FTA 500Fs4 Manual.pdf

CG Electric Systems Hungary Zrt. 1095 Budapest, Mrissy str.7. T:+36-1-483-6600 www.cgglobal.com

THREE-PHASE

WOUND ROTOR INDUCTION MOTOR

111.174

FTA 500 Fs4

TECHNICAL DESCRIPTION

OPERATING AND MAINTENANCE INSTRUCTION

CG ELECTRIC SYSTEMS HUNGARY Zrt. CONTENTS

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CONTENTS

1 TECHNICAL DATA .............................................................................................. 4

2 BEARINGS........................................................................................................... 5

2.1 TYPE AND LUBRICATION........................................................................... 5

2.2 BEARING SHIELDS...................................................................................... 5

3 TECHNICAL DESCRIPTION ............................................................................... 6

3.1 STATOR ....................................................................................................... 6

3.1.1 STATOR HOUSING............................................................................... 6

3.1.2 STATOR CORE..................................................................................... 6

3.1.3 STATOR WINDING ............................................................................... 7

3.1.4 STATOR HEATING, SLIPRING SPACE HEATING............................... 8

3.1.5 LOCATION OF THE THERMOMETERS............................................... 8

3.2 ROTOR ......................................................................................................... 9

3.2.1 SHAFT ................................................................................................... 9

3.2.2 LAMINATED ROTOR CORE ................................................................. 9

3.2.3 ROTOR WINDING................................................................................. 9

3.2.4 SLIPRINGS............................................................................................ 9

3.2.5 BALANCING, VIBRATION, OVERSPEED TEST ................................ 10

3.3 TERMINALS ............................................................................................... 10

STATOR TERMINAL BOX................................................................................. 10

3.3.1 ROTOR TERMINALS .......................................................................... 10

3.4 BRUSHGEAR ............................................................................................. 11

3.5 VENTILATION ............................................................................................ 12

3.5.1 INTERNAL VENTILATION CIRCUIT ................................................... 12

3.5.2 AIR TO AIR HEAT EXCANGER .......................................................... 12

3.5.3 VENTILATION OF THE SLIPRING SPACE ........................................ 12

3.5.4 CHANGING THE DIRECTION OF THE ROTATION ........................... 13

4 OPERATING AND MAINTENANCE INSTRUCTIONS....................................... 14

4.1 STORING, LIFTING.................................................................................... 14

CG ELECTRIC SYSTEMS HUNGARY Zrt. CONTENTS

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4.2 INSTALLATION .......................................................................................... 14

4.3 COUPLING TO THE DRIVEN MACHINE ................................................... 15

4.4 ELECTRIC CONNECTION ......................................................................... 17

4.5 PUTTING INTO OPERATION..................................................................... 18

4.6 CHECKING OF THE BRUSH GEAR .......................................................... 18

4.7 STARTING.................................................................................................. 19

4.8 MAINTENANCE.......................................................................................... 19

4.9 PREVENTIVE MAINTENANCE PROGRAMME ......................................... 20

4.10 LENGTH OF BRUSHES ............................................................................. 21

4.11 CHANGE OF BRUSHES AND BRUSH HOLDERS .................................... 22

4.11.1 PRELIMINARY CHECK ON BRUSHES AND BRUSH HOLDERS ...... 22

4.11.2 PUTTING NEW BRUSHES IN THE HOLDERS .................................. 22

4.11.3 CHANGE OF BRUSH HOLDERS........................................................ 22

4.12 MAJOR OVERHAUL WITH REMOVING THE ROTOR FROM THE STATOR

.................................................................................................................... 23

4.12.1 WORK STAGES.................................................................................. 23

4.13 TROUBLE SHOOTING CHECK LISTS ...................................................... 24

5 DRAWINGS AND ACCESSORIES.................................................................... 26

CG ELECTRIC SYSTEMS HUNGARY Zrt. TECHNICAL DATA

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1 TECHNICAL DATA

Type ......................................................................................... FTA 500 Fs4 Serial number ........................................................................... 451184 Mounting arrangement ............................................................. IM B3 Relevant standard .................................................................... IEC 34-1 Cooling method ........................................................................ IC 611 Protection of motor / slipring compartment............................... IP55 Protection of the terminal box................................................... IP55 Output ...................................................................................... 1130 kW Connection / number of terminals ........................................... Y/3

Rated voltage and its tolerance................................................ 6300 V 5 % Rated stator current.................................................................. 120 A

Frequency and its tolerance ..................................................... 60 Hz 2% Rated rotor voltage and current1010 V 680 A Power factor ............................................................................. 0.91 Efficiency.................................................................................. 94.9 % Rated torque............................................................................. 6050 Nm Maximum torque/rated torque .................................................. 2.6 Speed....................................................................................... 1785 rpm Sense of rotation ...................................................................... One (CW from DE) Max. vibration velocity .............................................................. 2,8 mm/sec Machine mass .......................................................................... 6950 kg Rotor mass ............................................................................... 2000 kg Rotor moment of inertia............................................................ 70 kgm

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Insulation class......................................................................... F Temperature rise ...................................................................... B=70 K Max. slot temperature............................................................... 125 C Max. bearing temperature ........................................................ 95 C Max. ambient temperature ....................................................... 50 C Stator heating........................................................................... 1 kW, 440 V, 60 Hz Slipring case heating ................................................................ 0,2 kW, 440 V, 60 Hz

CG ELECTRIC SYSTEMS HUNGARY Zrt. TECHNICAL DESCRIPTION

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2 BEARINGS

The machine is provided with grease lubricated antifriction bearings, located in the

shields. To prevent excessive lubrication the bearings are provided with a grease

control device. This device presses out the excessive grease -through the opening of

the external bearing cover -into a tank from where it can be removed at regular

intervals. Replenishment of the grease can be carried out by means of a ball greaser

with the aid of a lubricating press.

The lubricant is SHELL ALVANlA RL2 grease. The bearings on one side are fixed

while those of the other side are axially released to compensate for thermal dilatation.

2.1 TYPE AND LUBRICATION

Drive Side Drive Counter Side

Type of bearing 6230 M/C3

NU 230 EMC/C3 NU 230 EMC/C3

Regrease 0,12 kg / 550 WHR 0,06 kg / 550 WHR

Grease change 1 kg / 8700 WHR 1 kg / 8700 WHR

Type of grease Shell Alvania RL2

2.2 BEARING SHIELDS

Both the drive and the counter drive side bearing shields are steel structures.

Their fixation to the stator enclosure is ensured by bolts.


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3 TECHNICAL DESCRIPTION

3.1 STATOR

3.1.1 STATOR HOUSING

Its function is to hold the stator core and the winding, to protect the internal parts of

the machine against moisture, dust, penetration of foreign particles, and against

mechanical, thermical and other loads occurring in service.

Furthermore, this housing ensures support for other connecting parts, shield, cooler,

terminals, rotor, etc.

The stator housing is a welded construction.

Rigidity of the housing is ensured by the transversal main supports, the two end faces

and the longitudinal ribs holding together these formerly mentioned parts.

The cover is thin sheet. On the lower end of the housing a footplate can be found

with the holes of the fixing screws, threaded holes of the lifting bolts and taper holes

of the fitting studs on it.

The top of the housing is open, the cooler is connected here.

The shields are screwed on the fitting flanges of the end faces. The terminal

openings are on the two sides of the machine, in the middle. Below each of these

one respective earthing eye can be found. The auxiliary terminal box for RTD-s and

space heater is on the right side of the main terminal box.

3.1.2 STATOR CORE

The stator core is entirely laminated to minimize eddy current losses. Stator

laminations are made of insulated thin sheets of high-grade electrical steel. All stator

cores are manufactured as self-supporting components outside the motor frame. This

enables easy VPI treatment of the complete wound core. The core is fitted and

doweled to the frame.


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3.1.3 STATOR WINDING

MICASYSTEM, the Class F insulating system specially developed for stator windings

of AC motors and generators, is used for voltage ratings from 1200 to 15000 V.

This high-reliability, advanced insulating system is mainly based on the use of special

mica tapes and on the vacuum-pressure impregnation with a blend of solventless

epoxy resins. Due to the high mica content and the fully cured binder, the tape used

for ground insulation has exceptional dielectric strength. The VPI treatment improves

the dielectric properties of the insulating wall and helps to provide the thermal stability

necessary to satisfy the Class F requirements of the applicable Standards.

Due to the vacuum-pressure process, the resin fills all the voids in the insulation and

between the insulation and the stator core. This result in a significant improvement in

heat transfer between the winding and the core steel and prevents vibrations and

relative movements of the coils in the slots.

The coils are manufactured with rectangular copper wire, usually enameled and

covered with glass yarn or insulated with mica tape (selection based on machine

voltage and other functional parameters).

After winding the conductors in bobbin form, the design shape of the coils is obtained

by means of special forming machines. The ground insulation is applied by means of

programmable taping machines. The number of layers depends on motor rated

voltage. Armour tapes and corona suppressing materials are finally applied onto the

coils as required, depending on rated voltage.

Coils are then inserted into the stator slots and firmly held in place by means of glass

laminate wedges. After all connections between coils are completed, the coil ends

are tied together and braced by steel or polyester-fiberglass rings, using high-

resistance conformable materials.

After an oven drying process, the wound stators are impregnated under vacuum and

pressure. The number and duration of VPI cycle phases are selected on the basis of

the insulating wall thickness and the required degree of protection.

The impregnated stators are then cured in oven. During the oven treatment the

stators are rotated slowly by means of motor-driven rollers, to ensure a uniform

distribution of the resin within the insulation.


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MICASYSTEM, which was developed through long-term research work and extensive

testing, provides excellent dielectric and mechanical properties and all the other

physical characteristics needed for the specific applications. The main features are:

o outstanding mechanical strength, which allows the insulation to withstand the

stresses which can occur during motor transient operation;

o high resistance to long-term thermal overload and thermal cycling endurance

evaluation results meet Class F requirements with ample margins;

o outstanding resistance against moisture, tropical and marine environments,

common chemical contaminants and polluting agents;

o high surge voltage withstand capability;

o high resistance against radioactive radiation.

3.1.4 STATOR HEATING, SLIPRING SPACE HEATING

The electric properties of the winding insulation, the laminated core and the other

active structural elements are impaired by the humidity condensed on them in cold

environment.

Therefore, the machine is provided with anticondensation heating. The heaters are

located in the lower part of the stator case. The heating can be operated both

manually and automatically. Its function is to keep a certain temperature within the

machine being out of operation preventing the condensation of the humidity

without overheating the individual structural part of the machine. This heating is not

suitable for heating out the machine. No operating automatics are supplied with it.

3.1.5 LOCATION OF THE THERMOMETERS

The thermal protection of the machines is ensured by slot RTD-s built in between the

two coil sides. Thus, in each phase there are two Pt 100 Ohm RTD-s. Further 1 Pt

100 thermometers measures the temperature of each bearing.

Further thermometers and other instruments according to the Outline drawing and

Wiring scheme.


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3.2 ROTOR

3.2.1 SHAFT

The machine is manufactured with welded ribbed shafts. The shafts are made of

high-strength steel. There are longitudinal ribs and these are supported by

transversal ones. Before welding the shaft and the ribs should be checked for cracks

by ultrasonic tests and the quality of the seams should be checked by paint flowing

test.

3.2.2 LAMINATED ROTOR CORE

The rotor core is also fully laminated. The rotor consists of a stack of full-circle

laminations, which is shrunk onto the shaft.

The laminated core is manufactured in jig and it is pulled on the ribbed shaft in hot

state with overlapping. This shrinkage fit and a lock located in one of the

longitudinal ribs ensure perfect torque transmission.

3.2.3 ROTOR WINDING

Due to the half-closed slots the double-layer wavy type rotor winding is pushed-in.

The coils are fixed by plastic wedges. The insulation system complies with Class F

requirements. The coil ends are supported by the insulated coil holding rings.

The bars of the lower and upper layers of the winding are brazed together. Due to the

occurring centrifugal force the end windings are fixed with prestressed glass bandage

tape. The coil cross connections are formed on the counter drive side. The outlets

are connected to the pins of the sliprings by means of cross sections retained on the

shaft by glass bandage tape.

3.2.4 SLIPRINGS

The sliprings are made of steel. They are pulled on the insulated slipring hub in hot

state. The secure the position of the outlet pins the hub is prevented from swivelling

by means of a lock. The copper phase outlets are fixed with brazing.


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The outlet pins, between the rings are hermetically closed. The complete slipring unit

is impregnated in a vacuum oven.

After pulling onto the shaft, the surfaces of the sliprings are machined so as to ensure

coaxiality.

3.2.5 BALANCING, VIBRATION, OVERSPEED TEST

The finished rotor is dynamically balanced at rated speed without the coupling.

Rotors for keyed coupling are balanced with half-key inserted in the shaft extension.

After balancing the RMS value of the vibration velocity measured on bearings of the

machine corresponds to the grade "good" of VDI Standards. For 2 minutes the rotor

should be rotated at 1,2 times the rated speed.

3.3 TERMINALS

STATOR TERMINAL BOX

The main terminal box can be found on the stator casing. The main terminal box is of

welded steel on the aluminium terminal board on which there are the 3 main

terminals. Current buses are made of electrolytic copper. In the rear wall of the

terminal casing a lightened lobe is provided, which opens in case of incidental

exploding, thus protecting the staff and the terminals. The terminal lid is grounded to

the terminal casing and the terminal casing to the stator casing.

3.3.1 ROTOR TERMINALS

The rotor is similar to the stator terminal box.


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3.4 BRUSHGEAR

The brushgear is located in the slipring enclosure wich is connected to the stator

case at the counter drive side of the motor, and closed by the bearing shield at the

other end.

The brushgear is fixed onto the brush bridge. In the slipring enclosure the brush

bridges are retained by the brush holder pins. Insulated spacer rings are pulled on

the section of the pins falling between the brush bridges. The brushes are pressed

onto the surface of the sliprings by means of springs, the pressing force is:

(1.8 - 2)x104 N/m

2.

The metal content of the brushes is approximately 70%, the brushes are designed to

withstand a normal operation period of half year, depending on the environmental

circumstances, like:

o ambient temperature;

o relative humidity content;

o vibration level of the complete drive;

o changing of the load.

The optimum current density on the brushes RC 87 is cca 18 A/cm2 (~180 A/brush).

In case of longer underloaded periods (installation period, reduced production

capacity) the number of brushes should be reduced in order to provide the optimum

brush current load.

On the four sides of the brushes there is a groove, running along, ensuring that no

brush powder should jam in the brush holder.


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3.5 VENTILATION

3.5.1 INTERNAL VENTILATION CIRCUIT

The inner ventilation of the motor is two-sided radial one. The hot air flowing upwards

in the middle of the machine gets into the heat exchanger. Here-passing between the

pipes- it cools down then gets back into the motor at the ends of the enclosure. The

path of the airflow is ensured by deflecting and closing plates located in the cooler

box

3.5.2 AIR TO AIR HEAT EXCANGER

On the drive counter side of the shaft there is an outer fan. This fan absorbs cold air

through the grid cover of the fan enclosure. This cold air directed by deflecting plates

is forced back into the air space through the pipes of the cooler. These pipes run

parallel with the longitudinal axis of the machine and they are rolled in the walls-at the

end of the cooler- by flanging. The cooling tubes made of aluminum.

3.5.3 VENTILATION OF THE SLIPRING SPACE

The slipring space is separated from the motor inner space. Its ventilation is provided

by a small or separate fan.


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3.5.4 CHANGING THE DIRECTION OF THE ROTATION

Normally the machine is equipped a back-step blade ventilator, with clockwise or

counter clockwise direction of rotation.

If you want to change the direction of rotation:

1, Remove the 6 pcs M8 [1] screws and washers

2, Remove the mesh and the air baffle [2]

3, Remove the 8 pcs M10 screws[3] and washers

4, Remove the ventilator [3], turn it over and assembly again.

CG ELECTRIC SYSTEMS HUNGARY Zrt. OPERATING AND MAINTENANCE INSTRUCTIONS

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4 OPERATING AND MAINTENANCE INSTRUCTIONS

4.1 STORING, LIFTING

If, after delivery, the machine is not installed in its final place it can be expediently

stored in original factory packing. The temperature in the storeroom must not be

below +5 C and the atmosphere of the room must be dry, free of dust and chemical

vapours. The machine should be lifted by the lifting points formed on the stator

enclosure and the lifting should be free of jerks. If the manufacturer supplies a

separate lifting mechanism, it must be used. When selecting the proper lifting rope

the total weight indicated on the rating plate should be taken into consideration.

WARNING!

In case the motor is stored for a longer period place thin insulating plates

between the brushes and the slipring surface.

4.2 INSTALLATION

The architectural works have to be carried out as per the foundation drawing paying

special attention to the exact location of the fixing bolts. The requirement to start the

installation works is the proper machine foundation being true to size and loadable.

Before the works after alignment the beams should be carefully degreased because

the concrete will not set on a greasy or painted surface. After assigning the

centerline of the machine group with the aid of the spacers and wedges located on

the right and left sides of the fixing bolts the desired height level can be set as per

the drawing but close attention has to be paid to the dimensions of the driven unit.

It is very important that the base plate should not be distorted when tightening the

fixing bolts. Otherwise, the non-uniform positioning of the machine will result in

uneven running and vibration problems. When making the concrete structure great

care should be taken to avoid the existence of continuous voids because these are

liable to resonance. Prior to complete setting of the concrete it is strictly forbidden to


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load the base plate or to start the machine on it because owing to unavoidable

vibrations the concrete and the plate disjoin and this may result again in vibration

problems.

4.3 COUPLING TO THE DRIVEN MACHINE

The fine adjustment of the machine should be carried out by using the jacket on front

surface of the coupling halves. The accuracy is checked by dial gauge and a gap

gauge. If the manufacturer of the driven unit and the manufacturer of the coupling do

not give a stricter value, the accuracy of the adjustment of the half couplings may be

0.01-0.05 mm. The required corrections can be made by using insert plates.

Instructions for aligning couplings

The aim of the instructions given in the following is to attain proper alignment of the

shaft extension without angular or parallel mismatch.

This requirement can be fulfilled, as far as practically possible,by careful and

accurate workmanship. The alignment instructions are basically valid for all rigid and

flexible couplings and for all kinds of driven equipment. The manufacturers of the

machines to be coupled must advise by how much the shaft centre heights will

change under the influence of the operating and ambient temperatures. Based

on these values it must then be decided how much radial displacement is to be set

for the cold machine in order to have the ideal condition of zero misalignment at

those operating and ambient temperatures expected to be most predominant.

The relevant measurements require that the machine rotor can be turned.

In the case of vertical machines with plain bearings (Segmental thrust and guide

bearings) this can no longer be done manually above a certain machine size

because of the high bearing frictional torques involved. At the same time there is

also a danger that the bearing surfaces could be damaged by the slowly rotating

rotor. Therefore, all vertical plain bearing machines must be provided with a lifting

possibility at the top end of the shaft so that the rotor canbe suspended on the crane

or other lifting device. The kind of lifting possibility must be clarified before alignment

begins.

If for example, in the case of a vertical machine with plain bearings, more exact

values are required by the coupling


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manufacturer because of the coupling type, the radial clearance of the bearing can

be reduced to a minimum by the employment of a special centering tool. Even with

this reduced bearing clearance it must still be possible to turn the rotor. The

employment of the afore- mentioned centering tool for erecting such vertical

machines is described in a separate chapter.

If a horizontal machine with plain bearings has been at standstill for a longer

period of time, then the oil film between the bearing shells and the shaft will have

been pressed out by the weight of the rotor i.e. the bearings will be dry. Therefore,

before turning the rotor, approximately 100 ... 200 cm3 of oil must be manually fed

into each bearing. This can be done through the openings in the top of the bearing

housing. The oil should be poured in using a funnel. If the manufacturer has not

given details for setting radial displacement on the cold machine, then the rule is that

zero displacement should be set.

Alignment

The following must be observed when coupling two or more machines together:

The coupling halves must be exactly aligned to each other, following the

fundamental rule that the shaft train is to be exactly horizontal, or vertical for vertical

machines, at the main coupling location. The shafts being coupled must naturally be

exactly concentric to each other and the coupling end faces exactly parallel.


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4.4 ELECTRIC CONNECTION

When connecting up the HV cables care must be taken to follow the right sequence.

Have to reverse the sequence in case of counter clock wise (left) rotation direction.

WARNING!

The cooling fan must be rotated, if changing the

rotation direction of air-to-air cooled machines!

Inappropriate fan rotation direction cause overheating!

Connection to the heating and thermometer terminals should be made as per the

circuit diagram on the inner side of the cover. On both sides of the enclosure there is

one respective earthing eye for the purpose of earthing.


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4.5 PUTTING INTO OPERATION

In the course of the putting into operation the following checks and operations must

be carried out:

o Mechanical check. Mounting, alignment of coaxiality, checking of the rotor for

free motion with separated coupling.

o Checking of the electric connections. Checking of the correct phase sequence

of the HV cable connections and that of the thermometer terminals serving for

protection and indication purposes. The built-in thermometers should be

separately checked for breakage and body contact.

o Insulation resistance test. The stator winding can be considered dry if its

insulation resistance measured and evaluated as per IEEE 43 Standards is:

Rmin (Mom) = Urated (kV) + 1 at 40 C,

and the minimum polarisation index for Class F insulation is equal to 2, where the

polarisation index is:

R10 minutes / R1 minute

Machines provided with up-to-date insulation can comply with this requirement when

stored under proper circumstances. If the humidity in the machine deteriorates the

above value, heating out is required and it can be expediently carried out by the

machine's own winding at reduced voltage and at approximately 60% current

compared to the rated values. When checking the resistance continuously it can be

observed that at the beginning of the heating out the value of the resistance

decreases, then after reaching the minimum point it starts to increase again.

When the value calculated with the aid of the formula is reached, heating out can be

finished. In the case of heating out the phase coils with AC, their temperature must

not be checked by means of a mercury thermometer.

During heating out ventilation should be ensured so as to avoid overheating of

certain structural parts.

4.6 CHECKING OF THE BRUSH GEAR

Use 2-3 mm spacer to check the distance between the brush holder and the slipring.


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Check if the brushes and brush holder sliding part can move freely and easily.

Check the tightening of brush cable fixing screws.

Check the surface of the sliprings from the point of view of roughness and patina

layer.

Check the brushes edges that there is no chipping.

WARNING!

In case the motor is stored for more than two years, change the brushes,

because the cable tamping can be oxidised.

4.7 STARTING

The first starting must be carried out with disconnected coupling of the driving and

driven units. It is expedient to run the machine unloaded for approximately three

hours. If no irregularity is experienced, the linking of the coupling halves can be

performed.

At the first commissioning after a longer stoppage obviously the instructions of

Chapter Putting into operation should be followed.

4.8 MAINTENANCE

In addition to daily observation the overall condition and operation of the motors, it is

recommended that the machines be periodically and routinely checked for the

impending need of corrective maintenance.

A general maintenance program is given in the following table. Maintenance cycles

may be changed in relation to the specific customer experience.


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4.9 PREVENTIVE MAINTENANCE PROGRAMME

Periodicity Component Maintenance required

Weekly General Verify proper operation the motor, absence of evident

vibrations and noise, and overheating.

Brushgear Visual inspection of the slipring compartment through

the inspection cover in rotating state. Check the

insulated parts particulary the insulated bolts of

brushgear if they are clean.

Bearing Visual inspection Monthly

(On the base of

the operational

experiences of

the first period it

may be varied.)

Brushes: a.) Length a.) The wearing rate depends on the environmental

vibration and the speed, too). See figure Length of

brushes and chapter Change of brushes and brush

holders.

b.) Free motion in the

brush holder

b.) Check along the total length of the brushes.

c.) Cables c.) Integrity of insulating tubes, tightness of the

connecting screws.

Slipring and brush

structure insulators

Clean with electric detergent and dry.*

Slipring surface Check the patina (colour) of slipring running surface.

WARNING!

If the patina is damaged the following reasons can

initiate it.

- Captured brush in the brush holder and sparking

- Loose contacts

Find the reason and eliminate it.

Slipring compartment If the compartment and the brushgear are not clean

enough then clean them before the next start. Use

vacuum cleaner, textile and even solvent if needed.

* WARNING!

REPAIRING OF THE SLIPRING COMPARTMENT AND THE BRUSH HOLDER STRUCTURE

In case of any flash over in the slipring compartment, even if the slipring assembly seems to be

uninjured, disconnect the slipring electrically from the rotor winding, and a voltage test should be

performed with reduced / 80%/ test voltage.

The same test should be done on the brush structure insulators.


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Periodicity Component Maintenance required

Semi-annually Fixing Ensure that all fixing bolts are secured.

Terminal box Check conductors and clean the bushing insulators.

Ensure the connection terminals are tight.

Connections Check all electrical connections and ensure they are

tight.

Annually Cooler Cleaning of the internal surface of the tubes of the

coolers with proper pipe brush and of the external

surface with compressed air.

Every 2 years Windings: stator, rotor Measure the insulation resistance. See chapter 0

5 years Winding Blowing out with pure compressed air, clean and dry if

necessary.

Bearings See chapter Hiba! A hivatkozsi forrs nem tallhat.

Para 8.

4.10 LENGTH OF BRUSHES

Check the remaining length of brushes without removing them from the brush holder.

permitted distance 6mm

brush holder

brush

2-3mm slipring

WARNING!

Change the brushes when the remaining length of them decreases to 36mm.

Do not remove the brushes from the holder unless it is needed.


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4.11 CHANGE OF BRUSHES AND BRUSH HOLDERS

4.11.1 PRELIMINARY CHECK ON BRUSHES AND BRUSH HOLDERS

Check the brushes before changing.

o type of brushes ( they should be RC87)

o cross section of brushes:

dimensions, tolerance: 2,04,0

32

x 2,0

4,032

o see attached drawing

Check the brush holders before changing of the brushes in them

o check of cleanliness

o check if it moves well

o check the fixings

o check if the holder has loose or injured parts (spring, screw etc.)

If everything is OK. Leave as it is.

In other cases repair or change them. Before changing check the size of brush

holder dimensions (see the attached catalogue sheet).

4.11.2 PUTTING NEW BRUSHES IN THE HOLDERS

o Make the grinding and polishing of all the brushes

o Check the brushes then as follows:

If the running surface is min. 80 % then OK.

o Measure and record the length of brushes

o Make a map in order to identify the brushes

o Clean the slipring compartment as above mentioned

o Check the clearance between brush and brush holder (the right value is

0,2-0,25 mm on each side).

4.11.3 CHANGE OF BRUSH HOLDERS

Do not modify the adjustment of holders even do not change them only in case of

necessity (failure, damage, loosening etc.)

o Use 2 - 3 mm spacer to set the distance between the holder and the slipring.


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o Check the radiality visually. 2 - 3 difference can be recognised by visual

inspection. The setting by visual observation is sufficient.

o Check followings: fixing, proper moving.

4.12 MAJOR OVERHAUL WITH REMOVING THE

ROTOR FROM THE STATOR

When the overhaul includes disassembly of the machine for this purpose a proper

assembly room or at least a covered assembly place should be ensured. Its

atmosphere must be free of acid vapours, corrosive gases and dust and its relative

humidity must not exceed 60% while its temperature must not be below 10 C. The

assembly space should be clean and free of cuttings.

4.12.1 WORK STAGES

o Disconnection of the terminal leads mains supply cable, earthing and

thermometer terminals. Common marking of the terminals and connecting wire so

as to facilitate correct connecting up.

o Disconnection of the coupling.

o Removal of the base plate fixing bolts and taper pins.

o Taking the machine into the mounting space paying regard to the instructions for

lifting.

o Dismantling of the and shields and slide bearings, if applied , removal of the rotor

as per the assembly drawing.

o The following have to be checked:

clamping of the stator end windings

tightness of the slot closing wedges

mechanical state of the brush holders.

o Cleaning of the cooler is proposed only with mechanical method (pipe-brush).

See Installation, Operation and Maintenance Instruction.

o After checking and cleaning, the assembly of the machine is carried out obviously

in reversed sequence. Both on disassembling and on assembling care must be

taken to avoid damaging the matching surfaces.


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o After major overhaul, upon putting into operation the instructions of Putting into

operation should be followed.

4.13 TROUBLE SHOOTING CHECK LISTS

o If some operating difficulties occur, first of all make sure that:

o the rated voltage be actually present on the three stator phases;

o the supply voltage and frequency be consistent with the rated voltage and

frequency

o the protective devices be well-operating:

o the machine be not too overloaded (by comparing the absorbed current with the

specification one ).

Trouble Possible trouble Corrective action

1. Motor vibrations 1.a Misalignment with the coupled

machine.

1.a Verify and provide to align the

machine.

1.b Unbalanced or settled

foundation, lose hold-down

bolts, uneven air gap

alignment.

1.b Verify and provide as

required.

1.c Wear bearings. 1.c Replace the bearing shell.

2. Motor at no-load, does

not start up (without

noise)

2.a Two phases of the power

supply line interrupted.

2.a Verify and restore the

interrupted phases.

2. 2.b Power supply line without

voltage.

2.b Verify and provide to cut-on

power supply line.

3. Motor at no load does

not start up (with

magnetic noise)

3 One phase interrupted. The

motor can turn in no-load on

both directions in single phase.

3. Verify and restore the

interrupted phase.


25

4. Motor under load does

not start up (normal

magnetic noise)

4.a Supply line voltage too low. 4.a Check that the supply voltage

is in compliance with the

tolerance values.

4.b Resistant torque too high, as

consequence of locking of the

coupled machine or of the

rotor.

4.b Disconnect the motor from

the driven machine, check

and remove the lock.

5. 5.a A phase is fell down after the

start.

5.a Verify and restore the

interrupted phase.

Motor starts at no load

but it produce low toque

when under load. The

stator current oscillates.

5.b One rotor phase is interrupted. 5.b Verify, repair or replace the

rotor.

6. Motor, at no-load heats. 6.a Wrong connections between

stator winding and supply line

(i.e. delta instead of star

connect.).

6.a Verify the compliance with the

connection data detailed.

6. 6.b Supply line voltage too high. 6.b Verify that supply line voltage

is in compliance with the

tolerance values

6.c Improper or restricted

ventilation, obstructed air

passages.

6.c Check air passage for

obstruction. Remove

obstruction.

7. Motor under load heats

too much.

7.a Motor runs only in single phase

(supply line interrupted).

7.a Check the supply line and

provide to restore the

interrupted phases.

7.b Supply line voltage too high or

low.

7.b Verify that supply line values

are in compliance with

specifications.

8. 8.a Short circuit in the stator

winding.

8.a Verify and replace the stator

winding.

Local heat on the motor

with: noise, smoke,

spark, or flames. 8.b The rotor rubs on the stator

during running, causing sparks

in the air gap.

8.b Check the air gap and

eventually replace the

bearing shells.

9. Motor runs with

abnormal noise.

9.a Irregular air gap. 9.a Check the air gap and

eventually replace the

bearings.

9. 9.b Not correct coupling. 9.b Check the coupling of the

driven machine and provide

as consequence.

10. Abnormal bearing

temperature.

10.a Axial thrust too high. 10.a Verify operation of the driven

machine.

10.b External shocks. 10.b Verify and eliminate the

external cause.

10.c Poor bearing lubrication or

damaged bearing.

10.c Check lubrication system or

replace the bearing shell.

10.d Direct external heat radiation

towards the bearing, by driven

machine, sunray.

10.d Verify and use shadowing

screen.

CG ELECTRIC SYSTEMS HUNGARY Zrt. ANNEX

26

5 DRAWINGS AND ACCESSORIES

Outline drawings..........................................................................................1033288G

Instrumentation and wiring .......................................................................... 1033351C

Main terminal box assembly...........................................................................1043180

Rotor terminal box assembly..........................................................................1043170

Auxiliary terminal box .....................................................................................1033499

Heater terminal box ......................................................................................1108185F

Drive side bearing assembly ..........................................................................1110302

Drive counter side bearing assembly .............................................................1110306

Installation, operation and Maintenance Instruction for VC1100 C11

Datasheet for VS-069 vibration sensor

CG Electric Systems Hungary Co. Ltd. H-1095 Budapest Mrissy street 7. Registration Nr.: 01-10-044689 T:+36-1-483-6600 www.cgglobal.com

FTA 500Fs4 Manual.pdf

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Transcript of FTA 500Fs4 Manual.pdf