 (1002) horizontal
V = IM4011 vertical
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Bearing type,
A = antifriction
S = sleeve
standard
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Regrease antifriction bearings while the lowvoltage machine is running. Use right kind of
grease. Follow instructions on lubricating
plate. The possible grease collector box
should be emptied every third time.
In case of sleeve-bearing machines, observe
time-limit for oil-change and if equipped with
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For
further
details,
see
our
comprehensive operating manual.
Preserve these safety instructions!
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In this manual units of measure are based on the SI (metric) system and the US system. If
somewhere in these documents the units are presented in only a single system, the conversion can
be performed using the following formulas. Some precalculated temperature conversions are
presented in table 1. A few useful conversion factors are presented in table 2.
C =
F - 32
1,8
K = C + 273,2
10
20
30
40
50
60
70
80
90
100
110
32
50
68
86
104
122
140
158
176
194
212
230
PkW
0,746
Power conversions
Php =
TkNm =
601/s PkW
2 n r/min
TNm =
9550 PkW
nr/min
Tlbf ft =
5250 Php
n r/min
to SI unit
81,7
from SI unit
to US unit
1 foot
0,3048 m
length
1 meter
3,280 ft.
1 inch
25,4 mm (0.0254 m)
"
1 mm = 0,001 m
0,039 in.
0,0254 mm
"
1 square foot
10,76 sq.ft.
1 square inch
6,4516 cm2
"
1 square mil
"
1 cubic foot
28,317 x 10 -3 m3
volume
35,30 cb.ft.
1 cubic inch
16,387 cm3
"
1 US gallon
3,785 dm3
"
1 liter = 1 dm3
0,264 gallons
1 pound
0,4536 kg
weight
1 kg
2.205 Ib.
1 US short ton
907 kg
1 pound / sq.ft.
4,8824 kg / m 2
1 pound/cubic foot
16,02 kg/m3
density
1 pound force-ft
1,356 Nm
torque
1 Nm
0,737 Ibf-ft
1 pound-sq. foot
0,04214 J
inertia
1 J = kgm2
23,73 Ib-ft2
1 pound force
4,448 N
force
1 N = kgm / s2
0,225 Ibf.
6,895 kPa
1 kPa
0,145 psi
area
"
pressure
pressure
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Fig. 7.
Lifting possibilities.
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If there are any openings where cables are
not connected up to terminal boxes, or piping
to flanges etc., these are to be temporarily
sealed up.
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The conservation methods are to be given a
final check and recorded together with the
date of the beginning of the conservation
period.
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Insulation resistance:
The lowest rated value for insulation
resistance test at 40C (104F) is 40 M
[megaohms] (according to IEEE 43-1974
standard, IEEE recommended practice
for Testing Insulation Resistance of
Rotating Machines).
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F = 0 .5 g m
where
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A
US:
F = 0 .5 W
4T
A
[N]
2
[m/s ]
[kg]
[Nm]
where
[lbf]
[lbf]
[lbf x ft]
[ft]
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half-key
full-key
Clean the shaft extension from anticorrosive coating and check measurements
of extension and coupling against the
drawings provided.
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where
-1
= 10 10 K
T = 40 K
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L = T L
where
-1
= 12 10 K
T = 50 K
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mount the gauge to the coupling flanges by
means of suitable fastening devices.
It is practical to adjust the dial gauge in such
way that approximately half of the scale is
available in either direction.
Radial misalignment
Gap (angular displacement) b
Axial displacement
a
r, a
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r, a
Rigid flange coupling r 0.02 mm (0.8 mil)
r 0.05 mm (2 mil)
Gear coupling
r 0.10 mm (4 mil)
Flexible coupling
b (coupling flange diameter 100...250 mm)
Rigid flange coupling b 0.01 mm (0.4 mil)
b 0.03 mm (1 mil)
Gear coupling
b 0.05 mm (2 mil)
Flexible coupling
b (coupling flange diameter 250...500 mm)
Rigid flange coupling b 0.02 mm (0.8 mil)
b 0.05 mm (2 mil)
Gear coupling
b 0.10 mm (4 mil)
Flexible coupling
The normal accepted misalignments are as
above. A definite tolerance is impossible to
state because too many factors have an
influence.
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one decade or more lower than the value
measured in the factory, check the winding
for excess moisture or dirt, as well as the
calibration of the measuring device. The test
report contains the insulation resistance value
measured in the factory.
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Fig. 24. Measuring the insulation resistance
of an individual phase.
Disconnect the power supply cables before
measuring the insulation resistance. To meet
safety requirements, the frame and the
windings not being tested shall be earthed
during the insulation resistance test.
Required notes and measures:
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With Pt-100 and other corresponding elements,
alarm and trip temperatures should be set as
low as possible based on the test results and
operating temperature of the machine. Alarm
temperature can be set e.g., 10 K and trip
temperature 20 K higher than the operating
temperature of the machine at max load and
ambient temperature.
The maximum recommended values for
alarm and trip temperatures are:
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1 function:
trip
2 function:
160C (320F)
2 function:
trip
180C (355F)
trip
2 function:
120-140C (250-285F)
130-150C (265-300F)
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Based on the order the machine is equipped
with three or six thermistors. If the machine is
equipped with three thermistors, the
operating temperature of the thermistors is
150C (300F). Operating function can be
chosen to be alarm or trip signal. If the machine
is equipped with six thermistors, the operating
temperatures are 150C (300F) and 170C
(340F). In that case both alarm and trip
signals can be used.
In case of tripping, the reason must be found
out and eliminated before the machine is
restarted. Use trouble shooting 2 for finding
out the reason.
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trip
2 function:
90C (195F)
90C (195F)
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90C (195F)
For mechanical installation use check list 5.
trip
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The compliance with the EMC directive
requires high frequency earthing of main
cable. This is achieved by a 360 earthing of
the cable screens at the cable entries both in
the machine and in the converter. The
earthing at the machine is implemented for
example by means of the EMC ROX
SYSTEM cable transits for shielded
installations.
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The auxiliary cables must as well be
screened to meet the requirements of the
EMC directive. Special cable glands must be
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Fig 30.
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Measure the SPM-values from the SPMnipples and record them for future use as
reference values.
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Check always before starting that no shutdown means have been forgotten and that
the lubrication and cooling are functioning.
3 Miscellaneous
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- noise
- vibration level
- alarms and fault indications
2 Cooling
- check the temperature of the stator
winding
- observe if the flow of cooling air is
normal
- feel the machine
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The bearing constructions for different
bearing solutions are shown in appendices 26. Deep groove ball bearings both in the Dend the N-end is the standard solution. When
great radial forces appear, for example in belt
drives, a cylindrical roller bearing can be fitted
in the D-end. The complete bearing types are
stamped on the rating plate.
The bearing in the D-end is axially fixed for
horizontal machines when ball bearings are
used in both ends. This means that the
thermal growth will happen towards the Nend.
The bearing in the N-end is axially fixed for
horizontal machines, when a cylindrical roller
bearing is used in the D-end. In this case the
thermal growth will happen towards the Dend. This should be considered when
adjusting the coupling.
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The lubricating system of the machine is
shown in appendices 2-5. Grease is injected
to the inner side of the bearing through the
grease passage. After filling the free space in
the bearing, excessive grease will be
discharged out from the bearing passing the
grease valve. The excessive grease comes
out through the opening in the bottom of the
bearing construction.
The machines are equipped with a greasing
nipple in both ends for lubricating the
bearings. The grease nipples are located on
side of the machine in both ends. The
amount of grease and the interval of greasing
are stamped on the relubrication plate. These
can also be read from tables 3 and 4.
Table 3. Relubrication intervals and amount of grease for horizontally mounted machines.
Bearing
Amount
of
type
grease [g]
3600
3000
1800-1500
1200-1000
900-750
600-500
6317
6319
6322
6324
6326
6330
NU317
NU319
NU322
NU324
NU326
NU330
35
45
60
70
80
100
35
45
60
70
80
100
800
400
2200
1600
400
1100
8800
6600
6600
4400
4400
3300
4400
3300
3300
2200
2200
2200
8800
8800
8800
8800
8800
6600
8800
6600
6600
6600
6600
3300
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
6600
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
8800
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Table 4. Relubrication intervals and amount of grease for vertically mounted machines.
Bearing
Amount
of
type
grease [g]
3600
3000
1800 - 1500
1200 -1000
900 -750
600 -500
6317
6319
6322
6324
6326
6330
7317
7319
7322
7324
7326
7330
NU317
NU319
NU322
NU324
NU326
NU330
35
45
60
70
80
100
35
45
60
70
80
100
35
45
60
70
80
100
400
1100
800
4400
3300
3300
2200
2200
1100
4400
3300
3300
2200
2200
2200
2200
1600
1600
1100
1100
1100
4400
4400
4400
4400
4400
3300
4400
4400
4400
4400
4400
3300
4400
3300
3300
3300
3300
1600
6600
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
4400
3300
6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
6600
4400
4400
4400
4400
4400
4400
1100
800
400
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Quality
Thickener
Base oil
Temperature range
[C]
Kinematic
viscosity of
base oil
[mm2/s, cSt
at 40C]
Kinematic
viscosity of
base oil
[mm2/s, cSt
at 100C]
Consistency
[NLGI
scale]
ESSO
UNIREX N2
Li
Mineral
-30 to +165
115
12.2
ESSO
UNIREX N3
Li
Mineral
-30 to +165
115
12.2
ESSO
BEACON 2
Li
Mineral
-40 to +120
100
9.5
SKF
LGMT 2
Li
Mineral
-30 to +120
92
9.6
MOBIL OIL
Mobilux 2
Li
Mineral
-30 to +120
100
10.0
SHELL
Alvania Grease G2
Li/Ca
Mineral
-25 to +140
100
11
SHELL
Alvania Grease G3
Li/Ca
Mineral
-20 to +150
100
11
TEBOIL
Multi-Purpose
Grease
Li
Mineral
-30 to +110
110
10.5
BP
Energrease LS 2
Li
Mineral
-30 to +110
92
9.5
STATOIL
Uniway Li 42
Li
Mineral
-30 to +120
100
12.0
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AMA machines are lubricated in the factory with ESSO UNIREX N2, if nothing else is
specified.
Quality
Thickener
Base oil
Temperature range
[C]
Kinematic
viscosity of
base oil
[mm2/s, cSt
at 40C]
Kinematic
viscosity of
base oil
[mm2/s, cSt
at 100C]
Consistency
[NLGI
scale]
ESSO
UNIREX N3
Li-comp.
Mineral
-30 to +165
115
12.2
SKF
LGHT 3
Li-comp.
Mineral
-30 to +150
110
13.0
MOBIL OIL
Inorga.
Synthetic
-40 to +200
100
12.5
SHELL
Syntix 100
Li-comp.
Synthetic
-40 to +150
100
21.0
TEBOIL
Syntex Grease
Li-comp.
Synthetic
-40 to +140
150
20.0
STATOIL
Uniway LiX 42 PA
Li-comp.
Polyalfa
-35 to +150
100
18.0
CHEVRON
SRI 2
Polyr.
Mineral
-30 to +150
115
14.0
NESTE
Rasva 606
Li-comp.
Synthetic
-40 to +150
150
20.0
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It is important to consider the miscibility of
greases if it is necessary to change from one
grease to another. If incompatible greases
are mixed, the consistency can change
dramatically and the maximum operating
temperature of the grease mix can be so low
compared to the original grease, that bearing
damage cannot be ruled out.
Greases having the same thickener and
similar base oils can generally be mixed
without any detrimental consequences, e.g. a
lithium base grease can be mixed with another
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V = 7.1 mm/s
SHUTDOWN
V = 11.2 mm/s
RMS
RMS
9
2 9rms
9
6$ = 2 rms =
0. 225 rms
2
I
I
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the bearing plate of the bearing itself. The
bearings are rigidly mounted to the end
shields of the machine. The bearing in the Dend is usually the locating bearing (code B in
the type designation). This means that the
thermal growth will happen towards the Nend.
The bearing in the N-end is insulated. This
means that the inside spherical housing
surfaces are lined with nonconducting PTFE
film in order to avoid bearing currents (figure
35).
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The sleeve bearing type used in AMA
machines is a side flange bearing. Middle
flange sleeve bearings can be used too
(figure 34).
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Manufacturer
Quality
EXXON
Terresso
GULF
Harmony
MOBIL
DTE
SHELL
Tellus Oil
TEBOIL
Larita Oil
NESTE
Paine
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Do the following:
Vibration.
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A possibility to detect bearing failure by
vibration monitoring is to determine the
typical defect frequencies.
The decisive quantity is the rms value of the
vibration velocity measured on the bearing
housing. Measuring point arrangement in
accordance with ISO 3945.
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ALARM
V = 7.1 mm/s
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SHUTDOWN
V = 11.2 mm/s
RMS
RMS
9
2 9rms
9
6$ = 2 rms =
0. 225 rms
2
I
I
where
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Noise damper
Air guide
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SSPC-Vis 1-82
Touch-up
painting
is
sufficient
for
maintenance when the rusted area is less
than 8% of the painted surface that means
that the rust grade is Ri1 Ri3 (ISO 4628 and
SFS 3762). Damages caused by transport or
installation may also be repaired by touch-up
painting.
Repainting is necessary for maintenance
when the rusted area is 8% or more (the rust
grade is Ri4 or Ri5).
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Parts made of cold rolled sheet or light metal:
EPUR
320:
epoxy
undercoating,
polyurethane
finish
nominal
film
thickness 320 m
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Principles:
-
([WHULRULQVSHFWLRQ
Inspection interval
Maintenance
1 Heavy drives
Once a year.
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100
10
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0
10
20
30
40
50
60
70
80
90
100
110
Winding temperature,
Degrees Celsius C
Fig. 40. Correlation between the insulation resistance and the temperature.
Table 9. Temperature values in degrees Celsius (C) and degrees Fahrenheit (F).
C
10
20
30
40
50
60
70
80
90
100
110
32
50
68
86
104
122
140
158
176
194
212
230
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Degree of contamination
tightening *)
tightening, strengthen and re-varnish *)
strengthen or redo winding *)
Finishing varnish
Supporting parts
Ageing
*)
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Blowing and vacuuming are used if the dirt is
dry and can be removed easily. Vacuuming is
recommended, since blowing tends to
redistribute the dirt or move it deeper
between the insulation layers.
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Wiping is used when spray-wash is not
possible. Surfaces easily reached are wiped
clean with a cloth dampened with detergent.
In cramped areas of the windings, a special
brush may be more effective.
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A spray wash is carried out with an airless
high-pressure spray or a conventional spray.
The high-pressure spray is more effective in
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tightening of the slot wedges
tightening of the supporting parts.
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TEST RECORD
Machine, type
..............................
No:
..............................
..............................
No:
..............................
..............................
Annual inspection
Use
Voltage/output ..............................
Random inspection
kW
OK o
Observations:
........................................................
OK o
Observations:
........................................................
3. Contamination
Stator
windings
Rotor
windings
Air
ducts
Cooling
radiators
Explanations
End
D
OK
Observations
4. Windings
4.1 AC stator
Support
Coils
Connecting cables
Core laminations
4.2 Asynchr. rotor
Ends of squir. cage windings
Keys of squir. cage ring
Core laminations
5. Fan
6. Cooling system
Visible radiator parts
Inner radiator parts
Flow-switch
7.Elect. connections
Main connection
Control gear
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8. Electrical test
Insulation resistance to earth
QUANTITY ESTIMATION
0 = clean
1 = slight
2 = plentiful (ducts about to plug)
3 = very plentiful (ducts plugged)
ESTIMATION BASIS
1 = dropping
12 = risen bars
2 = loosening
13 = battered
3 = cracking
14 = knocking: doubtful
4 = breaking
15 = corrosion
16 = leakages
6 = swelling
17 = condensation
7 = darkening
18 = loose ribs
8 = embrittlement
19 = abrasion
9 = water marks
10 = tracking
11 = hair cracks
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Horizontal machines:
- N-end bearing is axially free
24)
Vertical machines:
- D-end bearing is axially free
25)
14)
26)
15)
27)
16)
28)
29)
30)
17)
18)
19)
20)
31)
21)
32)
33)
34)
22)
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with the machine seal (14). Use the
threaded holes to pull out the shield.
35)
36)
38)
39)
40)
II
Joint bolt
12
13
Retention pin
II
Lower shell
14
Machine seal
Upper shell
10
15
Machine shield
11
Seal carrier
16
Oil outlet
Fig 42.
Sleeve bearing.
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The Drive end:
41)
42)
43)
44)
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The drive end:
57)
58)
59)
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60)
61)
47)
48)
49)
50)
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The Non-drive end:
71)
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72)
73)
74)
75)
76)
77)
78)
63)
64)
65)
66)
67)
69)
70)
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Table 12.
Schedule for regular checkings.
PERIOD
MONTHLY
YEARLY
SUBJECT
Power
Current
P.F.
Excitation current
Winding temperatures
Bearing temperatures
Cooling air temperatures
Oil pressures
Bearing vibration
Heat exchangers
Contamination
Cleanliness of inner parts of the machine
Cleanliness of diodes and diode bridges
Condition and support of windings, lockings
Possible shifting of the slot wedges
Condition of the winding insulation and finishing
varnish
Possible shifting or loosening of the field windings
Insulating resistances of the windings
Condition of the fan(s)
Lockings in connection with the rotating parts
Painting and protection against corrosion
Checking the seals preventing the ingress of dirt
Checking the performances of control and regulation
equipment as well as protective relays
Checking the solderings and possible broken bars of
the rotor cage
Bearings and bearing seals
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THE
COMPLETE
OVERHAUL
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Mounting conditions
1RWH
1.
2.
3.
4.
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Operating conditions
1.
Over-loading.
2.
3.
Over-speed.
4.
Environmental conditions
1.
&ODVVLILFDWLRQRIEHDULQJIDLOXUHFDXVHV
2.
Electric arcing.
3.
Contamination
from
water,
chemical product, textiledebris ...
2.
3.
dust,
Lubrication conditions
1.
Improper lubricant.
2.
3.
Relubrication interval.
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4.
2.
These signals are:
Vibrations
Noise
3.
Temperature rise
Excess or lack of lubrication
Elimination of the internal clearance
Thrust overloading due to improper
mounting
Noise
Rolling element indentations
Spalling
False brinelling (indentations caused by
vibrations)
Foreign particles
Corrosion
Elimination of the internal clearance due
to excessive press fit
Cage or rolling element failure
Vibrations
Spalling
Abrasive wear - foreign particles
Corrosion
Unbalanced loads due to bearing wear
Excessive clearance
Under-tightening of a ring
1.
Temperature rise
4.
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Lubrication deterioration
Seal damage or displacement
5.
Torque
6.
Evolution of deterioration
7.
Orientation
assembly.
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Frequency of control
It essentially depends upon the expected
reliability, on the material usage and on many
other factors specific to each user. Sampling
controls based on the bearing life expectancy
could be regularly performed.
External control means
These means are very limited. However,
some control instruments detecting unusual
vibrations are available. "Sonic meters"
measuring the bearing noise level can also
be used. In any case, a reference level
should be determined in order to measure the
difference.
1.
2.
3.
4.
1.
Dirt
2.
Temperature
3.
Loss of lubricant
4.
Noise
bearing
in
the
2.
3.
4.
5.
6.
SKF,
SKF
Handbook
2)
3)
4)
5)
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Before removal:
the
After removal
0HWKRGVRIIDLOXUHLGHQWLILFDWLRQ
Failure identification is not always easy. The
following steps should be considered:
of
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3.
Spare machine.
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Customer
Machine type AMA
Machine serial no.
Signature of
the consignee
DATE
SIGNATURE
o Yes o No
o Yes o No
o Yes o No
Comments:
For files
To
From
Issued by
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Page
Register no.
Continues on page
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Customer
Machine type AMA
Machine serial no.
Damage(s):
o Machine
Signature of
the consignee
o Accessories
o Package
o Other...............................................
Dispatched by:
o Reported to
company
To carrier
o Railway
o Lorry/Truck
o Airfreight
o Post/Mail
o Shipped by the m/s ..................................
o Other.........................................................
For files
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Register no.
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Customer
Machine type AMA
Motor serial no.
Signature of
the consignee
From
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Register no.
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Customer
Machine type AMA
Machine serial no.
Storage date
Person responsible
for storage
Storage:
o Outdoors
o Indoors
o In packing case
o Protected by
waterproof cover
o Warm
o Cool
o External heating
is used
o Shaft end rust-proofing
material is checked
o Storage place is vibration-free
o Documentations are protected
o Space heaters
are used
o Absorbing
material is used
o Air is free of
corrosive gases
Comments:
Protective measures must be taken before operating the motor if it is stored for a long period.
The customer is responsible for the storage and the required protective measures.
The motor must be stored on a level surface in a vibration-free area. If storage is outdoors, the motor
must be protected against environmental effects.
If long-time storage under humid conditions is anticipated, connection of space heaters, efficient
coverage, and other protective measures must be arranged.
To
From
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Page
Register no.
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Customer
Machine type AMA
Machine serial no.
Measures:
o Foundation according to drawing................................................................
o Alignment checked according to instructions.
o Foundation bolts tightened with torque wrench.
o Assembly of coupling half checked.
o Bearings filled with lubricant - type..............................................................
o Bearings filled with lubricant - quantity........................................................
o Assembly of oil and coolant pipes checked, flanges tightened.
o Cooling water test run. Check for leakage.
o Stator terminal box mounted correctly.
o Rotor rotates without scrapings/sound (transport locking device dismantled).
Comments:
For files
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From
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Register no.
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Customer
Machine type AMA
Machine serial no.
5DGLDOPLVDOLJQPHQW
a1, b1, c1 and d1 are readings from the dial indicator "R" at the points a = top, b = bottom, c = right, d = left (4 turns, each of 90 angle).
The readings are entered in the formula to obtain the values of radial misalignment (table 1).
Table 1
Measuring points
1st measurement
2nd measurement
Example
9HUWLFDO
Top
Bottom
Difference
Vertical
misalignment
+
-
a1
b1
a1-b1
a2
b2
a2-b2
25
31
-6
28
28
0
D E
D E
-3
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Right
Left
Difference
Vertical
misalignment
+
-
c1
d1
c1-d1
c2
d2
c2-d2
38
18
20
28
28
0
F1 G1
2
F2 G 2
2
10
D + E
D + E
= =
F + G
F + G
Check
for
measuring error
38 + 18
= =
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The axial gap is determined by taking readings from the two dial indicators AI and AII, whereby the first reading from the top indicator AI is
designated by e1 and that from the bottom indicator AII by h1. The values for vertical and horizontal misalignment can be determined as shown in
table 2; axial displacement (in example 0.2 mm) during the measurement does not effect the results. Use a feeler gauge in case the gap is too
small to use a dial gauge.
Table 2
Measuring points
Dial AI
Dial AII
Example
9HUWLFDOJDS
Top
Bottom
Gap
+
-
e1
f1
g1
h1
(I1 H1 ) (J 1 K1 )
2
The gap is greater at the top
The gap is greater at the bottom
50
62
42
50
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Left
Right
i1
k1
40
48
36
40
( 48 40 ) ( 36 40 )
2
(N 1 L 1 ) ( O 1 P 1 )
2
Gap
+
-
l1
m1
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Customer
Machine type AMA
Machine serial no.
Safety:
o7KHLQFRPLQJFDEOHVDUHVHSDUDWHGIURPWKHHOHFWULFSRZHUQHWZRUN
o7KHFDEOHVDUHJURXQGHG
Electrical data:
Machine
Voltage.............................................V/VAC
Voltage.............................................V/VAC
Frequency........................................Hz
Frequency........................................Hz
o Space heater:.........................................V/VAC,
o External blower motor.............................V/VAC,
Insulation test:
...................W
...................W/HP
Winding temperature.............................C/F
R (40C/104F) = .................................. M
R (40C/104F) = .................................. M
Overload level................................................
Acceleration time............................................
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Monitoring equipment
Temperature monitoring
In stator winding
Alarm (C/F)
Trip (C/F)
Alarm
Trip
In bearing
In.......................................................
(m3/s or Pa)
(ft3/s or psi)
Lubricating oil
min
Lubricating oil
max
Cooling water
Filter guard
Vibration:
Comments:
For files
To
From
Issued by
3$0$HQ
Date
Page
Register no.
Continues on page
$%%
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Customer
Machine type AMA
Machine serial no.
Date
Name of
supervisor
Connections:
o The supply cables have been connected
First start
Direction of rotation:
o clockwise
o counter-clockwise (as seen from drive-end)
Noise:
o normal
o abnormal
Second start (to full speed)
Run:
o normal
o abnormal
Noise:
o normal
o abnormal
Vibration:
o normal
o abnormal
o Run OK
o operation stops (why ?).......................................................................
..................................................................................................................................................................
..................................................................................................................................................................
Time
Bearing
Temp.
Oil
Comments:
Stator
D-end
N-end
Temp.
(run, noise, vibration, etc.)
Current
Power
(C/F)
(C/F)
(C/F)
(A)
factor
Comments:
For files
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From
Issued by
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Register no.
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Customer
Machine type AMA
Machine serial no.
o Coupling is connected
o Load applied
Acceleration time:
o Coupling is disconnected
o No load applied
....................................
Time
or
Date
Bearing temp.
D-end
N-end
(C/F) (C/F)
Winding temperature
U / T1
V / T2
W / T3
(C/F) (C/F) (C/F)
Stator
Curr.
(A)
Power
factor
Vibr. (mm/s, m)
(in/sec,mil)
D-end
N-end
Load
(W)
(HP)
Comments:
For files
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Customer
Machine type AMA
Machine serial no.
Comments:
Loggings of operational data and remarks should be kept for reference during maintenance work,
trouble shooting, and repairs. Copies of loggings are not to be sent to ABB.
Year............. , Week.............
Point of inspection
Date
Load power
(W/HP)
Load current
(A)
Fault indication
(Yes/No)
Bearing temperature DE
(C/F)
Bearing temperature NDE (C/F)
Oil level
(Normal/Abnormal)
Oil leakage
(Yes/No)
Winding temperature U/T1 (C/F)
Winding temperature V/T2 (C/F)
Winding temperature W/T3 (C/F)
Coolant flow
(m3/h/Gpm)
Water leakage
(Yes/No)
Vibration level
(Normal/Abnormal)
Noise
(Normal/Abnormal)
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
For files
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Customer
Machine type AMA
Machine serial no.
Maintenance interval...........h,
Operating hours ............,
Number of starts......................
Bearings:
o Lubricant change
Lubricant type.................................
Quantity...........................................
o Oil filter change
Oil filter type....................................
o Flanges and pipes checked
Comments:
Cooling:
o Cleaned
o Cleaned
o Cleaned
Comments:
Electr. part:
Comments:
Mech. part:
o Couplings checked
o Foundation bolts checked
o Foundation checked
o Machine in general checked
o Machine opened and checked
o Bearings opened and checked
Comments:
For files
To
From
Issued by
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Page
Register no.
Continues on page
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Customer
Machine type AMA
Machine serial no
MACHINE
DOES NOT
START
One phase is
missing
Voltage drop
is too high
Load inertia is
too high
Load torque
is too high
1) If the load inertia is larger than has been reported, please contact ABB Company.
2) Starter can be star-delta connection, starting reactor or auto transformer. When the starter is used the
machine torque decreases and starting time increases. This must be noticed.
3) Driven machines may have different starting method. Many of them can be started without load. For
example compressors and blowers can be started with closed suction vanes. In refiners the pulp feeding
can be started after starting the motor. It is possible that the motor does not start loaded, if it has been
designed to start without load. The machine can be damaged when starting with load if it has been
designed for no load start.
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Customer
Machine type AMA
Machine serial no
Cooling air
is too hot
Air duct is
blocked
Ambient temperature
Cooling-water circulation
is too hot
is not working
Another machine
is too near
Water-pipes are
Air in the
blocked
water-pipes
Open and
Open and
adjust
adjust
the water-pipes
Cooling-water temperature
is too hot
Cooling-water pump
is not working
through bleeder
screw
Adjust sufficient ventilation
Adjust sufficient
condensation for
cooling-water
One phase is
Overload
missing
External blowers
is not working
External blowers
rotating in the
rotating in the
wrong direction
wrong direction
Change direction
of rotation
be changed
Blower motors
protection has
tripped
1) For example machines can be partitioned off, or if the room temperature is too high an air-conditioning
must be improved.
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Customer
Machine type AMA
Machine serial no
COMMON SYMPTOMS
A
B
C
D
Overheated bearing
Noisy bearing
Replacements are too frequent
Vibration
Typical conditions
Practical solution
Inadequate lubrication
Insufficient lubrication
E
F
G
Excessive lubrication
Insufficient
clearance
bearing
Foreign
matter
bearing housing.
Preloaded bearings
Improve the
expansion by
bearing cover .
Unbalanced load.
Outer ring
housing
in
spins
in
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possibility
machining
of
the
shaft
outer
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Customer
Machine type
Machine serial no
Noisy bearing
Rolling
dented.
Vibrations
Vibrations
Equipment is vibrating.
element
is
recommended
Bearing is discolored.
Bearing noisy
Bearing is exposed to
vibration while the machine
is idle.
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Customer
Machine type AMA
Machine serial no
Lubrication
insufficient
Continued to
page 2
Faulty oil
cooler
Oil temperature
too high
Faulty
coupling
High axial
forces
Faulty assembled
bearing
Damaged
linings
Impurities in
the oil?
Inductive bearing
currents?
Complete seizure
of bearing
Faulty
instrument?
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Open and
adjust
Change oil
Repair bearing
insulation
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Customer
Machine type AMA
Machine serial no
Continuing
from page 1
Low oil
level
Check maintenance
status
Low oil
flow
Oil filter
clogged
Reduction valve
shut?
Oil leaks ?
Motor protection
trips?
Check maintenance
status
Latest
adjustment?
Fault finding
and action
Faulty oil
heater
Unsuitable
oil quality
Check with
ABB Drives
recommendation
Change oil
quality
Check status of
oil change
Previous bearing
disassembly
Disassemble and
adjust
Add oil
UNSTABLE BEARING
TEMPERATURE
Oil ring working
unreliable
Open bearing
and adjust
Impurities in
the oil
Damaged
shaft seals
OIL LEAKS
Air-lock seals
out of action
Problem in oil
flow return
Incorrect inclination
of the return pipe?
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Add oil
Fault finding
and action
Replace filter
Adjust flow
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LINE
TYPE
AL
AM
AN
AP
BH
CL
DD
DE
DF
ZBHE 301
300
160
200
385
30
ZBHE 362
440
205
160
200
200
500
36
150
84
WEIGHT kg
AMA 400
30
60
Foundation plate
Fixing screw
Anchor bolt
Shim
Flange
Levelling plate
Nut
Conical cotter
Levelling screw
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