GE H-5304A User's Manual
Contents
1. Starting ossee 12 Bearngssand Coupling S si de cs etm NU eae 12 Comm tator and 1 12 Rectified Power Supplies esee e ente toe ne rto ad as etd tede d 12 Power Supply Identifiealfotiz tiri P RS MAR 14 15 Protective bou M 15 Motor Field Heatllle der ane 15 Thermostats 15 DEVICE dede d teme ene 16 Space Healer as cie nm tutes sab d Cote a ti ed bea ud data 16 17 General Mechanical 100 17 7 18 lucc o 18 Inspection After Starting oc Peco tau eas 18 BSG ANAS 18 Noise and VIDration o c area eee eke eee Steele 19 Inspection After Short Time In Service 19 Errare TT 19 S nalo h iow ppm 20 0 20 Irc E 21 Replacement of Bearings o ep edes 21 GEH 5304A Subject Page uil PME I 22 Brush Removal With Machines Stopped and Power 22 Brush Installation ee RERO EHE ERR RE oats ec data 23 C ommut at OE oco es e o e tee toe2. The nameplates of DC motors intended for operation from rectified power supplies will be stamped with a power supply identification as described below 1 When the test power supply used as the basis of rating is one of the five described below a single letter A D E or K will be used to identify the test power supply a Power Supply Identification Letter A This designates a DC generator battery or any power supply with enough series inductance to result in no more than 6 peak to peak armature current ripple Power Supply Identification Letter C This designates a three phase 60 hertz input full wave power supply having six total con trolled pulses per cycle The power supply has no free wheeling and no series inductance The input line to line AC voltage to the rectifier shall be 230 volts for 240 volt DC motor rat ings and 460 volts for 500 or 550 volt DC motor ratings Power Supply Identification Letter D This designates a three phase 60 hertz input semi bridge power supply having three controlled pulses per cycle The supply has free wheeling with no series inductance added ex ternally to the motor armature circuit The input line to line AC voltage to the rectifier shall be 230 volts for 240 volt DC motor ratings and 460 volts for 500 or 550 volt DC motor ratings Power Supply Identification Letter E This designates a three phase single way ha
3. 312 18 ENLARGED VIEW a 62 DEES AT ARROW ENLARGED VIEW 4 HOLES AT ARROW A T 34 COVER dia ACCESSOR AIR INLET amp AIR INLET RH Y MOUNTING FACE ISEE MACHINE OUTLINE COMMUTATOR END APPROX RET WT XE KG Sa um on o ae 7 CD2BIZAT E e wos en en enfe fol aither top or ade av inset by removing cavar A inset adapter May be mounted epica side of rachina Ganbecline DOM 033 1o side air inlat if both on Figure 5 Dimensions Air Openings for CD2512AT CD2813AT Frames 36 GEH 5304A Table 15 Air Flow Requirements For Separately Ventilated Motors Static Pressure Inches of Water A B Base Standard Enclosed Speed Separately Separately Frame RPM CFM Ventilated Ventilated 2512AT 2513AT All 380 4 85 6 1 2812AT 2813AT All 455 4 8 5 64 A Standard Separately Ventilated Air in one CE opening with solid covers on other CE openings Standard louvered covers on DE air outlets B Enclosed Separately Ventilated Air Ducted In and Air Ducted Out Air in one CE opening with solid covers on other CE opening Air out one DE opening Table 16 Renewal Parts For CD2512AT CD2813AT Frames Quick Kit Reference Frame Blower Kit Blower Kit C Face Kit PY Tach Kit BC Tach Kit Series Less Filter With F
4. C 104 F An ade quate supply of clean dry room air is required for self ventilated separately ventilated and blown motors Where motors must operate in dirty wet or contaminated environments protection in the form of filters or totally enclosed construction must be used to obtain long life with normal maintenance Do not obstruct ventilating openings When filters are supplied service them regularly Dirty filters shut off ventilating air Beware of recirculation Install motors so that hot exhaust air will not re enter the motor The use of electrical equipment in hazardous locations is restricted by the Na tional Electrical Code Article 500 Original equipment manufacturers and user customers must read understand and apply these rules for installation and use of all equipment in such locations and consult local code inspection and en Warning torcement agencies as necessary to ensure compliance Motors listed by Underwriters Laboratories Inc for use in specific locations have been designed tested and ap proved for use in such locations only Sections 501 8 and 502 8 now permit the use of totally enclosed motors with positive pressure ventilation or totally enclosed inert gas filled motors Class locations only when installation and operation conform to certain requirements Motors for Class I locations must have leads sealed at the frame exit and an explosion proof conduit box See Sections 501 4 and 501 5 Mo
5. GEH 5304A 2 00 2 501 Dim 3 udas BCA42 BC46 Tachometer adapter Form Y Tachometer adapter mounts on bracket shown in Fig 5 mounts on bracket shown in Fig 8 Tatsionaly rigid coupling rabad al 17 HP par 100 APM 10 32 tap Adapter amp Dowel 90 apart Figure 7 Accessory Mounting CD2512AT CD2813AT 39 GEH 5304A BLOWER VENTILATED SEPARATELY VENTILATED FROM EXTERNAL SOURCE a T be one of mont per motor Position s may be other than shown erar tate Ee rM ata ey EDU GENERAL ELECTRIC TYPE CD FRAMES 2512 AT TO 2813 AT DIRECT CURRENT MOTORS amp GENERATORS REF HO DESCRIPTION TE External Fan Guard w Thimble TF External Fan Guard Accessories w Thimble 7M Fan Hub Key TH External Fan Kil TP External Fan Hub 102 Cover Bottom CE 305A Blower Housing w Soreen 3058 Blower impeller 306 Frame Adapter Kit 307 Frame Shroud 310 Blower Motor 312 Blower Filler 313 Blower Filler Kil TOTALLY ENCLOSED FAN COOLED OR AIR OVER FRAME GEH 5304A Type CD Frames 2512AT 2813AT DC Motors amp Generators Figure 8 Type CD Frames 2512AT 2813AT 41 GEH 5304A To GE Industrial Systems Attn Industrial Engineering Reader Comments Technical Publications Editor 2000 Taylor Street General Electric Company Fort Wayne IN 46801 2205 Fax 1 219 439 3881 GE Internal
6. DC 8 380 3881 We welcome comments and suggestions to make this publication more useful Your Name Today s Date If needed how can we contact you Your Company s Name and Address Job Site Fax No GE Requisition No Phone No Your Job Function How You Use This Publication Publication No E Mail Publication Issue Revision Date Address General Rating Excellent Good Fair Poor Additional Comments Contents Organization O O O Technical Accuracy O Clarity Completeness Drawings Figures Tables O O Referencing Readability O O O Specific Suggestions Corrections information that could be expanded on and such Page No Comments Other Comments What you like what could be added how to improve and such Overall Grade Compared to publications from other manufacturers of similar products how do you rate this publication Superior Comparable Inferior Do not know Comment 42 GEH 5304A Detach and fax or mail to the address noted above 43 GEH 5304A ITE Fold here and close with staple or 2 Place Stamp Here GE INDUSTRIAL SYSTEMS INDUSTRIAL ENGINEERING TECHNICAL PUBLICATIONS EDITOR 2000 TAYLOR STREET FORT WAYNE IN 46801 2205 USA Fold h re first 44 GEH 5304A Document Revision History Rev Date Author ISAAC Descripti
7. bolt tension and possible bolt breakage 17 GEH 5304A Table 7 Bolt Tightening Torque Values Hex Head C1C5 Grade 5 Medium Carbon Steel Thread Sizes Without Lubricant UNC 2A Lb Ft N m 1 4 20 7 9 10 12 5 16 18 13 17 18 23 3 8 16 24 30 33 40 1 2 13 60 75 80 100 5 8 11 120 150 160 200 3 4 10 210 260 280 350 For lubricated bolts use 65 of value shown in Table 7 Accessory Mounting Provisions for mounting accessories on the commutator endshield is a standard feature The rabbet has NEMA type C Face mounting dimensions including the mounting bolt holes The standard stub shaft also permits coupling certain accessories To prevent injury from the rotating shaft the stub shaft cover must be main tained in position when the accessory mounting is not used Warning Standard accessories are available as kits These include a variety of tachometers speed limit switches and brakes A mounting adapter which can be machined for various accessories can be ordered separately Brakes Flange mounted brakes may be mounted on the accessory rabbet Since the accessory stub shaft is not suit able for use with a brake the standard NEMA commutator end shaft extension should be ordered when such use is planned Standard brakes are designed for horizontal floor mounting only When motors are sidewall or ceiling mounted the brake must be reassembled to maintain its relation to the horizontal Where mo
8. contacts of the speed limit device automatically reclose after the speed has fallen below the trip value In order to prevent property damage or injury to personnel the control circuit should be designed to prevent re energizing the 2 motor until the cause of the overspeed has been corrected Warning Table 6 Lead Markers Function Winding Armature A1 A2 Field Shunt F1 F2 F3 F4 etc Stator AC Machines Only T1 T2 T3 4 etc Type AN Tachometer Generator Accessories amp Special Device Markings Tachometer Generator Direct Current to Terminal Board A1 A2 Brake Coil Leads B1 B2 B3 B4 etc Heater Brake Space Heater BH1 BH2 BH3 BH4 etc Brake Interlock Switch BS1 BS2 BS3 BS4 etc Heater Space Heater in the Machine H1 H2 H3 H4 etc Thermostat P1 P2 P3 P4 etc Resistance Temperature Detector RTD R1 R2 R3 R4 etc Space Heater When furnished see Print Certification for Electrical Rating Space heaters are furnished in machines when ordered They should be energized with the correct AC volt age as shown on the nameplate 16 GEH 5304A The surface of a space heater block becomes hot when the heater is energized The temperature rise above the ambient temperature may be as high as 400 C Avoid touching heater blocks which have recently been energized to prevent burns Also to prevent fire or explosion ignitable dust or lint should not be Warning allowed to collect ar
9. protect them from corrosion The parts should be inspected occasionally to ensure their continuous usability 31 GEH 5304A Table 14 Recommended Spare Parts Number of Duplicate Motors in Service More Description 1 2 4 5 10 10 20 Than 20 With or Without Electrical Shop Facilities Complete Machine 1 2 Ball Bearing Sets 1 1 1 2 3 Brushes Sets 2 4 6 8 10 Brushholders Sets 1 2 1 2 1 1 Brushholder Springs Sets 1 2 1 1 2 2 Armature Complete 1 1 2 2 Wound Frame 1 2 2 Blower Ventilated Motors Blower Motors 1 1 2 2 With Electrical Shop Facilities Shaft 1 1 Armature Rewinding Supplies 0 0 1 1 2 f shop facilities are available the quantity of armatures may be reduced by stocking the armature parts listed in the second group Factory wound frames are wound using specialized equipment and then varnish dipped Although it is physically possible for a motor shop to rewind a failed field winding experience has shown that rewinds cannot offer an accept able service life due to the difficulty in winding the many turns of small diameter wire without damage 32 GEH 5304A Commutator Check Chart For Comparing Commutator Surface Markings SATISFACTORY COMMUTATOR SURFACES LIGHT TAN FILM over entire commu tator surface is one of many normal conditions often seen on well functioning machine MOTTLED SURFACE with random fi
10. system deterioration External connections should be re moved to isolate the windings to be tested and megger value logged A sudden drop or consistent trend toward low values of insulation resistance although possibly caused by moisture or contamina tion generally gives evidence the insulation system is deteriorating and that failure may be imminent High potential tests are not recommended on machines which have been in use If such a test is made immediately after installation the test voltage should not exceed 85 of the original factory test of two times the rated volts plus 1000 volts NOTE Surge testing and AC impedance tests of windings to detect shorts should be performed by trained personnel only Cleaning of Windings If windings become contaminated suitable cleaning methods can be used to alleviate the problem The machine should be de energized and slowly rotated by hand to permit maximum dust removal Dry dirt dust or carbon should first be vacuumed without disturbing adjacent areas or redistributing the contamina tion Use a small nozzle or tube connected to the vacuum cleaner to enter into narrow openings i e be tween commutator risers A soft brush on the vacuum nozzle will loosen and allow removal of dirt more firmly attached This vacuum cleaning may be supplemented by blowing with compressed air air pressure should be in ac cordance with OSHA standards which has passed through a dryer to remove moistu
11. the oil in the grease will ultimately become depleted it is necessary to relubricate ball bearing and roller bearing motors periodically depending on the size and type of service refer to Table 9 Avoid mixing different kinds of grease Lubricate the motor at standstill Make sure the top grease fitting is clean and free from dirt Remove one of the lower grease relief plugs Free the relief hole from any hard ened grease Use a hand operated grease gun only Pump in grease until new grease appears at lower grease hole After greasing allow the motor to run about ten minutes before replacing the grease relief plug to permit excess grease to drain out Extreme pressure EP greases should not be used in DC machines Insulation deterioration and increased brush wear may result from the presence of sili Warning D Replacement of Bearings After the bearing brackets have been removed a bearing puller may be used to pull the bearings from the shaft Protect the shaft center while using the puller Discard the old bearing The new bearing and all mating parts should be kept extremely clean during reassembly To install a new bearing heat the bearing to 116 127 C 240 260 F in oil or in an oven then slip or press the bearing on the shaft The bearing should be mounted tightly against the shoulder on the shaft After the bearing has cooled reinstall the retaining ring where used Fill the grease reservoir in the inner bearing cap or car
12. 00 650 850 1150 1500 2000 2500 3000 4000 5000 Life Factor 2 15 183 1 55 129 1 10 92 80 72 60 55 iggi 7E TTT E ee E Ls uh 4 Frame Sizes E CD2512AT and CD2513AT 5 2 1 500 ES onum z Description 3 di ids aimi inc T Shaft Shaft ES urve Bearing Diameter Material ERE Eft ti Lee rone 1 Standard Standard 1 5 8 Standard ia Ball 3 we i 309 2 Oversize Oversize 1 7 8 Standard 310 3 Oversize Oversize 1 7 8 Special Roller 310 10 998 i E Frame Sizes 3 pun TE CD2812AT and CD2813AT inen ea 5 9 2 200 5 Description mim 2 Shaft Shaft LL Curve Bearing Diameter Material 1 1 1 Standard Standard 1 7 8 Standard 8 Ball 310 2 Oversize Oversize 2 1 8 Standard E Ball 311 3 Oversize Oversize 2 1 8 Special Roller 311 1 th amp oen eon 3 008 nen 13 GEH 5304A Table 4 Power Supply Available 4 D E K 8 A xpo wo 2 D y V V yo 4 y 5 4 W VI Compatible power supply External inductance may be necessary to limit ripple current Power Supply Identification
13. 5 1000 1499 incl 002 999 and below 0025 3 Inspection After Short Time in Service New machines may smell warm or have the odor of varnish but should not smell scorched After a machine has been operating for a short time an inspection should be made to ascertain that there have been no changes since installation Check for increased vibration signs of change in alignment or foundation settling bolts that may have loosened rubbing parts loose connections and worsened commutation Proper steps must be taken to correct the trouble Also check the condition of air filters on blower ventilated machines The amount of dirt in the air varies widely between in stallations MAINTENANCE High voltage electric shock may cause serious or fatal injury Disconnect power before touching any internal part High voltage may be present even when the machine is not rotating If used with a rectified power supply disconnect all AC line connections the power supply With other power supplies disconnect Warning all DC line and field connections Also disconnect power from auxiliary de vices Ground the machine properly to avoid serious injury to personnel Grounding must be in accordance with the National Electrical Code and consistent with sound local practices Warning Replace covers and protective devices before operating Warning 19 GEH 5304A Disassembly The following procedure should be us
14. 6A2C13 Standard Oil Company Chevron SRI II 20 F to 350 F 225 Bush Street 28 C to 176 C San Francisco CA 94120 415 894 7700 E Brushes Refer to Figure 2 4 Warning High voltage and rotating machinery can cause serious or fatal injury Brushes may not be touched or replaced while the machine is energized or rotating Caution DC motors and generators operated for long periods of time at light loads or in contaminated atmospheres may be subject to abnormal brush and commutator wear This can result in commutator damage and or the need for excessive maintenance If the application requires operation under these conditions GE Industrial Systems will be pleased to suggest a change in brush grade or other measures to minimize the problem 1 Brush Removal With Machines Stopped and Power Off The following procedure should be used to remove brushes 22 GEH 5304A a Unfasten pigtail b Release spring by pushing in slightly to disengage locking tab then pull spring back e Remove brush Brush Installation The following procedure should be used to install brushes a Place brush in holder with bevel towards spring Brushes should move freely in holder b Push spring into position until lock tab engages slot and locks Connect pigtail The presence of silicone in DC motors particularly with totally enclosed con structions will cause rapid brush wear S
15. GEH 5304A GE Industrial Systems Instructions Direct Current Motors amp Generators Type CD Frames 2512AT 2513AT Frames 2812AT 2813AT GEH 5304A These instructions do not purport to cover all of the details or variations in equipment 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 sufficiently for the purchaser s purposes the matter should be referred to the General Electric Company Copyright 1985 1992 1999 General Electric Company GEH 5304A Table of Contents Subject Page 100 16110 5 ese ncaa ea ents eee ees 5 mr 5 8 6 Installation siti hd eap b da e aic i ated 7 Ive EM 7 amp E 8 Coupled 8 Alignment Procedure Flexible Coupling Non Self Supporting Bases 8 Alignment Procedure Flexible Couplings Self Supporting Bases 9 st dts acd os Rue Ag d LL cose 9 V Belt Drives et ed eec peii e veles eh in dudes ie eed e delude es 9 9 special Load Considerations 11 7 11 Thrust 1 0 aS 0 2 1 11
16. SEPARA VENTILATED BUT WITHOUT EXTERNAL AIR SU WITH RS WITH INTERNAL FAN CD2512AT 2513AT ipa JAJ AVERAGE SOUND POWER LEVEL Lw dB A RE 10 12 WATTS MOTOR SPEED RPM Figure 3 Application Information for CD2512AT CD2813AT Frames 34 GEH 5304A DIMENSIONS For ESTIMATING ONLY unless endorsed for construction MIT AT H Bi ax BLUWER zn T IE 2 88 73 be INLET FILTER WECH SPEL EO a HEE ae HIE Dui WO R RRA 6 er INI A OUTLET FG 4 m TOPMOUNTEp CosstaarastaaT soues an rs anso 306 sec SPUR comata 50185 riso 335 57 1 pe mez E aie eren me om oe x0 AIR INLET i EH LE mutum osnan soups uia wr 595 14 2 50058 rese rco 655 572 5 FIG 4E SIDE MOUNTED LEFT HAND SIDE FACING COMMUTATOR BLOWER RIGHT HAND SIDE FACING COMMUTATOR END From Jhan CA Pros aud chinga witfieor ibti Figure 4 Blower Unit Commutator End Mounted for Use With CD2512AT CD2813AT Frames 35 GEH 5304A DIMENSIONS For ESTIMATING ONLY unless endorsed for construction 5 70 AIR INLET 38 4 82 5 70 312 18 2 DEEP 2 HOLES lt
17. alignment of machines when using either solid rigid or flexible cou plings is essential to prevent excessive vibration and bearing or shaft failures Caution a Alignment Procedure Flexible Coupling Non Self Supporting Bases Before grouting the base the coupling should be checked as follows 1 Slide the sleeve from the coupling so that the hub faces are exposed 2 Check that the coupling hub spacing is in accordance with the outline dimensions with the units in the mechanical center of their end play 2 Check parallel alignment by using a straightedge across the hubs at both vertical and horizontal locations or by clamping a dial indicator to one hub and indicating the other hub on its outside diameter Be sure that the dial indicator supports do not bend or sag since this will give inaccurate readings 4 Use a dial indicator at hub faces and rotate both units together 90 180 270 and 360 or measure the gap at each position by inserting a feeler gage The reading should not vary more than 0 002 5 Correct any vertical misalignment by shimming between the base and the foundation 8 GEH 5304A Horizontal alignment should be corrected by shifting machines on the base b Alignment Procedure Flexible Couplings Self Supporting Bases Before operating the machine the base should be bolted down and the alignment checked as follows 1 Remove all of the coupling bolts and slide the shells back so tha
18. aling carbon and seater dust GE Industrial Systems recommends using a dust mask during sanding seating and blowing or vacuuming Caution High voltage and rotating parts can cause serious or fatal injury The use of all electric machinery like all other utilization of concentrated power and rotating equipment can be hazardous Installation operation and maintenance of elec tric machinery should be performed by qualified personnel Familiarization Warning with NEMA Safety Standards for Construction and Guide for Selection Installa tion and Use of Integral HP Motors and Generators National Electrical Code and sound local prac tices is recommended 23 GEH 5304A Do not use liquid solvents of any kind Solvents will not remove carbon dust accumulations but will spread and wash them into critical areas Caution E V 2 L T FS E iv Le gt i L n UE a Lx UL 0 1 I5 1 4 Figure 2 Brush Assembly Commutator Keep the commutator clean Ordinarily the commutator will require only occasional wiping with a piece of canvas or other nonlinting cloth Do not use lubricant or solvent on the commutator Check the commu tator for roughness while running by feeling the brushes with a fibre stick avoiding contact with live electri cal or moving mechanical parts Chattering brushes giv
19. below Belt Tension Factor K Ky Description 1 0 Chain and Sprocket Drive 12 Timing Belt 1 5 V Belt 1 1 Ratio 1 8 V Belt 2 1 Speed Decreased Ratio 2 0 Flat Belts The curves that follow can be used to determine the anticipated L10 life which is the life in hours that 90 of bearings with this load would be expected to exceed without failure The standard ball bear ing and standard shaft option will be the most economic if acceptable life is obtained from the curve A good commonly used design figure is 20 000 hours However applications with a calculated life of as low as 5 000 hours have sometimes been necessary to limit belt speeds to 6 000 feet per minute The curves are drawn for 1750 RPM average speed If the application has some other average speed the life can be adjusted by multiplying by the bearing life factor It is important to know that bearing life for V belt applications is independent of the motor load Once the belts have been tightened just enough to prevent slipping when the maximum torque is being delivered by the motor the radial load W on the shaft and bearing is there and remains constant re gardless of whether the motor is even turning For timing belts and chain drives the radial load W does not vary somewhat with motor load Therefore the motor load duty cycle as well as the average speed should be considered to estimate bearing life Belt tension should be checked and adjusted following t
20. duit box must be insulated When more than one terminal is marked with the same identification they should be joined in the same connection Refer to Table 6 for identification of wiring leads E Protective Devices Make certain that all protective devices overspeed devices bearing tempera ture relays etc are connected and function properly Also make certain that all coupling guards shaft protectors grounding connectors covers and other 2 safety devices are properly attached Caution F Motor Field Heating MOTOR FIELD HOUSING Unless specifically ordered motors are NOT capable of continuous standstill excitation at rated field current When the motor is shut down for more than 30 minutes one of the following options must be used Caution 1 De energize the fields completely 2 Use field economy relays to limit the field current to a maximum of 50 of the nameplate rating 3 When applicable fields may remain fully energized if the motor ventilation system blower or customer duct remains in operation G Thermostats The thermostat is a device that may be used in alarm or protective relay circuits within rating limits shown in Table 5 It is not intended to limit motor loading or provide normal insulation life When supplied it is mounted to a commutating coil which is the only accessible part of the armature circuit Since factors such as shaft speed ventilation blower or shaft fan c
21. dustrial Systems in all cases 7 Thrust Loads Due to the mounting position or type of drive arrangement a thrust load may be applied to the motor shaft The Kinamatic motor is designed to permit a limited amount of thrust load This permissible load will vary by mounting position and direction of the load due to the weight of the armature The permissible load in Table 2 is tabulated by frame diameter and mounting position These apply to ball bearings only For applications combining thrust and radial loads or where thrust loads exceed the values shown in Table 2 refer all details to GE Industrial Systems Table 2 Maximum Continuous Thrust Capacity Lbs Vertical Mounting Bearing Horizontal Thrust Load Thrust Load Frame Size Mounting Up Down 2512 Std 309 350 465 235 2512 O S 310 400 515 285 2513 Std 309 350 485 215 2513 O S 310 400 585 265 2812 Std 310 400 550 250 2812 5 311 500 650 350 2813 514 310 400 585 215 2813 O S 311 500 685 315 Based on L10 life of 20 000 hours and an average speed not exceeding 2500 RPM IV OPERATION 4 Disconnect power before touching any internal part High voltage be pres ent even when the machine is not rotating If used with a rectified power sup ply disconnect all AC line connections to power supply With other power supplies disconnect all DC line and field connections Also disconnect power Warning from auxiliary devices Ground the machi
22. e advance warning of deterioration of the commuta tor surface Refer to the Commutator Check Chart GEA 7053 for commutator surface marking and causes of poor commutator condition Commutator runout over 003 T I R Total Indicator Reading and bar to bar readings over 003 indicate need for repair Refer to Table 12 The presence of silicone in DC motors particularly with totally enclosed con structions will cause rapid brush wear Sources of silicone include oils RTV compounds hand creams mold release agents grease and some insulating varnishes These silicone substances must be avoided to ensure proper motor Caution performance Table 12 Commutator Diameters In Inches Frame Start Min Wear 00251241 5 30 5 02 0 140 00251341 CD2812AT 5 96 5 66 0 150 60281341 24 GEH 5304A Mechanical Check the condition of air filters and replace filters if they are dirty Check for unusual noises which were not present when the unit was originally installed Check all electrical connections for tightness Clean out any dirt from screens louvers etc which would interfere with the flow of cooling air Shaft End Play The CD2512AT CD2813AT designs use a wavy washer preload spring to eliminate endplay Waterproof Machines Waterproof machines require the use of sealing devices to exclude water from the bearings and from entering openings in the magnet fra
23. ed for disassembly 1 Remove all covers 2 Disengage brush springs 3 Remove complete brushholder assemblies 4 Remove four 4 nuts CE bracket 5 Remove commutator end cover plate if fitted 6 Remove four 4 CE bearing cap bolts 7 Using a soft mallet tap on CE bracket to remove it 8 Remove four 4 DE bearing cap bolts 9 If the machine is not filled with an internal fan pull the armature out of the commutator end 10 Ifthe machine has an internal fan remove four 4 3 8 through studs from the commutator end 11 Remove DE bracket 12 Pull armature out from drive end Reassembly The following procedure should be used for reassembly 1 2 Place armature into frame Install DE bearing bracket and bearing cap Install the four 4 3 8 through studs into DE bracket Install CE bearing bracket and bearing cap Loosely tighten four 4 nuts on the 3 8 through studs Set machine on a flat true surface to align feet on both brackets NOTE If Step 6 is not performed distortion or breakage of brackets may occur during bolt down of the 7 8 9 motor Torque four 4 nuts on CE bracket Reinstall brushholders and engage brush springs Replace all covers 20 GEH 5304A C Bearings Ball bearing and roller bearing housings are packed with grease at the factory Therefore greasing is not required before the motor is put into service Since
24. fied personnel Familiarization with Warning NEMA Safety Standard for Construction and Guide for Selection Installation and Use of Integral HP Motors and Generators National Electrical Code and sound local practices is recommended These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency or hazard to be met in connection with installation operation and maintenance Should further infor mation be desired or should particular problems arise which are not covered sufficiently for the purchaser s pur poses the matter should be referred to GE Industrial Systems RECEIVING The equipment should be placed under adequate cover immediately upon receipt as packing coverings are NOT suitable for out of doors or unprotected storage Each shipment should be carefully examined upon arrival Any damage should be reported promptly to the carrier and to the nearest office of GE Industrial Systems A Storage During installation or when in storage the machine and its parts must be protected from the following 1 Dirt of all kinds 2 Wetness and temperature extremes Protection from dirt can be achieved by covering the machine with a tarpaulin or polyethylene sheet or keeping it in a clean area Protection from wetness and temperature extremes includes moisture from the surrounding atmosphere con densing onto cooler machine surfaces This condensation on machine
25. g moment on the motor shaft it is always desirable to have the motor sheave located as close to the motor bearing as possible to minimize both bearing load and shaft stress This will result in increased bearing life For the load centered 2 in toward the bearing from the end of the shaft instead of at the end of the shaft the bearing load is reduced by 10 and the life increased by 33 The bearing life curves that follow assume the load is centered at the end of the shaft New improved V belts are now on the market that significantly reduce the number and size of belts required for a given load These new belts should always be considered since the sheave will be shorter and the load centered closer to the bearing The standard NEMA shaft extension is designed for belted loads Dimensions are provided on the standard dimension sheets A sliding base is available as an accessory to facilitate belt adjustment Bearing Life Bearing life for belted drives is determined by calculating the radial load at the end of the shaft GEH 5304A The radial load W produced by the belts when tightened just enough to transmit the load without slipping is given by the relation 126 000 x HP x lbs D x RPM Where D Sheave pitch diameter in inches for V belt application HP Maximum ratio of horsepower including overloads to the minimum speed at which that RPM power occurs Ky Belt tension factory from table
26. he belt manufacturers recommendations If slippage occurs after the belt tension has been correctly adjusted the belts and pulleys have not been chosen properly for the application Over tightening to avoid this slippage may result in early failures of belts shafts and bearings Caution There is normally a drop in tension during the first 24 to 48 hours of operation During this run in period the belts seat themselves in the sheave grooves and initial stretch is removed Belt tension should be re checked after a day or two of operation Matched belts run smoother and last longer Longer belt life results if the belts and sheaves are kept clean and the belts are prevented from rubbing against the belt guards or other obstructions 10 GEH 5304A Mounting may be either horizontal or vertical for these bearing life determinations as long as no axial load 1 6 suspended load other than the weight of the armature is present if vertical Special Load Considerations Where the load is overhung beyond the motor shaft extension or greater bearing life is desired the application should be referred to GE Industrial Systems 6 Pinion Drives While Kinamatic motors are not designed for overhung pinion drives they may be successfully ap plied under suitable conditions In addition to a radial load some gears produce thrust load on the bearing Complete details of the proposed gearing should be referred to GE In
27. ilter 8 5 Rabbet Less Tach Less Tach CD25XX 36A171113AAGO1 36A171113AAGO1 36A172476AAG01 36A171269AAG01 36A171270AAG01 CD28XX 36A171114AAG02 36A171114AAG01 36A167477AAG01 36A171269AAG01 36A171270AAG01 DC PY Tach Only DC BC 42 Tach Only DC BC 46 Tach Only Fits PY Kit Fits BC Kit Fits BC Kit 50 1000 RPM 897A594 002 50V 1000 RPM 897A590 032 50V 1000 RPM 897A591 041 100V 1000 RPM 897A594 001 100V 1000 RPM 897A590 024 100V 1000 RPM 8971591 029 Frame AN AC Tach AN DCTach AN DCTach ANDG240A4 ANDG240D4 Series 45 90V 1000 RPM 20V 1000RPM_ 50V I000RPM 240 PPR 240 PPR CD25XX 36 167715 1 36A167714AAGO1 36A167714ADGO1 36A167712AAG04 4 CD28XX 36A167715AAG01 36A167714AAGO01 36A167714ADGO1 36A167712AAG04 4 Blower motor is 230 460 volt 3 phase 60 hertz Requires motor disassembly by qualified service facility to install Bi directional dual output 37 GEH 5304A NOTES Accessories shat as shown furnished on afl ma chines mol having comenutator end shat eter sons Accessonas shaft is suitable tor driving achora ter and For brake application a keyed commutator end shaft extension is GISTO 52608 Deep 0 500 13 tap 1 25 Deep O30 as Dag center 0 74 Dia Deg canter 0 75 Dia Figure 6 Accessory Mounting CD2512AT CD2813AT 38
28. lf wave power supply having three total pulses per cycle and three controlled pulses per cycle The power supply has no free wheeling and no series inductance added externally to the motor armature circuit inductance The input line to line AC voltage to the rectifier shall be 460 volts for 240 volt DC motor ratings Power Supply Identification Letter K This designates a single phase full wave power supply having two total controlled pulses per cycle with free wheeling 60 hertz input and no series inductance added externally to the motor armature circuit The input AC voltage to the rectifier shall be 230 volts for 180 volt DC rat ings 14 GEH 5304A 2 When intended for use on a power supply other than D E or K the motor will be identified as follows M NF V H L Where M digit indicating total pulses per cycle N digit indicating controlled pulses per cycle F Free wheeling this letter appears only if free wheeling is used V Three digits indicating nominal line to line AC voltage to the rectifier H Two digits indicating input frequency in hertz L One two or three digits indicating the series inductance in millihenries may be zero to be added externally to the motor armature circuit inductance D Connections Terminal connections should be checked against the connection diagram shipped with the machine Bolted connections must be tight All exposed connections in the con
29. lm pattern is probably the most frequently observed condition of commutators in industry SLOT BAR MARKING a slightly dark er film appears on bars in a definite pattern related to number of conductors per slot HEAVY FILM can appear over entire area of efficient and normal commu tator and if uniform is quite accept able WATCH FOR THESE DANGER STREAKING on the commutator surface signals the beginning of serious metal transfer to the carbon brush Check the chart below for possible causes COPPER DRAG an abnormal build up of commutator material forms most often at trailing edge of bar Con dition is rare but can cause flashover if not checked on the commutator surface motor THREADING of commutator with fine lines results when excessive metal transfer occurs leads to resurfacing of commutator and rapid brush wear PITCH BAR MARKING produces low or burned spots The number of these markings equals half or all the number of poles on the GROOVING is a mechanical condition caused by abrasive material in the brush or atmosphere If grooves form start corrective action It usually HEAVY SLOT BAR MARKING can involve etching of trailing edge of commutator bar Pattern is re lated to number of conductors per slot CAUSES OF POOR COMMUTATOR CONDITION Frequent visual inspection of commutator surfaces can warn you when any of the above conditions are developing so that you can take early co
30. me When a waterproof machine has been disassembled it will be necessary to remove the old sealing compound from around the mating surfaces of the bearing brackets and magnet frame from underneath the field pole bolt heads and bearing cap to bearing bracket bolt heads and from around the conduit box adapter threads to the magnet frame Reapply new sealant use Titeseal T20 66 light weight GE Part No 905 999 009 to these areas and wipe excess sealant with a clean rag slightly dampened with mineral spirits Do not use silicone sealants When accessories such as brakes and ta chometers are disassembled it will be necessary to reseal at the accessory mounting face Prior to reassem bly inspect for damage at the gaskets around enclosure covers and at the shaft rubbing seals located in the bearing caps Lubrication of Flexible Couplings Flexible couplings are normally lubricated with a semi fluid grease or an oil The coupling manufacturers instructions should be followed in choosing a lubricant and setting relubrication intervals GE ball bearing grease D6A2C5 is a suitable lubricant for flexible couplings in most applications Flexible couplings which join a small machine to a large machine may have two different size coupling halves joined by an adapter plate Couplings of this type have a separate lubricant supply for each half Therefore both halves must be lubricated separately Insulation Caution Eliminate sources of c
31. n ducting contaminants metal dust carbon etc deep into hidden areas to pro duce shorts and grounds thus causing machine failure Mechanical compo nents may be cleaned by a wiping rag barely moistened not wet with a solvent gt Warning Solvents may be flammable and moderately toxic The usual precautions for handling chemicals of this type must be observed These include 1 Avoid excessive contact with skin 2 Use in well ventilated areas 3 Take necessary precautions to prevent fire or explosion hazards Oily Dirt The presence of oil makes thorough effective cleaning of machines in service virtually impossible and service shop conditioning is recommended Oil on a surface forms a fly paper effect which attracts and holds firmly any entrained dust Neither suction nor compressed air is effective Consequently only accessible areas may be cleaned First remove as much of the dirt as possible by scraping or brushing the dirty surfaces Then wipe away as much dirt as possible with dry rags For surfaces not readily accessible a rag on a hook wire can be used to clean dirt out of holes and crevices Rags should be changed frequently for clean ones so that contamination picked up from one area is not car ried to other less dirty areas While FREON TF is considered to be nonflammable and has a relatively low order of toxicity it should be used only in well ventilated areas that are free from
32. ne properly to avoid serious injury to personnel Grounding must be in accordance with the National Electrical Code and consistent with sound local practices One of the bolts holding the conduit box to the unit ac cessible from inside the conduit box is identified and may be used for attach Warning ing a grounding cable 11 GEH 5304A Before starting the motor remove all unused shaft keys and loose rotating parts to prevent them from flying off Warning A Inspection Before Starting These inspection procedures should be followed before starting the machine for the first time after an ex tended shutdown or after a teardown for extensive maintenance or repair 1 Bearings and Couplings Machines with ball or roller bearings are greased at the factory and will need no attention until relu brication is necessary as suggested in the Maintenance section of this instruction book If the flexible couplings are a lubricated type they should be checked to see that they contain the proper amount of lubricant Make sure that all grease plugs are tight 2 Commutator and Brushes Brushes should be worn in to have at least 85 contact over the brush surface and continuous contact from heel to toe The commutator surface and undercut mica should be clean and free from dirt grease paint spots or brush dust Brushes should be free to move in the holders and all springs should be down and latched Brush
33. not be used Some flow of air is desirable to allow moisture to be carried away Methods of generating heat include blowing hot air through the machine heating with heat lamps passing current through the main field coil windings etc If temperatures as high as 225 F 125 C can be attained they should be limited to six or eight hours dura tion Lower temperatures will cause correspondingly longer drying times Drying out can be ended when the insulation resistance to ground corrected to 40 C is restored to a satis factory value as described in the Insulation Resistance section If these values do not reach a proper level then a thorough cleaning or complete reconditioning may be necessary Service Shop Cleaning When the cleaning or drying methods described in preceding paragraphs do not result in restoration of ac ceptable insulation resistance and or when machines are extremely dirty or contaminated it is recommended that the reconditioning services of a GE Service Shop be obtained Service shops are knowledgeable and equipped for more sophisticated restoration methods such as hot water detergent wash solvent and abrasive cleaning revarnishing and rewinding if necessary Repair Repairs should be made only by qualified personnel using the materials and processes for which the motor was designed To protect the warranty during the warranty period all repairs must be made in a GE Service Shop or approved repair facility Many re
34. on 0 12 14 99 GJG N A Conversion from PageMaker 45
35. ontamination and moisture for maximum insulation life Air filters for blowers air piped from cleaner locations shielding from water leads or spray proper use of space heaters during downtime etc will all help to prolong insulation life Contamination includes excessive moisture oily vapors conducting and non conducting dust chips and chemical fumes Contamination is best avoided by proper enclosure and ventilation Filters ventilation from a remote clean air source unit coolers and a totally enclosed construction are all possible means of protecting DC machines in adverse environments Space heaters protect against moisture damage by main taining the machine above dew point during storage or when idle Space heaters should be arranged so that they are automatically energized whenever power is removed from the motor Space heaters do not supply enough heat for drying out windings which have been water soaked Mechanical factors include shock vibration overspeed etc Maintaining machines in good mechanical re pair including isolation from excessive external shock and maintenance of smooth running conditions will contribute to long insulation life The insulation system in these machines is capable of withstanding some short time periods of operation at temperatures higher than than used for the basis of machine rating Prolonged or excessively high tempera ture will cause the insulation to become brittle and crack leading to prema
36. open flames Avoid prolonged exposure to vapors Failure to observe Warning these precautions may result in injury to personnel FREON TF is the only recommended solvent for cleaning because it is nonflammable has good sol vency for grease and oil is considered safe with most varnishes and insulations and has a low order of toxicity Stoddard solvent has good solvency but is flammable and moderately toxic Before using any solvent consult the Material Safety Data Sheet Steam cleaning is not recommended because as with liquid solvents conducting contaminants may be carried deep into inaccessible areas resulting in shorts and grounds 29 GEH 5304A FREON TF is a chlorofluorocarbon Chlorofluorocarbons have been identified as upper atmosphere ozone depletors The use of Freon in industry is expected to be greatly reduced in the future The availability of Freon may be limited and Caution its use could be prohibited by regulations Caution Carbon brush performance may be ruined by absorbed solvents Remove brushes prior to solvent wiping N Drying of Windings Drying of machines is most effectively done by application of heat The windings and insulation should be heated so that their temperature does not exceed 225 F 125 C at any location Do not make local hot spots The machine s own frame and the addition of some covers usually will make an effective enclosure to contain the heat if an oven can
37. ound the surface of the heaters J Ventilation System Blowers or central systems must be in operation to supply cooling air before loading force ventilated ma chines Air filters should be in place Blowers should be checked for correct rotation See outline or rota tion arrow IMPELLER BLADES INTERNAL BAFFLE AIR FLOW AIR FLOW y VIEW LOOKING AT AIR INLET BLOWER MOTOR IS ON FAR SIDE 1 24875 Figure 1 Correct Arrangement Of Blower Housing Impeller Blades And Direction Of Rotation To Obtain Proper Pressure And Air Flow K General Mechanical Inspection Check the inside of the machine for tools metal chips or any other foreign material that may have accumu lated during storage or installation Make sure that all rotating parts have clearance from any stationary parts Turn the machine over by hand if possible and check for scraping noises or any other sign of me chanical interference Check the tightness of the bolts in the feet couplings bearing housings and any other bolts that may have been disturbed Standard motors as shipped are assembled with bolts without lubricant dry threads When necessary bolts may be replaced with bolts with dry threads or with bolts lubricated with a motor oil or other suitable thread lubricant When lubricated threads are used reduce torque to 65 of the value shown The Caution torque values shown when applied to bolts with lubricated threads can cause excessive
38. ources of silicone include oils RTV compounds hand creams mold release agents grease and some insulating varnishes These silicone substances must be avoided to ensure proper motor Caution performance Brushes should have their commutator contact surfaces curved to exactly fit the commutator surface This is accomplished by sanding in the brushes in each brushholder separately Draw a sheet of coarse non metallic sandpaper under the brushes with the rough side toward the brush while the brushes are pressed firmly toward the commutator Do not use emery cloth When sanding brushes do not get carbon dust into the windings The motor should be thoroughly blown out after sanding the brushes This can be accomplished by cleaning the dust from the commutator brushholders and adja cent parts with a vacuum cleaner air blast or other suitable means After the rough sanding the brushes should be finely ground to fit using a brush seater Rotate motor at around nameplate RPM Make sure there is no load on the machine armature current is nil Carefully and lightly rub the brush seater across the entire commutator surface for 10 or 15 seconds Repeat between each and every set of brush studs Reverse motor rotation and repeat Stop motor and cut all power to the mo tor and check brush face Continue seating until brush face is 85 seated Again the motor must be thoroughly blown out after brush seating the same as with sanding Avoid inh
39. oxic The usual precautions for handling chemicals of this type must be observed These include 1 Avoid excessive contact with skin Warning 2 Use in well ventilated areas 3 Take necessary precautions to prevent fire or explosion hazards Extreme care must be exercised in removing rust on shaft extensions near shaft seals since it is difficult and sometimes impossible to remove rust from these surfaces without damaging or deforming them Burrs or bumps on other machined surfaces should be carefully removed by using a fine file or scraper Machines in storage should be inspected have the insulation resistance checked at frequent and regular in tervals refer to Insulation Resistance section and a log kept of pertinent data When stored it is suggested that the armature be rotated every three months to prevent loss of grease protection on the bearings and races Loss of grease protection causes rust Caution B Handling Complete motors or generators can be lifted by using hooks or slings in the lifting lugs of the unit The lift ing lugs are designed to safely carry the weight of the individual machine DO NOT lift the machine with the shaft extensions Motor generator sets or units with heavy attachments such as gear boxes or pumps must not be lifted by using the lifting lugs of the individual machines Warning Motor generator set bases have lifting holes to be used with spreader bars or hooks Ca
40. pairs can be easily performed with only assembly operations if GE replacement parts are available If major repairs are undertaken such as rewinding an armature proper fa cilities should be used and suitable precautions observed When burning off old insulation materials or when welding near insulation during rewinding adequate ventilation must be provided to avoid exposing personnel to noxious fumes Combustion of exhaust fumes must be complete Warnin g and adequately vented to the outside atmosphere Warning Exposure of personnel to airborne inorganic fibers must be avoided by ade quate ventilation or by wetting the remaining insulation components following the burning off of the organic materials 30 Vi GEH 5304A An extreme overload or electrical failure may result in heating or arcing which can cause the insulation to give off noxious fumes All power should be re moved from the motor circuit as a precaution even though the circuit has overload protection Personnel should not approach the motor until adequate Warning ventilation of the area has purged the air of fumes When covers of a totally enclosed 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 ex amination or repair Water should not be applied to any electrically energized equipment becau
41. pigtail connections should be tight and the pigtails should not interfere with the action of the spring or brush and should be clear of any other part of the machine Rectified Power Supplies When DC motors are operated from rectified power supplies the pulsating voltage and current wave forms affect the motor performance by increasing motor heating and degrading commutation Because of these ef fects it is necessary that the motors be designed or specially selected to suit this type of operation The ratings of DC motors intended for operation from rectified power supplies are based upon motor tests using a suitable power supply The specific characteristics for three phase rectified power supplies described in the Power Supply Identification section are in common use For operation of motors from rectified power supplies other than those given in this section refer to GE Industrial Systems A motor may under some conditions be operated from a power supply different from that indicated on the nameplate Letters used to identify power supplies in common use have been chosen in alphabetical order of increasing magnitude of ripple current Power supply compatibility can be judged by Table 4 12 GEH 5304A Table 3 Bearing Life at 1750 RPM Average Speed Vs Load W For other average speeds multiply life by life factor Less Than Speed 5
42. re before entering the motor Dirt can collect on the inside surface of the drive end coil support and on the underside of the armature coils This dirt can be easily removed with compressed air or a vacuum It is important to realize that when blowing out a machine dirt may settle in a previously cleaned area and it may be necessary to repeat the cleaning process to ensure that a thorough job is done 28 GEH 5304A Dirt can be removed from stationary parts of the machine by either compressed air or a vacuum nozzle or a combination of both Air should be directed between the stator coils into the pocket corners of bearing brackets around the cables and onto the brush rigging Special care should be taken to keep the commutator clean The commutator should be wiped with a clean lint free cloth after blowing out e Warning Safety glasses and or other protective equipment should be used to prevent injury to eyes and respiratory organs e Warning High voltage electric shock can cause serious or fatal injury Electrical circuits must be de energized prior to cleaning or other maintenance activities Ground electrical circuits prior to cleaning or maintenance to discharge capacitors Failure to observe these precautions may result in injury to personnel Caution Liquid solvents should not be directly applied to the commutator armature field coils or any electrical part of a DC machine Liquid solvents carry co
43. re must be taken in handling to avoid twisting bases GEH 5304A Table 1 Typical Weights Motor Less Accessories Armature CD2512AT 500 120 CD2513AT 550 135 CD2812AT 650 160 CD2813AT 750 190 Typical weights For specific weight see certified outline INSTALLATION Installation should be in accordance with the National Electrical Code and consistent with all local codes Cou pling belt and chain guards should be installed as needed to protect against accidental contact with moving parts Machines accessible to the public should be further guarded by screening guard rails etc to prevent personnel from coming in contact with the equipment Fully guarded covers are supplied on motors and generators Shaft guards are supplied on motor generator sets Totally enclosed and waterproof motors must have all covers securely in place with gaskets intact in order to ex clude dirt oil and water It is generally preferred to remove plugs from drain holes at the bottom of the frame to ensure that no condensation will collect inside the motor However if the installation requires plugs to be installed they must be removed periodically to make certain that all water is eliminated A Location Motors and generators should be installed so that they will be readily accessible for routine inspection and maintenance They are suitable for use in ambient temperatures from 0 C 32 F to 40
44. rrective action The chart below may indi cate some possible causes of these conditions suggesting the proper productive maintenance Type of Brush Light Unbalanced Brush In Use Contamination Electrical Electrical Electrical Armature Shunt Pressure Abrasive Porous Abrasive Adjustment Overload Load Connection Field Light Vibration Brush Brush Gas Dust Streaking Threading x Grooving X X Copper Drag X X X X Pitch Bar Marking X X X X X Slot Bar Making X X x HOW TO GET THE MOST VALUE FROM THIS CHART The purpose of the Commutator Check Chart is to help you spot undesirable commutator conditions as they develop so you can take corrective action before the condition becomes serious This chart will also serve as an aid in recognizing satisfactory surfaces The box chart above indicates the importance of selecting the correct brush and having the right operating conditions for optimum brush life and commutator wear For additional information or help with carbon brush application or commutation problems Contact your nearest GE Sales Office or Distributor 25 GEH 5304A The Following Noise Levels Hove Bean Measured On Typical Machines Of The Listed Frame size And Are Hot Guorontesd Limlta NOISE LEVEL FOR TYPICAL DPFG DC MOTORS OPERATED FROM MG SET SUPPLY WITH INTERNAL FAN B WITHOUT INTERNAL ENCLOSED
45. s tel sida aenea bs mE ru 24 Mechanical ao ponia MAH 25 Shatt End wr AIR 25 Waterproof Machines 25 Lubrication of Flexible 23 eec ante eed 25 INNS LINES soso cee eae ies 26 Visual Inspection n vesci e d a ce SHEA 26 Insulation Resistance 26 Cleaning of Windings nents E eo a robe iustas etes 27 Oly qon ee d eii dE 28 Drying of Windings EP 29 PST VAC Shop CIO mir s oid Metus Umm ub Um DM ES 29 TE T EC EN 29 Renewal soos ener eonun dt oA RUE D dd ab M ELE un 30 Storage of Renewal Parts 5 5 rae e HD ARE HR sanded Eee EL PAN EAE EE EG P 30 Commutator Check C Bart eve E tatu sh meus du ees 32 GEH 5304A Direct Current Motors and Generators Type CD Frames 2512AT 2513AT 2812AT 2813AT INTRODUCTION This instruction book covers the CD2512AT CD2813AT line of DC motors and generators High voltage and rotating parts can cause serious or fatal injury The use of electric machinery like all other utilization of concentrated power and rotating equipment can be hazardous Installation operation and maintenance of elec tric machinery should be performed by quali
46. se 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 Warning Before operating any motor after a suspected failure it should be inspected for damage Remove covers and make visual inspections of the brushes commutator connections and windings Electrical tests of each winding to check for open or short circuit or grounds should be made Any arc damage should be cleaned up and repaired as necessary Brushes may need reseating before operation RENEWAL PARTS Using genuine GE renewal parts assures continued high performance and the full benefits of the long operating life designed into your GE motor Downtime can be minimized by having a protective stock of parts available for replacement Refer to Table 14 The permanently attached nameplate on your GE motor displays the model and serial number providing all the information needed for ordering Parts are available directly from authorized GE Industrial Systems parts dis tributors Direct electronic access to the factory database of motor information and warehouse inventories enables distributors to quickly identify part numbers delivery times and order status A Storage of Renewal Parts Store supply parts in a clean dry ventilated place protected from rodents and termites to prevent damage or loss Slush all finished iron or steel surfaces with heavy oil or compound to
47. surfaces can result in rusting or corro sion and the electrical windings may suffer serious damage Where wetness and or cold conditions are present the machine and its parts must be protected by a safe reli able heating system which at all times will keep the machine temperature slightly above that of the sur rounding atmosphere If a space heater is included in the machine it should be energized Smaller machines shipped in paper cartons are protected from condensing type wetness by the insulating characteristics of the carton To avoid sweating where these have been exposed to low temperature for an extended period allow the machine and carton to attain room temperature before unpacking GEH 5304A Brushes should not remain in contact with the commutator during prolonged storage because corrosion may occur and later result in flat spots on the commutator Release the brush springs and lift the brushes when stored for a period of more than six months All exposed machined steel parts are slushed with a rust preventative before shipment These surfaces should be examined carefully for signs of rust and moisture and reslushed if necessary Once started rust will continue if the surface is reslushed without first removing all rust and moisture Rust may be removed by careful use of fine abrasive paper Slushing compound can be removed by use of a suitable solvent such as mineral spirits Mineral spirits are flammable and moderately t
48. t the hub faces are ex posed 2 Check the coupling hub spacing in accordance with the outline dimensions with the units in the mechanical center of their end play 3i Check parallel alignment by using a straightedge across the hubs at both vertical and horizontal locations or by clamping a dial indicator to one hub and indicating the other hub on its outside diameter Be sure that the dial indicator supports do not bend or sag since this will give inaccurate readings 4 Use the dial indicator at hub faces and rotate both units together 90 180 270 and 360 or measure the gap at each position by inserting a feeler gage The readings should not vary more than 0 002 Correct any vertical misalignment by shimming under the units Horizontal alignment should be corrected by shifting machine on the base Grouting On concrete foundations a minimum of 1 should be allowed for grouting A rich non shrink grout should be used High grade grout mixtures are available commercially If the grout is to be prepared at the site a cement sand ratio of 1 2 is recommended No more than enough water should be used to give a stiff mixture The clean but rough surface of the foundations should be wet and the grout forced or puddled under the base V Belt Drives The V belt system produces a heavy shaft and bearing loading making it necessary that these factors be considered carefully for proper application Since belt drives impose a bendin
49. tion resistance measurements are affected by the following a Magnitude of test voltage b Time the test voltage is applied 6 Temperature d Surface condition contaminants Moisture When a 1000 volt megger is used taking readings of one minute and converting the data to 40 C 104 F the data will evaluate the other two factors 1 6 the contaminants and the moisture present The insulation resistance varies inversely with the winding temperature That is as the temperature decreases the insulation resistance increases in accordance with Table 13 27 GEH 5304A Table 13 Effect of Temperature on Insulation Resistance Winding Temperature Multiplying Factor to Obtain Insulation Degree C Resistance at 40 C 104 F 80 10 00 70 5 50 60 3 10 50 1 70 40 1 00 30 0 55 20 0 31 10 0 17 Note that for a 104 F 40 C decrease in temperature the insulation resistance is increased by a mul tiplier of ten The insulation resistance of a machine 15 affected by its design The insulation resistance of the ar mature circuit corrected to 104 F 40 C should measure at least 1 5 megohms If measured value is below 1 5 megohms clean and re test If the measurements are less than this limit the machine should be dried or cleaned to attempt to in crease the insulation resistance Regular periodic measurements of insulation resistance can give a useful indication of the rate of insulation
50. tors are to be mounted with the shaft greater than 15 from the horizontal special brakes should be specified Improper selection or installation of a brake and or lack of maintenance may cause brake failure which can result in damage to property and or injury to personnel Refer to the separate instruction book pertaining to the brake fur Warning nished N Inspection After Starting The following items should be checked after the machine is running 1 Bearings Ball bearing or roller bearing housing temperature should be no more than 80 C 176 F Excessive bearing temperature may be caused by misalignment or improper greasing Refer to Alignment and Bearing Maintenance sections 18 V GEH 5304A 2 Noise and Vibration Check for unusual vibration or noises that might indicate rubbing or interference Vibration of new machines at the bearing housings as measured by a vibration meter should not ex ceed the values shown in Table 8 Measurements are according to NEMA MG 1 12 06 and MG 1 12 07 The most likely cause of vibration in new machines is misalignment due to improper installation loose foot bolts uneven shimming under feet or damage to machine during shipment or installation Current ripple due to a rectified power supply may also be a source of vibration and audio noise Table 8 Maximum Amplitude in Inches RPM Peak to Peak 3000 4000 incl 001 1500 2999 incl 001
51. tors for Class locations must have leads sealed at the frame exit and a dust ignition proof conduit box See Sections 502 4 and 502 5 GEH 5304A B Mounting Motors and generators should be mounted on rigid and solid foundations Level the base or the machine Hold down bolts should be inspected regularly and kept tight The feet of the machine may be doweled to the foundation plates or base when alignment procedures are completed Sliding bases when used should be securely anchored to the foundation Motors are mechanically suitable for mounting with shaft horizontal or vertical on floor ceiling or sidewall When sidewall or ceiling mounted special provisions must be made to maintain the integrity of dripproof enclosures When motor is sidewall or ceiling mounted lifting points in addition to the standard lifting lugs may be required Lifting in these cases should be done by experienced riggers to avoid injury to personnel and damage to the motor Warning C Alignment Be sure to align or check alignment carefully on either motors or motor genera tor sets Misalignment can cause excessive vibration and damaging forces on shafts and bearings Caution Time taken to assure good alignment will be returned in reduced downtime 1 Coupled Drive When a motor is used to drive a unit flexible couplings must be used to facilitate alignment Three bearing construction requires a rigid coupling Careful
52. tridge 1 3 to 1 2 full of grease butter the bearings and fill the grease reservoir in the bear ing bracket 1 3 to 1 2 full of grease Table 9 Recommended Regreasing Periods Relubrication Interval In Hours Of Operation Frame Average Ball Roller Size RPM Bearing Bearing CD2512AT 500 36000 18000 CD2813AT 1150 15000 7500 1750 10000 5000 3000 5000 2500 Table 10 Standard Bearings for CD2512AT CD2813AT Motors Commutator End Drive End Standard Ball Standard Ball Oversize Ball Oversize Roller Frame Basic Basic Basic Basic Size Brg No AFBMA Brg AFBMA Brg No AFBMA Brg No AFBMA 25XX 307 35BCO3X3 309 45BCO3X8 310 50BCOSX3 310 50RU03X3 28XX 309 45BCOS3X3 310 50BCO3X3 311 558003 8 311 8 21 GEH 5304A Table 11 Sources of Supply for Bearing Greases GE Supplier s Temperature Designation Supplier Designation Standard Temperature D6A2C5 GE Supply GE Ball Bearing 15 F to 212 F 158 Gaither Drive Grease supplied in 10 C to 100 C Mt Laurel NJ 08054 In small tubes and cans 1 800 341 1010 Shell Oil Company Alvania No 2 P O Box 2463 One Shell Plaza Houston TX 77002 713 241 4201 Texaco Inc Regal AFB 2 200 Westchester Avenue White Plains NY 10650 914 253 4000 Low Temperature D6A4 Shell Oil Company Aeroshell No 7 60 F to 200 F P O Box 2463 51 C to 93 C One Shell Plaza Houston TX 77002 713 241 4201 High Temperature D
53. ture failure Application data is available from GE Industrial Systems for any particular machine giving suggested maximum loads for vari ous operating conditions Operation within these maximum loads will limit the temperature to suitable val 25 GEH 5304A ues 26 GEH 5304A For maximum insulation life these three causes of insulation failures should be prevented 1 2 3 Contamination Mechanical factors High temperatures L Testing Methods 1 Visual Inspection In addition to collecting contaminants insulation shrinks cracks and becomes brittle with heat and age These changes allow movement of coils loose filler strips loose ties chafing and abrasion all of which can be picked up by visual inspection Experience and judgement can be gained by careful observation and comparing results of visual in spections with insulation resistance measurement GE Service Shops have personnel who can inspect equipment and point out potential trouble areas Their services can help build experience and judge ment for future visual inspections Insulation Resistance Measurement A method of measuring the insulation resistance is described in Report 43 Recommended Practice for Testing Insulation Resistance of Rotating Machinery published by IEEE 345 E 47 Street New York NY 10017 The resistance measurements should be taken with a 500 or 1000 volt megger and corrected to 104 F 40 C The insula
54. urrent ripple SCR phase back and short time overload affect the temperature relationship between armature and commutating field complete protection from all conditions resulting from over temperature is not possible The device is intended to guard against complete loss of normal ventilation air high ambient temperature and prolonged operation of self ventilated motors at very low speeds 15 GEH 5304A Thermostats automatically reset after the motor has cooled somewhat In order to prevent property damage or injury to personnel the control circuit should be designed to prevent re energizing of the motor when the thermostat resets Warning Table 5 Maximum Current Ratings for Thermostats on Dripproof and Totally Enclosed Motors Normally open or normally closed contacts Load 125VAC 250VAC 600VAC 30VDC Do not use above 600 VAC or 30 VDC Resistive 5 Amps 2 5 Amps 1 Amp 5 Amps Inductive 3 Amps 1 5 Amps 0 5 Amps 1 5 Amps Suitable for pilot duty only relay coils H Speed Limit Device The mechanical speed limit device is non adjustable Tripping speed is specified by a note on the print cer tification for each specific order The speed limit electrical contacts are normally closed and are usually connected in relay or holding circuits Current ratings are the same as those listed in Table 5 A speed limit device is furnished on machines only when ordered The
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