WEG W22Xdb C 315 Installation, Operation And Maintenance Manual Download

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W22Xdb

– Flameproof Motors

Motors | Automation | Energy | Transmission & Distribution | Coatings



Rib-cooled



Tube-cooled

Installation, Operation and Maintenance
Manual

Summary of Contents for W22Xdb C 315

Page 1: ...W22Xdb Flameproof Motors Motors Automation Energy Transmission Distribution Coatings Rib cooled Tube cooled Installation Operation and Maintenance Manual ...

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Page 3: ... to ensure safe and continuous motor operation ensuring its safety and that of its installations In case of any remaining doubts please contact WEG Maintain this manual close to the motor at all times so it can be consulted whenever necessary W22Xdb Rib cooled W22XdbT Tube cooled www weg net w22xdb www weg net w22xdb tube This manual is also applicable for BFGC4 line motors ATTENTION Following the...

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Page 5: ... 15 3 7 6 INSULATION RESISTANCE 16 3 7 7 EXPOSED MACHINED SURFACES 16 3 7 8 FLAMEPROOF JOINTS 16 3 7 9 BEARINGS 16 3 7 9 1 ANTIFRICTION BEARINGS LUBRICATED BY GREASE 16 3 7 9 2 SLEEVE BEARINGS 16 3 7 10 CONNECTION BOX 17 3 7 11 INSPECTIONS AND RECORDS DURING STORAGE 17 3 7 12 PREPARATION FOR SERVICE AFTER LONG TERM STORAGE 17 3 7 12 1 CLEANING 17 3 7 12 2 BEARINGS LUBRICATION 18 3 7 12 3 INSULATIO...

Page 6: ...LLATION CHECKING 36 SPACE HEATERS 36 7 NOISE LEVEL 37 8 MAINTENANCE 37 CLEANLINESS 37 8 1 1 PARTIAL CLEANING 37 8 1 2 COMPLETE CLEANING 37 LUBRICATION 38 8 2 1 GREASE LUBRICATED BEARINGS 38 8 2 2 TYPE AND GREASE CHARACTERISTICS 39 8 2 3 LUBRICATION INTERVALS 39 8 2 4 LUBRICATION INTERVALS FOR HIGH TEMPERATURE 41 8 2 5 QUALITY AND QUANTITY OF GREASE 43 8 2 6 COMPATIBILITY 43 8 2 7 LUBRICATING INSTR...

Page 7: ...CE 58 COMMOM DAMAGE TO INDUCTION MOTORS 58 10 1 1 SHORT CIRCUIT AMONG TURNS 58 10 1 2 DAMAGE CAUSED TO THE WINDING 58 10 1 2 1 ONE PHASE OF THE BURNT WINDING 58 10 1 2 2 TWO PHASES OF THE BURNT WINDING 58 10 1 2 3 THREE PHASES OF THE BURNT WINDING 58 10 1 3 DAMAGE TO THE BEARINGS 59 10 1 4 SHAFT RUPTURE 59 10 1 5 DAMAGE DUE TO BADLY ADAPTED TRANSMISSION PARTS OR DEFECTIVE ALIGNMENT OF THE MOTORS 5...

Page 8: ...8 Flameproof motors www weg net ...

Page 9: ...d here may be changed without prior notice DANGER During operation such equipment has energized or rotating parts that may present high temperature Opened terminal boxes unprotected couplings or incorrect handling may cause serious accidents to people and or material damage The people responsible for installation safety should ascertain that Only qualified personnel perform installation and operat...

Page 10: ... and Maintenance Manual gets lost WEG may provide an additional sample WEG is prepared to solve any further doubt you may require In this case motor serial number should be also supplied Aiming a satisfactory motor performance we suggest to make the installation plan commissioning start up and maintenance in conjunction with WEG Service Department people ATTENTION To prevent from eventual motor op...

Page 11: ...g symbols must be considered DANGER Failure to observe the procedures recommended in this warning may result in death serious injuries and extensive equipment damage ATTENTION Failure to observe the procedures recommended in this warning may result in equipment damage NOTE This provides important information for correct understanding and proper operation of the product EX ATMOSPHERE INFORMATION Th...

Page 12: ... box holes if any These protection items must be kept in place until the final installation has been concluded For motors supplied with roller bearings shaft should be rotated manually a few times for a uniform grease distribution ATTENTION To ensure the degree of protection the connection box should be kept closed Before energise the motor check the cleanliness and moisture condition inside of th...

Page 13: ...nding insulation resistance must be measured before operating the motor If the ambient contains high humidity a periodical inspection is recommended during storage It is difficult to determine rules for the actual insulation resistance value of a motor as the resistance varies according to type size rated voltage condition of the insulating material used and method of construction of the motor A l...

Page 14: ...d the acceptable values according to Table 3 2 otherwise refers to WEG for instructions POLARIZATION INDEX The polarization index P I is traditionally defined as a ratio of the 10 min insulation resistance IR10 to the 1 min insulation resistance IR1 tested at a relatively constant temperature Through the polarization index the user can evaluate the motor insulation conditions according to the tabl...

Page 15: ...ire detection system Electrical supply for space heater and illumination must be provided If some of these requirements can not be attended by the storage environment WEG suggests that additional protections be incorporated in the motor packing during the storage period like follows Closed wooden or similar box with electrical installation enable to the space heaters supply Closed wooden box or si...

Page 16: ...ice and turn the shaft manually to conserve the bearing in good conditions After perform the shaft rotation this one shall be turned at 45º from the original position After 6 months of storage and before starting in operation the bearings should be regreased as item 8 2 7 of this manual If motor is kept in storage for approximately 2 years or more the bearings must be inspected and regreased accor...

Page 17: ...oxes must be done using certified cables glands with the same or higher protection of the motor Ex d IIB Ex d IIC Ex e Ex d I or Ex e I indicated in the motor nameplate If any of these items are not in proper condition an adequate maintenance should be performed and if necessary the damaged parts should be replaced EX ATMOSPHERE INFORMATION The use and assembling of the appropriate cable glands is...

Page 18: ... where was applied internally the protection product against corrosion and desiccant should be disassembled as the procedure described in the item 8 2 10 3 of this manual washed for remove the anti corrosive agent and the desiccants Assemble again the bearings as the procedure described in the item 8 2 10 4 of this manual and proceeds the re lubrication 3 7 12 3 INSULATION RESISTANCE VERIFICATION ...

Page 19: ...the original position 1M All inspections that must be performed and recorded on a monthly basis 2M All inspections that must be performed and recorded every two months 6M All inspections that must be performed and recorded every six months Table 3 5 Maintenance plan for outdoor storage Inspection Periodicity 1M 2M 6M 2Y BS Storage Cleanliness X X Humidity and Temperature X Check for signs of insec...

Page 20: ... all of eyebolts fixed in the frame supplied together with the motor Failure to observe these precautions may result in damage to the equipment injury to personnel or both When the risk of motor damage exists by the lifting chains special tools must be predicted by the customer 4 1 2 VERTICAL MOTORS Figure 4 2 W22Xd LINE vertical ribbed cooled motors The handling of the vertical ribbed cooled moto...

Page 21: ...rizontal tube cooled motors 4 2 2 VERTICAL MOTORS Figure 4 5 W22XdT LINE vertical tube cooled motors The handling of the WEG vertical motors must be done as as showed in the Figure 4 5 Always use the 4 eyebolts for motors movement in vertical position therefore the lifting chains or cables can also stay in the vertical position avoiding thus awful efforts to the eyebolts 4 2 3 VERTICAL TUBE COOLED...

Page 22: ...lift the crane that is fixed in the motor non drive end side until the motor reaches the balance Loosen the crane that is fixed in the motor drive end and turn it 180º to allow the fixation of the crane previously loosen in the other 2 eyebolts located in the motor non drive end Fasten the loosen crane in the other 2 eyebolts on the motor non drive end and lift it until the motor gets the vertical...

Page 23: ...ations Flexible Structures that Support Machines with Rotating Elements NOTICE With the machine mounted and coupled the relation between the foundation natural frequency and The motor speed frequency The double speed frequency The double line frequency Must be as specified according described bellow Foundation natural frequency of the 1st order 25 or 20 in relation to the above frequencies Foundat...

Page 24: ...electric motors The type and size of the foundation as well as other fixing devices for this purpose will depend on the type and size of the motor The motors can be mounted on a concrete base with four foundation blocks See dimensions of the installation components in the following tables Table 5 1 Fixation dimensions example of installation Hole diameter in the motor feet Foundation block Fasteni...

Page 25: ...est introduce two tapered pins for correct fastening For this purpose use the pre dilled holes in the feet 5 1 3 2 SLIDE RAILS When drive system is done by pulleys the motor should be mounted on slide rails and the lower part of the belt must be pulling The nearest rail to the drive pulley is positioned in such a way that the adjusting bolt 1 is between the motor and the driven machine The other r...

Page 26: ... driven machine should be taken into consideration Expansion effect of the components may change the alignment leveling conditions during motor operation After the set motor and base is perfectly aligned either at cold or at hot condition motor must be bolted as shown in Figure 5 8 There are instruments which use visible laser ray added by specific computer programs that can perform and ensure hig...

Page 27: ...ents can be checked by inserting a strip of paper on which the teeth marks will be traced after a single rotation 5 1 5 3 BELT AND PULLEY COUPLING Belt transmission is the most commonly used when a speed ratio is required The couplings used must be suitable to withstand radial and axial vibrations during operation Special care must be taken to avoid that the allowable load and speed limits given b...

Page 28: ...d unnecessary thrusts on the bearings by ensuring that the shafts are parallel and the pulleys perfectly aligned Figure 5 13 Laterally misaligned pulleys when running transmit alternating knocks to the rotor and can damage the bearing housing Belt slippage can be avoided by applying a resin for this purpose Figure 5 13 Correct pulley alignment Belt tension is only required to avoid slippage during...

Page 29: ...e tensiometer should be lined up with the bottom of a straight edge placed on the outside diameters of the two sheaves For a multiple belt drive the belt deflection is lined up with the top of the next belt Take a reading from each belt for an average The tensiometers instructions for use and belt tension measurement are supplied with the equipment and they are very simple allowing the installers ...

Page 30: ...ust be considered Bearing axial clearance which is shown on the table below for each bearing size Axial displacement of the driven machine if any Maximum axial clearance allowed by the coupling Table 5 3 Standard clearances applied to sleeve bearings Clearances applied to sleeve bearings for flameproof motors supplied by WEG Bearing size Axial clearance in mm 9 3 3 6 1 11 14 1 This is a standard v...

Page 31: ...e standards motor is balanced with half key that is the key way is fulfilled with a piece of metal of identical width thickness and height of the keyway The maximum allowable vibration levels recommended by WEG for motors in operation are according to ISO 10816 3 Standard This standard classifies the support class as rigid if the lowest natural frequency of the combined machine and support system ...

Page 32: ...e them at start up For details regarding activation of automatic lubricators refer to sub section 8 2 9 ELECTRICAL ASPECTS 5 2 1 POWER SUPPLY Make sure the motor is connected to the correct power supply Proper electric power supply is very important All the wires and protection system must ensure an excellent quality of electric power supply on the motor terminals The WEG motors are constructed in...

Page 33: ... an ambient temperature of 80ºC or above if indicated on a motor nameplate Make sure the cross section and insulation of connection cables are suitable for the motor current and voltage As standard W22Xd motors are prepared in accordance with LOW VOLTAGE 1 1kV Table 5 6 Terminal box entry holes and cables cross section Low voltage Terminal boxes with protection Ex d or Ex e Current No of entrance ...

Page 34: ...terminal box entrance and the motor terminals 5 2 3 ROTATION DIRECTION If the power supply cables are connected in the phase sequence L1 L2 L3 with U1 V1 W1 or T1 T2 and T3 motor will turn clockwise CW viewed from drive end DE side If two connections are reversed that is if the power supply with the same sequence of phase L1 L2 L3 is connected with V1 U1 W1 or U1 W1 V1 or W1 V1 U1 the motor will t...

Page 35: ...nnected directly to the motor terminal boxes or to connection heads with ATEX and or IECEX certification mounted in the motor endshields The references of the respective certificates must be considered EX ATMOSPHERE INFORMATION When the motors are equipped with thermal protectors Pt100 thermocouples with Intrinsic Safety Protection Ex i the safety parameters of the measurement or monitoring system...

Page 36: ...n it is completely stop and all phases disconnected from the power supply 6 MECHANICAL INSTALLATION CHECKING Check if all motor fixing bolts are duly fastened Guarantee that flameproof joints are in good condition perfectly clean without any deformation scratches marks etc before closing terminal boxes covers fixing gland plates and or threading cable glands Flameproof joints are protected against...

Page 37: ...cked in order to avoid bearing damage To lock the shaft use the shaft locking device shipped together with the motor See section 2 2 CLEANLINESS Motors should be kept clean free of dust dirt and oil Soft brushes or clean cotton rags should be used to clean the motors A jet of compressed air should be used to remove non abrasive dust from the fan cover and any accumulated grime from the fan and coo...

Page 38: ... A well tuned ear is perfect capable of distinguishing unusual noises even with rudimentary tools such as a screwdriver etc For a more reliable analysis of the bearings sophisticated equipment is required ATTENTION Bearing temperature control is also part of routine maintenance Max absolute temperature shall not exceed 100ºC Absolute temperature temperature rise ambient temperature For an ambient ...

Page 39: ...ocarbon 65 up to 204 Low temp Kluber Isoflex NBU 15 Barium Complex Mineral ester Synthetic Hydrocarbon 35 up to 90 High speed 3600 rpm ATTENTION For correct lubrication always use the type of lubricant indicated on the motor nameplate 8 2 3 LUBRICATION INTERVALS Lubrication intervals depend on the motor speed working temperature type of grease used and working conditions The lubrication interval a...

Page 40: ...or horizontal mounting ROLLER BEARING Bearing Poles Operating Hours h Grease Quantity g 50Hz 60Hz NU218 2 1200 1000 24 NU220 2 1000 31 NU319 4 3500 2500 45 6 4500 4500 8 NU322 4 2400 1600 60 6 4500 3500 8 4500 NU324 4 2000 1300 72 6 3900 3000 8 4500 4500 NU326 4 1700 1000 81 6 3500 2600 8 4500 4000 NU328 4 1400 1000 93 6 3000 2200 8 4400 3500 Lubrication intervals for horizontal mounted ribbed coo...

Page 41: ...ng at an ambient temperature range 20ºC up to 40ºC or 55ºC up to 40ºC are present in the Table 8 7 and Table 8 8 Table 8 7 Ball bearings lubrication intervals vertical mounting tube cooled motors BALL BEARING Bearing Poles Operating Hours h Grease Quantity g 50Hz 60Hz 6330 4 4100 2700 104 6 4500 4500 8 6332 4 3600 2300 116 6 4500 4500 8 6234 4 3900 2600 81 6 4500 4500 8 6238 4 3200 2000 81 6 4500 ...

Page 42: ...1700 1300 8 2400 2000 NU328 4 1000 1000 93 6 1500 1100 8 2200 1700 Lubrication intervals for horizontal mounted ribbed cooled and tube cooled motors 50Hz and 60Hz with special mounting of two 2 bearings one 1 roller bearing and one 1 ball bearing operating at an ambient temperature range 20ºC up to 55ºC are present in the Table 8 11 Table 8 11 Roller and Ball bearings lubrication intervals horizon...

Page 43: ...6 3200 2600 8 4100 3500 6234 4 1900 1300 81 6 3400 2800 8 4300 3700 6238 4 1600 1000 81 6 2900 2300 8 3800 3300 For motors working in ambient temperatures between 20ºC and 60ºC a derating factor of 0 8 must be applied to the values indicated in the Table 8 9 to Table 8 15 8 2 5 QUALITY AND QUANTITY OF GREASE The relubrication can only be made with compatible grease and in the amount indicated on t...

Page 44: ...amount of grease and run the motor at full speed for approximately one minute Switch off the motor and inject the remaining grease As a rule motors should be greased with the motor in operation Otherwise the grease instead of going through the bearing area will penetrate into the motor through the internal seal of the bearing housing NOTE Grease fittings and surrounding areas must be clean before ...

Page 45: ...housing the time setting for each lubricator for drive end and non drive end sides d Activate each lubricator accordingly If refilling is not allowed a Remove lubricator b Install new lubricator filled with the same grease or with a compatible one c Check in lubrication nameplates for each bearing housing the time setting for each lubricator for drive end and non drive end sides d Activate each lu...

Page 46: ...ine bolt 7 Lifting eyebolt 8 External cover bolts 9 External cover 10 Bearing liner bottom half 11 Bearing liner top half 12 Oil ring 13 Oil inlet 14 Connection for temperature sensor 15 Oil sight glass or oil outlet for circulating oil system 16 Tapped hole for oil sump temperature measurement 17 Stationary baffle bolt 18 Labyrinth seal carrier outboard 19 Labyrinth seal carrier inboard bearing h...

Page 47: ...ERISTICS Table 8 16 Oil specification and characteristics Polarity Lubricant Specification Viscosity Range ISO 40ºC cSt SSU 100ºF s 2 poles Mineral oil ISO VG32 28 8 35 2 137 164 4 poles Mineral oil ISO VG46 41 4 50 6 193 235 8 2 10 3 DISASSEMBLY OF THE SLEEVE BEARING SYSTEM TYPE EF To disassemble the bearing liner and all associated parts from the bearing housing carry out the following instructi...

Page 48: ...engage the dowels holding the oil ring halves together and remove the oil ring Remove the garter spring that encircles the labyrinth seal Remove the top half of the seal then rotate the bottom half of the seal out the groove in the bearing housing and remove it Disconnect and remove RTD s thermocouples or any other temperature detecting instruments that enter the lower half of the bearing liner Us...

Page 49: ... the seal fits properly into the groove Ensure also that the anti rotation pin is seated without any contact with the corresponding hole in the liner DANGER When assembling the fan cover of sleeve bearing motors care must be taken to correctly align the fan air defletor to avoid rubbing between parts ATTENTION Housing or liner may be interchanged as complete assemblies only Individual halves are n...

Page 50: ...in the upper half of the housing or carrier ring Incorrect installation destroys the seal The seal is to be carefully cleaned and coated with a non hardening sealing compound on the faces in contact with the grooves The drain holes in the lower part of the seal must be clean and remove obstruction When installing the bottom half of the seal press it lightly against the underside of the shaft 8 2 1...

Page 51: ...n Table 8 18 Figure 8 6 Disassembly of terminal box cover SAFETY MEASURES FOR EXPLOSIVE GAS ATMOSPHERES A safe work procedure should be implemented to permit ignition sources to be used in a hazardous area under prescribed conditions A safe work permit should be issued when a specific location has been assessed to ensure that gas or vapour is not present and is not expected to be present in quanti...

Page 52: ...ld 8 5 1 STANDARD SOLUTION Pull the bearing probe cable until the connecting point Disconnect the both sides of the connector Remove the endshield completely A B Figure 8 9 Disconnecting the connectorl RE ASSEMBLY THE ENDSHIELD When proceeding to the re assembly care must be taken with the re connection of the conectors Connect both sides of the connector A B C Figure 8 10 Reconnecting the connect...

Page 53: ...X ROTATION PROCEDURE For motors equipped with Power Terminal Box PTB located at top of the motor with cable entries from drive end side Figure 8 12 Example of Motor with PTB with cable entries from DE side Procedure to rotate the Power Terminal Box example for 90º CCW seen from top of PTB Remove the PTB cover a Unbolt the PTB cover 8 bolts b Install a magnet in the center of PTB cover c Pull the m...

Page 54: ...wer Terminal Box and Adapter cylindrical joints ALTERNATIVE PROCEDURE TO ROTATE THE POWER TERMINAL BOX EXAMPLE FOR 90º CCW SEEN FROM TOP OF PTB Remove the PTB cover a Unbolt the PTB cover 8 bolts b Install a magnet in the center of PTB cover c Pull the magnet to remove the PTB cover Loose the PTB a Unbolt the PTB remove the 8 bolts inside terminal box b Fix two eyebolts in the fixing holes of the ...

Page 55: ...possible at constant temperature Any intervention on the motor may only be performed by a specialized WEG certified technician 9 MAINTENANCE PLAN Damaged parts with cracks damaged machined parts and defective threads must be replaced It is recommended not to repair such parts All services described herewith should be carried out by skilled and experienced people so as to avoid damage to the equipm...

Page 56: ...ged and gaskets if any are satisfactory and positioned correctly x 14 Condition of enclosure gaskets is satisfactory x x 15 There is no evidence of ingress of water or dust in the enclosures in accordance with the IP rating x x 16 Dimensions of flanged joint gaps are within the limits in accordance with manufacturer s documentation or within maximum values permitted by relevant construction standa...

Page 57: ... using electrical test equipment EVERY 3 YEARS Complete revision Complete motor Take motor apart Check spare parts Stator and rotor winding Clean it Check winding and wedges winding Measure insulation resistance Bearings Clean bearings Replace if require Check half coupling and replace it if required Check shaft seat and repair it if required Terminal box grounding Clean inside and refasten bolts ...

Page 58: ...est of the winding at the same time the rotation drops drastically If the motor stops the current will rise from 3 5 to 4 times its rated value Most of the time when this default occurs it s because a protection switch has not been installed or because this switch has received an excessively high regulation 10 1 2 2 TWO PHASES OF THE BURNT WINDING This default will occur due to lack of current on ...

Page 59: ...ternate flexion efforts that require the shaft in motion the ruptures get deeper from the outside in until they culminate with the rupture when the resistance of what s still left of the shaft section is no longer sufficient Avoid using additional millings on the shaft holes for fastening bolts etc because this can cause stress concentrations The replacement of only one or other parallel belts of ...

Page 60: ... cables Excessive no load current Very high power supply voltage Measure the power supply voltage and set it to the correct value Heating on the stator winding Short circuit among turns Rewind Interruption of parallel wires or winding phases of the stator Defective connection Provide reconnection Stator winding becomes very hot under load Insufficient cooling due to dirty air channels Open and cle...

Page 61: ...alance of the components or the driven machine Perform new balance Defective coupling Repair or replace the coupling Wrong rotation direction of the motor Invert 2 phase connection Noisy operation when uncoupled Unbalance Noise continues during deceleration after switching off the voltage Perform new balancing Interruption on one phase of the stator winding Measure the current input of all the con...

Page 62: ...n plug and let the motor run until the excess of grease comes out Excessive axial or radial load Decrease the belt tension Unsatisfactory engagement of connecting gears To be reconditioned Bent shaft excessive vibration Correct the shaft and check the rotor balance Check the source of the vibration and correct it Lack of grease Add grease to the bearing Hardening of grease results in locking of ro...

Page 63: ...riting by Weg This constitutes WEG only warranty in connection with this sale and is in lieu of all other warranties expressed or implied written or oral There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale No employee agent dealer repair shop or other person is authorized to give any warranties on behalf of WEG nor to assume for WEG any ot...

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WEG W22Xdb C 315, Installation, Operation And Maintenance Manual

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