GE GEI-M1025 Installation Instructions

g GE Energy

GEI-M1025-B

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: 5KEXXXDTTXXXX

GEI-M1025-B

Table of Contents

I. General Information ................................................................................................................................................. 1

A. How to Properly Use this Instruction Manual ................................................................................. 1

B. Safety Symbols ............................................................................................................................................. 1

C. Safe Motor Operation Information ...................................................................................................... 2

D. Description of Labels and Nameplates ............................................................................................. 3

E. Model and Serial Numbers ...................................................................................................................... 3

F. Relevant Industry Standards .................................................................................................................. 3

II. Receiving ....................................................................................................................................................................... 3

A. Unpacking ....................................................................................................................................................... 4

B. Temporary Storage ..................................................................................................................................... 4

C. Extended Storage ........................................................................................................................................ 4

D. Handling .......................................................................................................................................................... 4

III. Installation .................................................................................................................................................................... 4

A. Location ........................................................................................................................................................... 4

B. Mounting .......................................................................................................................................................... 5

C. Power Supply and Connections ............................................................................................................ 5

IV. Operation…………………………………………… .................................................................................................................... 6

A. Steps Prior to Starting ................................................................................................................................ 6

B. Initial Start ....................................................................................................................................................... 7

C. Jogging and Repeated Starts ................................................................................................................. 7

V. Maintenance ................................................................................................................................................................ 8

A. General ............................................................................................................................................................. 8

B. General Cleanliness .................................................................................................................................... 8

C. Insulation and Windings ........................................................................................................................... 8

D. Vacuum and Compressed Air Cleaning ............................................................................................ 8

E. Cleaning with Water and Detergent.................................................................................................... 9

F. Bearings and Lubrication ......................................................................................................................... 9

G. Couplings ...................................................................................................................................................... 11

H. Re-Assembling the Upper End ............................................................................................................. 12

VI. Operational Difficulties ......................................................................................................................................... 13

VII. Failure ........................................................................................................................................................................... 14

VIII. Repair ............................................................................................................................................................................ 14

IX. Renewal Parts ........................................................................................................................................................... 14

X. Fastener Torques ..................................................................................................................................................... 15

XI. Coupling Assembly ................................................................................................................................................. 16

A. 210 – 280 Frame Non-reverse and Bolted Coupling ................................................................. 16

B. 320 – 449 frame Non-Reverse and Bolted Coupling ................................................................. 18

GEI-M1025-B

The use of a lightning bolt within an arrowhead symbol, enclosed in a yellow triangle warns of dangerous electrical voltage that could cause an electric shock to a person.

This symbol identifies a terminal, which is intended for connection to an external grounding conductor for protection against electric shock in case of a fault.

The use of an exclamation point within a yellow triangle indicates to the user that important installation, operating and maintenance instructions must be followed.

The use of a small case “i” enclosed in a square indicates a general note.

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.

WARNING:

Indicates a procedure or condition that, if not strictly observed, could result in personal injuries or death.

This symbol instructs one to read the

manufacturer’s instruction manual before

installation, operation and maintenance.

CAUTION:

Indicates a procedure or condition that, if not strictly observed, could result in minor injuries to personnel.

This symbol indicates the need to wear hearing protection.

I. GENERAL INFORMATION

A. How to Properly Use this Instruction Manual

This installation 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.

GEI-M1025-B

WARNINGS: High voltage and rotating parts can cause serious or fatal injuries. Qualified 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.

Installation

 Avoid contact with energized circuits and rotating parts.  Avoid bypassing or rendering inoperative any safeguards or protective devices.  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.

 Use proper protective gear, care and procedures when handling, lifting, installing, operating and maintaining the

motor.

 If 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 0°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.

 Do not use the motor shaft as a means for lifting.  Do not lift both the motor and driven equipment with the motor lifting means.  Do not stand on or place objects on the motor.

Maintenance Safe maintenance practices performed by qualified personnel are imperative. Before starting maintenance procedures, be positive that:

 Equipment connected to the shaft will not cause mechanical rotation.  Main motor windings and all accessory devices associated with the work area are disconnected from electrical

power sources.

 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 are 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.

C. Safe Motor Operation Information

GEI-M1025-B

MOD – GE model number

RPM = Motor speed at full

MASS = Motor mass

Typical Packing Label

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.

KW = Motor power rating

load VOL – Motor voltage ENCL = Enclosure code FR = Frame size

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 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

2. Motors that have the IECEx designation have also been designed to meet the requirements of the

3. Motors with the CE Mark have also been designed to meet the requirements of the following EU

II. 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.

latest revision of the following standards:

a. NEMA MG-1

following standards:

a. IEC and/or BS/EN 60079-0 b. IEC and/or BS/EN 60079-15

directives:

a. Machinery safety b. Low Voltage c. Electromagnetic Compatibility d. Conformity Assessment

GEI-M1025-B

WARNING: Lifting lugs on the motor are designed for handling only the motor. They are not to be 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

or by other lifting means provided on the base

WARNING: Installation should be in accordance with the ‘USA-National Electric Code’ or ‘BS/EN 602041’ and ‘BS/EN 60204-11’ and consistent with sound National and local practices. Coupling, belt and

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. 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 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 rustinhibiting 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 longer than six months, please refer to GE Instruction Manual GEK-97427.

D. Handling

III. INSTALLATION

A. Location

Locate the motor in a clean, well ventilated area. The motor enclosure is designed such that dripping, windblown 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.

GEI-M1025-B

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.

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.

2. 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.

3. 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.

4. 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 balls 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.

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.

5. 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 that the lineup be checked with a dial 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 ±10%.

2. Dual voltage motors can be connected for the desired voltage using instructions on the nameplate or the

connection diagram.

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