LEESON Permanent Magnet AC Motors User Manual
Installation, Operation, and Maintenance
Instructions
NEMA 182T – 286T, IEC 112 -180
Permanent Magnet Motors Operated On
Variable Frequency Drives (VFD)
www.leeson.com
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE
OWNER: READ AND SAVE THESE INSTRUCTIONS
SAFETY INSTRUCTIONS
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
WARNING: Warning indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Caution indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE: Notice indicates a situation not related to personal injury which, if not
avoided, may result in motor or equipment damage.
Before installing, using, or servicing this product, carefully read and fully understand
the instructions including all warnings, cautions, & safety notice statements. To reduce
risk of personal injury, death and/or property damage, follow all instructions for proper
motor installation, operation and maintenance.
Although you should read and follow these instructions, they are not intended as a
complete listing of all details for installation, operation, and maintenance. If you have
any questions concerning any of the procedures, or if you have a safety concern not
covered by the instructions, STOP, and contact the motor manufacturer.
Table of Contents
_________________________________________________________________________________________________________________________
1.0 SAFETY INFORMATION
1.1 Electrical Safety
1.2 Mechanical Safety
1.3 Environmental Safety
2.0 RECEIVING & INSPECTION
2.1 Initial Inspection
2.1.1 Packing List & Inspect
2.1.2 Turn Motor Shaft
2.1.3 Check Nameplate
2.2 Handling
2.2.1 Lifting Angle Limitations
2.3 Storage
2.3.1 Bearing Lubrication
2.3.2 Shaft Rotation
2.3.3 Damp or Humid Storage Locations
3.0 INSTALLATION AND OPERATION
3.1 Location
3.1.1 Selecting a Location
3.1.2 Ambient Temperature Limits
3.1.3 Construction Selection per Location
3.1.3.1 Totally Enclosed
3.1.3.2 Hazardous Locations Motors
3.2 Mounting Motor
3.2.1 Rigid Base (Footed)
3.2.2 Rigid Base Hole Selection -6 or 8 Hole Bases
3.2.3 Vertical Mounting
3.3 Application Assembly to Motor
3.3.1 General: Proper Alignment
3.3.2 Direct Coupling
3.3.3 Direct Connected
3.3.4 Belted
3.3.4.1 Sheave Diameter Requirements
3.3.4.2 Number of Belts
3.3.4.3 Sheave Location
3.3.4.4 Belt Tension
3.3.5 Permanent Magnet Motor VFD Operation
3.3.5.1 Overspeed Capability
3.3.5.2 Cable Lengths
3.3.5.3 VFD Grounding
3.3.5.4 Stray Voltage On Accessory Leads
3.3.6 Accessories
3.3.6.1 General
3.3.6.2 Brake Motors
3.3.6.3 Space Heaters
3.3.6.4 Thermal Protection
3.3.6.5 RTD Alarm & Trip Settings
3.3.7 Guards
3.4 Electrical Connections
3.4.1 Power Supply / Branch Circuit
3.4.1.1 Fuses, Breakers, Overload Relays
3.4.1.2 AC Power Supply Limits
3.4.2 Terminal Box
3.4.2.1 Conduit opening
3.4.3 Lead Connections
3.4.4 Ground Connections
3.4.4.1 Electrical Interference
3.4.5 Start Up
3.4.5.1 Start Up – No Load Procedure
3.4.5.2 Start Up – Load Connected Procedure
4.0 MAINTENANCE
4.1 General Inspection
4.1.1 Ventilation
4.1.2 Insulation
4.1.3 Electrical Connections
4.1.4 Seal Condition
4.1.5 Safety Labels
4.2 Lubrication and Bearings
4.2.1 Grease Type
4.2.2 Bearing Operating Temperature
4.2.3 Lubrication Interval
4.2.4 Lubrication Procedure
4.2.5 Lubrication Example
4.3 Trouble Shooting
4.3.1 General Trouble-Shooting Warnings
1.0 SAFETY INFORMATION
1.1
ELECTRICAL SAFETY
WARNING:
Electrical connections shall be made by a qualified electrician in
accordance with all applicable codes, ordinances and sound practices.
Failure to follow these instructions could result in serious personal
injury, death and/or property damage. Only qualified personnel who
are familiar with the applicable National Code (USA = NEC) and local
codes should install or repair electrical motors and their accessories.
WARNING:
motor and variable frequency drive in accordance with the drive
manufacturer’s documentation may result in serious injury, death,
and/or property damage.
WARNING:
Do not touch electrically live parts. Disconnect, lockout and tag input
power supply before installing or servicing motor (includes accessory
devices). Use a voltmeter to verify that power is off before contacting
conductors.
WARNING:
Shaft rotation produces voltage in PM motors even when motor is
disconnected from power source. Do not open terminal box or touch
unprotected terminals while the motor shaft is rotating. Failure to do so
may cause serious injury or death to personnel.
WARNING:
Shaft rotation produces voltage in PM motors even when motor is
disconnected from power source. Do not operate the motor or allow
equipment to back drive the motor above the maximum RPM listed on
the motor nameplate. Failure to do so may cause serious injury or
death to personnel or damage the motor or system equipment.
WARNING:
Failure to properly ground motors, per the National Electrical Code
(NEC) Article 430 and local codes may cause serious injury or death to
ELECTRICAL SHOCK HAZARD
ELECTRICAL HAZARD: Failure to connect
ELECTRICAL LIVE CIRCUIT HAZARD
ELECTRICAL SHOCK HAZARD
ELECTRICAL HAZARD
ELECTRICAL GROUNDING HAZARD
personnel. For general information on grounding refer to NEC Article
250. (Also see “Ground Connections section 3.4.4“).
WARNING:
Permanent magnet motor rotors, when removed from the stator,
expose surrounding personnel and equipment to powerful magnetic
fields which may cause serious health hazards to persons with
pacemakers, hearing aids, or other implanted electronic medical
devices and may impact other electronic devices such as mobile
phones, credit cards, etc.
MAGNETIC FIELD HAZARD
NOTICE:
Permanent magnet (PM) motors can only be operated by a PM motor
compatible VFD (Variable Frequency Drive). Connecting directly to
line power may result in motor damage.
1.2
Before starting the motor, remove all unused shaft keys and loose
rotating parts to prevent them from flying off. Failure to follow these
instructions could result in serious personal injury, death and/or
property damage.
Keep extremities, hair, jewelry and clothing away from moving parts.
Failure to follow these instructions could result in serious personal
injury, death and/or property damage. See section 3.3.7.
Due to powerful magnetic fields, disassembly and assembly of
permanent magnet motors should only be performed by the
manufacturer or specialized personnel authorized by the manufacturer.
Only qualified personnel who are familiar with the applicable national
codes, local codes and sound practices should install or repair electric
motors and their accessories. See the Magnetic Field Hazard in
section 1.1.
MOTOR NOT SUITED FOR OPERATION ON LINE POWER
MECHANICAL SAFETY
WARNING:
WARNING:
WARNING:
LOOSE PARTS HAZARD
ROTATING PARTS HAZARD
DO NOT DISASSEMBLE:
1.3
ENVIRONMENTAL SAFETY
WARNING:
The NEC and the local authority having jurisdiction must be consulted
concerning the installation and suitability of motors for use in
Hazardous Locations, in accordance with NEC Article 500. The local
authority having jurisdiction must make the final determination of what
type of motor is required. The application and operation is beyond the
control of the motor manufacturer. Failure to do so may cause serious
injury or death to personnel.
HAZARDOUS LOCATIONS
2.0 RECEIVING AND INSPECTION
2.1
INITIAL INSPECTIONS
WARNING:
Shaft rotation produces voltage at motor leads and connected
equipment even when motor is disconnected from power source. Do
not open terminal box or touch unprotected terminals while the motor
shaft is rotating. Failure to do so may cause serious injury or death to
personnel.
2.1.1
packaging to make certain no damage has occurred in shipment.
If there is visible damage to the packaging, unpack and inspect
the motor immediately. Claims for any damage done in shipment
must be made by the purchaser against the transportation
company.
2.1.2
above) by hand to be certain that it rotates freely. Note: Motor will
not turn freely if leads are shorted together. User may feel small
pulsations when turning shaft due to the magnets in rotor. Shaft
seals and bearing seals may add drag.
keyways. Finger or ring contact may cause injury.
2.1.3
order requirements and compliance with power supply and control
equipment requirements.
2.2
HANDLING
WARNING:
Eyebolts or lifting lugs, where provided, are intended for lifting only the
motor and accessories mounted by the motor manufacturer (unless
specifically stated otherwise on the motor). Utilizing the motor lifting
provision to lift other components such as pumps and gear boxes
could result in serious personal injury, death and/or property damage.
WARNING:
Before using the lifting provision, check the eyebolts and/or other lifting
means to assure they are not bent or damaged and are completely
threaded, seated & secured to the motor. Equipment to lift motor must
have adequate lifting capacity. While lifting the motor, DO NOT stand
under or in the vicinity of the motor. Failure to follow these instructions
could result in serious personal injury, death and/or property damage.
2.2.1 LIFTING ANGLE LIMITATIONS
2.3 STORAGE:
be stored indoors in a clean, dry location. Avoid locations with large
temperature swings that will result in condensation. Motors must be
ELECTRICAL SHOCK HAZARD
CHECK PACKING LIST AND INSPECT
TURN MOTOR SHAFT
(see Electrical Shock Hazard
CAUTION:
CHECK NAMEPLATE
Observe caution when working near threads or
for conformance with purchase
FALLING OBJECT HAZARD
FALLING OBJECT HAZARD
Motors, not put into service immediately, must
the
covered to eliminate airborne dust and dirt.
exhibits high vibration, place isolation pads under motor to minimize
damage to motor bearings.
2.3.1
BEARING LUBRICATION:
packed at the factory; relubrication upon receipt of motor or while
in storage is not necessary. If stored more than one year, add
grease per lubrication instructions (Table 4-4) before start-up.
2.3.2
SHAFT ROTATION:
Warning in section 2.1) It is recommended that the motor shaft be
rotated 5 to 10 rotations every three months to distribute the
grease in the bearings. This will reduce the chance for corrosion
to form on the bearing rolling elements and raceways. Note: User
may feel small pulsations when turning shaft due to the magnets
in rotor. Shaft seals and bearing seals may add drag.
2.3.3
DAMP OR HUMID STORAGE LOCATIONS:
unpainted flanges, shafts, and fittings with a rust inhibitor. Apply
appropriate power to the motor’s space heaters (if so equipped).
If the storage location
Bearings are grease
(see Electrical Shock Hazard
Treat
3.0 INSTALLATION AND OPERATION
WARNING:
Only qualified personnel who are familiar with and understand the
appropriate national codes, local codes and sound practices should
install or repair electrical motors and their accessories. Installation
should conform to the appropriate national code as well as local codes
and sound practices. Failure to follow these instructions could result in
serious personal injury, death and/or property damage.
WARNING:
Do not touch electrically live parts. Disconnect, Lockout and Tag input
power supply before installing or servicing motor (includes accessory
devices). Use a voltmeter to verify that power is off before contacting
conductors.
WARNING:
Shaft rotation produces voltage at PM motor leads and connected
equipment even when motor is disconnected from power source. Do
not open terminal box or touch unprotected terminals while the motor
shaft is rotating. Failure to do so may cause serious injury or death to
personnel.
WARNING:
Refer to Section 1.0 for additional warnings before proceeding with
installation and operation.
3.1
LOCATION
3.1.1
given to environment and ventilation. Motors should be installed
in an area that is protected from direct sunlight, corrosives,
harmful gases or liquids, dust, metallic particles, and vibration. A
motor with the proper enclosure for the expected operating
condition should be selected. Provide accessible clearance for
cleaning, repair, service, and inspections (See section 3.1.3 for
construction clearances). The location should be considered for
possible future motor removal or motor handling. The free flow of
air around the motor should not be obstructed.
3.1.2
temperatures of the air inlet to the motor should not exceed 40°C
(104°F) or be less than -30°C (-22°F) unless the mo tor nameplate
specifically states an ambient temperature outside of these limits.
The ambient inside an enclosure built around the motor shall not
exceed the nameplate ambient. For ambient temperatures outside
of these limits consult the motor manufacturer.
NOTICE:
Insulation at high temperatures ages at an accelerated rate. Each
10°C increase in temperature reduces the insulation life by one
half.
ELECTRICAL SHOCK HAZARD
ELECTRICAL LIVE CIRCUIT HAZARD
ELECTRICAL SHOCK HAZARD
ELECTRICAL SAFETY
SELECTING A LOCATION:
Consideration should be
AMBIENT TEMPERATURE LIMITS:
INSULATION DEGRADATION WARNING
The ambient
3.1.3
Max
Location 1 and 3 holes for short frame:
CONSTRUCTION SELECTION PER LOCATION
3.1.3.1
TOTALLY ENCLOSED MOTORS are suitable for
indoor or outdoor standard service applications. Severe duty
construction is recommended for severe service applications.
TEAO or AOM (Totally Enclosed Air Over) motors must be
mounted in the air stream. When the motor nameplate states
a minimum airflow the motor must be mounted in an air
stream meeting this minimum value.
TEFC (Totally Enclosed Fan Cooled) motors must meet a
minimum distance equal to ½ the shaft height between the
fan guard grill openings and the nearest obstruction.
3.1.3.2
motors covered by this manual are intended for hazardous
duty locations. Motors intended for hazardous duty locations
are labeled with the division and class.
Hazardous Locations motors are intended for installations in
accordance with NEC Article 500. For all installations involving
Hazardous Locations motors, consult the applicable national
codes, local codes, and the authority having jurisdiction. Failure
to do so may cause serious injury or death to personnel.
Division 2 Installations – Class I only: Use only motors
that are CSA Certified and bear the CSA Certification Mark.
These motors include a phrase on the main motor
nameplate that indicates the motor is CSA Certified for Class
I, Division 2 / Zone 2 locations.
A motor should never be placed in an area with a hazardous
process or where flammable gases or combustible materials
may be present unless it is specifically designed and
nameplated for this type of service. Hazardous Locations
motors are intended for installations in accordance with NEC
Article 500. For all installations involving Hazardous Locations
motors, consult the NEC, local codes, and the authority having
jurisdiction. Failure to follow these instructions could result in
serious personal injury, death and/or property damage. (For
other limitations see section 1.3).
3.2
MOUNTING MOTOR
3.2.1
securely installed to a rigid foundation or a mounting surface to
minimize vibration and maintain alignment between the motor
shaft and the load’s shaft. The mounting surfaces of the four
mounting pads must be flat within 0.01 inches for 210 frame &
smaller; 0.015 inches for 250 frame & larger. [IEC 0.25 mm for
130 frame & smaller, 0.38 mm for 160 frame & larger]. This may
be accomplished by shims under the motor feet. For special
isolation mounting, contact manufacturer for assistance.
HAZARDOUS LOCATIONS MOTORS: Not all
WARNING:
WARNING:
RIGID BASE (FOOTED):
HAZARDOUS LOCATIONS
EXPLOSION HAZARD
The motor must be
3.2.2
RIGID BASE HOLE SELECTION -6 OR 8 HOLES
(NEMA) 182, 213, 254, 284
(IEC) 112S, 132S, 160M, 180M
Location 2 holes are for F1,
F2 Conversion (if provide)
Location 1 and 4 holes for long frames:
(NEMA) 184, 215, 256, 286
(IEC) 112M, 132M, 160L, 180L
3.2.3
VERTICAL MOUNTING
WARNING:
The lifting provision on standard horizontal footed motors is not
designed for lifting the motor in a vertical shaft up or shaft down
position. (see Diagram 2.2.1). Doing so may cause the motor to
fall. Lifting method / provisions for mounting a rigid base (footed)
motor vertically is the responsibility of the installer.
FALLING OBJECT HAZARD
VERTICAL SHAFT DOWN: Most standard horizontal motors
through 449 Fr. (excluding brake motors) can be mounted in a
vertical shaft down orientation. For vertical brake motors see
section 3.3.6.2.
VERTICAL SHAFT UP:
WARNING:
MOUNT: Hazardous locations motors must NOT be mounted
vertically shaft up without approval by the motor manufacturer.
Without proper retaining provisions the rotor may move axially
and contact components, creating a spark hazard.
HAZARDOUS LOCATIONS VERTICAL
Belted or Radial Load when mounted vertically
following frame sizes / constructions with applied (axial) down
loads within the limit stated are acceptable when mounted vertical
shaft up.
Table 3-1 Belted or Radial Load Applications (All speeds)
Frame
Notes:
The max applied down load is any applied load external to the
motor, including such things as sheave weight, fan loads, axial
belt force, pump load, etc. If the application is direct drive with
no applied radial load or is beyond the limits listed, consult the
motor manufacturer.
3.3
NOTICE:
Do not connect or couple motor to load until correct rotational direction
is established.
3.3.1
and driven equipment minimizes vibration levels, maximizes
bearing life, and extends the overall life of the machinery. Consult
the drive or equipment manufacturer for more information.
NOTICE:
During assembly do NOT force components onto the shaft.
Striking or hammering the component may result in bearing
damage.
3.3.2
possible.
For applications that apply radial, axial or moment loading on the
motor shaft see section 3.3.3.
NOTICE:
Unless approved by the motor manufacturer, do NOT direct
couple a vertical shaft up motor or roller bearing motor. Direct
coupling a vertical shaft up motor or a motor with a roller bearing
may result in bearing damage.
3.3.3
connected equipment (gears, fans etc.) must be approved by the
motor manufacturer unless within the maximum overhung load
limits (Table 3-2). Combined loading (axial, radial and/or
moments) must be approved by motor manufacturer. For belted
loads see section 3.3.4.
Enclosure Construction
Size
180 TEFC All Yes 35 lbs
210 TEFC All Yes 40 lbs
250 TEFC All Yes 40 lbs
280 TEFC Cast Iron Yes 30 lbs
APPLICATION ASSEMBLY TO MOTOR
EQUIPMENT DAMAGE
GENERAL: PROPER ALIGNMENT
BEARING FAILURE
DIRECT COUPLING:
BEARING FAILURE
Use flexible couplings if
DIRECT CONNECTED:
Shaft Up
OK
Radial loading for direct
: The
Applied
Down
Load2
of the motor
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