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Mechanical

Faults and remedies

Fault

Possible cause

Remedy

Rough running

When coupled, machine runs

unevenly or with strong vibration,

with no fault when uncoupled

Fault in power transmission

components or in driven equipment

Check power transmission, drive

components and alignment

Settling of foundation

Restore correct foundation level,

realign machine set

Transmission or driven equipment

badly balanced

Rebalance

Machine runs roughly when

uncoupled

Bearing damage

Holding-down bolts loose

Refer to bearing faults below

Tighten and lock

Post-mounted coupling adversely

affecting rotor balance

Rebalance rotor with coupling

Damage to rolling bearings

Overheating immediately after

starting or regreasing

Too much grease filled

Fill and press in only the prescribed

amount of grease (See rating plate).

Overheating automatically disappears

after some time

Overheating after long period of

operation

Bearing cover seals rubbing

Remachine bearing cover, replace

damaged seals

Scraping, rubbing or knocking

noises in bearing

Change bearing (cause to be

determined by specialists)

Whistling sounds in grease

lubricated bearings

Bearing is dry

Inject grease

Damage on bearing cage

Replace bearing

Formation of indentations when

machine stationary

Vibrations being transferred to

bearings from external source

Isolate motor from external vibration or

keep rotor turning continuously

Formation of indentations when

machine in operation

Electric current flowing through the

bearing

Consult ABB

Содержание DC Machines DMI

Страница 1: ...DC Machines DMI Operating and Maintenance Instructions ...

Страница 2: ... ...

Страница 3: ...rical connection and commissioning 5 6 Operation 5 7 Maintenance and servicing 5 Insulation resistance Measuring insulation resistance 19 Filter Fans with air filters 27 Machines with heat exchangers 27 Dismantling and reassembling Dismantling 41 Reassembling 41 EC Directives Declaration of Incorporation 46 EC Declaration of Conformity 47 Commutator out of true 23 Drying of windings 26 Specificati...

Страница 4: ...per instal lation e g separation of signal lines and power cables screened cables etc is the responsibil ity of the erector of the installation For installa tions with power converters the EMC instruc tions of the converter manufacturer must be taken into account 3 Transport storage Report damage discovered after delivery to the transport company immediately If necessary stop commissioning Tighten...

Страница 5: ...e electrical connection is ensured no loose wire ends Use correct cable terminals Maintain clearances between live uninsulated parts and between such parts and earth There must be no foreign objects dirt or moisture in the terminal box Close unused cable entrance holes and the box itself in a dust and water tight manner For the trial run without output elements fix the key to the shaft For the con...

Страница 6: ...ne description The exact type designation and the most im portant technical data are shown on the rating plate located on the terminal box Technical data on rating plate Figure 1 Rating plate for DMI machine ...

Страница 7: ... 46 50 Armature DC voltage for alternative operation 39 43 47 51 Armature DC current for alternative operation 40 44 48 52 Speed rpm for alternative operation 53 Field exciter voltage alternative operation 54 Field exciter current alternative operation 55 Open row 56 Method of cooling 57 Degree of protection 58 Valid temp range for operation 59 Motor end for cooling air intake 60 Volume of cooling...

Страница 8: ...x complete 46 Gasket 47 Box bottom plate 48 Mounting rail 49 Terminal block 50 Terminal block 51 Earthing bar 52 Gasket 53 Box frame 54 Bar holder 55 Connection bar 56 Box cover 57 Gasket 58 Gasket 59 Connection cover 60 Bracket for brush gear positioning device 61 Screw for push gear positioning device 62 Earthing bar on 315 400 63 Spacer O ring on 315 400 Part No Description 22 Pressure finger s...

Страница 9: ... Machine description ...

Страница 10: ...omplications if corrosive gases are present which attack the commutator surface The gases that gives the greatest problems and should be avoided during storage are sulphurous gases chlorine ammonia If the machine is stored on a vibrating surface the antifriction bearings are subject to damage If this is the case the bearings may have to be replaced before the machine can be put into operation If v...

Страница 11: ...a thyristor fed DC machine The mass of the foundation of a foot mounted motor should be five times the mass of the motor or higher Remark Adequate space for inspection maintenance electrical cables and cooling ducts must be provided Grouting To ensure satisfactory results shrink free con crete should be used The instructions supplied by the manufacturer of the shrink free concrete should be follow...

Страница 12: ...ith a flexible coupling As standard the armature is balanced with a half key The balancing method is described on the rating plate When assembling the coupling halves take into account the following instructions R Remove the anti corrosion coating from the shaft extension R Follow the coupling supplier s assembly instructions Assembly of coupling The normal procedure of assembly is by heating the ...

Страница 13: ...are obtained To ensure correct alignment of the machine place suitable metal shims between machine feet and mounting blocks Installation instructions from the suppliers of pumps gear drives etc of ten specify the vertical and lateral displacement of the driving shaft at operating temperature It is important that these instructions are observed during alignment in order to avoid vibrations and othe...

Страница 14: ...nection from the left hand side or from the non drive end or drive end is possible by removing the terminals from A1 and A2 bar Turn the box frame so that the ter minal opening faces the desired direction If the terminals from the main field coils are obstructing the main cable entrance it is possible to interchange positions with the grounding bar Make sure that all cable shoes are connected to t...

Страница 15: ...ld coil 113 and interpole field coil series con nected switch off 1 115 116 Connection thermostats 3BSM 004641 on main field coil 115 and interpole field coil series con nected alarm 1 117 118 Connection brush wear protection acc to order 1 121 122 Connection heater 1 131 132 133 Connection PT 100 for bearings on D end 1 141 142 143 Connection PT 100 for bearings on D end 1 1 If provided Generator...

Страница 16: ...16 Machine installation Terminal diagram Terminal diagram for DMI 315 400 standard design shunt wound machine 2 Fig 10 Terminal diagram Formerly designated F4 Changed to F2 according to IEC 60034 8 ...

Страница 17: ... the values should be below 80 C measured on the outer bearing cover R that no unusual bearing noise is heard R that all instruments show normal readings R the control system of the thyristor converter R the shape and form of the current response R the commutation of the machine R that the vibration level does not exceed 4 5 mm s r m s WARNING If one of the covers close to the cooling air inlet is...

Страница 18: ... as well as air leakage filter in the cooler R If necessary replace the fan s filter Every 4 month R Measure the insulation resistance of the windings using a 500 V megger both before and after cleaning R Inspect all connections including the brush flexibles General Careful maintenance is the best insurance against failures and interruption of operation The maintenance schedule shown below is the ...

Страница 19: ... measured at the same time to enable the insulation resistance to be recalculated to correspond to a temperature of 40 C This can be accomplished by using the following formula 2 R40 C Kt40 C x Rt 2 R40 C insulation resistance corrected to 40 C Rt measured insulation resistance in MΩ at t C Kt40 C correction factor according to the diagram below Example In the winding of a 750 V motor the insulati...

Страница 20: ...tion of the contact surfaces wedging effect lateral wear Environment air humidity oil mist dust chemical vapours and surrounding air tem perature Patina A new commutator has a clean copper surface After some time of operation a patina is formed consisting of copper oxides mixed with particles from the brushes which together produce a hard resistant coating which protects the commutator A homogeneo...

Страница 21: ...e g as sparking high brush wear or scratched commutator The gases that give the greatest problem and should be avoided are sulphur dioxide hydro gen sulphide chlorine and ammonia These gases in sufficient concentration attack the patina break through it and attack the com mutator Caution If the measured vibration level exceeds 4 5 mm s r m s appropriate measures should be taken to reduce the level...

Страница 22: ...edding in and cleaning of the entire brush gear may the machine be started Fig 12 Brush Caution All brushes must be present for each commutator track surface in use otherwise brush wear will be increased Use only one brush grade per DC machine Commutation problems and consequential damage to machines equipped with different type of brush grade than the original type or the type suggested by ABB is...

Страница 23: ...In addition there is also a requirement that the difference in radius from one lamination to the next must not exceed 0 004 mm The surface roughness should be Ra 1 6 µm After skimming the segment insulation may have to be undercut according to the figure be low The insulation must be cut back far enough so that chamfering is possible Type Commutator diameter D mm DMI New Min Depth of wear 180 178 ...

Страница 24: ...0 C by induction by placing in an oven or dipping it in an oil bath Note The new bearing must be of the same type as shown on rating plate Fit the bearing on the shaft and hold it against the shoulder for 60 90 seconds Remove the pressure applied and check that the inner ring does not rotate on the shaft Fill the bearing with grease Note Use only grease that fulfils ABB requirements see page 25 Fi...

Страница 25: ...d the shaft into the machine and may cause serious contamination Use only high quality grease equivalent to ABB grease Use a manual grease gun and lubricate while the machine is running with the amount and within the intervals specified on the rating plate Use only high quality grease Lubrication during operation ABB grease is equivalent to Shell Albida EMS2 with the basic data below NLGI class 2 ...

Страница 26: ... surfaces which should be carefully cleaned A spray wash is done with an airless high pres sure spray or a conventional spray The high pressure spray is more effective in removing dirt The detergent used should remove the dirt without softening or damaging the insulation Avoid using excessive amounts of the cleaning agent A dip wash can be used if the detergent does not soften or damage the insula...

Страница 27: ...exchangers Specification of filter material If new filter material is to be bought the following specifications must be met by the vendor a The filter must be made of 100 continuous glass fibre b The filter must have an open structure at the air intake side but the fibre structure must get tighter toward the air exit side c Allowed air flow 3 m sec d Tests according to ASHRAE standard 52 76 with a...

Страница 28: ...t of the coupling 1b with paraffin oil and assemble it on the part inside the shaft 6 Assemble the last part of the coupling 1c with the shaft of the speed control device 6 Check the distance B For Leine Linde speed control devices 7 Assemble the speed control device on the tachoadapter 2 with three bolts 5 8 Assemble the adapter package on the bearing cover with four bolts and washers 3 4 Tighten...

Страница 29: ...ing torque M6 10Nm with a dynamometric wrench For shaft heights 315 400 assemble the adapter 2 on the bearing cover with four bolts and washers 3 7 Tightening torque M8 24 5Nm with a dynamometric wrench 8 Assemble the speed control device 6 on the tachoadapter 2 with six bolts and washers 4 5 Be gentle when pressing the coupling parts together Maximum axial assembly force 100N ...

Страница 30: ... Carbon dust is filtered out by a polyamide filter A second filter is included for leakage air Air water heat exchangers A totally enclosed motor with an air water heat exchanger is recommended for polluted operat ing environments The heat exchanger unit which is supplied separately is located on top of the motor as standard Unless otherwise stated on the deliv ery orders the cooling equipment mus...

Страница 31: ...31 Heat exchangers Figure 18 Mounting of heat exchanger for DMI 180 280 Note Do not lift the motor and heat exchanger by the heat exchanger s lifting eyes ...

Страница 32: ... Heat exchanger spacers must be in position inside the punched holes at the sealing strip 3 Remove the covers A and B if the heat ex changer is equipped with it from the heat exchanger 4 Place the heat exchanger on top of the DMI machine and joint the heat exchanger at the flat point set screws of the DMI machine item 2 5 Tighten the heat exchanger with the plain washers and nuts item 5 6 and 7 6 ...

Страница 33: ... seen from D end towards N end 2 Water connection on right side seen from D end towards D end 3 Water connection on left side seen from D end towards N end Label on cooling coil shows the in and outlet of water depend ing on the air direction NB The air direction through the cooling coil is always towards the fan motor 4 Water connection on left side seen from D end towards D end Figure 20 ...

Страница 34: ... end 2 Water connection on left side seen from D end towards N end 3 Water connection on right side seen from D end towards D end Label on cooling coil shows the in and outlet of water depend ing on the air direction NB The air direction through the cooling coil is always towards the fan motor 4 Water connection on right side seen from D end towards N end ...

Страница 35: ...e housing and rotate as shown above 3 Slide the coil into the housing and replace the screws 4 Replace the cover at the opposite side Figure 22 1 Remove screws holding the cooling coil 2 Slide the coil out of the housing and rotate it 180 according to the picture above 3 Slide the coil back into the housing and re place the screws Figure 23 ...

Страница 36: ...s or incorrectly fitted inspec tion covers This is an instruction in how to verify that the monitoring devices on the heat exchangers are working properly Monitoring devices 1 8 mentioned in this chapter are optional and not included in the heat exchanger Pictures and text in this chapter apply to top mounted air water heat exchangers For side mounted air water heat exchangers and air air heat exc...

Страница 37: ... an alarm Shut the fan down and the alarm should go off Adjustment Setting is same for all sizes of heat exchangers for DMI 180 400 The settings from the factory should not be changed 3 Thermostat Trafag MST 9515 Function Gives an alarm if the air intake temperature is above the maximum allowable temperature for the specific DC motor Verification Open the casing and turn the adjustment knob The al...

Страница 38: ...arm goes off Verification Top mounted heat exchangers Remove the make up filter box from the heat exchanger as seen in picture 25 Then remove the filter and the grating The alarm must go off when touching the sensor by hand or pouring some water on it Side mounted heat exchangers Unscrew the detector from the heat exchanger The alarm must go off when touching the sensor by hand or pouring some wat...

Страница 39: ... Q TERMINAL LIVE WITH WATER PRESENT ALARM AIR WATER HEAT EXCHANGER ONLY 51 52 53 MURPHY EL15OK1 LEAK WATER DETECTOR RED LIVE WITH WATER PRESENT ALARM AIR WATER HEAT EXCHANGER ONLY 61 62 63 UNIFLOW WATER FLOW GUARD BLACK TERMINAL LIVE WHEN WATER FLOW IS OK AIR WATER HEAT EXCHANGER ONLY 71 72 73 WEBER 4120 13M WATER FLOW GUARD BLACK TERMINAL LIVE WHEN WATER FLOW IS OK AIR WATER HEAT EXCHANGER ONLY 8...

Страница 40: ...he leakage air filter will provide substitute air if an unwanted leak has occurred somewhere else in the air circuit Rapid clogging of the leakage air filter indicates that an unwanted leak is present If so do the necessary tightening and change the filter Nor mally use the same filter as above In environments with harmful contaminations use filter EU5 according to Eurovent 4 5 or simi lar filters...

Страница 41: ...arings against contamination by suitable means R Remove the main gasket very carefully from the stator R Clean the bearing covers and remove the old grease Reassembling R Wrap a piece of 1 mm thick insulating material around the commutator R Place a suitable piece of insulating material into the lower part of the stator R Inspect the main gaskets on the stator for damage Make sure that the mating ...

Страница 42: ...umber of sets 1 1 1 2 Set of armature coils 4 resp 6 commutating coils 1 Armature complete main field coil 4 resp 6 commutating coils 1 Motor complete 1 Also two compensating windings incl slot insulations and slot keys when the machine has compensating windings Remark Please state when ordering motor type motor serial number and part number ...

Страница 43: ...ling bearings Overheating immediately after starting or regreasing Too much grease filled Fill and press in only the prescribed amount of grease See rating plate Overheating automatically disappears after some time Overheating after long period of operation Bearing cover seals rubbing Remachine bearing cover replace damaged seals Scraping rubbing or knocking noises in bearing Change bearing cause ...

Страница 44: ...ne in opposite direction to rotation position Set brush bracket to mark under load Fault in field circuit Eliminate fault Auxiliary series winding wrongly connected Check connection and correct Generator not supplying voltage Open circuit in excitation circuit Check excitation circuit for fault Short in main circuit Check circuit Open circuit or interturn short circuit in rotor winding Check windi...

Страница 45: ...13 Current surges Choose suitable brush types 14 The air is too damp Let in fresh air select suitable brushes 15 The air is too dry Let in fresh air select suitable brushes 16 Dust or sand suspended in the air Fit filters and eliminate the causes 17 Gases or acids in the air Let in fresh air select suitable brushes 18 Excessive brush friction Reduce brush pressure make use of non abrasive brushes ...

Страница 46: ...46 EC Directives Declaration of Incorporation ...

Страница 47: ...47 EC Directives EC Declaration of Conformity ...

Страница 48: ...ABB Automation Technologies DC Motors SE 721 70 Västerås Sweden Telephone 46 0 21 32 90 00 Telefax 46 0 21 32 95 15 www abb com motors drives 3 BSM 003045 1 Edition 3 Elanders 06 02 ...

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