Datasheet XP2506R Reference Drawing (Teco)

AEHHXU

250

186.5

4

CONT.

460

60

1200

9. WEIGHT 4330 LBS.

FEBRUARY 2, 2016

CATALOG #

XP2506R

6

NU324

ISSUED

06/08/16

TYPE

AEHHXU

PERFORMANCE DATA

3-PHASE INDUCTION MOTOR

NAMEPLATE INFORMATION

OUTPUT

HP KW

250 187 60

POLE

6

FRAME

SIZE

5007B

VOLTAGE

460

TYPICAL PERFORMANCE

FULL

LOAD

RPM

FULL LOAD

MIN. % NOM. %

EFFICIENCY

3/4 LOAD

%

1/2 LOAD

95.0

HZ

RATED

AMBIENT

40oC

%

INS.

CLASS

F

POWER FACTOR

F. L.

%

3/4 LOAD%1/2 LOAD

87.095.8 95.4 81.5

ENCLOSURE

CATALOG#

NEMA

DESIGN

B

%

86.2 81.5

TEXP

XP2506R

TIME

RATING

CONT.

POWER FACTOR

CORRECTION

SERVICE

FACTOR

1.15

MAXIMUM

KVAR571186

NO LOAD

FULL LOAD

72 281

TORQUE

FULL LOAD

lb-ft

LOCKED

ROTOR

%FLT

153 120 100

SAFE STALL

TIME IN

SECONDS

COLD HOT

2 1

APPROVED:

CURRENTS

PULL

UP

%FLT

ALLOWABLE

STARTS

PER HOUR

COLD

M. PRATER

LOCKED ROTOR

1825

BREAK

DOWN

%FLT

ROTOR

WR
lb-ft

190.2

SOUND

PRESSURE

LEVEL @ 3 FT

HOT

1

DRAWING NO.

CODE LETTER

2
2

dB(A)

812

NEMA KVA

G

INERTIA

NEMA

LOAD

WK
lb-ft

2743

2
2

MAX

ALLOWABLE

WK

lb-ft

2
2

4937

31057XP2506R

ACCEL TIME

NEMA

LOAD

WK

Sec

2

MAX

ALLOWABLE

WK

Sec

2

47.12200 82.37

REVISION

0

DATE:

REGARDING THE MOTOR CONNECTION.

CATALOG NO.:

May 14, 2011

CONNECTION DIAGRAM

SCHEMATIC - ∆ / Y CONNECTION

ACROSS THE LINE CONNECTION

XP2506R

460 VOLT CONNECTION

*CONTACT TWMC IF YOU HAVE ANY QUESTIONS

PH: 1-800-873-8326

6DWG NO.

DAC-1545-4

OPERATION

&

MAINTENANCE

MANUAL

FOR

THREE PHASE

INDUCTION

MOTORS

Frame Size 5000 and Larger

INDEX PAGE

1. INTRODUCTION .......................................................................................................... 1

2. ACCEPTING, INSPECTION, STORAGE, TRANSPORTATION ................................. 2

3. INSTALLATION ........................................................................................................... 4

3.1 Site and environment for motor installation ...................................................... 4

3.2 Foundation ............................................................................................................ 4

3.3 Installation of shaft coupling ............................................................................... 6

3.4 Installation of belt drive ....................................................................................... 9

3.5 Conveyance with chain or gear ........................................................................... 10

3.6 Electrical connections ......................................................................................... 11

4. OPERATION ................................................................................................................ 12

4.1 Examination before starting ................................................................................ 12

4.2 Starting operation ................................................................................................. 15

5. MAINTENANCE ........................................................................................................... 17

5.1 Major points in regular inspection and maintenance ........................................ 17

5.2 Motor windings ..................................................................................................... 18

5.3 Cleaning of the interior of the motor .................................................................. 18

5.4 Cleaning of the exterior of the motor .................................................................. 19

5.5 Maintenance of anti-friction bearings ................................................................. 19

5.5.1 Frequency of re-lubrication ......................................................................... .19

5.5.2 Kinds of grease ............................................................................................ 20

5.5.3 Grease quantity ............................................................................................ 20

5.5.4 Re-greasing .................................................................................................. 20

5.5.5 Oil re-lubrication .......................................................................................... 22

5.5.6 Cleaning and installation of bearings ........................................................ 23

5.6 Maintenance of sleeve bearings .......................................................................... 24

5.6.1 Daily inspection ............................................................................................ 24

5.6.2 Regular examination .................................................................................... 24

5.6.3 Disassembly ................................................................................................. 25

5.6.4 Re-assembly ................................................................................................. 26

5.7 Maintenance of slip rings (for Wound Rotor only) ............................................ 27

5.8 Maintenance of non-reverse ratchet mechanism (Vertical Motors only) 29

6. FAULT FINDING AND RECOGNITION ....................................................................... .31

1. INTRODUCTION

This and the following instruction address the more common situations encountered in motor
installation, operation and maintenance. For the TWMC motor warranty to be and to remain in
effect, the motor must be installed and operated in strict accordance with the outline drawing,
motor nameplates and these instructions and must not be altered or modified in any unauthorized
manner.

During the installation and operation of motors in heavy industrial applications there is a danger of
live electrical parts and rotating parts. Therefore to prevent injury and/or damage the basic
planning work for installation, transportation, assembly, operation, etc... needs to be done and
checked by authorized and competent personnel only.

Since these instructions cannot cover every installation, operation, and maintenance the following
points should be considered and checked.

● The technical data and information on permissible use such as assembly, connection,
ambient and operating conditions given in the related catalogue, operating instructions,
nameplates and other production documentation.

● The general erection and safety regulations.

● The local and plant-specific specifications and requirements.

● The proper use of transport, lifting devices and tools.

● The use of personal protective equipment.

Following indications should be observed when reading these instructions.

Safety instructions are marked as follows:

Warning of electric hazards for personnel.

Warning of dangers for personnel.

ATTENTION!
Warning of damage for the motor or installation.

1

2

2. ACCEPTING, INSPECTION, STORAGE, TRANSPORTATION

2.1 Inspection upon receipt

Check the following points upon receipt:

• Are the nameplate ratings identical with what you ordered?

• Are dimensions and color in compliance with your specifications?

• Are the nameplate ratings for space heater, thermal protector, temperature detector, etc.

identical with what you ordered?

• Is there any damage?

• Are all accessories and accompanying instruction manuals in good order?

• Please ensure that the arrow head indicator really indicates direction of rotation.

• If there is any specific requirements, please ensure they are in conformity with your

specifications.

•

Motor stator housing may be outfitted with condensation drain holes that are

either open holes, drain holes with plugs or drain holes with breather drains. For
horizontally mounted motors position the drain holes at the lowest point possible
to allow for the egress of condensation. For vertical shaft installations the lower
end bracket must be outfitted with drains at the lowest point possible. Prior to
installation remove drain plugs if fitted.

•

2.2.1
Storage

When motors are not in operation, the following precautionary measures should be undertaken to
assure best performance.

2.2.2
Place

(a) High and dry, well ventilated without direct sun, dust or corrosive gas.
(b) Not located near a boiler or freezer.
(c) Entirely free from vibration and easy movement.
(d) Motors should be put on pallets to prevent moisture.

2.2.3

Motors should be well-shielded form dust, but under well-ventilated circumstances.

2.2.4 Moisture prevention

Since moisture can be very detrimental to electrical components, the motor temperature should
be maintained about 3ºC above the dew point temperature by providing either external or internal
heat. If the motor is equipped with space heaters, they should be energized at the voltage shown by
the space heater nameplate attached to the motor. Incandescent light bulbs can be placed within
the motor to provide heat. However, if used, they must not be allowed to come in contact with any
parts of the motor because of the concentrated hot spot that could result.

2.2.5

Even during storage, the insulation resistance should be kept above the specified values.

(a) For measurement of insulation resistance and acceptable standard values, please refer to

measures stated in 4.1.2 “Measurement of insulation resistance”.

ATTENTION!

(b) Insulation resistance test should be performed once every three months.

2.2.6

If the motor is not in operation for a long period (one week and above) after installation or has
been in operation but stopped for a period of time, the following precautions must be taken.

(a) Protect the motor as measures stated in 2.2.4.
(b) Insulation resistance test should be performed as stated in 2.2.5.

2.2.7 Bearing protection

(a) If the motor has been provided with a shaft shipping brace to prevent shaft movement

during transit, it must be removed before operating the motor. It is very important that
this brace be re-installed exactly as it was originally, before the motor is moved from
storage or any time when the motor is being transported. This prevents axial rotor
movement that might damage the bearings.

(b) Motors equipped with sleeve bearings are shipped from the factory with the bearing oil

reservoirs drained. In storage, the oil reservoirs should be properly filled to the center of
the oil level gauge with a good grade of rust inhibiting oil. This will keep the bearing
journals well oiled to prevent rusting. The motor shaft should be rotated several
revolutions every month ensuring the shaft does not come to rest in its original position.
While the shaft is rotating, it should be pushed to both extremes of the endplay.

(c) Motors with anti-friction bearings are properly lubricated with the correct grade of

grease at the factory and no further greasing is required in storage. The shaft should be
rotated several revolutions every month to maintain proper distribution of the grease
within the bearings. However, re-greasing is required if a significant period has

elapsed between manufacture and use, or while in storage for extended time. It is
It is a good practice to always replenish and purge with fresh grease at start up.

(d)
(e) Tilt-pad bearings are a type of sleeve bearing used in special design applications. Due to

the nature of this bearing, a loose oil ring for delivering lubricant cannot be provided.
Therefore, during the storage internal, oil must be periodically manually introduced into
the pads and housing to prevent the occurrence of oxidation of the precision machined
components.
(1) Remove the pipe plug from the bearing cap located above the tilt-bearing shell.
(2) Pour in approximately one cup of oil every month and rotate the shaft a few

revolutions about every two (2) weeks.

(3) For long periods of storage, the oil that accumulates in the housing should be

removed.

Care should be taken to keep parts such as fitting surfaces, key, shaft extension and axial
central hole from any collision with foreign matter. Grease should also be generously
applied to prevent rusting.

2.2.9 Transportation

To keep the rotating parts of motors from moving, thus preventing damage and scratching during
transportation, they should be held securely with a locking device. Remove all transit clamps

3

before operating the motor. It is very important that this device be reinstalled exactly as it was

Do not use the hoisting hook/eyebolts to lift more

than the motor itself. They are

and the sling angle is correct.

originally, before the motor is moved from storage or any time when the motor is being
transported. The vertical mounting type motors should be transported in the vertical position.

designed to support the motor only. Make sure the hoisting hook is correctly
attached to the eyebolt(s)/lug(s) and that they are fully screwed in before hoisting.
Also note such parts as fan cover, ventilation box, bracket, slip-ring, etc. may have
their own hoisting lugs which can only carry their own weight. Nothing extra
should be attached while hoisting.
Do not twist the steel wires and make sure the eyebolts have been firmly screwed

3 INSTALLATION

Motor installation – site and environment

3.1.1

Standard environment and site conditions for the installation of motors are usually set as follows:

(a) Ambient temperature: -10~40ºC
(b) Humidity: Relative humidity below 90%RH for totally enclosed types, and below 80%RH for

semi-enclosed types.
(c) Elevation: below 1000 meters or 3300 feet.
(d) Harmful gases, liquids, dusts, high moisture should be absent.
(e) Foundations should be strong and free of vibration.

If there are any special environmental conditions, please inform TWMC prior ordering.

3.1.2 Ventilation and space

(a) Installation area should be well ventilated.
(b) The installation space should be large enough to facilitate heat dissipation and

maintenance.

3.2 Foundation

4

3.2.1

Use rigid and solid sole plate or common bed as foundation.
For best motor performance, it is advisable to use a sole plate or common bed, particularly when using
a shaft coupling.

3.2.2 Installation

(a) Select an appropriate foundation surface for the sole plate or common bed, which will be,

considered the ultimate level.
(b) Align the position of the common bed with reference to that level.
(c) Align the level accuracy at least at four points such as bearing mounting, shaft extension etc.

The accuracy should be within 0.04mm or

.0015 inches
(d) Sole plate or common bed should be

embedded in concrete foundation as illustrated
in Fig. 3. Stiff pads should also be installed
beneath the wedges, which are welded
together at various spots about 400-500mm
(15.75-1 9.70 inches) apart. This will enable the
foundation to evenly carry the weight of the
whole motor.

(e) The base should be sturdy and rigid to keep it

flat and level.
(f) Make sure th e mo rta r and con cret e are

completely dry, and the precision of the level is acceptable, and then set the motor on the
mounting foundation.

(g) Accurately install shaft couplings, belt sheaves etc., then weld the wedges solid to prevent any

change in position.

3.2.3 The foundation of vertical induction motors: (Also the foundation of pump)

(a) Foundation of motor/pump must be rigid and secure to provide adequate support. There must

be no vibration, twisting, misalignment etc. due to inadequate foundations.

(b) A massive concrete foundation is preferred in order to minimize vibration. Rigidity and

5

stability are enhanced by prop plate and foundation bolt. As shown in Fig. 4.

ATTENTION!

ATTENTION!

3.2.4 Installation of vertical motors:

(a) All mounting surfaces must be clean and level.
(b) Foundation must be leveled at least at 4 points and guaranteed to be below 0.04mm

(.0015 in.) flat and level.

(c) Make sure the mortar and concrete are completely dry, and the precision of the level is

acceptable, and then set the motor on the mounting foundation.

(d) Accurately install shaft couplings.

3.3 Installation of shaft coupling

3.3.1

Motors must always be accurately aligned, and this especially applies where they are
directly coupled.
Incorrect alignment can lead to bearing failure, vibration and even shaft fracture. As soon
as bearing failure or vibration is detected, the alignment should be checked.

3.3.2

Field application of a coupling to the motor shaft should follow the procedures recommended by
the coupling manufacturer. The motor shaft extension must not be subjected to either extreme
heat or cold during coupling installation.

Basically, the coupling should be heated and pushed onto the shaft extension with slight
axial force. To prevent damages to the bearing do not hammer the coupling.

3.3.4

Although the sleeve bearings are equipped with thrust faces, these are intended only to provide
momentary axial restraint of rotor movement either during start-up or when operating the motor
disconnected from the driven equipment. They must not be operated under a constant thrust
load unless they were originally designed for this condition.

6

Motors with either sleeve or anti-friction bearings are suitable for connection to the driven load
through a flexible coupling. Solidly coupling to the load is not acceptable. With sleeve bearings, the
flexible coupling should be of the limited end float type to prevent the possibility of any end thrust
from load being transmitted to the motor bearings, which could cause bearing damage. The
recommended limits of end float are as follows:

(a) When the motor is in operation after installation, be sure that the end-play indicator is

within the 6mm (.236 in.) of the groove on the shaft or aligned to the shaft shoulder

immediately outboard of the drive-end bearing to assure there is low friction between shaft

and bearing.
(b) Unless otherwise specified, the designed end-play value X of the groove for TWMC

motors in general is within 6mm (.236 in.) as illustrated in Fig. 6. In essence, the endplay

indicator is adjusted to point at the center of the groove or the drive-end shaft shoulder; thus

X equals to 6±1 mm or so, and the endplay value (Y) of the couplings should equal or be

smaller than 3mm (.118 in.).
(c) If the desired value Y is greater than 3mm (.118 in.) caused for instance by a thrust load and/or

load machine with large endplay, please inform TWMC prior to entering an order.

3.3.5

In aligning the motor (and rotor) axially with the driven equipment, consideration should be given not
only to the endplay indicator position but also to axial shaft expansion and increase in shaft centerline
height due to thermal effects. In general, the axial shaft growth for motors can be disregarded since
neither bearing is fixed and any shaft growth due to temperature increase will produce an elongation
away from the coupling.

Shaft height growth (change in shaft centerline elevation) for TEFC machines can be calculated as
follows:

∆=(0.0005”) x (motor foot to shaft £ dimension)

For non-TEFC machines, divide the number by 2.

3.3.6

It is desirable, in normal operation that the motor operates on its magnetic center, so that no axial
force is exerted on the coupling.

7

The motor shaft and the driven shaft should be aligned within the following tolerances in both
angular and parallel alignment:

Unit: mm

TIR Range of rotating speed Solid coupling Flexible coupling

C

A

Angular misalignment is the amount by which the centerlines of driver and driven shafts are
skewed. It can be measured using a dial indicator set up as shown in Fig. 7. The couplings are
rotated together through 360 degrees so that the indicator does not measure runout of the
coupling hub face. The shafts should be forced against either the in or out extreme of their end
float while being rotated.

2500 rpm and above 0.03 0.03

Below 2500 rpm 0.04 0.05

2500 rpm and above 0.03 0.03

Below 2500 rpm 0.03 0.04

Parallel misalignment is the amount by which the centerlines of the driver and driven shafts are
out of parallel. It can be measured using a dial indicator set up as shown in Fig. 8. Again, the
couplings are rotated together through 360 degrees so that the indicator does not measure runout
of the coupling hub outside diameter.

3.3.7

After the motor has been properly aligned with the driven equipment and the hold-down bolts
have been installed and tightened, for motors with fabricated frames, at least two dowel pins
should be installed in two diagonally opposite motor feet.

3.3.8 Installation of shaft coupling: (Vertical hollow shaft motor only)

Bolted Coupling as shown in Fig. 9

(a) Bearings are provided to absorb some upward shaft thrust when the coupling is fitted.
(b) The coupling is fastened with bolts.
(c) This coupling type is not auto-release type.

Note: Standard high thrust motors can absorb momentary up-thrust load up to 30% of the

standard down thrust load. If the up-thrust is long in duration (over 10 Seconds) and/or
exceeds 30% of the standard high thrust rating, special design arrangements are
required and standard motor is not suitable.

8

3.3.9 Non-reverse ratchet/coupling, as Fig. 10 (If necessary)

ATTENTION!

The non-reverse coupling is also a bolted type and,

(a) It prevents the pump and motor from rotating in the reverse direction.
(b) It also prevents damage from over speeding and damage to pump shaft and bearings.
(c) The ratchet pins are lifted by the ratchet teeth and are held clear by centrifugal force and

friction as the motor comes up to speed.

(d) When power is removed, speed decreases, and the pins fall. At the instant of reversal, a

pin will catch in a ratchet tooth and prevent backward rotation.

(e) When installing the non-reverse coupling, do not use lubricant. Lubricant will interfere with

proper operation. The top half of the coupling should seat solidly on the lower half and the
pins should touch the bottom of the pockets between the teeth in the plate.

(f) As with the bolted coupling, the up-thrust capabilities are 30% of the standard high thrust

rating for down thrust.

Do not apply non-reverse ratchets on applications in which the pump reversal time from
shutdown (the instant the stop button is pressed) to zero speed is less than one second.

3.4 Installation for belt drive

In general, power transmission through direct flexible coupling is appropriate for large motors.
Such motors are not suitable for belt, chain or gear connection unless specially designed for such
service. However, for small and medium motors with outputs within the ranges shown on the
table below, it is acceptable to use belt transmission as indicated. Beyond these ranges, do not
apply belt sheaves unless specially designed.

3.4.1

The diameter ratio between conveyance sheaves should not be greater than 5 to 1 for flat belts,
and 8 to 1 for V-belts. It is also advisable to limit the belt velocity to under 35m/sec (115 ft/sec) to
limit belt abrasion and vibration. The smaller the outer diameter of the V-belt sheave, the greater
the shaft bending stress will be. If the bending stress is in excess of the shaft fatigue stress, the
shaft may break. Therefore, please inform TWMC when you have decided the size of the
sheaves and the length of the belts upon ordering.

9

ATTENTION!

Conventional V

-

Belts

Narrow V

-

Belts

V-Belt

Place the sheave and belt as close as possible to the motor
body (it is advisable to make x as shown in Fig. 11 equal to 0)
to reduce the bending moment and improve shaft life.

3.4.2 Table of belt-sheave application for general electric motors

Output

(KW/HP)

4P 6P 8P

11/15 - - B 4 160 82 3V 4 125 48

- 11/15 - B 5 170 101 3V 5 140 59

- - 11/15 B 5 190 101 3V 6 160 69

15/20 - - B 5 170 101 3V 6 125 69

- 15/20 - B 5 224 101 3V 6 160 69

- - 15/20 C 4 224 111 5V 3 180 60

18.5/25 - - B 5 200 101 3V 6 140 69

- 18.5/25 - C 4 224 111 5V 3 180 60

- - 18.5/25 C 5 224 136 5V 4 180 78

22/30 - - B 5 224 101 5V 6 160 69

- 22/30 - C 5 224 136 3V 4 180 78

- - 22/30 C 5 250 136 5V 4 200 78

30/40 - - C 5 224 136 5V 4 180 78

- 30/40 - C 5 265 136 5V 4 224 78

- - 30/40 C 6 265 162 5V 5 224 95

37/50 - - C 6 224 162 5V 4 200 78

- 37/50 - C 6 265 162 5V 4 224 78

- - 37/50 C 7 280 187 5V 5 250 95

45/60 - - C 6 265 162 5V 4 224 78

- 45/60 - C 7 280 187 5V 5 224 95

- - 45/60 C 7 315 187 5V 6 250 113

55/75 - - C 7 265 187 5V 5 224 95

- 55/75 - C 8 300 213 5V 6 250 113

- - 55/75 D 5 355 196 5V 6 280 113

75/100 - - C 8 315 213 5V 6 250 113

- 75/100 - D 6 355 233 5V 6 315 113

- - 75/1 00 D 6 400 233 5V 6 355 113

- 90/120 - D 6 400 233 5V 6 355 113

- - 90/120 D 6 425 233 8V 4 355 124

- 110/150 - D 7 400 270 8V 4 355 124

- 132/175 110/150 D 7 450 270 8V 4 400 124

- 160/200 132/1 75

V-Belt
Type

D 9 450 344 8V 4 450 124

Number

Of

Belts

Min.

PCD

(mm)

V-Belt Sheave

Max
Width
(mm)

Type

Number

Of

Belts

Min.
PCD

(mm)

Width

Max

(mm)

3.5 Conveyance with chain or gear

3.5.1

Make sure the loading capacity of shaft and bearings is appropriate for the size and installation
position (overhung) of chain and gear. If necessary, please contact us to ensure the shaft and
bearings will meet your requirements.

10

3.5.2

ATT

ENTION!

Pay close attention to ensure the parallelism of shafts.

3.5.3

The teeth of couplings should be correctly and precisely matched; the force conveyance
centers should lie on the same line.

3.5.4

There should be no skip, jumping, vibration or unusual noises.

Do not hammer conveyance devices such as couplings, belt sheaves, chain wheels, gears
etc. onto the shaft. Conveyance devices should be fitted and removed only by means of
suitable devices. Heat shrinking may be a better alternative to avoid damaging bearings
and components.

3.6 Electrical connections

All interconnecting wiring for controls and grounding should be in strict accordance with local
requirements such as the USA National Electrical Code and UK IEE wiring regulations. Wiring of
motor and control, overload protection and grounding should follow the instructions of connection
diagrams attached to the motor.

3.6.1 Power

The rated conditions of operation for the motor are as shown on the nameplate. Within the limits,
given below, of voltage and frequency variation from the nameplate values, the motor will
continue to operate but with performance characteristics that may differ from those at rated
conditions:

Operating the motor at voltages and frequencies outside of the above limits can result in both
unsatisfactory motor performance and damage to or failure of the motor.

3.6.2

The main lead box furnished with the motor has been sized to provide adequate space for the
make-up of the connections between the motor lead cables and the incoming power cables.

3.6.3

Either fabricated motors or fan cooled cast frame, motors are all provided with grounding pads or
bolts.

The exposed rotating parts should be covered to prevent accidents.

±10% of rated voltage
±5% of rated frequency
±10% combined voltage and frequency variation so long as frequency variation is
no more than ±5% of rated.

The bolted joints between the motor lead and the power cables must be made and
insulated in a workman-like manner following the best trade practices.

The motor must be grounded by proper connection to the electrical system ground.

11

3.6.4

During and immediately after measuring, the terminals must not be touched as they

The rotation direction of the motor will be as shown by either a nameplate on the motor or the
outline drawing. The required phase rotation of the incoming power for this motor rotation may
also be stated. If either is unknown, the correct sequence can be determined in the following
manner: While the motor is uncoupled from the load, start the motor and observe the direction of
rotation. Allow the motor to achieve full speed before disconnecting it from the power source.
Refer to the operation section of these instructions for information concerning initial start-up. If
resulting rotation is incorrect, it can be reversed by interchanging any two (2) incoming cables.

3.6.5 Auxiliary devices

Auxiliary devices such as resistance temperature detectors, thermocouples, thermoguards, etc.,
will generally terminate on terminal blocks located in the auxiliary terminal box on the motor.
Other devices may terminate in their own enclosures elsewhere on the motor. Such information
can be obtained by referring to the outline drawing. Information regarding terminal designation
and the connection of auxiliary devices can be obtained from auxiliary drawings or attached
nameplates.
If the motor is provided with internal space heaters, the incoming voltage supplied to them must
be exactly as shown by either a nameplate on the motor or the outline drawing for proper heater
operation.

Caution must be exercised anytime contact is made with the incoming space
heater circuit as space heater voltage is often automatically applied when the
motor is shutdown.

4. OPERATION

4.1 Examination before start

4.1.1

When motors are installed in good manner, ensure the wiring is according to the diagram. Also,
the following points should be noted:

(a) Make sure all wiring is correct.
(b) Ensure the sizes of cable wires are appropriate and all connections are well made for the

currents they will carry.

(c) Ensure all connections are properly insulated for the voltage and temperature they will

experience.

(d) Ensure the capacity of fuses, switches, magnetic switches and thermo relays etc. are

appropriate and the contactors are in good condition.
(e) Make sure the frame and terminal box are grounded.
(f) Make sure that the starting method is correct.
(g) Make sure switches and starters are set at their right positions.
(h) Motor heaters must be switched off when the motor is running.

4.1.2 Measurement of insulation resistance

may carry residual dangerous voltages. Furthermore, if power cables are
connected, make sure that the power supplies are clearly disconnected and there
are no moving parts.

12

(a) For rated voltage below 1000V, measured with a 500VDC megger.
(b) For rated voltage above 1 000V, measured with a 1 000VDC megger.

(c) In accordance with IEEE 43, clause 9.3, the following formula should be applied:

Rated voltage (v)

R≥( 1000 + 1) x 10(MΩ)

(d) On a new winding, where the contaminant causing low insulation resistance is generally

moisture, drying the winding through the proper application of heat will normally increase
the insulation resistance to an acceptable level. The following are several accepted
methods for applying heat to the winding:
(1) If the motor is equipped with space heaters, they can be energized to heat the

winding.

(2) Direct current (as from a welder) can be passed through the winding. The total current

should not exceed approximately 50% of rated full load current. If the motor has only
three leads, two must be connected together to form one circuit through the winding.
In this case, one phase will carry the fully applied current and each of the others, one­half each. If the motor has six leads (3 mains and 3 neutrals), the three phases should
be connected into one series circuit.

ATTENTION!
Caution must be exercised, when heating the motor with any source of heat other than self
contained space heaters, to raise the winding temperature at a gradual rate to allow any
entrapped moisture to vaporize and escape without rupturing the insulation. The entire
heating cycle should extend over 15-20 hours.

(e) Should the resistance fail to attain the specified value even after drying, careful

Ensure there is adequate guarding so live parts cannot be touched.

(3) Heated air can either blown directly into the motor or into a temporary enclosure

surrounding the motor. The source of heated air should preferably be electrical as
opposed to fueled (such as kerosene) where a malfunction of the fuel burner could
result in carbon entering the motor.

Insulation resistance measurements can be made while the winding is being heated.
However, they must be corrected to 40°C for evaluation since the actual insulation
resistance will decrease with increasing temperature. As an approximation for a new
winding, the insulation resistance will approximately halve for each 10°C increase in
insulation temperature above the dew point temperature.

examination should be undertaken to eliminate all other possible causes, if any.

4.1.3 Power Source

(a) Ensure the capacity of the power source is sufficient.
(b) Ensure the supply voltage and frequency ratings are identical to those on the nameplate.

(c) Voltage variation should be confined to within ±10% of the rated value and the phase to
phase voltages should be balanced.

13

4.1.4 Bearing lubrication

(a) For sleeve bearing motors, the oil reservoir must be filled with oil to the correct level. On

self-lubricated bearings, the standstill oil level will be at the center of the oil gauge. The
proper oil is a rust and oxidation inhibited, turbine grade oil. Refer to the lubrication
nameplate for the recommended viscosity.

(b) Motors, which are supplied with provision for flood lubrication, have an inlet orifice to

meter the oil flow to the bearing. Refer to the outline drawing for these values. If the
supply pressure does not match that stated on the outline, the orifice size must be
adjusted to produce the specified flow rate. The drain adapter (also provided) has a weir
plate fixed to the inside of the pipe to permit the establishment of the proper oil level. This
weir plate must be located at the bottom of the pipe and must be parallel to the plane of
the motor feet. To ensure optimum flow, the drain line should be vented to the
atmosphere.

Oil inlet temperature: Normal below 50°C

Alarm 60°C

Trip 65°C

(c) If the motor is in storage for over three (3) months, refilling of some new oil should be

undertaken before operation to prevent bearing damage due to dry friction. The oil level
should be kept at the center of the oil gauge. If necessary, drain some oil after refilling.

(d) Motors that have been designed with anti-friction bearings for use with an oil mist

lubrication system have been packed at the factory with a small amount of grease for short
test runs. Continuous running should not be considered unless the oil mist system is
installed and operating.

(e) Grease lubricant type

(1) The bearings have been well greased at the factory before delivery.

However, regreasing is required if a significant period has elapsed between
manufacture and use or in storage. It is a good practice to always replenish
and purge with fresh grease at start up.

(2) Unless otherwise specified, Exxon Polyrex EM is the standard applied to TWMC

motors.

ATTENTION!

Do not mix different kinds of grease.
Mixing grease with different type of thickeners may destroy its composition and physical
properties. Even if the thickeners are of the same type, possible differences in the
additive may cause detrimental effects.

4.1.5 Cooling water for the cooler on water-cooled motors

Make sure the quality, volume and inlet temperature of cooling water for the motors are normal

before the machine is in operation.

Water: General tower water or industrial water.
Volume: Please see outline drawing
Inlet temperature: Normal below 30°C

Alarm 35°C

Trip 40°C

4.1.6

14

ATTENTION!

Make sure all locks, which fasten the movable parts of the motors during transportation,

The keys fitted to the shaft extensions are held by plastic tape only to prevent

being fitted to the shaft extension.

ATTENTION!

are dismantled and the shaft can rotate freely.

4.1.7

ATTENTION!

Ensure there are no foreign matter or tools inside the motors before starting motors.

4.1.8

Make sure the transmission system, including belts, screws, bolts, nuts and set pins are in good

condition.

them from falling out during transportation or handling. The shaft key shall be
removed to avoid flying out, when the motor is operated prior to the couplings etc.

4.1.9

Make sure the items above are examined. Test the motor running with or without load. Record

and check according to “Maintenance” at 15-minute intervals during the first three hours of

operation. Then regular examinations should take place at longer intervals. If all goes well the

motor can be classified as “in good order”.

4.2 Starting operation

4.2.1 Starting load

Initially run the motor unloaded prior to coupling to other machines. Unless otherwise specified, a

motor usually starts with light load, which is then gradually increased, proportional to the square

of the speed and at last reaches 100% load at full load speed.

4.2.2 Starting

Too frequent starts can be harmful to the motors. The following restrictions should be observed:

(a) Motor can be restarted should the initial start fail. Two starts are generally permissible

when the motor is cold.
(b) Motor can be started only once when it is at normal running temperature.
(c) Should additional starts be necessary beyond the conditions stated above, the following

restrictions should be noted:
(1) Let the motor cool down for 60 minutes before restarting, fully loaded.
(2) Let the motor cool down for 30 minutes before restarting, unloaded.
(3) Two inching starts can be regarded as one normal start.

If the motor rotor fails to start turning within one or two seconds, shut off the power
supply immediately.
Investigate thoroughly and take corrective action before attempting a restart.

Possible reasons for not starting are:

(1) Too low a voltage at the motor terminals.

ATTENTION!

ATTENTION!

(2) The load is too much for the rotor to accelerate.
(3) The load is frozen up mechanically.
(4) All electrical connections have not been made.
(5) Single-phase power has been applied.
(6) Any combination of the above.

4.2.3 Rotating direction

(a) Most TWMC motors are bi-directional. However, when some special types, such as high

speed 2-Pole, certain large capacity motors, those with a non-reversing ratchet etc.,
should rotate in one direction, please ensure the rotation is in conformity with the
directional arrow-mark shown on the attached nameplate.

(b) To reverse a bi-directional motor, cut the power and wait until the motor stops. Then

interchange any two of the three phases.

4.2.4 Power source, Voltage, Current

(a) Ensure the voltage and frequency of the power source are identical to the ratings shown

on the nameplate.

(b) Voltage variation should be confined to within ±10% of the rating and the three phase

voltages should be in full balance

(c) Ensure the motor phase currents, when without load, are within ±5% of the average

values.

4.2.5

Frequency variation should be confined to within ±5% of the rating. The aggregate variation of
voltage and frequency should be confined to within ±10% of the absolute value of the ratings.

4.2.5 Starting time and unusual noises

Starting time is longer for the motors with large inertia. However, if starting time is longer
than usual or if there is difficulty in starting, or there is abnormal noise, do not run the
motor and refer to TWMC Service representative.

4.2.6 Sleeve bearing oil rings (sleeve bearing types only)

As the oil ring is used to carry lubricant to sleeve bearings, frequently check to ensure the oil ring
is in motion.

4.2.7 Bearing temperature rise

Following the initial start-up, the bearing temperatures should be closely monitored. The rate of
rise in bearing temperature is more indicative of impending trouble than is the actual temperature.

If the rate of rise in temperature is excessive or if the motor exhibits excessive vibration or
noise, it should be shut down immediately and a thorough investigation made as to the
cause before it is operated again.

If the bearing temperature rise and motor operation appear to be normal, operation should

16

continue until the bearing temperature stabilizes.

ATTENTION!

Recommended limits on bearing temperature are as follows:

Sleeve Bearings Total measured temperature

● By permanently installed detector 90°C

● By temporary detector on top of the bearing 85°C

sleeve near the oil ring

Anti-Friction Bearings Total measured temperature

● By permanently installed detector 100°C

● By temporary detector measuring the outside 95°C

of the bearing housing

ATTENTION! (For sleeve bearing)

(1) It must be noted that when operating flood lubricated sleeve bearings without outside

lubrication supplied, the bearing temperature must not be allowed to exceed 85°C total
temperature

(2) Under normal condition, for the self-lube bearing, the rate of temperature rise should

be from 11 to 14°C for the first ten (10) minutes after starting up and approximately
22°C at thirty (30) minutes. The rate of bearing temperature rise is a function of the

natural ventilation and operating conditions.

(3) When the rate of bearing temperature rise is less than 1°C per half-hour, the bearing

temperature is considered to be stabilized.

(4) If the total bearing temperature exceeds 95°C, the motor should be shut down

immediately.

4.2.8 Noise and Vibration

Any abnormal noise or vibration should be immediately investigated and corrected.
Increased vibration can be indicative of a change in balance due to mechanical failure of a
rotor part, a stator winding problem or a change in motor alignment.

5. MAINTENANCE

5.1 Major points in regular inspections and maintenance.

For safety, maintenance and repairs must only be carried out by properly trained personnel.

Some testing, such as insulation resistance, usually requires the motor to be stopped

High temperature may arise under operating conditions on the motor surfaces, so

and isolated from power supplie(s).

Routine inspection and maintenance are usually performed by looking, listening, smelling and
simple meters.

that touching should be prevented or avoided. Keep away from moving and live

parts. Unless deemed necessary, do not remove guards whilst assessing the

motor.

Timely replacement of worn parts can assure longevity and prevent breakdown.

Routine inspection and regular inspection and maintenance are important in preventing
breakdown and lengthening service life.

Owing to the varied time and circumstances, motors are used, it is difficult to set the items and
periods for regular inspection and maintenance. However, as a guide it is recommended to be
performed periodically according to factory maintenance program. Generally, the inspection
scope determined by the following factors:

(a) Ambient temperature.
(b) Starting and stopping frequency.
(c) Troublesome parts usually affecting motor functions.
(d) Easily abraded parts.
(e) The important position of motor in the operational system of a factory should be duly

recognized. Therefore, its health and wellbeing should be fully protected especially when it
is operating in severe conditions.

5.2 Motor windings:

(a) Measurement of insulation resistance and standards to determine quality of insulation

resistance, please refer to measures stated in 3.1.2 “Measurement of insulation

resistance”.
(b) Inspection of coil-ends:

(1) Grease and dust accumulated on coils may cause insulation deterioration and poor

cooling effect.

(2) Moisture must not accumulate. Keep coils warm when motor is not in use if moisture can

be seen.

(3) Discoloring. This is mainly caused by overheating.
(c) Ensure no untoward change of wedges from original position.
(d) Ensure the binding at the coil end is in its normal position.

5.3 Clean the interior of the motor:

(a) After a motor is in operation for some time, accumulation of dust, carbon powder and grease

etc., on the inside is unavoidable, and may cause damage. Regular cleaning and

examination is necessary to assure top performance.
(b) Points to note during cleaning:

(1) If using compressed air or blower:

18

(a) Compressed air should be free of moisture.

ATTENTION!

ATTENTION!

(b) Maintain air pressure at 4 kg/cm², since high pressure can cause damage to coils.

(2) Vacuum

Vacuum cleaning can be used, both before and after other methods of cleaning, to
remove loose dirt and debris. It is a very effective way to remove loose surface
contamination from the winding without scattering. Vacuum cleaning tools should be
non-metallic to avoid any damage to thee winding insulation

(3) Wiping

Surface contamination on the winding can be removed by wiping using a soft, lint-free
wiping material. If the contamination is oily, the wiping material can be moistened
(not dripping wet) with a safety type petroleum solvent. In hazardous locations, a
solvent such as inhibited methyl chloroform may be used, but must be used sparingly
and immediately removed. While this solvent is non-flammable under ordinary
conditions, it is toxic and proper health and safety precautions should be followed
while using it.

Solvents of nay type should never be used on windings provided with abrasion protection.
Abrasion protection is a gray, rubber-like coating applied to the winding end-turns.

Adequate ventilation must always be provided in any area where solvents are
being used to avoid the danger of fire, explosion or health hazards. In confined
areas (such as pits) each operator should be provided with an airline respirator, a
hose mask or a self-contained breathing apparatus. Operators should wear
goggles, aprons and suitable gloves. Solvents and their vapors should never be
exposed to open flames or sparks and should always be stored in approved safety
containers.

(4) Keep core ducts completely clean. The difference in temperature rise could be

around 10°C before and after cleaning

5.4 Clean the exterior of the motor:

(a) On open ventilated motors, screens and louvers over the inlet air openings should not be

allowed to accumulate any build-up of dirt, lint, etc. that could restrict free air movement.

Screens and louvers should never be cleaned or disturbed while the motor is in operation
because any dislodged dirt or debris can be drawn directly into the motor.

(b) If the motor is equipped with air filters, they should be replaced (disposable type) or

cleaned and reconditioned (permanent type) at a frequency that is dictated by conditions.
It is better to replace or recondition filters too often than not often enough.

(c) Totally enclosed air to air cooled and totally enclosed fan cooled motors require special

cleaning considerations. The external fan must be cleaned thoroughly since any dirt
build-up not removed can lead to unbalance and vibration. All of the tubes of the air-to­air heat exchanger should be cleaned using a suitable tube brush having synthetic fiber
bristles (not wire of any type).

5.5 Maintenance of anti-friction bearings

ATTENTION!

If re

-

lubrication is to be performed when the motor is running, stay clear of rotating

5.5.1 Frequency of re-lubrication:

The life of grease varies greatly as a result of types of model, revolution speed, temperature,
operational conditions etc. It is, therefore, impossible to be precise about replenishment intervals.
However, for normal direct coupling transmission, the periods shown as Table 1 may be used as
a guide.

Remarks:

(a) The periods shown in Table 1 should be halved where bearings are used for belt drive

and/or in dirty or high ambient temperature or high humidity environments.
(b) Please refer to the lubrication nameplate, if attached to the motor.
(c) For bearing numbers outside the range of Table 1, please contact TWMC

(d) If the periods referred to in Table 1 for drive-end bearing and opposite drive-end are

different, for the convenience of maintenance operation, please take the shorter one the
required grease replenishment period of these bearings.

5.5.1 Kinds of grease:

Exxon Polyrex EM (polyurea base grease) will be used for all models with open bearings. Please
check and follow lubrication nameplate for any special grease used in bearings. Please us
identical grease or its equivalents when maintaining motor.

Do not mix different kinds of grease.
Mixing grease with different type of thickeners may destroy its composition and physical
properties. Even if the thickeners are of the same type, possible differences in the
additive may cause detrimental effects.

5.5.2 Grease quantity

The amount of grease per replenishment depends on the type, size and construction of the
bearings. The maximum amount of replenishment for each bearing is shown in Table 2.

This replenishment amount is also the amount used at the time the motor is initially started.

5.5.3 Re-greasing

It is advisable to re-grease when the motor is running to allow the new grease to be evenly
distributed inside the bearing.
Before re-greasing, the inlet fitting should be thoroughly cleaned to prevent any accumulated dirt
from being carried into the bearing with the new grease. The outlet of grease drainage should be
opened to allow the proper venting of old grease. Use a grease gun to pump grease through
grease nipple into the bearings. After re-greasing, operate the motor for 10-30 minutes to allow any
excess grease to vent out.

parts.

20

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

Bearing

Number

10

16

20

22

24

26

38

14

18

18

20

22

24

30

32

34

36

38

40

48

Number

RPM

RPM

RPM

RPM

RPM

RPM

RPM

1500

26

28

300 Hrs.

24

32

34

36

40

44

600

720

750

TABLE 1.

900

1000

1200

1500

1800

3000

3600

62XX
63XX
72XX
73XX

Bearing

13

15

28

30
32
34
36

NU214

15
16
17

12

17

600

720

3000 Hrs.

2000 Hrs.

750

3000 Hrs.

900

1000

2000 Hrs.

1500 Hrs.

1000 Hrs.

1200

2000 Hrs.

1000 Hrs.

720 Hrs.

2000 Hrs.

1500 Hrs.

1000 Hrs.

500 Hrs.

1800

RPM

2000 Hrs.

1500 Hrs.

1000 Hrs.

NU2XX
NU3XX

Bearing
Number

222XX
223XX

26

44

22220

22

30

38

28

48

600

RPM

2000 Hrs.

1000 Hrs.

RPM

500 Hrs.

300 Hrs.

720

1000 Hrs.

750

RPM

2000 Hrs.

1000 Hrs.

RPM

500 Hrs.

300 Hrs.

900

1000
RPM

2000 Hrs.

1000 Hrs.

1200
RPM

500 Hrs.

300 Hrs.

1500
RPM

500 Hrs.

1800
RPM

23

ATTENTION!

Bearing No. Amount of replenishment

6210

30 g

6212

40

6213

50

6214

50

6215

60

6216

60

6217

80

6218

80

6220

100

6222

120

6224

120

6226

140

6228

160

6230

180

6232

200

6234

250

6236

300

6238

350

6240

400

6244

450

6248

500

62XX
72XX

NU2XX

222XX

TABLE 2.

Bearing No. Amount of replenishment

6310 40 g
6312 60
6313 80
6314 80
6315 100
6316 100
6317 120
6318 120
6320 160
6322 220
6324 270
6326 300

6328 400
63XX
73XX

NU223XX

223XX

6330 450

6332 500

6334 600

6336 700

6338 800

6340 900

6344 900

6348 900

*Fill new grease until it overflows and the old grease is entirely replaced.

5.5.4 Oil re-lubrication (For oil lubrication types only)

Maintain proper lubrication by checking the oil level periodically and adding oil when necessary.
Because of the initial clearing action of the bearing and the expansion of the oil as it comes up to
operating temperature, the oil level will be higher after the motor has been in operation for a while
than it is with the motor at standstill.
Overfilling should be avoided not only because of the possibility that expansion may force the oil
over the oil sleeve and on to the rotor, but also because too high an operating oil level prevents
the bearing form clearing itself of excess oil. The resultant churning can cause extra loss, high
temperatures, and oxidized oil. If, during operation, the oil level goes above the maximum shown
on the sight gauge, drain enough oil to bring the level back within the recommended operating
range. Do not permit the operating level to fall below the minimum shown on the gauge.

Should it ever become necessary to add excessive am

ount of make-up oil, investigate

immediately for oil leaks.

Change the oil at regular intervals. The time betwe

en oil changes depends upon the severity of
operating conditions and, hence, must be determined by the motor user. Two or three changes a
year is typical, but special conditions, such as high ambient temperature, may require more
frequent changes. Avoid operating the motor with oxidized oil.
Use only good grade, oxidation-corrosion-inhibited turbine oils produced by reputable oil
companies.

22

The viscosity of the oil to be used depends upon the type and size of the bearings, its load and

Angular contact ball

And/or (62XX, 63XX)

ATTENTION!

ATTENTION!

speed, the ambient temperature, and the amount and temperature of the cooling water (if used)).
The lubrication nameplate or instructions with each motor specifies the viscosity range of oil
suitable for average conditions. The usual oil viscosity range of oil suitable for average
conditions. The usual oil viscosity recommendations are summarized in Table 3. Operation in
ambient temperatures that are near or below freezing may require preheating the oil or the use of
special oil. Whenever the motor is disassembled for general cleaning and reconditioning, the
bearing housing may be washed out with a suitable cleaning solvent. Be sure that the oil­metering hole is clear, and then dry the housing thoroughly before re-assembly, and ensure all
traces of cleaning solvent have been removed.

TABLE 3 Oil Viscosity**

Bearing function

and location

Bearing

Type

@ 100°F @ 200°F

Oil Viscosity - SSU

72XX, 73XX

150 45

Thrust Bearing

Spherical roller 300 53
Plate (Kingsbury Type) 300 53

**Remark: When a lubrication nameplate attached to the motor, use lubrication oil it stipulates.

5.5.5 Cleaning and installation of bearings

(a) Apply the proper amount of grease to the disassembled parts of the bearing after they

have been thoroughly cleaned with high quality cleaning oil. Then protect them from
contamination before and during assembly.

(b) Bearing installation

Before installing the bearings, make sure that the shaft-mounted parts inside the bearings
are in place before installation.

Since the bearing is a high precision component, it is important to avoid ingression of dust
and foreign matter, and hammering during cleaning and installation. Use extreme care
and insure clean conditions during installation and assembly.

The best way for bearing installation is heat shrinking. Knocking and hammering during
installation should be avoided absolutely.

The bearing should be heated in a bath of clean oil at a temperature of approximately
80°C. After warming, slide the bearings in place quickly and nimbly so that it has not
shrunk before being fully in position.
Grease the bearing after the temperature returns to normal, and then reassemble the
motor.

25

5.6 Maintenance of sleeve bearings

5.6.1 Daily inspections

(a) Ensure the volume and quality of lubrication oil is in compliance with specifications.

(b) Ensure there is motion of the oil ring and it is not clamped.
(c) The indicator of the shaft endplay should be restricted within the specified range of the red

groove of the shaft or the ±3mm (.118 in.) range of the drive-end shaft shoulder, or the
bearing may be damaged.

5.6.2 Regular
examination

(a) Periodical change
of oil

The oil reservoirs
of self (not flood)
lubricated bearings
should be drained and refilled about every six- (6) months. More frequent changes may be
needed on high-speed (3600-rpm) motors or if severe oil discoloration or contamination
occurs. In conditions where contamination does occur, it may be advisable to flush the
reservoir with kerosene to remove any sediment before new oil is added. Proper care must
be taken to thoroughly drain the reservoir of the flushing material before refilling with the
new oil.
Refill the reservoir to the center of oil sight glass with a turbine grade of oil that is rust and
oxidation inhibited. Refer to the outline and lubrication nameplate for the correct viscosity.

(b) Quantity of lubrication oil

Please refer to the lubrication nameplate for oil quantity.
(c) Oil viscosity
(d)

ISO Equivalents Viscosity (SUS/100°F)

VG32 Esso Teresso 32 150

VG46 Esso Teresso 46 200

VG68 Esso Teresso 68 300

24

5.6.3 Disassembly

Prior to disassembling,

ensure the power supplies are disconnected and there

The bearing sleeve is of the spherically seated, self-aligning type. The opposite drive end
bearing is normally insulated for larger motors (or when specified). On some motors, the
insulation is bonded to the spherical seat of the bearing housing.

ATTENTION!
Extreme care must be exercised in removing the bearing sleeve from the insulated support
to avoid damaging this insulation.

The following is the recommended procedure for removing the bearing sleeve:

are no moving parts.

(a) Remove the oil drain plug in the housing bottom and drain the oil sump.

(b) Remove all instrumentation sensors that are in contact with the bearing sleeve. These

would include resistance temperature detectors, thermocouples, thermometers, etc.

(c) Remove the socket head bolts holding the bearing cap and the inner air seal. The end

cover plate must also be removed if the non-drive end bearing is being disassembled.
Remove the bearing cap and top half of the inner air seal. Place them on a clean, dry
surface to avoid damage to the parting surfaces.

(d) Remove the top half of the bearing sleeve using suitable eyebolts in the tapped holes

provided. Lift the bearing top straight up and avoid any contact with the shoulders of the
shaft journals that might damage the thrust faces of the bearing. Place on a clean, dry
surface taking care to prevent damage to either the parting surfaces or the locating pins
that are captive n the top bearing half.

(e) Remove the screws at the partings in the oil ring and dismantle the ring by gently tapping

the dowel pin ends with a soft face mallet. Remove the ring halves and immediately
reassemble them to avoid any mix up I parts or damage to the surfaces at the partings.

(f) Pull up on the garter spring that surrounds the floating labyrinth seal and carefully slip out

the top half. Rotate the garter spring until the lock is visible. Twist counter-clockwise to
disengage the lock, remove the garter spring then rotate the lower half of the seal out of
the groove in the bearing housing. Note the condition of these floating labyrinth seals. If
they are cracked or chipped, they must be replaced. Do not attempt to reuse a damaged
seal.

(g) To remove the bottom bearing half, the shaft must be raised a slight amount to relieve

pressure on the bearing. On the drive end, jacking or lifting the shaft extension will relieve
the pressure on the bearing for removal. Protect the shaft. On the non-drive, jacking or
lifting can be done using bolts threaded into the tapped holes provided in the shaft end.

25

(h) Roll the bottom bearing half to the top of the shaft journal and then lift it using suitable

Use extreme care when rolling out the lower bearing half. Keep the hands and

personal injury could result.

eyebolts threaded into the holes provided. Again avoid any contact with the shaft
shoulders that could damage the bearing thrust faces. Place the lower bearing half on a
clean, dry surface to protect the parting surfaces.

fingers well clear of any position where they might be caught by the bearing half if
it were accidentally released and rotated back to its bottom position. Serious

(i) Protect the shaft journal by wrapping it with clean, heavy paper or cardboard.

5.6.4 Re-assembly

Bearing re-assembly is basically a reverse of the disassembly procedures outlined above, with
the following suggestions:

(a) The interior of the bearing housing should be cleaned and then flushed with clean oil or

kerosene.

(b) The bearing halves and the shaft journal should be wiped clean using lint-free cloth soaked

with clean oil.

(c) All parts should be carefully inspected for nicks, scratches, etc., in any contract surfaces.

Such imperfections should be removed by an appropriate method such as stoning,
scraping, filling, etc., followed by thorough cleaning.

(d) Before installing the floating labyrinth seal halves, observe their condition. Do not attempt

to use a cracked or chipped seal. The bottom half seal has a set of drilled holes in its side

face. These must be place at the bottom toward the inside of the bearing so that

accumulating oil may drain back into the housing.

(e) Put a bead of Curil-T around the seal half outside diameter on both sides adjacent to the

garter spring groove. This will prevent oil by-passing the seal around its outside.

(f) Place the bottom seal half on top of the shaft and roll it into position. Install the top half and

insert the garter spring pulling up on both ends to permit engaging the lock. Run a bead of

Curil-T around the outside diameter on both sides adjacent to the garter spring groove on

this half also.

(g) Carefully reassemble the two oil ring halves. Inspect the dowel pins for burrs and

straightness and make any corrections required. Do not force the ring halves together.

Excessive force may alter the roundness or flatness of the oil ring, which can change its oil

delivery performance.

(h) Some of the pipe plugs in the housing are metric thread type. These are identified as

those, which have a copper, lead, or similar material washer. If these plugs are removed,

26

be careful not to lose the washers. Before re-assembly, inspect the washers and replace

ATTENTION!

Ensure motor is disconnected from power supplies and there are no accessible

them as required.

(i) Before installing the bearing cap, observe the position of the floating labyrinth seal. The

“tab” must be on top to engage the pocket. Failure to position the seal properly will result
in damage when the cap is assembled.

(1) Curil-T is the only approved compound for use in the assembly of the bearings on this

motor. Other products may harden and impede the operation.

(2) During the re-assembly of the bearing parts, a thin layer of Curil-T should be applied to

all gaskets and machined interface surfaces. This suggestion does not apply to the
machined surfaces of the bearing liner halves.

(3) When seating the bearing shell, apply a thin layer of lube oil at the spherical surface of

the liner. Slowly roll the lower bearing liner into the bearing housing making sure that
the splinted surface of the liner and the housing are flush. Gradually lower the shaft
onto the bearing. The weight of he shaft will help rotate the bearing liner so that the
babbitt surface of the liner will match the slope of the journal. Sometimes it is required
to use a rubber mallet to tap lightly on the bearing housing while slowly rolling the
shaft to help this seating operation.

5.7 Maintenance of slip ring (For Wound Rotor Motors only)

5.7.1 Adjustment of carbon brush

moving parts before maintenance operation.

(a) Brush pressure for normal operation:

● Electro-graphite brush... 0.2~0.25 kg/cm²
When frequent vibrations are evident or the brush is small (area below 0.5 cm²), the
pressure should be greater than as shown.

(b) Adjustment of brush pressure:

The brush pressure should be adjusted to keep normal operation as it wears.

● The brush pressure may be reduced after use, so it is necessary to re-adjust. For
adjustment, please turn adjusting screw, pressure adjusting pin or pressure adjusting
plate as shown in Fig. 14 to obtain the correct tension (=0.23 x brush cross sectional
area in cm²) ±10% kg.

(c) Brush pressure need not be adjusted if constant force spring is used as shown in Fig. 15

and Fig. 16.

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5.7.2 Brush replacement

The carbon brush is a part of the equipment which is easily worn away, replace it after it is worn
to V ~ 3/4 of original size.

(a) Brush material

The brush material is important to the performance of the motor. Only the most
appropriate materials are chosen by TWMC, and are listed on the nameplate of the motor.
It is important to know this when you replace the brush, so a recommended type is used.

(b) Dimensions

Brush, holder and gap between them, please refer to CNS 2322 C4051 or JIS C2802.

ATTENTION!
The gap between a brush and it holder is important for good performance and safety of the
motor.

(c) Adjustment of new brushes (Shown in Fig. 17)

(1) Polish the new brush with a file until is assumes the appropriate contour of the slip ring

that it touches.

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(2) Place sandpaper (JIS R6252 No. 40... 50) on the slip ring with the abrasive face of the

paper against the brush to induce a closer contact by rubbing against each other.

(3) Repeat item 2 with fine sand –paper (JIS R6252 No. 100 to 200) until the contact

surface between brush and slip ring exceeds 80%.

(4) Finally, clean the contaminated slip ring and brush with clean cloth or compressed air.

5.8 Maintenance of non-reverse ratchet mechanism
(For Vertical high Thrust motor only)

5.8.1

In the pump piping system, a check valve and a stop valve should be installed in the discharge
line. The check valve, placed between the pump and the stop valve, is to protect the pump from
reverse flow and excessive pressure. The stop valve is used in priming, starting and when
shutting down the pump. It is advisable to close the stop valve before stopping the pump. This is
especially important when the pump is operated against a high static head.

TWMC vertical high thrust motors are equipped with non-reverse ratchet (N.R.R.) mechanism
only when requested by the pump manufacturer. Typical construction of the N.R.R. mechanism
is shown as Fig 18 below.

The N.R.R. mechanism keeps the pump and motor from rotating in the reverse direction. Thus
prevents damage from over-speeding and damage to water-lubricated pump shaft bearings.

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When, on shutdown, the falling water column tends to drive the pump in the reverse direction.

ATTENTION!

In normal operation, the ratchet pins are lifted by the ratchet teeth and are held clear by
centrifugal force and friction as the motor comes up to speed. When power is removed, the
speed decreases and the pins fall. At the instant of reversal, a pin will catch in a ratchet tooth
and prevent backward rotation.

5.8.2

The service life of ratchet pins depends not only on the reverse shock load between the pin and
ratchet tooth when pump stopped but also the frequency of pump starting and stopping while in
service. Provided that the pins are deformed due to this reverse shock load, then the up and
down motion of the ratchet pins could be sluggish or jammed and unusual noises shall arise.

The recommended replacement period for these ratchet pins is every three- (3) years. If the
reverse shock load is greater than 30% of motor rated torque or the starting frequency is more
than twice per day, then the replacement period should be halved.

The check valve and stop valve in the discharge line should be regularly inspected and
maintained to assure the normal function of these valves. This is important to protect the
pump and motor from damage and increase the service life of the N.R.R. mechanism.

SECTION A-A

ITEM NAME

104 RATCHET
214 BEARING SEAT
402 EXTERNAL FAN
704 RATCHET PIN CARRIER
816 RATCHET PIN

Fig. 18

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6. FAULT FINDING AND RECOGNITION

No fuse

Kinds of

Symptoms Possible

Breakdown

Power-off Consult power company
Switch-off Switch-on

Install fuse
Motionless and
soundless

Broken wiring Check wiring and repair
Broken lead Check wiring and repair
Broken windings Check windings and repair
Short circuit of circuit switches Check circuit switches and replace
Incorrect wiring Check wiring according to

Poor contact at terminal Lock tightly
Windings grounded Factory repair

Fail to start
without load

Fuse blowing.
(Automatic
switch trips off,
slow start with
electromagnetic
noise)

Broken windings Factory repair
Poor contact of circuit switches Check and repair
Broken wiring Check and repair
Poor contact of starting switches Check and repair
Short circuit of starting switches Check and repair
Incorrect connections of starting
switches

Fuse blowing.
Fail to restart due
to trip-off of

Insufficient capacity of fuse Replace fuse if wiring permits
Overload Lighten load
High load at low voltage Check circuit capacity and reduce

automatic switch

Overload or intermittent
overload

Under-voltage

Over-voltage Check power source
Ventilation duct clogged

Ambient temperature exceeds

Overheating motor

104°F (40°C)
Friction between rotor and stator Factory repair

Loading after
start

Fuse blown (Single-phase
rotating)

Poor contact of circuit switches Check and repair
Poor contact of circuit starting
switches
Unbalanced three-phase voltage

Causes

Remedies

nameplate

Connect according to nameplate

load
Lighten load

Check circuit capacity and power
source

Remove the foreign matter in the
duct

Correct insulation class to B or F, or
lower ambient temperature

Install the specified fuse

Check and repair

Check circuit or consult power
company

31

Kinds of

Breakdown

Possible

Slack belt tension

Adjust belt ten

sion

repaired at the factory

key and screw

foreign matter

ducts

Noise induced by air flowing through

Unbalanced rotor

Factory repair

the same level

to the same level

Symptoms

Speed falls
sharply

Switch overheat

Causes

Remedies

Voltage drop Check circuit and power source
Sudden overload Check machine
Single-phase rotating Check circuit and repair
Insufficient capacity of switch Replace switch
High load Lighten load
High belt tension Adjust belt tension

Loading
after start

Noise

Bearing over­heating

Electromagnetic
noise induced by
electricity

Bearing noise

Mechanical noise
caused by
machinery

Electromagnetic
vibration

Misalignment between motor and
machine shafts

Re-align

Over speed of bearing outer-ring Adjust bracket
High bearing noise Replace the damaged bearing
Occurrence from its first operation May be normal

Sudden sharp noise and smoking

Short circuit of windings should be

Noise of low shishi or Thru-Thru May be normal
Kala-Kala as a result of poor lubrication Grease
Kulo-Kulo as a result of poor lubrication Clean bearing and grease
Sa-Sa or larger noise Replace the damaged bearing
Loose belt sheave Adjust key and lock the screw

Loose coupling or skip

Adjust the position of couplings, lock

Loose screw on fan cover Lock fan cover screw tightly
Fan rubbing Adjust fan position

Rubbing as a result of ingress of

Wind noise

Clean motor interior and ventilation

ventilation ducts
Induced by conveyance machine Repair machine
Short circuit of winding Factory repair
Open circuit of rotor Factory repair

Vibration

Mechanical
vibration

Remarks:

(1) Circuit switches: These include knife switches, electromagnetic switches, fuses and other connection

switches etc.

(2) Starting switches: These include Delta-Star starters, compensate starters, reactance starters, resistor

starters, starting controller’s etc.

Unbalanced fan Factory repair
Broken fan blade Replace fan
Unsymmetric centers between belt

sheaves

Central points of couplings do not lie on

Align central points

Adjust the central points of couplings

Improper mounting installation Lock the mounting screws

Motor mounting bed is not strong
enough

Reinforce mounting bed

32