GE I-M1025 Installation Instructions
Contents
1. t O Vin f TEE STE GEI M1025 B 2 Bolted Coupling Steel balls not used on Bolted Coupling assemblies COUPLING BOLTS GIB KEY COUPLING LOCK WASHERS NOTE pre UN clean coupling amp all related pre UN prior to mounting on motor UPPER HALF COUPLING COVER PLATE BOLTS COVER PLATE COVER PLATE LOCK WASHERS LOWER HALF COUPLING LOCATED ON MOTOR 17 GEI M1025 B B 320 449 Frame Non Reverse and Bolted Coupling Coupling Kit Packing List Item Quantity Upper Half Coupling 1 Coupling Bolts Coupling Lock Washers Cover Plate Cover Plate Bolts Cover Plate Lock Washers Balls Gib Key Instructions Fr O Ov n e eje Bolt Torque Chart Part Name Frame Size Item Torque Ft Lb Torque N M Cover Plate Bolts 320 440 1 4 20 UNC x 5 8 Bolt 8 11 Coupling Bolts 320 360 1 2 13 UNC x 2 1 2 Bolt 75 102 Coupling Bolts 400 440 5 8 11 UNC x 3 1 2 Bolt 150 203 It is the installer s responsibility in all cases to ensure these torque values are used and maintained This includes those instances when the coupling comes mounted in the motor Failure to comply may Caution cause the coupling bolts to break with resultant extensive damage to the equipment 1 Non Reverse Coupling NOTE Thoroughly clean coupling amp2. Lubricated Bearings Maintain proper lubrication by checking the oil level periodically and adding oil when necessary Because of the clearing action of the bearing as it accelerates and the expansion of the oil as it gets hotter the oil level at the sight glass will be higher after the motor has been in operation for a while than it is with the motor at standstill and cold The normal level with the motor stopped and the oil cold is marked STANDSTILL LEVEL on the sight gage Overfilling should be avoided not only because of the possibility that expansion may force the oil over the oil sleeve and into the motor but also because operating with the oil level too high prevents the bearing from clearing itself of excess oil The resultant churning can cause extra loss high temperatures and oxidized oil 10 GEI M1025 B If during operation the oil level goes above the maximum shown on the sight gage drain enough oil to bring the level back within the operating range To drain the oil remove the drain plug below the sight gage Do not permit the operating oil level to fall below the minimum shown on the gage If it ever becomes necessary to add excessive amounts of make up oil investigate for oil leaks Change oil at regular intervals The time between oil changes depends upon the severity of operating conditions and hence must be determined by the motor user One or two changes a year is average but special conditions such as h
3. Stainless steel fasteners per ASTM F593 C Threaded holes in parts for fasteners are per System 21 ASME ANSI B1 3 D SAE Grade 5 bolts have 3 radial marks on the head E SAEGrade 8 bolts have 5 radial marks on the head F Low carbon steel bolts have no marks on the head G Low carbon steel bolts Use 5096 of the Grade 5 Torque Medium Carbon Steel SAE Hardware Grade 5 Fastener Torques Unless otherwise specified Torque Torque Screw Bolt Size Typical Application Inch Lb N M 10 Low Carbon Steel Bearing Cap 15 25 1 7 2 8 74 Low Carbon Steel M6 Bearing Cap 35 60 4 0 6 8 14 M6 All Parts except Bearing Cap and Fan Cover 70 96 79 108 4 Grade 8 M6 Fan Cover Mounting 100 145 11 16 5 16 M8 Bearing Cap 78 120 88 14 5 16 M8 All Parts except Bearing Cap 170 250 19 28 3 8 Low Carbon Steel M10 Conduit Box Cover 180 240 20 27 3 8 M10 All Parts except Conduit Box Cover 250 370 28 42 M12 All Parts 610 920 70 100 5 8 M16 All Parts 1440 2160 163 244 34 M20 All Parts 2150 3200 240 560 Stainless Steel SAE Hardware Property Class 50 Fastener Torques Torque Torque Screw Bolt Size Typical Application Inch Lb N M 10 Bearing Cap 15 25 1 7 2 8 14 M6 Bearing Cap 35 60 4 0 6 8 4 M6 All parts except Bearing Cap 60 75 6 8 8 5 5 16 M8 Bearing Cap 78 120 8 8 14 5 16 M8 All parts except Bearing Ca
4. and serial numbers Data and information regarding an individual motor model number can be obtained from the Data Pack for the motor or through EliteNet or by contacting your local GE Energy representative F Relevant Standards 1 Motors shipped with this Installation and Maintenance Instruction have been designed and built to the latest revision of the following standards a NEMA MG 1 2 Motors that have the IECEx designation have also been designed to meet the requirements of the following standards d IEC and or BS EN 60079 0 b IEC and or BS EN 60079 15 3 Motors with the CE Mark have also been designed to meet the requirements of the following EU directives a Machinery safety b Low Voltage c Electromagnetic Compatibility d Conformity Assessment Il RECEIVING Each motor should be carefully inspected upon receipt Motor rating and identification data are furnished on a packing label for verification purposes Any damage should be reported promptly to the carrier and a claim filed The nearest GE Energy sales office may provide additional guidance GEI M1025 B A Unpacking If the motor has been exposed to low temperatures unpack it only after it has reached the temperature of the room in which it will be unpacked Otherwise the motor windings will be exposed to condensing moisture B Temporary Storage Up to 6 Months If the motor will not be put into service immediately certain precautions should be
5. are required the motor must be repaired by operators trained in the understanding of BS EN 60079 1 and BS EN 60079 15 standards The motor has been designed to meet the rigid requirements of these standards Repair or alteration of the motor may result in the motor no longer meeting the requirements of these standards If major repairs are undertaken such as rewinding a stator proper facilities should be made available and suitable precautions observed rewinding adequate ventilation must be provided to avoid exposing personnel to noxious fumes f A WARNING When burning off old insulation materials or when welding near insulation during Combustion of exhaust must be complete and adequately vented to the outside atmosphere in compliance with acceptable standards Exposure of personnel to air borne inorganic fibers must be avoided by adequate ventilation or by wetting the remaining insulation components following the burning of the organic materials IX RENEWAL PARTS The use of only GE Energy renewal parts is recommended When ordering specify the model number and the serial number of the motor complete nameplate data is desirable Specify quantity and describe the part For information and service refer to the nearest GE Energy Sales Office or a GE Energy Authorized Service Shop 14 GEI M1025 B X FASTENER TORQUES A Medium carbon steel fasteners per ASTM A449 Type 1 B
6. hand After slightly preloading the bearings back off the shaft locknut approximately 1 4 turn If the equipment is available it is desirable for the shaft endplay be checked using a dial indicator to measure movement as the rotor and shaft are raised and lowered Shaft endplay should be 0 005 in to 0 020 in 0 127 mm to 0 508 mm When proper endplay is established lock the nut in place with the shaft lock washer 12 GEI M1025 B VI OPERATIONAL DIFFICULTIES Some operating difficulties may occur Common causes are given in the table below and should be corrected as soon as possible Trouble Shooting Table Affected Parts Difficulty What to Check Calibration of measuring instrument Unbalanced voltage Unbalanced Current Excessive Current Windings Overheating Variable Frequency Drive Harmonics Improper or restricted ventilation Dirty windings Excessive ambient temperature Short circuited coil or windings Calibration of measuring instrument Oil Viscosity Worn out or dirty oil Worn out or dirty grease nsufficient Oil Excessive or insufficient grease Misalignment Excessive thrust or radial loading Shaft currents ncorrect Endplay Bearing preload Bearings Overheating Mechanical Unbalance Misalignment mproper or settled foundation Non uniform air gap Rubbing parts Bent shaft Unbalanced stator current Damaged bearing Reed Critical frequency ncorrect Endplay Bearing preload Motor Ex
7. provide maximum bearing life Type of Grease Motors are assembled with Shell Alvania R3 grease in the factory Some equivalent greases are Polyrex EM Exxon BRB 2 Chevron AeroShell 5 Shell Oil Company Hi Temp Texaco Inc The table below lists relubrication intervals for motors under normal steady running conditions in a relatively clean atmosphere at 40 C ambient temperature or less A standard 10 000 PSI 68 950 kPa 16 ounce 473 mL grease gun delivers approximately 0 04 oz 1 18 mL of grease with each pump and a 24 oz 710 mL gun delivers approximately 0 06 oz 1 77 mL of grease GEI M1025 B Amount and Interval Table for Grease Lubricated Bearings Lubrication Intervals Number of Pumps Number of Pumps days 16 Oz 24 Oz 16 Oz 24 Oz Upper Gun Gun Lower Gun Gun Frame Thrust Approx Approx Guide Approx Approx Size Brg 473 mL 710 mL Brg 473 mL 710 mL 2Pole 4Pole 6Pole 213 215 7309 25 17 6209 25 17 120 180 180 254 256 7311 25 17 6309 25 17 120 180 180 284 286 7311 25 17 6311 25 17 120 180 180 324 326 OilLube Oil Lube Oil Lube 6312 25 17 120 180 180 364 365 OilLube Oil Lube Oil Lube 6313 25 17 120 180 180 404 405 OilLube Oil Lube Oil Lube 6314 44 29 80 180 180 444 445 OilLube Oil Lube Oil Lube 6314 44 29 N A 180 180 447 449 OilLube Oil Lube Oil Lube 6218 44 29 N A 180 180 4 Procedure f
8. EI M1025 B B Mounting 1 Motors with Oil Lubricated bearings must be mounted on a level surface to prevent oil leakage and for proper operation of the oil sight glass The motor base should be bolted down square with the pump head and at right angles with the pump shaft Bolt the motor to the pump head using bolts of the largest size permitted by the clearance holes in the motor base The mounting bolts must be tightened to prevent changes in alignment and possible damage to the equipment It is recommended that a washer be used under each nut or bolt head to get a secure hold on the base As an alternative flanged nuts or bolts may be used The recommended torques are listed in the FASTENER TORQUES section below Vertical Hollow Shaft Motors VHS Remove the hood or top hat and the upper half coupling from the motor Lower the motor onto the pump head with the pump shaft extending through the motor s hollow shaft The pump shaft should be centered within the motor s hollow shaft Non Reverse Coupling NRC See the Coupling Assembly Section below These motors are typically equipped with a Non reverse coupling NRC that permits rotation in the CCW direction viewed from the coupling end of the motor The NRC system consists of a stationary ratchet plate with slotted ramps and a rotating ball carrier that retains several steel balls When the motor starts in the forward CCW direction the slotted ramps in the ratchet plate lift the b
9. GEI M1025 B GE Energy Motor Installation And Maintenance Instructions Vertical AC Small Industrial Motors NEMA Frame Sizes 213 to 449 NEMA Type P Base Weather Protected Type 1 High Thrust Hollow and Solid Shaft Ball Type Non Reverse Couplings And Bolted Couplings Models 5KXXXDTTXXXX Models SKEXXXDTTXXXX Copyright 2012 General Electric Company 2012 0 7 02 GEI M1025 B Table of Contents VI VII VIII IX xI General INFOP MATION eeeeecssssssssssesesscccessssssesesccccessssnssscsescsssssnesssecesssssssuessessessssssnesseeseesssssuusesseesssnsusssseseesssnaneses 1 A How to Properly Use this Instruction Manuol aeree tte tette 1 p Suteb SVIDIbO Su sa iot aaa a ESET rAr oin Pas eT 1 Cod le Motor Operation MOM MOHON cessa sonde certitude ttt tee E e ret e 2 D Description of Labels and Nameplates e esesttttttennnnttcctttt 3 E Model and Serial DMIF tc i a a ee a hs edt 3 Fy Relevant Industry Standards rereana rt ta diu te ie E R 3 RECEIVING irin n a e E EEEE ADI oR Maa AE nde MD dtd AM ARN UR 3 A UNPA e IRIS MNT A OD Dm 4 B Uerporarssterdge Moblin debetis a alaot ant atas bti stone li 4 E ERTS IOS ASTON io adea ARM ARR d NU TAREA REA URN s teres 4 S PN Tolg T0 9 ea EN Ne SION MSN TN NRI TN e e I RR S 4 aS TONGUE coin de nane aa anon inb ho ERO Robo OR Proba eon be aero bh hoeeprbud 4 Pa LOCOHON S NeRUEEGUNEEUNE DEGERE DUE MELDE EDU DEED NEED SUE 4 BOBO es ond t Som E E EE E entes
10. al indictor and checking bars connected to the motor and load machine shafts The space between coupling hubs should be maintained as recommended by the coupling manufacturer Shaft offset should not exceed 0 002 Angular misalignment should be less than 0 002 C Power Supply and Connections 1 Nameplate voltage and frequency should agree with the power supply Motors will operate satisfactorily on line voltage within 10 of the nameplate value or frequency within 5 combined variation not to exceed 1096 Dual voltage motors can be connected for the desired voltage using instructions on the nameplate or the connection diagram GEI M1025 B 3 When made mounting conditions permit the conduit box may be rotated so that the conduit entrance can be upward downward or from either side AN AX WARNING Motor and control wiring overload protection and grounding should be in accordance with the USA National Electric Code or BS EN 60204 1 and or BS EN 60204 11 and consistent with sound local practices IV OPERATION A Steps Prior to Starting 1 Oil lubricated bearings Drain any oil from the oil reservoir that was put in upon receipt of the motor or during long term storage by removing the drain plug located at the bottom of the oil sump Replace the drain plug Refer to the lubrication nameplate on the motor With the motor at standstill fill the oil reservoir per the information on the lu
11. all related components prior to mounting on motor Coupling Bolts Gib Key Upper Half Coupling Cover Plate Bolt Cover Plate Lock Washer ag a Cover Plate SD Steel Ball Ball Carrier Located on motor 18 GEI M1025 B 2 Bolted Coupling Steel balls not used on Bolted Coupling assemblies NOTE Thoroughly clean coupling amp all related components prior to mounting on motor Coupling Bolts Gib Key Coupling Lock Washers Upper Half Coupling Cover Plate Bolt Cover Plate Lock Washer a Cover Plate Ball Carrier Located on motor Ratchet Plate 19
12. alls above the ratchet plate where they are held in place by centrifugal force as the motor speed increases When the motor speed decreases the balls move down due to the decreasing centrifugal force and then prevent CW reverse rotation by locking against the vertical edge of the slots in the ratchet plate Coupling halves should have a close sliding fit on their mating parts and must be securely locked to avoid damage in operation If it is necessary to drive the coupling into position it is important that the other end of the shaft be supported so the force of driving on the coupling does not damage the lower end bearing Failure to comply may result in extensive damage to the bearing Fit the upper half coupling onto the motor and key it to the pump shaft with the gib key Put on the adjusting nut supplied with the pump and draw up on the impellers Lock the adjusting nut in place with a screw through the nut into a tapped hole in the coupling Vertical Solid Shaft Motors VSS These motors are provided with a shaft extension suitable for direct coupled loads Use flexible couplings if possible Accurate mechanical lineup is essential for successful operation Mechanical vibration and roughness in running the motor may be an indication of poor alignment In general lineup by straight edge across and feeler gauges between coupling halves is not sufficiently accurate It is recommended thot the lineup be checked with a di
13. brication nameplate Replace the filler plug 2 Insulation Resistance AA WARNING If the motor has been in a damp location dry it out thoroughly before operating Before energizing the motor for the first time or after an extended shut down it is advisable to check the insulation resistance power supply and mechanical freedom of the motor In accordance with established standards the recommended minimum insulation resistance for the stator winding when measured with a 500 volt DC direct indicating ohmmeter with self contained power supply megger shall not be less than 5 mega ohms at 40 C for a motor rated under 1000 volts and not less than 100 mega ohms at 40 C for a motor rated over 1000 volts If the insulation resistance is lower than this value it is advisable to eliminate the moisture in one of the following ways d Dry the winding in an air circulating oven with the air surrounding the winding at 110 C 5 15 C until the winding has been above 90 C for at least four hours Then the air temperature may be raised to 150 C 5 C 15 C Continue to heat until the insulation resistance is constant for a one half hour period b Enclose the motor with canvas or a similar covering Leave a hole at the top for moisture to escape Insert heating units or lamps and leave them on until the insulation resistance is constant for a one half hour period c With the rotor locked mechanically and using ap
14. cessive Vibration Moisture dirt metal particles oil or other contaminants on the windings Moisture from a Wash Down Moisture from severe weather Low insulation resistance Wrong voltage or insulation failure Excessive temperature Voltage surges lightning Mechanical damage Excessive vibration with resultant mechanical damage Single phasing Winding Insulation 13 GEI M1025 B VII FAILURE cause the insulation to give off noxious fumes All power should be removed from the motor circuit as a precaution even though the circuit has overload protection Personnel should not approach the motor until adequate ventilation of the area has purged the air of fumes When covers of a motor are removed after a failure care should be observed to avoid breathing fumes from inside the motor Preferably time should be allowed for the motor to cool before attempting any examination or repair f h WARNING An extreme overload or electrical failure may result in heating or arcing which can shock could result in serious or fatal injury In case of fire disconnect all power and use a carbon dioxide extinguisher to quench the flame Before operating any motor after a suspected failure it should be inspected for damage A A WARNING Water should not be applied to any electrically energized equipment because electric VIII REPAIR If a motor is marked with IECEx or ATEX designation and repairs
15. ction manual before CAUTION if not strictly observed could result in installation operation and maintenance minor injuries to personnel This symbol indicates the need to wear hearing protection GEI M1025 B C Safe Motor Operation Information personnel should perform installation operation and maintenance of electrical machinery For equipment covered by this instruction manual it is important to observe safety precautions to protect personnel from possible injury Be sure to keep the installation and maintenance information for future reference All warnings and cautions must be followed WARNINGS High voltage and rotating parts can cause serious or fatal injuries Qualified Installation e Avoid contact with energized circuits and rotating parts e Avoid bypassing or rendering inoperative any safeguards or protective devices e Avoid use of automatic reset thermal protection where unexpected starting of equipment might be hazardous to personnel Avoid contact with capacitors until safe discharge procedures have been followed Be sure the motor shaft key is captive before the motor is energized Avoid long exposure in close proximity to machinery with high noise levels When the motor is coupled to equipment ensure that system vibrations are within acceptable limit per ISO 10816 1 to avoid failure of the motor e Use proper protective gear care and procedures when handling lifting installing operatin
16. d be kept clean from dirt oil metal particles and other contaminants A variety of satisfactory and acceptable methods are available for keeping the windings clean The choice of method will depend greatly on time availability of equipment and on the insulation system Vacuum cleaning with non metallic hose tips should precede cleaning with water and detergent or witt solvents Tightly adhering dirt will require removal by gentle brushing or wiping AN WARNING To prevent injury to the eyes and respiratory organs safety glasses and suitable ventilation or other protective equipment should be used D Vacuum and Compressed Air Cleanin Compressed air should be used to remove loose dirt and dust from air passages Suction should be used to remove dirt from the windings to avoid damaging the coils CAUTION Care must be taken to make sure the air is dry and that the air pressure is not more than 21 x 103kg m 30 psi AN AN WARNING Operator must not use compressed air to remove dirt or dust from his or her person and clothing GEI M1025 B E Cleaning with Water and Detergent This method is very effective in cleaning windings when used with a low pressure steam jenny with maximum steam pressure 30 psi and 90 C AN CAUTION To minimize possible damage to varnish and insulation a fairly neutral non conductive type of detergent such as DuBois Flow should be used A pint of
17. detergent to 76 liters 20 gallons of water is recommended If a steam jenny is not available the cleaning solution may be applied with warm water by a spray gun After the cleaning operation the windings should be rinsed with water or low pressure steam Dry the windings Refer to the Insulation Resistance section above for instructions on how to proceed F Bearings and Lubrication Grease Lubricated Bearings The grease used as a lubricant in grease lubricated anti friction bearings loses its lubricating ability over a period of time For a given bearing construction and assembly the lubricating ability of a grease over time depends primarily on the type of grease the size of the bearing the speed at which the bearing rotates and the severity of operating conditions As a result it is not possible to accurately predetermine when new grease must be added Good results can be obtained if the general recommendations stated in this manual are followed The primary function of grease is to supply the essential lubrication oil from the sponge like reservoir of its soap structure Grease lubricated bearings consume only a small amount of lubricant This lubricant must always be present to avoid rapid wear and bearing failure Excessive or too frequent lubrication may also damage the motor Grease lubricated bearings are lubricated at the factory Motors with grease fittings should be lubricated in accordance with these instructions to
18. e not covered sufficiently for the purchaser s purposes the matter should be referred to the General Electric Company This document contains proprietary information of General Electric Company USA and is furnished to its customer solely to assist that customer in the installation testing operating and or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy GEI M1025 B D Description of Labels and Nameplates Motor rating and identification data are furnished on packing labels and motor nameplates Motor nameplates provide a permanent record of motor characteristics plant identification and date of manufacture Below is an example of a label that is attached to the shipping package MOD 5KS184SAA305D 9262MC02 MOD GE model number KW Motor power rating RPM Motor speed at full load VOL Motor voltage KW 1 5 RPM 1170 VOL 230 460 ENCL TEFC ENCL Enclosure code FR 184T FR Frame size MASS 45 8 KG MASS Motor mass SERIAL EDFT148U02 S O 9262MC02 Typical Packing Label E Model and Serial Numbers As discussed in section D every motor that is manufactured by GE Energy has a model number and a serial number which are permanently marked on the motor nameplate When contacting a GE Energy Service Shop or representative please provide the model
19. er than six months please refer to GE Instruction Manual GEK 97427 D Handling used to lift the motor plus additional equipment such as pumps compressors or other driven equipment In the case of assemblies on a common base lugs or eyebolts provided on the motor are not to be used to lift the assembly and base The assembly should be lifted by a sling around the base i WARNING Lifting lugs on the motor are designed for handling only the motor They are not to be or by other lifting means provided on the base Il INSTALLATION 1 and BS EN 60204 11 and consistent with sound National and local practices Coupling belt and 1 WARNING Installation should be in accordance with the USA National Electric Code or BS EN 60204 chain guards should be installed as needed to protect against accidental contact with moving parts Motors accessible to personnel should be further guarded by screening guard rails etc to prevent personnel from coming in contact with the equipment A Location Locate the motor in a clean well ventilated area The motor enclosure is designed such that dripping wind blown and splashing water will not damage the motor Under conditions of extreme weather and moisture additional protection such as a pump house is recommended The free flow of air around the motor must not be obstructed The ambient air temperature should not exceed the value on the motor Nameplate G
20. f coupling and be sure the pump shaft is well centered in the motor shoft Rotate the motor by hand to ensure there is no interference between the shafts Do not try to run the motor uncoupled by just removing the gib key If itis necessary to change rotation interchange any two line leads After inspecting the motor carefully make the initial start by following the regular sequence of starting operations in the motor starter control instructions Check motor operation under load for an initial period of at least one hour to observe whether any unusual noise or hot spots develop In the event of excessive vibration or unusual noise disconnect the motor from the load and check the mounting and alignment Check the operating current against the nameplate value Do not exceed the value of nameplate current multiplied by the motor service factor if any under steady continuous load 10 Space heaters if supplied should be de energized during motor operation C J Oo ing and Repeated Starts AN CAUTION Repeated starts and or jogs of induction motors greatly reduce the life of the winding insulation The heat produced by each acceleration or jog is much more than that dissipated by the motor under full load If it is necessary to repeatedly start or jog a motor it is advisable to check the application with the local GE Energy sales office GEI M1025 B V MAINTENANCE WARNING Before initia
21. g and maintaining the motor e f eyebolts are used for lifting motors they must be securely tightened and the direction of the lift must not exceed a 15 angle from the shank of the eyebolt Do not use eyebolts in an ambient below O F At temperatures below 0 F the eyebolt could fail resulting in injury to personnel and or damage to equipment Drop forged eyebolts per American Society of Testing Materials A489 or equivalent must be used e Donotuse the motor shaft as a means for lifting e Donotlift both the motor and driven equipment with the motor lifting means e Donotstand on or place objects on the motor Maintenance Safe maintenance practices performed by qualified personnel are imperative Before starting maintenance procedures be positive that e Equipment connected to the shaft will not cause mechanical rotation e Main motor windings and all accessory devices associated with the work area are disconnected from electrical power sources e The motor has been given time to cool Failure to properly ground the frame of the motor can cause serious injury to personnel Grounding should be in accordance with National and local Standards and consistent with sound practice These instructions do not purport to cover all the details in motors nor to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which ar
22. igh ambient temperature may require more frequent changes Avoid operating the motor with oxidized oil Use only best grade oxidation and corrosion inhibited turbine oil produced by reputable oil companies The lubrication nameplate on each motor specifies the viscosity range of oil suitable for average conditions Operation in ambient temperatures that are near or below freezing may require preheating the oil or the use of a special oil Too viscous an oil could cause the following a Increased fluid friction losses resulting in higher operating temperatures Higher temperatures will cause the oil to oxidize and break down at an accelerated rate b Oil tends to churn or foam more than a less viscous oil C Bearings may run warmer because of reduced oil circulation through and around the bearings Too light an oil may allow the oil film to wipe or break down Inspecting Thrust bearings and Couplings The parts should be removed in the following order 1 top hat 2 drive nut on the pump shaft 3 upper half coupling 4 ball carrier 5 ratchet balls 6 locknut and washer 7 ratchet plate 8 lower half coupling and bearing When the thrust bearing is removed the upper bracket can be lifted off the frame after removing the bracket bolts If required the rotor and shaft can be lifted out with the upper bracket by removing the lower bearing cap bolts Li NOTE Warranty may be voided if internal maintenance or repair
23. n and maintenance manual has been written to assist the user with proper procedures when handling installing operating and maintaining the equipment All of the safety warnings and instructions in this manual must be followed to prevent injury to personnel This manual must be kept for future reference during installation operation and maintenance B Safety Symbols Below is a safety symbol table that identifies the safety symbols that appear in this manual and on the motors The use of a lightning bolt within an This symbol identifies a terminal which arrowhead symbol enclosed in a yellow A s is intended for connection to an triangle warns of dangerous electrical external grounding conductor for voltage that could cause an electric shock to protection against electric shock in a person case of a fault The use of an exclamation point within a yellow triangle indicates to the user that The use of a small case i enclosed in important installation operating and a square indicates a general note maintenance instructions must be followed The use of wavy lines enclosed in a yellow triangle indicates that the motor can be hot and should not be touched without taking proper precautions Indicates a procedure or condition that WARNING if not strictly observed could result in personal injuries or death gt gt D This symbol instructs one to read the Indicates a procedure or condition that manufacturer s instru
24. oii bn diss E E 5 C Power Supply and Connections e desasendietvipa papa dBRRIRedURH RU 5 Operati OM T 6 A COLES Prior tO Stanin gsang Ep ADREIU DN UN Retna DNA U RNT I RA ON RUD E M RS 6 Ba Initial Sta Petre 7 C Jogging and Repeated Starts aerer viata ett t ttt eta ates etii O RE 7 BIOTECH E dois RU ER E E A EE ams O RUN RATION EE 8 PE ATEO NND ET T 8 B oensrdl CledAlInES Saeta iura ati ata fai no ats aen td cesare et 8 C Insulation amd WIDCIFIS sao sattmaittors en EUR qu nS RUE SENI oque EN NEN DNIA 8 D Vacuum and Compressed Air Cleaning 3st tsatsor tte teo arto ettari 8 E Cleaning with Water and Deterdepltossoo bep oe baba daban tss ERE 9 F Bearings and bubrcatoEnas o cou estende dud uu E 9 CFR i011 9 ges pee enero Mere DORUM M NEA heme TTT ere ert tr 11 Hz ResAssembliripthie Upper EMC oobdavddied taceat RU BHER B DRE GARE 12 OS OM NS sts rae ae a eo a ee ee 13 FOUTE Ea aE MA MIR A CM A A Mees ete M M M M M UC AAO 14 RAE N once DE ue b dame e E EE E UE 14 Renewal POTS i ssaa EN E E E E E E E ENN 14 PAStENEF TOLQUGS moi aea odes ta te odas t at st aaa hale 15 C pling ASSEM Bly nire itudin ceto itor arenes EOE tt D D pe ec ona ed aed 16 A 210 280 Frame Non reverse and Bolted Coupling 16 B 320 449 frame Non Reverse and Bolted Coupling s 18 GEI M1025 B l GENERAL INFORMATION A Howto Properly Use this Instruction Manual This installatio
25. or Regreasing WARNING Lubrication maintenance should be performed with the motor stationary and AN AN disconnected from the power source Extreme caution must be exercised to avoid contact with rotating parts or electrical wiring if the motor must be lubricated while running Failure to observe these precautions may result in damage to the equipment injury to personnel or both a Stop the motor and disconnect it from the power supply b Clean dirt and debris from around the grease inlet fitting and the grease outlet plug c Remove the grease outlet plug and clean the opening and outlet tube of hardened grease This may be accomplished with a twisted wire brush or sturdy pipe cleaner d Add grease with a hand lever operated gun only Add only the amount of grease specified in the table above e Run the motor for about ten minutes before replacing the outlet plug CAUTION Failure to observe the foregoing instructions for re greasing may result in over greasing grease leakage and or bearing damage To avoid damage to equipment bearings and grease must be kept free of dirt Because this method of greasing bearings tends to purge the housing of used grease over a period of time removal of all grease should be required infrequently A GE Energy Authorized Service Shop can clean the bearing cavity and replace the bearings and grease when the motor is removed from service for maintenance or reconditioning 5 Oil
26. p 130 155 15 18 3 8 M10 All Parts 250 275 26 31 v M12 All Parts 550 670 62 76 5 8 M16 All parts 1100 1340 120 150 34 M20 All Parts 2000 2560 250 270 15 GEI M1025 B Xl COUPLING ASSEMBLY A 210 280 Frame Non Reverse and Bolted Coupling Coupling Kit Packing List Item Quantity Coupling al Coupling Bolts 3 Coupling Lock Washers 3 Cover Plate 1 Cover Plate Bolts 5 Cover Plate Lock Washers 5 Steel Balls 10 Gib Key 1 Instructions 1 Bolt Torque Chart Frame Size Item Torque Ft Lb Torque N M 210 5 16 18 UNC x 1 3 4 Coupling Bolt 17 23 250 280 3 8 16 UNC x 2 1 4 Coupling Bolt 30 41 210 280 1 4 20 UNC x 1 2 Cover Plate Bolts 8 11 It is the installer s responsibility in all cases to ensure these torque values are used and maintained This includes those instances when the coupling comes mounted in the motor Failure to comply may Caution cause the coupling bolts to break with resultant extensive damage to the equipment 1 Non Reverse Coupling COUPLING BOLTS mt COUPLING LOCK WASHERS PS NOTE Thoroughly clean coupling amp all related components prior to mounting on motor UPPER HALF COUPLING COVER PLATE BOLTS OC COVER PLATE COVER PLATE 7 i e BALLS LOCK WASHERS y LOWER HALF COUPLING re i LOCATED ON MOTOR U ux RATCHET PLATE HH Una E
27. proximately 10 of rated voltage pass a current through the stator windings Increase the current gradually until the winding temperature reaches 90 C Do not exceed this temperature Maintain a temperature of 90 C until the insulation resistance becomes constant for a one half hour period GEI M1025 B B Initial Start WARNING Be sure the motor is not running and the power supply is disconnected before performing the final checks Whenever possible examine the interior of the motor for loose objects or debris and remove any such foreign material If possible turn the rotor by hand to ensure that it rotates freely Check all connections with the connection diagramls including auxiliary devices Check all accessible factory made connections for tightness to make sure none has become loose during shipment Some motors are designed for unidirectional rotation Rotation of these motors must be in accordance with the rotation indicated on the motor s nameplate and the outline furnished with the equipment Connection plates on the motor have been furnished to assist in obtaining the proper rotation It is best to run the motor uncoupled from its load during the initial start to make certain it rotates in the correct direction Vibration noise voltage and current unbalance can also be checked To run a VHS motor uncoupled it is recommended that the pump head shaft be removed If this cannot be done remove the upper hal
28. s are not performed by a GE Energy Authorized Service Shop G Couplings The condition of non reverse couplings should be checked periodically If dirt has caused the action of the balls to become sluggish the ball carrier should be removed disassembled and thoroughly cleaned with a suitable solvent The parts should then be dried and reassembled See the Coupling Assembly section below Sometimes after a long period of operation with frequent stops and starts the surface of the holes in the ball carrier becomes polished so that friction forces will no longer hold the balls clear of the ratchet plate when the motor is running This condition can be remedied by roughening these surfaces with a piece of emery paper wrapped around a rod Bolts on both bolted couplings and non reverse couplings should be checked periodically to be sure they are tight See FASTENER TORQUES below 11 GEI M1025 B H Re Assembling the Upper End The lower guide bearing is restrained to take momentary up thrust When reassembling the upper bearing and coupling it is important to avoid a preload stress on the guide and thrust bearings The following assembly procedure should be used 1 2 Leave the shaft locknut loose Tighten the lower bearing cap bolts Tighten shaft locknut and raise the shaft until the bearings are just starting to preload When slight preloading is experienced there is no endplay and the rotor will not turn as freely by
29. taken to protect the motor while in storage It is recommended the motor be placed under cover in a clean dry location During storage windings should be protected from excessive moisture by some safe and reliable method of heating such as space heaters to keep the temperature of windings above the temperature of the surrounding air It is recommended that the motor in storage be inspected at periodic intervals the windings meggered and a log kept of pertinent data Refer to the OPERATION section Any significant drop in insulation resistance should be investigated Precautions are taken by the factory to guard against corrosion The machined parts are coated to prevent rust during shipment If the equipment is to be stored examine the machined parts carefully for rust and moisture and recoat where necessary Motors with oil lubricated or oil mist lubricated bearings are normally operated and tested in the factory with a rust inhibiting oil in the lubrication system A rust inhibiting film remains on critical bearing surfaces during transit and for up to six months in storage Rotate the shaft of all grease lubricated motors 10 20 revolutions at two month intervals If the purchaser has specified the machine be packaged for long term storage the foregoing recommendations do not apply and the packing should be left intact during the period of storage C Extended Storage Longer than 6 months In the event the motor is to be stored long
30. ting maintenance procedures disconnect all power sources to the motor and accessories For motors equipped with surge capacitors do not handle the capacitors until they are discharged by a conductor simultaneously touching all terminals and leads including earth This discharge conductor should be insulated for handling Replace all normal grounding connections prior to operating A General If the motor is dismantled during maintenance sealing compounds if any need to be removed from the machined rabbets spigots When reassembling the motor all machined surfaces forming metal to metal joints should be sealed with watertight sealing compound Tite Seal GE Spec A50CD427A or equivalent Inspect the motor at regular intervals depending on service Keep the motor clean and the ventilation openings clear In addition to the daily observation of the overall condition it is recommended that a general inspection routine be set up to check periodically the following items FWNE General cleanliness Insulation and windings Lubrication and bearings Coupling Bolt tightness B General Cleanliness The interior and exterior of the motor should be kept free from dirt oil grease and conducting dust Debris and or dust may build up and block off ventilation Any of these contaminants can lead to early motor failure C Insulation and Windings To obtain a long life and satisfactory operation of insulated windings they shoul
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