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ABB AMA Series Manual

For induction motors and generators
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Manual for Induction Motors and Generators
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  • Page 1 Manual for Induction Motors and Generators...
  • Page 2 Manual for Induction Motors and Generators Safety Instructions AMA, AMB, AMG, AMH, AMI, AMK, AMZ, HXR, M3BM, M3GM 1. General General safety regulations, specific agreements made for each work site and safety precautions shown in this document must be observed at all times. 2.
  • Page 3 Manual for Induction Motors and Generators Follow the manufacturer's instructions when mounting or removing couplings or other drive elements and cover them with a touch guard. For trial run in uncoupled state, lock or remove the shaft end key. Avoid excessive radial and axial bearing loads (note manufacturer's documentation).
  • Page 4 Manual for Induction Motors and Generators case of sleeve-bearing machines, observe time-limit for oil-change and if equipped with oil supply system make sure the system is working. 7. Maintenance and servicing Follow the manufacturer's operating instructions. For further details, see the comprehensive User´s Manual.
  • Page 5 Maintenance and servicing Permanent magnet synchronous machines must only be serviced by repair shops qualified and authorised by ABB. For more information concerning service of permanent magnet synchronous machines, please contact ABB. WARNING: Only qualified personnel familiar with the relevant safety requirements are allowed to open and maintain permanent magnet synchronous machines.
  • Page 6 94/9/EC and have a CE-mark on the rating plate. Validity These instructions are valid for the following ABB Oy's electrical motor types, when the machine is used in explosive atmosphere. Non-sparking Ex nA, Class I Div 2, Class I Zone 2...
  • Page 7 Std. concerning combustible dust, Ex tD protection NFPA 70; National Electric Code (NEC) C 22-1-98; Canadian Electrical Code, Part I (CE Code) ABB machines (valid only for group II) can be installed in areas corresponding to following marking: Zone (IEC) Category (EN) Marking...
  • Page 8 • Do not install any new equipment to terminal boxes without asking for advises from ABB • Be sure that air gap between rotor and stator is measured after any maintenance for the rotor or bearings.
  • Page 9 Manual for Induction Motors and Generators Pre-start ventilation • Ex nA and Ex e machines may, or in some cases, have to be equipped with a provision for pre-start ventilation. • Before starting, check the need to purge the machine enclosure to make sure that the enclosure is free of flammable gases.

  • Page 10: Table Of Contents

    Manual for Induction Motors and Generators Chapter 1 - Introduction General information....................1 Important note......................1 Limitation of liability....................2 Documentation......................2 1.4.1 Documentation of the machine ..............2 1.4.2 Information not included in documentation..........3 1.4.3 Units used in this User’s Manual............... 3 Identification of the machine ..................
  • Page 11 Manual for Induction Motors and Generators 3.3.6 Drain plugs ....................22 Installation on concrete foundation................23 3.4.1 Scope of delivery..................23 3.4.2 General preparations ................23 3.4.3 Foundation preparations................23 3.4.3.1 Foundation and grouting hole preparations...... 23 3.4.3.2 Foundation studs or sole plate preparations ..... 23 3.4.4 Erection of machines................
  • Page 12 Manual for Induction Motors and Generators 4.3.2 Safety ....................... 39 4.3.3 Insulation resistance measurements............39 4.3.4 Main terminal box options............... 40 4.3.4.1 Delivery without main terminal box ......... 40 4.3.5 Insulation distances of main power connections ........40 4.3.6 Main power cables ................... 40 4.3.7 Secondary cables for slip ring connections..........
  • Page 13 Manual for Induction Motors and Generators Chapter 6 - Operation General ........................53 Normal operating conditions..................53 Number of starts....................... 53 Supervision....................... 54 6.4.1 Bearings....................54 6.4.2 Vibrations....................54 6.4.3 Temperatures................... 54 6.4.4 Heat exchanger..................55 6.4.5 Slip ring unit.................... 55 Follow-up .........................
  • Page 14 Manual for Induction Motors and Generators 7.5.4 Bearing insulation and bearing insulation resistance check ....75 7.5.4.1 Procedure ................75 7.5.4.2 Cleanliness of bearing insulation ........77 Maintenance of stator and rotor windings ..............78 7.6.1 Particular safety instructions for winding maintenance......78 7.6.2 The timing of the maintenance ..............
  • Page 15 Manual for Induction Motors and Generators 8.2.7 Use verification ..................103 Electrical performance, excitation, control and protection ........106 8.3.1 Protection trips ..................106 8.3.2 Pt-100 resistance temperature detectors..........106 Slip rings and brushes .................... 108 8.4.1 Brush wear .................... 108 8.4.2 Brush sparking ..................

  • Page 16: Chapter 1 Introduction

    This document and parts thereof must not be reproduced or copied without the express written permission of ABB, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

  • Page 17: Limitation Of Liability

    In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document.

  • Page 18: Information Not Included In Documentation

    Manual for Induction Motors and Generators 1.4.2 Information not included in documentation This User’s Manual does not include any information about any starting, protection or speed control equipment. This information is provided in the user’s manuals for respective equipment. 1.4.3 Units used in this User’s Manual The measurement units used in this User’s Manual are based on the SI (metric) system and the US system.
  • Page 19 Manual for Induction Motors and Generators Figure 1-2 Rating plate for frequency converter machines manufactured according to IEC Figure 1-3 Rating plate for direct on line machines manufactured according to NEMA 1. Type designation 2. Manufacturing year 3. Duty 4. Type of connection 5.
  • Page 20 Manual for Induction Motors and Generators 9. Mounting arrangement [IM code] (IEC) 10. Additional info 11. Manufacturer 12. Serial number 13. Output [kW] or [HP] 14. Stator voltage [V] 15. Frequency [Hz] 16. Rotating speed [rpm] 17. Stator current [A] 18.

  • Page 21: Chapter 2 Transport And Unpacking

    Manual for Induction Motors and Generators Chapter 2 Transport and Unpacking 2.1 Protective measures prior to transport 2.1.1 General The following protective measures are taken before delivery of the machine from the factory. The same protective measures should be taken, whenever the machine is moved: •...
  • Page 22 Manual for Induction Motors and Generators ***Following figure for bearing type: Rolling bearing Figure 2-1 Bearing plate for grease lubricated rolling bearings Bearing type of D-end Bearing type of ND-end Lubrication interval Quantity of grease for D-end bearing Quantity of grease for ND-end bearing Additional information Type of grease delivered from factory ***Following figure for bearing type: Sleeve bearing...

  • Page 23: Lifting The Machine

    Manual for Induction Motors and Generators Bearing type for D-end Bearing type for ND-end Oil change interval Viscosity class Oil quantity for D-end bearing (for self lubricated) Oil quantity for ND-end bearing (for self lubricated) Method of lubrication for D-end bearing. Oil flow and pressure for flood lubricated bearing Method of lubrication for ND-end bearing.

  • Page 24: Lifting A Machine On A Pallet

    Manual for Induction Motors and Generators Figure 2-3 Lifting of horizontal and vertical machines in seaworthy packages 2.2.2 Lifting a machine on a pallet A machine mounted on a pallet should be lifted by crane from the lifting eyes of the machine, see Figure 2-4 Lifting of horizontal and vertical machines on pallets, or by forklift from the bottom of the pallet.

  • Page 25: Lifting An Unpacked Machine

    Manual for Induction Motors and Generators Figure 2-4 Lifting of horizontal and vertical machines on pallets 2.2.3 Lifting an unpacked machine Suitable lifting equipment must be used! The machine should always be lifted by crane from the lifting eyes on the frame of the machine, see Figure 2-5 Lifting of unpacked machines. The machine should never be lifted by forklift from the bottom or the feet of the machine.

  • Page 26: Turning A Vertically Mounted Machine

    Manual for Induction Motors and Generators Figure 2-5 Lifting of unpacked machines ***Following chapter for mounting type: Vertical 2.3 Turning a vertically mounted machine Vertically mounted machines may be necessary to turn from vertical to horizontal position, e.g. when changing the bearings, and vice versa. This is shown in Figure 2-6 Machine with turnable lifting eyes: lifting and turning.

  • Page 27: Checks Upon Arrival And Unpacking

    Manual for Induction Motors and Generators 2.4 Checks upon arrival and unpacking 2.4.1 Check upon arrival The machine and the package must be inspected immediately upon arrival. Any transport damage must be photographed and reported immediately, i.e. within less than one (1) week after arrival, if the transport insurance is to be claimed.

  • Page 28: Installation Of Cooler Parts

    Manual for Induction Motors and Generators Lift the main terminal box directly onto the machine frame at the position where the main terminal box has to be connected (see Dimension Drawing included in the project documentation). For NEMA main terminal box only: pull the stator cables through the ceiling membrane. Connect the main terminal box with the screws delivered with the machine frame.

  • Page 29: Long Term Storage (More Than 2 Months)

    Manual for Induction Motors and Generators and preventing moisture from condensing in the machine must be used • A stable support free from excessive vibrations and shocks. If vibrations are suspected to be too high, the machine should be isolated by placing suitable rubber blocks under the machine feet •...

  • Page 30: Rolling Bearings

    Manual for Induction Motors and Generators Figure 2-7 Ventilation holes ***Following paragraph for cooling method: Water jacket Machines with so-called water jacket cooling are to be filled with a mixture of water and glycol with a minimum of 50% glycol. Instead of glycol, another similar liquid can be accepted. Make sure that the liquid mixture tolerates the storage temperature without freezing.
  • Page 31 Manual for Induction Motors and Generators ***Following table for mounting type: Horizontal Table 2-1. Tightening torque for horizontal machines (lubricated screw) Axially locating bearing Tightening torque [Nm] Tightening torque type [pound foot] 6316 6317 6319 6322 6324 6326 6330 6334 6034 6038 6044...

  • Page 32: Sleeve Bearings

    Manual for Induction Motors and Generators ***Following table for mounting type: Vertical Table 2-2. Tightening torque for vertical machines (lubricated screw) Axially locating bearing Tightening torque [Nm] Tightening torque [pound type foot] 7317 7319 7322 7324 7326 7330 7334 ***Following chapter for bearing type: Sleeve bearing 2.6.4 Sleeve bearings Apply the following measures: •...

  • Page 33: Openings

    Manual for Induction Motors and Generators Table 2-3. Tightening torque (lubricated screw). Axially locating bearing carries the locking force Axially locating bearing Tightening torque [Nm] Tightening torque type [pound foot] ZM_LB 7 EF_LB 9 EF_LB 11 EF_LB 14 EM_LB 14 EF_LB 18 2.6.5 Openings If there are any openings where cables are not connected to terminal boxes or flanges that are...

  • Page 34: Chapter 3 Installation And Alignment

    2 mm (0.8 inch) shim plate. NOTE: The calculation and design of the foundation is not included in the ABB scope of supply and the customer or a third party is therefore responsible for it. Furthermore, the grouting operation is also normally outside the scope and responsibility of ABB.

  • Page 35: Forces To The Foundation

    Manual for Induction Motors and Generators 3.2.2 Forces to the foundation The foundation and the mounting bolts must be dimensioned to withstand a sudden mechanical torque, which occurs every time the machine is started, or at short circuit. The short circuit force is a gradually damped sine wave that changes direction.

  • Page 36: Disassembly Of The Transport Locking Device

    Manual for Induction Motors and Generators 3.3.2 Disassembly of the transport locking device Some machines and all machines with sleeve or roller bearings have transport locking devices installed. For machines with sleeve or cylindrical roller bearings, the transport locking device is made of a steel bar attached to both the bearing shield on the D-end and to the end of the shaft extension.

  • Page 37: Assembly

    Manual for Induction Motors and Generators 3.3.4.2 Assembly The following instructions must be taken into account when assembling the coupling half. • Follow the general instructions of the coupling supplier • The weight of the coupling half can be considerable. A suitable lifting gear may be needed •...

  • Page 38: Installation On Concrete Foundation

    The machine delivery does not normally include installation, shim plates, mounting bolts, foundation plate set or sole plate set. These are delivered according to special orders. If new fixing holes need to be drilled, please contact ABB to ensure suitability. 3.4.2 General preparations Before starting the installation procedure, consider the following aspects: •...
  • Page 39 Manual for Induction Motors and Generators NOTE: To ensure that the foundation studs will be satisfactorily attached to the concrete, they must be unpainted and free from pollution and dust. Figure 3-1 Typical foundation stud assembly In order to assemble the foundation stud or sole plate set, the machine must be suspended above the floor by a crane.

  • Page 40: Erection Of Machines

    Manual for Induction Motors and Generators • After the assembly of the foundation plates is done; the machine should be lifted up and suspended above the floor. The machine feet, and the side and bottom surfaces of the foundation plates as well as anchor bolts should be cleaned with white spirit •...

  • Page 41: Covers And Enclosures

    The machine delivery does not normally include installation, shim plates or mounting bolts. These are delivered according to special orders. If new fixing holes need to be drilled, please contact ABB to ensure suitability. 3.5.2 Check of foundation Before lifting the machine onto the foundation, the following checks should be made.

  • Page 42: Covers And Enclosures

    The purpose of a mounting flange for vertically mounted machines is to enable an easy installation and coupling connection, as well as an easy inspection of the coupling during operation. In order to fit the ABB machines, the mounting flanges shall be designed according to the IEC standard.

  • Page 43: Rough Levelling

    Manual for Induction Motors and Generators angular deviation between the two shafts of the machines have to be minimized. The alignment must be performed with great caution because alignment errors will lead to bearing and shaft damages. Before the alignment procedure is started, the coupling halves have to be installed, see Chapter 3.3.4 Assembly of the coupling half.
  • Page 44 Manual for Induction Motors and Generators BRACKET WITH ADJUSTING SCREW Figure 3-4 Positioning of bracket plates Bracket plates are placed against the foundation edge and tied down with expansion bolts, see Figure 3-5 Mounting of the bracket plate. Move the machine by using the adjusting screws until the shaft centerline and the driven machine centerline are aligned roughly and the desired distance between the coupling halves is reached.

  • Page 45: Correction For Thermal Expansion

    Manual for Induction Motors and Generators POINTER OUTER SEAL RUNNING CENTER ROTOR END FLOAT LIMITS Figure 3-6 Markings on shaft and running center pointer 3.6.4 Correction for thermal expansion 3.6.4.1 General Running temperatures have a considerable influence on the alignment, and should therefore be considered during the alignment.

  • Page 46: Thermal Axial Growth

    Manual for Induction Motors and Generators 3.6.4.3 Thermal axial growth The thermal axial expansion needs to be taken into consideration if the axial movement of the non-drive end bearing is locked. See the dimension drawing in order to determine which end is locked.

  • Page 47: Parallel, Angular And Axial Alignment

    Manual for Induction Motors and Generators Figure 3-7 Measuring the run-out at the coupling half 3.6.5.3 Parallel, angular and axial alignment After the machine has been roughly positioned, as described in Chapter 3.6.2 Rough levelling and Chapter 3.6.3 Rough adjustment, the final alignment can start. This step must be performed with great caution.

  • Page 48: Alignment

    Manual for Induction Motors and Generators Figure 3-8 Definition of misalignment 3.6.5.4 Alignment The alignment of the machine is performed according to these guidelines. The machine should stand on its jacking screws Rotate the rotor and check the axial end float, see Chapter 3.6.3 Rough adjustment ***Following note for bearing type: Sleeve bearings NOTE: Sleeve bearings must be filled with oil before turning.

  • Page 49: Permissible Misalignment

    Manual for Induction Motors and Generators Measure and note readings for parallel, angular and axial misalignment in four different positions: top, bottom, right and left, i.e. every 90°, while both shafts are turned simultaneously. The readings are recorded Align the machine vertically by turning the jacking screws or by jacking with hydraulic jacks.

  • Page 50: Care After Installation

    Manual for Induction Motors and Generators Table 3-1. Recommended permissible misalignments Coupling Information Permissible Misalignment Coupling Coupling Type Parallel Angular Axial ∆ r ∆ b ∆ a Diameter 100 – 250 mm Rigid Flange 0.02 mm 0.01 mm 0.02 mm (4 –...

  • Page 51: Chapter 4 Mechanical And Electrical Connections

    Manual for Induction Motors and Generators Chapter 4 Mechanical and Electrical Connections 4.1 General Mechanical and electrical connections are made after the installation and alignment procedures. The mechanical connections include the connection of air ducts, water tubes and/or oil supply system where applicable.

  • Page 52: Sleeve Bearing Oil Supply

    Manual for Induction Motors and Generators The cooling water circulates in ducts integrated in the machine frame. The material of the frame and ducts is carbon steel according to the standard EN 10025: S235 JRG2, equivalent with DIN 17100 - RSt 37-2. This material is prone to corrosion in saline and foul water. The corrosion products and fouling deposits might block the water flow in the ducts.

  • Page 53: Connection Of Purging Air Pipe

    Manual for Induction Motors and Generators Fill the oil supply system with appropriate oil with correct viscosity. The correct type of oil and viscosity is indicated on the dimensional drawing. If in any doubt of the cleanness of the oil, use a 0.01 mm (0.4 mil) mesh to filter unwanted debris from the oil.

  • Page 54: Safety

    The frequency converter must be designed to operate with a permanent magnet synchronous machine. If there is uncertainty concerning the compatibility of the permanent magnet synchronous machine and the frequency converter, please contact ABB Sales Office. 4.3.2 Safety Electrical work must be carried out only by skilled persons. The following safety rules must be applied: •...

  • Page 55: Main Terminal Box Options

    Manual for Induction Motors and Generators 4.3.4 Main terminal box options The inside of the main terminal box must be free from dirt, moisture and foreign debris. The box itself, cable glands, and unused cable entrance holes must be closed in a dust- and watertight manner.

  • Page 56: Secondary Cables For Slip Ring Connections

    Manual for Induction Motors and Generators The main power cable connections should be tightened correctly to ensure reliable operation. For details, see Appendix Typical main power cable connections. ***Following note for protection type: All hazardous areas NOTE: For Ex-machines, cable glands or cable bushings for supply cables must be Ex certified.

  • Page 57: Connection Of Auxiliaries And Instruments

    Manual for Induction Motors and Generators Figure 4-1 Typical auxiliary terminal box 4.3.8.1 Connection of auxiliaries and instruments Connect the instruments and auxiliary equipment according to the connection diagram. NOTE: Study the connection diagram delivered with the machine carefully before connecting any cables.

  • Page 58: Requirements For Machines Fed By Frequency Converters

    EN 50081-2. For further information, see ABB manual Grounding and cabling of the drive system (3AFY 61201998 R0125 REV A). 4.3.10.2 Earthing of main cable The compliance with EMC directive requires high-frequency earthing of the main cable.

  • Page 59: Chapter 5 Commissioning And Start-Up

    Check alignment of the machine prior to commissioning: • Go through the alignment report and ensure that the machine is accurately aligned according to ABB alignment specifications in Chapter 3.6 Alignment • The alignment protocol should always be included in the commissioning report Check that the machine is properly anchored to the foundation: •...

  • Page 60: Control And Protection Equipment

    Manual for Induction Motors and Generators • Check that the power cables are suitably routed • Check that the power cables are stress-relieved in a proper way • Check the connections of the auxiliary equipment. NOTE: If the machine is delivered without a main terminal box, see Chapter 4.3.4.1 Delivery without main terminal box.

  • Page 61: Resistance Temperature Detectors

    Manual for Induction Motors and Generators 5.5.2.2 Resistance temperature detectors Recommended maximum temperature settings: For determining the temperature settings, see the Connection Diagram delivered with the machine. It is recommended to apply the method described in Chapter 5.5.1 General when setting the temperature alarm.

  • Page 62: First Test Start

    Manual for Induction Motors and Generators The machine parameter values for relay settings are informed in the document “Performance data of machine” which is included in the documentation provided with the machine. NOTE: The machine manufacturer is not responsible for the adjusting the protection equipment at the site.

  • Page 63: Starting

    Manual for Induction Motors and Generators 5.6.3 Starting The first start should last only about one (1) second, during which the direction of rotation of the machine is verified. The direction of rotation of possible external blower motors must also be verified.

  • Page 64: Running The Machine The First Time

    During the first days of running, it is important to keep a close surveillance of the machine in case of any changes in vibration or temperature levels or abnormal sounds should occur. 5.7.3 Bearings The rotating electrical machines manufactured by ABB are equipped with either rolling or sleeve bearings. 3BFP 000 050 R0101 REV E...

  • Page 65: Machines With Rolling Bearings

    Manual for Induction Motors and Generators ***Following chapter for bearing type: Rolling bearing 5.7.3.1 Machines with rolling bearings In case of a newly installed machine or a machine, which has been out of service for more than 2 months, inject new grease into the bearings immediately after start-up. New grease must be injected when the machine is running, and is injected until old grease or excess new grease is discharged through the lubrication channel in the bottom of the bearing housing, see Figure 5-1 Example of lubrication channel through bearing arrangement of horizontal machine.

  • Page 66: Machines With Sleeve Bearings

    Manual for Induction Motors and Generators ***Following chapter for bearing type: Sleeve bearing 5.7.3.2 Machines with sleeve bearings Verify that no rotating parts rub against any stationary parts. Verify through the oil sight glass that the oil level inside bearing is correct. The correct oil level is in the middle of the oil sight glass, but as long as the oil level is within the oil sight glass, the level is acceptable.

  • Page 67: Heat Exchangers

    Manual for Induction Motors and Generators ***Following chapter for cooling type: Air-to-air and air-to-water 5.7.6 Heat exchangers Prior to start, check that the connections are tight and there is no leakage in the system. After running the machine for some time, the cooling system should be checked. Verify that the cooling fluid, where applicable, and air is circulating without any obstruction.

  • Page 68: Chapter 6 Operation

    NOTE: Overloading the machine may cause demagnetization of the permanent magnets as well as winding damages. 6.2 Normal operating conditions The machines manufactured by ABB are individually designed to operate in normal operation conditions according to the IEC or NEMA standards, customer specifications and internal ABB standards.

  • Page 69: Supervision

    Manual for Induction Motors and Generators For information on the allowed consecutive or annual starts, please see the performance data sheet or consult the manufacturer. The load characteristics of the application are needed for determining the starting frequency. As a guideline, the maximum number of starts in a typical application is 1000 starts per year.

  • Page 70: Heat Exchanger

    Manual for Induction Motors and Generators ***Following chapter for cooling type: Air-to-air, and air-to-water 6.4.4 Heat exchanger Check that the connections are tight and there is no leakage in the system. Verify that the cooling fluid, where applicable, and air is circulating without any obstruction. ***Following chapter for rotor type: Slip rings 6.4.5 Slip ring unit Follow the wear of the carbon brushes and change them before the wear limit is reached.

  • Page 71: Chapter 7 Maintenance

    ABB recommends the use of experts in the creating maintenance programs, as well as in performing the actual maintenance and possible trouble shooting. The ABB After Sales organization is happy to assist in these issues. The ABB After Sales contact information can be found in Chapter 9.1.5 After Sales contact information.

  • Page 72: Maintenance Program

    7.3 Maintenance program This chapter presents a recommended maintenance program for ABB machines. This maintenance program is of a general nature, and should be considered as a minimum level of maintenance. Maintenance should be intensified when local conditions are demanding or very high reliability is required.
  • Page 73 Manual for Induction Motors and Generators ***Following paragraph for application type: Variable speed drive Equivalent operating hours (Eq. h) = Actual operating hours ***Following paragraph for application type: Constant speed drive Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts x 20 Level 1 (L1) Level 1 or L1 maintenance consists of visual inspections and light maintenance.

  • Page 74: Recommended Maintenance Program

    Manual for Induction Motors and Generators The Level 3 maintenance should be performed after every 24 000 equivalent operating hours or at a three to five year interval. When L3 maintenance is conducted it replaces the L1 or L2 maintenance otherwise scheduled, and it leaves their rotation unaffected, see Table 7-1 Maintenance intervals.

  • Page 75: General Construction

    Manual for Induction Motors and Generators Table 7-1. Maintenance intervals MAINTENANCE INTERVAL In equivalent operating hours or time period, which ever comes first 4 000 Eq. h 8 000 Eq. h 24 000 Eq.h 80 000 Eq.h 12 000 Eq. h 16 000 Eq.

  • Page 76: Stator And Rotor

    Manual for Induction Motors and Generators 7.3.1.3 Stator and rotor Maintenance object Check / Test Stator core V / C Fixing, cracks, welds Stator winding insulation V / T V / T / C V / T / C Wear, cleanliness, insulation resistance, turn insulation test, (high voltage test) Stator coil over hangs Insulation damages...

  • Page 77: Slip Ring Unit

    Manual for Induction Motors and Generators ***Following table for rotor type: Slip rings 7.3.1.5 Slip ring unit Maintenance object Check / Test Assembly V / C V / C V / C Mounting, insulation Brush holders V / T V / T V / T Alignment Brushes...

  • Page 78: Cooling System

    Manual for Induction Motors and Generators Maintenance object Check / Test Lubrication oil V / R V / R V / R V / R Quantity, quality, flow Oil ring Operation Oil flow regulator V / T V / T V / T / D Operation Oil tank...

  • Page 79: Maintenance Of General Constructions

    Manual for Induction Motors and Generators Maintenance object Check / Test Plate fins V / C V / C V / C General condition Vibration dampers Condition and profile Protective anodes V / C V / C Condition, activity Water flow regulator V / T V / T V / T...

  • Page 80: Vibration And Noise

    Manual for Induction Motors and Generators Table 7-2. General tightening torques Tightening torque in Nm (pound-feet) Property class 8.8 for bolts Size Oiled [Nm] Oiled [pound Dry [Nm] Dry [pound feet] feet] M 10 M 12 M 14 M 16 M 20 M 24 M 27...

  • Page 81: Vibrations

    Manual for Induction Motors and Generators • Loose fastenings or anchor bolts, see Chapter 3 Installation and Alignment • Rotor imbalance • Coupling. 7.4.3 Vibrations The following instructions are part of the following two ISO standards: ISO 10816-3:1998 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and 15 000 r/min when measured in situ and ISO 8528-9:1995 Reciprocating internal combustion engine driven alternating current generating sets: Part 9: Measurement and...

  • Page 82: Classification According To Support Flexibility

    Manual for Induction Motors and Generators Figure 7-1 Measuring points 7.4.3.2 Classification according to support flexibility Two conditions are used to classify the support assembly flexibility in specified directions: • rigid supports • flexible supports These support conditions are determined by the relationship between the machine and foundation flexibilities.

  • Page 83: Maintenance Of Bearings And Lubrication System

    Manual for Induction Motors and Generators Zone C: Machines with vibration within this zone are normally considered unsatisfactory for long-term continuous operation. Generally, the machine may be operated for a limited period in this condition until a suitable opportunity arises for remedial action. Zone D: Vibration values within this zone are normally considered to be of sufficient severity to cause damage to the machine.

  • Page 84: Sleeve Bearings

    7.5.2 Lubrication of sleeve bearings The machines are equipped with sleeve bearings with a very long service life provided that the lubrication functions continuously and that the oil type and quality are as per ABB recommendations, and that the oil change instructions are followed.

  • Page 85: Control Of The Lubricant

    Manual for Induction Motors and Generators 7.5.2.2 Control of the lubricant During the first year of operation, it is advisable to take samples of the lubricating oil after about 1000, 2000 and 4000 operating hours. The sample should be sent to the oil supplier for analysis. Based on the results it is possible to determine a suitable oil change interval.

  • Page 86: Oil Change Schedule For Mineral Oils

    Manual for Induction Motors and Generators ISO VG 22 ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100 Viscosity 22 cSt Viscosity 32 cSt Viscosity 46 Viscosity 68 Viscosity 100 at 40 °C at 40 °C cSt at 40 °C cSt at 40 °C cSt at 40 °C Environmentally...

  • Page 87: Rolling Bearings

    Re-greasing intervals for frequency converter drives Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy load will require shorter lubrication intervals or a special lubricant. Consult manufacturing ABB factory After Sales department in such cases. NOTE: The constructional maximum speed of the machine must not be exceeded. The suitability of the bearings for high-speed operation must be checked.

  • Page 88: Re-Greasing

    Manual for Induction Motors and Generators 7.5.3.4 Re-greasing All rolling bearings of rotating electrical machines need to be re-greased, see Chapter 7.5.3.3 Re-greasing intervals. The re-greasing can be performed either manually or by means of an automatic system. In either case, it has to be verified that a suitable amount of the correct grease is entering the bearing at suitable intervals.

  • Page 89: Bearing Grease

    Manual for Induction Motors and Generators Automatic re-greasing A variety of automatic re-lubrication systems is available on the market. However, ABB recommends only the use of electromechanical re-lubrication systems. The quality of the grease entering the bearing has to be checked at least once per year: the grease has to look and feel like new grease.

  • Page 90: Bearing Maintenance

    If there is a need to change bearings, please contact ABB After Sales. See After Sales contact information in Chapter 9.1.5 After Sales contact information.
  • Page 91 Manual for Induction Motors and Generators end bearing insulation resistance test, to remove the drive-end bearing shells or the bearing shield and to lift the shaft. This ensures that there is no electrical contact between the shaft and any other part, for example, frame or bearing housing. Figure 7-2 D-end bearing earthing cable For all machines any optional shaft earthing brush, rotor earth fault brush and coupling (if it is made out of conductive material) must be removed.

  • Page 92: Cleanliness Of Bearing Insulation

    Manual for Induction Motors and Generators Figure 7-4 Measuring the insulation resistance of a roller bearing ***Following chapter for bearing type: Roller bearing 7.5.4.2 Cleanliness of bearing insulation The bearing insulations are installed in the end shields. To avoid decrease of the insulation resistance caused by foreign agents (salt, dirt) building up on the insulation surface, the cleanliness of the bearing insulation and the end shield surfaces around it should be checked regularly and cleaned if necessary.

  • Page 93: Maintenance Of Stator And Rotor Windings

    This chapter offers a general description on how to perform basic maintenance and tests. In many countries, ABB Service offers complete service maintenance packages, which include comprehensive testing. Before conducting any maintenance work on the electrical windings, general electrical safety precautions are to be taken and local regulations are to be respected in order to prevent personnel accidents.

  • Page 94: The Timing Of The Maintenance

    Manual for Induction Motors and Generators • Spray-varnish equipment, the frame of the machine, and the windings should be earthed during spray varnishing • Take necessary precautions when working in pits and cramped places • Only people trained to do high-voltage work can carry out a voltage test •...

  • Page 95: Conversion Of Measured Insulation Resistance Values

    Manual for Induction Motors and Generators For new machines with dry windings, the insulation resistance is very high. The resistance can, however, be extremely low if the machine has been subjected to incorrect transportation and storage conditions and humidity, or if the machine is operated incorrectly. NOTE: Windings should be earthed briefly immediately after measurement in order to avoid risk of electric shock.

  • Page 96: General Considerations

    Manual for Induction Motors and Generators R40 = 0.25 x 30 MΩ = 7.5 MΩ Table 7-4. Temperature values in degrees Celsius (ºC) and degrees Fahrenheit (ºF) °C 100 110 °F 104 122 140 158 176 194 212 230 7.6.4.2 General considerations The following consideration should be noted, before deciding any actions based upon the insulation resistance tests: •...

  • Page 97: Stator Winding Insulation Resistance Measurement

    Manual for Induction Motors and Generators 7.6.4.4 Stator winding insulation resistance measurement The insulation resistance is measured using an insulation resistance meter. The test voltage is 1000 VDC. The test time is 1 minute, after which the insulation resistance value is recorded. Before the insulation resistance test is conducted, the following actions must be taken: •...

  • Page 98: Rotor Winding Insulation Resistance Measurement

    Manual for Induction Motors and Generators MΩ MΩ MΩ Figure 7-7 Connections of the stator windings for insulation resistance measurements a) Insulation resistance measurement for star connected winding b) Insulation resistance measurement for delta connected winding Ω c) Insulation resistance measurement for one phase of the winding. The 'M ' represents the insulation resistance meter.

  • Page 99: Insulation Resistance Measurement For Auxiliaries

    Manual for Induction Motors and Generators MΩ Figure 7-8 Insulation resistance measurement of the rotor winding In the figure above the rotor is star-connected. 7.6.5 Insulation resistance measurement for auxiliaries To ensure correct operation of the machines protections and other auxiliaries, their condition can be determined by an insulation resistance test.

  • Page 100: Other Maintenance Operations

    If extraordinary circumstances occur and other maintenance is required, it is best to acquire professional help. The ABB After Sales organization is eager to assist in questions regarding maintenance of electrical machine winding, for contact information see Chapter 9.1.5 After Sales contact information.

  • Page 101: Brush Pressure

    Manual for Induction Motors and Generators 7.7.2.1 Brush pressure The brush pressure should be evenly distributed over the whole contact surface, i.e. the brush should conform to the slip ring curvature. Brush pressure is one of the most important single factors in brush operation.

  • Page 102: Cleaning Of Filters

    Manual for Induction Motors and Generators If the winding or cooling air temperature detectors show an abnormal temperature, a check of the cooling system has to be made. The two maintenance issues are to check the condition of air filters and to ensure good air circulation inside the machine. The machine interior should be cleaned and checked during overhauls or if problems arise.

  • Page 103: Cleaning

    Manual for Induction Motors and Generators Figure 7-10 Cooling air flow (typical asymmetric construction) The machine can be equipped with temperature detector(s) for monitoring the internal cooling air. If the temperature detectors show normal temperature, no additional maintenance to the supervision inspection is usually required for the cooling system.

  • Page 104: Repairs, Disassembly And Assembly

    ***Following note for rotor type: Permanent magnet NOTE: The permanent magnet synchronous machine must only be serviced by repair shops qualified and authorized by ABB. For more information on permanent magnet motors, please contact ABB. 3BFP 000 050 R0101 REV E...

  • Page 105: Chapter 8 - Trouble Shooting

    Chapter 8 Trouble Shooting 8.1 Trouble shooting This chapter is intended as a help in the event of an operational failure with an ABB delivered rotating electrical machine. The trouble shooting charts given below can aid in locating and repairing mechanical, electrical and thermal problems, and problems associated with the lubrication system.

  • Page 106: Mechanical Performance

    Axial load coming from connected machinery Check alignment and coupling function and type Faulty or incorrectly assembled coupling Check coupling function Insufficient foundation strength Reinforce foundation as per ABB instructions Winding fault Check windings Excessive network unbalance Check that network balance fulfils requirements...

  • Page 107: Lubrication System And Bearings

    Possible cause Corrective action Insufficient amount of grease Check bearing condition, add grease Insufficient lubrication Check ABB grease recommendations, change grease Unsuitable grease quality or viscosity Faulty coupling or mounting Check coupling, mounting and alignment Excessive axial forces Incorrect regreasing period...

  • Page 108: Lubrication System And Sleeve Bearings

    Possible cause Corrective action Low oil level Check bearing for leakage, add oil Insufficient lubrication Check ABB oil recommendations Unsuitable oil quality Incorrect oil change period Clean bearing and change oil Oil quality is reduced Faulty coupling or mounting...
  • Page 109 Check oil pump, oil reduction valve and oil filter Insufficient lubrication Oil viscosity too high Check oil temperature and oil type Check ABB oil recommendations Unsuitable oil quality Check lubrication system and adjust oil temperature Oil inlet temperature too high...

  • Page 110: Thermal Performance

    Replace fan(s) or change rotating direction of external fan Overload Control system setting Check machine controls, eliminate overload Overspeed Check actual speed and ABB speed recommendations Network unbalance Check that network balance fulfils requirements Faulty instrumentation or measurement system Check measurements, sensors and wiring...

  • Page 111: Thermal Performance, Air-To-Air Cooling System

    Place heat sources further away, check ventilation Overload Control system setting Check machine controls, eliminate overload Overspeed Check actual speed and ABB speed recommendations Network unbalance Check that network balance fulfils requirements Faulty instrumentation or measurement system Check measurements, sensors and wiring...

  • Page 112: Thermal Performance, Air-To-Water Cooling System

    Manual for Induction Motors and Generators ***Following chapter for cooling type: Air-to-water 8.1.3.3 Thermal performance, air-to-water cooling system Trouble shooting Thermal performance air-to-water cooling system Experienced malfunction Possible cause Corrective action Damaged cooling fan Replace fan Low primary cooling Fan rotating in wrong direction Change shaft mounted fan or correct external blower motor operation circuit performance Dirty machine interior Clean machine parts and air gaps...

  • Page 113: Thermal Performance, Rib Cooled

    Possible cause Corrective action Control system setting Check machine controls, eliminate overload Overload Check actual speed and ABB speed recommendations Overspeed Check that network balance fulfils requirements Network unbalance Check measurements, sensors and wiring Faulty instrumentation or measurement system...

  • Page 114: Oil Leakage Of Sleeve Bearings

    Manual for Induction Motors and Generators ***Following chapters for bearing type: Sleeve bearing 8.2 Oil leakage of sleeve bearings The construction of a sleeve bearing is such that it is very difficult to avoid oil leakage completely, and therefore small amounts of leakage should be tolerated. However, oil leakage can also appear because of reasons other than the bearing design, such as incorrect oil viscosity, overpressure inside the bearing, underpressure outside the bearing, or high vibration levels at the bearing.

  • Page 115: Sleeve Bearings

    In order to prevent the oil from leaking from the bearing through any split lines, sealant is applied on the split lines. ABB recommends the Hylomar Blue Heavy sealing compound. Curil T or other similar compounds can be used as well.

  • Page 116: Oil Container And Piping

    Manual for Induction Motors and Generators ***Following chapter for bearing type: Sleeve bearing with flood lubrication 8.2.4 Oil container and piping A separate oil container and piping is used only for flood-lubricated bearings. Oil container The oil container can be either a separate container, or in some cases, the crankcase of a diesel engine.

  • Page 117: Use

    Manual for Induction Motors and Generators 8.2.6 Use Causes for bearing leakages, apart from being installation-related, some causes are 'use' related. ***Following paragraphs for bearing type: Sleeve bearing with flood lubrication Oil pressure The inlet oil pressure for each bearing is calculated according to the desired oil flow, and therefore the oil pressure should be adjusted accordingly during commissioning.

  • Page 118: Use Verification

    Manual for Induction Motors and Generators Under pressure inside the bearing is normally not caused by the bearing itself, but by parts outside the bearing. Under pressure near the bearing housing is caused by rotational parts moving the air next to them in such a way that a local under pressure is formed next to the exit of the shaft of the bearing.
  • Page 119 Manual for Induction Motors and Generators • Make a U-shaped 'water lock' on the oil return piping • Install a breather on top of the bearing housing. Air pressure outside the bearing The air pressure near the exit of the shaft from the bearing needs to be verified. This is especially important if the bearing is flange mounted to the machine, or if the shaft is mounted inside a cover or other construction which might form a 'centrifugal fan' together with the shaft.
  • Page 120 Manual for Induction Motors and Generators Figure 8-1 Verification of air pressure inside and outside of a sleeve bearing If a large under pressure is found to be inside the machine, e.g. between the end shield and the machine seal, the situation is tricky; it is normally very difficult to remove the machine seal, and to re-seal it.

  • Page 121: Electrical Performance, Excitation, Control And Protection

    Manual for Induction Motors and Generators 8.3 Electrical performance, excitation, control and protection The electrical performance of a rotating electrical machine is mostly defined by the condition of the rotor and stator windings, and the operation of the excitation system, if applicable. The main machine winding maintenance is described in Chapter 7.6 Maintenance of stator and rotor windings.
  • Page 122 Manual for Induction Motors and Generators Table 8-1. Temperature values for Pt-100 elements PT100 TEMP TEMP PT100 TEMP TEMP PT100 TEMP TEMP °C °F °C °F °C °F 100.00 32.00 127.07 158.00 153.58 284.00 35.60 127.84 100.78 161.60 154.32 287.60 39.20 128.60 101.56 165.20 155.07...

  • Page 123: Slip Rings And Brushes

    Manual for Induction Motors and Generators There are two possible remedies for stator Pt-100 detector damage. If there are operational spare detectors remaining in the stator core, they can be taken into use. If all the working factory assembled detectors are in use, a new detector can be retrofitted in the winding end. ***Following chapter for rotor type: Slip rings 8.4 Slip rings and brushes 8.4.1 Brush wear...

  • Page 124: Thermal Performance And Cooling System

    Manual for Induction Motors and Generators 8.5 Thermal performance and cooling system There are two fundamental reasons that might cause an increase in the machine's temperature: • The effect of the cooling system has declined • The machine is producing excessive amount of heat. If the machine temperature exceeds the normal values, measures should be taken to determine which one of the above mentioned two causes is dominant cause in a particular incident.

  • Page 125: Chapter 9 After Sales Support And Spare Parts

    Manual for Induction Motors and Generators Chapter 9 After Sales Support and Spare Parts 9.1 After Sales The After Sales support for rotating electrical machines manufactured by ABB, and Strömberg in Helsinki, Finland since 1889. 9.1.1 Site Services The Site Services department provides: •...

  • Page 126: Spare Parts For Rotating Electrical Machines

    9.2 Spare parts for rotating electrical machines 9.2.1 General spare part considerations The machines manufactured by ABB are designed and manufactured to provide reliable and trouble-free operation for decades. This requires, however, that the machines are properly maintained and operated. This maintenance includes changing of parts subjected to normal wear.

  • Page 127: Selection Of The Most Suitable Spare Part Package

    To receive a quotation for specific parts for a specific machine, please contact the ABB After Sales organization. Please note that even though ABB has customized the spare part sets to match the machine, they might contain references to accessories not found on all machines.

  • Page 128: Recommended Spare Part Package

    Manual for Induction Motors and Generators Spare part Amount Bearing shell for DE 1 pc Bearing shell for NDE 1 pc Bearing oil ring for DE 1 pc Bearing oil ring for NDE 1 pc Bearing labyrinth seals for 2 pcs Bearing labyrinth seals for 2 pcs 9.2.5.2 Recommended spare part package...

  • Page 129: Recommended Spare Part Package

    Manual for Induction Motors and Generators Spare part Amount Alternatively for sleeve bearing machines: Bearing shell for DE 1 pc Bearing shell for NDE 1 pc Bearing oil ring for DE 1 pc Bearing oil ring for NDE 1 pc Bearing labyrinth seals for 2 pcs Bearing labyrinth seals for...

  • Page 130: Operational Spare Part Package

    Manual for Induction Motors and Generators ***The following chapters for product family: AMK 9.2.5.7 Operational spare part package Spare part Amount Air filters (for IPW24/IC01 1 set machine) Air filter for slip ring carbon 1 pc dust Brushes 1 set Brush holder 1 set Water leakage detector (for...

  • Page 131: Recommended Spare Part Package

    In addition, provide specific and detailed information about the parts ordered. The contact information of ABB's After Sales organization can be found in Chapter 9.1.5 After Sales contact information.

  • Page 132: Chapter 10 Recycling

    Chapter 10 Recycling 10.1 Introduction ABB is committed to its environmental policy. ABB continuously strives to make its products more environmentally sound by applying results obtained in recyclability and life cycle analyses. Products, manufacturing processes and even logistics have been designed to take environmental aspects into account.

  • Page 133: Dismantling Of The Machine

    NOTE: The heat treatment process and the maintenance of the heat treatment equipment require special care in order to avoid any risk for fire hazards or explosions. Due to various installations used for the purpose it is not possible for ABB to give detailed 118 - Recycling...

  • Page 134: Permanent Magnets

    Manual for Induction Motors and Generators instructions of the heat treatment process, or the maintenance of the heat treatment equipment and these aspects must be taken care of by the customer. 10.5.3 Permanent magnets If the permanent magnet synchronous machine is melted down as a whole, nothing needs to be done to the permanent magnets.

  • Page 135: Commissioning Report

    Manual for Induction Motors and Generators COMMISSIONING REPORT Rating plate information: Serial no. Manufacturer: ABB Oy Address: P.O. Box 186 FIN-00381 HELSINKI FINLAND Telephone: +358 (0) 10 22 11 Fax: +358 (0) 10 22 22544 Customer: Customer address: Contact person:...
  • Page 136 Manual for Induction Motors and Generators 1 Transportation General: Arrival date of the machine: Inspection date and location: Signature of consignee: Open box inspection: yes, done by: Damages: yes, missing items: Packing list: yes, what kind of: Machine: yes, what kind of: Package: yes, what kind of: Accessories:...
  • Page 137 Manual for Induction Motors and Generators 2 Storage General: yes, begin:_______________end:_____________________ Storage: Storage time longer than 6 months: Person responsible for storage: Storage place: indoors outdoors in packing case protected by a waterproof cover º Daily temperature: min/max._______ - _______ C Humidity:_______% Storage actions: Transportation package is ventilated:...
  • Page 138 Manual for Induction Motors and Generators 3 Mechanical Installation Foundation is checked according to machine yes, drawing number:_____________________________ drawing: Possible foundation anchor bolts or sole plates are mounted according to instructions: Exciter N-end D-end N-end Air gap is measured, if applicable: For pedestal bearings, mark values 1-4, and for flanged bearings, values A-D 1 ____________ A ____________...
  • Page 139 Manual for Induction Motors and Generators 4 Lubrication check 4.1 Self lubrication Bearing oil: Manufacturer:__________________ Type:_________________________ The oil quality is the same as recommended: Bearing oil is filled up to the indicated level: Please mark the level in the sight glass circle Sight Glass on the right Lubrication rings rotate freely:...
  • Page 140 Manual for Induction Motors and Generators 5 Electrical installation yes, voltage:______-______V, frequency:_____-______Hz Network variation: manual automatic, controlled by:_________________ Space heater operation: yes, voltage:_____________V, power:_______________W Space heater for slip ring unit: 5.1 Insulation resistance test Ω, ______º Stator winding (1 min., 1000 VDC): __________M tested by________ kV, winding temperature: ______º...
  • Page 141 Manual for Induction Motors and Generators 6 Machine protection settings Overcurrent tripping: _______________A _________________ s Instant overcurrent tripping: _______________A _________________ s yes, setting: Overvoltage setting: yes, setting: Earth fault setting: yes, setting: Reverse power setting: yes, setting: Differential protection setting: yes, alarm:__________mm/s, trip:______________mm/s Vibration monitoring: Temperature monitoring:...
  • Page 142 Manual for Induction Motors and Generators 7 Test Run 7.1 First start (a few seconds only) Note: Check that possible flood lubrication is on! Direction of rotation (viewed from D-end): yes, from: Are there abnormal noises? 7.2 Second start (uncoupled, if possible) Note: Check that possible flood lubrication is on! yes, from: Are there abnormal noises?
  • Page 143 Manual for Induction Motors and Generators 8 Test run (with load) Checking schedule and information Time Load Bearing temp. Bearing vibration levels Stator Stator winding temperature D-end N-end D-end N-end Current Power Excit. mm/s mm/s Factor Current φ º º º...
  • Page 144 Manual for Induction Motors and Generators Fax Cover Sheet Date: ABB Oy Telefax: +358 (0) 10 22 22544 From: Fax number: Phone number: Email: Number of pages: 1 + 9 + _________ Message: 3BFP 000 050 R0101 REV E Commissioning Report - 129...

  • Page 145: Typical Position Of Plates

    Manual for Induction Motors and Generators Typical position of plates 3BFP 000 050 R0101 REV E Typical Position of Plates - 130...

  • Page 146: Typical Main Power Cable Connections

    Manual for Induction Motors and Generators Typical main power cable connections 3BFP 000 050 R0101 REV E Typical Main Power Cable Connections - 131...
  • Page 147 ABB Oy Machines P.O. Box 186 FIN-00381 HELSINKI FINLAND Telephone + 358 (0)10 2211 Telefax + 358 (0)10 22 22141 www.abb.com/motors&drives...

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