User Manual - MSIMMA - Rev5 PDF

GE Energy
Power Conversion
MSIMMA
MANUAL OF SAFETY, INSTALLATION AND MAINTENANCE FOR
ASYNCHRONOUS MOTORS SERIES FL-F3-N3-N4
Customer reference:
©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. GE Energy Power Conversion Proprietary Technical Information
GE Energy
Power Conversion
GE ENERGY POWER CONVERSION
MSIMMA
SAFETY, INSTALLATION AND MAINTENANCE MANUAL OF

ASYNCHRONOUS MOTORS
FL-F3-N3-N4 series
Author: I. Schneider
Design Office: RM-Nancy
Reason for new revision: Update
(see last page for
modification record)
©COPYRIGHT 2007-2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information
contained herein is GE Energy Power Conversion Proprietary Technical Information that belongs to the General
Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express
reason of restricted private use. All persons, firms, or corporations who receive such information shall be deemed
by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use
whatsoever for any, or all such information except as expressly authorized in writing by the General Electric
Company, GE Energy (USA), LLC and/or its affiliates.
Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Project : MSIMMA Ref : MSIMMA - EN
Document : Safety, Installation and Maintenance manual of asynchronous Revision : 05
motors Date : 25 apr 12
File : / MSIMMA_EN_rev.5.doc Page : 1/99
©COPYRIGHT 2007-2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. GE Energy Power Conversion Proprietary Technical Information
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CONTENTS
1. SAFETY INSTRUCTIONS ................................................................................................................................. 5

1.1 WARNING ............................................................................................................................................................................. 5
1.1.1 Scope of manual ...................................................................................................................................................... 5
1.1.2 Keep your eye on safety....................................................................................................................................... 5
1.1.3 Limit of responsibility and warranty conditions ....................................................................................... 6
1.2 SAFETY ................................................................................................................................................................................... 6
1.2.1 Conditions governing use of motors .............................................................................................................. 6
1.2.2 Symbols and pictograms used in this document .................................................................................... 7
1.2.3 Applicable regulations ....................................................................................................................................... 12
1.3 POWER CONVERSION CONTACT DETAILS ......................................................................................................... 13
1.4 DOCUMENTS TO BE COMPLETED AND SENT TO POWER CONVERSION .............................................. 13
2. DESCRIPTION OF THE MACHINE ................................................................................................................ 14
2.1 DEFINITION OF TYPES OF INDUCTION MOTORS (FL-F3-N3-N4 SERIES)............................................... 14
2.2 MACHINE IDENTIFICATION........................................................................................................................................ 16
2.2.1 Motor designation ................................................................................................................................................ 16
2.2.2 Production number.............................................................................................................................................. 20
2.2.3 Nameplates ............................................................................................................................................................. 20
3. HANDLING – TRANSPORT – STORAGE ...................................................................................................... 24
3.1 RECEIVING INSPECTION ............................................................................................................................................. 24
3.2 HANDLING PRINCIPLES .............................................................................................................................................. 24
3.2.1 General measures ................................................................................................................................................ 24
3.2.2 Turning over a vertical motor to the horizontal position .................................................................. 29
3.2.3 Rotor locking system .......................................................................................................................................... 30
3.3 STORAGE PRECAUTIONS ............................................................................................................................................ 30
3.3.1 Storage instructions lower than 6 months .............................................................................................. 30
3.3.2 Storage instructions between 6 and 12 months (according to IP806) ....................................... 31
3.3.3 Storage instructions higher than 12 months (according to IP784) .............................................. 33
4. INSTALLATION “PRE-COMMISSIONING” .................................................................................................. 35
4.1 GENERAL RECOMMENDATIONS.............................................................................................................................. 35
4.2 LUBRICATION .................................................................................................................................................................. 35
4.2.1 Lubrication by grease......................................................................................................................................... 35
4.2.2 Oil lubrication (splash or pressurized) ......................................................................................................... 36
4.3 RECOMMENDATIONS CONCERNING MECHANICAL EQUIPMENT ............................................................ 36
4.3.1 Assembling the coupling................................................................................................................................... 36
4.3.2 Installation of motor on base ......................................................................................................................... 39
4.3.3 Check of shaft line - alignment ...................................................................................................................... 41
4.3.4 Connection of bushed bearings lubricated by force-feed lubrication ....................................... 47
4.3.5 Connections to cooling circuit........................................................................................................................ 47
4.4 SPECIAL MEASURES RELATIVE TO MOTORS INSTALLED IN AN AREA HAVING EXPLOSION
HAZARDS ........................................................................................................................................................................... 48
4.4.1 “Pressurized” motors........................................................................................................................................... 49
4.4.2 “Enhanced safety” anti-spark motors ........................................................................................................ 49
4.5 ELECTRICAL RECOMMENDATIONS: ELECTRICAL CONNECTIONS ............................................................ 50

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4.5.1 Insulation resistance measurement and drying method ................................................................. 50
4.5.2 Wiring and grounding ........................................................................................................................................ 51
4.5.3 Connection of main terminal box ................................................................................................................. 52
4.5.4 Connection of auxiliary and protection circuits .................................................................................... 52
4.5.5 Special measures relative to asynchronous generators .................................................................. 53
4.5.6 Ring motors: special measures relative to synchronous induction motor ............................... 54
5. COMMISSIONING ......................................................................................................................................... 55
5.1 PRELIMINARY CHECKS ................................................................................................................................................ 55
5.1.1 Mechanical checks .............................................................................................................................................. 55
5.1.2 Electrical checks.................................................................................................................................................... 56
5.1.3 Special checks for equipment located in a hazardous area ........................................................... 56
5.2 ADJUSTMENTS OF PROTECTION INSTRUMENTATION.................................................................................. 57
5.2.1 Thermal protection .............................................................................................................................................. 57
5.2.2 Vibration protection ............................................................................................................................................ 58
5.2.3 Electrical protection ............................................................................................................................................ 58
5.2.4 Protection on hydro-cooler.............................................................................................................................. 59
5.3 START-UP / INITIAL USE.............................................................................................................................................. 60
5.3.1 Start-up control ..................................................................................................................................................... 60
5.3.2 On-going checks ................................................................................................................................................... 61
5.4 STOPPING THE MACHINE........................................................................................................................................... 61
6. OPERATION ................................................................................................................................................... 62
6.2 SPECIAL OPERATING CONDITIONS........................................................................................................................ 62
6.2.1 Monitoring ................................................................................................................................................................ 62
6.2.2 Points monitored .................................................................................................................................................. 63
6.2.3 Monitoring when motor is shut down ........................................................................................................ 63
7. MAINTENANCE ............................................................................................................................................. 64
7.2 STRUCTURE OF RECOMMENDED MAINTENANCE ACTIONS ...................................................................... 64
7.2.1 Maintenance levels .............................................................................................................................................. 64
7.2.2 Check points and interventions required to ensure correct operation of the machine .... 65
7.2.3 General recommendations relative to maintenance interventions ............................................ 69
7.2.4 What to do if a malfunction is observed ................................................................................................... 85
8. SERVICE DEPARTMENT / REPLACEMENT PARTS ..................................................................................... 91
8.1 PRESENTATION OF SERVICE DEPARTMENT AND CONTACT DETAILS .................................................... 91
8.2 REPLACEMENT PARTS.................................................................................................................................................. 92
8.2.1 Evaluating replacement part needs ............................................................................................................ 92
8.2.2 Standard replacement parts .......................................................................................................................... 92
8.2.3 “Major” replacement parts ............................................................................................................................... 95
8.2.4 Storage of replacement parts ........................................................................................................................ 96
9. RECYCLING AND WASTE MANAGEMENT ................................................................................................. 97
9.1 GENERAL INFORMATION............................................................................................................................................ 97
9.2 PROCESSING PACKAGING AND PROTECTION COVERINGS........................................................................ 97
9.3 SORTING AND RECLAMATION OF MATERIALS ................................................................................................. 98
9.3.1 Reclamation of cast iron and steel .............................................................................................................. 98

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9.3.2 Reclamation of copper ...................................................................................................................................... 98
9.3.3 Reclamation of aluminium............................................................................................................................... 98
9.3.4 Reclamation of electronic components .................................................................................................... 98
9.3.5 Reclamation of plastic ....................................................................................................................................... 98
9.3.6 Elimination of oils ................................................................................................................................................. 98
10. MODIFICATION RECORD ............................................................................................................................. 99

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1. SAFETY INSTRUCTIONS
1.1 WARNING
1.1.1 Scope of manual

This manual is intended for users. It provides all the essential information for safe transport, storage,
installation, commissioning, operation and maintenance of the induction motors built by GE Energy’s
Power Conversion business (here below designated Power Conversion).
The term motor used in this manual refers to an asynchronous motor or generator.
These machines are intended for industrial installations as component as defined in the European
Machinery Directive 2006/42/EC. In Europe, commissioning is prohibited until conformity of the complete
machinery complies with the Directive and local safety and installation rules, such as EN60204-11 for
example.
High voltage, rotating parts, hot surfaces can cause serious injury. A risk assessment was performed
regarding these dangers. Despite safe design in accordance with relevant Standards (serie
IEC/EN60034), some residual risks remain and result in following requirements:
- All operations on the motors, described or not in the manual, must be performed by skilled and
trained personnel.
- Instructions given in this manual must be strictly followed. The pictogram , which means
“warning or caution” is used to draw your attention to important points.
- General and local health and safety rules must be observed.
- Personnel intervening on the motor must be perfectly familiar with information and instructions
contained in this manual. This manual should be read hand in hand with the outline dimensions
drawing, the connection diagram and the technical data sheet of the machine. These documents
define all the necessary data relative to the specifics involved in using the machine for each
customer.
In the event of any contradictory information between the various documents covering the motor, the
specific contractual documents shall take precedence over the manual, except as concerns the
information stipulated in paragraph “1.1.3 Limit of responsibility and warranty conditions”.
Should any differences be observed on the equipment with respect to this manual, the user shall make
the decisions which he may deem necessary, in accordance with the user’s engineering skills. Should
any incomprehension or doubt remain, the user should contact Power Conversion Services Department.
1.1.2 Keep your eye on safety

Be careful and vigilant when working on your machine! Your safety depends on it.
To prevent accidents, the safety measures and devices implemented must be compliant with the
regulations applicable at the place of work. In practice, all rules and regulations applicable in the
concerned country of use, safety rules specific to the site, instructions given in this manual and specific
safety instructions supplied with the motor must be strictly observed.
For motors located in a dangerous area (potentially explosive atmospheres), the instructions given in
paragraph “1.2.3 Applicable regulations” must be strictly applied.

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CAUTION
Whenever working on the motor :
• Shutdown and lock out the concerned motor installation.
• Make sure that it is impossible, even unintentionally, to power up the installation or rotate
the machine during any intervention.
• Take all necessary measures to ensure the safety of the personnel and equipment
concerned.
1.1.3 Limit of responsibility and warranty conditions

Power Conversion shall not be held responsible for any consequences, direct or indirect, resulting from
incorrect reading or interpretation of this manual. Failure to observe the instructions given in this
manual will cancel the motor warranty. In such a situation, Power Conversion shall not be held liable for
any reason whatsoever.
The warrant is limited solely to conformity of the motor with the contractual specifications.
The warranty shall only apply provided the motor is used in compliance with the contractual
specifications and in strict observance of the information and instructions given in this manual.
The warranty obligations shall be cancelled should any motor be modified or repaired without the prior
written approval of Power Conversion.
On installation of the motor and prior to final commissioning, the installation report must be
filled in. An example of this report is given in the paragraph “1. Safety instructions” of this
manual. The installation and commissioning report must be sent to the Power Conversion
projects department. This report will be requested for all interventions during and after the
warranty period.
The warranty will only be effective provided the instructions given in this manual are thoroughly and
strictly observed and provided the installation report has been submitted to Power Conversion as
required.
1.2 SAFETY
The information and instructions relative to safety given in this manual must be strictly observed at all
times.
1.2.1 Conditions governing use of motors

The motor must be used in compliance with the conditions given in its technical data sheet and the
contractual documents joined to the manual (comprising, among others, the number of consecutive
start-ups acceptable, the maximum start-up time accepted, the voltage and frequency at the motor
terminals, etc.).
The customer shall ensure, under its sole responsibility, that all the necessary measures relative to
electrical and mechanical protection of the motor have been taken prior to installation and/or
commissioning of the motor.
The customer shall also ensure that the installation is compliant with the standards governing the
protection of persons and that all persons working in the vicinity of the motors are correctly trained and
informed on the dangers specific to the installation.

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1.2.2 Symbols and pictograms used in this document
1.2.2.1 Symbols concerning packaging and handling

Key Symbol Indication
Indicates :
a) that content of shipping container is
Fragile, handle with care
fragile,
b) that container must be handled with care.
iso 7000/No. 0621
Indicates that hooks are prohibited for lifting

Do not use hooks
shipping container
iso 7000/No. 0622
Indicates the correct vertical position of the

Up
shipping container
iso 7000/No. 0623
Indicates that container must not be exposed

Keep away from light
to sun light
iso 7000/No. 0624
Indicates that content of container could

Protect against radioactive sources become damaged or made entirely unusable
due to effects of penetrating radiation
iso 7000/No. 2401
Indicates location where sling(s) must be

Sling here
secured for lifting shipping container
iso 7000/No. 0625

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Indicates that shipping container

Keep dry
must be kept in a dry environment.
iso 7000/No. 0626
Indicates centre of gravity of

Centre of gravity
shipping container
iso 7000/No. 0627

Do not roll
must not be rolled
iso 7000/No. 2405
Indicates locations on shipping

Do not place this side against container against which handling
handling truck trucks or trolleys must not be
placed.
iso 7000/No. 0629
Indicates maximum stacking load

Weight stacking limit
allowed on shipping container
iso 7000/No. 0630
Indicates temperature limits within

Temperature limit which shipping container must be
preserved and handled
iso 7000/No. 0632

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Indicates position for clamps when

Lateral clamping positions
handling shipping container
iso 7000/No. 0631

Do not use lateral clamps must not be handled with clamps
against sides as shown
iso 7000/No. 2404

Use of forklifts prohibited must not be handled using a fork
lift
iso 7000/No. 2406
Indicates maximum number of

identical containers which can be
Stacking number limit
stacked on each other, where “n” is
the limit number
iso 7000/No. 2403
Indicates :
a) that stacking of shipping
Do not stack containers is prohibited,
b) that no load should be placed
on shipping container.
iso 7000/No. 2402

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1.2.2.2 Abbreviations and direction of rotation
DE : coupling side NDE : Drive End / side opposite coupling
DIRECTION OF ROTATION
The direction of rotation is always defined for an observer viewing the motor coupling side (DE) and is
identified by a unidirectional arrow for one direction of rotation only and by two arrows for a motor with
two directions of rotation.
The motor must only be used for the original direction for which it has been designed.
F
DE NDE Counter-clockwise Clockwise
F
NDE Counter-clockwise Clockwis e
DE

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1.2.2.3 Safety pictograms
Definition of main pictograms used on machine:
Symbol Key
Electrical hazards
Ground connection point
Stay at a safe distance
KEEP AWAY
EC protection marking relative to an explosive atmosphere

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1.2.3 Applicable regulations

Reminder about essential data of ATEX marking:
Manufacturer: GE Energy
Power Conversion
Address: 442, Rue de la Rompure
54250 Champigneulles (France)
Type: xxxxxxxxxx x / xx
Manufacturing year: 20xx
EC marking: xxxx - xx x x
Marking: xx x x xx xxx xx
Number of EC examination type certificate: xxxxxx xxxxxx xxxxx
For a reliable use of this machine, particular cautions* have to be taken, including the following
complementary conditions:
- The heating resistors must be switched on as of shutdown of the motor if in air, and just prior to start-
up if in oil. In all cases, the heating resistors must be stopped during operation of the motors.
- All electrical accessories ensuring proper service and safety of the machine shall be of recognized
protection mode for the considered use, if they are placed in a hazardous area.
- Installation, maintenance and eventual repairs on the motor have to be executed under appropriated
conditions. It is recommended to refer to the following standards:
• IEC / EN60079-14: Electrical installations in hazardous sites (except mines).

• IEC / EN60079-17: Recommendations for inspection and maintenance of electrical
installations into hazardous sites (except mines).
• IEC / EN60079-19: Repairs and revision of material used under explosive atmospheres
(except mines).
• Eventually, IEC / EN 61241-14: Electrical materials to be use into dusty combustible area –
Selection and installation.
• Decree, orders, laws, directives, circulars of application, norms, art rules and all other
document concerning its installation place.
User has to take into account external conditions (humidity, salinity, altitude, etc.) and take the
appropriate measures to protect the motor.
The compliance to these is the fully responsibility of the user.
(*): Subject to the installation, maintenance and use in compliance with their destination, the regulation, installation standards in
effect (IEC/ EN 60079-14, (61241-14 – for dust)) to the manufacturer instructions and good engineering practices.

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1.3 POWER CONVERSION CONTACT DETAILS

The Power Conversion Service department has been operational since the electrical rotating machines
first began to be manufactured in 1904.
Power Conversion Service excels in performance and innovation. Our experienced specialist teams
travel throughout the world ensuring minimum intervention time, providing our customers with the
technical and research resources of a major manufacturer.
Our Service department comprises sections for: replacement parts and motors, maintenance and repair,
expertise and diagnostics, installation & commissioning. You can contact our Service department by:
- Telephone, from 7h00 to 17h00: + 33 (0)3 83 38 40 00
- Fax: + 33 (0)3 83 38 42 94
- E-mail: servicesmotors@converteam.com
We provide assistance in the following areas:

- supply of replacement parts:
• coordination of replacement parts batches recommended for machines supplied
• sale of replacement parts suited to the concerned machine
- supply of spare motors:

• complete interchangeability assurance
• installation and commissioning by specialised teams
- on-site interventions:
• adjustments and commissioning
• expert analyses under actual operating conditions
• modifications required by developments in use of machines
• normal and exceptional maintenance works
• repairs
- handling of assistance and warranties:

• practical advice for commissioning
• processing of written complaints during warranty period
• implementation of corrective measures
1.4 DOCUMENTS TO BE COMPLETED AND SENT TO POWER CONVERSION

Acceptance report
Storage report
Installation report

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2. DESCRIPTION OF THE MACHINE
2.1 DEFINITION OF TYPES OF INDUCTION MOTORS (FL-F3-N3-N4 SERIES)

The Power Conversion induction motors range comprises three major series:
Flowpack series
The Flowpack series forms part of a range of closed-cage (horizontal or vertical) motors for voltages up
to 11 000V and power levels up to 850kW.
They are available with:
• 4 shaft heights of 280, 315, 355 and 400,

• 2 to 12 poles with rolling element or bushed bearings.
The frames and bearing caps are made of high quality cast iron with deep exterior fins for cooling. The
bearing caps are nested on the frame and contain the bearing housing.
F3 series
The F3 series comprises a range of modular, multipurpose efficient motors with power levels of 200kW
to 2500kW.
These are available with:
• 5 shaft heights from 355 to 560,

• 4 iron lengths,
• 6 types of cooling,
• 2 to 12 poles,
• cage rotor or slip ring rotor.
These motors can be horizontal or vertical.

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N3 series
The N3 series comprises a range of motors for all types of drives in most areas of application with
voltages of up to 20 000V.
These motors are highly modular and offer a wide variety of construction combinations.
The construction is based on a stator assembly mounted in a fabricated one-piece frame ensuring, in
vertical machines in particular, high vibration resistance performance. High quality windings are
ensured through a definition for each command and a vacuum-impregnated insulation system.
The rotor assembly is formed by:
• either bars and rings embedded together and brazed by an induction heating method to
form a squirrel cage.
• or, by windings, in the case of a wound rotor, according to the same principles applied for
the stator
N4 series
The N4 series comprises a range of motors for all types of drives in most areas of application with
voltages of up to 20 000V. Heights of shaft are from 630mm to more and poles number is from 6 to
more.
These motors are highly modular and offer a wide variety of construction combinations.
The construction is based on a stator assembly mounted in a fabricated one-piece frame. High quality
windings are ensured through a definition for each command and a vacuum-impregnated insulation
system.
The rotor assembly is formed by either bars and rings embedded together and brazed by an induction
heating method to form a squirrel cage.

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2.2 MACHINE IDENTIFICATION

The Power Conversion motors are identified by the motor designation and production number.
2.2.1 Motor designation

The FL-F3-N3 series motors are designated by their type, followed by various characters to indicate the
following:
Designation model - Flowpack series:

Example:
FL X C N 355 Y 08 G
Series name
Voltage
T : low voltage U < 1000 V
X : medium voltage 1 000 V < U < 10 000 V
Y : high voltage 10 000 V < U < 11 000 V
Rotor type
C : copper cage
Protection (only if applicable)
N : anti-spark machine
Sizes (height of shaft in mm for horizontal machines)
280, 315, 355, 400
Magnetic circuit length code
E, G, J, M, P, R, T, V, Y, Z
Polarity
02, 04, 06, 08, 10, 12
Type of bearings
G : bushed bearings in oil
C : rolling element bearings lubricated by grease
H : rolling element bearings in oil

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Designation model - F3 series:
Example:
F3 R Y C N 355 G 04 C
Series name
Cooling
R : air-air exchanger
H : air-water exchanger
M : fan and motor
P : open witout filtre
N : open with filtres (NEMA WPII)
G : connected by duct to ventilation
Voltage
Y : high voltage 10 000 V < U < 11 000 V
Rotor type
C : copper cage
A : aluminum cage
S : rings without retraction of brushes or permanent contact type
L : rings with retraction of brushes
P : internal overpressure
E : enhanced safety
N : anti-spark machine
Sizes (Height of shaft in mm for horizontal machines)
355 ; 400 ; 450 ; 500 ; 560
G;J;K;L
Polarity
02 ; 04 ; 06 ; 08 ; 10 ; 12
Types of bearings
G : ball-bearings lubricated by grease
C : self-lubricated bushes, or force-feed oil circulation

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Designation model - N3 series:
Example:
N3 R Y C (N) 630 K 04 C
Series name
Cooling
M : fan and motor
P : open without filter
N : open with filters (NEMA WPII)
Voltage
Y : medium voltage 10 000 V < U < 13 800 V
Z : high voltage U > 13 800 V
Rotor type
C : copper cage
A : aluminum cage
S : ring type
P : internal overpressure
E : enhanced safety
N : anti-spark
Polarity
Type of bearings
C : bushed bearings in oil
G : lubricated by grease

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Designation model - N4 series:
Example:
N4 R Y C 630 K 04 C
Series name
Cooling
M : fan and motor
P : open without filter
N : open with filters (NEMA WPII)
Voltage
Y : medium voltage 10 000 V < U < 13 800 V
Z : high voltage U > 13 800 V
Rotor type
C : copper cage
Polarity
Type of bearings
C : bushed bearings in oil
G : lubricated by grease

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2.2.2 Production number

Each motor is also identified by a production number stamped on the nameplate. This number is formed
by 9 characters (example: 06A281-001).
• The first 6 characters designate the internal order number.

• The last 3 digits represent the motor number of the series.
This number must be indicated in all correspondence with Power Conversion for any questions
concerning the machine.
2.2.3 Nameplates
The essential information concerning the motor is referenced and identified by nameplates.
2.2.3.1 Machine nameplate
5 11 17 12 7 8 14 9
5
1 10 6 24 2 13 3 4 21
15 23 29 30 31 25 26 27 35
22 16 32 33 34 18 19 20 28

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1. Motor type designation
2. Production number
3. Production year
4. Machine weight
5. Power
6. Power factor
7. Type of cooling
8. Assembly diagram
9. Protection degree
10. Construction standard
11. Acceptable ambient temperature
12. Type of service
13. Frequency
14. Efficiency at full load
15. Type of stator
16. Rated voltage of stator
17. Rated current of stator
18. Number of stator phases
19. Stator connection type
20. Stator insulation class
21. Overheat temperature rise (stator)
22. Type of rotor
23. Rated voltage of rotor
24. Rated current of rotor
25. Number of rotor phases
26. Rotor connection type
27. Rotor insulation class
28. Overheat temperature rise (rotor)
29. Type of bearing DE
30. Type of lubrication oil or grease DE
31. Oil flow DE or grease quantity, lubrication frequency DE
32. Type of bearing NDE
33. Type of lubrication oil or grease NDE
34. Oil flow NDE or grease quantity, lubrication frequency NDE
35. General information: - ATEX protection marking
- EC type approval certificate number

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The following plates are given for information and depend on the motor design.
2.2.3.2 Hydrocooler information nameplate
1. Dissipated power
2. Rated water flow
3. Load losses in water circuit
4. Rated pressure of water circuit
5. Test pressure of water circuit
2.2.3.3 Magnetic centering plate
1. Dimension X of magnetic centering taken from end of surface of bearing DE when sleeve coupling
is used.
2. Dimension Y of magnetic centering taken from end of surface of bearing DE when coupling
flange-type shaft is used.

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2.2.3.4 Pressurization plate
3
4
10
1. Protective gas.
2. Internal free volume.
3. Minimum air flow rate for purging before start-up.
4. Maximum flow under normal operation at maximum overpressure.
5. Minimum acceptable overpressure.
6. Maximum acceptable overpressure.
7. Maximum temperature of protective gas.
8. Minimum operating pressure.
9. Plant alarm pressure.
10. Plant trip pressure.

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3. HANDLING – TRANSPORT – STORAGE
3.1 RECEIVING INSPECTION

Check the condition of the containers and packaging to make sure that the equipment has not been
subject to any damage during transport.
Make sure that the resources at the site are appropriate for handling of the equipment,
weights and volumes.
Take all the necessary measures to prevent any damage to the equipment during handling on site.
Take inventory of the various items, referring to the shipping vouchers and by visually inspecting the
equipment, including accessories.
The receiving report joined to the paragraph “1. Safety instructions” must be filled in and returned to
the Power Conversion projects department once the inspection has been completed.
If you observe any malfunctions:
Any signs of damage or impact must be reported.
Issue all the necessary official reservations with the carrier within 24 hours and inform Power
Conversion within the same time by fax or by registered later.
Take all the necessary protective measures to ensure the safety and condition of the equipment.
Have a legal (preferably) statement drawn up and, in all cases, take explicit pictures of the damage
observed.
3.2 HANDLING PRINCIPLES
3.2.1 General measures

Motor in crate
Fit slings as indicated on package only.
Pay attention to the position of the centre of gravity which may be offset with respect to the centre of
the crate.
Should a forklift truck be used to move the crate, make sure it is properly centred on the forks, keeping in
mind the dimensions and centre of gravity of the crate.
The crate must not be turned over or carried on its side under any circumstances.
The crate must be correctly secured to prevent impacts or overturning.
Do not stack several crates; this can result in damage.

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TOP
TOTAL
WEIGHT
BOTTOM
Example centre of gravity
Motor out of crate

The motor is delivered entirely assembled.
Weight: see nameplate on motor.
Fragile equipment. Handle with care.
Use a lifting beam* or adjustable slings*.

Fit the lifting shackles* in the holes of the lifting lugs.
When handling the complete motor, use the lugs located on the upper part of the frame.
Do not handle the motor without first having checked that the rotor locking system is in place.
(*) Lifting beam, slings, lifting shackles not included in our supply.
Refer to the outline dimensions drawing before handling the motor. This drawing
indicates the weights, center of gravity and overall dimensions.

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Handling diagram examples
When handling the motor, fit the slings using a lifting beam to prevent any damage to the air/air or
air/water cooler mounted on the upper part of the rotor.
Horizontal motor, Flowpack 2 type:
Adjustable slings
Horizontal motor, F3 type:

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Horizontal motor, N3 type:
Vertical motor, Flowpack 2 type:

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Vertical motor, F3 type: Vertical motor, N3 type:

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3.2.2 Turning over a vertical motor to the horizontal position

1 2
• Using 2 bridge cranes (1 and 2), sling
the motor by the 4 lifting lugs on the
motor.
• Choose the side with the fewest

accessories (terminal box, etc.) for
removal of the motor.
• Raise the 2 bridge cranes (motor no

longer seated on 4 legs).
• Release the slings on one side 1 2 1 2

(bridge crane 1). The motor is held by
only one bridge crane (No. 2), aligned
on its centre of gravity.
• Turn the motor by 180° on its axis.
• Sling the motor, coupling side, by the

flange stiffener using bridge crane
No.1 and 2 shackles (the 4 lifting lugs
are on the same side as bridge
crane No. 2)
• Lift the lower part of the motor to the 1 2

same height as the upper part (the
motor is now in the horizontal
position).
• Set the motor on its 4 lifting lugs and

remove the slings.

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3.2.3 Rotor locking system

Whenever handling or transporting the motor, the rotor locking system supplied by Power Conversion
must be installed.
This system is used to prevent any movement of the rotor during transport and handling in order to
protect the bearings.
The locking system must be installed so that the rotor is locked without any stress applied. Failure to
satisfy this condition can result in damage to the shaft line components.
3.3 STORAGE PRECAUTIONS
3.3.1 Storage instructions lower than 6 months
3.3.1.1 Storage conditions

The equipment must be stored in a clean, dry and properly ventilated location.
5 The storage temperature must be greater than -20°C, except where specifically stipulated by contract.
The equipment must not be set directly on the ground. The equipment should be set on wood beams to
prevent any damage from the bottom and to facilitate the circulation of air around the motor.
The storage area must be free of any vibration which could result in damage to the equipment.
The storage location must ensure maximum protection against possible nuisances such as: flooding,
pests, etc.
Do not forget to carefully blank the cable lead-ins.
Avoid any sharp temperature variations which could create condensation (with closed motors, remove
the drain plugs provided on certain types of machines, or on customer request).
Storage in a saline or corrosive atmosphere is prohibited unless otherwise specified by contract.
3.3.1.2 Protection concerning mechanical equipment

Be sure to protect non-painted parts (shaft ends, mounting bases, etc.).
• Cover these with a film of non-acid oil or rust preventive varnish.

• Regularly monitor this protection.
All our bearings are protected against corrosion for up to two years following departure from factory
and do not require any intervention on site.
All our motors are equipped with a red silicon packing seal inside, at the bearing/shaft interface (bearing
baffle); this seal has no functional purpose relative to operation of the motor. On first start-up, this seal
may come off its support but will not interfere with normal operation of the motor in any way.
• The rotor locking system must be maintained in place.

NOTA • Where different storage conditions have been defined in the contract, these conditions
shall override those defined above

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3.3.1.3 Protection concerning electrical equipment
Periodically check the insulation resistance of the stator winding, which must never be below 3000
Ohms per Volt of the operating voltage, increased by 1000 V.
Example:
- for a 5 kV motor = Insulation resistance 18 Megohms.
- for a 20 kV motor = Insulation resistance 63 Megohms.
These minimum values are valid for measurements taken at ambient temperature, between winding
and ground, and between phases if the motor design so allows.
For wound rotor motors, retract the brushes or place a sheet of insulating material (mica or other)
between the brushes and the rings; the insulating material must neither be porous or hygroscopic. The
minimum insulation value at the wound rotor will depend on the rotor voltage, but must always be
checked on the basis of 3000 Ohms per volt of the rotor voltage, increased by 1 000V.
Should the insulation resistances drop below the minimum values indicated, start by checking if the drop
in insulation is located at the insulators in the terminal boxes.
If an abnormal drop in insulation resistance is observed, the storage conditions must be modified to
prevent the humidity from impacting the motor windings any further. This measure will reduce motor
drying complications before commissioning. We recommend that you immediately proceed to fully dry
the motor windings. This procedure is mandatory prior to commissioning. The recommended drying
method is detailed in paragraph “4.5.1 Insulation resistance measurement and drying method”.
3.3.2 Storage instructions between 6 and 12 months (according to IP806)
3.3.2.1 Storage condition

The following conditions concerning the storage area (only without taking into account the motor is
packed or not) must be respected. The storage must be carry-out:
- in a ventilated and covered premises, in dry surrounding air, protected from dust, and from corrosive,
explosive or gaseous atmosphere,
- not exposed to liquids (water, acid, oil, fuel and other),
- not exposed to major vibrations (floor of storeroom, frame or other), if the concrete base or the skid are
not installed on vibration absorbers the motor itself has to be placed on such absorbers (ex stringers
made of restricted hygrometry wood -class C22 plate with class 3 pressure-sealed treatment- or buffers
pads Grypsol type),
- within the temperatures range:
minimum from -20°C without any tolerance,
maximum to +40°C with tolerance (+10°C / -0°C),
- with a controlled rate of humidity < 70%. If this rate is increasing, a heating of the premises have to be
ensured.
- the motor covered by a tarpaulin

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3.3.2.2 Conditioning and protection of the equipment
The motor space heater has to be switched on during storage.
The rotor has to be uncoupled from the driven machine.

The tool delivered with the motor for protection of the rotor during transport should be installed so far
possible.
An anti-oxydizing protection must be applied on:

- the shaft ends
- the bearings
- the main terminal, auxiliary and exciter boxes
- the coolers (water, air)
For more details on the execution of these different actions, refer to IP806 “Manufacturer
recommendations for medium time storage during completion of the site installation” attached to this
manual.
3.3.2.3 Prescriptions for the equipment control

Following recommendations concerns the technical controls that the client can carry out during the
non-use period of the material.
Control of the pollution in the main stator and exciter windings:
- polarisation index
- measure of the total insulation resistor
- visual control of surface quality of the tinned lugs
- sealing joints quality between covers and terminal boxes cabinets.
Control of the internal pollution of the bearings.
For more details on the execution of these different controls, refer to IP806 “Manufacturer
recommendations for medium time storage during completion of the site installation” attached to this
manual.
3.3.2.4 Temporary interruption or end of storage period

Refer to IP806 “Manufacturer recommendations for medium time storage during completion of the site
installation” attached to this manual.

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3.3.3 Storage instructions higher than 12 months (according to IP784)
3.3.3.1 Storage condition

In case of storage higher than 12 months, the following conditions on the storage area (only without
taking into account the motor is packed or not) must be respected. The storage must be carry-out:
- in a ventilated and covered premises, in dry surrounding air, protected from dust, and from corrosive,
explosive or gaseous atmosphere,
- not exposed to liquids (water, acid, oil, fuel and other),
- not exposed to major vibrations (floor of storeroom, frame or other),
- within the temperatures range :
minimum from -20°C without any tolerance,
maximum to +40°C with tolerance (+10°C / -0°C),
- with a controlled rate of humidity < 70%. If this rate is increasing, a heating of the premises have to be
ensured.
In this conditions and following the periodicity of equipment checks and reconditioning, certified by our
care, such a protected equipment gives a very long life, however restricted to 5 years.
3.3.3.2 Conditioning and protection of the equipment

An anti-oxydizing protection must be applied on:
- the shaft ends
- the bearings
- the main terminal, auxiliary and exciterl boxes
- the water coolers
- the pressurization system (if exists)
An anti-vibration and mechanical protection must be installed.

An anti-condensation protection must be installed (heating resistors).
For more details on the execution of these different actions, refer to IP784 “Manufacturer
recommendations Long time storage” attached to this manual.
3.3.3.3 Prescriptions for the equipment control

Control of the pollution in the main stator and exciter windings:
- polarisation index
- measure of the total insulation resistor
- visual control of surface quality of the tinned lugs
- sealing joints quality between covers and terminal boxes cabinets.

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Control of the internal pollution of the bearings.
For more details on the execution of these different controls, refer to IP784 “Manufacturer
recommendations Long time storage” attached to this manual.
3.3.3.4 Extension of storage duration with SEI 4C WRAPPING

If the motor is to be used as a spare or if commissioning of the motor is planned for a date more than 6
months into the future, we advise our customers to order a « maritime » packaging system (SEI 4C type)
which should remain in place, undamaged, throughout the storage period. In this way, the motor will be
sheltered from humidity in a heat-sealed cover with desiccant bag.
If the equipment is not used during 24 months under the storage conditions described in the § 2 and
with an SEI 4C packing, the client can extend the conservation of the material by taking the following
precautions:
Every 6 months:
• Open the wooden box.

• Open the internal cover neatly in order to reuse it.
• Check the state of the preserved material.
• Put in new bags of desiccant.
• Close the cover with welding clip.
• Evacuate air from the cover with suction cleaner.
• Check the welds and the air tightness of the cover.
• Close the wooden box.
• Note the check date on the box.
For more details concerning the long time storage, refer to IP784 “Manufacturer recommendations Long
time storage” attached to this manual.
3.3.3.5 End of storage period

Refer to IP784 “Manufacturer recommendations Long time storage” attached to this manual.

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4. INSTALLATION “PRE-COMMISSIONING”
4.1 GENERAL RECOMMENDATIONS

Certain machines are equipped with at least one insulated bearing to prevent circulation of bearing
currents. Be careful not to short-circuit this insulation, in particular by the shielding of the bearing sensor
connection cables.
4.2 LUBRICATION
Depending on the motor speed, the operating conditions or the customer’s requirements, the motors will
have different types of bearings and/or lubrication systems. These can include bearings with :
- rolling element bearings lubricated using grease
- self-lubricated rolling element bearings lubricated using oil by rings and splash system
- self-lubricated bushed bearings using oil by rings and splash system
- forced lubrication bushed bearings with rings, requiring an auxiliary lubrication unit.
- forced lubrication bushed bearing without rings, requiring an auxiliary lubrication unit, backed up for
protection against electrical cut out.
- shoes lubricated by splash system or by auxiliary lubrication unit.
In certain cases, the oil may be cooled using a water cooling coil, or heated using a
NOTA
submerged heating element.
4.2.1 Lubrication by grease

Mixing greases of different quality is prohibited as this is dangerous for the “life” of the bearings.
A plate indicating the greasing frequency, the quantity and quality of lubrication is secured to each
bearing (these values can be different according to bearing).
Unless otherwise specified in the bearing manual or on the lubrication plates, a lithium base grease
should be used.
We recommend that you use, for example, the greases defined paragraph “7.2.3.2 Equivalence table”
for ambient temperatures of -20°C to +40°C.
For temperatures above or below these values, refer to the specifications given in the contract.
If automatic oilers are used :
• You must refer to the utilization conditions for the automatic oiler model defined in the
manufacturer’s manual.
• Failure to observe these conditions can result in serious overheating and irreparable
damage to the bearings.

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4.2.2 Oil lubrication (splash or pressurized)

Before you connect the exterior circuit to the oil inlets and outlets of the motor, YOU MUST carefully
CLEAN the AUXILIARY LUBRICATION CIRCUIT, and more particularly the pipe, to prevent any foreign
matter from getting into the motor bearings.
We recommend « Flushing », which consists in running pressurized hot oil in both directions (pressurized
to 1.5 times the operating pressure).
If by inadvertence, the cleaning operation has not been performed prior to starting up the lubrication
system, you must immediately stop the installation and clean the auxiliary lubrication circuit and the
motor bearings (this will required disassembly).
With a force-feed lubrication system, the oil circuit must be equipped with a filter with mesh width of
between 10 and 20 microns.
Certain bearings require a raising unit. When this is the case, the bearing must be equipped with a high
pressure oil circuit.
4.3 RECOMMENDATIONS CONCERNING MECHANICAL EQUIPMENT
4.3.1 Assembling the coupling

In all cases, other than that of a pulley and belt transmission, we recommend that you use a set of 2 to
3mm thick shims under the motor feet. This will greatly facilitate alignment of the machines.
Make sure that the coupling has been properly balanced, in compliance with the applicable standards,
for a balancing class less than or equal to that of the motor.
Reminder: The rotors used in our motors are balanced with a half-key, except where otherwise specified
in contract.
Where a keyed sleeve is used, with no axial locking system, we believe that a minimum amount of
tightening is required to ensure that the sleeve does not slip (reminder: recommended fit H7m6).
Be careful not to compromise the balancing by the section of key coming out of the shaft behind the
sleeve.
When:
- the transmission component is shorter than the shaft end key,
- the balancing has been defined and carried out using a ½ key,
- the rated speed (or maximum, if variable speed) is > 1800 rpm, or whatever the speed if the command
makes reference to API 541.

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you must:
- either mill-off the section of key which protrudes as shown in the figure below;
Coupling sleeve
Section of key to be machined
Key
Shaft end
- or, fit a spacer, as shown in the figure below, having the following characteristics :
- same number of grooves as sleeve
- sliding fit on shaft (H7m6)
- min. outside diameter = 1.4 ø shaft.
Coupling sleeve
Spacer
Key Shaft end
4.3.1.1 Coupling by sleeve

Use of toothed couplings is subject to Power Conversion approval on order. Failing this,
NOTA
damage can occur at the rolling element bearings.
In this respect, toothed couplings tend to generate, by their design, thrust which must be taken into
account in the design and construction of the motor.

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With this important remark in mind, you must:
- Remove the anti-rust protection and any signs of rust which you may have observed on the shaft end.
Using a fine stone, carefully remove any scratches or signs of impact if necessary.
Clearance 1/10
Fit in shaft
N9 - h9
H7 m6
Sectional view of sleeve-shaft assembly

(standard tolerances to be checked, case-by-case, with respect to outline dimensions drawing)
- Check the fit of the key which could slide in the sleeve slot with clearance at the top.
- Fit the transmission component (sleeve) without impacts to prevent any deterioration to the shaft
and/or bearings.
Use of a special lubricant (Molikote) is recommended except for taper fit assemblies which must be
performed dry.
In general, the sleeve can be heated in an oil bath or oven to 80/100° C, then placed in position by hand
and maintained in position (or fully in if a stop is used) by the shaft end screw. A shrink fit is always
performed when the sleeve is intended for mounting on a plain shaft without key (do not forget removal
system).
Immediately cool the shaft end, sleeve and bearing using a compressed air jet. Install the sleeve locking
system if necessary (example: washer and shaft end screw).

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4.3.1.2 Coupling by hydraulic coupler
This coupling method requires the written authorization of Power Conversion. To check that it is possible
to fit the primary of the coupler directly on the motor shaft end, you must inform us on the weight which
will be effectively supported by the shaft end and the distance from the point of application of the
weight to the shaft collar.
4.3.1.3 Coupling by pulley and belts

As indicated above, the coupling method is subject to the written authorization of Power Conversion in
order to check that there will not be any unwanted effect on correct operation of the motor.
We will need the following information:
- Pitch diameter of pulley.
- Width of pulley.
- Number of belts to be used and their characteristics.
- Intensity and direction of pulling force which will be applied.
- Weight of pulley.
The pulley hub must be locked on the shaft to prevent it from moving axially.
The centre of gravity of the pulley must also be as near as possible to that of the motor shaft collar.
4.3.2 Installation of motor on base
4.3.2.1 Important information concerning seating and anchoring of motor

The final mounting base for the motor must be sufficiently rigid to prevent any damage and must be
designed to eliminate any possible resonance due to excitation of the motor.
It must be either entirely separate, or uncoupled from the base of the driven machine.
The bearing surface of the motor legs on the base must be horizontal and flat.
The seating and anchoring of the motors must be designed to ensure the necessary strength with
respect to the fundamental efforts defined on the machine outline dimensions drawing.
4.3.2.2 Motor positioning

When handling, transporting and positioning the motor next to the driven machine, the rotor locking
system must be in place.
The rotor locking system must be removed:
• for a horizontal motor, prior to the shaft line adjustment,

• for a vertical motor, prior to placing it opposite the shaft end of the driven machine.
Following final installation and alignment of the motor, the motor should be pinned in order
NOTA
to determine the correct position of the motor should it be moved at a future date.
For the pinning, two holes must be drilled diagonally opposite each other on a diameter of sufficient size
in the baseplate or chassis. This operation is performed after final tightening of the motor.

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4.3.2.3 Supply of baseplates and tie rods (optional)
Adjusting shims placed between the baseplates and the motor legs are used to adjust the heights of the
centre lines of the two machines.
The upper level of the baseplates must be adjusted as shown in the diagram below:
Moto r
Driven machine
Motor Driven machine

baseplates centerline
X + 1mm
10/+2 mm
Baseplate X = height of motor centerline
NOTA The adjusting shims must be positioned using, insofar as possible, the jack screws.
4.3.2.4 Special measures concerning environment

Special attention must be given to the location of the motor in its environment. The following basic
information is given for guidance:
- The cooling air must reach the motor freely. For this reason, all the necessary precautions must be
taken to prevent recycling of the hot air due to shields which are too near to the motor (partitions – walls
– neighbouring machines - for example) ; the room in which the motor is mounted must be sufficiently
ventilated to prevent the ambient temperature from exceeding the maximum operating temperature
limit.
- The cooling air must not contain solid particles which could foul the cooling ducts or cause wear by
abrasion. This remark can of course be ignored when the specific features of the ambient air have been
indicated in the order. In the latter case, the motor supplied will have been designed to satisfy the
requirements of the conditions indicated, including chemical atmospheres for which the characteristics
will have been indicated to us.
- For wound rotor motors, correct operation of the permanent contact brush and ring system calls for an
absolute moisture content of the cooling air of between 6 and 15 grams of water per cubic meter (m3) of
air. A cooling air which is too dry would result in excess wear of the brushes. This drawback can be
sometimes avoided by the use of special brushes. Such a case must always be indicated on order.

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4.3.3 Check of shaft line - alignment
4.3.3.1 General information concerning adjustment of machine

The shafts and sleeves used as reference for the alignment must have a run-out of less than 3/100 mm.
Measuring coupling hub run-out:

The coupling hub run-out is measured to detect possible defects of the shaft-coupling hub system.
This measurement is performed using dial gauges to take a measurement with respect to the machine
bearing, positioned as shown in the figure below.
Coupling hub
It is necessary to adjust the parallelism (angular misalignment) and the concentricity (parallel
misalignment) of the coupling sleeves of the drive and driven machines. Jack screws and adjusting
shims supplied with the motor are used for this purpose. The alignment can be performed using a
system of dial gauges as described below, or using a laser system.
Angular misalignment
Rigid collar
Parallel misalignment
Rigid collar
The machine must be adjusted using a system for fine adjustment (longitudinal and transverse) of the
jack or adjustment screw.
For the vertical direction, threaded holes and jack screws are provided on the motor legs for adjustment.

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4.3.3.2 Special features: machines with axially unlocked rotor
Not taking into account exceptional cases, for the Power Conversion motors equipped with standard
construction bushed bearings and implementing a “floating rotor” (axially free with a lateral clearance
around the magnetic centre), the axial clearance will depend on the size of the motor and will vary from
± 5 mm for small motors to ± 12 mm for the larger motors. These values are indicated on the motor
outline dimensions drawing.
Coupling to driven machine

The motor rotor must be maintained axially using a limited play coupling for the link with the driven
machine which must be equipped with a thrust bearing. The maximum axial movement of the rotor
(sum of play of thrust bearing, play of coupling and value of thermal expansion between thrust bearing
and motor bearing DE) must be substantially lower than the possible play of the rotor in the motor
bearings. In general, the limitation is ± 0.5 to 1 mm and must be, in all cases, less than ±1.5 mm.
The purpose of this type of coupling is to prevent lateral contact between the shaft collars and the
bearings whose side faces are not designed for this purpose. Failure to observe these conditions will
result in a serious risk of damaging the bearing bushes.
Position of magnetic centre

The magnetic centre can differ slightly (generally, by less than ± 3 mm) with respect to the geometric
centre. During the factory tests, the magnetic centre is marked. Its position is indicated in the test report
and on a special plate secured on the motor flange above the bearing, coupling side, using a dimension
“X” or “Y” detailed below. This position must be reached when the shaft line is hot.
Outer cover Shaft shoulder, sle eve side

of bearing box X= mm
Case of coupling
sleeve
Case of coupling
flange
Y= mm

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Installation of bushed bearing motors
As for all motors, it is necessary to adjust the parallelism (angular misalignment) and the concentricity
(parallel misalignment) of the coupling sleeves of the drive and driven machines. Use the jack screws
and adjusting shims supplied with the motor for this purpose.
In addition, for rotors unlocked axially, the rotor must be correctly centred in the motor by observing
the "X" or "Y" dimension defined in the previous section.
If the rotor is correctly centred in the stator, the axial thrust transmitted during operation of the motor to
the thrust bearing will be null or very low. Otherwise, a magnetic force will appear and may cause
interference for the coupling and/or the driven machine. This force depends on the size of the motor and
the value of the off-centering; it can reach several thousand newtons. It is therefore very important to
correctly adjust the magnetic centering during the motor installation and commissioning
procedures.
Rotor movements during start-up period

When the motor is idle, the rotor can be offset with respect to the magnetic centre for any given reason
which may also result from the previous shutdown. This in itself is not a problem, but on the next start-
up, the rotor may sway forward and backward around the magnetic centre until the natural recentering
places the rotor in the correct position. This is normal and there are no unwanted effects.
Thrust due to fan(s)

In general, any possible force due to the fan(s) installed on the motors is balanced by the magnetic
return effort and the rotor stays within the axial clearance of the bearings.
Our experience and feedback has shown that our customers have damaged bearings DE on machines
with axial ventilation not equipped with a fixed bearing for a properly sized shoulder.
2
For these motors, manufactured before 2001, the uncoupled rotation conditions are as follows:
- Check the position of the magnetic centering at nominal speed for 1 minute. Motors with axial
ventilation (external fan) are more sensitive to this phenomenon.
- If the rotor position:
does not reach the axial clearance min./max. limits (1mm), uncoupled rotation (solo run) is
possible with no limitation in time,
reaches one of the axial clearance min./max. limits (shaft shoulder in contact with bearing),
uncoupled rotation (solo run) is not possible. It can only turn for a few minutes (<10 min)
uncoupled.
- The bearing must be lubricated.

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For motors built starting in 2001, uncoupled rotation (solo run) is authorised provided the bearings are
correctly lubricated.
On request, the thrust can be cancelled by intentionally off-centering the rotor on assembly. The force
created artificially will cancel the thrust of the fan(s). In this case once again, the "X" or "Y" dimensions
described above must be observed.
4.3.3.3 Compensation of thermal expansion during alignment
When aligning the motor and the driven component, the various thermal expansion constraints must be
taken into account.
The outline dimensions plan for each motor gives the following thermal expansion values in the three
axes:
- Transverse movement of shaft in bearing: ∆Xm
- Vertical expansion (including expansion of frame and movement of shaft in its bearing: ∆ym
- Axial expansion
The concentricity and axial clearance of the coupling between the motor and the driven component
must be adjusted to compensate for the alignment performed with the motor hot as represented below.
The cold alignment must take account of the differential expansions when the motor is hot with respect
to the driven machine to ensure correct alignment of the machines when hot.
Representation of parallel misalignment corresponding to cold and hot states with horizontal or
vertical projection
Hot
alignment
∆xo or ∆yo driven
component
∆xm or ∆ym
motor Driven component in
cold state
∆DH or ∆DV
Motor in cold
state
Cold horizontal misalignment ∆DH= ∆Xm - ∆Xo

Cold vertical misalignment ∆DV = ∆ym - ∆yo

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Representation of parallel misalignment corresponding to cold and hot states in two dimensions
∆xm
Hot
alignment
∆ym
∆yo
∆DV
Motor in cold Driven component

state ∆DH in cold state
∆xo
Front view at motor shaft end
Angular misalignment: ∆DA

Consistent with the design of the bearings (with or without axial clearance), the coupling must be chosen
so that the variation between the hot and cold states is within the maximum axial range of movement
allowed by the rotor. The axial position with the rotor hot must between +/- 1 mm with respect to the
magnetic centre.
For motor bearings with axial clearance, the alignment adjustment with the rigid coupling should allow
avoiding contact between the shaft collars and the bearings resulting from the sum of the thrust
bearing clearance, the coupling play and the value of the overall axial thermal expansion between the
thrust bearing and the bearing DE of the motor (∆DA: Overall expansion of shaft line between thrust
bearing and motor shaft end).
Outside cover Shaft shoulder, slive side
X m= mm
of bearing box
Case of coupling
sleeve
Minimum limit position of rotor: X min
Maximum limit position of rotor: X max
∆DA must be less than the maximum mechanical position allowed by the bearings, subtracted from the
position of the magnetic centre, decreased by 5/10 mm, i.e.:
∆DA < Xm – Xmin – 0,5 mm
∆DA < Xm – Xmax – 0,5 mm
For a motor bearing without clearance, the flexible coupling should allow for the value of the overall
thermal axial expansion of the shaft line with no resulting effort.

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4.3.3.4 Tolerances
The alignment tolerances indicated by the coupling manufacturers are not acceptable to Power
Conversion. The position of our bearings allows for tolerances with values as follows:
Semi-flexible couplings Rigid couplings
Speed > 1500 rpm Speed ≤ 1500 rpm
Outside diameter Outside diameter Outside diameter Outside diameter For all sleeve
of sleeves ≤ 200 of sleeves > 200 of sleeves ≤ 200 of sleeves > 200 diameters
mm (or 8'') mm (or 8'') mm (or 8'') mm (or 8'')
Alignment Alignment Alignment Alignment Alignment
tolerance: 0.03 tolerance: 0.05 tolerance: 0.05 tolerance: tolerance: 0.03 mm
mm (or 0.0012'') mm (or 0.002'') mm (or 0.002'') 0.1 mm (or 0.004'') (or 0.0012'')
These values do not take account of the normal vertical or radial expansion deviations due to thermal or
mechanical phenomena occurring during operation of the driven or drive machine.
The instructions for vertical adjustment and alignment of the motor are those defined by the driven
machine manufacturer.
The curve of the radial and axial forces of the drive component as a function of misalignment must be
taken into account to define the maximum acceptable misalignment tolerance between the two
machines.
Observance of guidelines
Failure to observe the guidelines and values indicated above will result in :
• a high vibration level,

• significant overheating of the bearings,
• premature wear or destruction of bearing or shaft components.
4.3.3.5 Tightening of machine mounting screws

The tightening torques specified in paragraph “7.2.3.1 Check of fastenings" must be observed to
prevent any damage to the screws due to fatigue, or tearing of threads, or damage to motor due to
vibration.
In general, our motors are secured by screws directly in the chassis or baseplates.
If the motor is secured with threaded anchor rods sealed in concrete, the tightening torque will be
defined in accordance with the diameter and quality of the tie rod.
Soft foot adjustment

Purpose: This adjustment is performed to eliminate any stresses due to mechanical deformation in the
motor structure resulting from poor clamping conditions. These stresses can directly impact the
vibration level and movement of the machine shaft.
Adjustment principle: When securing the machine, you must check that the motor leg does not
descend by more than 5/100 mm at the clamping point when torque-tightening each screw (paragraph
“7.2.3.1 Check of fastenings”). Use a dial gauge or a laser system for this purpose.
If the value exceeds 5/100 mm (outside API requirements), but 25/1000 mm for an installation governed
by the API standards, shims must be placed under the mounting points to compensate up to the
acceptable value.

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4.3.3.6 Systematic check of machine alignment
The indications given by the coupling manufacturers concern the misalignment tolerated for proper
functioning of their own supply, whereas the bearings and rolling element bearings of the machines
cannot accept such misalignments as these will result in an abnormal work rate on the rolling element
bearings and bushes, or even the shaft.
Precise instruments are required to measure the misalignment (dial gauges, laser) and the instruments
must be correctly mounted (free of any deformation of supports, etc.).
The measurement resources used should make it possible to cancel the effects of run-out.
4.3.3.7 Pinning the motor

Pin the motor. This will be useful for reinstallation of the machine at a future date (see principle
described in paragraph “4.3.2.2 Motor positioning”).
4.3.4 Connection of bushed bearings lubricated by force-feed lubrication

The oil inlet and outlet pipes for the motors with force-feed lubricated bushes must be equipped with
isolating valves (customer supply, or on request).
These correctly sized lines must be equipped with a flowmeter and possibly an oil circulation indicator at
the oil inlet and/or outlet of each bearing.
The pipe must be connected using appropriate connection fittings and seals to eliminate any risk of
leakage. After connecting, the tightness of the oil circuit and the oil pressure and flow on each bearing.
The oil inlet diaphragm on each bearing is not drilled. Therefore, it must be drilled to diameter, taking
account of the pressure upstream of each bearing and the required oil flow (paragraph “7.2.3.2
Diaphragm”) must be checked.
The bearings are not lubricated. For more details on the lubrication systems to be implemented, refer to
paragraph “7.2.3.2 Lubrication of bushed bearings”.
4.3.5 Connections to cooling circuit
4.3.5.1 Air/air cooling by duct

The external air lines must be cleaned before making any connections to avoid clogging the cooling
system and the resulting loss of heat exchanger efficiency.
Motors designed for cooling by air must be connected to the air lines using appropriate seals to prevent
leaks.
At the duct air inlets, grills should be installed to prevent penetration of any solid foreign matter; this can
include filters for dust. The load losses in these ducts including grills and possible filters must be
indicated to us at the moment of design of the motor.
4.3.5.2 Air/water cooling

For motors equipped with a hydro-cooling system, the external lines must be systematically cleaned to
prevent any risk of fouling and clogging of the air/water exchanger.
Before connecting, you must check that the water used is compliant with the contractual specifications
communicated to the motor builder.

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The following is required:
- complete cleaning of water inlet and return pipes (flushing).
- check for absence of foreign matter suspended in cooling water.
- appropriate analysis confirming contractual characteristics of water supplied to motor builder.
It is also necessary to ensure that the cooling fluid is protected against freezing.
The inlet and/or outlet pipe must be equipped with an isolating valve and a system for adjusting the
water pressure and flow as required by the hydro-cooler utilisation conditions defined on the nameplate.
The hydro-cooler must be connected using appropriate connection fittings and seals to prevent any risk
of leakage and must be compatible with the operating pressure. The circuit must be equipped with a
safety valve calibrated to the maximum test pressure of the cooler.
After filling the heat exchanger with water, the tightness of the circuit, its pressure and flow rate must be
carefully checked.
For any extended period of non-use, the cooling circuit must be drained.
4.4 SPECIAL MEASURES RELATIVE TO MOTORS INSTALLED IN AN AREA HAVING

EXPLOSION HAZARDS
Remember that the manufacturer is not responsible for the choice of motor protection defined in
accordance with the installation area and that it is the sole responsibility of the user to define the type of
motor protection.
Depending on the nature, the quantity of gases in the environment and the classification of the AREA,
the following main motor designs may be encountered:
“PRESSURISED” motors - Ex. P

The envelope used with these motors is not designed to withstand an internal explosion; however,
explosion is prevented by pressurising the internal atmosphere of the motor. The atmosphere
used for pressurisation is in general an inert gas; in all cases, this gas will not contain any
explosive elements. These motors are referred to as “active safety” motors.
“ENHANCED SAFETY” motors, Ex. E

The envelope used with these motors is not designed to withstand an internal explosion. They are
designed mainly to:
- Not produce a spark
- Ensure a maximum heating of the windings which is compliant with the applicable standard.
- Have a maximum surface temperature which is compliant with the specification.
- Have a blocking time (rotor blocked) which is sufficient and compliant with the applicable
standard and which does not result in any dangerous overheating, or damage to the windings.
Motors of this type are referred to as “active safety” motors.

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“ANTl-SPARK” motors
These motors must not produce sparks. They are generally used in areas having very low
explosion risks. This specific protection can be associated to a limit surface temperature.
For all the equipment, the following special precautions must be taken, in addition to those detailed in
this manual:
4.4.1 “Pressurized” motors

The connection to the pressurisation device is made at the automatic leak compensation system.
As for the other lines indicated above, these must be cleaned beforehand. These connection
lines must be purged by supplying them with the gas to be used for pressurization. The
pressurized air inlet lines must only be connected when no further fluid (water, oil, etc.)
and/or particles will be carried by the pressurization air.
• Check that all the terminal boxes and access covers are correctly closed.
• Check that the gas used for pressurization does not contain any inflammable and/or
explosive gas.
• Ensure that the cable glands are compatible with the motor certification.
• Before start-up, perform a rinsing operation, strictly following the manufacturer’s
instructions and making sure that the pressurization air evacuation hole is free.
• The motor must only be started up after the required rinsing cycle has been completed
and the compensation state indicated on the automatic leak compensation system has
been achieved.
• The alarm contacts and the status switch signals of the compensation system must be
connected to the control system of the main circuit-breaker of the motor (Ex p) to ensure
that it is impossible to power up before the purging operation has been completed and
the motor has been pressurized.
DO NOT STOP THE PRESSURIZATION AIR SUPPLY AFTER THE RINSING OPERATION.
NOTA
DO NOT OPEN THE COVERS OF ANY OF THE TERMINAL BOXES AFTER RINSING.
4.4.2 “Enhanced safety” anti-spark motors

Check that the power supply cable ends are properly tightened on the connection strips provided for this
purpose in the motor terminal boxes. If rinsing before start-up is required by the manufacturer, the
rinsing flanges must be connected to the customer circuit provided for this purpose. The air used must
be clean, dry and free of any oil, or inflammable or explosive gas. The pressure, flow rate and rinsing
time must be compliant with the data supplied by the manufacturer.
If a rotation sensor is to be used on the motor, it must be included in the motor start-up and protection
chain with the timing corresponding to the contractual values.

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4.5 ELECTRICAL RECOMMENDATIONS: ELECTRICAL CONNECTIONS
4.5.1 Insulation resistance measurement and drying method

Humidity is particularly harmful to correct operation of electrical motors.
Before powering up:
• check the insulation resistances of the stator windings with respect to ground.
• perform a bias index procedure.
• check the tightening torque (paragraph “7.2.3.1 Check of fastening”) of all the power cable
electrical connections on the HV and neutral terminals.
The insulation and bias index values of the machines must be entered in the insulation report.
When performing the insulation measurement, the auxiliaries must be connected to ground.
The measurement instrument must supply a measurement voltage consistent with the conditions
indicated in the table below:
1 000 V< Un 3 000 V < Un < 6 000 V< Un
Motor voltage Un< 1 000 V Un> 13 800 V
<3 000 V 6 000 V < 13 800 V
Applicable insulation
500 V 1 000 V 2 500 V 5 000 V 10 000 V
measurement voltage
- Stator voltage > 2500 Volts

For these measurements, use a 2500 V megohmmeter (minimum).
To authorise start-up, the insulation resistance measured must be at least:
R=3 (1+U)
• R= insulation resistance in megohms
• U= nominal voltage in kV
- Stator voltage < 2500 Volts

Use a 500 V megohmmeter.
The insulation resistance must be at least 10 megohms.
- Rotor voltage < 2500 Volts

Use a 500 V megohmmeter.
With a wound rotor, the minimum insulation value at the rotor will depend on the rotor voltage, but must
always be calculated on the basis of 3000 Ohms per Volt of rotor voltage increased by 1000 V.
For values below the values defined above, perform a drying procedure before starting the
motor.

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Drying
Supply the stator with three-phase current applying a voltage not exceeding 1/10 of the nominal
voltage, with rotor blocked (and rings short-circuited where a wound rotor is concerned).
During the drying procedure, check the heating on the stator windings using stator temperature
sensors, or using a thermometer. The maximum acceptable temperature is 80°C.
Once the drying is completed, disconnect the power supply and allow the motor to cool down to the
ambient temperature. Check the insulation level again and if the value measured is correct, set up the
normal connections for start-up. If the value is not correct, resume the procedure and check again.
The motor winding should be ventilated using dry air to eliminate excess humidity during the drying
procedure.
On customer request, certain motors are equipped with heating resistors. These resistors are used to
obtain an internal temperature which is greater than the outside temperature to avoid any
condensation.
These resistors can remain powered continuously when the motor is stopped; the resistors should be
switched off as soon as the motor is started.
Insulation variation
Perform an insulation measurement at 3-hour intervals. To do so, disconnect the stator supply and
proceed as instructed in the paragraph “4.5.1 Insulation resistance measurement and drying
method”.
At the start of the operation, the insulation resistance will decrease, then gradually increase.
Drying must be interrupted 2 or 3 hours after the insulation resistance has reached the required value.
Drying can take time (up to 48 hours).
Note that the insulation resistance measured after the machine has cooled can be higher than the value
when the machine is hot after drying has been stopped.
4.5.2 Wiring and grounding

The electrical installation of the machine must be carried out in compliance with:
- the applicable local regulations.
- the standards.
- the classification rules.
- the risk area classifications
To ensure long, trouble-free operation and the safety of personnel and equipment, the installation work
must only be carried out by qualified personnel.
Grounding must be performed in compliance with the local regulations before the machine is connected
to the power supply.

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4.5.3 Connection of main terminal box
Make sure the electrical installation is shutdown and locked up before starting any work on
the terminal box.
On the electrical power supply circuit for the motor, we recommend use of a safety system protecting
the motor against overloads and operation in single phase mode.
On request, or if the characteristics of the power supply cables have not been submitted to us, the motor
terminal boxes will implement clamp connections without holes, or a cable gland mounting plate
without holes. Carefully take the necessary measures to ensure the desired protection degree. Where
the Ex machine is concerned, this operation must be performed by qualified technicians. Make sure that
the safety features of the terminal box have been preserved. This is the responsibility of the person in
charge of the connections.
Before proceeding with the installation, and more particularly where a risk area is concerned, the
incoming cables must be separated from the power supply network and must be connected to ground.
The cable glands must be checked with respect to the power supply cables and must be certified Ex-
compatible with the machine certification.
The cable terminations must be ensured in compliance with the cable and termination manufacturers
instructions (ex. : Raychem, Elastimold, 3M, etc.). Make sure that the cable diameter is compatible with
the selected termination.
The cables must be secured to the terminals in such a way that no mechanical stresses are created. The
insulation distances of the connections and leak lines must comply with the applicable regulations. The
insulation distance and leak line principles apply between two terminals with different phases, and also
between a phase terminal and ground.
Connection of cables to terminals of HV terminal box

The customer cables must be connected in accordance with the connection diagram and the coupling
plate on the motor.
Network
The network must be designed to avoid any overvoltage exceeding the IEC values (including opening
and closure of circuit-breaker(s)). Capacitors and lightning arrestors should be set up near the motor to
limit the impact of overvoltages.
4.5.4 Connection of auxiliary and protection circuits

The auxiliary circuits to be connected are the stator temperature sensors, the bearing temperature
sensors, the heating resistors and possibly the vibration sensors, the cold air/hot air temperature
sensors, and the speed sensor (tachometer or GI, etc.).
These connections must be made in accordance with the indications on the connection diagram.
An insulation resistance measurement must be performed with a maximum voltage of 500V for the
sensors and with an appropriate voltage for the other auxiliary components. Where relevant, it may be
necessary to perform a fault isolation and repair procedure, to be entered on a follow-up data sheet.
On request, or if the characteristics of the power supply cables have not been communicated to us, the
terminal boxes of the motors are supplied with a cable gland mounting plate without holes.

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Take the necessary measures to ensure the desired protection degree. Where an Ex machine is
concerned, this operation should be performed by qualified technicians. Make sure that the safety
features of the terminal box have been preserved. This is the responsibility of the person in charge of the
connections.
The compatibility of the cable glands must be checked with respect to the connection cables. Where
operation in an hazard area is concerned, the cable glands must be certified Ex-compatible with the
machine certification and mounted as instructed by the manufacturer.
Protection
The machine must be grounded in compliance with the local regulations before it is connected to the
electrical power supply.
The machine chassis, terminal boxes and associated equipment must be connected to ground to ensure
ground continuity between the parts, thus protecting the personnel and equipment against dangerous
voltages.
The warranty does not cover damages resulting from inappropriate wiring or grounding. These potential
damages may concern, more particularly, the bearings.
4.5.5 Special measures relative to asynchronous generators
4.5.5.1 Type of network

The network must be balanced (equal voltages across network phases). An unbalanced network can be
detrimental to correct operation of the generator, in particular as concerns the additional heating due to
the inverse component.
The manufacturer cannot guaranty correct functioning of the generator in such a case, either in steady
state operation (risk of overheating), or for the consequences which may result from these couplings
under poor conditions.
4.5.5.2 Protection is indispensable

It is the customer’s responsibility to provide the various protections required and to ensure that the
protections function correctly.
These protections comprise:
- The classic protections for continuous operation and the start-up and shutdown sequences with, in
particular, a device preventing coupling on the network outside a +/ 3% bracket with respect to the sync
speed.
- This device must prevent, in particular, starting the motor when the turbine is coupled.
- A device limiting the speed to the speed limit indicated by the manufacturer; operation at maximum
speed is limited over time.
- A protection against any fault occurring on the network and which could have an impact on the
service life of the generator (unbalanced network, micro-cutouts, overvoltages etc.)
4.5.5.3 Coupling on network

The network coupling device (not forming part of our supply) must be tested with no load (after
ascertaining the direction of rotation with respect to the phase succession order of the network).
With the generator driven in rotation, check that the power up contactor closes within a speed bracket
of +/-3% with respect to the sync speed.
The sync speed can be calibrated using a strobe synchronised by the network.

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4.5.6 Ring motors: special measures relative to synchronous induction motor
A synchronous induction motor is a specific form of induction motor with ring-type wound rotor.
This motor starts in a very conventional way using a resistor-type rotor starter (rheostat or resistor-
contactor system).
At the end of the start-up cycle, the motor is running at a speed slightly lower than that of the
synchronism, but at a speed sufficient to become synchronous.
D.C.
To achieve this, the DC current must be adjusted in the rotor as shown in the drawing above to produce
the synchronising torque which will allow the rotor to reach the sync speed.
Then, so long as the DC current supply is maintained, the motor will operate as a synchronous motor
under the conditions defined in the specification for the considered motor.
The DC supply must be able to provide a high intensity for a few volts.
The basic precautions (additional to those of other induction motors) are as follows:
- Do not short-circuit the DC power supply during the transitional period between asynchronous and
synchronous motor operation. A special protection will be required in this respect.
- Take all the necessary precautions to prevent the dangerous effects of the overvoltages which can
occur on cut out of the excitation.
- To ensure balanced wear of the rings, invert the polarity of the DC power supply at the terminals of the
rings, at least once per year.

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5. COMMISSIONING
The commissioning procedure is an essential step in invalidating the quality of the motor installation in
its functional unit.
The installation report in the paragraph “1. Safety instructions” must be filled in and sent to the Power
Conversion projects department once the commissioning procedure has been completed.
5.1 PRELIMINARY CHECKS

The following preliminary checks must be carried out before starting the motor.
5.1.1 Mechanical checks
For a motor with rotor not locked in axial direction: Referred to as “FLOATING” rotor.
The coupling must be equipped with an axial clearance limiter (±0.5mm max.)
During the motor installation procedure, the position of the rotor must be respected: “X” (or “Y”)
dimension. This dimension is specified on a special nameplate and is indicated in the factory test report.
In all cases, the following preliminary checks must be carried out to ensure that:
• the motor alignment has been systematically carried out in accordance with the
recommendations specified in paragraph “4.3.3 Check of shaft line - alignment” and entered in
the installation report.
• the coupling has been correctly mounted and secured between the drive and driven machines
(only after check on start-up of motor).
• the casings protecting the moving parts are in place and secured to the floor or to a static part.
• the rotating parts have been protected by appropriate means.
• the personnel is not intervening on the drive or driven machine.
• there are no heterogonous objects in or on the drive or driven machine.
In accordance with the type of power transmission components on the motor, the following checks
must be performed to ensure that:
• with force-feed lubricated bearings, the diaphragms are correctly perforated and installed and
the oil is circulating in accordance with the specified oil flow rates and pressures. If necessary,
refer to the lubrication instructions defined on the outline dimensions drawing and in paragraph
“7.2.3.2 Lubrication of bushed bearings”.
• the bearing oil tanks have been filled in compliance with the oil level filling indications
The oil bath type bushes are supplied without oil.
• with grease-lubricated bearings, greasing is ensured in compliance with the recommendations

detailed in paragraph “7.2.3.2 Lubrication of rolling element bearings”.

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• with rolling element bearings, the rotor assembly can be rotated manually (or with a lever arm)
with no blocking and with no contact with the fixed parts.
• the water circulates in the hydro-cooler and the bearing cooling water coils (bush cooled by
water coil) at the recommended water pressures and flow rates.
• the access covers and doors are closed.
• the protection degree and certification of the electric motor and its equipment is consistent with
the risks present in the operating area.
• the terminal boxes are closed.
5.1.2 Electrical checks

All of the electrical components of the motor must be taken into account when commissioning the
motor. The following preliminary checks must be carried out to ensure that :
• the frame is correctly grounded, to ensure the safety of the personnel.

• the electrical connections and instruments are compliant with the connection diagram.
• the insulation of the insulated bearing(s) is appropriate.
• the cables are properly connected on the motor terminals (See specific wiring manuals provided
inside the terminal boxes).
• the correct tightening torque has been applied to all the power cable electrical connections on
the terminals of the HV terminal boxes and neutral (paragraph “7.2.3.1 Check of fastening”).
• all the protection systems (thermal, electrical, etc.) function correctly and are properly calibrated.
• the insulation resistance measured is compatible with the acceptance criteria defined in
paragraph “4.5.1 Insulation resistance measurement and drying method” to authorise start-up
of the machine.
5.1.3 Special checks for equipment located in a hazardous area
5.1.3.1 General information

In certain cases, these motors can produce sparks during start-up.
The motor should be rinsed prior to any start-up, even after an accidental, short-duration shutdown.
When the motor is equipped by Power Conversion with a rinsing or pressurization control system, you
must comply with the instructions specific to this system given in the paragraph “1.2.3 Applicable
regulations”.

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5.1.3.2 Protection equipment Ex "e"; Ex "N"; Ex "n"; Cl1 div.2 (zone 2 per IEC, Class 1 division 2 per
NEC)
These motors must be rinsed in accordance with the data given in the table below and on the
information plate on the motor frame.
Make sure the rinsing operation takes place correctly. This control procedure must form part of the
motor start-up logic. This logic must be checked before each rinsing operation.
Motor Rinsing rate (m3/h) Rinsing time (min)
FL 30 15
F3 60 30
N3 < 630 60 30
N3 > 630 140 30
5.1.3.3 Protection equipment Ex"p" (zone 1 or 2)

You must observe the rinsing and pressurization values indicated on the approval certificate and on the
information plate on the motor frame.
The motor must be immediately shut down if any pressurization fault is observed.
Make sure the rinsing operation takes place correctly. This control procedure must form part of the
motor start-up logic. This logic must be checked before each rinsing operation.
5.2 ADJUSTMENTS OF PROTECTION INSTRUMENTATION

Each asynchronous machine is equipped with a set of specific instruments to protect the motor in
operation.
The primary protection aspects for the motors are defined in accordance with the contractual
specifications and indicated on the connection diagram provided with the machine.
5.2.1 Thermal protection

In accordance with the customer’s contractual requirements, the thermal protection is ensured by
thermal sensors at the bearings, cooler and stator, corresponding to the type of circuit chosen. If the
machine is certified for use in an explosive area, the supply circuit must be compatible with the area for
connection of our accessories (Exe, Exi, Exd, etc.).
The sensors must be set to the alarm and tripping thresholds specified on the connection diagram.
- Protection of stator
The stator sensor alarm thresholds are defined to protect against abnormal temperatures which
could result in damage to the winding insulation. The tripping threshold settings must ensure
immediate shutdown of the motor in the event of an excess temperature condition, exceeding
the maximum permissible temperature according to the contractual insulation and heating class.
Where air sensors are requested, the cold air/hot air sensor alarm and tripping thresholds are
defined to prevent a loss of heat exchanger efficiency resulting in a temperature rise which is
incompatible with the acceptable operating temperatures of the motor.
- Protection of bearings
The bearing sensor alarm thresholds are defined to indicate any temperature malfunction related
for example to an incorrect oil flow, rolling element bearing defects, insufficient grease, bearing
wear, etc. The tripping thresholds must be set to immediately shut down the motor.

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5.2.2 Vibration protection
Where requested, vibration sensors will be installed in compliance with the contractual specifications.
The vibration limits must always be no greater than those of standard CEI 34-14. (accelerometers mm/s
RMS) or API 541/546/ISO 7919 for shaft movement values (peak-to-peak microns).
The values acceptable by Power Conversion for the alarm and tripping thresholds are defined in the
connection diagram.
Any overshoot of the limit thresholds can result in destruction of the bearings (rolling element or bushed),
and possibly of the shaft.
These values should be recorded to draw up a diagnostic and correct the vibration malfunction.
5.2.3 Electrical protection

Where current transformers (IT) are integrated in the neutral or supply terminal boxes of the motors in
accordance with contractual specifications, make sure the electrical protection system is compatible
with the protection class, power and ratio of the current transformers.
As a general rule, the relays of the motor electrical protection system must be adjusted to prevent any
phase unbalances, overloads, and any other functioning outside the specifications; the thresholds
should be adjusted in accordance with the data given in the table below.
Function Threshold Time delay Remarks Alarm Motor shutdown
Maximum 1,2 Un 1-5s Unless existent on * *
voltage power supply station
Minimum 0,75 Un 1-3s Unless existent on * *
voltage power supply station
Unbalance 5% 1-3s * *
Inverse curve
Maximum 1.2 Id (start-up 1s * *
current current)
Overloads Values acceptable for Time constant If used at nominal rate * *
class B operation: with heating class F:
1,1 In = 1h the thresholds must be
1,2 In = 15 min set consistent with the
1,3 In = 7 min thermal limit curves for
1,5 In = 4 min the stator in overload
2 In = 1 min operating conditions,
supplied by Power
Conversion
Differential 5% In, 0 * *
Slope 5 – 25 %
Differential 20 – 50 % In, Slope 10 0 In accordance with * *
(transformers – 50 % characteristics of
– motor unit) transformer and
operation
Stator ground 5 % In 0 – 0.3 s Serious fault requiring * *
intermediate
intervention
Min. power In cos φ (with load) > 1-5s Adjustment to be * *
I > In cos φ (de- defined with driven
priming) machine. Can be
achieved by a minimum
current threshold

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Function Threshold Time delay Remarks Alarm Motor shutdown
Start-up too I > 1.5 In after start- 1.1 * Starting Can be achieved by a * *
long up time speed threshold
Locked rotor To be defined in If necessary, provide a * *
accordance with speed control system to
specific protect motor
provisions of
order, defined by
thermal limit
curves of locked
rotor, supplied by
Power
Conversion
Start-up rate Case of low inertia motor (pump To be reviewed in * *
application): accordance with start-
- Nbr of cold start-ups: 3 up conditions with
- Nbr of hot start-ups: 2 respect to starter
- Nbr of start-ups during the hour: 3 possibilities for ring-
Case of high inertia motor (fan type motors
application):
- Nbr of cold start-ups: 2
- Nbr of hot start-ups: 1
- Nbr of start-ups during the hour: 2
* the motor alarm and shutdown thresholds must be specifically defined as part of this study.
This list is not all-inclusive and should only be considered as a standard guideline for the
motors. If other contractual limit values have been defined during the motor construction
project, these values must be applied.
Power Conversion is not responsible for the choice of the electrical protection devices or
adjustment methods implemented for electrical protection of the motors on the site. The
NOTA
motor user must conduct an engineering study to ensure safe integration of the motor in its
operating unit.
5.2.4 Protection on hydro-cooler

If the motor is equipped with a hydro-cooler, a water leak detector can be installed. The detector must
be connected in the motor protection chain (alarm or tripping). Any delay in the shutdown process can
result in electrical risks and damage to the motor.
Failure to protect the hydro-cooler appropriately can result in modification to the maximum surface
temperature of the motor.
The water/air temperature requirements must be observed continuously in accordance with the
contractual specifications.

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5.3 START-UP / INITIAL USE
5.3.1 Start-up control

Machines with axially unlocked rotor:
Caution, when conducting tests with no load before coupling machines with bearings
unlocked, make sure that the shaft remains in the magnetically centered position and that
the temperature of the bearings remains below the alarm thresholds to prevent destruction
of the bearings. If the shaft is not in the magnetically centered position, it can be within 0.5
mm of the axial displacement limits of the rotor so that it is not in axial contact with the
bearing displacement limiters.
Destruction of the bearings can be linked to :

- the ventilation thrust of the machine, generating an axial force on the bearings, which are
not designed to operate continuously under these conditions. This ventilation thrust is due to
a pressure unbalance inside and outside the machine, or in machines with unilateral cooling.
- the impacts of the shaft on the bearings when the rotor is not magnetised.
With all the above conditions satisfied, the motor can be started up.
On the first turns, make sure that:
• the direction of rotation is correct,

• there is no abnormal vibration at the bearings,
• there is no abnormal temperature at the bearing or in the bearing box,
• there is no abnormal noise.
Check the vibration and temperature at the bearings after 1, 2, 3, 4, 5, 8, 12 and 24 hours of operation.
Record these values in the installation report.
If a malfunction is observed, refer to paragraph “7.2.4 What to do if a malfunction is observed”.
Case of induction motors with slip rings:

Where slip rings are implemented, the following is systematically required:
- use of a variable resistance starter adapted to the resisting torque of the driven machine and to the
permissible start-up current.
- or, use of an appropriate electronic speed regulation system (Varotor or other).
Before start-up, be sure to check that:

5 - the contact area of the earthing brushes has been cleaned (cleaning of the protection product with a
SOLVASEC type solvent),
- the brushes have been properly lapped,
- the brushes are correctly positioned on the rings and in their brush holders,
- the brush holder springs press correctly against the brushes.

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On start-up, check:
- for absence of sparks on rings. Any inappropriate contact could cause sparks resulting in complete
damage to the slip ring system.
- that the patina (brownish colour of rings on contact with brushes) forms properly on the rings after a
few hours of operation.
5.3.2 On-going checks

The indications given by the protection instruments (temperature, vibration, speed sensors, etc.) must
remain below the threshold values specified on the connection diagram.
5.3.2.1 Initial use

Once the test start-up procedure has been completed, the driven machine can be coupled to the motor.
This initial use of the motor under actual operating conditions must be monitored and maintained
continuously during the first days of operation.
The information given by the protection sensors must therefore be checked continuously to ensure that
the parameters remain stable with respect to the values given on the connection diagram during the
first hours of operation. In general, stabilisation of the stator and bearing temperatures is only effective
after the first 4 to 8 hours of operation at full load.
During operation, it is also important to check that the cooling and lubrication fluid systems (oil, water,
air) do not leak and are not obstructed.
As concerns lubrication of the bearings, proceed as instructed in paragraph “7.2.3.2 Lubrication”.
With a grease lubrication system, a temporary temperature rise (+ 10 to 20°C) is generally accepted, due
to the time required to eliminate the surplus grease before a normal running state can be established.
For oil-lubricated bearings, any sudden increase in the temperature of the bearings should be followed
by immediate shutdown of the machine to determine the cause of the overheating.
If a malfunction is observed, refer to paragraph “7.2.4 What to do if a malfunction is observed”.
5.4 STOPPING THE MACHINE

The procedures for stopping the motor are directly tied to the conditions in which the driven machine is
used.
The following procedure should be followed to limit the various disruptive effects on the motor:
- If possible, decrease the mechanical load applied.
- Switch off the power supply to the motor.
- Switch on the heating resistors as soon as the motor is stopped to prevent condensation.

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6. OPERATION

The motor operating parameters during operation must be monitored regularly to ensure the integrity of
the motor with respect to various disturbances which may affect the motor.
The parameters monitored should be recorded regularly to ensure the contractual utilisation conditions
and to detect the source of any possible malfunction.
This database will form a useful source of information for possible future corrective maintenance
operations which may be required.
Where any overshoot of the operating thresholds be observed relative to the contractual operating
conditions, the motor should be shut down immediately to prevent a minor deviation from becoming a
major source of damage to the motor.
If any special problems are encountered, contact the Power Conversion Service department for
assistance in solving the problem encountered.
6.2 SPECIAL OPERATING CONDITIONS

All Power Conversion motors are designed for operation consistent with the contractual specifications
and the CEI or NEMA standards relative to the operating modes.
Refer to the technical data sheet of the motor to check that the special operating conditions effectively
correspond to the design of the motor ordered.
6.2.1 Monitoring
Operation of the motor must be monitored regularly by skilled and qualified technicians to ensure the
required operating conditions.
As part of monitoring, the operating parameters of the motors as defined in the installation report must
be periodically recorded in the report given in paragraph “1. Safety instructions” of this manual.
During the first two weeks of operation, the operating parameters must be monitored continuously.
Then, once the motor is in a stable and steady operating state, periodic entry of the parameter readings
taken will suffice.
All the readings must be entered in a monitoring record; these readings will be useful not only to the
user, but also to the manufacturer should an intervention be required.

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6.2.2 Points monitored

The points monitored and logged for an induction motor should comprise the following parameters:
- temperatures at windings, bearings and cooling air
- vibration (additionally, recording the vibration on the driven machine will form a useful source of
information when monitoring a possible malfunction)
- observance of the number of consecutive start-ups authorised.
It is the customer’s responsibility to provide the various protections related to monitoring of the electrical
power supply network for the motor, and to ensure that these protection systems function correctly.
Where slip rings are used, it will be necessary to monitor these areas to ensure that no particles or
foreign matter interfere with the slip ring - brush system and generate sparks.
6.2.3 Monitoring when motor is shut down

On complete shutdown of the machine, heating resistors must be systematically switched on to prevent
condensation which could result in insulation faults on the windings.

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7. MAINTENANCE

The maintenance concept is aimed at reducing the probability of failure or damage to the motor under
intensive use and under the environmental operating conditions at the site.
The various preventive maintenance actions must therefore be programmed to ensure:
• the operational availability of the motor in accordance with the functional requirements, at
optimum cost efficiency.
• the operational safety of the motor, personnel and environment in observance of the applicable
regulations.
• the forecast service life of the asynchronous machines.
Failure prevention must therefore be covered by a preventive maintenance task schedule defined in
accordance with the various functionalities of the motor components and predefined criteria relative to
their state of deterioration.
This section gives general recommendations aimed at maintaining the functional reliability of the
motors. The maintenance actions recommended are not all-inclusive as each site will have its own
special operating features. By intensifying and continuously developing maintenance and monitoring,
enhanced motor reliability will be ensured.
We strongly recommend that you call on Power Conversion’s expert services for assistance in isolating
the causes of a malfunction and the procedures to be applied when a malfunction is observed. All work
performed must be logged in a maintenance record; this work record will be useful to both the customer
and the manufacturer.
7.2 STRUCTURE OF RECOMMENDED MAINTENANCE ACTIONS

Unless otherwise specified by contract, a general inspection should be carried out at least two times per
year (or after 4000 hours of operation).
7.2.1 Maintenance levels

As a general rule, we recommend that you set up, at the least, a maintenance program based on the
following recommendations defined in accordance with the complexity of use of the operating unit in
which the motor is integrated.
For induction motors, a maintenance concept with 3 levels is generally implemented.
These maintenance levels are implemented in accordance with standard intervention intervals to ensure
effective failure prevention. The frequency of the maintenance operations must be consistent with the
operating mode of the motor and the material and financial risks linked to the conditions which may
impact the functional reliability of the motor.
1st level maintenance
1st level maintenance consists in simple visual checks and minor tests required for operation using the
integrated support equipment and the mechanical and electrical tools required for normal servicing of
the motor.
These checks are aimed at evaluating and correcting minor faults by analysing the evolution of critical
parameters with respect to predetermined thresholds governing the state of deterioration of the motor
components.
These procedures are generally short and require around 8 hours.
The parameters should be checked every 4000 hours of operation, representing a bi-annual periodicity.

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2nd level maintenance
2nd level maintenance involves additional inspections on points not covered during the previous
interventions and securing the reliability of critical points observed on the state of components by
repairs or replacement of parts.
These inspections are aimed at performing a complete overhaul by opening sub-assemblies of the
motor: cooling systems, bearings, junction boxes, stator and rotor access covers.
This maintenance level involves the use of the instruments measuring the electrical characteristics of
the machine.
A spectral analysis of the motor can be conducted to detect various malfunctions in the components:
- wear on rolling element bearings,
- mechanical rupture,
- out of balance, alignment,
- sealing; resonance faults,
- electrical faults,
- etc.
This information is used to anticipate corrective or intermediate maintenance actions.
These checks should be performed every 8000 hours of operation, i.e. annually.
3rd level maintenance

3rd level maintenance consists in performing a complete inspection of the machine components and
major maintenance work aimed at fully correcting any defects or failures observed.
As may be required, these operations can include complete disassembly of major components such as
the rotor using special tools.
These operations call for specialised know-how covering all the preventive and corrective maintenance
tasks which may be required. Third level maintenance is performed by specialised teams qualified for
this level using general and specific maintenance instructions.
To limit repair time, the replacement parts required for these operations must be determined on this
basis of previous inspections.
The procedures conducted at this maintenance level are carried out every 40 000 hours of operation, i.e.
every 5 years of operation approximately.
7.2.2 Check points and interventions required to ensure correct operation of the
machine
The check points are specific to the various components of the motor. Within the framework of a specific
maintenance program defined for your machine, checks and tests must be performed to evaluate the
condition of the components, and to repair them as may be required by replacement of sub-assemblies.
In general, these actions can be organised in accordance with the various operational units
implementing the motor to ensure its integrity.

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7.2.2.1 General behaviour
As part of preventive maintenance, the operating parameters should be monitored to ensure effective
control of possible drifts.
Recommended Application to
Maintenance points Recommended check criteria
equipment maintenance level(s)
Recording of characteristics Multimeter, on-board
Machine operations 1
with no load and with load instrumentation
Motor foundation and Visual inspection and vibration Portable or on-board
1
anchoring measurement vibration meter
7.2.2.2 High-voltage connections

The HV cables and their supports and fasteners must be properly insulated to prevent any electrocution
or fire hazards.
Tightened to appropriate
HV cable fasteners torque (paragraph “7.2.3.1 Torque wrench 1
Check of fastening”)
Inspection of
components (TI,
Visual inspection and tightening
rogowski coils) of 1
of connections
motor protection
system
Protection of HV cable Condition of sheaths and cable
1
passage fasteners in cable glands
7.2.2.3 Protection system

In addition to regular checks (temperatures, vibration) on the instruments used to monitor and protect
the motors, the electrical condition of these components should be checked periodically.
Maintenance Recommended Application to
Recommended check criteria
points equipment maintenance level(s)
Thermal sensors Visual inspection, ohm resistance Megohmmeter 1
Lighting arresters Visual inspection 1
Current
Visual inspection 1
transformers
Movement
Visual inspection 1
sensors
Vibration sensors Visual inspection 1
Continuity, ohm resistance, Multimeter,
Heating resistor 1
insulation and ground megohmmeter
It is always useful to compare the resistance values for instruments of the same type to detect possible
electrical malfunctions.

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7.2.2.4 Stator and rotor assembly
Be sure to check that the various disturbances acting on this assembly do not create any faults relative
to the insulation of the windings, the mechanical balancing, the rotor centering (gap), the mechanical
strength of the shaft or proper functioning of the brushes.
Stator and possible Insulation measurement and bias
Megohmmeter 2
rotor windings index
Insulation of
interconnection
Insulation measurement Megohmmeter 2
cables at HV
terminal box
Check that shims are properly
Stator slot shims 3
maintained in place
Instrumentation Visual inspection of condition of
2
cables outer sheaths
Balancing weight
Visual inspection Borescope 3
mounting
Uniformity of gap Visual inspection Calibrated shims 3
Check that brushes are properly
Condition of
maintained in contact on shaft 1
grounding brushes
(cleanliness)
Mechanical
Visual inspection for possible
condition of shaft Borescope 3
mechanical defects
and rotor cage
Motor with ring-brush system on rotor

The condition of the rings and brushes must be checked to reduce the risk of generating sparks.
Visual inspection of clearances
Brushes (check tightening of connections) and 1
deformations
Visual inspection for wear, surface
Dial gauge 2
condition (patina)
Rings Condition of propeller (angles) Fine stone for honing 2
Check using dial
Out of round condition 2
gauge
Inspection and check for position
holding (perpendicularity and
Rule, dial gauge, keys 1
alignment (taking account of brush
alignment defect))
Pressure on brushes 2
Brush-holder
Insulation with respect to ground
Megohmmeter 2
(disconnect rotor cables)
Vacuum cleaner for
Cleanliness (disassembly and
dust and “electrical” 1
cleaning)
solvent for cleaning

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7.2.2.5 Cooling system
Check that the motor cooling system is functioning efficiently by checking the following points:
• Air inlets not obstructed.
• Frost prevention.
• Fluid flow rates OK (air, water).
• Filters in good condition.
Application to
Recommended
Maintenance points Recommended check criteria maintenance
equipment
level(s)
Air/air cooling sub- Cleanliness condition, air inlet Borescope, vacuum
2
assembly not obstructed cleaner
Condition, position and Borescope (internal parts),
Stator seals 2
tightness visual (external parts)
Check condition (leak and
Borescope, vacuum
corrosion risks) and perform 2
cleaner
Air/water cooling sub- cleaning
assembly Disassembly and cleaning of Wrenches, vacuum
3
boxes and tubing cleaner, cleaning brush
Pressure test Water pump 3
Check of coolant (antifreeze)
Air/water cooling freeze point if closed circuit is
2
subassembly used, and check for presence of
frost prevention additives
7.2.2.6 Bearing and lubrication system assembly

To ensure optimum motor service life, perform the following checks to ensure it is functioning correctly.
Insulation of rolling
element bearing
Quality, quantity, frequency of
Lubrication of rolling grease applied – drain grease
1
element bearings boxes each time re-greasing is
performed
Insulation of bushed
bearings
Oil quality Viscosity meter 2
Cleanliness of filters 1
Oil circulation system Condition of seals, visual
1
inspection for possible leaks
Check of flow rates 1
Bush Visual inspection for wear 3
Oil heating and Thermometer or on-
Temperature check 1
cooling system board system
Condition of seals, Visual inspection for wear and
2
baffles tightness
Raising unit (if used) Functional test 2

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7.2.3 General recommendations relative to maintenance interventions
7.2.3.1 Check of fastenings

Controlling the mechanical tightness of the parts subject to vibration is essential to ensuring long-
lasting, reliable motor operation. Unwanted mechanical play at the mounting points or fastenings, or on
the various elements securing the rotor, can result in serious damage to the sensitive parts forming the
motor bearings.
The mountings and fastenings should be torque-checked periodically using a torque wrench in
accordance with the torque values indicated in the table below.
These tightening torques are defined for the screw products used to secure the mechanical
and electrical functions of the motor, except for the Elastimold connectors optionally
NOTA
integrated in the HV terminal box. Where specific accessories are concerned, be sure to refer
to the manual provided by the suppliers of this equipment.
The motor must be entirely shut down before performing any tightening on the power supply
cable fastening points.

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COUPLES DE SERRAGE – TIGHTENING TORQUES

Assemblages mécaniques et électriques
Mechanical and Electrical assembly
Visserie d’usage général, vis montées graissées – Bolting for general service, lubricated bolts
Les couples indiqués ci-dessous s’appliquent lorsque le plan ou la notice du composant ne spécifient pas la valeur
The hereunder tightening torques are to be applied when drawing or notice of component do not specify any value
Couple de serrage maximum pour utilisation avec écrou de même classe, ou implantation mini de 1,5 x ∅ vis dans tôle de
construction ou dans fonte. En cas de matériaux de faible limite élastique, consulter le service technique Power Conversion.
Maximum tightening torque for use with nut of the same grade, or mini 1.5 x ∅ bolt implantation in structural carbon steel or
in cast iron. In case of low strength material, refer to Power Conversion technical department.
INOX A2 ou A4 INOX A2 ou A4 Laiton CuZn37 Vis classe 8.8

Matière Acier classe 8.8 Acier classe 12.9 (304 ou 316L) (304 ou 316L) (Cu2) dans FONTE
Classe 70 Classe 80
Material Steel class 8.8 Steel class 12.9 Stainless steel Stainless steel Brass CuZn37 Screws class 8.8
Class 70 Class 80 (Cu2) in CAST IRON
∅ Vis
N.m m.kg N.m m.kg N.m m.kg N.m m.kg N.m m.kg N.m m.kg
Bolt ∅
M4 2,4 0,24 4,1 0,4 1,7 0,2 2,3 0,2 1,6 0,16
M5 4,7 0,47 7,9 0,8 3,3 0,3 4,4 0,4 1,5 0,15 3,5 0,35
M6 8,2 0,82 14 1,4 5,8 0,6 7,7 0,8 2,6 0,3 6,0 0,6
M8 20 2 33 3,3 14 1,4 18,4 2 6,1 0,6 14 1,4
M 10 40 4 65 6,5 27 3 36 4 12 1,2 30 3
M 12 65 6,5 110 11 46 5 62 6 20 2 45 5
M 14 105 11 175 18 73 7 98 10 33 3 70 7
M 16 165 17 280 28 116 12 154 15 50 5 110 11
M 18 225 23 380 38 160 16 210 21 70 7 150 15
M 20 320 32 540 54 225 23 300 30 100 10 215 22
M 22 440 44 740 74 310 31 410 41 290 29
M 24 550 55 930 93 390 39 520 52 370 37
M 27 810 81 1370 137 570 57 760 76 540 54
M 30 1100 110 1860 186 777 78 1040 104 740 74
M 33 1500 150 2520 252 1050 105 1400 140 980 98
M 36 1900 190 3240 324 1350 135 1800 180 1280 128
M 39 2500 250 4200 420 1750 175 2340 234 1600 160
M 42 3100 310 5200 520 2170 217 2900 290 2000 200
M 45 3850 385 6500 650 2710 271 3600 360 2500 250
M 48 4650 465 7850 785 3270 327 4360 436 3050 305
M 52 6000 600 10100 1010 4200 420 5600 560 3800 380
M 56 7400 740 12500 1250 5200 520 6940 694 4750 475
M 60 9100 910 15400 1540 6400 640 8540 854 5800 580

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7.2.3.2 Lubrication
Lubrication of rolling element bearings

A plate indicating the frequency of greasing, and the quantity and quality of the grease is fastened on
each bearing (these values can be different between bearings).
These instructions given on the plate must be observed.
We recommend use of the grease specified on the information plate, or any other equivalent, miscible
grease.
The lubricants recommended and their equivalent products can be used at ambient temperatures of –
20°C to + 40°C. For higher or lower temperatures, refer to the specific provisions in the contract.
Equivalence table
Mobil Oil Mobilux n° 2 ou 3
Esso Standard Esso Beacon n° 2 ou 3
Roller Grease 2
Esso Unirex N3
Caltex Caltex Régal Starfack Special
Hougton Cossolube n° 2
Antar Antar RT 33
BP BP Energrease LS 2 ou 3
ELF Rolexa 2 ou 3
Total Multis EP 1 ou EP 2
Shell Albida RL 2
Alvania G3
Lubrication instructions
The need for properly performed lubrication
Rolling element bearings must be lubricated progressively and, if possible, at low speed over a
period of several minutes to ensure optimum initial distribution of the grease.
Indicated below are the risks encountered when lubrication is performed too quickly, or when too
much grease is used, or when the lubrication is incorrectly performed:
• Grease escapes and leaks through baffles due to excess grease pressure in bearing
(lubrication performed too quickly or too much grease used).
• Increase, prior to end of removal of excess grease, of temperature of rolling elements from
10 to 25°C or more, with respect to the normal operating temperature.
• Braking due to surplus grease in bearing cages resulting in the possibility of rolling element
slippage (balls, rollers) with respect to tracks, producing overheating, intermittent noise and
damage to rolling element bearing (chipping, micro-seizure), and also deterioration of the
grease (shearing of lubricant film and overshoot of acceptable temperature by grease in
local slippage area, in addition to pollution by metal particles subsequent to tearing of
material in non-lubricated area).
• Seizure of rolling element bearing within minutes following lubrication, above all starting at
an rpm speed of 3000 rpm.
These risks are even greater when:

• The grease is injected too quickly (continuous injection),
• The internal radial clearance of the rolling element bearing is low (small ball-
bearings),
• The motor rpm speed is high (3000 – 3600 rpm).

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Commissioning and servicing the bearings
On commissioning of the motor, inject 2 quantities of grease at an interval of 5 minutes. The
quantity of grease is indicated on the information plates on the bearing. Except where
characteristic bearing noises are heard due to insufficient initial grease, do not lubricate again
before 24 hours.
Several hours are required (above all for the bearings used with vertical motors) to allow the
ejecting disk to evacuate the surplus grease.
After 24 hours, inject 1 quantity of the recommended grease. After two weeks of operation of the
machine, inject 1 quantity of the recommended grease, followed by another 24 hours later.
Following this, observe the normal servicing indicated on the information plates on the bearings
(quantity of grease, lubrication interval). For severe operating conditions, for example with bearing
temperatures exceeding 80°C, the intervals between each lubrication can be divided by two.
Lubrication guidelines
a) Determining the number of pump cycles for 1 quantity of grease
To inject the precise quantity of grease recommended on the information plates, carefully check
and calibrate the quantity of grease delivered by the lubrication unit. For a grease pump, for
example, weigh 10 pump cycles:
• M = weight of 10 pump cycles

• Q = quantity of recommended grease
• n = number of pump cycles for 1 quantity Q
• n = ( 10*Q ) / M
b) Lubrication procedure
The grease fitting must be cleaned to prevent injection of impurities or particles in the bearing
lubrication circuit. Similarly, the grease and the lubrication unit must be cleaned.
The following general rules must be applied to ensure the lubrication procedure is performed
correctly:
• observe a pause of at least 5 seconds per g or cm3 of grease injected if the rpm speed is
less than 3000 rpm.
• example: 1 pump cycle = 4g, therefore 4g* 5sec = 20 seconds pause between each pump
cycle.
near to or greater than 3000 rpm, with a maximum quantity of grease of 5g or cm3
injected for 1 cycle.
Certain lubrication instructions can be more detailed depending on the type of motor:

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c) Fixed speed motors operating continuously
Where there is no possibility to vary the motor speed or to stop it during production (continuous
operation), the following rules must be strictly observed:
• Observe a pause of at least 5 seconds per g or cm3 of grease injected when the rpm speed
is less than 3000 rpm.
near to or greater than 3000 rpm, with a maximum quantity of grease of 5g or cm3
injected for 1 cycle.
Beware that lubricating the machine without observing the above rules at 3000 or 3600 rpm can
result in major damage to the rolling element bearings (fast overheating, seizure, etc.). It is
therefore very important to observe the pause periods between each grease injection, and the
maximum quantity of 5 g or cm3 for one cycle.
d) Fixed speed motors with fast slow-down after shutdown

If it is not possible to lubricate the motor at low speed (fixed speed motors with slow-down taking
place too quickly after shutdown), lubrication should be performed just a few minutes after the
motor has been shut down. In this way, the overheating of the rolling elements due to the
lubrication will be dissipated while the motor is stopped and will therefore not impact the rolling
element.
• Fixed speed motor running at less than 3000 rpm
The following rules must be observed:
• Observe a pause of at least 3 seconds per g or cm3 of grease injected.

• Reduce the waiting time (<1 minute) as much as possible between lubrication of each
bearing.
• On completion of lubrication of the last bearing, wait 2 minutes before stopping the motor
to allow the grease to spread in the last bearing lubricated.
• Wait 45 minutes before restarting the motor to allow the high temperature in the rolling
elements due to the lubrication to dissipate.
• Fixed speed motors running at around 3000 rpm or higher
The following rules must be observed:
• Observe a pause of at least 5 seconds per g or cm3 of grease injected.

• Reduce the waiting time (<1 minute) as much as possible between lubrication of each
bearing.
• On completion of lubrication of the last bearing, wait 30 seconds before stopping the
motor to allow the grease to spread in the last bearing lubricated, but not more than 30
seconds due to the heating of the bearings lubricated.
• Wait 1h15 minutes before restarting the motor to allow the high temperature in the rolling
elements due to the lubrication to dissipate.

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e) Variable speed motors and motors with slow slow-down after shutdown
• If the nominal rpm speed of the motor is less than 3000 rpm, lubrication must be carried
out at between 30 and 60% of the nominal rpm speed.
• If the nominal rpm speed is near to or greater than 3000 rpm, lubrication must be carried
out at between 10 and 40% of the nominal rpm speed.
This procedure is possible on variable speed motors and motors with slow slow-down speed
when shutting down, allowing during the slow-down period, to be within the speed range
recommended above, while observing the following condition : minimum pause of 3 seconds per
g or cm3 of grease injected.
• Variable speed motors
After completing lubrication of the last bearing, wait 10 minutes at low speed as indicated above
in order to allow the grease to spread correctly in the bearing, before gradually increasing the
speed. If the nominal speed is near to or greater than 3000 rpm, wait 20 minutes at the
corresponding low speed before you gradually increase the speed.
• Fixed speed motors running at less than 3000 rpm.
When the motor has fully slowed down, wait 30 minutes before restarting the motor to allow the
high temperature in the rolling elements due to the lubrication to dissipate.
Fixed speed motors running at around 3000 rpm or higher
When the motor has fully slowed down, wait 1 hour before restarting the motor to allow the high
temperature in the rolling elements due to the lubrication to dissipate.
Lubrication of bushed bearings

Identification of bearings
Read the information plate on the side of the bearing
Example: E F Z L K 14 – 125
1 2 3 4 5 6
1 Type E
2 Bearing body F = Bearing with end shields, fins
3 Heat dissipation
N = Natural cooling
Z = Lubrication by continuous oil circulation with external cooling
W = Cooling by water (oil coil cooler)
U = Force-feed pump and natural cooling
T = Force-feed pump and water cooling

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4 Shape of bore and lubrication method
L = Cylindrical bore with free lubrication ring.

C = Cylindrical bore without free lubrication ring.
Y = Bore with two oil wedges, without lubrication ring.
V = Bore with four oil wedges, without lubrication ring.
Where a lubrication method without lubrication ring (C, Y, V) is used, a backup lubrication unit
must be available in the event of a power cutout.
5 Stops
B = Guide bearing with smooth shoulders, with oil sumps (does not accept axial load)
K = support type (thrust values defined in contract must be observed)
Q = no stop
6 Size of bearing and diameter of shaft
Independent lubrication by free ring
Motors with splash lubrication system are supplied without oil in the bearings; the
motors must be shut down to perform filling.
Filling
The oil quality must be compliant with the data specified on the information plates on the motor
and in the equivalence tables below.
The oil is filled through the hole of the level indicator on the lubrication ring located at the upper
part of the bearing (see motor cross-sectional view).
The indicator must be carefully removed, if necessary using an adjustable pin wrench.
Fill with new oil.
To prevent alteration to the quality of the new filling oil, which could result in premature wear of
the bearings, take all the necessary precautions to prevent any unwanted elements from getting
into the oil (dust, sand, water, grease, rags, papers, etc.).
Check that the oil level is at around the centre of the oil level indicator. It is located on the side of
the bearing. This operation must be performed with the motor shut down.
Reinstall the filler plug, tightening it correctly.

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Oil change
ENVIRONMENT HAZARD
Do not dispose of oil indiscriminately.

Observe the oil using rules. The manufacturer will indicate the way to eliminate used oils.
Use a recipient having a sufficient volume to allow the oil to fully flow out.
Remove the plug located at the lower part of the bearing (see cross-sectional view).
Reinstall the plug using a new seal, observing the tightening torques indicated below:
Size of bearings 9 11 14 18 22 28
Tightening torque in Nm 30 30 30 40 60 60
Drain the oil while it is hot to avoid deposits in the tank.

Perform the first oil change after 150 hours of operation.
Oil change frequency: every 8000 hours
Force-feed lubrication
The oil quality must be compliant with the data specified on the information plates on the motor and
with the equivalence tables below.
Oil supply
To avoid running the bearings dry, the lubrication system must have a sufficiently long safety
margin before start-up and after shutdown of the motor.
The oil outlet is provided with a half-moon in the pipe to ensure a minimum oil level.
This pipe must not be removed under any circumstances.
The system used to circulate the oil must ensure the recommended normal flow rate.
Diaphragm
A stainless steel diaphragm, supplied with the motor, is located between the oil inlet pipe flange
of each bearing (see diagram below).
D iaph ra gm
Be aring
O il level
Oil outlet
O il inlet
15° min.

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This diaphragm has a punch mark at the centre. It must be carefully perforated and deburred
when installing, to the diameter calculated using the formula given below:
Q
d = 1,265 *
∆P
d: drilling diameter (mm)

Q: required oil flow (litre/min.)
∆P: Pressure difference between circuit upstream and downstream of diaphragm (barg)
Note: The downstream pressure is considered the atmospheric pressure.
This drilling diameter is valid for:
- oils ISO VG 32 and ISO VG 46.
- an oil filtered to 20µ max.
- a minimum drilling diameter of 1 mm (risk of fouling).
Following installation, the recommended flow rate must be checked (should be less
NOTA
than maximum flow rate required, indicated on formation plate on bearings).
In practice, each diaphragm must be provided with a hole ensuring a flow which is sufficient to
achieve:
- an optimum oil level in each bearing (see paragraph “7.2.4.5 Check for oil leaks at bushed
bearings”),
- and, a bearing and oil temperature compatible with normal operation, i.e. an operating
temperature below 90°C (alarm threshold) and 95°C (tripping threshold).
Oil return
The oil return pipe between the bearings and the lubrication system must not generate any
backups in the circuit.
The oil return pipe must have a minimum slope of 15°. Any obstacle in the circuit can result in an
increase in the oil level inside the bearings, and subsequent leaks.
Oil change
ENVIRONMENT HAZARD
Do not dispose of oil indiscriminately.

The lubrication system installation must undergo a complete oil change every 20 000 hours, and
in compliance with the instructions given by the manufacturer.
Observe the oil utilisation rules. The manufacturer will indicate the way to eliminate used oils.
Oil change for 2 bearings
Use a recipient having a sufficient volume to allow the oil to fully flow out.

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Remove the plug located at the lower part of the bearing (see cross-sectional view).
Reinstall the plug using a new seal, observing the tightening torques indicated below:
Size of bearings 9 11 14 18 22 28
Tightening torque in Nm 30 30 30 40 60 60
Before starting up, run the lubrication unit to establish a correct oil level in the bearings
(paragraph “7.2.3.2 Oil supply”).
Lubrication oil equivalence tables

Oil quality: ISO VG 32
Dynamic viscosity in
Kinematic viscosity in centiStokes at:
centiPoises at:
40°C 50°C 60°C 50°C 60°C
AGIP
30 14.8 12.8
Ote 32
ARAL
32 22 19.3
Motanol GM 32
B.P.
32.6 21.9 15 18.7 12.7
Energol CS 32
CASTROL
32 15 12.6
Perfecto T 32
CHEVRON
32 16 14
Mechanism LPS 32
ELF
32 14.9 13
Elfolna 32
ESSO
30 23 14.4 19.8 12.4
Teresso 32
FINA
31 21 18.3
Cirkan 32
MOBIL
29.6 20.2 14.3 17.1 12.4
DTE Oil Light
SHELL
Turbo T 32 32 15.3 13.3
Tellus oil C 32 32 22 18.7
TEXACO
Regal R et O 32 32.5 14.5 12.2
Rando oil 32 32 21 17.8
TOTAL
32 16 13.5
Azolla ZS 32

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Power Conversion
centiPoises at:
40°C 50°C 60°C 50°C 60°C
AGIP
44 20 17.4
Ote 46
ARAL
46 30 26.5
Motanol HK 46
B.P.
47 30.7 20.5 26.3 17.4
Energol CS 46
CASTROL
46 20.4 17.2
Perfecto T 46
CHEVRON
46 22 19
Mechanism LPS 46
ELF
46 20 17.5
Elfolna 46
ESSO
44.7 30 19.6 26 17
Teresso 46
FINA
46 30 26.3
Cirkan 46
MOBIL
46 28.7 19 24.4 16.6
DTE Oil Medium
SHELL
Turbo T 46 46
20.1 17.6
Tellus oil C 46 46 30 21.9
TEXACO
Regal R et O 46 47.6
21.2 18
Rando oil 46 46 29 25
TOTAL
46 22 18.7
Azolla ZS 46

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Power Conversion
centiPoises at:
40°C 50°C 60°C 50°C 60°C
AGIP
64 27 23.6
Ote 68
ARAL
68 43 38
Motanol HK 68
B.P.
68 42.6 28 36.0 23
Energol CS 68
CASTROL
64 27 22.8
Perfecto T 68
CHEVRON
68 29 25
Mechanism LPS 68
ELF
68 28.9 25
Elfolna 68
ESSO
64 43 26.7 37 23.2
Teresso 68
FINA
69 44 33
Cirkan 68
MOBIL
63.9 41 27.2 35.1 23.8
DTE Oil Medium
SHELL
Turbo T 68 68
23.4 24.9
Tellus oil C 68 68 43 28.7
TEXACO
28.5 24.2
Rando oil 68 68 41 35.3
TOTAL
68 29 24.9
Azolla ZS 68

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Power Conversion
centiPoises at:
40°C 50°C 60°C 50°C 60°C
AGIP
100 40 35.4
Ote 100
ARAL
100 61 54
Motanol HK 100
B.P.
96 67.6 38.55 59 33
Energol CS 100
CASTROL
96 38.3 32.3
Perfecto T 100
CHEVRON
100 41 36
Mechanism LPS 100
ELF
105 40.5 35.8
Elfolna 100
ESSO
Teresso 100 154
56 50
Nuray 100 100 59 53
FINA
107 65 58
Cirkan 100
MOBIL
100
DTE 27 53
94 48 47.2
DTE Vactra Oil Heavy 50
SHELL
Turbo T 100 100
40 35
Tellus oil C 100 100 62 53.3
TEXACO
39.39 33.6
Rando oil 100 100 62 54.1
TOTAL
100 39 33.5
Azolla ZS 100

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Power Conversion
7.2.3.3 Insulation of bearings
The bearings are insulated to prevent the appearance of currents due to excessive electromotive forces
in the moving shaft.
These currents can damage certain components of the machine, such as the rolling element bearings
and the bushes.
The bearings are not systematically insulated on all the motors. Where required, the insulation is
indicated by a specific marking on the bearing(s).
The insulation measurement can only be carried out in those cases where the two bearings are
insulated.
In certain cases, a grounding braid is mounted at the machine coupling side bearings to short-circuit the
insulation.
Insulation measurement
To perform the insulation measurement, it is necessary to remove all the elements which may form an
electrical contact between the shaft and the other parts of the bearing (in particular the grounding
brushes for the shaft and/or the grounding braid, coupling side).
The insulation of the shaft with respect to ground can then be measured using an ohmmeter in
accordance with standards IEEE Std 115 and IEEE Std 112. The minimum acceptable value is 10
megohms (without oil in bearings) when a dc measurement voltage of 45V is applied.
If an inappropriate insulation value is observed, it is necessary to clean any conducting impurities
located between the specific insulation surfaces of the side plate of the bearing considered.
An abnormal insulation value or an inappropriate assembly could result in significant damage to the
machine. An acceptable insulation value must be preserved.
7.2.3.4 Maintenance of stator and rotor windings
Insulation value of windings

As part of the maintenance program for the stator and rotor windings, the insulation of the major
electrical components of the motor must be monitored. An insulation measurement must be performed
to ensure that the condition of the insulators is acceptable before the machine is restarted.
This insulation check must be performed as described in paragraph “4.5.1 Insulation resistance
measurement and drying method”.
Windings with leak line are highly sensitive to the effects of dirt and humidity.
To better isolate the cause of an insufficient insulation, this check should be periodically completed by a
bias index (IP) measurement to verify the level of cleanliness and aging of the windings every 6 months
as part of the first level maintenance operations.
The measurement instrument should give a measurement voltage consistent with the values given in
the table below:
Motor voltage Un < 1000 V 3000 V< Un < 5500 V Un < 6000 V
Applicable insulation measurement voltage 500 V 2500 V 5 000 V
The value of the bias index (IP) is defined using the following formula:
IP = R10 min/ R1 min
This value is used to represent the capacitive state of the coils.

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Power Conversion
Diagnostics
The bias index and insulation measurement values should be logged in accordance with the frequency
of the first level maintenance operations.
This history of bias index variations is highly significant as concerns pollution of the coils and premature
aging of the insulation.
A significant reduction in bias index generally reflects pollution of the coil insulation by humidity, or
possibly dust. Where this is the case, the coils should be dried or cleaned to reduce the insulation
deterioration factors.
If the insulation reconditioning operations produce a bias index value near to that registered during the
previous maintenance operation, this situation will not point to significant damage of the winding.
In the opposite case, attention should be given to the causes and consequences of the damaged
insulation. A chart showing the evolution of the bias index will allow you to estimate the significance of
the aging, and the need to plan, in the near future, replacement of the considered winding.
Coil cleaning recommendations

If necessary, the coils should be cleaned using non-flammable solvents and varnishes appropriate to the
winding resin. This type of cleaning must only be performed by qualified personnel due to the dangerous
substances handled and the tests to be performed at high voltages.
During the warranty period, this type of cleaning, required by the operating conditions on site, can only
be performed by personnel qualified by Power Conversion. When such cleaning becomes necessary, you
should contact the Power Conversion service department (see paragraph “8.1 Presentation of Service
department and contact details”).
7.2.3.5 Maintenance of brush and ring system

The ring-brush system should be monitored regularly to avoid any functional drift due to the natural
wear of the ring-brush system.
Incorrect maintenance of the rings and brush-holders can result in sparking, leading to complete
damage of the system.
The out-of-round and irregular deformation of the surface of the rings should therefore be regularly
monitored in order to correct any drifts observed.
For any out-of-round greater than 0.03 mm, the rings should be ground.
If excess wear is observed, the ring system should be replaced.
The positioning of the brush holder system must be systematically checked to ensure proper alignment
and engagement of the brushes with respect to the rings. An alignment defect can sometimes be due to
incorrect mounting of the motor coupling. Furthermore, the perpendicularity of the brush with respect to
the ring should be checked to avoid any premature damage of the brushes.
The insulation surface of the brush holders should be cleaned of the carbon dust which inherently
occurs due to the wear of the brushes to avoid the risk of electrical discharges. This residual dust should
be eliminated by vacuuming.

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Power Conversion
Filter maintenance: When to change the filter media?
The filter media must be changed when the filtration efficiency decrease. That means when the filter is
clogged.
The filter can be consider clogged when the pressure drop is too big, at this moment the pressure switch
trip.
The pressure switch trip value is given on connection diagram.
Also, the filter media must be changed if you see damage (hole, crack, etc.) on his surface during motor
maintenance.
Filter maintenance: Filter media replacement
Caution, it is forbidden to clean filter, this action can cause damage..
• Remove filter casing from the motor
• Remove polluted filter media from filter casing
• Cut new filter media. Caution filter media must be in single part (see next figure).
A
Filter casing
20mm more
B
Filter media pad cutting dimension:

Filtre media A+20mm * B+20mm
• Mount new filter media pad in the filter casing. Respect air flow direction (see next picture).
Air polluted by
carbon dust Air cleaned
Air flow direction
80 mm filter media thickness are compressed to 50mm in filter casing to increase filter efficiency.
• Clean slip ring casing
• Remount filter casing on motor

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Power Conversion
7.2.3.6 Maintenance of cooling systems
The motor cooling systems are generally covered by a limited preventive maintenance program.
Air/air cooling
Where air/air cooling is implemented, supplied by a duct with air filter, the differential pressure should be
measured to evaluate the load loss inherent to fouling of the filter.
When the load loss produces a reduction in the ventilation flow required for the motor, the filters should
be cleaned or replaced in accordance with the manufacturer’s instructions.
For a motor without internal air propulsion system, the differential pressure should be checked between
the motor inlet and outlet to maintain the ventilation flow required and prevent overheating of the
motor.
Air/water cooling
Where air/water cooling is implemented, the quality of the water used should be checked regularly; this
water can be the source of corrosion or development of micro-organisms resulting in a loss of heat
exchanger efficiency.
If the operating temperatures of the motor remain within the normal operating limits and no hydro-
coolant leak is observed, there is no need to perform any more extensive monitoring.
7.2.4 What to do if a malfunction is observed

If a malfunction is observed, a preliminary diagnostic procedure should be performed before taking any
corrective maintenance action on the motor.
It is necessary to determine the source of a malfunction by isolating, insofar as possible, the mechanical,
electrical or thermal nature of the malfunction, or the lubrication problem at the source of the
malfunction.
Proceed by analyzing the situation using the characteristic fault isolation tables given below.
If you have any doubt as concerns the source of the malfunction or the corrective action to be taken, do
not hesitate the contact the Power Conversion Service department.

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Power Conversion
7.2.4.1 Mechanical malfunction
Malfunction Diagnostic Corrective action
No rotor rotation with Driven machine “seizure” problem. Uncouple motor and turn it with
load Resisting torque too high. Rotor friction. no load to identify problem
Rotor friction or friction of its accessories. Re-center parts at source of
friction
Motor starts with Bearing noisy: Rolling elements damaged Replacement of rolling element.
abnormal noise by wear or lubrication Cleaning and relubrication
impurities
Rolling elements damaged Change rolling element. Repair
by circulating currents bearing insulation.
Incorrect assembly Correct alignment fault.
Motor – driven machine Realign assembly.
alignment defect
Incorrect lubrication Check efficiency of lubrication.
High bearing Probable causes identical to Same corrective actions
vibration those of noisy bearing
Shaft line with coupling Balance the shaft line
unbalanced (1/2 key or
whole key)
Axial thrust on shaft Check assembly of coupling
and alignment of shaft. Check if
thrust concerned is appropriate
to motor design.
Seating not sufficiently Reinforce stability in
stable accordance with fundamental
forces applied.
Irregular gap Rotor centering
Friction of Ventilation rubbing on air Center air guide – fan system
mechanical parts guide
Foreign matter in machine Vacuum out any foreign matter
Rotor elements have shifted Repair elements and their
fasteners.
7.2.4.2 Electrical malfunction

Motor does not start No voltage Check fuses, supply lines and,
above all, terminals
Possible magnetic Unbalance in electrical power supply network Check balancing of network
noises, followed by phases
overheating
Electrical faults and Abnormal reading, sensors faulty Check measurement devices
measurement faults on
sensors

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7.2.4.3 Thermal malfunctions
Motor overheats Direction of rotation incorrect with respect to arrow Check direction of phases and
with no load power supply cable connections
Network unbalance Check voltage on each phase of
network
Overshoot of required ambient temperature Ensure room is correctly
ventilated
Hot air recycled Clear air passages and external
obstacles producing
recirculation between outlet
and inlet air
Internal air circulation Cooling system fouled Perform internal cleaning of
is insufficient and machine and air filtering system
incorrect Air leak Check seals and integrity of
air/air exchanger
Fans mounted backwards Mount fans correctly
Fans damaged Replace fans
Water cooling Water temperature too Adjust cooling water
conditions are incorrect high temperature
Water flowrate incorrect Regulate water flowrate and
water injection system
Cooling pipes obstructed Clean pipes
Air blocked inside hydro- Purge hydro-cooler using purge
cooling system components
Abnormal heating Motor overloaded Lower load to nominal load
with load Hydro-cooler tubes blanked Disassemble water box and
clean it
Insufficient cooling Same causes as for Perform same checks
overheating with no load
Overheating Motor started up under inappropriate conditions Allow machine to cool and
subsequent to too check machine control system
many consecutive (start-up time delay)
start-ups Number of start-ups authorized not observed Allow machine to cool and be
attentive to number of
consecutive start-ups
authorized ; failure to do so can
result in breakdown

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7.2.4.4 Lubrication malfunction
Overheating or Insufficient lubrication Check lubrication and add grease
abnormal noise and without exceeding recommended
lubricant leaks at rolling quantities.
elements bearings Viscosity of grease inappropriate, with Check and clean rolling element
leaks bearing. Open and drain grease boxes.
Replace grease as instructed.
Excessive lubrication, with leaks Clean rolling element bearing and
lubricate as instructed.
Seals of rolling element bearings are Check seals of rolling element bearing
defective, with lubricant leaks and quality of lubricant
Oil leaks at bushed Excessive oil flow Regulate oil flow
bearings Bearing seals damaged Replace seals
Balancing of internal and external Check pressure of internal circuit of
pressure bush. Vent using a breather.
Oil return circulation problem Provide a minimum continuous slope
of 15°, with no obstacle.
Tightness of oil line Tighten couplings on line or replace
seals.
Tubes too small, resulting in : Use larger diameter lines.
- fluid speed < 1.5 m/s for supply.
- fluid speed < 0.15 m/s for oil outlet.
Overheating, or Insufficient Oil level too low for Check condition and add oil to
abnormal noise and lubrication self-lubricated required level.
vibration at bushed bearings
bearings Problem concerning Check force feed circulation system
regulation of oil (pump, condition of filters), calibrate
circulation at flowmeter, check diaphragm hole.
bearings Check condition of lubrication ring and
operation of ring.
Oil viscosity modified by temperature Control feed oil temperature.
Oil viscosity incorrect Use oil specified.

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Power Conversion
7.2.4.5 Special recommendations for malfunction checks
Check for oil leaks at bushed bearings

Self-lubricated bushed bearings
When the motor is stopped, the oil level in the bearings should be around 5mm below the average level
marked on the oil level indicator.
Average level on
indicator
5 mm
Recommended
oil level
Be sure to check that the bottom of the oil ring is properly submerged.
The bearing should be filled slowly to gradually control the rising oil level. If the required oil level is
overshot, you must remove the excess oil.
Any signs of oil in the floating baffles can result in leaks.
If this occurs, remove the bearing cap and the floating baffles to clean them with solvent, and dry them
before reassembly.
Force-feed lubricated bushed bearings

The following principles should be observed to prevent oil leaks:
- The gravity oil return line should be installed correctly, i.e. with a minimum slope of 15° along its entire
length.
- This oil return line must have a null internal pressure. A venting system should be installed if necessary.
- The line (or lines) must be sized to ensure a natural oil flow (the oil flow required must never result in an
oil height exceeding half the section of the return line).
- The oil return line must lead into a “buffer” tank above the oil level at atmospheric pressure as shown in
the diagram below. Under no circumstances should the end of the line be situated below the oil level in
the tank.
Venting breather

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Power Conversion
- The flow must be adjusted using a diaphragm(s) at the oil inlet on each bearing. The oil flow must never
exceed the value indicated on the information plate for each bearing.
- As for the self-lubricated bearings, be sure to check that the internal pressure of each bearing is not
positive. Additionally, the oil level must not exceed a maximum height of 5mm on the oil level indicator
as shown in the diagram below:
Average level
on indicator
5 mm max., i.e. ¼
Height of indicator
This oil level corresponds to a state of the oil force feed system in service with the motor
NOTA
stopped.
- If a closed coupling protection casing is used, make sure that it is vented and that there is an
evacuation hole at the lower part to prevent vacuum or overpressure problems causing oil leaks in the
bearing.
Check of protection system

Machines equipped with protection and monitoring systems require adjustments on the alarm
components to prevent the occurrence of abnormal operating conditions.
In the event of a failure of the measurement sensors or the replacement sensors, it will be necessary to
reinitialize the alarm and tripping threshold settings of the protection system.

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Power Conversion
8. SERVICE DEPARTMENT / REPLACEMENT PARTS
8.1 PRESENTATION OF SERVICE DEPARTMENT AND CONTACT DETAILS

The Power Conversion Service department has been operational since the electrical rotating machines
first began to be manufactured in 1904.
Power Conversion Service excels in performance and innovation. Our experienced specialist teams
travel throughout the world ensuring minimum intervention time, providing our customers with the
technical and research resources of a major manufacturer.
Our Service department comprises sections for: replacement parts and motors, maintenance and repair,
expertise and diagnostics, installation & commissioning. You can contact our Service department by:
• Telephone, from 7h00 to 17h00: + 33 (0)3 83 38 40 00
• Fax : + 33 (0)3 83 38 42 94
• E-mail : servicesmotors@converteam.com
We provide assistance in the following areas:

- supply of replacement parts:
• coordination of replacement parts batches recommended for machines supplied,

• sale of replacement parts suited to the concerned machine,
- supply of spare motors:
• complete interchangeability assurance,

• installation and commissioning by specialized teams,
- on-site interventions:
• adjustments and commissioning,

• expert analyses under actual operating conditions,
• modifications required by developments in use of machines,
• normal and exceptional maintenance works,
• repairs,
- handling of assistance and warranties:
• practical advice for commissioning,

• processing of written complaints during warranty period,
• implementation of corrective measures,

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Power Conversion
8.2 REPLACEMENT PARTS
8.2.1 Evaluating replacement part needs

During production of Power Conversion motors, a list of replacement parts is generally drawn up
consistent with the specific features of each machine.
Backed by our extensive experience in design and construction, Power Conversion’s motors are able to
meet the high-reliability requirements demanded by the operating conditions of our customers, and the
applicable standards governing construction of motors.
Yet, determining the necessary replacement part inventory is particularly difficult as it is dependent on
the wear inherent to the conditions under which the motors are used at the site.
Determining the nature and extent of the replacement part inventory is essentially the responsibility of
the maintenance personnel on the site.
The best qualified personnel must therefore select the type and quantity of replacement parts keeping in
mind the application for which the motor is used and the financial risks to which the operator is exposed
in the event of an unexpected shutdown of a production unit.
8.2.2 Standard replacement parts

The motors built by Power Conversion are covered by a systematic internal coding system for the
various components of the machine.
To assist you in identifying the parts concerned by wear, standard lists are given below indicating those
parts which may be useful as replacement parts.
These lists use the tree structure of the parts lists for parts mounted on the motor, as established on the
cross-sectional drawing for the concerned motor.

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Power Conversion
List of wear and replacement parts (see cross-sectional view)
Indicative Replacement part

Family Sub-family Designator Consumable
service life (security inventory)
115 Air inlet silencer 10 years
110 116 Air outlet silencer
117 Ring filter unit 1 year
120 122 Filter unit (WPII) 2 years
Ring filter unit
130 133 1 year
100 (hydro)
(Ventilation) Motor-fan unit, complete,
142
internal air
140
Motor-fan unit, complete,
146
external air
Motor-fan unit, complete,
150 152
ring unit
Rolling element
211 40 000 hours
bearing
Compression
210 212 40 000 hours
washer
(Rolling element
214 Ejector disk
bearing assembly)
215 Retaining ring 40 000 hours
216 V ring seal
200 217 Grease fitting
(Bearing DE) 251 Bush
252 Oil ring
253a External floating seal
250
254 Internal floating seal
(Bushed bearing
255 Type 12 special seal
assembly)
256a Filler plug
256b Drain plug
256c Oil level indicator
Rolling element
311 40 000 hours
bearing
Compression
310 312 40 000 hours
washer
(Rolling element
314 Ejector disk
bearing assembly)
315 Retaining ring 40 000 hours
316a V ring seal
300 317 Grease fitting
(Bearing NDE) 351 Bush
352 Oil ring
353a Full external seal
350
354 Internal floating seal
(Bushed bearing
355 Type 12 special seal
assembly)
356a Filler plug
356b Drain plug
356c Oil level indicator

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Power Conversion
List of wear and replacement parts (see cross-sectional drawing)
Indicative Replacement part

Family Sub-family Designator Consumable
service life (security inventory)
410 411 Insulators
(Main) 412 Connection strips
421 Insulators
400 420
422 Connection strips
(Terminal box) (Neutral)
423 Connection bars
450
457 Complete auxiliary unit
(Auxiliaries)
511 Metal bearing sensor
512 Metal bearing sensor
515 Internal air sensor
510
516 External air sensor
(Temperature
control) Water inlet temp.
517
sensor
Water outlet temp.
518
sensor
500 530
531 Heating resistor
(Instrumentation) (Heating resistor)
540
Leak detector,
(Water leak 541
complete
control)
550 551 Complete system
(Pressurization
552 Valve
control)
560 561 Brushes 1 year
(Rotor insulation
562 Brush-holder
control)
610
(Ring 611 Ring unit, complete
compartment)
621 Short-circuit knife
622 Power connector
620
Complete fork with
(Ring short- 623
rolling element bearing
circuiter)
Motor reduction gear
600 624
unit + nut
(Rotor
connections) 1 set of brushes
(if no brush
651 1 year
retraction
650 implemented)
(Brush holder 1 set of brushes (if
system) 651 brush retraction
implemented)
653 1 set of brush holders
654 Solenoids

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Power Conversion
8.2.3 “Major” replacement parts

Depending on the importance given to the availability of the motor within its installation, it may be
financially significant to consider the procurement of “major” replacement parts should an emergency
replacement become necessary.
The replacement parts to be considered are: - 1 rotor
- 1 stator
or
- 1 replacement motor
8.2.3.1 Disassembly of rotor
1/5 X X
2a/5 2b/5
3a/5 3b/5
4a/5 4b/5
5/5

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Power Conversion
This procedure must be carried out by an experienced, qualified technician under Power
Conversion supervision.
To disassemble the rotor, the following preliminary steps must be carried out:
• Disconnect all the cables (power supply, protection systems, accessories, etc.)
• Use the cross-sectional drawing provided with the motor.
• Drain the oil circuits for the concerned motors.
• Drain and remove the external ventilation systems to facilitate access to the bearings.
• Prepare a steel tube to handle the rotor. The inside diameter of the tube must be 3 to 6 mm
greater than the outside diameter of the shaft. The tube length must be X mm, where X
represents the length of the motor shaft. Prepare a sheet of copper (thickness of 0.5 to 1mm)
which will serve to protect the machined surfaces between the shaft end and the extension arm.
• Prepare the supports required to receive the rotor withdrawn from the stator, or a trolley.
Step 1/5: The rotor must be withdrawn by the coupling side (DE) or side opposite the coupling (NDE) after
the motor has been uncoupled from the driven machine. For this disassembly operation, the motor must
be positioned horizontally (for motor used in vertical position, see paragraph “3.2 Handling principles”).
If an internal fan is used (DE or NDE), respectively perform procedures ‘2a’ to ‘4a’ or ‘2b’ to
NOTA
‘4b’.
Step 2/5: Remove the shaft end sleeve, coupling side. Remove the bearing bottom. Place a copper sheet
on the shaft end. Insert the tube on the shaft end, side opposite coupling (“a” sequence) or coupling side
(“b” sequence) over a length of 150mm. Place the slings at each end of the “shaft+extension tube”
assembly.
Step 3/5: Move the rotor in translation, avoiding any stator/rotor contact which could damage the
magnetic circuits and windings. Set the rotor on the supports intended for this purpose and remove the
slings.
Step 4/5: Sling and move the frame outside of the work area to be able to safely perform the next step.
Step 5/5: Remove the extension tube. Sling the rotor and move it to its storage location.
8.2.4 Storage of replacement parts

Not having a complete knowledge of the storage conditions near the installation, it may be useful to
integrate, in the replacement part order, a “maritime” packaging system. Care should be taken not to
damage the packaging throughout the storage period as the replacement parts are protected against
humidity in a heat-sealed cover containing desiccant bags.

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Power Conversion
9. RECYCLING AND WASTE MANAGEMENT
9.1 GENERAL INFORMATION

As part of the constantly-evolving measures aimed at reducing the environmental impact of industrial
activities, Power Conversion recommends the following principles aimed at ensuring an economic and
ecological management of the materials forming an induction motor.
These recommendations must not be understood, under any circumstances, as an alternative to the
specific laws and measures concerning protection of the environment applicable in the location where
the motors are installed.
The environmental principles recommended are directly based on the nature of the materials which are
recyclable to 98%, selected by Power Conversion for the design of its motors.
The current policies governing the collection and management of waste call for separation of the
various recyclable components of the motor at the source for channeling to the appropriate waste
management structures.
The portion of the recyclable materials used in our motors is essentially broken down in accordance with
the proportions given in the table below.
Motors with cast iron frame Motors with modular steel

(Flowpack type) frame (type N3 – F3)
Steel 57 – 63 % 76 – 84 %
Copper 10 – 14% 10 – 14 %
Cast iron 25 – 32 % 1–2%
Aluminium 0% 0–2%
Plastic 1–2% 1–2%
Integrated electrical and
<1% <1%
electronic devices
Incinerable parts (electrical
<1% <1%
insulation)
Stainless steel <1% <1%
Wood containers (optional –
percentage relative to total 13 - 19 % 13 - 19 %
weight of motor)
9.2 PROCESSING PACKAGING AND PROTECTION COVERINGS

All the packaging used with the Power Conversion motors is entirely recyclable as concerns the wood
part, whatever the country our products are exported to.
The non-impregnated packaging wood can be directly recycled after grinding by composting.
Where impregnated wood is used, the maritime transport regulations governing pest and disease
control with regard to packaging specify that wood crates can be recycled after grinding in the form of
chip wood.
The standard products (Rhodorsil Paste 5, Tectyl 511M, Grypsol) applied to the surfaces of the motor for
protection against corrosion must be cleaned using a detergent with surface active agents which do not
represent any special toxicity hazard for the environment.

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9.3 SORTING AND RECLAMATION OF MATERIALS
Except for copper and aluminium, the various components used in the motor can be easily dismantled
owing to the modular design of the motor construction by sub-assemblies.
9.3.1 Reclamation of cast iron and steel

The materials forming the frame, fans, covers and bearings can be dismantled and reclaimed by melting
in a blast furnace in accordance with the approved recycling practices used in the metal production
industry.
The steel in the magnetic circuits (stator and rotor) and shaft can only be recycled following complete
extraction of the copper rotor bars and windings.
9.3.2 Reclamation of copper

Reclamation of the copper used in the electrical conductors of the stator and rotor in induction motors
calls for extraction by skilled personnel qualified for cutting of metals.
The copper in the windings can only be extracted and separated from the electrical insulation
components by a heat process at 380-420°C in a combustion oven lasting 5 minutes.
The combustion gases must be processed by a gas purification system with a residence time of at least
3 seconds at 850-920°C to reduce the toxic nature of the gas emissions.
This separation method must be stringently monitored in accordance with the regulations applicable to
the incineration system.
9.3.3 Reclamation of aluminium

The aluminium tubes used in the motor heat exchangers must, in principle, be cut out or extracted for
recycling through appropriate channels.
9.3.4 Reclamation of electronic components

The components forming part of the electrical and electronic instrumentation of the motors are
compliant with the requirements of the European Directive covering electrical and electronic equipment
waste DEEE 2002/96/CE. These components do not contain any dangerous substances as defined by
the terms of directive RoHS 2002/95/CE. Sorting, selective processing, management and destruction of
this waste must be carried out through the appropriate approved channels.
9.3.5 Reclamation of plastic

Certain plastic components used, in particular in the N3 motor (air guide, terminal box mounting plate),
are made of polyester. This material can be reclaimed by grinding and integration in cement industry
products.
9.3.6 Elimination of oils

Lubrication oils represent a dangerous waste for the environment; used lubrication oils must be stored
and processed in compliance with all applicable regulations covering the elimination of this category of
waste.

GE Energy
Power Conversion
10. MODIFICATION RECORD
Revision Date Author Checked by Approved by Details

00 02 august 07 S. Basso B. Basquin J-C. Demard Initiale issue
- Tilting over a vertical motor
01 21 may 08 S. Richardet - J-C. Demard
- Disassembly of rotor
02 25 nov 09 S. Richardet B. Trapletti J-C. Demard Rotation uncoupled (§ 4.2.3.2)
03 15 feb 10 S. Richardet - B. Rouat Update to standards (DM 2006/42/CE)
J. Enon - Update about Safety instructions
04 24 june 11 G. Delhaye - - - Update about N4 serie
Y. Viry - Filter maintenance of slip ring casing
- Update of the name plate and the magnetic
centering plate
05 25 apr 12 I. Schneider B. Schnabel J-C. Demard - Update of the storage precautions
- Modification of the start-up control precautions
for induction motors with slip rings

FAX MESSAGE
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Power Conversion Page 1 Total: 1 page(s)
ATTENTION: PROJECTS DEPARTMENT
FROM: DATE:
COMPANY:
RECEPTION REPORT
For a better quality of our allowances, please transmit this document to the receiver of the motor, to complete it and return it to us by fax
or eventually by mail to: GE Energy – Power Conversion – Department Projects - 442, rue de la Rompure – BP 90 - 54250 Champigneulles -
FRANCE.
Type of motor: ...........................................................................................................................................................................................................................................................................
Serial number: ...........................................................................................................................................................................................................................................................................
Installation address: ..............................................................................................................................................................................................................................................................
----------------------------------------------------------------------------
RECEPTION
Is the motor inside a thermosealed packaging? YES ❑ NO ❑
The packaging state is: Correct ❑ Defective ❑ (*)
Will the motor be stored more than 6 months? YES ❑ NO ❑
If you answer ‘YES’, clarify the number of months: ...............................................................................................................................................................................................

Ask the procedure of long-term storage to GE Energy – Power Conversion and plan to complete report of storage below.
At the opening of boxes:
Painting state Correct ❑ Defective ❑ (*)
Locking of the rotor Correct ❑ Defective ❑ (*)
Instrumentation Correct ❑ Defective ❑ (*)
Are the supplies in conformity with shipping documents? YES❑ NO ❑ (*)
(*) Detailed description of the defects
...........................................................................................................................................................................................................................................................................................................
...........................................................................................................................................................................................................................................................................................................
...........................................................................................................................................................................................................................................................................................................
...........................................................................................................................................................................................................................................................................................................
A specimen of this document is included inside the safety, installation and maintenance manual. Page 1 / 12
FAX MESSAGE
DEST: GE Energy Fax N°: (33) (0) 3. 83. 38. 42. 99.
FROM: DATE:
COMPANY:
STORAGE REPORT
For a long storage period, please pass on this document to the person responsible for storing your motor, to complete it and return it to
us by fax or eventually by mail to: GE Energy – Power Conversion - Department Projects - 442, rue de la Rompure – BP 90 - 54250
Champigneulles - FRANCE.
Type of motor: ...........................................................................................................................................................................................................................................................................
Serial number: ...........................................................................................................................................................................................................................................................................
1- KNOWLEDGE OF THE STORAGE INSTRUCTIONS
Did you acquaint storage instructions of the motor as defined in this manual? YES ❑ NO ❑
For a long period storage, did you receive special recommendations from the manufacturer? YES ❑ NO ❑
If not, ask the long period storage procedure, to the service:
Projects Department – GE Energy Power - Conversion - 442, rue de la Rompure – BP 90 - 54250 Champigneulles - FRANCE.
Tel: 33 (0)3 83 38 40 00.
2- REGISTERING OF THE STORAGE PERIOD
Responsible person for storage: ......................................................................................................................................................................................................................................
Duration of the storage: - Date of the beginning: ..................................................................................................................................................................................................
- Date of end: ...................................................................................................................................................................................................................
3 – REGISTERING OF THE STORAGE MODALITIES
Generalities
- Condition of packaging during the storage: Without protection ❑ Marine packaging SEI IV C ❑
- Storage place: Open / ventilated place ❑ Without corrosive product ❑
Without vibration ❑
Respect of the limit storage conditions (temperature, rate of humidity)
- Range of controlled temperatures: Min/Max:...../......°C; Maximum rate of controlled humidity: ..........%
In case of long storage period:
Motor nb
Long time storage
Check points Operations of control Done Date Conform Not conform Controller visa
A. Anti-oxidizing protection of the motor components :
Paws of the frame Maintenance of the intermediate paint
Flange (vertical motor) Maintenance of the intermediate paint
Chemical encapsulation :
Application of anti-oxidizing on the surfaces (type : Rhodosil pâte 5)
Protection of the shaft end face with intermediate paint
Mechanical cladding of the shaft end :

Coupling shaft end and shaft parts out of the enclosures Filling of the key’s cavities with stainless keys
Heat shrinkable cladding of the shaft end
Tightness of the thermoretractable cladding
Protection of the ground brushes :
Disassembling of the ground brushes and protection of the earthing surface
Application of anti-oxidizing on the surfaces

Shaft end cotters
Wrapping in the lubricated paper during the storage
Application of Tectyl 511M protection on the internal components surfaces of the bearing
Sealing of the bearing joints with 3M adhesive band

Smooth bearings
Plugging of orifices from oil pipes
Sealing off with elastomer band of silicone between baffles and shaft
Junction boxes Tightness of joints (cover-box) with 3M adhesive band
Hydro cooler Sealing application of the clearance (flange-companion flange) with 3M adhesive tape
B. Anti-vibratory protection:
Positioning of the motor on wood stringers having restricted hygrometry
Insert damper pads of Grypsol type

C. Anti-condensation protection:
A specimen of this document is included inside the safety, installation and maintenance manual.
Permanent connection of the space heaters for a long time storage
D. Periodicity of the material reconditioning:
In case of non use of the material during 24 month :
Control of the winding contamination :
Measure of polarization index (IP)
Insulation measurement
Visual checks on quality of surface of tin-plated terminal lugs
Visual control of sealing quality between covers and boxes, then reconditioning if necessary
Control of internal contamination to the bearings :
Case of the non-contaminated bearing : reconditioning of the anti-oxidizing protection
Page 3 / 12
Case of the contaminated bearing :Cleaning and reconditioning of the anti-oxidizing protection from the smooth
Control of the other points :

Visual examination without dismantling
Notes about reconditioning during 24 months:

FAX MESSAGE
DEST: GE Energy Fax N°: (33) (0) 3. 83. 38. 42. 99.
FROM: DATE :
COMPANY:
INSTALLATION REPORT
At the installation of your motor, please complete this document and return it to us by fax or eventually by mail to: GE Energy – Power
Conversion– Département projets - 442, rue de la Rompure – BP 90 - 54250 Champigneulles - FRANCE.
Type of motor: ...........................................................................................................................................................................................................................................................................
Serial number: ...........................................................................................................................................................................................................................................................................
Did you read completely this manual? YES ❑ NO ❑
This report is conditional for the validity of the warranty GE Energy – Power Conversion. It is imperative to complete this report in
compliance with the safety, installation and maintenance manual instructions. Otherwise, the warranty delivered by GE Energy – Power
Conversion is cancelled.
APPROVAL DATE OF THE MACHINE FOR EXPLOITATION: ......................................
PERSONNE RESPONSIBLE FOR THE INSTALLATION ON SITE
Company: ......................................................................................................................................................................................................................................
Name – Given name: ...............................................................................................................................................................................................................
Telephone number: ...................................................................................................................................................................................................................
Fax number: .................................................................................................................................................................................................................................
Date: ......................................................................................................................................................
Signature
FINAL CLIENT
Company: ......................................................................................................................................................................................................................................
Name – Given name: ...............................................................................................................................................................................................................
Telephone number: ...................................................................................................................................................................................................................
Fax number: .................................................................................................................................................................................................................................
Date: ......................................................................................................................................................
Signature
1 – ELECTRICAL CHECKS
Action achieved Not Controller

Check points Date Conform
Expected values Measured values conform visa
1.1. MEASUREMENT OF INSULATION REISITOR (before start-up)
Stator winding Value: .............. Mohm (2500 V during 1 Value: .............. Mohm (2500 V during 1
minute) minute)
Rotor winding (if applicable) Value: .............. Mohm (1000 V during 1 Value: .............. Mohm (1000 V during 1
minute) minute)
Insulation value of the space Value: .............. Mohm (500 Vcc during 45 Value: .............. Mohm (500 Vcc during 45
heater sec) sec)
Insulation value of the thermal Value: .............. Mohm (500 Vcc during 45 Value: .............. Mohm (500 Vcc during 45
probes resistance sec) sec)
Value in case of two insulated Value: .............. Mohm (45 VCC during 45 Value: .............. Mohm (45 VCC during 45
bearings sec) sec)
1.2. VALUE OF POLARIZATION INDEX (before start-up)
IP = R10 min / R1 min Value : ..............
1.3. MEASUREMENT OF THE INSTRUMENTATION RESISTANCE (before start-up)
Platinium thermal probes 100 Values: 1 : .............. ; 2: .............. ; Values: 1: .............. ; 2: .............. ;
ohms at 0°C stator 3: .............. ; 4: .............. ; 3: .............. ; 4: .............. ;
5: .............. ; 6: .............. ; 5: .............. ; 6: .............. ;
7: .............. ; 8: .............. ohms 7: .............. ; 8: .............. ohms
Platinium thermal probes 100
DE/NDE: .............. / .............. ohms DE/NDE: .............. / .............. ohms
ohms at 0°C bearing
Platinium thermal probes 100
Input/Output: ............ / ............ ohms Input/Output: ............ / ............ ohms
ohms at 0°C air
Space heater .......................................... ohms .......................................... ohms
1.4. ELECTRIC NETWORK
Voltage variation on the network .................... - .................... Volts .................... - .................... Volts
Frequency variation on the network .................... - .................... Hz .................... - .................... Hz
1.5. CONNECTIONS
Space heaters Introduced
correction:
...................
Brushes Introduced
correction:
...................
Protection devices Introduced
correction:
...................
Phases and/or neutral Introduced
correction:
...................
Tightening torque of the HV supply Tightening torque: Tightening torque applied:
cables – Type de connections: .................... .................... N.m .................... .................... N.m
1.6. ADJUSTEMENTS OF THE PROTECTION DEVICE
Probes of the stator windings Alarm threshold: ................... °C Alarm threshold: ................... °C
Trip threshold: ................... °C Trip threshold: ................... °C
Bearing probes Alarm threshold: ................... °C Alarm threshold: ................... °C
Air input probe Alarm threshold: ................... °C Alarm threshold: ................... °C
Air output probe Alarm threshold: ................... °C Alarm threshold: ................... °C
Other: .................... Alarm threshold: ................... °C Alarm threshold: ................... °C
Maximum voltage Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Motor stop: ................................. Motor stop: .................................
Minimum voltage Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Unbalance Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Motor stop: ................................. Motor stop : .................................
Maximum current Carried out adjustments :
Alarm: ......................................... Alarm : .........................................
Overload Carried out adjustments :
Alarm: ......................................... Alarm: .........................................
Differential protection Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Differential protection block Carried out adjustments:
(transformers – motor) Alarm: ......................................... Alarm: .........................................
Stator mass Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Minimum power Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Too long start Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Locked rotor Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Cadence of start-up Carried out adjustments:
Alarm: ......................................... Alarm: .........................................
Other chosen protection mode : If applicable, indicate chosen modalities: ............................................................................................................................................
....................................................................................................................................................................................................................
....................................................................................................................................................................................................................
2 – MECHANICAL CHECKS
2.1. AIR-GAP MEASUREMENT (in case of single bearing motor)
Air-gap measurement done in 4 Expected values according to Figure 1: Expected values according to Figure 1:
points every 90 degrees on the DE A: ......... B: ......... C: ......... D: ......... A: ......... B: ......... C: ......... D: .........
side Expected value according Figure 2 : Expected value according Figure 2 :
1: ......... 2: ......... 3: ......... 4: ......... 1: ......... 2: ......... 3: ......... 4: .........
2.2. MOTOR SHAFT
Free rotation of the shaft (not applicable for the motors equipped with sleeves)
Direction of rotation View from drive end: ..................
Confirmation of clockwised direction: ..................
Confirmation of counter clockwised direction: ..................
Confirmation of both directions: ..................
2.3. COUPLING
Balancing of coupling With half key: ..................
With full key: ..................
If not applicable, indicate the type of coupling: ..................
Conical coupling: ..................
Smooth shrinked coupling: ..................
Type of coupling achieved Type of the Figure 3: ..................
Type of the Figure 4: ..................
Picture 1 Picture 2
A
1 2
D B
4 3
C
Picture 4
Picture 3(*)
Half coupling Half coupling
Spacer
Key section to be machined
Key Shaft end Key Shaft end
(*) If the mounting is achieved as in the Picture 3, to avoid an unbalance, it is necessary to machine the part of the cotter over-passing
the coupling, as represented on this picture.
2.4. – CHECK THE SHAFT LINE
Not Controller
Check points Action achieved Date Conform
conform visa
2.4.1. ALIGNMENT CONTROL BEFORE STARTING THE MOTOR
Alignment control Copy of the measurements in the rectangle shaped boxes in the Figure 5
2.4.2. CONTROL THE ALIGNMENT FROM COLD
Alignment control Copy of the measurements according the modalities defined in the Figure 6:
control alignment control
Picture 5
Top
Left side Right side
Bottom
View DE side of the motor

0.000 0.000
0. 0. 0. 0.
0. 0.
Axial misalignment axial in mm. Radial misalignment in mm.
Tolerance of expected axial alignment :…..mm Tolerance of expected radial alignment :..…mm
Axial misalignment axial
Radial misalignment
radial
Picture 6: alignment control from cold
Representation of the radial misalignment corresponding to the cold and hot states in horizontal or vertical projection
Alignment when
∆xo or ∆yo driven machines are hot
organ
∆xm or ∆ym
motor
Cold state of the driven
Cold state of the organ
motor ∆DH or ∆DV
Representation of the radial misalignment corresponding to the cold and warm states in two dimensions
∆xm
Alignment when machines are

hot
∆ym ∆yo
∆DV
Cold state of the Cold state of the driven

motor organ
∆DH
∆xo
View in front of the motor shaft end
Theoretical value of horizontal misalignment from cold: ∆DH(th) = ∆xm - ∆xo = ….….-………..=…………….
Theoretical value of vertical misalignment from cold: ∆DV(th) = ∆ym - ∆yo =………-……….=…………….
Measured value horizontal misalignment from cold: ∆DH(mes) = ……………….

Measured value vertical misalignment from cold: ∆DV(mes) = ……………………..……….
∆DH(th)-∆DH(mes) =……………. Respecting the tolerances (chapter 3 –paragraph III.3.4.)

∆DV(th)- ∆DV(mes) = …………. Respecting the tolerances (chapter 3 –paragraph III.3.4.)
External cove r X m = mm (magnetic Shaft shoulder on coupling side

centring)
of the bearing housing
Case of
coupling
Minimum extreme postion of the rotor: X min
Maximum extre me position of the rotor: X max
∆DA: Global dilation of the shaft line between thrust bearing and the shaft end of the motor
∆DA (theoretical from hot) =……………………....
Dimension X when cold: Xcold =…………….…….
Conditions to respect:
∆DA (theoretical from hot) < Xm – Xmin – 0.5 mm

∆DA (theoretical from hot) < Xm – Xmax – 0.5 mm
Xm – 1 mm < Xcold + ∆DA (theoretical from hot) < Xm + 1 mm
2.5. – GENERAL COMPLEMENTARY CHECKS

Expected values Expected values conform visa
Control of the motor anchoring according to the fastening mode expected in the outline drawing
Control of the tightening Torques value: Torques value
.................................... N.m .................................... N.m
(bolting sizes: .................................... ) (bolting sizes: .................................... )
Check of the crankshaft flexibility
Control of the cooling water Water flow rate: Water flow rate:
Water temperature Water temperature
Water pressure Water pressure
Components values of the water Components values of the water
analyzed: analyzed:
................................................................. .................................................................
................................................................. .................................................................
3 – CHECKS OF THE SLEEVES BEARINGS

3.1. OIL USED
Nature of oil Type: .......................................... Type: ..........................................
Viscosity: .......................................... Viscosity: ..........................................
Manufacturer: ........................................ Manufacturer: ........................................
Conformity to the specification plate
3.2. LUBRIFICATION BY SPRAYING OR UNDER PRESSURE
3.2.1. PIPING (sleeves bearings by oil circulation)
Cleanliness of the oil piping
Correct flowing of oil
3.2.2. DIAPHRAGM
Correct drilling of diaphragm
Diaphragm positioning at each oil input of the bearings
3.2.3. OIL FILTRATION
Equipment of oil flowing system with a clean filter of mesh from 10 to 20 microns
3.2.4. OIL PRESSURE AND FLOW
Control of oil pressure and flow Oil flow rate on DE bearing: ................. Oil flow rate on DE bearing: .................
rate to the input of bearing Oil flow rate on NDE bearing: ............... Oil flow rate on NDE bearing: ...............
upstream to the diaphragm Oil pressure on DE bearing: ................. Oil pressure on DE bearing: .................
Oil pressure on NDE bearing: ................ Oil pressure on NDE bearing: ................
3.3 SELF-LUBRICATION
Conformity of the oil quantity in relation with indication plates
Control of oil filling to the required level (generally to the ¾ of the expected indicator of level)
Control of the free rotation of lubrication rings
4 – CHECKS OF THE BEARINGS LUBRICATED WITH GREASE

4.1. GREASE USED
Nature of grease Type: .......................................... Type: ..........................................
Viscosity: .......................................... Viscosity: ..........................................
Manufacturer: ........................................ Manufacturer: ........................................
Conformity to the specification plate
4.2. MODALITIES START-UP AT NO LOAD
Grease injection during the 2 weeks DE side:
Nb of injections: ........ Quantity: ........ Nb of injections: ........ Quantity: ........
NDE side:
5. – CONTROL OF THE START-UP TRIAL (subject to the measures, among others, of chapter 4 –paragraph III.1)
Non Visa
Points de contrôle Action réalisée Date Conforme
conforme contrôleur
5.1. STARTING AT NO LOAD DURING FEW SECONDS
Control of abnormal noise if existing, indicate: ..........................................
Direction of rotation View from coupling side:
Confirmation of clockwised direction: ..........................................
Confirmation of counter clockwised direction: ..........................................
Confirmation of both directions: ..........................................
5.2. SECOND START-UP AT NO LOAD
Measure of the cold dimension (see
Expected value ‘X’ or ‘Y’: ............ mm Expected value ‘X’ or ‘Y’: ............ mm
the plate hereafter)
Control the abnormal noise If existing, indicate: ...............
Control of bearings vibrations at no Copy the measures in Table 1
load (mm/sec r.m.s.):
Registering of electrical values at Copy the measures in Table 2
no load :
Thermal control of the motor: Copy of the measures in Table 3
5.3. START-UP OF THE COUPLED MACHINE WITH PROGRESSIVE LOAD UNTIL FULL LOAD
Measurement of the dimension
Expected value ‘X’ or ‘Y’: ............ mm Expected value ‘X’ or ‘Y’: ............ mm
from hot (see plate hereafter)
Control of bearings vibrations at no Report des mesures en Table 4
load (mm/sec r.m.s.):
Registering of electrical values at Report des mesures en Table 5
no load:
Thermal control of the motor: Report des mesures en Table 6
X= mm Shaft shoulder on coupling side
Case of coupling
External cover of the

bearing hoousing
Y= mm
Case of flanged-shaft
Table 1: Control of the bearings vibrations (mm/sec. r.m.s.) at no load
Coupling side Opposite coupling side
Direction Axial Vertical Horizontal Axial Vertical Horizontal
Measured values at no
load
Expected values
Table 2: Registering of the electrical values at no load
Voltage (V) Intensity (A) Absorbed power (W) Excitation current (A)
Phase U V W U V W
Measured
values at
no load
Expected .
values
Table 3: Thermal protection of the motor at no load
Temperature to the stator’s phases (°C) Temperature of bearing (°C) Ambient temperature
U V W DE NDE (°C)
Measured values out
of charge
Expected values
Table 4: Control of bearings vibrations (mm/sec. r.m.s.) with progressive load until full load
Hour Charge Coupling side (DE) Opposite coupling side (NDE)
% Axial Vertical Horizontal Axial Vertical Horizontal
After 2 min
After 1 H.
After 3 H.
After 4 H.
After 5 H.
Table 5: Registering of electrical ranges with progressive load until full load
Hour Charge Voltage (V) Intensity (A) Power factor Absorbed Excitation
U V W U V W cos Ф power (W) current (A)
%
After 2 min
After 1 H.
After 2 H.
After 3 H.
After 4 H.
After 5 H.
Table 6: Thermal control of the motor with progressive load until full load
Measures carried out until temperature stabilisation (+/- 2°C):
On the bearing housing ❑
With the temperature probe expected on the bearing ❑
Hour Charge Temperature to the stator Bearing Air temperature (°C) Water temperature
phases (°C) temperature (°C) (°C)
%
U V W CA COA Inlet Outlet Inlet Outlet
After 2 min
After 1 H.
After 2 H.
After 3 H.
After 4 H.
After 5 H.
6 – SASTIFACTION DEGREE OF THE CLIENT
Excellent ❑ Very good ❑ Good ❑ Indifferent ❑ Bad ❑
PRINCIPAL REMARKS
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GE Energy
Power Conversion
MANUFACTURER RECOMMENDATIONS
MEDIUM TIME STORAGE DURING COMPLETION OF THE SITE

INSTALLATION
Change Number:
Reason for new revision: Initial issue
(see last page for
©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained
herein is GE Energy Power Conversion Proprietary Technical Information that belongs to the General Electric
Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act
of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any,
or all such information except as expressly authorized in writing by the General Electric Company, GE Energy (USA),
LLC and/or its affiliates.
CLASS II (GE INTERNAL NON-CRITICAL)

Customer : GE Energy Power Conversion Ref : IP806
Project : Manufacturer recommendations Revision : 00
Document : Medium time storage during completion of the site installation Date : 26 apr 12
File : / IP806_ENG (Rev.00).doc Page : 1/9
GE Energy
Power Conversion
CONTENT
1. REFERENCES ................................................................................................................................................... 3
2. REQUIRED ENVIRONMENTAL STORAGE CONDITIONS............................................................................. 3
3. PRESCRIPTIONS OF EQUIPMENT CONDITIONING/PROTECTION ........................................................... 4

3.1 SPACE HEATER ................................................................................................................................................................... 4
3.2 MOTOR ROTOR .................................................................................................................................................................. 4
3.3 ANTI-OXIDIZING PROTECTION .................................................................................................................................... 4
3.3.1 Shaft ............................................................................................................................................................................... 4
3.3.2 Smooth bearings ..................................................................................................................................................... 4
3.3.3 Main terminal box, exciter and auxiliary ...................................................................................................... 5
3.3.4 Coolers .......................................................................................................................................................................... 5
4. PRESCRIPTIONS FOR THE MATERIAL CONTROL........................................................................................ 6
4.1 CONTROL OF THE POLLUTION IN THE MAIN STATOR AND EXCITER WINDINGS .............................. 6
4.2 CONTROL OF THE INTERNAL POLLUTION OF THE BEARINGS...................................................................... 7
4.3 CONTROL OF THE OTHER POINTS ............................................................................................................................ 7
5. TEMPORARY INTERRUPTION OR END OF STORAGE ................................................................................. 7
5.1 TEMPORARY INTERRUPTION ....................................................................................................................................... 7
5.2 END OF STORAGE PERIOD ............................................................................................................................................ 7
6. MODIFICATION RECORD ............................................................................................................................... 9

GE Energy
Power Conversion
The present instruction describes all manufacture recommendations for storage and preservation of an
electrical motor of the series F3 and N3 for 12 month during the completion of the site installation. During
this period of completion of the site installation the motor remains on its foreseen operation place.
The present recommendations only have an informative purpose.
In any case, storage of equipments provided by GE Energy’s Power Conversion business (here below
designated Power Conversion) remains the only and whole responsibility of the customer which assumes
alone costs and risks, the responsibility of Power Conversion being not searchable in any circumstance.
1. REFERENCES
This instruction is based on the following documents:
• MSIMMA (Safety, installation and maintenance manual of asynchronous motors) which is
delivered with the motor,
• IP784: Manufacturer recommendations Long time storage
• IP707: Storage and preservation of bearings against oxidation.
2. REQUIRED ENVIRONMENTAL STORAGE CONDITIONS

The following conditions concern the storage area only without taking into account if the motor is
packed or not. The medium time storage must be carry-out:
• in a ventilated and covered premises, in dry surrounding air, protected from dust, and from
corrosive, explosive or gaseous atmosphere,
• not exposed to liquids (water, acid, oil, fuel and other),
• not exposed to major vibrations (floor of storeroom, frame or other), if the concrete base or the
skid are not installed on vibration absorbers the motor itself has to be placed on such absorbers
(ex stringers made of restricted hygrometry wood –class C22 plate with class 3 pressure-sealed
treatment- or buffers pads Grypsol type),
• within the temperatures range:
• minimum from -20°C without any tolerance,
• maximum to +40°C with tolerance (+10°C / -0°C),
• with a controlled rate of humidity < 70%. If this rate is increasing, a heating of the premises have
to be ensured,
• the motor covered by a tarpaulin.

GE Energy
Power Conversion
3. PRESCRIPTIONS OF EQUIPMENT CONDITIONING/PROTECTION
3.1 SPACE HEATER

The motor space heater has to be switched on during storage.
3.2 MOTOR ROTOR
• The rotor has to be uncoupled from the driven machine
• The tool delivered with the motor for protection of the rotor during transport should be installed
so far possible.
3.3 ANTI-OXIDIZING PROTECTION
3.3.1 Shaft
Protect the shaft end using a chemical and mechanical encapsulation. To do that:
(so far the coupling hub is installed, it has to be included on the protection)
• Dry clean using a rag, the whole not painted machining surfaces including cavities.
• Apply, under ambient temperature, using a brush a product TECTYL 506 VALVOLINE type
(temperature resistance from -20°C to +200°C), on the whole not painted machining
surfaces including cavities.
• Protect the face of the shaft end with a layer of 60 to 100 microns of intermediate or
final paint, after having properly takes any grease marks out from all surfaces to paint.
• Protect the cylinder of the shaft end with a plastic wrap.
• Protect the whole of the shaft sections with a product Tectyl 506 Valvoline type, including
under instrumentation
Ex.: Earthing brushes: Remove the earthing brush(es) from the shafing and temporarily
protect the surface. Store the earthing brush(es) in the main terminals box.
The surface under shaft displacement instrumentation (ex.: Bently Nevada sensor) does
NOTA
not require additional protection.
• Protect keys with a product TECTYL 506 VALVOLINE type. Pack each key in oiled paper.
Put the keys in a plastic bag and store it in the packing case provided with the motor.
3.3.2 Smooth bearings

After draining oil from the bearing tank:
• Remove caps of bearings and the upper half-bushings.
• Relieve shaft by a few tenths of millimeter (3 or 4ths) with a jack in order to free the lower half-
bushings.
• Extract the lower half-bushing by rotating it around the shaft. Take the usual safety precautions
to protect hands, feet, eyes and head.
• Spray a product Tectyl 511M type over the whole internal surfaces of the bearings and their
auxiliary equipment, such as shaft journals and bores from the two half-bushings.
• Reinstall whole parts, avoiding friction between parts as far as possible, to preserve the previous
chemical protection.

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Power Conversion
• Screw the bearings caps according to the recommended torques of the provider manual (RENK).
• Seal, using wide adhesive band 3M tape type, the joint of the bearings and the whole orifices
beforehand plugged, either with screw plugs or Kapsto type plugs (indicator light, filing port, oil
drain).
• Close inlet and outlet of oil nozzle.
• Seal joints between the bearings baffles and the motor shaft, with applying an elastomer silicone
joint Silicomet type.
3.3.3 Main terminal box, exciter and auxiliary

Complete the sealing made by the joints between covers and cabinets with sealing off the clearance
between the two parts with a wide adhesive band of 3M tape type.
In case of the terminal box is dismantled, these recommendations must be applied.
3.3.4 Coolers
3.3.4.1 Air coolers

Seal hermetically the air inlet and the air outlet to avoid any foreign object entering the cooler.
3.3.4.2 Water-coolers
Before any packaging operation, the water-cooler and the leakage detectors have to be totally drained.
• If the water-cooler is equipped with counter flanges: install the counter flanges and seal the joint
with a wide adhesive band of 3M tape type.
• In others cases: seal the flanges opening gap applying a wide adhesive band of 3M tape type.

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Power Conversion
4. PRESCRIPTIONS FOR THE MATERIAL CONTROL

4.1 CONTROL OF THE POLLUTION IN THE MAIN STATOR AND EXCITER WINDINGS
• Polarisation index (IEEE 43):
• Test method: Use a megohmmeter to apply a voltage on the three phases connected to
the windings. This voltage has to be 2500VCC for a nominal winding voltage higher or
equal to 2500V and 1000VDC in the other cases. The measures read 1 minute and 10
minutes after the voltage application.
Absorption current
Conduction current
• General method of calculation:
I1. min I Conduction + I Absorption R10. min

Ip = = =
I 10. min I Conduction R1. min
• Method of interpretation:
• Ip ≤ 1.5 : Isolation very low due to a deep hydration or to important leakage currents
due to an aging or an important pollution on the surface.
• 1.5 < Ip ≤ 2.5 : Humid or polluted insulation.
• 2.5 < Ip ≤ 4 : Dry or clean insulation.
• 4 < Ip : Very dry and clean insulation.
• Acceptation criterion: Ip > 2 (measures are reported on a record mentioning the product
reference, the test voltage, the test temperature, the values measured every minute, as the
index value).
• Measure of the total insulation resistor:
• The measure is realised with a megohmmeter following several possibilities:

• On all the windings in comparison with the magnetic core set to the ground in the
case of a closed and not accessible neutral,
• On each winding in comparison to the magnetic core set to the ground in the case
of an open and accessible neutral,
• On each winding in comparison with the other windings in the case of an open and
accessible neutral.

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Power Conversion
• Method of interpretation and acceptation criterion:
The measures, read about 1 minute after the voltage application, depends on UR (reception
voltage) and UN (nominal voltage), so:
• 2500VCC for the stators MT (medium voltage) after impregnation 2195V < UR <
9319V,
• or 5000VCC for the stators MT after impregnation UR > 9319V
• 1000VCC for the other parts (rotors, exciters, stators BT (low voltage), etc.).
Since the on site commissioning, the minimum acceptable value at 20°C is 3(UN(kV)+1). The
measured values will be recorded on the corresponding data sheet.
• Visual control of surface quality of the tinned lugs.
• Sealing joints quality between covers and terminal boxes cabinets.
After control, recondition as described to the § 3.3.3. If necessary, change the sealing joints between
covers and cabinets.
4.2 CONTROL OF THE INTERNAL POLLUTION OF THE BEARINGS

a) Not polluted bearing
Repackage as described in § 3.3.2.
b) Polluted bearing
Clean the polluted zones and repackage as described in § 3.3.2.
Check that all storage prescriptions are applied.
4.3 CONTROL OF THE OTHER POINTS

Perform a visual check without dismantling.
5. TEMPORARY INTERRUPTION OR END OF STORAGE
5.1 TEMPORARY INTERRUPTION

It might be necessary to use temporary the equipment for example for testing of any supply to the
motor (oil, water etc.) during completion of the construction.
In case of temporary use, a reconditioning of the equipment following this procedure has to be realised
afterwards!
In any case of moving the motor the locking device for the rotor has to be installed!
For both, installation and exploitation, refer to the safety, installation and maintenance manual delivered
with the machine.
5.2 END OF STORAGE PERIOD

After the end of the storage period, prepare the equipment for the exploitation as follows:
• Remove the chemical and mechanical encapsulation of the shaft end (see § 3.3.1.).
• Reinstall the keys previously stored in the packing case (see § 3.3.1).
• Remove the TECTYL 506 VALVOLINE type protection product of the shaft part where the earthing
brushes are rubbing by cleaning it with a SOLVASEC type solvent.

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Power Conversion
• Reinstall and reconnect the brushes removed during the packaging (see § 3.3.1).
• Remove the sealing from the bearings and carry-out the filling of the bearings tanks with the
recommended oil or its equivalent (with respecting the levels).
The oils recommended by our company are miscible with a product Tectyl 511 type and do not
necessitate to remove this one before to fill the bearings.
• Remove the sealing on the terminal boxes.
• Remove the sealing between flanges and mating flanges of the water supply to the water-cooler.
IMPORTANT: The locking system of the rotor must ONLY be removed after the installation of the
equipment on its exploitation site.
The motor shall be protected with a tarpaulin between its storage area and the
exploitation area.
For both installation and exploitation, refer to the safety, installation and maintenance
manual delivered with the machine.

GE Energy
Power Conversion
Revision Date Author Checking Approving Details

00 26 apr 12 I. Schneider B. Schnabel J-C. Demard Initial issue

GE Energy
Power Conversion
MANUFACTURER RECOMMENDATIONS
LONG TIME STORAGE
Change Number:
Reason for new revision: Update
(see last page for
©COPYRIGHT 2007-2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information
contained herein is GE Energy Power Conversion Proprietary Technical Information that belongs to the General
Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express
reason of restricted private use. All persons, firms, or corporations who receive such information shall be deemed
by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use
whatsoever for any, or all such information except as expressly authorized in writing by the General Electric
Company, GE Energy (USA), LLC and/or its affiliates.

Project : Manufacturer recommendations Revision : D
Document : Long time storage Date : 06 apr 12
File : / IP784_ENG (Rev.D).doc Page : 1/9
GE Energy
Power Conversion
CONTENT
1. REFERENCES ................................................................................................................................................... 3
2. REQUIRED CONDITIONS OF STORAGE/MECHANICAL AND ELECTRICAL WARANTIES ....................... 3
3. PRESCRIPTIONS OF EQUIPMENT CONDITIONING/PROTECTION ........................................................... 3

3.1 ANTI-OXIDIZING PROTECTION .................................................................................................................................... 3
3.1.1 Shaft ............................................................................................................................................................................... 3
3.1.2 Smooth bearings ..................................................................................................................................................... 4
3.1.3 Main terminal box, exciter and auxiliary ...................................................................................................... 4
3.1.4 Water-coolers ........................................................................................................................................................... 4
3.1.5 Pressurization system (if exists) ........................................................................................................................ 5
3.2 ANTI-VIBRATION AND MECHANICAL PROTECTION........................................................................................... 5
3.3 ANTI-CONDENSATION PROTECTION ....................................................................................................................... 5
4. PRESCRIPTIONS FOR THE MATERIAL CONTROL........................................................................................ 6
4.1 CONTROL OF THE POLLUTION IN THE MAIN STATOR AND EXCITER WINDINGS ................................ 6
4.2 CONTROL OF THE INTERNAL POLLUTION OF THE BEARINGS...................................................................... 7
4.3 CONTROL OF THE OTHER POINTS ............................................................................................................................ 7
5. CASE OF AN SEI 4C WRAPPING .................................................................................................................... 7
6. DESTOCKING OF THE EQUIPMENT .............................................................................................................. 8
7. MODIFICATION RECORD ............................................................................................................................... 9

GE Energy
Power Conversion
The present recommendations only have an informative purpose.
In any case, storage of equipments provided by GE Energy’s Power Conversion business (here below
designated Power Conversion) remains the only and whole responsibility of the customer which assumes
alone costs and risks, the responsibility of Power Conversion being not searchable in any circumstance.
1. REFERENCES
This instruction is based on the following documents:
• MSIMMA (Safety, installation and maintenance manual of asynchronous motors) which is
delivered with the motor,
• IP707: Storage and preservation of bearings against oxidation.
2. REQUIRED CONDITIONS OF STORAGE/MECHANICAL AND ELECTRICAL

WARANTIES
The following conditions concerns the storage area only without taking into account the motor is packed
or not. The long time storage must be carry-out:
• in a ventilated and covered premises, in dry surrounding air, protected from dust, and from
corrosive, explosive or gaseous atmosphere,
• not exposed to liquids (water, acid, oil, fuel and other),
• not exposed to major vibrations (floor of storeroom, frame or other),
• within the temperatures range:
• minimum from -20°C without any tolerance,
• maximum to +40°C with tolerance (+10°C / -0°C),
• with a controlled rate of humidity < 70%. If this rate is increasing, a heating of the premises have
to be ensured.
In this conditions and following the periodicity of equipment checks and reconditioning, certified by our
care, such a protected equipment gives a very long life, however restricted to 5 years.
3. PRESCRIPTIONS OF EQUIPMENT CONDITIONING/PROTECTION
3.1 ANTI-OXIDIZING PROTECTION
3.1.1 Shaft
a) Shaft end on coupling side
Protect the shaft end using a chemical and mechanical encapsulation. To do that:
• Remove the keys at the shaft end (case of a keyed shaft end).
• Dry clean using a rag, the whole not painted machining surfaces including cavities.
• Apply, under ambient temperature, using a brush a product TECTYL 506 VALVOLINE type
(temperature resistance from -20°C to +200°C), on the whole not painted machining
surfaces including cavities.
• Fill in cavity(ies) of key(s) with half-key(s) of non oxidizing and non hydrophobic material
(stainless steel 304, exotic wood, marine plywood).
• Protect the cylinder of the shaft end with a plastic wrap.
• Protect the face of the shaft end with a layer of 60 to 100 microns of intermediate or
final paint, after having properly takes any grease marks out from all surfaces to paint.

GE Energy
Power Conversion
b) Section of shaft not enclosed in frame and bearings sealing systems
Protect the whole of the shaft sections with a product Tectyl 506 Valvoline type, including under
instrumentation
Ex.: Earthing brushes: Remove the earthing brush(es) from the shafing and temporarily protect
the surface. Store the earthing brush(es) in the main terminals box.
The surface under shaft displacement instrumentation (ex.: Bently Nevada sensor) does
NOTA
not require additional protection.
c) Keys at shaft end
• Protect keys with a product TECTYL 506 VALVOLINE type.

• Pack each key in oiled paper.
• Put the keys in a plastic bag and store it in the packing case provided with the motor.
3.1.2 Smooth bearings
After draining oil from the bearing tank:
• Remove caps of bearings and the upper half-bushings.
• Relieve shaft by a few tenths of millimeter (3 or 4ths) with a jack in order to free the lower half-
bushings.
• Extract the lower half-bushing by rotating it around the shaft. Take the usual safety precautions
to protect hands, feet, eyes and head.
• Spray a product Tectyl 511M type over the whole internal surfaces of the bearings and their
auxiliary equipment, such as shaft journals and bores from the two half-bushings.
• Reinstall whole parts, avoiding friction between parts as far as possible, to preserve the previous
chemical protection.
• Screw the bearings caps according to the recommended torques of the provider manual (RENK).
• Seal, using wide adhesive band 3M tape type, the joint of the bearings and the whole orifices
beforehand plugged, either with screw plugs or Kapsto type plugs (indicator light, filing port, oil
drain).
• Close inlet and outlet of oil nozzle.
• Seal joints between the bearings baffles and the motor shaft, with applying an elastomer silicone
joint Silicomet type.
3.1.3 Main terminal box, exciter and auxiliary

Complete the sealing made by the joints between covers and cabinets with sealing off the clearance
between the two parts with a wide adhesive band of 3M tape type.
In case of the terminal box is dismantled, these recommendations must be applied.
3.1.4 Water-coolers
Before any packaging operation, the water-cooler and the leakage detectors have to be totally drained.
• If the water-cooler is equipped with counter flanges: install the counter flanges and seal the joint
with a wide adhesive band of 3M tape type.
• In others cases: seal the flanges opening gap applying a wide adhesive band of 3M tape type.

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Power Conversion
3.1.5 Pressurization system (if exists)
The pressurization system could be stored in a cold temperature but no lower than -50°C if the following
conditions are respected:
• The pressurization system is weather protected from direct climate conditions. No moisture can
enter the pressurization system housing during the storage period.
• The pressurization system is not subjected to cyclic thermal loads.
• It is not connected to a compressed air supply during cold storage.
• It is not subjected to rough handling or transport that may cause components to crack while cold
(the force applied does not to exceed 1G).
3.2 ANTI-VIBRATION AND MECHANICAL PROTECTION
• Protect the shaft end with a steal cover, fitted inside with neoprene rubber.
• Fix to the end of the shaft a locking tool link to the bearing flange with threaded rods + bolts.
• Place the motor on stringers made of restricted hygrometry wood (class C22 plate with class 3
pressure-sealed treatment), having a minimum length equal to the frame plugs. This allows the
air to circulate under the frame.
• Insert between wood stringers and the motor plugs, buffers pads Grypsol type, to reduce residual
vibration from the ground.
3.3 ANTI-CONDENSATION PROTECTION

Power the heating resistors permanently, except in the particular case of a drained bearing, fitted with a
heater working only when completely dive in the oil.

GE Energy
Power Conversion
4. PRESCRIPTIONS FOR THE MATERIAL CONTROL

4.1 CONTROL OF THE POLLUTION IN THE MAIN STATOR AND EXCITER WINDINGS
• Polarisation index (IEEE 43) :
• Test method: Use a megohmmeter to apply a voltage on the three phases connected to
the windings. This voltage has to be 2500VCC for a nominal winding voltage higher or
equal to 2500V and 1000VDC in the other cases. The measures read 1 minute and 10
minutes after the voltage application.
Absorption current
Conduction current
• General method of calculation:
I1. min I Conduction + I Absorption R10. min

Ip = = =
I 10. min I Conduction R1. min
• Method of interpretation:
• Ip ≤ 1.5 : Isolation very low due to a deep hydration or to important leakage currents
due to an aging or an important pollution on the surface.
• 1.5 < Ip ≤ 2.5 : Humid or polluted insulation.
• 2.5 < Ip ≤ 4 : Dry or clean insulation.
• 4 < Ip : Very dry and clean insulation.
• Acceptation criterion: Ip > 2 (measures are reported on a record mentioning the product
reference, the test voltage, the test temperature, the values measured every minute, as the
index value).
• Measure of the total insulation resistor:
• The measure is realised with a megohmmeter following several possibilities:

• On all the windings in comparison with the magnetic core set to the ground in the
case of a closed and not accessible neutral,
• On each winding in comparison to the magnetic core set to the ground in the case
of an open and accessible neutral,
• On each winding in comparison with the other windings in the case of an open and
accessible neutral.

GE Energy
Power Conversion
• Method of interpretation and acceptation criterion:
The measures, read about 1 minute after the voltage application, depends on UR (reception
voltage) and UN (nominal voltage), so:
• 2500VCC for the stators MT (medium voltage) after impregnation 2195V < UR <
9319V,
• or 5000VCC for the stators MT after impregnation UR > 9319V
• 1000VCC for the other parts (rotors, exciters, stators BT (low voltage), etc.).
Since the on site commissioning, the minimum acceptable value at 20°C is 3(UN(kV)+1). The
measured values will be recorded on the corresponding data sheet.
• Visual control of surface quality of the tinned lugs.
• Sealing joints quality between covers and terminal boxes cabinets.
After control, recondition as described to the § 3.1.3. If necessary, change the sealing joints between
covers and cabinets.
4.2 CONTROL OF THE INTERNAL POLLUTION OF THE BEARINGS

a) Not polluted bearing
Repackage as described in § 3.1.2.
b) Polluted bearing
Clean the polluted zones and repackage as described in § 3.1.2.
Check that all storage prescriptions are applied.
4.3 CONTROL OF THE OTHER POINTS

Perform a visual check without dismantling.
5. CASE OF AN SEI 4C WRAPPING

If the equipment is not used during 24 months under the storage conditions described in the § 2 and
with an SEI 4C packing, the client can extend the conservation of the material by taking the following
precautions:
• Open the wooden box.
• Open the internal cover neatly in order to reuse it.
• Check the state of the preserved material.
• Put in new bags of desiccant.
• Close the cover with welding clip.
• Evacuate air from the cover with suction cleaner.
• Check the welds and the air tightness of the cover.
• Close the wooden box.
Note the check date on the box.

GE Energy
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6. DESTOCKING OF THE EQUIPMENT

During destocking, prepare the equipment for the exploitation as follows:
• Remove the chemical and mechanical encapsulation of the shaft end (see § 3.1.1.).
• Reinstall the keys previously stored in the packing case (see § 3.1.1.c).
• Remove the TECTYL 506 VALVOLINE type protection product of the shaft part where the earthing
brushes are rubbing by cleaning it with a SOLVASEC type solvent.
• Reinstall and reconnect the brushes removed during the packaging (see § 3.1.1.b).
• Remove the sealing from the bearings and carry-out the filling of the bearings tanks with the
recommended oil or its equivalent (with respecting the levels).
The oils recommended by our company are miscible with a product Tectyl 511 type and do not
necessitate to remove this one before to fill the bearings.
• Remove the sealing on the terminal boxes.
• Remove the sealing between flanges and mating flanges of the water supply to the water-cooler.
• Pressurization system (if exists):
- Heat up the system by either placing the system in an ambient greater than freezing (>0ºC) or
using the low temperature anti-condensation heaters where applicable. The system should not
be placed close to a direct heat sources.
- Prior to connecting any compressed air to the system, bring up the ambient temperature above
the freezing point (>0ºC) to allow all ice to melt.
- Maintain the component surface temperature above freezing for at least 1 hour to ensure that
all internal components have defrosted.
IMPORTANT: The locking system of the rotor must ONLY be removed after the installation of the
equipment on its exploitation site.
The motor shall be protected with a tarpaulin between its storage area and the
exploitation area.
For both installation and exploitation, refer to the safety, installation and maintenance
manual delivered with the machine.

GE Energy
Power Conversion
Revision Date Author Checking Approving Details

- S. Richardet Initiale Issue
A 05 dec 07 S. Richardet M. Dubas Y. Wazylezuck Complete rewritting
B 26 oct 09 S. Richardet Reformulation §3.3.
Recommendation for dismantled terminal box
C 14 dec 09 S. Richardet
(§3.1.3.)
Addition of recommandations for the anti-oxidizing
D 06 apr 12 I. Schneider E. Virot B. Schnabel protection (§3.1.), for the pressurization system
(§3.1.5) and for the destocking (§6.)


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GE ENERGY POWER CONVERSION

SAFETY, INSTALLATION AND MAINTENANCE MANUAL OF

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1. SAFETY INSTRUCTIONS ................................................................................................................................. 5

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1.1.1 Scope of manual

1.1.2 Keep your eye on safety

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1.1.3 Limit of responsibility and warranty conditions

1.2.1 Conditions governing use of motors

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1.2.2.1 Symbols concerning packaging and handling

iso 7000/No. 0621

Indicates that hooks are prohibited for lifting

iso 7000/No. 0622

Indicates the correct vertical position of the

Indicates that container must not be exposed

iso 7000/No. 0624

Indicates that content of container could

iso 7000/No. 2401

Indicates location where sling(s) must be

iso 7000/No. 0625

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Key Symbol Indication

Indicates that shipping container

iso 7000/No. 0626

Indicates centre of gravity of

Indicates that shipping container

iso 7000/No. 2405

Indicates locations on shipping

Indicates maximum stacking load

iso 7000/No. 0630

Indicates temperature limits within

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Key Symbol Indication

Indicates position for clamps when

Indicates that shipping container

Indicates that shipping container

iso 7000/No. 2406

Indicates maximum number of

iso 7000/No. 2403

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

Ground connection point

Stay at a safe distance

EC protection marking relative to an explosive atmosphere

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1.2.3 Applicable regulations

• IEC / EN60079-14: Electrical installations in hazardous sites (except mines).

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

1.3 POWER CONVERSION CONTACT DETAILS

We provide assistance in the following areas:

- supply of spare motors:

- handling of assistance and warranties:

1.4 DOCUMENTS TO BE COMPLETED AND SENT TO POWER CONVERSION

Customer : GE Energy Power Conversion CLASS II (GE INTERNAL NON-CRITICAL)

2. DESCRIPTION OF THE MACHINE

2.1 DEFINITION OF TYPES OF INDUCTION MOTORS (FL-F3-N3-N4 SERIES)

• 4 shaft heights of 280, 315, 355 and 400,

• 5 shaft heights from 355 to 560,