Teco PG4004 Reference Drawing

PG4004R

CURRENTS

TORQUE

POWER FACTOR

ACCEL TIME

ISSUED

EFFICIENCY

INERTIA

R

May 5, 2016

TYPE

AMHG

PERFORMANCE DATA

3-PHASE INDUCTION MOTOR

NAMEPLATE INFORMATION

OUTPUT

HP KW

400 298 60

POLE

4

FRAME

SIZE

5009C

VOLTAGE

2300/4000

TYPICAL PERFORMANCE

FULL

LOAD

RPM

1782

FULL LOAD

MIN. % NOM. %

94.5

3/4 LOAD

%

RATED

HZ

AMBIENT

1/2 LOAD

%

40oC

F. L.

%

84.095.0 94.5 93.4

INS.

CLASS

F

3/4

LOAD

81.1

NEMA

DESIGN

B

1/2 LOAD

ENCLOSURE

CATALOG#

TIME

RATING

CONT.

%

73.1

ODP

PG4004

SERVICE

FACTOR

1.15

MAXIMUM

POWER FACTOR

CORRECTION

KVAR115

NO LOAD FULL LOAD LOCKED ROTOR

AT

2300

VOLT

FULL LOAD

lb-ft

AT

4000

VOLT

LOCKED

ROTOR

%FLT

1179 115 110

SAFE STALL

TIME IN

SECONDS

COLD HOT

17 12

APPROVED:

AT

2300

VOLT

94.0

PULL

UP

%FLT

AT

4000

VOLT

54.3 364.0 G

BREAK

DOWN

%FLT

200

ALLOWABLE

STARTS

PER HOUR

COLD HOT

2 1

M. PRATER

AT

2300

VOLT

633.026.1 15.9

ROTOR

WR

lb-ft

113

SOUND

PRESSURE

LEVEL @ 3 FT

DRAWING NO.

2
2

dB(A)

86

NEMA

AT

4000

VOLT

NEMA

LOAD

WK
lb-ft

1553

2
2

KVA

CODE

LETTER

MAX

ALLOWABLE

WK
lb-ft

2
2

2330

31057PG4004

NEMA

LOAD

WK

Sec

2

MAX

ALLOWABLE

WK

Sec

5.27 7.73

REV.

2

0

ROTATION

DATE: CATALOG NO.:

ONNECTION DIAGRAM

October 14, 2013

VOLTAGE CONNECTION

PG4004

SCHEMATIC DIAGRAM - 6 LEADS

(VIEWED FROM

2300

4000

DRIVE END)

DWG. NO.

3A061H475

OPERATION

&

MAINTENANCE

MANUAL

FOR

THREE PHASE

INDUCTION

MOTORS

56 thru 449T

Frame Motors

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 eventuality of 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. ACCEPTING, INSPECTION, STORAGE, TRANSPORTATION

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 are 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.

2.1 Storage

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

2.2 Place

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

2.3 Moisture prevention
Since moisture can be very detrimental to electrical components, the motor temperature should be
maintained about 37ºF (3°C) 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

2.4

ATTENTION!

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”.

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

2.5

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 in accordance with measures stated in 2.3.
(b) Insulation resistance test should be performed as stated in 2.4.

2.6 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. To keep the bearing journals
well oiled and to prevent rusting, the motor shaft should be rotated several revolutions
about 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 about every month to maintain proper distribution of the grease within
the bearings.

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

However, re-greasing is required if a significant period of time has

(d) 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 interval, 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 free from any foreign matter. Grease should also be generously applied to
prevent rusting.

3

2.7 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
before operating the motor. It is very important that this device be reinstalled exactly as it was
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.

Do not use the hoisting hook/eyebolts to lift more that the motor itself. They are
designed to support the motor only. Make sure the hoisting hook is correctly
attached to the eyebolt(s)/lug(s) and 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
in and the sling angle is correct. See figure 1.

3 INSTALLATION
Site and environment for motor installation

3.1.1

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

(a) Ambient temperature: -14~104ºF (-10~40°C)
(b) Humidity: Relative humidity below 90%RH for totally enclosed types, and below 80%RH for

semi-enclosed types.
(c) Elevation: below 3,300 feet (1,000 meters).
(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 to 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.

4

3.2 Foundation

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. See figure 2.

3.2.2 Installation

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

considered the final level.

(b) Align the position of the common bed with

reference to that level.

(c) Align the level accuracy at a minimum of four

points such as bearing mounting, shaft
extension etc. The accuracy should be
within .0015 inches (0.04mm).

(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 15.75-19.70 inches
(400-500mm) apart etc., to enable the

foundation to carry evenly the weight of the whole motor.
(e) The base should be sturdy and rigid to keep it flat and level.
(f) 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.
(g) Accurately install shaft couplings, belt sheaves etc., then weld the wedges solid to prevent

untoward 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