Rockwell Automation 1325L User Manual

Installation, Operation

and Maintenance Manual

DC Motors

• Frames DC180ATZ, C180ATZ and DC210ATZ

2 DC Motors

General Description

The products described in this publication are designed speciﬁcally for use on rectiﬁed power. The basic design includes Class F Insulation, 1.0 Service Factor, 40 degree C (104 degree F) ambient, continuous duty, with drip-proof guarded and force-ventilated enclosure, with horsepower speed ratings, overload and voltage in accordance with NEMA Standards. A wide variety of modiﬁcations, enclosures and accessories is available.

ATTENTION: Only qualiﬁed electrical personnel familiar with the construction and operation of this equipment and the hazards

involved should install, adjust, operate, and/or service this motor. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in personal injury or loss of life.

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly & Reassembly Instructions. . . . . . . . . . . . . . . . . . . . .

12 15 21

2 2 3 8

Acceptance

Thoroughly inspect this equipment before accepting shipment from the transportation company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight or express agent at once and request him to make an inspection. We are willing to assist you in collecting claims for loss or damage in shipment; however, this willingness on our part does not remove the transportation company's responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the invoice, nor should payment of the invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe delivery.

If considerable damage has been incurred and the situation is urgent, contact the nearest Allen-Bradley Sales Ofﬁce for assistance. Please keep a written record of all such communications.

DC Motors 3

Handling

ATTENTION: Eyebolt(s) or lifting lug(s) are intended for lifting the motor only with the standard accessories such as

tachometer, brakes, etc., mounted by Allen-Bradley. The lifting means on the motor must not be used to lift the unit plus additional equipment. The lifting means on the motor cannot be used to lift assemblies or equipment mounted on a common base. Failure to observe this precaution could result in personal injury.

In all cases, care should be taken to assure lifting in the direction intended in the design of the lifting means. Lift using all lugs provided. Likewise, precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or shock forces.

Angle of lift with rope or chain must be greater than 45 degrees from horizontal.

For unusual conditions, such as side-wall and ceiling mounting of horizontal motors or installation of vertical motors shipped in a horizontal position, special precautions must be taken. It is recommended that an experienced rigger be employed.

Installation

Storage

Motors must be stored in a clean, dry area protected from extremes of temperature, moisture, shock and vibration. Storage temperatures of 10 to 49 degrees C (50 to 120 degrees F) with a maximum relative humidity of 60% must be observed. In addition, motors subjected to extended storage must be handled and treated per the requirements speciﬁed in publication “Motors-5.0.” This publication is available from your Allen-Bradley Sales Ofﬁce or online at: http://www.controlmatched.com.

DC motors have characteristics which can cause serious or fatal injury unless they are selected, installed, maintained and operated by qualiﬁed personnel familiar with special requirements of DC machines. Allen-Bradley DC motors are designed and built in accordance with Safety

Standard for Construction and Guide for Selection, Installation and Use Of Electric Motors And Generators published by the National Electrical

Manufacturers Association (NEMA), publication MG-2-1983 (ANSI C51.5). It is recommended that this publication be referred to whenever you select or install any motor.

The application of motors and other electrical equipment in hazardous locations is restricted by the National Electric Code. Users must observe these regulations and consult with local code inspection and enforcement agencies to insure compliance.

4 DC Motors

Location

Locate the machine where the ambient temperature is not over 40 degrees C (104 degrees F) and where clean air has free access to ventilating intake and outlet openings. Except for machines with a suitable protective enclosure, the location should be clean and dry.

Important: Sufﬁcient clearance must be provided on all inlet and outlet

openings to provide for unrestricted ﬂow of air. Separately ventilated motors with exhaust to ambient (pipe-in only) must have at least 152.4 mm (6 in.) of clearance between the opening and adjacent walls or ﬂoor.

Air Supply

Cooling air through a self-ventilated or forced-ventilated motor must be clean and have relative humidity between 30 and 100% with no free water in the air. Use of damp, cool outside air with high humidity and free water may cause the motor to ﬂash over. Use of excessively dry air may cause excessive brush and commutator wear. Cooling air temperature must not exceed the maximum ambient temperature indicated on the motor nameplate (standard 40 degrees C/104 degrees F). Cooling air temperature must not be lower than 0 degrees C (to provide base speed and regulation within NEMA limits). Use of outside air below 0 degrees C may cause excessive brush and commutator wear due to the low humidity. Cooling air absolute humidity must be at least 2 grains per cu. ft.

Important: Motors located in damp, moist environment must have space

heater or ﬁelds energized at 50% voltage to protect against condensation when motor is not operating.

Separately ventilated motors must have the following volume of air to adequately cool the motor unless the motor nameplate speciﬁes a different value.

Frame

DC180ATZ, C180ATZ and DC210ATZ

Base Speed

RPM

2500 152 2.0

1750 and lower 105 0.95

Air Volume

CFM

Static Pressure

Inches of Water

Power Supply

Check the motor nameplate to be sure the voltage and type of power rating is the same as that of the power source.

A code stamped on the nameplate identiﬁes the type of power supply that must be used to supply armature power to the motor in order to obtain the rated nameplate output. Since the code letter has been selected in alphabetic order of increasing magnitude of ripple current, a motor may be operated on a power supply having a letter designation prior in the alphabet to the letter stamped on the nameplate, with no loss in nameplate rating.

DC Motors 5

For example, a motor designed for a D type of power supply may be used on a C power supply having the same voltage rating. The types of power supplies are deﬁned as follows.

Description Code

DC generator, battery or twelve pulse/cycle, 6 phase, full control A

Six pulse cycle, 3 phase, full control 230 or 460 volt, 60 Hz input to rectiﬁer C

Three pulse/cycle, 3 phase, semi-bridge, half control 230 or 460 volt, 60 Hz input to rectiﬁer D

Three pulse/cycle, 3 phase, half-wave (single way) 460 volt, 60 Hz input to rectiﬁer E

Two pulse/cycle, 1 phase full wave (bridge circuit with 2 controlled rectiﬁers and

2-uncontrolled rectiﬁers with free wheeling rectiﬁer) 230 volt, 60 Hz input

When the armature power supply cannot be designated by a single letter code (A. K etc.) the power supply shall be identified by the following code stamped on the motor nameplate: “M/N F-V-H-L.”

where M = Total pulses per cycle

N = Total controlled pulses per cycle

F = Free wheeling (if used)

V = Nominal line-to-line a-c voltage to rectifier

H = Line frequency-Hz

L = Value of series inductance (in millihenries) to be added externally to the motor armature circuit.

Examples:

A. "6/3 F-380-50-12" defines a power supply having 6 total pulses per cycle, 3 controlled pulses per cycle

(S-3), with free wheeling, 380 volts. 50 Hz AC input to bridge, and a 12 millihenry choke to be added externally to the motor armature circuit.

B. "3/3 480" defines a power supply having three total pulses per cycle, three control pulses per cycle. 480

volts line-to-line input to the rectifier. 60 Hz power supply and no external inductance required in the armature circuit. Note that since the power source is 60 Hz and no series inductance is required. both quantities may be omitted from the code. If one of the quantities is indicated, both must be included to avoid confusion.

Conduit Box

Conduit boxes can be rotated in 90 degree increments for lead outlet at top, sides or bottom.

Conduit box locations can be changed from F1 to F2 or F2 to F1 by rotating the commutator end bracket 180 degrees and reconnecting the leads. The conduit box location cannot be changed on DC180ATZ & DC210ATZ frames.

Connections

Important: If motor has parallel leads, all lugs with the same marking: For

example, A1, A1, must be connected together.

Figure 1 Basic DC Motor and Generator Connections

Rotation Facing Commutator End

Type

Motor

Generator

+A1

+A2

CCW

–S2

+F1

–F2

–S2

–F1

+F2

+A2

–S1

–S2

+F1

–F2

+F1

–F2

If machine has no series ﬁeld, disregard S1 and S2 above. For machines with special windings, refer to motor or generator and controller diagrams.

6 DC Motors

Thermostat (Thermal Protector)

Important: When motors are provided with thermal protection (typically

thermostats), it is important to properly connect and apply the devices. This will ensure that the motor is properly protected from being operated if thermal limits are reached and/or exceeded. The control system must be conﬁgured to reduce the motor load and/or shut down the motor control system to allow the motor to cool to a level within acceptable operating ranges. If the motor is operated with the thermal protective devices tripped (indicating an over temperature condition), the motor insulation could be damaged and complete failure of the motor insulation is possible. In the event of motor failure due to an over temperature condition, Rockwell Automation requires that motor thermal protective devices (when supplied) be adequately monitored and incorporated into the motor control system to maintain warranty. Failure on the part of the individual installing this equipment to take these steps will result in the factory warranty being voided.

Important: Motors may have one or more thermostats (leads marked P1,

P2, etc.) designed to trip before the frame reaches the maximum allowable temperature for speciﬁc class and group. The normally closed contacts of the thermostat must be connected in that motor control circuit so that power to the motor armature and ﬁeld is removed immediately when the thermostat trips. An explosion-proof tachometer mounted on the motor will also have an internal thermostat which must be connected to stop the drive within 30 seconds upon tripping. Failure to connect the thermostat leads will void the motor warranty. the rating of the thermostat contact is:

Maximum Voltage 250V, 60 Hz

Rated Current 6.3 amps

Maximum Breaking Current 20 amps

Important: Motors with an overspeed switch must have the overspeed

switch terminals properly connected in the control circuit to remove armature power when the switch reaches the set speed.

Grounding

The user is responsible for assuring that the grounding method is in accordance with the National Electric Code and the applicable local codes. The ground connection should be a solid and permanent metallic connection between the ground point, the motor terminal housing and the motor frame. On two pole units, DC180ATZ, C180ATZ & DC210ATZ, the ground connection is a tapped hole in the end bracket adjacent to the conduit box.

DC Motors 7

Mounting

Motors must be mounted on a rigid, solid base or foundation. Poor base construction may cause resonances in the motor/base assembly which can result in bearing failure and other motor damage. All hold down bolts must be the correct grade for the type of mounting and must be torqued to their recommended value.

Table A Recommended Torque

Frame

C180ATZ 11.2 (0.44) 3/8-16 1.81 (16)

Hole Diameter

mm (in.)

Bolt Size and Thread

SAE Grade I Dry Components-Not Lubricated

N-m (lb.-ft.)

Belted Drive

Motor slide bases or rails, when used, must be securely anchored to the foundation with the proper bolts.

Important: The motor shaft and load shaft must be parallel and the sheaves

aligned. Refer to

“Motor Application Data” on page 8.

Coupled Drives

Important: Flexible couplings must be used between the motor shaft and

the load shaft. Motor shaft and load shaft must be aligned to values recommended for the speciﬁc coupling before coupling is connected.

Important: Motors will operate successfully mounted on the ﬂoor, wall or

ceiling, and with the shaft at any angle from horizontal to vertical. Special mountings, duty or thrust demands may, however, require a different bearing system. Drive-end bracket and/or outer caps can be rotated either 90 or 180 degrees to conveniently locate grease ﬁttings, or air outlet openings. Handhole covers can be interchanged as necessary.

Important: Vertical mount drip covers are required to provide protection to

vertically mounted Drip-Proof motors. Stock motors and other motors designed for horizontal mounting can be adapted for vertical mounting by ordering vertical mount drip covers. Self-ventilated frames cannot be mounted vertical shaft up and retain the drip-proof feature due to louvers on the drive end bracket.

Motor C-Face is intended for mounting auxiliary equipment such as pumps, gears, etc. When mounted horizontally, these motors should be supported by the feet and not by the C-Face. Installations requiring a horizontally mounted motor without feet should use a D-Flange.

ATTENTION: Surface temperature of the motor enclosure may reach temperatures which can cause discomfort or injury to

personnel coming into contact with hot surfaces. The user must apply appropriate guards and/or shields to protect against accidental contact with motor surface. Failure to observe this precaution may result in personal injury.

8 DC Motors

Direction of Rotation

Unless otherwise ordered, brush rigging is assembled for NEMA standard direction of rotation, counterclockwise for motors and clockwise for generators facing the commutator end. These motors will operate in either direction of rotation, without changing the angle of the brush holders for normal ﬁeld weakened speed ranges. Extended ﬁeld weakened speed range motors should have the direction of rotation speciﬁed.

Drive

DC180ATZ, C180ATZ & DC210ATZ frame motors are supplied with a shaft suitable for a belt or coupled drive.

Proper alignment is a key step for long life of bearings, shafts and belts, and minimum downtime. Misalignment can cause excessive vibration and damaging forces on shaft and bearings. For direct coupled drives, ﬂexible couplings facilitate alignment. For belt drives, the driving and driven tension must be adjusted as required for proper operation. The belt sheaves should be placed as close as possible to the motor bracket.

Motor Application Data

ATTENTION: To guard against personal injury and/or machine damage caused by incorrect motor rotation, verify direction of

motor rotation before coupling motor to load.

ATTENTION: Ensure that all guards are properly installed, to guard against personal injury caused by contact with rotating

parts,

Shipping Blocks

Motors supplied with roller bearings at the drive end are shipped with wooden blocking to prevent axial movement of the shaft during shipment. Remove the blocking and bolts securing it and discard. Make sure motor shafts turn freely. If motor is to be reshipped, blocking of bearing is required.

Maximum Safe Speed

ATTENTION: The machinery builder and/or user are responsible for assuring that all drive train mechanisms, the

driven machine, and process material are capable of safe operation at the maximum speed at which the machine will operate. Failure to observe these precautions could result in personal injury.

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