GE NEMA Premium Efficient XsD Ultra Installation and Maintenance Manual
Contents
1. END SHIELO BOLTS SHIELD 3 DRAIN PLUG 4 SHAFT SEAL plici 27 5 SHAFT B 6 KEY 1 SLEEVE BEARING 5 BEARING BOLT 9 SENSOR MOUNTING BRACKET 10 MACHINE SEAL STATOR WINDING COIL BRACING 4 BALANCING ROTOR WINDING 15 ROTOR PUNCHING 16 EL PIN DOWEL 11 STATOR FRAME 18 MACHINE SEAL 9 FAK COVER 20 END SHIELD FAM COVER BOLITS 22 FAN COVER ACCESS BOLT 23 FAN 24 GRILL 25 SLEEVE BEARING 26 SHAFT SEAL 21 CONDUIT BOX 28 FAK SCREW 29 SENSOR MOUNTING BRACKET 30 FAK STOP WASHER 31 CUSTOMER DOWEL PIN 32 FRAME GROUNDING BOLT 33 CUSTOMER MOUNTING BOLTS 18 Xl Lubrication Guide Excerpt from 72836 Table 5 Motor Lubrication Guide GEI 56128H Type of HP Lubrication Interval Vrs Service Typical Examples Range Horizontal Vertical Easy Valves door openers portable floor 1 7 5 10 9 sanders motor operating 10 40 7 3 infrequently one hour per day 50 150 4 1 5 200 350 3 9 months 400 1000 T Standard Machine tools air conditioning 1 7 5 7 3 apparatus conveyors one or two 10 40 4 1 shafts garage compressors 50 150 1 5 6 months refrigeration machinery laundry 200 350 1 3 months machinery oil well pumps water 400 1000 6 months pumps woodworking machinery Severe Motor for fans MG sets etc that 1 7 5 4 1 5 run 24 hour2. GEI 56128H Typical 210 to 440 Frame Dripproof Construction GEI 56128H uonongjsuo 2331 Opt 01 jeoid 39 5NINV38 12 300 5NI3V38 702 33A03 X08 LINGNOD 61 14579 81 AQ08 XO8 LINGNOD ZI XO8 dWvid 1355 9 9I 30 ST 30 4V2 vI A33 LAVHS 1345 ZI SNOILVNINV YOLOY SNTY 40104 OT SNOIIVNIWV YOLVIS 6 861102 01 15 3WVH3 401 16 300 4 2 8 YSHSVM 45 300 QT3IHSQN3 SNILISVO eC st 17 GEI 56128H Typical 500 Frame TEFC Construction Ball Bearing End shield Aglis 2 Reducer Bushing 3 Drain Plug 4 Grease Fitting 21 5 Shaft 6 Key T Anti Frictiog Bearing 8 Bearing Bolt 9 End Shield 10 Bearing Cap Il Stator Windida 12 Coil Bracing 7 13 Balancing 14 Rotor Windin 9 15 Rotor Punchi 16 Dowel Pin 17 Stator Frame 18 Bearing Cap 19 Fan Cover 20 End shield 21 Fon Cover Bolts m N 22 Fan Cover Bolt SSF a d Anti Friction Bearin H 26 Button 5 1 Conduit Box 28 Fan Screw 29 External Sligger 30 External Sligger 31 Stop Washer 32 Frame Ground ng Bolt 33 Customer Mounting Bolts 34 Customer Dowd Pin 24
3. Screw Bolt Size Typical Application Sm 10 Low Carbon Steel Bearing Cap 15 25 17 28 1 4 in Low Carbon Steel Bearing Cap 35 60 4 0 6 8 1 A in All Parts 70 96 79 108 1 4 in Grade 8 Fan Cover Mounting 100 145 11 16 5 16 in Bearing Cap 78 120 88 14 5 16 in All Parts except Bearing Cap 170 250 19 28 3 8 Low Carbon Steel Conduit Box Cover 180 240 20 27 3 8 in All Parts Box 250 370 28 42 1 2 in All Parts 610 920 70 100 3 4 in All Parts 2150 3200 240 360 Table 4B Tightening Torque Range Stainless Steel SAE Hardware Property Class 50 Screw Bolt Size Typical Application Torque Inch Ibs N m 10 Bearing Cap 15 25 17 28 1 4 in Bearing Cap 35 60 4 0 6 8 1 4 in All parts except Bearing Cap 60 75 6 8 8 5 5 16 in Bearing Cap 78 120 88 14 5 16in All parts except Bearing Cap 130 155 15 18 3 8 in All Parts 230 275 26 31 1 2 All Parts 550 670 62 76 5 8 in All parts 1100 1340 120 150 3 4 All Parts 2000 2560 250 270 15 QOLuOruunzz 2 1 Hh Ld Ruin oo ere ZU AE E E OO eC unun un oco MANO SLALOM oo 16 SHAFT 10 SHAFT KEY 9 11 BEARING DE 12 ENDSHIELD DE 13 GASKET FRAME BOX 14 CONDUIT BOX BODY GASKET 15 16 CONDUIT
4. WARNING Be sure the motor is not running and the power supply is disconnected 1 For sleeve bearing motors flush out all sleeve bearings with kerosene to remove any dust or grit which may have accumulated during storage Make sure that the oil plugs are tight and fill the oil wells with the oil recommended in the Maintenance section under Sleeve Bearings of this book to center GEI 56128H of the oil level sight gauges The oil level should be checked only when the machine is not running Do not flush out anti friction bearings The bearing grease supplied is sufficient for initial operation 2 Whenever possible examine the interior of the motor for loose objects or debris which may have accumulated and remove any foreign material 3 f possible turn the rotor by hand to be sure that it rotates freely 4 Check connections with the connection diagram Check all accessible factory made connections for tightness to make sure none has become loose during shipment 5 When the driven load is likely to be damaged by the wrong direction of rotation it is best to uncouple the motor from its load during the initial start and make certain it rotates in the correct direction If it is necessary to change rotation interchange any two line leads Some motors are designed for unidirectional rotation Rotation of these motors must be in accordance with the rotation indicated on the motor s nameplate and
5. sue LER 9 C Jogging and Repeated ki pd hn p hk ERN 10 Mic PMAINtENAN CE nsa 10 Ie ha Leu DM 10 ROO 10 C Division 1 Explosion Proof 10 D Insulation and VV IVT TA CIS tos damen MS teu 10 E Vacuum and Compressed Air Cleaning sectam pap ated Baba decl maar IR 10 Cleaning with Water and 11 G Anti Friction Bearings and Lubrication noi tiia ri ay Rain liti p 11 H Sleeve EOS dt 12 Vi Operational dent torium et 13 EEE EEES 14 RE aT oh oe URS en ntu eo 14 Renewal Par Senn Tae T 15 Tightening Torque for SAE HardWare sts ueste idet tereti 15 Al ERU SUN 19 GEI 56128H GENERAL INFORMATION A Howto Properly Use this Instruction Manual This installation and maintenance manual has been written to assist the user with proper procedures when handling installing operating and maintaining the equipment All of the safety warnings
6. C Extended Storage Longer than 6 months In the event the motor is to be stored longer than six months please refer to GE instruction manual GEK 97427 D Handling WARNING Lifting lugs on the motor are designed for handling only the motor They are not to be used to lift the motor plus additional equipment such pumps compressors or other driven equipment In the case of assemblies on a common base lugs or eyebolts provided on the motor are not to be used to lift the assembly and base The assembly should be lifted by a sling around the base or by other lifting means provided on the base In the case of unbalanced loads such as couplings or other attachments additional slings or other effective means should be used to prevent tipping Il INSTALLATION WARNING Installation should be in accordance the USA National Electric Code or BS EN 60204 1 and BS EN 60204 11 and consistent with sound National and local practices Coupling belt and chain guards should be installed as needed to protect against accidental contact with moving parts Motors accessible to personnel should be further guarded by screening guard rails etc to prevent them from coming in contact with the equipment A Location Install the motor in a well ventilated area Make sure there is a minimum clearance of one foot around the motor to allow normal flow of air 1 Dripproof
7. 002 Angular misalignment should be less than 0 002 4 The application of pulleys sheaves sprockets and gears on the motor s shaft is shown in NEMA Standard MG1 14 07 The application of the V belts dimensions for alternating current motors is in MG1 14 42 V belt sheave pitch diameters should not be less than the values shown in Table 14 1 of NEMA MG 1 Sheave ratios greater than 5 1 and center to center distances less than the diameter of the large sheave should be referred to the Company certain that the minimum allowed diameter of the motor pulley and the maximum belt tension are not exceed because an excessive pull may cause bearing trouble and shaft failures Tighten belts only enough to prevent slippage Belt speeds should not exceed 5000 feet per minute 25 meters per second When V belts GEI 56128H are used sheave ratios greater than 5 1 and center to center distances less than the large sheave shall not be used The dimensions of the belt pulley are to be determined according to the kind of belt transmission and capacity to be transmitted Vent holes have to be kept free and required minimum distances are to be observed in order not to obstruct the flow of cooling air In addition make sure that the discharged hot air is not re circulated into the motor C Sleeve Bearing Endplay On sleeve bearing motors the feet should be located at a correct distance from the load so that the motor s rotor is in the
8. Data Pack for the motor or through EliteNet or by contacting your local GE Energy representative F Relevant Standards Motors shipped with this installation instruction have been designed and built to the following standards to the latest revision NEMA MG 1 Motors that have the IECEx designation have also been designed to meet the requirements of the following standards GEI 56128H IEC and or BS EN 60079 0 IEC and or BS EN 60079 15 RECEIVING Each shipment should be carefully inspected upon arrival Motor rating and identification data are furnished on a packing label for verification purposes Any damage should be reported promptly to the carrier and a claim filed The nearest GE Energy sales office may provide additional guidance A Unpacking If the motor has been exposed to low temperatures unpack it only after it has reached the temperature of the room in which it will be unpacked Otherwise the motor windings will be exposed to condensing moisture B Temporary Storage Up to 6 Months If the motor will not be put into service immediately certain precautions should be taken to protect the motor while in storage It is recommended the motor be placed under cover in a clean dry location During storage windings should be protected from excessive moisture by some safe and reliable method of heating such as space heaters to keep the temperature of windings above the temperature of the surrounding
9. and instructions in this book must be followed to prevent injury to personnel This manual must be kept for future reference during installation operation and maintenance B Safe Motor Operation Information WARNINGS High voltage and rotating parts can cause serious or fatal injuries Qualified personnel should perform installation operation and maintenance of electrical machinery For equipment covered by this instruction book it is important to observe safety precautions to personne from possible injury Be sure to keep the installation and maintenance information for future reference All warnings and cautions must be followed Installation Avoid contact with energized circuits and rotating parts Avoid bypassing or rendering inoperative any safeguards or protective devices e Avoid use of automatic reset thermal protection where unexpected starting of equipment might hazardous to personnel Avoid contact with capacitors until safe discharge procedures have been followed Be sure the motor shaft key is captive before the motor is energized Avoid long exposure in close proximity to machinery with high noise levels e When the motor is coupled to equipment ensure that system vibrations are within acceptable limit per ISO 10816 1 to avoid failure of the motor Use proper protective gear care and procedures when handling lifting installing operating and maintaining the motor e I
10. motors are intended to be used in a well ventilated place reasonably free of dirt and moisture GEI 56128H 2 General Purpose enclosed motors can be used where they are exposed to dirt moisture and most outdoor conditions 3 Severe duty enclosed motors can be used in highly corrosive or excessively moist areas 4 Zone 2 Hazardous Locations All motors marked with an IECEx or ATEX designation are suitable for Zone 2 locations Before the motor is install in the hazardous location the marking must be reviewed for the intended location If the motor marking does not meet the intent of the location do not install or operate the motor Refer to BS EN 60079 0 and BS EN 60079 15 Motor marking for IECEx will have a nameplate with the IECEx logo IECEx certification number and marking codes An example of the IEC Ex marking is as follows Ex nA IIC T3 Gc Where symbol Ex provides assurance of protection per IEC standards b nA indicates non sparking is a code to indicate the type of explosive gas atmosphere T3 is a code for the maximum surface temperature Gc is a code for the motor protection level d e Refer to B EN 60079 0 and BS EN 60079 15 for the meaning and understanding of all symbols and codes 5 Division 1 Explosion proof motors bearing the Underwriters Laboratories label designating the motor s Class and Group as defined in the National Electrical Code NEC are designe
11. to the equipment It is recommended that a washer be used under each nut or bolt head to get a secure hold on the motor feet As an alternative flanged nuts or bolts may be used The recommended tightening torques for medium carbon steel mounting bolts SAE Grade 5 are listed below in Table 1 For recommended tightening torques of other hardware on the motor see tables 4A and 4B in the Tightening Torque section of this book Table 1 Recommended Torque Bolt Size in Ft Lb N M Inch Metric Minimum Maximum 1 4 M6 7 9 11 15 5 6 M8 14 19 21 28 3 8 M10 25 34 37 50 1 2 M12 60 81 90 122 5 8 M16 120 163 180 244 3 4 M20 210 285 320 433 Note For low carbon steel bolts use 5096 of the above recommended tightening torques There are no ID marks on low carbon steel bolts 4 For direct coupled applications use flexible couplings if possible Accurate mechanical lineup is essential for successful operation Mechanical vibration and roughness in running the motor may be an indication of poor alignment In general lineup by straight edge across and feeler gauges between coupling halves is not sufficiently accurate It is recommended that the lineup be checked with a dial indictor and checking bars connected to the motor and load machine shafts The space between coupling hubs should be maintained as recommended the coupling manufacturer Shaft offset should not exceed 0
12. 19 03 S Long 02 3231 Revised to remove references to vertical oil lubed motors 06 22 10 M Bruin 10 0443 Added Quantum 315 and 20
13. GE Energy GEI 56128H NEMA 140 to 500 Frame Horizontal AC Small Industrial Motors Motor Installation And Maintenance Instructions imagination at work GEI 56128H Table of Contents OI bunte 3 A How to Properly Use this Instruction OREDONAS ou o t nt 3 Safe Motor ODSratomdntoreg HOP tud tetas 3 C LI M UM MM 4 D Description of Labels and Nameplates 1 1 essent 5 E Moderand NUT Dress aatia edat ote oie podere 5 Relevan pd ea totiens retta vtto rro 5 IRGC ANIC 5 AA UNPOCKINO A eeu M MM M M EM ME 5 B Temporary STOLA nnn EO 5 Stord Lene eee aren een nr ee E E E 6 WM foie Eo TRE a a a 6 IS no aon 6 6 MOUNN eE EREE O 6 C Sleeve Bearing e vtero etie oett rebat rat SUA 8 D Power Supply and COnnectionS dad qa a aaa pP es 8 IL eno I cence eae a eee ER Quat talcm md 9 Steps Prior to SCIEN TC nat TNR NE e br 9
14. able precautions observed Recommended tightening torques for various parts is listed in Tables 4A and 5B below WARNING When burning off old JAN insulation materials or when S welding near insulation during rewinding adequate ventilation must be provided to avoid exposing personnel to noxious fumes Combustion of exhaust must be complete and adequately vented to the outside atmosphere in compliance with acceptable standards Exposure of personnel to air borne inorganic fibers must be avoided by adequate ventilation or by wetting the remaining insulation components following the burning of the organic materials IX RENEWAL PARTS The use of only GE Energy renewal parts is recommended When ordering specify model number and the serial number of motor complete nameplate data is desirable Specify quantity and describe the part For information and service refer to the nearest GE Energy Sales Office or a GE Energy Authorized Service Shop X TIGHTENING TORQUE FOR SAE HARDWARE General Notes related to fasteners 1 Medium carbon steel fasteners per ASTM A449 Type 1 2 Stainless steel fasteners per ASTM F593 3 Threaded holes in parts for fasteners are per System 21 ASME ANSI 1 3 Table 4A Tightening Torque Range Medium Carbon Steel SAE Hardware Grade 5 Unless specified in below table GEI 56128H
15. ad or electrical failure may result in 4 heating or arcing which can cause the insulation to give off noxious fumes All power should be removed from the motor circuit as a precaution even though the circuit has overload protection Personnel should not approach the motor until adequate ventilation of the area has purged the air of fumes When covers of a motor are removed after a failure care should be observed to avoid breathing fumes from inside the motor Preferably time should be allowed for the motor to cool before attempting any examination or repair WARNING Water should not be applied to any electrically energized 4 equipment because electric shock could result in serious or fatal injury In case of fire disconnect all power and use a carbon dioxide extinguisher to quench the flame Before operating any motor after a suspected failure it should be inspected for damage VIII REPAIR If a motor is marked with IECEx or ATEX designation and repairs are required the motor must be repaired by operators trained in the understanding of BS EN 60079 1 and BS EN 60079 15 standards The motor has been designed to meet the rigid requirements of these standards Repair or alteration of the motor may 14 GEI 56128H result in the motor no longer meeting the requirements of these standards If major repairs are undertaken such as rewinding a stator proper facilities should be made available and suit
16. air It is recommended the motor in storage be inspected at periodic intervals the windings meggered and a log kept of pertinent data Refer to the OPERATION section Any significant drop in insulation resistance should be investigated Precautions are taken by the factory to guard against corrosion The machined parts are coated to prevent rust during shipment If the equipment is to be stored examine the machined parts carefully for rust and moisture and recoat where necessary Motors with oil lubricated or oil mist lubricated bearings are normally operated and tested in the factory with a rust inhibiting oil in the lubrication system rust inhibiting film remains on critical bearing surfaces during transit and for up to six months in storage However when the machine is received it is recommended that the bearing oil reservoirs on sleeve bearing motors be filled to the proper oil level with a good grade of rust inhibiting oil Rotate the shaft of two bearing machines 10 to 25 revolutions until the journals are thoroughly coated with oil The bearings of grease lubricated motors are greased at the factory with the grease cavity approximately 50 full Rotate the shaft of all grease lubricated motors 10 20 revolutions at two month intervals If the purchaser has specified the machine be packaged for long term storage the foregoing recommendations do not apply and the packing should be left intact during the period of storage
17. approximate mid point of its endplay The mid position of the rotor s endplay is indicated with a mark on the motor s shaft Locate this mark flush with the bearing housing D Power Supply and Connections 1 Nameplate voltage and frequency should agree with the power supply Motors will operate satisfactorily on line voltage within 10 of the nameplate value or frequency within 5 combined variation not to exceed 1096 2 Dual voltage motors can be connected for the desired voltage using instructions on the nameplate or the connection diagram 3 Wiring of motor control overload protection and grounding should meet the National and Local codes 4 When mounting conditions permit the conduit box may be rotated so that the conduit entrance can be made upward downward or from either side For oversize conduit boxes the mounting height of the motor may have to be increased for accessibility WARNING Motor and control JAN overload protection and grounding should be in accordance with the USA National Electric Code or BS EN 60204 1 and or BS EN 60204 11 and consistent with sound local practices IV OPERATION A Steps Prior to Starting WARNING Ifthe motor has been in a damp location it thoroughly before operating Before energizing the motor for the first time or after an extended shut down it is advisable to check the insulation resistance power supply a
18. assembly the lubricating ability of a grease over time depends primarily on the type of grease the size of the bearing the speed at which the bearing rotates and the severity of operating conditions As a result it is not possible to accurately predetermine when new grease must be added But good results can be obtained if the general recommendations stated in this manual are followed The primary function of grease is to supply the essential lubrication oil from the sponge like reservoir of its soap structure Grease lubricated anti friction bearings consume only a small amount of lubricant This lubricant must always be present to avoid rapid wear and bearing failure However excessive or too frequent lubrication may also damage the motor Ball bearing motors are adequately lubricated at the factory Motors with grease fittings should lubricated in accordance with these instructions to provide maximum bearing life To obtain optimum results Mobil Polyrex General Electric Specification D6A2C23 polyurea grease should be used for lubrication unless special grease is specified on the motor s nameplate See Section Lubrication Guide for greasing frequency and recommended quantity of grease If in doubt refer to GE Energy 11 GEI 56128H CAUTION Failure to use polyurea base NLGI Grade 2 or known compatible grease could result in premature bearing failure The proc
19. be used E Vacuum and Compressed Air Cleaning Compressed air should be used to remove loose dirt and dust from air passages such as air ducts Suction should be used to remove dirt from the windings and to avoid damaging the coils CAUTION Care must be taken to make sure the air is dry and that air pressure of not more than 21 x 105kg m 30 psi WARNING Operator must not use compressed air to remove dirt or dust from his person or clothing F Cleaning with Water and Detergent This method is very effective in cleaning windings when used with a low pressure steam jenny maximum steam flow 30 psi and 90 CAUTION To minimize possible damage to varnish and insulation a fairly neutral non conductive type of detergent such as DuBois Flow should be used A pint of detergent to 76 liters 20 gallons of water is recommended If a steam jenny is not available the cleaning solution may be applied with warm water by a spray gun After the cleaning operation the windings should be rinsed with water or low pressure steam Dry the windings Refer to the Insulation Resistance section in IV above for instructions on how to proceed G Anti Friction Bearings and Lubrication The grease used as a lubricant in grease lubricated anti friction bearings does not lose its lubricating ability suddenly but over a period of time For a given bearing construction and
20. d For RENK bearings remove the cover plate that is bolted to the upper half of the bearing housing and endshield The name Zollern or RENK will be embossed in the bearing housing 3 Remove the four socket head screws that secure the top half of the bearing housing to the bottom half 4 Remove the upper half of the bearing housing 5 Remove the four socket head screws on the bearing 6 Remove the upper half of the bearing 7 Jack up the shaft a few mils to remove the weight of the rotor from the lower bearing surface 8 Remove the split line screws from the oil ring and remove the split parts 9 Rotate the lower half bearing around the shaft and remove b Cleanliness is important when working with bearings Before reassembling a bearing all bearing and machine surfaces should be thoroughly cleaned with a suitable solvent Examine all machined fits for burrs Remove all oil sealing compound from sealing surfaces Prior to actual reassembly the following precautions should be observed 1 Inspect the bearing housing and related parts for foreign matter Clean if necessary 2 Inspect the journals and polish them with crocus clothe if any scratches are detected Do not allow any metal dust to fall into the housing when polishing the journals 3 Spread a thin coat of oil over the journal and bearing surfaces before reassembling VI OPERATIONAL DIFFICULTIES GEI 56128H 4 The sealing sur
21. d for operation in areas classified by local authorities as hazardous in accordance with the NEC B Mounting 1 Mount motors securely on a firm flat base Grout in larger motors if necessary Grease lubricated motors can be wall or ceiling mounted with the shaft horizontal Grease lubricated motors in NEMA 140 320 frame ratings can be wall mounted with the shaft vertical The standard transition and or sliding bases are only suitable for floor mounting For other mounting positions please refer to your local GE representative Oil lubricated sleeving bearing motors shall always be mounted with the shaft horizontal The endshield shall be located with the oil ring sight gage in the twelve o clock position GEI 56128H WARNING Remove drain plugs from the 2 On motors with dual mounting holes frame or end shields of enclosed motors use the holes indicated per Figure 2A and 2B used outdoors or in other high moisture areas Use these mounting holes for frames 143 182 213 254 lt gt Use these mounting holes for frames 145 184 215 256 1 286 326 365 405 445 449 1 1 1 284 324 364 404 444 447 1 1 LI Figure 2A Mounting 5010 509 5011 5013 Figure 28 Mounting 7 3 For base assembly motor mounting the mounting bolts must be tightened to prevent changes in alignment and possible damage
22. damage to equipment bearings and grease must be kept free of dirt Since this method of greasing bearings tends to purge the housing of used grease over a period of time removal of all grease should be required infrequently A GE Energy Authorized Service Shop can clean the bearing cavity and replace the bearings and grease when the motor is removed from service for maintenance or reconditioning NOTE Warranty may be voided if internal maintenance or repairs are not performed by a GE Energy Authorized Service Shop 4 Sleeve Bearings Motors with sleeve bearings have a removable top half bearing housing cover By removing this cover each bearing and the oil in the reservoir can be inspected without disturbing the line up Prior to operation of the motor both oil reservoirs should be filled to the center of the oil level gage The oil should be maintained at this level determined with the motor at stand still Oil is added through the oil sight gauge hole above each bearing or through the inlet pipe provided 1 Oil For motors operating between 10 C and 50 C use a good grade of mineral oil having a viscosity of ISO 32 Consult GE Energy sales office regarding special lubricants for unusual operating conditions 2 Cleaning Sleeve Bearings Sleeve bearings housings are provided with liberal settling chambers into which dust dirt and oil sludge collect The only cleaning necessary is to r
23. edure below must be followed for safe and effective re greasing The recommended frequency and quantity of grease is stated in tables 5 and 6 WARNING Lubrication maintenance should be performed with the motor stationary and disconnected from the power source Extreme caution must be exercised to avoid contact with rotating parts or electrical wiring if the motor must be lubricated while running Failure to observe these precautions may result in damage to the equipment injury to personnel or both 1 Run the motor until warm 2 Stop the motor and disconnect it from the power supply 3 Clean dirt and debris from around the inlet lubrication fitting and the grease relief plug 4 Remove the relief plug and clean the opening and relief tube of hardened grease This may be accomplished with a twisted wire brush or sturdy pipe cleaner 5 Insert brush into the relief hole While the motor is still warm add grease with a hand operated grease gun until fresh grease appears on the end of the brush or until grease has been added up to the amount listed in Table 6 6 Leave the relief plug temporarily off Start the motor and run for 10 to 20 minutes to expel any excess grease 7 Stopthe motor Replace the relief plug 8 Restart the and operation motor resume CAUTION Failure to observe the foregoing instructions for regreasing may result in grease leakage and or bearing damage To avoid
24. electric shock in case of a fault The use of a small case i enclosed in a square indicates a general note Indicates a procedure or condition that if not strictly observed could result in personal injuries or death Indicates a procedure or condition that if not strictly observed could result in minor injuries to personnel This symbol indicates the need to wear hearing protection D Description of Labels and Nameplates Motor rating and identification data are furnished on labels and nameplates Packing nameplates provide a permanent record of motor characteristics plant identification and date of manufacture Below is an example of a label that is attached to the shipping package 9262 02 MOD 5KS184SAA305D KW 1 5 RPM 1170 VOL 230 460 e ENCL TEFC FR 184T MASS 45 8 KG SERIAL EDFT148U02 S O 9262 02 Figure 1 Packing Label MOD GE model number KW Motor power rating RPM Motor speed at full load VOL Motor voltage ENCL Enclosure code FR Frame size MASS Motor mass SERIAL Motor serial number E Model and Serial Numbers As discussed in section D every motor that is manufactured by GE Energy has a model and serial number which are permanently marked on the motor nameplate When contacting a GE Energy Service Shop or representative please provide to the model and serial numbers Data and information regarding an individual motor model can be obtained from the
25. emove the drain plug from beneath the oil level indicator or bearing housing as the case may be After draining seal the threads of the drain plug with an oil sealing compound and refill the oil reservoir Whenever the motor is disassembled for general cleaning the bearing housing may be washed out with a suitable solvent In washing the bearing housing the bearing and bearing housing assembly should be disassembled only to the extent that is absolutely necessary Dry the bearing lining and shaft with a film of oil before reassembling 3 Sleeve Bearing Replacement Extreme care is required the disassembly of a bearing to prevent nicking or burring of the bearing or machined surfaces In addition the surfaces of the journal and the bearing must be protected from damage when exposed during the process of disassembly 12 GEI 56128H Remove all bearing sensors prior to disassembly of the bearing The drive end and opposite drive end sleeve bearing may be replaced by the following procedure 1 For the opposite drive end the fan cover must be removed first Use the lifting eye on the fan cover to support and move the fan cover during disassembly There are 5 socket head cap screws that secure the fan cover These must be removed 2 For Zollern bearings remove the three socket head cap screws on the outer flange of the upper half of the bearing housing which secure it to the endshiel
26. f eyebolts are used for lifting motors they must be securely tightened and the direction of the lift must not exceed a 15 angle from the shank of the eyebolt Do not use eyebolts in an ambient below O F At temperatures below 0 F the eyebolt could fail resulting in injury to personnel and or damage to equipment Drop forged eyebolts per American Society of Testing Materials A489 or equivalent must be used Donot use the motor shaft as a means for lifting Donot lift both the motor and driven equipment with the motor lifting means Donot stand on or place objects on the motor Maintenance Safe maintenance practices performed by qualified personnel are imperative Before starting maintenance procedures be positive that Equipment connected to the shaft will not cause mechanical rotation motor windings and all accessory devices associated with the work area are disconnected from electrical power sources motor has been given time to cool Failure to properly ground the frame of the motor can cause serious injury to personnel Grounding should be in accordance with National and local Standards and consistent with sound practice These instructions do not purport to cover all the details in motors nor to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered suf
27. faces of the bearing should be coated with a sealing compound such as No 5 Permatex 5 To replace the bearing reverse the disassembly procedure Some operating difficulties may occur Common causes are given in Table 2 and should be corrected as soon as possible TROUBLE SHOOTING CHART Table 2 Affected Parts Difficulty What to Check Windings Overheating Calibration of measuring instrument Excessive Current Unbalanced AC current Improper or restricted ventilation Excessive ambient temperature Short circuited coil or windings Dirty windings Unbalanced voltage Bearings Overheating Calibration of measuring instrument Worn out or dirty oil Rough journal Oil rings jammed Insufficient Oil Misalignment Excessive end thrust or radial loading Shaft currents Excessive or insufficient grease Worn out or dirty grease Motor Excessive Vibration Unbalance Misalignment mproper or settled foundation Non uniform air gap Rubbing parts Bent shaft Unbalanced stator current Damaged bearing Low insulation resistance or insulation failure Winding Insulation Moisture dirt metal particles oil or other contaminants on the windings Wrong voltage Excessive temperature Voltage surges Mechanical damage Excessive vibration with resultant mechanical damage 7 Sleeve bearings Anti friction bearings 13 VII FAILURE WARNING An extreme overlo
28. ficiently for the purchaser s purposes the matter should be referred to the General Electric Company This document contains proprietary information of General Electric Company USA and is furnished to its customer solely to assist that customer in the installation testing operating and or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy C Safety Symbols Below is a safety symbol table that identifies the safety symbols that appear in this manual and on the motors The use of a lightning bolt within an arrowhead symbol enclosed in a yellow triangle warns of dangerous electrical voltage that could cause an electric shock to a person The use of an exclamation point within a yellow triangle indicates to the user that important installation operating and maintenance instructions must be followed The use of wavy lines enclosed in a yellow triangle indicates that the motor can be hot and should not be touched without taking proper precautions This symbol instructs one to read the manufacturers instruction manual before installation operation and maintenance Copyright 2010 General Electric Company WARNING CAUTION GEI 56128H This symbol identifies a terminal which is intended for connection to an external grounding conductor for protection against
29. nd mechanical freedom of the motor In accordance with established standards the recommended minimum insulation resistance for the stator winding when measured with a 500 volt DC direct indicating ohmmeter with self contained power supply shall not be less than 5 mega ohms at 40 for a motor rated under 1000 volts and not less than 100 mega ohms at 40 for a motor rated over 1000 volts If the insulation resistance is lower than this value it is advisable to eliminate the moisture in one of the following ways 1 Dry the winding in an air circulating oven with the air surrounding the winding at 110 C 5 15 until the part has been above 90 for at least four hours Then the air temperature may be raised to 150 C 5 15 Continue to heat until the insulation resistance is constant for a one half hour period 2 Enclose the motor with canvas or similar covering leave a hole at the top for moisture to escape Insert heating units or lamps and leave them on until the insulation resistance is constant for a one half hour period 3 With the rotor locked mechanically and using approximately 1096 of rated voltage pass a current through the stator windings Increase the current gradually until the winding temperature reaches 90 C Do not exceed this temperature Maintain a temperature of 90 until the insulation resistance becomes constant for a one half hour period B Initial Start
30. nded that a general inspection routine be set up to check periodically the following items 1 General cleanliness 2 Insulation and windings 3 Lubrication and bearings 10 GEI 56128H B General Cleanliness The interior and exterior of the motor should be kept free from dirt oil and grease and conducting dust Paper textile or dusts may build up and block off ventilation Any of these contaminants can lead to early motor failure C Division 1 Explosion Proof Motors Division 1 Explosion proof motors have special features and are manufactured in accordance with UL and carry its label Therefore repairs need to be made at a GE Service Shop which has been authorized to make such repairs D Insulation and Windings To obtain a long life and satisfactory operation of insulated windings they should be kept clean from dirt oil metal particles and other contaminants A variety of satisfactory and acceptable methods are available for keeping the windings clean The choice of method will depend greatly on time availability of equipment and on the insulation system Vacuum and or compressed air cleaning with non metallic hose tips should precede cleaning with water and detergent or with solvents Tightly adhering dirt will require removal by gentle brushing or wiping WARNING To prevent injury to the eyes and respiratory organs safety glasses and suitable ventilation or other protective equipment should
31. nt multiplied by the motor service factor if any under steady continuous load C Jogging and Repeated Starts CAUTION Repeated starts and or jogs of induction motors greatly reduce the life of lt the winding insulation The heat produced by each acceleration or jog is much more than that dissipated by the motor under full load If it is necessary to repeatedly start or jog a motor it is advisable to check the application with the local GE Energy sales office V MAINTENANCE WARNING Before initiating maintenance procedures disconnect all power sources to the motor and accessories For motors equipped with surge capacitors do not handle the capacitors until they are discharged by a conductor simultaneously touching all terminals and leads including earth This discharge conductor should be insulated for handling Replace all normal grounding connections prior to operating A General If the motor is dismantled during maintenance sealing compounds if any shall be removed from machined rabbets spigots When reassembling the motor all machined surfaces forming metal to metal joints should be sealed with watertight sealing compound Tite Seal GE Spec 50 427 or equivalent Inspect the motor at regular intervals depending on service Keep the motor clean and the ventilation openings clear In addition to the daily observation of the overall condition it is recomme
32. s per day 365 days per 10 40 1 5 6 months year coal and mining machinery 50 150 9 months 3 months motors subject to severe vibration 200 350 6 months 1 5 months steel mill machinery 400 1000 3 months Very Dirty vibrating applications where 1 7 5 9 months 6 months Severe end of shaft is hot pumps and fans 10 40 4 months 3 months high ambient temperature 50 150 4 months 2 months 200 350 3 months 1 month 400 1000 2 months Table 6 Number of Grease Gun Pumps Bearing Size on Motor Nameplate Bearing Size on Number of Pumps Motor Nameplate 16 Oz Gun Approx 475 mL 24 Oz Gun Approx 700 mL 6205 6206 6208 6210 6213 6220 6309 6310 Number of Pumps 16 Oz Gun 24 Oz Gun Approx 475 mL Approx 700 mL 5 3 6 4 10 7 25 17 55 25 58 39 20 13 25 17 6312 6314 6315 C 2315 6516 6518 NU 518 6320 NU 320 C 2320 6321 6324 NU324 n NOTE A standard 10 000 PSI 69 kPa 16 ounce 475 mL grease gun delivers approximately 0 04 oz 1 18 mL of grease with each pump and a 24 oz 710 mL gun delivers approximately 0 06 oz 1 77 mL of grease The number of pumps listed represents approximately 2096 of the total grease cavity volume in the end shield 19 Rev GEI 56128H Document Revision History Date Author ISAAC Description 09 01 99 G Garver N A Conversion from PageMaker 02
33. the outline furnished with the equipment Connection plates on the motor have been furnished to assist in obtaining the proper rotation 6 After inspecting the motor carefully make the initial start by following the regular sequence of starting operations in the motor starter control instructions 7 For sleeve bearing machines after starting verify that the oil rings are operating properly and that oil is being fed to the shaft The temperature of the sleeve bearings as measured by bearing temperature detectors should not exceed 93 C 200 F At initial start the rate of rise of the bearing temperature is more indicative of trouble than is total temperature When starting a machine for the first time the bearing temperature should be observed for minimum of 2 hours If at any time the rate of temperature rise exceeds 2 C minute shut down the motor immediately and make an investigation of lineup conditions and if necessary the bearing and oil ring assembly 8 For anti friction bearings check motor operation under load for an initial period of at least one hour to observe whether any unusual noise or hot spots develop 9 the event of excessive vibration or unusual noise disconnect the motor from the load and check the mounting and alignment 10 Space heaters should be de energized during motor operation 11 Check the operating current against the nameplate value Do not exceed the value of nameplate curre
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