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1. or JHXA are stored at temperatures up to 20 C 4 F the following must be ob served in addition to the instructions in Points 8 1 and 8 2 The water has to be removed completely from the air water coolers In any case the coolers must be dried completely with hot air at max 60 C 140 F and then sealed Motors with coolers must be stored in a dry and dustfree room Further to these storage instructions all data in these operating instruc tions must be taken into account The manufacturer s warranty is only applicable if all of the above men tioned items are strictly observed Page 23 of 25 Faults and remedies Bearing is too hot Motor does not start Faults and remedies Fault Bearing noise Fault High de Motor is too hot crease in speed Page 24 of 25 Motor runs unevenly Protective device triggers Possible causes No or insufficient oil circuit in case of circulating oil lubrication Bearing surface dirty Wrong oil viscosity Coupling forces are pulling or pushing Too little oil in the bearing Coolant temperature above 40 C 104 F Bearing shell worn e g caused by motor start without bearing oil Inbalance caused by coupling Motor fastening too unstable Possible causes Countertorquetoo high Mains voltage too low Phase interruption Wrong winding connection Overload Too many starts per hour Insufficient ventilation I2. Str 32 e 94099 RUHSTORF GERMANY Phone 49 8531 39 0 e Fax 49 8531 32895 E Mail info loher de http www loher de Satz Loher Druck Loher 12 04 Printed in Germany
3. filter must be provided in the pressure pipe to the motor Further before every bearing a suitable pressure reducing valve must be provided in the pressure pipe using which the oil pres sure can be adjusted from 0 2 to 0 8 bar at operating temperature We recommend installing elec tronic flow indicators in the discharge lines behind the bearings to be able to check the oil circuit Flow inspection glasses are provided as a standard feature Page 11 of 25 312 Installation and commissioning 4 6 4 7 Page 12 of 25 Sleeve bearings In order to avoid leaking of the oil during transport the bearings of the motors are delivered without bearing oil from the factory Prior to commissioning the bearings must be filled with oil up to the oil level mark and up to the oil return respectively The viscosity class acc to DIN 51519 of the bearing lube oil and the oil quality respectively are indicated on an instruction plate at the motor In general any branded mineral oil with low foaming property and good ageing stability which has the specified viscosity can be used as lubricant If for any reason a lube oil with a viscosity deviating from that specified is to be used a confirmation from the motor manufacturer is required In case of greater deviations the calculations for the bearings must be performed afresh If synthetic oils are used attention must be paid to ensure that only PAO Poly Alpha Olefine oils are used For all other
4. synthetic oils it is necessary to consult the motor manufacturer The use of motors with sleeve bearings is generally permissible from an ambient temperature of 0 C unless special measures have been taken e g bearing heating The lower limiting temperature is then specified on the rating plate At lower ambient temperatures the lubricating oil must have a pour point of at least 10 Kelvin below the ambient temperature In the case of sleeve bearings that are lubricated with oil circulation in order to ensure suffi cient oil flow in the oil inlet pipes the inflow temperature of the oil must not drop below 10 C Sleeve bearings for oil ring lubrication with water cooling See dimension drawing or instruction plate on the motor Make sure that the motor is only switched on when the cooling water circuit is operating It must be kept running till the motor comes to a stillstand after switch off Cooling water supply for sleeve bearings In order to achieve an effective cooling of the bearings the cooling water inlet temperature should be kept as low as possible The water speed should not exceed 1 5 m s to avoid damage by cavitation which occurs particu larly in the pipe elbows The customer should provide the corresonding regulating devices Unpressurized discharge of the water is required It must be possible to drain the cooling water circuit To control the cooling water circuit it is recommended that electronic flow
5. 10 M 30 150 Screwed joints strength class 8 8 and A4 70 Tightening torques for screws of the strength class 8 8 and A4 70 A4 80 only in components with higher strength e g grey cast iron steel Thread Tightening torque Nm Thread Tightening torque Nm M4 2 3 M 14 105 M5 4 6 M 16 160 M6 7 9 M 20 330 M8 19 M 24 560 M10 38 M 30 1100 M12 66 M 36 1900 Screwed joints strength class 5 6 Tightening torques for screws of the strength class 5 6 4 6 A2 or for screws in components with lower strength e g aluminium Thread Tightening torque Nm Thread Tightening torque Nm M4 1 1 M 14 49 M5 2 1 M 16 75 M6 3 7 M 20 150 M8 8 9 M 24 260 M10 18 M 30 520 M12 30 M 36 920 H R 258 en 12 04 Maintenance 5 Maintenance 5 1 5 1 1 H R 258 en 12 04 The person responsible for the facility must ensure that the specified maintenance work is carried out properly Bearings lubrication and cooling of the bearings The bearings of these motors are constructed in two parts The bearing shells allow self adjust ment under load The bearing surfaces are subjected to a precise machining Rescraping of the surfaces should therefore be strictly avoided under any circumstances The oil rings are essential for the bearings and require careful treatment They must be protected against damage and deformations Sleeve bearings with oil ring lu
6. Eee Operating Instructions H R 258 en 12 04 Three phase motors with squirrel cage for high voltage with sleeve bearings AHTA 355 to 560 AHQA 630 to 800 AHXA 355 to 560 JHTA 315 to 800 JHQA 500 to 800 JHXA 355 to 800 LOHER GmbH P O Box 1164 e 94095 RUHSTORF Hans Loher Str 32 e 94099 RUHSTORF GERMANY Phone 49 8531 39 0 e Fax 49 8531 32895 E Mail info loher de http www loher de Table of contents Page 1 Safety and commissioning instructions 22222 nennen 2 2 DESCIDUOM yd ld ea te ad e re 5 3 Transporten cp ds aos 7 4 Installation and commissioning sort ti 8 5 M lnlenanee wa tepic Be eee eee Bae ye t 15 6 Additional equi tx dad e O E AS Saas 19 7 Spare pals sist e ta ed eta e boto ee late pl dote el 19 8 Storage instructions hate as os 20 9 Faullsandiremedies ui ui pea oak ales wake So ke 24 Appendix 1 Alignment Check oooccoooccccccoc eee 25 Subject to modifications Loher GmbH 2004 All rights reserved H R 258 en 12 04 Page 1 of 25 Safety and commissioning instructions A 1 Safety and commissioning instructions 1 1 Safety symbols in these instructions The symbols are used in this user manual in order to draw attention to special dangers AN This symbol indicates a dangerous situation Fatal or serious injuries or larger material damage can result Danger This symbol shows a situation that may be da
7. air can flow unhindered into the air inlet openings and freely pass through the air outlet openings and cannot be directly sucked in again Suction and outlet openings must be protected from obstructions and coarse dust The motors with water jacket cooling Type AHXA 355 to AHXA 560 Before commissioning the water cooled motors the trouble free working of the cooling water cir cuit must be ensured It must be ensured that the motor will only be switched on when the cooling water circuit is in operation The circuit must be kept in operation until the motor comes to standstill after it is switched off The inlet and outlet openings are located on the motor housing The cooling water circuit is to be monitored Normally the motor is equipped with PTC thermistor sensors which switch off the motor if the cooling water circuit fails If the housing is provided with vent plugs for the water chamber venting should be done for the first filling and thereafter at regular intervals Only clean non aggressive cooling water must be used The permissible content of suspended solids is max 10mg l The inlet temperature of the cooling water should be at least 20 C 68 F Temperatures below 20 C 68 F result in higher formation of condensation water and motor fail ure The permissible inlet and outlet temperature maximum pressure and the required amount of cooling water are indicated on the motor plates If the motors are on
8. ase to earth before starting up again Damp windings can result in leakage currents arc overs and blow outs The insulation resistance for the windings must reach the following values Stator winding 4 Ustator kV 1 MQ measured at a winding temperature of 20 C Any available overvoltage surpressors that are connected to the motor may falsify the insula tion resistance If there is any doubt disconnect the overvoltage surpressors If the insulation resistance is lower dry the windings also refer to item 8 1 2 H R 258 en 12 04 32 Installation and commissioning 4 3 4 3 1 4 3 2 4 3 3 4 4 4 5 H R 258 en 12 04 Direction or rotation and designation of the terminals acc to DIN VDE 0530 8 IEC 60034 8 In the case of motors with only one direction of rotation the direction of rotation is marked on the motor with an arrow Terminals U1 V1 W1 to phases L1 L2 L3 in alphabetical or natural order always results in right handed rotation This applies to all motors even if they are not suited for right handed rotation Changing the direction of rotation The rotational direction can be switched by exchanging two supply lines on the motor terminal board For a machine with only one shaft end or two shaft ends with different thicknesses the direction of rotation is that seen an observer when he views the outer face of the only shaft end or the thicker shaft end In case of forced ventilation the di
9. brication natural cooling The big ribbed housing surface of the bearings guarantees good cooling The bearing housings must be kept clean form the outside in order not to affec the heat radiation owing to dust or dirt deposits Lubrication is done automatically by oil ring lubrication The oil rings are absolutely essential for the bearing Prior to commissioning the bearings must be filled with oil up to the oil level mark Commissioning After starting the bearings must be continuously monitored during the first hours for the following parameters a Bearing temperature The temperature should rise constantly up to the steady state temperature If the steady state point does not occur below 90 C 194 F the equipment must be stopped and the reasons determined If operating temperatures have been indicated for the bearings the reasons have to be found in case of downward deviations cold bearings as well For example it is possible that the thermometers are defective Ss Oil leaks The bearings must not lose oil neither on the lateral bore holes nor at the parting line or the oil levels screw plugs etc Check whether unused connection holes are plugged In case of oil ring lubricated bearings an oil loss can quickly result in destruction of the bearing surfaces c Running smoothness The running smoothness of an equipment depends on many influencing factors If uneven running occurs during the commissioning the equipment mus
10. by means of a flow monitoring system to be provided by the owner operator If the per missible limiting values are exceeded or undershot the machine must be switched off without delay In case of circulation system lubricated bearings continuous oil filtering must be provided The mesh width of the oil filter must not exceed 20 um Terminal locations terminals ventilating passages Depending on the operating conditions the following should be done at certain intervals cleaning the terminal locations and terminals checking the electrical connections with regard to firm seating see Paragraph 4 9 2 for tightening torques cleaning the cooling air passages The cooling air inlets and the cooling surfaces must be protected against obstruction and contamination If required the water chambers must be flushed and cleaned of deposits Never use sharp edged tools for cleaning Air water heat exchanger Motors with air water heat exchangers of the type JHXA For maintenance please consider the instructions for the air water heat exchangers Condensation water drain hole If the motor has a condensation water drain hole it has to be opened at regular intervals to have the accumulated condensation water can drain off Care must be taken to seal the condensation water drain hole by a screw with lock washer to ensure the method of protection H R 258 en 12 04 4 2 Additional equipment 6 Additional equipment On
11. cause of the risk of bearing damage When replacing the bearings they must only be removed and reinstalled by means of suit able devices using the shaft centering Only original spare parts must be used The rotor of the motor is dynamically balanced The balance state is indicated on the shaft end face or the rating plate H half key F full key Take care of the balance for installation of the driving element The balancing of the transmission elements to be fitted must be adapted to the rotor balancing In case of half key balancing any protruding and visible part of the key must be removed The motor must only be mounted and operated according to the specified mounting arrangement see rating plate Connection insulation resistance Connection must only be made by an expert and in accordance with the valid safety regulations The relevant installation and operating instructions as well as national and international rules must be observed Note the data on the rating plate Compare the type of current mains voltage and frequency refer to item 4 3 1 Check the wiring diagram Observe the rated current for setting the protective switch Connect the motor in accordance with the wiring diagram provided in the terminal box The motor must be protected against excessive heating For earthing the motor is provided with an earthing terminal which depending on the mounting ar rangement is either located on the frame or on the
12. e bearing machines observe time limit for oil change Refer to manufacturer s documentation for sound power level and information about the use of ap propriate sound reducing measures Maintenance and servicing Follow manufacturer s operating instructions H R 258 en 12 04 Description 2 Description 2 1 Overall construction and design Mounting arrangement acc to EN 60034 7 see dimension drawing or rating plate Horizontal arrangement IM B3 Vertical arrangement IM V1 or IM V10 Connection designations acc to DIN VDE 530 part 8 IEC 60034 8 see wiring diagram Degree of protection acc to EN 60034 5 see rating plate Cooling acc to EN 60034 6 IC 411 surface cooling or hollow fin cooling IC 511 tube cooling IC 01 internal cooling IC 611 internal cooling with mounted on air to air heat exchanger IC 81 W internal cooling with air water heat exchanger IC 71 W water jacket cooling Details of the motor design are indicated in the relevant technical catalogues 2 2 Bearings The motors are equipped with sleeve bearings The bearings are provided with oil ring lubrica tion with natural cooling or with circulating oil lubrication external oil cooling or water cooling The rotor has axial play The axial play is indicated in the dimension drawing and marked on the motor The additional operating instructions Axial Play Indicator must be observed It is not permissible that axial forces from the co
13. es have been taken earthing Check coolant temperature Check whether additional equipment if present is functioning Check whether the cooling air inlet openings and cooling surfaces are clean If a condensation water drain hole exists open the hole for a short time so that the condensation water that may have accumulated can be drained Check the insulation resistance of the stator winding Check whether the motor is securely fixed In case of a belt drive check the belt tension Check whether the cover of the terminal box is closed and whether the cable entrances are properly sealed In cade of water cooled motors check whether the cooling water circuit is in operation For motors with forced ventilation check whether the forced ventilation is functioning and in operation when the main motor is switched on H R 258 en 12 04 Page 13 of 25 Installation and commissioning 4 9 4 9 1 4 9 2 4 9 3 4 9 4 Page 14 of 25 Tightening torques for screwed joints General If no other data is indicated the following torque limits screw and nut are applicable to threaded joints Note Screws which become unusable have to be replaced by new ones of the same strength class and type Screwed joints for electrical connections Thread Tightening torque Nm Thread Tightening torque Nm M4 1 2 M12 15 5 M5 2 M 16 30 M6 3 M 20 52 M8 6 M 24 80 M10
14. f terminal boxes and covers As protection against dust and humidity grease seals with antifriction bearing grease must be instal led at the shaft opening b A hygroscopic substance e g Branogel must be filled in the terminal boxes of the motors c The machines are to be stored dry dustfree and in a temperature controlled room d For the additional measures the specifications according to the items 8 1 1 2 8 1 1 5 are appli cable Page 21 of 25 Storage instructions 8 1 3 2 8 1 3 3 8 2 8 2 1 8 2 1 1 8 2 1 2 8 2 1 3 8 2 1 4 8 2 2 8 2 2 1 8 3 8 3 1 8 3 2 Page 22 of 25 Commissioning Before commissioning the hygroscopic substance e g Branogel must be removed from the ter minal boxes and the measures according to 8 1 2 must be carried out For outdoor storage the following is additionally required Protective cover must be provided against the influence of sun and rain exchange of air must be possible to avoid condensation water After 2 months a check must be carried out whether the protective measures according to 8 1 3 1a are still present and functioning For motors which are stored for more than 2 and up to 3 years before commission ing the following apllies in addition Storage The manufacturer must be informed about the storage time in the purchase order Terminal box covers must be provided with grease seals e g antfriction bearing grease A hygroscopic substance e
15. flange end shield as the case may be In addition all motors have a protective conductor terminal inside the terminal box Page 9 of 25 Installation and commissioning gt gt Page 10 of 25 As protection against dust and humidity unused cable entries in the terminal box must have a tor sionproof seal All terminal screws and nuts have to be securely tightened to avoid excessive transition resistances see paragraph 4 9 2 Protective measures are to be taken In case of terminal boxes that have ground surfaces between the cover and the base a thin grease film is to be applied for sealing and against corrosion High voltage terminal boxes have a pressure relief valve with predetermined breaking joint in the bottom part of the terminal box The valve and sealing must not be damaged during the installation The method of protection must be guaranteed In case of damage the sealing must be renewed only with original sealing material During operation the terminal box must always be tightly closed The cable entries lead entries and connecting cables must be suitable for the ambient tem peratures that occur Terminal boxes with current transformer When current transformers are used it must be ensured that the secondary circuit of the cur rent transformer is protected from unintentional opening during operation After storage for a prolonged period or a shutdown see 8 1 2 the winding must be measured phase to phase and ph
16. g Branogel must be present in the terminal boxes Further measures according to Paragraph 8 1 1 4 Commissioning Before commissioning the hygroscopic substance e g Branogel must be removed from the terminal boxes Further measures according to Paragraph 8 1 2 For motors with sleeve bearings that are stored for more than 3 years Paragraphs 8 1 1 and 8 1 3 are applicable and in addition for the sleeve bear ings as follows Storage The sleeve bearings must be completely dismantled and all points and components subject to cor rosion including the motor shaft have to be treated with Valvoline Tectyl 164 for conservation The dry film thickness is 100 to 150 um wet film thickness 200 um Seaworthy packing of the com ponents is required The conservation of the dismantled bearing and of the motor shaft must be checked in regular inter vals of 2 years and renewed if insufficient Commissioning Prior to commissioning the conservation has to be removed by means of solvent Valvoline 150 or kerosene or a general solvent Assemble the bearing and fill it up with bearing oil up to the marking on the oil level indicators The viscosity class of the bearing oil and the oil change intervals are indicated on an additional plate Further measures according to Paragraph 8 1 2 and 8 2 2 H R 258 en 12 04 Storage instructions 8 4 8 5 H R 258 en 12 04 If motors with direct water jacket cooling or with air water cooler Type AHXA
17. indicators be installed behind the bearings in the discharge lines The cooling water requirement max cooling water inlet temperature max cooling water pressure etc are indicated on the instruction plates at the motor H R 258 en 12 04 32 Installation and commissioning 4 8 Check before commissioning AN Observe data on the rating plate Check whether voltage and frequency of the motor comply with the mains data Check whether the bearing lock has been removed See Paragraph 3 2 Bearing lock Check whether the bearing is properly filled with oil Check whether the oil ring is seated on the shaft in the correct position Check whether for the bearings the oil circuit for oil lubrication is in operation Check whether the rotor is located in the magnetic center Check at starting up whether the oil ring is running freely and provides a perfect oil supply for the sleeve bearing Check at the bearings for water cooling whether the cooling water circuit is in operation Check whether the direction of rotation is correct Check whether the motor is protected as specified in the regulations Check whether the electrical connections are securely tightened and whether the monitoring devices are correctly connected and adjusted Visual check whether the pressure reduction flap and seal in the high voltage terminal box is in tact Check whether protective measur
18. ith dust or dirt deposits Lubrication takes place automatically via the loose ring lubrication The lubrication rings are essen tial for the bearing Before commissioning the bearings must be filled with oil up to the oil level mark For commissioning bearing temperature oil sealing running quietness and control after commis sioning refer to section 5 1 1 Bearing insulation short circuiting If both bearings are insulated the bearing insulation on the drive end has to be neutralized during operation by attachment of a short circuiting jumper cable This measure avoids the build up of a dangerous voltage potential in the rotor The motor has an instruction plate attached with the following text Attention both bearings insulated During operation the DE bearing insulation must be short circuited H R 258 en 12 04 Maintenance 5 3 5 4 gt gt 5 5 5 6 H R 258 en 12 04 Checking the bearing insulation The bearing insulation short circuit may be neutralized by disconnecting the short circuiting cable only at stillstand Insulation of the bearings can now be checked Upon completion of the insulation test reconnect the short circuiting cable Venting filters The sleeve bearing on the driven side or with air outflow dampers even the drive side sleeve bearing have screwed on venting filters The venting filters must be subjected to a visual inspection The visual inspection can be carried ou
19. ive elements only with appropriate means heat and cover them with touch guard Avoid excessive radial and axial bearing loads note manufacturer s docu mentation The balance of the high voltage machine is indicated H Half F Full key With half key models the coupling too must be half key balanced In case of protruding visible part of key establish mechanical balance Make necessary ventilating pipe connections Models with shaft ends pointing upward to be pro vided with cover by customer The ventilation must not be obstructed and the exhaust air also of neighbouring sets not taken in directly Electrical connection All operations must be carried out only by skilled persons on the high voltage machine at rest Before starting work the following five safety rules must be strictly applied De energize Provide safeguard against reclosing Verify safe isolation from supply Connect to earth and short Cover or provide barriers against neighbouring live parts De energize auxiliary circuits e g anti condensation heating Exceeding of limit values of zone A in EN 60034 1 DIN VDE 0530 1 voltage 5 frequency 2 form and symmetry leads to higher temperature rise Note rating plate particu lars and connection diagram in terminal box The connection must be so made that permanently safe electrical continuity is maintained Use appropriate cable terminations Establish and maintain safe eq
20. ly allowed to operate at a coolant temperature below 0 C 32 F then because of the reduced cooling action owing to the addition of antifreeze consultation with the motor manu facturer is necessary The motors with mounted on air water heat exchanger for the Type JHXA Before commissioning the motors the trouble free working of the cooling water circuit must be ensured It must also be ensured that the motor will only get switched on if the cooling water circuit is in operation The cooling water circuit must be kept working until the motor comes to standstill after it has been switched off The permissible inlet and outlet temperature maximum pressure and the required amount of cool ing water are indicated on the motor plates H R 258 en 12 04 Installation and commissioning 4 1 4 2 H R 258 en 12 04 Mounting Fitting of pulleys or couplings First the shaft end should be cleaned not with emery cloth and then greased The Pulley or coupl ing should be fitted only with the aid of a fitting device The threaded centering hole in the shaft end can be used for this purpose Insert a threaded bolt into the threaded hole Then put into place the steel washer the diameter of which is large enough to cover the hub borehole of the pulley or coupling Then fit the pulley and coupling onto the shaft end by means of a nut or a suitable hydraulic device The fitting of the drive elements by means of hammer blows is not permitted be
21. n when the main motor is switched on On special order only 7 Spare parts and components When ordering spare parts please state Spare part designation Motor type Motor serial number Example End shield DE AHTA 450LM O2A 5 134 004 The type and serial number of the motor can be taken from the rating plate H R 258 en 12 04 Page 19 of 25 Storage instructions 8 Storage specifications 8 1 8 1 1 1 8 1 1 2 8 1 1 gt gt _ _i gt gt 8 1 1 5 A Page 20 of 25 For motors which have to be stored for a period of up to 2 years the fol lowing must be observed Storage The motors are to be stored dry dustfree and at room temperature No special packing is then re quired Otherwise the motors must be packed in plastic foil with hygroscopic substances e g Bra nogel or sealed in an air tight foil Protective cover must be provided against sun and rain In order to avoid secondary failures at the bearings caused by vibrations at standstill for example by adjacent running machines the motors are only allowed to be stored in vibrationless rooms For transport motors with sleeve bearings must be equipped with a bearing lock on the drive side lt must remain locked until commissioning or re installed after an inspection or a trial operation The motors are delivered and stored without oil filling in the bearings In order to protect the sleeve bearings incl the motor shaft again
22. ngerous If not avoided injuries or material damage may result High voltage machines rated at more than 1 kV have dangerous live and rotating parts and may have hot surfaces All operations serving transport connection putting into service and mainten ance shall be carried out by responsible skilled persons in conformity with EN 50 110 1 DIN Danger VDE 0105 IEC 60364 Improper handling may cause serious personal injury and damage to property Danger 1 2 General 1 3 Intended use These high voltage machines are intended for industrial installations They comply with the har monized standards of the series EN 60034 DIN VDE 0530 Their use in hazardous areas is pro hibited unless they are expressly designed for such use follow supplementary instructions On no account use degrees of protection lt IP 23 outdoors Air cooled models are designed for ambient temperatures of 20 C up to 40 C and altitudes of lt 1000 m above sea level Ambient temperature for air water cooled models should be not less than 5 C for sleeve bearing machines see manufacturer s documentation By all means take note of deviating information on rating plate Field conditions must conform to all rating plate par ticulars High voltage machines are components for installation in machinery within the meaning of the Machinery Directive 98 37 EC Putting into service is prohibited until conformity of the end product with this directive has been e
23. nsufficient cooling Ventilation passages dirty or cooling water circuit obstructed Short circuit of winding or terminal board Starting time exceeded Activate the oil circuit Clean bearing surface Check oil quality Realign motor exactly correct cou pling Fill up according to specifications Adjust temperature of cooling air Replace bearing shell Exact balancing Check fastening Check motor torque and load torque Check mains conditions Check mains supply Follow the wiring diagram and rating plate Compare data on rating plate Observe rated duty type Check ventilation passages check direction of rotation Cooling water Check inlet and out let temperature Clean Measure insulation resistance Check starting conditions H R 258 en 12 04 Appendix 1 Servicebericht Service report berpr fung der Ausrichtung Alignment check Bestellnr Order No Seriennr Serial No Empfohlene Ausrichtgenauigkeit Recommended accuracy for alignment 1 100 mm 1 100 mm pro 1 100 mm each 1500 6 5 3 2 5 Gemessene Werte an der Kupplung Measured values at the coupling llelversa Offse Winkelversatz Angular offset Bemerkungen Comments Falls keine Werte vom Kupplungshersteller vorgeschrieben sind If no values were specified by the coupling manufacturer H R 258 en 12 04 Page 25 of 25 LOHER LOHER GmbH P O Box 1164 e 94095 RUHSTORF Hans Loher
24. ocking mechanism must be reused for further transports Prevent failures and thus avoid damage to persons and property The person responsible for the installation has to make sure that AN safety instructions and operating instructions are available and observed the operating conditions and technical data acc to the order are observed protective equipment is used the specified maintenance work is carried out H R 258 en 12 04 Page 7 of 25 Installation and commissioning 4 Installation and commissioning Page 8 of 25 A most careful mounting and alignment of the motors on an absolutely even surface is impera tive to avoid distortions when the screws are being tightened For machines which are to be coupled attention must be paid to careful alignment See Appendix 1 for alignment checking Couplings that are as elastic as possible should be used When using pulleys gear wheels etc ensure that the permitted radial and axial shaft loads are not exeecced Motors with surface cooling TEFC hollow fin cooling or tube cooling internal cooling or internal cooling with air to air heat exchanger for all specified types except Type AHXA and JHXA The maximum permissible coolant temperature ambient temperature at installation site acc to EN 60034 1 IEC 60034 1 is 40 C 104 F and a permissible altitude up to 1000 m above mean sea level other values see rating plate Care must be taken that the cooling
25. pated through air as the cooling medium 2 3 5 Water jacket cooling for the Type AHXA 355 to AHXA 560 The stator housing has a double casing It is sub divided by spirals for water channelling and the cooling water passes through it This results in a good heat dissipation Additionally this reduces the danger of suspended matters carried along in the water getting deposited H R 258 en 12 04 Page 5 of 25 Description 2 4 2 4 1 2 4 2 2 4 3 2 4 4 2 4 5 2 5 2 6 2 7 2 8 Page 6 of 25 Motor frame Construction for surface cooling TEFC hollow fin cooling or tube cooling Depending on the frame size the stator frame and end shields are made of grey cast iron or steel The fan cover is made of sheet steel The stator frame surface is provided with cooling fins hollow fins or tubes and an attached terminal box Construction for internal cooling ODP for the Type JHTA Depending on the frame size the stator frame and end shields are made of cast iron or steel The stator frame has an even surface with an attached terminal box There are spacer fins between stator jacket and stator pack to facilitate internal cooling Construction for internal cooling with air water heat exchanger for the Type JHXA The stator frame and end shields are of steel The stator frame surface is plain with mounted on terminal box Between the stator jacket and the stator core there are spacing ribs to facilitate the in
26. rection of rotation is separately marked by an arrow on the forced ventilation system itself Air water heat exchanger motors with air water heat exchanger of the type JHXA For connection and commissioning the instructions for air water heat exchangers must be con sidered The permissible inlet and outlet temperature maximum pressure and the required amount of cooling water are indicated on the motor plates Oil supply The diameter of the piping must be chosen in such a way that for the supply line the flow rate does not exceed 1 5 m s approx for the return line the flow rate should not exceed 0 15 m s If a gradient of 15 in the return line cannot be realized because of constructional reasons correspondingly large diameters must be installed in order to avoid a back draft of oil which could cause overflowing of the bearing Welded and hot bent rusty or internally significantly dirty piping must be pickled before installation After installation of the piping the whole oil circuit must be flushed in order to avoid bearing damage by contamination Use kerosene or flushing oil For this purpose all measuring fittings pressure switches etc must be removed and their connections must be closed After flushing the filters must be cleaned The bearings must never be left in the flushing circuit under any circumstances For filling the bearing lube oil by collecting units for example in connection with gears a corre sponding
27. resistance of the winding must be measured by qualified personnel phase to phase and phase to ground Damp windings may cause leakage currents ar cing and ruptures In case of values lt 4 Un kV 1 MQ measured at a winding temperature of 20 C 68 F the winding must be dried Drying is possible by passing a single phase AC current through the winding The voltage has to be adjusted in such a way that the recommended values of the heating current in accordance with Illustrations a and b are not exceeded The temperature should reach approx 80 C 176 F and be in effect for several hours Drying is also possible in a drying kiln Recommended heating circuits and maximum heating currents H R 258 en 12 04 Imax 65 Ir Imax 75 Ir In the case of motors with a bearing lock the bearing lock must be removed before commissioning Prior to commissioning the hygroscopic substances must be removed from the bearing housings and the sleeve bearing must be filled up with bearing oil up to the marking on the oil level indicators The viscosity class of the bearing oil and the oil change intervals are indicated on an additional plate For motors which are transported and stored in assembled condition with the machine to be driven the following must be observed Storage a The free shaft ends must be greased before installation of the motors as also the other naked metal parts e g foot and flange surfaces or supporting faces o
28. s an extra see dimensional drawing The number of available terminals can be seen in the wiring diagrams Monitoring devices Monitoring devices are only available if specially ordered See the wiring diagram H R 258 en 12 04 Transport 3 Transport For handling during transport the stator construction of the motor is equipped with lifting lugs to AN which the lifting hooks can be fixed Check whether the screwed lifting lugs are securely tightened Lift motors only by using these lifting lugs Several lifting lugs must always be used together considerable damage The lifting lugs are only suitable for the motor weight Additional loads attached to the motor must never be lifted using these lugs Lifting the motors from other parts e g shaft ends is not permitted since this might result in 3 1 Check before installation Check whether the motor has been damaged during transport If the packing is damaged to such an extent that motor damage is to be assumed the packing should be removed in the presence of a representative of the carrier 3 2 Bearing lock for motors with cylindrical roller bearings only The rotor of the motor is axially locked by a securing device for transport that is fixed on the shaft AN end or on the mounted coupling braced against the bearing body Before the motor is commissionined the securing device must be removed Thereafter it must be possible to easily rotate the shaft The transport l
29. special order only 6 1 Temperature monitoring The temperature sensors for monitoring e g the stator winding temperature the bearings the coolant must be connected by one or several additional terminal boxes The temperature sensors have to be connected according to the relevant connection diagram The specifications and instructions acc to Paragraph 4 2 Connection are applicable to the con nection 6 2 Space heater Heating capacity and connection voltage See instruction plate on the motor The space heater has to be connected by an additional terminal box according to the relevant connection diagram The specifications and instructions according to Paragraph 4 2 Connection are applicable to the connection Operation of the space heater is only allowed when the motor is switched off The space heater must never be switched on during motor operation 6 3 Forced ventilation Observe direction of rotation see arrow for direction of rotation Forced ventilation must be connected according to the wiring diagram inside the terminal box During operation of the main motor the forced ventilation motor must be switched on The forced ventilation dissipates the heat loss during operation of the main motor When switching off the main motor the forced ventilation must be continued on a a temperature dependant basis 6 3 1 To be checked when commissioning the main motor Check whether the forced ventilation works and is in operatio
30. st corrosion until commissioning the following measu res must be taken All the openings must be sealed the threaded holes must be fitted with plugs the connection flanges must be fitted with blank flanges the gap between gasket and shaft or gasket and housing must be covered self adhesive durable tape Remove the glass cover on the bearing housing with a pneumatic spraying gun spray an anti corrosive through this opening This medium e g Valvoline Tectyl 511 M must be such that it does not have to be removed for commissioning the motor Put a bag with hygroscopic filling e g Branogel below the glass cover to avoid condensation water being generated Then screw down the bearings tight again If the period of 1 2 year from the date of conservation to the date of commissioning is exceeded the conservation steps described above must be repeated Prior to commissioning the hygroscopic fillings must be removed from the bearing housings and the sleeve bearing must be filled up with bearing oil up to the marking on the oil level indicators The viscosity class of the bearing oil and the oil change intervals are indicated on an additional plate In case of motors with sealed condensation water drain holes it might be necessary to have the condensation water drain out Afterwards the boreholes must be sealed again H R 258 en 12 04 Storage instructions 8 1 2 8 1 2 1 Commissioning Before commissioning the insulation
31. stablished follow particular local safety and installation rules as e g EN 60204 1 4 Transport Storage Immediately report damage established after delivery to transport company If appropriate pre vent putting into service of machine Eyebolts are dimensioned for the weight of the high voltage machine do not apply additional loads If necessary use suitable adequately dimensioned means of transport e g rope guides Remove shipping brace e g antifriction or sleeve bearing locks vibration dampers before putting machine into service Reuse it for further transports When storing high voltage machines make sure of dry dust free and low vibration Vims lt 0 2 mm s location danger of bearing damage at rest Measure insulation resistance be fore putting machine into service With values of lt 4 Un kV 1 MQ at 20 C winding tempera ture dry the winding Refer to the section Storage regulations Page 2 of 25 H R 258 en 12 04 Safety and commissioning instructions A 15 A Danger 1 6 A Danger H R 258 en 12 04 Installation Make sure of even support solid foot or flange mounting and exact alignment in case of direct coupling Avoid resonances with rotational frequency and double mains frequency as a result of assembly Turn rotor listen for abnormal slip noises Check direction of rotation in uncoupled state refer to the section Electrical connection Mount or remove couplings or other dr
32. t be stopped at once and the cause must be eliminated Page 15 of 25 Maintenance 5 2 Page 16 of 25 Check after commissioning Check whether the motor is running smoothly Check whether the oil ring is seated on the shaft and runs freely Oil change periods The first oil change should be done after 600 700 operating hours Die Olwechselfristen sind auf einem Hinweisschild am Motor gestempelt Plain bearings for oil circulation lubrication external oil cooling Bearing cooling is ensured through the oil circulation lubrication The maintenance of the oil circulation must be monitored by the system The large fanned housing surface of the bearings guarantees additional cooling The bearing housings must be kept clean externally in order not to disturb the heat radiation with dust or dirt deposits Lubrication is carried out automatically via the loose ring lubrication The lubrication rings are abso lutely essential for the bearing For commissioning bearing temperature oil sealing running quietness and checking refer to sec tion 5 1 1 Plain bearings with loose ring lubrication and water cooling Bearing cooling is guaranteed by the oil circulation lubrication The maintenance of the oil circulation must be monitored by the system The large fanned housing surface of the bearings guarantees additional cooling The bearing housings must be kept clean externally in order not to hinder the heat radiation w
33. t while the machine is running Danger of accidents Pay attention to rotating parts No dirt or dust may be allowed to penetrate into the air pipe of the sleeve bearing The lubricating oil must not get dirty Cover the air pipe during the visual inspection Do not forget Put the venting filter on again Maintenance of the venting filters A visual inspection of the venting filters is neessary with normal use after 1 year and in case of applications with dust and sand pollution after year In case of intense dirtying the venting filter must be replaced with an original spare part Avoiding mechanical damage bearing damage All machines must be regularly inspected for mechanical damage Particular attention must be paid to compliance with the prescribed oil changing intervals In case of bearings with external oil supply the owner operator must monitor the preservation of the lubrication by suitable means The plant must be switched off when the permissible temperature is exceeded but not later than at 100 C The bearing insulation if present must always conform to DIN 31692 4 and must never be bridged e g by a thermometer or reduced Page 17 of 25 Maintenance 5 7 5 8 5 9 Page 18 of 25 Regular checking of the lubricant level must be carried out in case of self lubricating bearings through the oil level glass or with level monitoring or in the case of externally lubricated bea rings
34. ternal cooling An air water circuit cooler is mounted on the ventilation open ings Construction for internal cooling with air to air heat exchanger for the Type JHQA Like for the internal cooling with air water heat exchanger however an air to air heat ex changer is mounted onto the ventilation openings Construction for water jacket cooling Type AHXA 355 to AHXA 560 Stator frame and end shields are made of grey cast iron or steel The stator jacket is designed as a double casing through which the cooling water is led The housing is provided with an inlet and outlet for the cooling water Stator winding The stator winding is made in an insulation class see rating plate acc to EN 60034 1 High quality winding wires suitable surface insulating materials and the type of impregnation pro vide a high level of mechanical and electrical stability with a high utilization factor and a long service life Rotor The rotor has a hard soldered cage The rotor is dynamically balanced The balance is indicated on the shaft end or the rating plate see Paragraph 4 1 Installation The motors in standard design meet the requirements of vibration level N acc to DIN EN 60034 14 IEC 60034 14 in special cases level R reduced or S special Terminal boxes Apart from the motor connector boxes additional connection boxes for monitoring equipment are available if required A neutral point box is only attached if ordered a
35. uipotential bonding The clearances between uninsulated live parts and between such parts and earth must not be below the following values 36 mm at Un lt 3 3 kV 60 mm at Un lt 6 6 kV 100 mm at Un lt 11 kV No presence of foreign bodies dirt or moisture is allowed in the terminal box Close unused cable entrance holes and the box itself in a dust and watertight manner For trial run without output elements lock fitting key For high voltage machines with accessories check satisfactory functioning of these before put ting into service he proper installation e g segregation of signal and power lines screened cables etc lies within the installer s responsibility If no further information is given the torque for the contact screws and nuts should be used accord ing to section 4 9 2 Page 3 of 25 Safety and commissioning instructions A 1 7 A Danger 1 8 Page 4 of 25 Operation Vibration severities in the satisfactory range Vrms lt 4 5 mm s according to ISO 3945 are accept able in coupled mode operation In case of deviations from normal operation e g elevated temperature noises vibrations disconnect machine if in doubt Establish cause consult manufacturer if necessary Do not defeat protective devices not even in trial run In case of heavy dirt deposits clean cooling system at regular intervals From time to time open closed condensate drain holes if any In case of sleev
36. upling or from the working machine are transmitted to the motor bearings Special bearings for taking up axial forces will only be provided if specially ordered 2 3 Cooling 2 3 1 Surface cooling TEFC for the Type AHTA AHQA Design for fin hollow fin or tube cooling where an external fan takes in the cooling air through the openings in the fan cover and presses the air over the surface or through the cooling tubes of the stator housing In case of hollow fin or tube cooling the heat dissipation is supported by a closed cooling air circuit inside the motor 2 3 2 Internal cooling for the Type JHTA In case of motors with method of protection IP 23 the cooling air ambient air is taken in by internal fans through air inlet openings led over the heat generating elements in the motor and blown out through air outlets 2 3 3 Internal cooling with mounted on air water heat exchanger for the Type JHXA The motors are equipped with air water circuit coolers The cooling air led through the heat ex changer and motor is recooled in the heat exchanger and the heat loss is dissipated through the cooling water The heat exchangers are provided with special ribbed tubes 2 3 4 Internal cooling with mounted on air to air heat exchanger for the Type JHQA The motors are equipped with an air to air heat exchanger The cooling air led through the heat exchanger and motor is recooled in the heat exchanger and the heat loss is dissi
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