Beruflich Dokumente
Kultur Dokumente
DC-Motor
Type : G5L160M34-2
Order- No : 723589 (051132)
Mach.- No : 06-042429
Subject : MD Gottwald
Contents:
2 Arbeitssicherheitshinweise 1
Seite / page I
LDW 12.300/0499 DE/EN
Sicherheitsinformationen
1.1 Arbeitssicherheitssymbol
1.2 Achtungs-Hinweis
2 Arbeitssicherheitshinweise
Dieses Informationsblatt mit den Warnhinweisen gilt als Zusatz zur produktspezifischen
Betriebsanleitung und muß aus Sicherheitsgründen besonders beachtet werden.
Die elektrischen Maschinen sind Betriebsmittel zum Einsatz in industriellen Anlagen.
Während des Betriebes haben diese Betriebsmittel gefährliche, spannungsführende blanke
Teile, ggf. auch bewegte bzw. rotierende Teile. Sie könnten deshalb, z. B. bei
unzulässigem Entfernen der erforderlichen Abdeckungen, bei unsachgemäßem Einsatz,
falscher Bedienung oder unzureichender Wartung, schwerste gesundheitliche oder
materielle Schäden verursachen.
Die für die Sicherheit der Anlage Verantwortlichen müssen deshalb gewährleisten, daß
• nur qualifizierte Personen mit Arbeiten an den Maschinen bzw. Geräten
beauftragt werden.
• diese Personen u. a. die mitgelieferten Betriebsanleitungen und übrigen
Unterlagen der Produktdokumentation bei allen entsprechenden Arbeiten stets
verfügbar haben und verpflichtet werden, diese Unterlagen konsequent zu
beachten.
• Arbeiten an den Maschinen bzw. Geräten oder in deren Nähe für
nichtqualifizierte Personen untersagt werden.
Qualifiziertes Personal sind Personen, die aufgrund ihrer Ausbildung, Erfahrung und
Unterweisung sowie ihrer Kenntnisse über einschlägige Normen, Bestimmungen,
Unfallverhütungsvorschriften und Betriebsverhältnisse, von dem für die Sicherheit der
Anlage Verantwortlichen berechtigt worden sind, die jeweils erforderlichen Tätigkeiten
Seite 1
LDW 12.300/0499 DE
Sicherheitsinformationen
auszuführen und dabei mögliche Gefahren erkennen und vermeiden können (Definition für
Fachkräfte siehe auch DIN VDE 0105 oder IEC 364). Unter anderem sind auch Kenntnisse
über Erste-Hilfe-Maßnahmen und die örtlichen Rettungseinrichtungen erforderlich.
Für Arbeiten z. B. an Starkstromanlagen ist das Verbot des Einsatzes nichtqualifizierter
Personen geregelt.
Es wird vorausgesetzt, daß die grundsätzlichen Planungsarbeiten der Anlage sowie alle
Arbeiten zu Transport, Montage, Installation, Inbetriebsetzung, Wartung und Reparaturen
von qualifiziertem Personal ausgeführt werden.
Hierbei sind insbesondere zu beachten:
• Technische Daten und Angaben über die zulässige Verwendung (Montage-,
Anschluß-, Umgebungs- und Betriebsbedingungen) die u. a. im Katalog, den
Auftragsunterlagen, der Betriebsanleitung, den Schildangaben und der übrigen
Erzeugnisdokumentation enthalten sind.
• die allgemeinen Einrichtungs-und Sicherheitsvorschriften, die örtlichen
anlagenspezifischen Bestimmungen und Erfordernisse.
• der fachgerechte Einsatz von Werkzeugen, Hebe- und Transporteinrichtungen.
• die Benutzung persönlicher Schutzausrüstungen.
• Im Betrieb muß der erforderliche Berührungsschutz vorhanden bzw. eine
gefährliche Annäherung verhindert sein. Dies gilt nicht nur bezüglich der
Gefährdung durch bewegte Maschinenteile oder elektrische Spannung führende
Teile, sondern auch durch erhöhte Oberflächentemperaturen der Maschinen.
Falls im Sonderfall bei beabsichtigtem Einsatz der Maschinen in nicht industriellen
Bereichen eventuell erhöhte Anforderungen gestellt werden, müssen diese Bedingungen
bei der Montage durch zusätzliche Schutzmaßnahmen anlagenseitig gewährleistet werden.
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LDW 12.300/0499 DE
Sicherheitsinformationen
Die Entsorgung von verbrauchten Reinigungsmitteln ist problematisch. Sie enthalten oft als
Bestandteile eine wassergefährdenden Chlorkohlenwasserstoffe. Sie müssen deshalb
unbedingt getrennt gesammelt und entsogt werden.
Ähnliches gilt auch für die Entsorgung verbrauchter Kühl- und Schmierstoffe. Sie dürfen auf
keinen Fall in den Boden oder in die Kanalisation gelangen.
Ausgelaufener Schmierstoff ist sofort mit einem geeigneten Bindemittel zu beseitigen.
Verschlissene Keilriemen, Brems- und Kupplungsbeläge, Kunststoffteile, ausgewechselte
Teile aus Schichtwerkstoffen usw. gehören nicht in den Hausmüll. Sie müssen gesondert
abgeführt werden.
Seite 3
LDW 12.300/0499 DE
Safety Information
This symbol marks all those safety instructions where life and limb are at
risk. Please read and follow these instructions with special care. Always
pass on instructions on safety to other users. The general notes on safety
and accident prevention must be observed.
1.2 Warnings
CAUTION! This word ”WARNING” marks those parts of the text which must be
followed in order to ensure that instructions, regulations, notes and
correct sequences are adhered to, and to avoid damage to, or
destruction of, the machine and/or other parts of the system.
page 1
LDW 12.300/0499 EN
Safety Information
equipment is also essential. According to regulations, unqualified personnel are forbidden
to work for example on power installations.
It is a pre-condition that the basic planning work for the machine as well as all operations
involving transportation, assembly, installation, commissioning, maintenance and repair is
carried out by qualified personnel.
In this connection, the following must be especially complied with:
• he technical data and details on the permitted use (assembly, connection, site
and operating conditions) which are also contained in the catalogue, the order
documentation, the Operating Instructions, the machine labels and other product
documents,
• the general regulations on setting up and safety, the local regulations and
requirements specific to the system,
• the proper use of tools, lifting gear and transportation equipment,
• the presence of the necessary contact prevention guards or prevention of
potentially dangerous approach. This applies not only to dangers associated with
moving or electrically live machine parts, but also with parts of the machine with
raised surface temperatures.
If, in special cases where it is intended to use the machine in non-industrial situations, more
stringent requirements are called for, these must be reliably provided by supplementary
safety measures provided at the installation stage.
CAUTION!
Avoid pollution of the ground, sewage systems and bodies of water.
The disposal of used cleaning agents may be a problem. They often contain chlorinated
hydrocarbons which represent a pollution threat to water. They must, therefore, be
collected and disposed of separately.
This is also valid for the disposal of used coolants and greasing substances. They must
never enter into the ground or sewage systems.
page 2
LDW 12.300/0499 EN
Safety Information
Any lubricating material which has escaped must be cleared by means of a fixing agent
immediately.
Worn fan belts, brake and coupling linings, plastic parts, replaced parts made of stratified
composites do not belong in household waste. They must be disposed of specially.
page 3
LDW 12.300/0499 EN
DC Machines
System Series 5
Models G5.090M.. to G5.160M..
LDW 12.184/1100 EN
Printed in Germany Lloyd Dynamowerke GmbH
Subject to revision Hastedter Osterdeich 250
D–28207 Bremen
Lloyd Dynamowerke GmbH
2 Installation 13
2.1 Delivery and storage 13
2.2 Commutator Protection for Transport and Storage 13
2.2.1 How to insert the protective tape 14
2.3 Installation 14
2.4 Pulling on the coupling or pulley 15
2.5 Alignment 15
2.6 Connection 16
2.7 Terminal box 16
3 Commissioning 18
3.1 Mechanical inspection 18
3.2 Insulation resistance 18
3.3 Drying 18
4 Maintenance 19
4.1 Bearings 19
4.1.1 Minimum service life of the grease for long-term lubricated bearings 20
4.2 Commutator 21
4.3 Brushes 21
4.3.1 General 21
4.3.2 Overload 22
4.3.3 Brush pressure 22
4.3.4 Service life 22
4.3.5 Striation 22
4.3.6 Maintenance instructions and spare brushes 22
4.4 Brush assembly 23
4.5 Brush monitoring system 24
4.6 Filter unit 25
4.7 Pressure switch unit (for monitoring the air flow) 26
4.8 Differential pressure switch unit (for monitoring filter contamination) 27
4.9 Tachometer unit 28
4.10 Brake unit 30
4.11 air/air heat exchanger unit 32
4.12 Dismantling and reassembly 33
5 Mounting modifications 35
5.1 Alternative ways of fitting terminal box 35
5.2 Alternative ways of fitting separate fan 36
5.3 Alternative ways of fitting separate fan 37
5.4 Alternative ways of fitting pipe connection 38
5.5 Alternative ways of fitting pipe connection 39
5.6 Alternative ways of fitting pipe connection 40
5.7 Alternative ways of fitting air/air heat exchanger 41
6 Circuit diagrams 42
6.1 Main circuit diagrams (examples) 42
6.2 Additional circuit diagrams (examples) 43
6.3 Connection diagrams for fan motors 43
7 After-sales service 44
9 Standards 45
9.1 European standards 45
9.2 International standards 45
9.2.1 IEC standards: 45
9.3 National standards 45
9.3.1 DIN standards: 45
9.3.2 DIN VDE guidelines: 45
9.3.3 DIN ISO standards: 46
9.3.4 Lloyd Dynamowerke (LDW) company standards: 46
9.3.5 VDI specifications: 46
1 General
1.1 Scope
These operating instructions apply to DC machines with the following model designations :
G5L090M.. to G5L160M.. Forced ventilation with radially mounted fan, with air/water heat exchanger mounted
on machine orusing pipe connection, type of cooling IC 06, IC 86 W, IC 17
G5F090M.. to G5F160M.. Forced ventilation with axially mounted fan, type of cooling IC 06
G5L132M..+LLK to G5L160M..+LLK Separate cooling with air/air heat exchanger mounted on machine, type of cooling:
IC 666
The motor (generator) is designed according to the scope of the confirmed order.
The company ordering the unit must ensure that the protection system of the machine complies with the provisions of the
machinery protection legislation for the particular application.
The electrical machines are equipment for use in industrial power plants. During operation this equipment has dangerous, live
bare parts, which may also be moving or rotating. It can therefore cause extremely serious injuries or damage, for instance if
the covers required are removed in contravention of the regulations, the equipment is used improperly, operated incorrectly or
not maintained adequately.
Those responsible for the safety of the plant must therefore ensure that
• only qualified personnel are to be entrusted with working on the machines or equipment.
• these persons amongst others are to have the operating instructions and other product documentation supplied
available at all times when carrying out such work, and agree to follow this documentation consistently.
• Unqualified personnel are prohibited from working on the machines in their vicinity.
Qualified personnel are persons who on account of their training, experience and instruction as well as their knowledge of
relevant standards, requirements, accident prevention regulations and operating conditions, have been authorised by those
responsible for the safety of the plant to carry out the various jobs required, being able to recognise and avoid possible
dangers involved (see also DIN VDE 0105 or IEC 364 for definition of qualified employees). A knowledge of first-aid measures
and the local rescue services etc is also required.
Unqualified personnel are prohibited from working on power plants, eg in DIN VDE 0105 or IEC 60364.
It is assumed that the basic planning of the plant and all transport, installation, commissioning, maintenance and repair work
will be carried out by qualified personnel.
For planning, installation, commissioning and servicing it is advisable to take advantage of the support and services of the
LDW Service Centre responsible.
If there are any deviations from normal operation (higher power consumption, temperatures, vibration, noises etc or operation
of the monitoring equipment) it may be presumed that operation is impaired. To avoid faults that could give rise directly or
indirectly to severe injuries or damage, the maintenance personnel responsible must then be notified immediately.
WARNING!
In case of doubt switch the equipment concerned off immediately!
It is stressed that the contents of the operating instructions and product documentation do not form part of or serve to modify
any former or current agreement, undertaking or legal relationship.
All of LDW’s obligations arise from the particular contract of purchase, which also contains the complete warranty conditions,
which alone have legal force. These contractual warranty conditions are neither extended nor limited by the contents of these
instructions and documentation.
The provisions of the machinery protection legislation are satisfied by protection systems IP 23 and IP 44. Any second shaft
extensions ordered shall have protective caps fitted by the manufacturer if they are not being used. The same applies to the
couplings, pinion or belt drives mounted. The dimensions of the machinery comply with IEC 60072, those of the shaft
extensions to DIN 748-3.
According to the following standards the motors can be operated at the ratings listed; in some cases this means utilisation
exceeding insulation class F:
Taking account of the static converter supply the machines are designed with laminated cores. This allows them to withstand
current harmonics during stationary operation, and makes them suitable for rapid changes in current or load during dynamic
operation (see subsection entitled ”Dynamic shock loads”).
The main and commutating pole cores and the stator yoke are a one-piece design. The main pole coils are wound into the
finished frame by machine. The commutating pole coils are wound separately. The entire frame is impregnated with a high-
quality class H resin.
Over the entire area at shaft height the connection between the coils and the pole system guarantees low resistance to heat
transmission, and uses special insulation elements to prevent vibration. The accurate pitch of the pole system benefits
commutation. The winding is impregnated and consolidated with resin using a special technique. The rotor is also
impregnated with class H resin.
All of the connecting dimensions, including the axial spacing of the mounting holes (IEC dimension B), comply with the IEC
standards.
Key:
G5 - series 5 DC machine
K - natural cooling, totally-enclosed
L - forced ventilation - radial with fan, cooler or pipe connection
1st digit - shaft height in mm
M - separating character
2nd digit - length code
Example: G5L132M26+LLK
G= DC machine
Series 5
separate ventilation
Shaft height 132 mm
Machine length code = 26
LLK = air/air heat exchanger
1.5.1 Rating
The ratings specified in the tables apply under the following conditions :
• Continuous duty S1
• Utilisation without filter according to insulation class F, utilisation with filter exceeding insulation class F
• Maximum cooling air temperature of 40°C
• Maximum installation height of 1000 m ASL
• Specification : EN 60034-1
• Rotor supply as specified
Under different conditions the following tables can be used to roughly determine the model. The conditions must always be
specified when ordering, so that the motors can be designed and tested accordingly.
S2 - short-time duty
Table 1
Table 2
The permissible output is about 80% of the listed rating in the case of the G5L and about 70% in the case of the G5K model.
According to EN 60034-1 the motors must generally have an overload capacity of up to 1.6 times the rated torque at the rated
speed for 15 s. About 1.8 times the rated current is required to produce this.
The agreed shock load, for the field weakening range as well, can be taken from the test certificate.
The laminated core design of the commutating field circuit allows any rate of increase in current encountered in practice to be
achieved. In order to optimise the machine the value required is to be specified when ordering. This rate (di/dt) is specified in
A/s, the associated current surge as a multiple of the rated current (IN). The values agreed can be taken from the test
certificate.
Guide values for the permissible duration of the load at zero speed can be taken from the following table:
Table 5
200 10
100 30
50 90
20 600
15 continuous
1.6.4 Voltage
The voltages specified in the tables are taken from DIN 40030 and DIN IEC 38. Intermediate values are possible. The rated
speeds and outputs resulting for these can be converted linearly with the rotor voltage with sufficient accuracy, using the next
higher voltage in the table as the starting point. If the voltage required lies above the highest value in the table, or below 80%
of the smallest value in the table, it is necessary to consult the manufacturer about the machine.
Table 6
Rated voltage
3ph mains Static converter single- four-
(50 Hz) circuit quadrant operation
220 V B2H 170 V -
380 V B2H 300 V -
400 V B2H 310 V -
220 V B2 - 150 V
380 V B2 - 260 V
400 V B2 - 300 V
1.6.5 Speed
The speeds specified in the tables are met with a tolerance to EN 60034-1. At intermediate speeds the data of the rotor circuit
with the next lower speed is to be used. The slight increase in speed can be achieved by using a matching exciting voltage.
A speed adjustment range of up to about 20 rpm at constant torque is permissible with all of the machines on this list.
Lower speeds are generally not possible. Please enquire in such cases.
An increase in the speed through field weakening is permissible at constant rotor voltage up to the speeds and shock loads
specified in the tables. The output remains constant with this increase.
To enable optimal design and testing of the machines, field weakening range and shock load must be specified in the order.
1.6.7 Excitation
The machines are designed for 200 V separate excitation. Other exciting voltages, between 110 V and 340 V for example, are
generally possible. The excitation outputs specified in the tables are maximums used to design the supply unit. Exact values
and data for different operating conditions (see subsection entitled ”Rating”) are available on request or will be communicated
in the event of an order being placed.
In order to protect them against self-induced voltages, machines whose exciter circuit is opened are to be equipped with
protective resistors of the following size connected in parallel:
Table 7
The motors on this list can be fitted with an auxiliary series winding if required (at additional cost).
It is used to increase the torque in the event of an overload (twice the current then also corresponds to twice the torque) and
to achieve a stable speed characteristic even in the case of unregulated drives. The rated speed may turn out to be slightly
higher.
1.6.9 Efficiency
The efficiencies specified in the tables apply at the rated output, speed and voltage. They are determined according to EN
60034-2 and include the excitation losses. The power consumption of the motors of separate fans is not taken into account.
If degree G (basic) radio interference suppression is specified in the order, the commutating poles are normally connected
symmetrically in relation to the rotor.
Please consult the manufacturer about machines that are to be provided with degree N or K radio interference suppression.
The machines are designed so that the thermal time constants of the rotor and commutating pole windings are about the
same. The machine can therefore be protected effectively by fitting thermal sensors (eg thermistor protection) or resistance
thermometers (eg PT 100) in the commutating and main pole windings (except in exceptional circumstances, such as in the
event of the rotor jamming).
The requisite inductance of any smoothing reactor needed is specified in the output table.
More detailed information on reactors that can be supplied with machines are to be found under ”Accessories” in the other
part of the list.
The two end plates have 3 identical square air vents at the top and on the right and left of the feet. An identical additional vent
at the bottom (between the feet) is possible at additional cost. The covers, fans or heat exchangers appropriate to the type of
cooling and protection system are fitted on these vents. The identical square vents allow the machines to be installed in the
horizontal or vertical attitude with the same components. If the installation is changed subsequently, ventilation covers must
be turned or re-fitted to suit the protection system.
The separate fan and terminal box are arranged on top. With this arrangement the separate fan only projects slightly beyond
the width of the machine and the terminal box is fully accessible. It is also possible to fit this fan on the side (see subsection
entitled ”Alternative ways of fitting separate fan”). All of the separate fans can be provided with a filter at additional cost.
The air/air heat exchanger is arranged on top and the terminal box on the right. It is possible at additional cost to mount the
air/air heat exchanger on the side with the additional spacer plates required (see subsection entitled ”Alternative ways of
fitting air/air heat exchanger”). The terminal box is then fitted on top (or opposite - depending on what is specified in the
order).
The top air vents are provided for the connection when pipe ventilation is used. Side connection is also possible, even when
retrofitting is involved (see subsection entitled ”Alternative ways of fitting pipe connection”).
The brush assembly can be turned ±90°, allowing the brushes to be changed through the servicing openings without any
problems. Accurate marking ensures that the brush assembly can be moved back into the neutral zone.
Monitoring devices such as pressure switches for monitoring the air flow, differential pressure switches for the filter,
microswitches for brush wear are available at additional cost.
1.7.2 Types
The most commonly used types are shown in the following figures. The designation complies with IEN 60034-7, but code I
(top line) is preferably to be used. The flange-type machines are also supplied with feet. Machines with air/air heat
exchangers fitted can also be produced in flanged form without foot mounting. It is generally necessary to consult the
manufacturer about the maximum speeds of flange-type machines.
The air must enter at the non-drive end (commutator end). For a pipe connection, separately installed fan and separately
supplied heat exchanger the end plate is to be provided with a plate marked ”Air inlet”.
Cooling provided by connecting the machines to a ventilation system via pipe connections fitted
Model G5L
Model G5L
Model G5F
IP23 - IC06
Figure 4
Cooling provided by an air/water heat exchanger.
Air flow generated by separate fan.
Water inlet temperature 25°C. Water heated about 5 K. Cooling air temperature about
40°C. Different water temperatures have a linear
effect on the temperature of the cooling air (see Section
entitled ’Rating’, different cooling air temperature)
Please consult the manufacturer about these machines Model IP44 - IC86W (ICW37A86) G5L + LWK
Figure 5
Natural cooling. Losses dissipated via the surface
Model G5K
Cooling provided by an air/air heat exchanger. Internal IP44 - IC410 (IC 0041)
and external air flow provided by separately driven fans Figure 6
Model G5L + LLK
1.10 Cooling
The fan is mounted at the drive end of the self-cooled machines. The cooling air enters the non-drive end radially and is
drawn through the machine. It leaves the machine radially as well. Connection of air supply and exhaust lines to self-cooled
machines is not permitted.
Depending on the type of machine, separate cooling can be provided by radially or axially mounted fans, the plant’s own
cooling air system, or an LLK air/air heat exchanger mounted on the machine (only in the case of machine models G5L 132...
and G5L 160...)
Power consumptions and flow rates of the fans and air/air heat exchangers and the cooling air flow rates required with the
static back pressure of the DC machines are assembled in the following tables.
The exact data for the particular machine is to be found on the name plates of the fan motors and the DC machine.
WARNING!
The direction of ventilation is from the non-drive end to the drive end. The air inlet
end is provided with a corresponding plate.
A subsequent change in the air direction, which is possible in mechanical terms
using the identical openings in the two end plates, may only be made after
obtaining the agreement of the manufacturer of the motor.
The losses of this enclosed machine are radiated from its surface as heat.
WARNING!
Dangerously hot surface temperature!
Table 9
Machine model Cooling air flow rate [m3/s] Static back pressure [hPa)
Figure 8
The drive-end shaft extensions of the normal model are designed for the fully rated torque to DIN 748-3.
In the adjacent diagrams the permissible additional forces Fr are specified for normal drive-end shaft extensions and bearings
with a calculated bearing service life of 20,000 operating hours. To avoid compromising the fatigue strength of the shaft
extension these limits must on no account be exceeded.
The additional forces specified do not mean that masses (couplings, flywheels etc) of this magnitude may be mounted on the
shafts.
The normal non-drive end shaft extension is designed for the full torque with coupling operation. Only small additional forces
are permitted; please ask the manufacturer of the motor about these.
1.12 Flanges
The dimensions of the flanges of type IMB35, IMV15, IMV36 and IMB5, IMV1, IMV3 machines comply with IEC 60072-1. The
outside diameters of the flanges are only squared off to an extent that still leaves an adequate sealing surface for mounting
on oil-lubricated gearboxes for instance. All flanges are oil-tight.
To seal the bearing the flange end is provided with a shaft seal which runs on a hardened bush.
1.14 Drive
With direct coupling an elastic or flexible coupling is the only possibility for the model with antifriction bearings. The machines
must be aligned carefully. Converter machines mounted on base frames are to be realigned carefully at the installation
location in relation to the foundations of the base frame and only then bolted up if necessary.
Shear loads (eg with belt or pinion drive) must not exceed the permissible additional radial forces (diagrams entitled
”Additional radial forces without axial external force”, Subsection 1.11).
1.15 Noises
The levels of noise produced by the machines lie within the permissible limits to EN 60034-9. Special noise reduction
measures are possible if more stringent requirements are imposed.
The sound pressure and acoustic power levels are to be found in the table.
1.16 Vibration
The machines are designed with vibration severity levels between ”N” and ”R” to DIN ISO 2373 as standard. Based on VDI
2056, the following externally excited vibration up to 63 Hz measured in the vicinity of the bearing is permissible:
- standard machines v eff = 4.5 mm/s, but vibration amplitude not exceeding 100 µm
- vibration-resistant machines (at additional cost) v eff = 11 mm/s, but vibration amplitude not exceeding 250 µm.
1.17 Insulation
The machines on this list are designed to thermal insulation H. This ensures a long service life. High-quality insulating
materials and appropriate impregnation are used to protect all of the windings to a certain degree against the effectives of
moisture, non-conductive dust and chemically active gases and vapours in the cooling air. The resins, varnishes and
impregnating techniques used ensure adequate protection when the machine is installed in a humid climate. If there are acid
fumes in the cooling air the type of acid and its concentration are to be specified. Only with these details can suitably resistant
insulation giving protection against acid be selected at additional cost. In cases in which the environmental conditions are
particularly difficult, the type of cooling is to be selected in a similar manner at the planning stage (eg central ventilation
system).
1.19 Accessories
Unless mounted on a base frame or support structure, belt-drive machines are to be secured on the foundation with the aid of
clamping rails, and direct-coupled machines with foundation blocks. Bottom-ventilated machines installed on a concrete
foundation require a special foundation plate (at additional cost) for each end plate. Special foundation work is required for
this when installing on a concrete foundation. Direct installation on a concrete or masonry foundation is not permitted.
2 Installation
If the machine is not being commissioned immediately it must be stored in a dry, dust-free room that is as free from vibration
as possible. Avoid letting the temperature fall below the dew-point. Building dust can lead to striation on the commutator.
When storing for over 6 months it is advisable to seal the entire machine in sheet polyethylene. A dessicant such as silica gel
is to be placed in this envelope and replaced according to the manufacturer’s instructions when its moisture absorption
capacity is exhausted.
For lengthy storage (over about 3 months) the carbon brushes are to be raised to prevent corrosion underneath while the
machine is idle.
Every 8 to 12 weeks the rotor is to be turned about 15 to 20° to prevent pressure points in the rings of the antifriction bearings
as a result of the static loads from the rotor. If the machine is packed in a case a hatch is to be provided in one the end of the
case, through which the rotor can be turned using the coupling or shaft extension at the drive end.
WARNING!
Do not subject to vibration while idle!
After opening the hatch turn the rotor about 15 to 20° clockwise every 8 to
12 weeks
The case must also be marked to indicate that the hatch must remain accessible during storage.
The temperature range over which the bearing grease can be used to provide lubrication is about -20 to +140°C, but the
grease can be stored at temperatures down to -40 °C.
Impairment of the lubricating capacity is not to be expected if the machine is stored under dry conditions free from dust and
vibration for up to 2 years. Before commissioning, the machines with hydraulic-type tapered grease nipples are to be re-
greased with twice the amount of grease indicated on the lubrication plates.
In machines with long-term lubrication (including fan motors) the service life of the grease is about 4 years. It is advisable to
replace or clean and re-grease the bearings after this period.
For the protection of the commutator slipring surface during transport and storage, parts of the machines are equipped with a
protective tape wound around the commutator (see figure 9). Please observe that this tape is removed before taking the
machine into service.
Figure 9
WARNING!
Remove protective tape between the commutator and the coal brushes
before taking the machine into service.
After having taken the machine into service, standstill periods may frequently occur. Before the temperature falls below the
thaw point, the protective tape must be inserted between the coal brushes and the commutator, or the coal brushes have tobe
lifted.
adhesive tape
protective tape
wire tie
protective tape
direction of rotation
Figure 10
ashesive tape (see fig. 10) Figure 11
2. Turn the rotor so that the protective tape is drawn between the brush and the commutator. After a full rotation, or
as soon as all brushes are separated from the commutator, the adhesive tape has to be detaches and
withdrawn from the machine.
3. The ends of the protective tape are put together and connected by means of wire ties (see figure 11)
2.3 Installation
The installation area must allow the amount of cooling air required to flow to and from the machine unhindered. The
installation must ensure that the heated exhaust air is not drawn directly into the intake. To avoid compromising the protection
system the slits of the ventilation grilles must face downwards. Any transportation covers for the air supply and exhaust
openings are to be removed.
If the machine has not been supplied with base frame or clamping rails, it is to be installed mounted on a torsionally stiff steel
foundation or a concrete plinth into which foundation blocks have been cast. Levelling of the machine with foundation blocks
must be carried out with the blocks firmly screwed to the feet of the machine. Shims with a total thickness of about 2 mm are
to be inserted between the foundation blocks and the feet of the machine. Packing during initial levelling of the machine must
only take place under the foundation blocks if possible. Re-levelling of the machine is always necessary after the foundation
block mix has set completely. Check that the feet surfaces rest evenly without distorting the frame before tightening the
holding-down bolts.
It is advisable to remove the electrical machines, gearboxes etc mounted on the machine base frame to enable it to be
levelled. The machine base frame is levelled on the prepared surfaces with a spirit level and secured firmly to prevent it
shifting subsequently. After this the machines can be mounted. Note that the first machine mounted is provided with shims
with a total thickness of about 2 mm between the feet of the machine and the base frame bearing surfaces as a levelling aid.
In the case of machine base frames on which machines are mounted that cannot be removed when the base frame is
anchored, the levelling is to be checked and corrected as necessary before commissioning the machines.
Couplings, pulleys etc may only pulled on and off with suitable equipment. A tapped hole is provided in the end of the shaft for
this equipment. Make sure when using it that no impact loads are transferred into the shaft and the centring hole is not
damaged.
The rust protection coating on the shaft extension is to be peeled or washed off beforehand with Siwapur 99 or diesel oil. The
stub shaft is then to be greased or oiled. Any shaft seals present are to be lubricated with a few drops of oil.
The diameters of the shaft extensions of model G5.090... have a j6 and those of other models a k6 tolerance zone, unless a
different zone has been specified in the order. The hub hole of the parts to be pulled on is to have an H7 tolerance zone and
be balanced without keys inserted. The machine is balanced in the factory with full keys and the shaft extension marked with
an ”F”, unless balancing with half keys has been expressly specified in the order; in which case the shaft extension is marked
with an ”H”.
2.5 Alignment
Even when elastic or flexible couplings are being used the machines must be carefully aligned, otherwise operation may be
noisy and the bearings could be overloaded. The shafts of the coupled machines must not be angled or offset parallel to one
another.
The shafts are brought to the same height by inserting or removing shims
under the feet of the frame. The two shafts are aligned accurately axially
(Fig. 12) and radially (Fig. 13) with dial gauges, deviations being measured
as the shaft is rotated through a full 360°. Both measurements are to be
carried out simultaneously, so that correction according to one dial gauge
does not upset the alignment according to the other one. The biggest
difference between the values measured at two opposite positions is not to
exceed 0.05 mm. If personnel have sufficient experience in carrying out
alignment and the coupling is suitable, the alignment can also be carried out
with a straight-edge. The straight-edge is to be placed on a common line
scribed on the two halves of the coupling and the light gap under it used to
check the alignment. The axial gap between the halves of the coupling is Figure 12
measured with feeler gauges (see Fig. 14).
To prevent any axial forces that could damage the bearings arising, the axial
gaps between the halves of the coupling specified by the coupling
manufacturer are to be observed carefully.
In the case of belt drives the motor pulley and the driven pulley must always
have parallel axes and be concentric. To avoid damage to the bearings and
shaft the belt must never be stronger than needed to transmit the forces. Figure 13
See the diagrams in Subsection 1.11 for the maximum permissible radial
forces.
Figure 14
2.6 Connection
The machines must always be connected as shown on the circuit diagrams provided, observing the direction of rotation and
the DIN VDE safety regulations.
The circuit diagrams show the terminals in their actual position. The connections are always made according to the terminal
markings. To allow connection of the machine the terminals are exposed by removing the cover of the terminal box. The leads
are to be provided with terminals and, after removing the hexagonal nuts, laid on the corresponding stud terminals, directly on
the terminals of the cables leading into the machine.
The contact nuts are then to be retightened firmly. Torque values to DIN 46200: M6 -> 3 Nm, M8 -> 6 Nm, M12 -> 15.5 Nm. It
must be ensured that the terminals of the leads are connected as far away as possible from the neighbouring terminals.
Leads for the monitoring system (for excitation as well from model G5.112 onwards) are to be introduced into the terminal
strip immediately after stripping and clamped in place. Terminal points for connecting an earth wire and marked with the earth
symbol are provided in the terminal box (see view of the inside of the terminal box). The leads are to be connected with strain
relief for the terminals using plastic Pg fittings (see table for standard components).
Should the terminal box have to be turned through 90° subsequently, the machine cables are to be marked before being
disconnected from the terminals. The bottom part of the terminal box can then be removed from the stator, turned 90° and the
machine cables re-introduced through the next opening in the bottom part. Depending on the routing of the mains cables it
may be necessary to also release the additional terminal and turn through 90°.
When re-fitting the bottom part of the terminal box, washers are to be inserted in the same position under the bolts. The
torque values to which the bolts are to be tightened are: M6 -> 6 Nm, M8 -> 10 Nm.
In the case of machines with a radially or axially mounted separate fan unit or LLK heat exchanger fitted it must be checked
that the direction of rotation of the fan’s impeller is correct as shown by the arrow on its housing. If necessary the direction of
rotation of the fan motor is to be changed by swopping the U1 and W1 leads of the mains supply on the terminal board. The
fan’s motor is to be wired according to the mains voltage available. Its power consumption is to be checked with the servicing
openings of the DC machine closed and the fan motor at operating temperature. The measurement is to be carried out with
the DC machine running and stopped.
Due to the symmetrical arrangement of the terminals the mains cables can be connected from the right or left. Turning the
terminal box through 90 degrees allows the cables to be routed axially from the drive or non-drive end as well.
As a special design the terminal box can be fitted on the side (right or left). In the case of sizes 90 and 100 this requires a
special stator frame (see subsection entitled ”Alternative ways of fitting terminal box).
With a side terminal box it must be ensured that the cable entries screwed on the bottom do not project below the feet!
PTC resistor, Pt 100 or microswitch connections are made to additional terminals (see subsection entitled ”Alternative ways of
fitting terminal box” and Assignment of terminal boxes).
Marked terminals are provided in the terminal box on the stator for connecting the earth and neutral wires.
Machine model Pg thread* each end Main terminals Excitation/ additional Earth wire
terminal connection
G5.090 2 x Pg21 4 x M6 4 x 4 mm2 U terminal
G5.100 1 x Pg16
G5.112 2 x Pg29 4 x M10 6 x 4 mm2 Terminal plate
2 x Pg16
G5.132 2 x Pg36 4 x M12 6 x 4 mm2 Terminal plate
G5.160 2 x Pg16
* All Pg threads are sealed with plugs if Pg fittings are not specified in the order.
View of the inside of the terminal box (example: Circuit diagram for separate excitation)
Figure 15
3 Commissioning
3.3 Drying
If the insulation resistance of the winding is less than 1 MΩ and the machine has been stored in a very moist environment, the
machine must be dried to avoid damage. The simplest way of carrying this out is in a closed room or area that has been
partitioned off, which is heated with heating resistors or incandescent lamps with the air being changed at an appropriate rate.
The windings should not generally be heated to more than 75°C - measured at the winding overhangs, this temperature
should not be reached in less than six hours, and no part of the machine get hotter than 90°C.
Drying can also be carried out with direct current, the machine being driven mechanically, its shunt winding excited
separately, its series winding disconnected and its rotor winding short-circuited at the terminals via protective switches. During
this process it is necessary to check the current, which must not lie above the rated value!
This short-circuit drying technique is only to be carried out by a suitably qualified electrician. Current must not be passed
through the stationary rotor from outside under any circumstances. Once the prescribed insulation value has been achieved
the machine is to be allowed to run without any load for a period of time.
4 Maintenance
Dust, oil and dirt are to be cleaned off the machines thoroughly from time to time. In the case of the enclosed model G5 K
machine, dust and dirt deposits are to be removed from the surface as well to ensure it radiates sufficient heat. Any cleaning
may only be carried out with the machine disconnected from the power. The inside of the machine is not to be cleaned with
trichloroethylene, but with a steam jet for instance.
The maintenance of the machines primarily relates to inspection of the bearings, the commutator, the brush-holders and the
brushes. It is particularly important to ensure that the commutator has a smooth and clean ground surface and the brushes
rest on it properly. A dark brown patina on the commutator is normal and should not be removed. Any brush discharge
occurring is often attributable to mechanical causes. Other points to look for include the commutator becoming out- of-round,
the mica protruding between the commutator segments, the brushes jamming in the holders and the entire machine running
noisily as a result of having become unbalanced or installed incorrectly. In all these cases suitable remedial measures must
be taken.
4.1 Bearings
All of the machines of this series are fitted with antifriction bearings.
The service life of these bearings also depends on that of the lubricating grease. The bearings are long-term lubricated and
protected against dirt. The bearing at the drive end is a fixed design. To protect the bearings against external vibration and
make them runner quieter a ball bearing shim is fitted at the non-drive end (moveable bearing end) of the machine. The
springiness of this shim pushes the outer ring of the ball bearing at the non-drive end and the inner ring of the ball bearing at
the drive end axially, far enough to take up the play in the bearings.
As a guide, the number of operating hours are tabulated below as a function of the speed for ”Klüber STABURAGS NBU 8EP”
grease. Re-greasing is to be carried out with the same grade of grease.
If the machine is continually being operated over a range of speeds, the value used in the table must correspond to their root
mean square taking into account the times.
The values specified for the number of operating hours relate to operation at a room temperature of 40°C. The service life can
be expected to double at a room temperature of 25°C.
Machines with a lubricator have lubrication plates with the following data:
- grade of grease
- after how many greasings is the spent grease to be removed from the collection
cavity in the end plates
Re-greasing must be carried out with the same grade of grease. Since they do now allow the old grease to escape, the end
plates of these machines must be removed after the interval specified on the lubrication plate, and the grease removed from
their collection cavity.
It is possible to fit measuring nipples for monitoring using the intermittent pulse method.
The normal bearing system is generally adequate even for the vertical types, unless unusually heavy couplings or high
speeds necessitate special measures that make it necessary to consult the manufacturer.
4.1.1 Minimum service life of the grease for long-term lubricated bearings
4.2 Commutator
The commutator is supplied by the factory precision ground, the running surface does not have to be re-finished when the
machine is commissioned provided no damage has been suffered in transit. The commutator is only to be re-finished if it has
been attacked over time by aggressive elements in the circulating air. The running surface of the commutator is particularly
liable to attack if the circulating air is dry and the machine is continually operated under a fractional load.
If possible, re-finishing is to be carried out with the brushes raised and with the aid of carborundum cloth, using a wooden
block hollowed out to conform to the curvature of the commutator, or with the aid of a rubber polisher for the commutator.
Under no circumstances may emery cloth be used for this purpose. The commutator may only be re-finished with the machine
cold.
Commutators that have become out-of-round are to be turned on a lathe with a very sharp cutting tool or a diamond. Ensure
accurate concentricity (≤ 0.02 mm). The smallest commutator diameters permissible after re-finishing are specified in the
following table.
Table 14
After the outside diameter has been turned the mica must be scratched out over the full width with a suitable metal saw blade
or milling cutter, to a depth of about 1 to 1.5 mm, and the burr produced removed completely. Any mica particles left behind in
the slits scratched out can lead to commutation faults. After this work the commutator is to be re-finished in the manner
described above. The machine is to be cleaned thoroughly before re-commissioning.
4.3 Brushes
4.3.1 General
Carbon brushes from well-known specialist manufacturers are fitted to the DC machines we manufacture.
As a result of many years’ experience, test bay trials, regular contact with our carbon brush suppliers and feedback from
service engineers, we are in a position to specify a grade of brushes suitable for normal conditions for the wide range of
application of the DC machines.
A compromise often has to be made between good commutation and good running characteristics.
Depending on the way they are manufactured the brushes break down into three groups, each of which is reserved for a
certain application.
1. Special graphite brushes
2. Electrographitised brushes
3. Metallised brushes
Thanks to their high series and shunt resistances special graphite brushes are preferred for particularly difficult commutation
conditions with moderate current densities (up to about 9 A/cm2). They are also used for static converter supplies with high
levels of current ripple. They also have good running characteristics.
Electrographitised brushes are the most important group, and come in grades covering the wide field of DC machines. Their
permissible continuous load lies between 10 and 13 A/cm2. The current densities can be exceeded by about 100% in
intermittent operation, and by up to 400% in the case of some grades.
Metallised brushes are used for low-voltage machines (10 to 100 V), where brush current densities from 14 to 25 A/cm2 are
permissible and particularly low brush losses are required for heating reasons. The current densities can be exceeded by
about 100 % in intermittent operation.
4.3.2 Overload
Lengthy overloading accelerates brush wear, impairs the commutation capacity of the brushes and increases the tendency to
distribute the current unevenly.
The correct brush pressure for normal stationary-type DC machines is 2.5 N/cm2.
The service life of the brushes essentially depends on the load and the condition of the circulating air. At a humidity of 6 to 12
g of water per m3 of air, normal wear can be assumed to be 5 mm at 1000 operating hours. Since the humidity and
contamination of the circulating air have a very marked effect on the ”carbon brush/commutator” unit, this value can fluctuate
by about 100% even under normal loading conditions.
4.3.5 Striation
The brush cross section of each DC machine is determined by the design data. A brush that is too lightly loaded, ie when the
machine is operated under a fractional load for a long period, can be the cause of striation. In these circumstances reducing
the number of brushes per bolt is a way of increasing the current density and hence preventing the striation. If this measure
cannot be applied or does not lead to success, a carbon brush manufacturer must be consulted who can determine the most
suitable grade of brush on site - possibly by means of brush trials - taking into account the actual operating and circulating air
conditions.
The machines are supplied with the brushes bedded in to avoid the
need for this during commissioning. All that needs to be checked is
that the brushes move freely in the holders and that the spring
tension of the teeth is sufficient to ensure that all brush-holders
achieve a brush pressure of eg 2.5 N/cm2 (depending on the grade
of brush and purpose of the machine).
Spare brushes with insulated stranded leads are to be used. If brushes with uninsulated stranded leads are used it must be
ensured that the lead cannot come into contact with the bearing plate or the service plates. The minimum air gap is ≥ 4.5 mm.
To ensure the entire running surface of these brushes rests on the commutator, they are bedded in with the aid of a strip of
sandpaper held taut around the commutator, with the abrasive side facing outwards, which is pulled to and fro until the
running surfaces of the brushes have adopted the curvature of the commutator. Finally the bedding in is to be carried out
several times in the direction of rotation only. The process is to be started with coarser and finished with fine sandpaper. Then
the carbon dust removed carefully. The brushes will be fully bedded in after several hours of operation.
If the brush-rocker has been pushed out of the neutral zone in the factory to achieve a particular motor speed characteristic or
generator voltage characteristic, this brush position must always be reset. When a rotor is replaced it should be noted that the
neutral zone may shift, making it necessary to reset the assembly.
This resetting and checking of the neutral zone can only be carried out with the brushes well bedded in and resting fully on
the commutator. It is to be carried out as follows:
A mV meter with a FSD of about 600 mV is connected to the stranded lead of each plus and minus brush. The exciting
current is limited to about 20 to 30% of the design value by drop resistance with field resistance connected. This current is
then switched on and off with the rotor stationary. The position producing the lowest pointer deflection on the meter is to be
sought by pushing the brush-rocker. In the course of this the rotor is to be turned several times in the direction of rotation in
which the brushes have been bedded in. The rotor must not spring back (flipping the brushes). This setting of the neutral zone
is adequate for machines with only one direction of rotation.
For reversing motors it is better to determine the neutral zone by running clockwise and anticlockwise at the same speed, with
the same rotor voltage and the same rotor and exciting current, and with brushes bedded in perfectly for the direction of
rotation concerned.
Maintenance of the complete brush assembly mainly involves keeping the insulating elements clean.
The microswitches are designed as ”normally closed contacts” and connected in series (see following wiring diagram).
connection at the
brush yoke
Figure 17
The carbon brush that wears down to its minimum permissible length first opens the circuit with its microswitch as a result.
This type of switching ensures that the circuit monitors itself for any break in a cable.
An evaluation unit or an isolating transformer (not supplied with the machine) can be connected via terminals 901 and 902 in
the terminal box.
Inductive load DC 4A 28 V
AC 2A 220 V
The minimum voltage required is 24 V; the minimum current 100 mA. To ensure reliable switching, particularly after the
machine has been idle for a long time, the current should not fall below the minimum, and when there are several
microswitches connected in series the minimum current should be increased.
Excessively dirty filters impair the cooling of the machines and lead to heat damage.
The fine filters we use (fibre layer filters) can be cleaned by washing in water (up to about 40°C), knocking, suction or blowing
out with compressed air. Dusts containing grease may have to be washed out in warm water (maximum of 40°C, possibly
adding commercial detergents). Avoid wringing the fine filter material out and spraying it clean. It is however generally
advisable to replace dirty filter materials.
Coarse (metal) filters an be cleaned by blowing them out with compressed air or washing in solvents.
Pos. Description
Figure 18
Pos. Description
- Align pipe bend tangentially in relation to the impeller and screw pressure switch tight with lock-nut.
- Transfer the dot marking of the pressure switch to the wall of the frame.
- The contact can be adjusted with the fan running, by turning the plastic main adjusting screw and the secondary
(cheese-head) adjustment screw if necessary. The cover must be removed to gain access.
- Maximum load on the switching contacts 1.0 A at 250 V AC; range of adjustment 2 to 8 mbar.
Figure 20
- Suction tube (hose end fitting) fitted in front of air inlet in the middle of the filter directed towards the fan.
- Switch fan on, set for reliable contact when connected to 2 (normally closed contact).
- Cover 50% of filter. Contact must open. Maximum load on the switching contacts 1.0 A at 250 V AC
Pos. Description
104 differential pressure switch, complete
105 flexible tube
106 clip schema of connection
107 screw for clip 1 lead
108 spring ring for clip 2 normally closed contact
109 hose stem 3 offnormal contact
110 fixed link
111 screw dor hose stem
112 nut for fixed link
113 spring ring for hose link
114 screw for fixed link
115 spring washer for fixed link
Figure 21
If it is necessary to remove the complete rotor, in order to turn the outside diameter of the machine’s commutator for instance,
to allow the rotor to be held between the lathe’s centres the tachometer driver screwed on is to be removed to expose the
shaft’s centring hole.
If the machine has a driver screwed into the thread of the shaft centring hole (evident from the hexagonal head for a 19 mm
spanner), this is to be heated to a maximum of 100°C to release the Loctite compound so that it can be unscrewed.
Reassembly is carried out in the reverse order, the driver being secured again with ”Loctite 75” or a equivalent compound.
The concentricity of both types of driver is to be checked about 5 mm from the end of the shaft with the machine installed
without the tachometer fitted. The maximum permissible deviation is 0.05 mm, and the driver is to be corrected to achieve this
if necessary. Only then is the tachometer to be fitted, and the rotor is to be pushed onto the shaft first. After fitting the
tachometer housing the thrust bush is to be tightened to be secure the rotor. It must be ensured with a visual inspection
through the brush-holders that the centre of the commutator is in the middle of the brush-holders. The concentricity, measured
on the surface on the commutator, is to be re-checked through the brush-holders, with the maximum permissible deviation
again being 0.05 mm. It can be corrected by for instance turning the tachometer rotor 90o on the driver.
In the case of a tachometer unit with coupling (see 5.5), after undoing the bolts securing the tachometer, the tachometer
including coupling half is to be pulled off. Lantern wheel, second half of coupling and driver can then be removed. When the
tachometer is reassembled the concentricity of the driver is to be checked (maximum deviation 0.05 mm). The gap between
driver and tachometer shaft (> 4 mm), and the gap between the coupling hubs (3-part curved tooth coupling = 4 mm, 2-part
curved tooth coupling = 2 mm), are also to be checked.
Pos. Description
59 driver A (cone)
60 driver B (flange)
61 screw for driver B
62 spring ring for driver B
63 adapter ring
64 screw for adapter ring
65 spring ring for adapter ring
66 tacho
67 screw for tacho
Figure 22
Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 tacho
77 screw for tacho
78 spring ring for tacho
79 coupling
80 adapter ring for brake
81 screw for adapter ring
82 spring ring for adapter ring
83 brake
84 adapter ring for tacho
85 Threaded rod for brake and adapter ring
86 Nut for brake and adapter ring
87 spring ring for brake and adapter ring
88 straight dowl
89 spring ring
Figure 23
If the brake is mounted on the end plate at the non-drive end with an intermediate plate, this is also to be removed if the end
plate is to be removed (otherwise the bearing cap bolts will not be accessible).
When fitting, the concentricity of the intermediate plate for the tachometer unit is to be checked and the plate realigned if
necessary (maximum deviation 0.05 mm) and bolted up. Pay attention to the previous marks.
Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 tacho
77 screw for tacho
78 spring ring for tacho
79 coupling
80 adapter ring for brake
81 screw for adapter ring
82 spring ring for adapter ring
83 brake
84 adapter ring for tacho
85 Threaded rod for brake and adapter ring
86 Nut for brake and adapter ring
87 spring ring for brake and adapter ring
88 straight dowl
89 spring ring
Figure 24
Pos. Description
68 driver A (cone)
69 driver B (flange)
70 screw for driver B
71 spring ring for driver B
72 key for driver A/B
73 skirt
74 screw for skirt
75 spring ring for skirt
76 Tacho
77 screw for Tacho
78 spring ring for Tacho
79 coupling
83 brake
88 straight dowl
89 spring ring
90 adapter ring for tacho
91 screw for brake and adapter ring
92 spring ring for brake and adapter ring
Figure 25
Pos. Description
Figure 26
Removing the rotor necessitates removing the end plates for example. To replace a bearing it is only necessary to remove the
end plate concerned. Replacing a commutating pole coil necessitates dismantling the machine into its main parts and
disconnecting the circuit connections involved. However even for partial dismantling it is better not to dismantle the machine
further than is absolutely necessary in order to clean it thoroughly or investigate whether all of its parts are in good operating
order.
Marks are to be made from the stator to the end plates before dismantling.
Before starting work it is necessary to make absolutely certain that the machine is disconnected from the mains. One half of
the coupling, the pulley or the like is then to be pulled off the stub shaft. After exposing the commutator service openings all of
the carbon brushes are to be lifted off the commutator and clamped firmly in the holder guide boxes with the aid of the
pressure lever, in order to prevent the remaining work causing any damage to the surface of the commutator. For the same
reason it is advisable to wrap the commutator in a protective envelope of cardboard.
To prevent the rotor falling onto the bottom pole, the air gap between rotor and pole is to be filled with cardboard before
continuing dismantling.
After removing the bearing head bolts from the drive and non-drive ends, the end plates are to be separated from the frame
after undoing the retaining bolts. The plates are separated with the aid of two large screwdrivers driven into the outer ring gap.
The plates are levered out of the frame’s centring aperture axially with the screwdrivers. It must be noted that with ball
bearings the bearing head (bearing seat in the plate) has to slide over the outer ring of the bearing. The end plates are
therefore not to be tilted, and are to be driven out over the outer rings of the bearings as evenly as possible, possibly by
tapping their flanges lightly.
However when removing the end plate from the non-drive end, the leads on the brush assembly are to be marked and
disconnected beforehand. Moreover any tachometers are to be removed before removing the end plate.
It is possible to remove the rotor of the small machines by hand. Any lifting cables or other aids that have to be used must not
be slung around unprotected shaft extensions and on no account around the commutator or fans. The rotor must not be
deposited on the bandages.
Refitting and reassembly are to be carried out similarly in the reverse order.
Reassembly is to be carried out on a aligning plate. The marks from the stator to the end plates are to be brought into
coincidence. This ensures that the feet are in one plane and the neutral zone marks remain valid.
Replacing a bearing requires pulling it off the shaft of the machine with a puller. The legs of the puller grip the outer ring of the
bearing, leading to deformation of the races or balls or rollers. It is always advisable not to reuse a bearing pulled off in this
way, even if it still appears to be suitable.
New bearings may be pulled onto the shaft cold, but it is advisable to heat them to about 100°C.
2/3 of the free space inside bearings with long-term lubrication must be filled with grease. After they have been cleaned and
dried carefully the outside grease collection cavities in the end plates are to be filled to 3/4 of their capacity with the same
grade of grease.
In machines with a lubricator for the bearings the new bearing is also to be filled to 2/3 of its capacity with grease, but the
collection cavities of the cap left empty!
Any shaft seals present are to be renewed at the same time when a bearing is replaced. Fill the lip cavity facing outwards with
the bearing grease.
In order to retain the machine’s original thermal characteristic (defined air throughput), renewing of the insulation system and
rewinding of the main pole coils are only to be carried out in the factory.
To allow mounting of the inner bearing cap an auxiliary stud or threaded rod is to be screwed into one of the tapped holes in
the cap before refitting the end plate. The stud is then to be guided though a bearing head hole in the end plate. The exposed
length of the stud must be about the width of the bearing +30 mm.
The ball bearing shim at the non-drive end is to be reinserted in the same position when the machine is reassembled.
Further dismantling of the machine and reassembly requires the measures described in the Subsections concerned. Marking
in advance individual parts where it is not absolutely clear how they belong together is strongly recommended. It is particularly
important during reassembly to pay attention to good insulation, sufficient spacing between live parts, good contacts, secure
connection of all screw joints and ensure that the bearings are in perfect condition. It is advisable to carry out insulation and
operating tests after completing the work.
5 Mounting modifications
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
O = Standard
L, R = Special mounting (additional price)
Figure 34
6 Circuit diagrams
Motor
clockwise rotation
anti-clockwise rotation
Generator
clockwise rotation
anti-clockwise rotation
Figure 35
EGZ-003
Additional terminals 101-102 thermal sensor (advance warning)
103-104 thermal sensor (cut-out)
EGZ-004
Additional terminals 201-202 heating
EGZ-007
Additional terminals 101-102 thermal sensor
201-202 heating
EGZ-020
Additional terminals 701-702 tachometer
EGZ-021
Additional terminals 101-102 thermal sensor
701-702 tachometer
EGZ-094
Additional terminals 301-302 thermometer (PT 100) laminated paper
303-304 thermometer (PT 100) non-laminated paper
305-306 thermometer (PT 100) non-laminated paper
EGZ-300
Additional terminals 901-902 Brush monitoring system (microswitch, normally closed contact)
L1 L2 L3 L1 L2 L3
U1 V1 W1 U1 V1 W1
U2 V2 W2 U2 V2 W2
Figure 36
7 After-sales service
Please consult our After-Sales Service Department if you have a problem.
Experienced experts will help you. Please give your statement if possible via telefax, telex
or by phone.
: +49(0)421 4589-247
: +49(0)421 4589-305
@ : service@ldw.is-bremen.de
: http://www.ldw.de
+49(0)170 8568251
9 Standards
The following list makes no claim to completeness; it simply lists the main standards and guidelines relating to rotating
electrical machinery. This list of standards will be amended continuously with view to the conformity between national
standards (DIN) and European standards (EN/CEN/CENELEC).
Description Number