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Table of Contents
Related Manuals for ABB AMA
Summary of Contents for ABB AMA
- Page 1 Manual for High Voltage Process Performance Motors...
- Page 2 Manual for High Voltage Process Performance Motors Safety Instructions AMA, AMB, AMG, AMH, AMI, AMK, AMZ, HXR, M3BM, M3GM 1. General General safety regulations, specific agreements made for each work site and safety precautions shown in this document must be observed at all times.
- Page 3 Manual for High Voltage Process Performance Motors Follow the manufacturer's instructions when mounting or removing couplings or other drive elements and cover them with a touch guard. For trial run in uncoupled state, lock or remove the shaft end key. Avoid excessive radial and axial bearing loads (note manufacturer's documentation).
- Page 4 Manual for High Voltage Process Performance Motors case of sleeve-bearing machines, observe time-limit for oil-change and if equipped with oil supply system make sure the system is working. 7. Maintenance and servicing Follow the manufacturer's operating instructions. For further details, see the comprehensive User´s Manual.
- Page 5 Maintenance and servicing Permanent magnet synchronous machines must only be serviced by repair shops qualified and authorised by ABB. For more information concerning service of permanent magnet synchronous machines, please contact ABB. WARNING: Only qualified personnel familiar with the relevant safety requirements are allowed to open and maintain permanent magnet synchronous machines.
- Page 6 94/9/EC and have a CE-mark on the rating plate. Validity These instructions are valid for the following ABB Oy's electrical motor types, when the machine is used in explosive atmosphere. Non-sparking Ex nA, Class I Div 2, Class I Zone 2...
- Page 7 Std. concerning combustible dust, Ex tD protection NFPA 70; National Electric Code (NEC) C 22-1-98; Canadian Electrical Code, Part I (CE Code) ABB machines (valid only for group II) can be installed in areas corresponding to following marking: Zone (IEC) Category (EN) Marking...
- Page 8 • Do not install any new equipment to terminal boxes without asking for advises from ABB • Be sure that air gap between rotor and stator is measured after any maintenance for the rotor or bearings.
- Page 9 Manual for High Voltage Process Performance Motors Pre-start ventilation • Ex nA and Ex e machines may, or in some cases, have to be equipped with a provision for pre-start ventilation. • Before starting, check the need to purge the machine enclosure to make sure that the enclosure is free of flammable gases.
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Page 10: Table Of Contents
Manual for High Voltage Process Performance Motors Chapter 1 - Introduction General information....................1 Important note......................1 Limitation of liability....................2 Documentation......................2 1.4.1 Documentation of the machine ..............2 1.4.2 Information not included in documentation..........3 1.4.3 Units used in this User’s Manual............... 3 Identification of the machine .................. - Page 11 Manual for High Voltage Process Performance Motors 3.4.3 Foundation preparations................19 3.4.3.1 Foundation and grouting hole preparations...... 19 3.4.3.2 Foundation studs or sole plate preparations ..... 19 3.4.4 Erection of machines................21 3.4.5 Alignment....................21 3.4.6 Grouting ....................21 3.4.7 Final installation and inspection..............
- Page 12 Manual for High Voltage Process Performance Motors 4.2.9.2 Earthing of main cable ............35 4.2.9.3 Auxiliary cables ..............35 Chapter 5 - Commissioning and Start-up General........................36 Check of mechanical installation................36 Insulation resistance measurements................36 Check of electrical installation ................. 36 Control and protection equipment ................
- Page 13 Manual for High Voltage Process Performance Motors 7.3.1 Recommended maintenance program ............. 49 7.3.1.1 General construction............49 7.3.1.2 Stator and rotor ..............50 7.3.1.3 Auxiliaries ................ 50 7.3.1.4 Lubrication system and bearings ........51 Maintenance of general constructions..............51 7.4.1 The tightness of fastenings..............
- Page 14 Manual for High Voltage Process Performance Motors 9.1.4 Support for Service Centers..............72 9.1.5 After Sales contact information ............... 72 Spare parts for rotating electrical machines.............. 73 9.2.1 General spare part considerations ............73 9.2.2 Periodical part replacements..............73 9.2.3 Need of spare parts ..................
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Page 15: Chapter 1 Introduction
This document and parts thereof must not be reproduced or copied without the express written permission of ABB, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. -
Page 16: Limitation Of Liability
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. -
Page 17: Information Not Included In Documentation
Manual for High Voltage Process Performance Motors 1.4.2 Information not included in documentation This User’s Manual does not include any information about any starting, protection or speed control equipment. This information is provided in the user’s manuals for respective equipment. 1.4.3 Units used in this User’s Manual The measurement units used in this User’s Manual are based on the SI (metric) system and the US system. - Page 18 Manual for High Voltage Process Performance Motors Figure 1-1 Rating plate for direct on line machines manufactured according to IEC Figure 1-2 Rating plate for direct on line machines manufactured according to NEMA 1. Type designation 2. Manufacturing year 3. Duty 4.
- Page 19 Manual for High Voltage Process Performance Motors 9. Serial number 10. Output [kW] or [HP] 11. Stator voltage [V] 12. Frequency [Hz] 13. Rotating speed [rpm] 14. Stator current [A] 15. Power factor [cosf] 16. Standard 17. Frame 18. Product code 19.
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Page 20: Chapter 2 Transport And Unpacking
Manual for High Voltage Process Performance Motors Chapter 2 Transport and Unpacking 2.1 Protective measures prior to transport 2.1.1 General The following protective measures are taken before delivery of the machine from the factory. The same protective measures should be taken, whenever the machine is moved: •... -
Page 21: Bearing Plate
Manual for High Voltage Process Performance Motors 2.1.2 Bearing plate A stainless steel bearing plate is attached to the machine frame. For the location of the bearing plate, see Appendix Typical position of plates. The bearing plate indicates the type of the bearings and lubrication to be used, see Figure 2-2 Bearing plate for grease lubricated rolling bearing. -
Page 22: Lifting A Machine In A Seaworthy Package
Manual for High Voltage Process Performance Motors NOTE: Check that eyebolts or the lifting lugs integrated with the machine frame are undamaged before lifting. Damaged lifting lugs must not be used. NOTE: Lifting eyebolts must be tightened before lifting. If needed the position of the eyebolt must be adjusted with suitable washers. -
Page 23: Lifting A Machine On A Pallet
Manual for High Voltage Process Performance Motors Figure 2-3 Lifting of horizontal and vertical machines in seaworthy packages 2.2.2 Lifting a machine on a pallet A machine mounted on a pallet should be lifted by crane from the lifting eyes of the machine, see Figure 2-4 Lifting of horizontal and vertical machines on pallets, or by forklift from the bottom of the pallet. -
Page 24: Turning A Vertically Mounted Machine
Manual for High Voltage Process Performance Motors Figure 2-5 Lifting of unpacked machines 2.3 Turning a vertically mounted machine Vertically mounted machines may be necessary to turn from vertical to horizontal position, e.g. when changing the bearings, and vice versa. This is shown in Figure 2-6 Machine with turnable lifting eyes: lifting and turning. -
Page 25: Checks Upon Arrival And Unpacking
Manual for High Voltage Process Performance Motors 2.4 Checks upon arrival and unpacking 2.4.1 Check upon arrival The machine and the package must be inspected immediately upon arrival. Any transport damage must be photographed and reported immediately, i.e. within less than one (1) week after arrival, if the transport insurance is to be claimed. -
Page 26: Long Term Storage (More Than 2 Months)
Manual for High Voltage Process Performance Motors • Covered, as to completely prevent rain from entering the machine. The cover should allow ventilation of the machine • Placed on at least 100 mm (4”) high rigid supports, as to make sure that no moisture can enter the machine from below •... -
Page 27: Rolling Bearings
Manual for High Voltage Process Performance Motors 2.5.3 Rolling bearings Apply the following measures: • Rolling bearings should be well lubricated during storage. Acceptable grease types are presented in Chapter 2.1.2 Bearing plate • Turn the rotor 10 revolutions every three months to keep the bearings in good condition. Remove any possible transport locking device during turning the rotor •... -
Page 28: Openings
Manual for High Voltage Process Performance Motors 2.5.4 Openings If there are any openings where cables are not connected to terminal boxes or flanges that are not connected to the piping, they are to be sealed. The coolers and the piping within the machine are to be cleaned and dried before they are sealed. -
Page 29: Chapter 3 Installation And Alignment
2 mm (0.8 inch) shim plate. NOTE: The calculation and design of the foundation is not included in the ABB scope of supply and the customer or a third party is therefore responsible for it. Furthermore, the grouting operation is also normally outside the scope and responsibility of ABB. -
Page 30: Forces To The Foundation
Manual for High Voltage Process Performance Motors 3.2.2 Forces to the foundation The foundation and the mounting bolts must be dimensioned to withstand a sudden mechanical torque, which occurs every time the machine is started, or at short circuit. The short circuit force is a gradually damped sine wave that changes direction. -
Page 31: Coupling Type
Manual for High Voltage Process Performance Motors NOTE: In order to avoid bearing damages, the transport locking device must be fitted to the machine whenever the machine is moved, transported to another location or stored. See Chapter 2.1 Protective measures prior to transport. 3.3.3 Coupling type Machines with rolling bearings must be connected to the driven machine with flexible couplings, e.g. -
Page 32: Belt Drive
The machine delivery does not normally include installation, shim plates, mounting bolts, foundation plate set or sole plate set. These are delivered according to special orders. If new fixing holes need to be drilled, please contact ABB to ensure suitability. 3.4.2 General preparations Before starting the installation procedure, consider the following aspects: •... -
Page 33: Foundation Preparations
Manual for High Voltage Process Performance Motors 3.4.3 Foundation preparations 3.4.3.1 Foundation and grouting hole preparations Foundation studs or sole plates are used when the machine is anchored to a concrete foundation. Consider the following aspects when preparing the foundation: •... - Page 34 Manual for High Voltage Process Performance Motors Figure 3-1 Typical foundation stud assembly In order to assemble the foundation stud or sole plate set, the machine must be suspended above the floor by a crane. Proceed as follows, see Figure 3-1 Typical foundation stud assembly: •...
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Page 35: Erection Of Machines
Manual for High Voltage Process Performance Motors • Mount the assembled foundation studs or sole plates under the machine feet with the mounting bolt (part 6) and washer (part 3). Center the mounting bolt (part 6) in the hole of the machine by wrapping e.g. -
Page 36: Covers And Enclosures
The machine delivery does not normally include installation, shim plates or mounting bolts. These are delivered according to special orders. If new fixing holes need to be drilled, please contact ABB to ensure suitability. 3.5.2 Check of foundation Before lifting the machine onto the foundation, the following checks should be made. -
Page 37: Covers And Enclosures
The purpose of a mounting flange for vertically mounted machines is to enable an easy installation and coupling connection, as well as an easy inspection of the coupling during operation. In order to fit the ABB machines, the mounting flanges shall be designed according to the IEC standard. -
Page 38: Rough Levelling
Manual for High Voltage Process Performance Motors must be performed with great caution because alignment errors will lead to bearing and shaft damages. Before the alignment procedure is started, the coupling halves have to be installed, see Chapter 3.3.4 Assembly of the coupling half. The coupling halves of the driving and driven machines must be bolted together loosely in order to move freely in respect to each other during the alignment. -
Page 39: Correction For Thermal Expansion
Manual for High Voltage Process Performance Motors BRACKET WITH ADJUSTING SCREW Figure 3-4 Positioning of bracket plates Bracket plates are placed against the foundation edge and tied down with expansion bolts, see Figure 3-5 Mounting of the bracket plate. Move the machine by using the adjusting screws until the shaft centerline and the driven machine centerline are aligned roughly and the desired distance between the coupling halves is reached. -
Page 40: Thermal Expansion Upwards
∆L = α × ∆T × Lwhere ∆L=thermal expansion[mm] α=10 × 10 ∆T=50 K (for AMA, AMB, AMK, AMI), 80 K (for AMH, HXR, M3BM, M3GM) L=frame length [mm] NOTE: Make sure that a continuous free axial movement is possible between the coupling halves (excluding rigid couplings) in order to permit axial thermal expansion of the machine shaft as not to damage the bearings. -
Page 41: Run-Out Of The Coupling Halves
Manual for High Voltage Process Performance Motors 3.6.5.2 Run-out of the coupling halves The alignment procedure is started by measuring the run-out of the coupling halves. This measurement will show any inaccuracy of the shaft and/ or coupling halves. The run-out of the coupling half in respect to the bearing housing of the machine is measured. Place the gauges according to Figure 3-6 Measuring the run-out at the coupling half. -
Page 42: Alignment
Manual for High Voltage Process Performance Motors Figure 3-7 Definition of misalignment 3.6.5.4 Alignment The alignment of the machine is performed according to these guidelines. The machine should stand on its jacking screws Rotate the rotor and check the axial end float, see Chapter 3.6.3 Rough adjustment Mount the alignment equipment. -
Page 43: Permissible Misalignment
Manual for High Voltage Process Performance Motors Align the machine vertically by turning the jacking screws or by jacking with hydraulic jacks. To facilitate the alignment in the vertical plane, jacking screws are fitted to the feet of the horizontal machine, see Figure 3-3 Vertical positioning of machine foot. The alignment accuracy of the machine is sometimes affected by the thermal expansion of its frame, see Chapter 3.6.4 Correction for thermal expansion Measure the distance between the bottom of the machine feet and the bedplate and make... -
Page 44: Care After Installation
Manual for High Voltage Process Performance Motors 100 – 250 mm Rigid Flange 0.02 mm 0.01 mm 0.02 mm (4 – 10”) (0.8 mil) (0.4 mil) (0.8 mil) Gear 0.05 mm 0.03 mm 0.05 mm (2 mil) (1 mil) (2 mil) Flexible 0.10 mm 0.05 mm... -
Page 45: Chapter 4 Mechanical And Electrical Connections
Manual for High Voltage Process Performance Motors Chapter 4 Mechanical and Electrical Connections 4.1 General Mechanical and electrical connections are made after the installation and alignment procedures. The mechanical connections include the connection of air ducts, water tubes and/or oil supply system where applicable. -
Page 46: Insulation Resistance Measurements
Manual for High Voltage Process Performance Motors • If the secondary circuit of the current transformer is extended, make sure that it does not become open-circuited in use 4.2.3 Insulation resistance measurements Before a machine is started up for the first time, after a long period of standstill or within the scope of general maintenance work, the insulation resistance of the machine must be measured, see Chapter 7.6.4 Insulation resistance test. -
Page 47: Main Power Cables
Manual for High Voltage Process Performance Motors the shortest distance through air between two points with different electrical potential (voltage). The surface creepage distance is the shortest distance along surfaces next to each other between two points with different electrical potential (voltage). 4.2.6 Main power cables The size of the input cables has to be adequate for the maximum load current and in accordance with local standards. -
Page 48: Connection Of Auxiliaries And Instruments
Manual for High Voltage Process Performance Motors Figure 4-1 Typical auxiliary terminal box 4.2.7.1 Connection of auxiliaries and instruments Connect the instruments and auxiliary equipment according to the connection diagram. NOTE: Study the connection diagram delivered with the machine carefully before connecting any cables. -
Page 49: Requirements For Machines Fed By Frequency Converters
EN 50081-2. For further information, see ABB manual Grounding and cabling of the drive system (3AFY 61201998 R0125 REV A). 4.2.9.2 Earthing of main cable The compliance with EMC directive requires high-frequency earthing of the main cable. -
Page 50: Chapter 5 Commissioning And Start-Up
Check alignment of the machine prior to commissioning: • Go through the alignment report and ensure that the machine is accurately aligned according to ABB alignment specifications in Chapter 3.6 Alignment • The alignment protocol should always be included in the commissioning report Check that the machine is properly anchored to the foundation: •... -
Page 51: Control And Protection Equipment
Manual for High Voltage Process Performance Motors • Check that the power cables are suitably routed • Check that the power cables are stress-relieved in a proper way • Check the connections of the auxiliary equipment. NOTE: If the machine is delivered without a main terminal box, see Chapter 4.2.4.1 Delivery without main terminal box. -
Page 52: Thermistors
Manual for High Voltage Process Performance Motors 5.5.2.3 Thermistors If the machine is equipped with thermistors (PTC), the operating temperature of the thermistors is found on the Connection Diagram. The operating function can be chosen to be an alarm or a trip signal. -
Page 53: First Test Start
Manual for High Voltage Process Performance Motors 5.6 First test start 5.6.1 General The first test start is a standard procedure after the installation and alignment procedure is finished, the mechanical and electrical connections are made, the commissioning procedure is gone through and the protective devices are active. -
Page 54: Running The Machine The First Time
During the first days of running, it is important to keep a close surveillance of the machine in case of any changes in vibration or temperature levels or abnormal sounds should occur. 5.7.3 Bearings The rotating electrical machines manufactured by ABB are equipped with either rolling or sleeve bearings. 5.7.3.1 Machines with rolling bearings In case of a newly installed machine or a machine, which has been out of service for more than 2 months, inject new grease into the bearings immediately after start-up. -
Page 55: Vibrations
Manual for High Voltage Process Performance Motors D-END N-END Figure 5-8. Example of lubrication channel through bearing arrangement of horizontal machine NOTE: The re-lubrication interval will never be longer than 12 months. The type of original grease used is found on the bearing plate on the machine. Acceptable types of grease can be found in Chapter 7.5.1 Rolling bearings. -
Page 56: Shut Down
Manual for High Voltage Process Performance Motors Recommended settings for alarm and trip levels see main connection diagram and Chapter 7.4.3.3 Evaluation. 5.9 Shut down The shutdown of the machine depends on the application, but main guidelines are: • Reduce the load of the driven equipment, if applicable •... -
Page 57: Chapter 6 Operation
NOTE: The machine may have hot surfaces when running with load. 6.2 Normal operating conditions The machines manufactured by ABB are individually designed to operate in normal operation conditions according to the IEC or NEMA standards, customer specifications and internal ABB standards. -
Page 58: Supervision
Manual for High Voltage Process Performance Motors A counter system for controlling the number of starts should be used and maintenance intervals should be determined based on equivalent operating hours, see Chapter 7.3 Maintenance program. NOTE: The safety precautions shown in the Safety Instructions at the beginning of the manual must be observed at all times. -
Page 59: Shut Down
Manual for High Voltage Process Performance Motors 6.6 Shut down When the machine is not in operation, anti-condensation heaters have to be switched on where applicable. This is to avoid condensation effect inside the machine. NOTE: Voltage may be connected to the terminal box for heating element. Operation - 45 3BFP 000 063 R0101 REV D... -
Page 60: Chapter 7 Maintenance
ABB recommends the use of experts in the creating maintenance programs, as well as in performing the actual maintenance and possible trouble shooting. The ABB After Sales organization is happy to assist in these issues. The ABB After Sales contact information can be found in Chapter 9.1.5 After Sales contact information. -
Page 61: Maintenance Program
7.3 Maintenance program This chapter presents a recommended maintenance program for ABB machines. This maintenance program is of a general nature, and should be considered as a minimum level of maintenance. Maintenance should be intensified when local conditions are demanding or very high reliability is required. - Page 62 Manual for High Voltage Process Performance Motors The first Level 1 maintenance should be performed after 4 000 equivalent operating hours or six months after commissioning. Subsequently the L1 maintenance should be performed yearly halfway between Level 2 maintenances, see Table 7-1 Maintenance intervals. Level 2 (L2) Level 2 or L2 maintenance consists mainly of inspections and tests and small maintenance tasks.
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Page 63: Recommended Maintenance Program
Manual for High Voltage Process Performance Motors The Level 4 maintenance should be performed after every 80 000 equivalent operating hour. When a L4 maintenance is conducted it replaces the L1, L2 or L3 maintenance otherwise scheduled, and it leaves their rotation unaffected, see Table 7-1 Maintenance intervals. 7.3.1 Recommended maintenance program Abbreviation used in maintenance program: •... -
Page 64: Stator And Rotor
Manual for High Voltage Process Performance Motors Maintenance object Check / Test Terminal box accessories, General condition i.e. surge capacitors, arrestors and current transformers Cable transits Condition of cables entering the machine and inside the machine 7.3.1.2 Stator and rotor Maintenance object Check / Test Stator core... -
Page 65: Lubrication System And Bearings
Manual for High Voltage Process Performance Motors 7.3.1.4 Lubrication system and bearings Maintenance object Check / Test Bearing during operation T / R T / R General condition, extra noise, vibration Waste grease V / C V / C V / C Condition, purging Re-greasing V / R... -
Page 66: Vibration And Noise
Manual for High Voltage Process Performance Motors Table 7-2. General tightening torques Tightening torque in Nm (pound-feet) Property class 8.8 for bolts Size Oiled [Nm] Oiled [pound Dry [Nm] Dry [pound feet] feet] M 10 M 12 M 14 M 16 M 20 M 24 M 27... -
Page 67: Vibrations
Manual for High Voltage Process Performance Motors • Loose fastenings or anchor bolts, see Chapter 3 Installation and Alignment • Rotor imbalance • Coupling. 7.4.3 Vibrations The following instructions are part of the following two ISO standards: ISO 10816-3:1998 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and 15 000 r/min when measured in situ and ISO 8528-9:1995 Reciprocating internal combustion engine driven alternating current generating sets: Part 9: Measurement and... -
Page 68: Classification According To Support Flexibility
Manual for High Voltage Process Performance Motors Figure 7-1 Measuring points 7.4.3.2 Classification according to support flexibility Two conditions are used to classify the support assembly flexibility in specified directions: • rigid supports • flexible supports These support conditions are determined by the relationship between the machine and foundation flexibilities. -
Page 69: Maintenance Of Bearings And Lubrication System
Manual for High Voltage Process Performance Motors Zone C: Machines with vibration within this zone are normally considered unsatisfactory for long-term continuous operation. Generally, the machine may be operated for a limited period in this condition until a suitable opportunity arises for remedial action. Zone D: Vibration values within this zone are normally considered to be of sufficient severity to cause damage to the machine. -
Page 70: Rolling Bearings
Re-greasing intervals for frequency converter drives Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy load will require shorter lubrication intervals or a special lubricant. Consult manufacturing ABB factory After Sales department in such cases. NOTE: The constructional maximum speed of the machine must not be exceeded. The suitability of the bearings for high-speed operation must be checked. -
Page 71: Re-Greasing
Manual for High Voltage Process Performance Motors 7.5.1.4 Re-greasing All rolling bearings of rotating electrical machines need to be re-greased, see Chapter 7.5.1.3 Re-greasing intervals. The re-greasing can be performed either manually or by means of an automatic system. In either case, it has to be verified that a suitable amount of the correct grease is entering the bearing at suitable intervals. -
Page 72: Bearing Grease
If equipped with a handle, close it. Automatic re-greasing A variety of automatic re-lubrication systems is available on the market. However, ABB recommends only the use of electromechanical re-lubrication systems. The quality of the grease entering the bearing has to be checked at least once per year: the grease has to look and feel like new grease. -
Page 73: Bearing Maintenance
If there is a need to change bearings, please contact ABB After Sales. See After Sales contact information in Chapter 9.1.5 After Sales contact information. -
Page 74: Particular Safety Instructions For Winding Maintenance
Manual for High Voltage Process Performance Motors 2. IEEE Std. 432-1992, IEEE Guide for Insulation Maintenance for Rotating Electrical Machinery (5 hp to Less Than 10 000 hp) 7.6.1 Particular safety instructions for winding maintenance Some of the hazardous works of the winding maintenance include: •... -
Page 75: The Correct Operating Temperature
Manual for High Voltage Process Performance Motors NOTE: As a thumb rule, an insulation resistance test should be made once a year. This should suffice for most machines in most operating conditions. Other tests should only be conducted if problems arise. A maintenance program for the complete machine, including windings, is presented in Chapter 7.3 Maintenance program. - Page 76 Manual for High Voltage Process Performance Motors Figure 7-2 Correlation between the insulation resistance and the temperature R = Insulation resistance value at a specific temperature R40 = Equivalent insulation resistance at 40°C R40 = k x R Example: R = 30 MΩ measured at 20°C k = 0.25 R40 = 0.25 x 30 MΩ...
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Page 77: General Considerations
Manual for High Voltage Process Performance Motors 7.6.4.2 General considerations The following consideration should be noted, before deciding any actions based upon the insulation resistance tests: • If the measured value is considered too low the winding must be cleaned and/or dried. If these measures are not sufficient, expert help should be acquired •... -
Page 78: Insulation Resistance Measurement For Auxiliaries
Manual for High Voltage Process Performance Motors • Verify that the frame of the machine and the stator windings not being tested are earthed • The winding temperature is measured • All resistance temperature detectors are earthed • Possible earthing of voltage transformers (not common) must be removed. The insulation resistance measuring should be carried out in the terminal box. -
Page 79: The Polarization Index
If extraordinary circumstances occur and other maintenance is required, it is best to acquire professional help. The ABB After Sales organization is eager to assist in questions regarding maintenance of electrical machine winding, for contact information see Chapter 9.1.5 After Sales contact information. -
Page 80: Chapter 8 - Trouble Shooting
Chapter 8 Trouble Shooting 8.1 Trouble shooting This chapter is intended as a help in the event of an operational failure with an ABB delivered rotating electrical machine. The trouble shooting charts given below can aid in locating and repairing mechanical, electrical and thermal problems, and problems associated with the lubrication system. -
Page 81: Mechanical Performance
Axial load coming from connected machinery Check alignment and coupling function and type Faulty or incorrectly assembled coupling Check coupling function Insufficient foundation strength Reinforce foundation as per ABB instructions Winding fault Check windings Excessive network unbalance Check that network balance fulfils requirements... -
Page 82: Lubrication System And Bearings
Corrective action Insufficient lubrication Insufficient amount of grease Check bearing condition, add grease Unsuitable grease quality or viscosity Check ABB grease recommendations, change grease Excessive axial forces Faulty coupling or mounting Check coupling, mounting and alignment Incorrect regreasing period Check ABB recommendations, regrease... -
Page 83: Thermal Performance
Corrective action Control system setting Check machine controls, eliminate overload Overload Overspeed Check actual speed and ABB speed recommendations Network unbalance Check that network balance fulfils requirements Faulty instrumentation or measurement system Check measurements, sensors and wiring Too many starts... -
Page 84: 100 Resistance Temperature Detectors
Manual for High Voltage Process Performance Motors Examples of protections that, if they give an alarm or trip, may need further investigation: • Diode fault protection • High temperature in bearing, see Chapter 7.5 Maintenance of bearings and lubrication system •... - Page 85 Manual for High Voltage Process Performance Motors Table 8-1. Temperature values for Pt-100 elements PT100 TEMP TEMP PT100 TEMP TEMP PT100 TEMP TEMP °C °F °C °F °C °F 32.00 127.07 100.00 158.00 153.58 284.00 100.78 35.60 127.84 161.60 154.32 287.60 101.56 39.20 128.60...
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Page 86: Chapter 9 After Sales Support And Spare Parts
Manual for High Voltage Process Performance Motors Chapter 9 After Sales Support and Spare Parts 9.1 After Sales The After Sales support for rotating electrical machines manufactured by ABB, and Strömberg in Helsinki, Finland since 1889. 9.1.1 Site Services The Site Services department provides: •... -
Page 87: Spare Parts For Rotating Electrical Machines
9.2 Spare parts for rotating electrical machines 9.2.1 General spare part considerations The machines manufactured by ABB are designed and manufactured to provide reliable and trouble-free operation for decades. This requires, however, that the machines are properly maintained and operated. This maintenance includes changing of parts subjected to normal wear. -
Page 88: Selection Of The Most Suitable Spare Part Package
To receive a quotation for specific parts for a specific machine, please contact the ABB After Sales organization. Please note that even though ABB has customized the spare part sets to match the machine, they might contain references to accessories not found on all machines. -
Page 89: Recommended Spare Part Package
In addition, provide specific and detailed information about the parts ordered. The contact information of ABB's After Sales organization can be found in Chapter 9.1.5 After Sales contact information. -
Page 90: Chapter 10 Recycling
Chapter 10 Recycling 10.1 Introduction ABB is committed to its environmental policy. ABB continuously strives to make its products more environmentally sound by applying results obtained in recyclability and life cycle analyses. Products, manufacturing processes and even logistics have been designed to take environmental aspects into account. -
Page 91: Dismantling Of The Machine
NOTE: The heat treatment process and the maintenance of the heat treatment equipment require special care in order to avoid any risk for fire hazards or explosions. Due to various installations used for the purpose it is not possible for ABB to give detailed 3BFP 000 063 R0101 REV D... -
Page 92: Permanent Magnets
Manual for High Voltage Process Performance Motors instructions of the heat treatment process, or the maintenance of the heat treatment equipment and these aspects must be taken care of by the customer. 10.5.3 Permanent magnets If the permanent magnet synchronous machine is melted down as a whole, nothing needs to be done to the permanent magnets. -
Page 93: Commissioning Report
Manual for High Voltage Process Performance Motors COMMISSIONING REPORT Rating plate information: Serial no. Manufacturer: ABB Oy Address: P.O. Box 186 FIN-00381 HELSINKI FINLAND Telephone: +358 (0) 10 22 11 Fax: +358 (0) 10 22 22544 Customer: Customer address: Contact person:... - Page 94 Manual for High Voltage Process Performance Motors 1 Transportation General: Arrival date of the machine: Inspection date and location: Signature of consignee: Open box inspection: yes, done by: Damages: yes, missing items: Packing list: yes, what kind of: Machine: yes, what kind of: Package: yes, what kind of: Accessories:...
- Page 95 Manual for High Voltage Process Performance Motors 2 Storage General: yes, begin:_______________end:_____________________ Storage: Storage time longer than 6 months: Person responsible for storage: Storage place: indoors outdoors in packing case protected by a waterproof cover º Daily temperature: min/max._______ - _______ C Humidity:_______% Storage actions: Transportation package is ventilated:...
- Page 96 Manual for High Voltage Process Performance Motors 3 Mechanical Installation Foundation is checked according to machine yes, drawing number:_____________________________ drawing: Possible foundation anchor bolts or sole plates are mounted according to instructions: Exciter N-end D-end N-end Air gap is measured, if applicable: For pedestal bearings, mark values 1-4, and for flanged bearings, values A-D 1 ____________ A ____________...
- Page 97 Manual for High Voltage Process Performance Motors 4 Lubrication check 4.1 Self lubrication Bearing oil: Manufacturer:__________________ Type:_________________________ The oil quality is the same as recommended: Bearing oil is filled up to the indicated level: Please mark the level in the sight glass circle Sight Glass on the right Lubrication rings rotate freely:...
- Page 98 Manual for High Voltage Process Performance Motors 5 Electrical installation yes, voltage:______-______V, frequency:_____-______Hz Network variation: manual automatic, controlled by:_________________ Space heater operation: yes, voltage:_____________V, power:_______________W Space heater for slip ring unit: 5.1 Insulation resistance test Ω, ______º Stator winding (1 min., 1000 VDC): __________M tested by________ kV, winding temperature: ______º...
- Page 99 Manual for High Voltage Process Performance Motors 6 Machine protection settings Overcurrent tripping: _______________A _________________ s Instant overcurrent tripping: _______________A _________________ s yes, setting: Overvoltage setting: yes, setting: Earth fault setting: yes, setting: Reverse power setting: yes, setting: Differential protection setting: yes, alarm:__________mm/s, trip:______________mm/s Vibration monitoring: Temperature monitoring:...
- Page 100 Manual for High Voltage Process Performance Motors 7 Test Run 7.1 First start (a few seconds only) Note: Check that possible flood lubrication is on! Direction of rotation (viewed from D-end): yes, from: Are there abnormal noises? 7.2 Second start (uncoupled, if possible) Note: Check that possible flood lubrication is on! yes, from: Are there abnormal noises?
- Page 101 Manual for High Voltage Process Performance Motors 8 Test run (with load) Checking schedule and information Time Load Bearing temp. Bearing vibration levels Stator Stator winding temperature D-end N-end D-end N-end Current Power Excit. mm/s mm/s Factor Current φ º º...
- Page 102 Manual for High Voltage Process Performance Motors Fax Cover Sheet Date: ABB Oy Telefax: +358 (0) 10 22 22544 From: Fax number: Phone number: Email: Number of pages: 1 + 9 + _________ Message: 3BFP 000 063 R0101 REV D...
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Page 103: Typical Position Of Plates
Manual for High Voltage Process Performance Motors Typical position of plates D-END N-END N-END RATING PLATE OF THE MACHINE BEARING PLATE OF THE MACHINE ADDITIONAL PLATE MARKING PLATE FOR DIRECTION OF ROTATION HANDLE OF WASTE GREASE EXHAUST VALVE DIRECTION OF ROTATION SEEN FROM THE DRIVE END TOWARDS THE MACHINE CLOCKWISE COUNTER-CLOCKWISE... -
Page 104: Typical Main Power Cable Connections
Manual for High Voltage Process Performance Motors Typical main power cable connections 3BFP 000 063 R0101 REV D Typical Main Power Cable Connections - 90... - Page 105 ABB Oy Machines P.O. Box 186 FIN-00381 HELSINKI FINLAND Telephone + 358 (0)10 2211 Telefax + 358 (0)10 22 22141 www.abb.com/motors&drives...