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Motors I Automation I Energy I Transmission & Distribution I Coatings
Low and high voltage three phase
induction motors
M line - Squirrel cage rotor - Vertical
Installation, Operation and Maintenance Manual
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Installation, Operation and Maintenance Manual
Document Number: 11371757
Models: MGA, MGP, MGD, MGT, MGV, MGF, MGR, MGI, MGW and MGL
Language: English
Revision: 7
May 2018
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Dear Customer,
Thank you for purchasing a WEG motor. Our products are developed with the highest standards of
quality and efficiency which ensures outstanding performance.
Since electric motors play a major role in the comfort and well-being of mankind, it must be identified
and treated as a driving machine with characteristics that involve specific care, such as proper
storage, installation and maintenance
All efforts have been made to ensure that the information contained in this manual is faithful to the
configurations and applications of the motor.
Therefore, we recommend that you read this manual carefully before proceeding with the installation,
operation or maintenance of the motor in order to ensure safe and reliable operation of your
equipment and facility. If you need any further information, please contact WEG.
Always keep this manual close to the motor, so that it can be consulted whenever necessary.
ATTENTION
1. It is imperative to follow the procedures contained in this manual for the warranty to be valid;
2. The motor installation, operation and maintenance procedures must be performed only by qualified
personnel.
NOTES
1. The total or partial reproduction of information supplied in this manual is authorized, provided that
reference is made to its source. If this manual is lost, an electronic PDF file is available at www.weg.net
or another printed copy may be requested.
WEG EQUIPAMENTOS ELÉTRICOS S.A.
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TABLE OF CONTENTS
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1 INTRODUCTION ............................................................................................... 11
1.1 SAFETY WARNINGS IN THE MANUAL ........................................................................................... 11
2 GENERAL INSTRUCTIONS ............................................................................... 12
2.1 QUALIFIED PERSONNEL ................................................................................................................ 12
2.2 SAFETY INSTRUCTIONS ................................................................................................................ 12
2.3 STANDARDS ................................................................................................................................... 12
2.4 ENVIRONMENTAL CONDITIONS .................................................................................................... 13
2.5 OPERATING CONDITIONS ............................................................................................................. 13
2.6 VOLTAGE AND FREQUENCY ......................................................................................................... 13
3 RECEIVING, HANDLING AND STORAGE ........................................................... 14
3.1 RECEIVING ..................................................................................................................................... 14
3.2 HANDLING ...................................................................................................................................... 14
3.2.1 Motor positioning ................................................................................................................................ 15
3.3 STORAGE ....................................................................................................................................... 15
3.3.1 Outdoor storage ................................................................................................................................. 15
3.3.2 Extended storage ............................................................................................................................... 15
3.3.2.1 Storage location .................................................................................................................. 15
3.3.2.1.1 Indoor storage ................................................................................................ 16
3.3.2.1.2 Outdoor storage ............................................................................................. 16
3.3.2.2 Separate parts .................................................................................................................... 16
3.3.3 Preservation during the storage ........................................................................................................... 16
3.3.3.1 Space heater ....................................................................................................................... 16
3.3.3.2 Insulation resistance ............................................................................................................ 16
3.3.3.3 Exposed machined surfaces ................................................................................................ 16
3.3.3.4 Sealing ................................................................................................................................ 16
3.3.3.5 Bearings .............................................................................................................................. 17
3.3.3.5.1 Grease-lubricated rolling bearing ..................................................................... 17
3.3.3.5.2 Oil-lubricated rolling bearing ............................................................................ 17
3.3.3.5.3 Sleeve bearing ................................................................................................ 17
3.3.3.6 Terminal boxes .................................................................................................................... 17
3.3.3.7 Air-water heat exchanger .................................................................................................... 18
3.3.3.8 Cleanliness and conservation of the motor during storage ................................................... 18
3.3.3.9 Inspections and records during storage ............................................................................... 18
3.3.3.10 Predictive / preventive maintenance..................................................................................... 18
3.3.3.11 Maintenance plan during storage ......................................................................................... 19
3.3.4 Preparation for commissioning ............................................................................................................ 20
3.3.4.1 Cleaning .............................................................................................................................. 20
3.3.4.2 Bearing inspection ............................................................................................................... 20
3.3.4.3 Bearing lubrication ............................................................................................................... 20
3.3.4.4 Insulation resistance verification ........................................................................................... 20
3.3.4.5 Air-water heat exchanger .................................................................................................... 20
3.3.4.6 Others ................................................................................................................................. 20
4 INSTALLATION ................................................................................................. 21
4.1 INSTALLATION SITE ....................................................................................................................... 21
4.2 SHAFT LOCK .................................................................................................................................. 21
4.2.1 Axial lock ............................................................................................................................................ 21
4.2.2 Radial lock .......................................................................................................................................... 21
4.2.3 Procedure for replacing the radial locking device ................................................................................. 21
4.3 ROTATION DIRECTION ................................................................................................................... 21
4.4 INSULATION RESISTANCE ............................................................................................................. 22
4.4.1 Safety Instructions .............................................................................................................................. 22
4.4.2 General considerations ....................................................................................................................... 22
4.4.3 Measurement on the stator windings................................................................................................... 22
4.4.4 Additional Information ......................................................................................................................... 22
4.4.5 Polarization Index ................................................................................................................................ 22
4.4.6 Conversion of the measured values ..................................................................................................... 23
4.4.7 Insulation assessment ......................................................................................................................... 23
4.5 PROTECTIONS ............................................................................................................................... 23
4.5.1 Thermal protections ............................................................................................................................ 23
4.5.1.1 Temperature limits for the windings ..................................................................................... 24
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4.5.1.2 Alarm and trip temperatures ............................................................................................... 24
4.5.1.3 Temperature and ohmic resistance of the PT100 thermoresistance .................................... 25
4.5.1.4 Space heater ...................................................................................................................... 25
4.5.2 Water leak sensor ...............................................................................................................................25
4.6 COOLING ....................................................................................................................................... 25
4.6.1 Air-water heat exchange cooling .........................................................................................................25
4.6.1.1 Radiators for application with seawater ............................................................................... 25
4.6.2 Independent ventilation cooling ...........................................................................................................26
4.7 ELECTRICAL ASPECTS ................................................................................................................. 26
4.7.1 Electrical connections .........................................................................................................................26
4.7.1.1 Main electrical connections ................................................................................................. 26
4.7.1.2 Grounding .......................................................................................................................... 26
4.7.2 Connection diagrams ..........................................................................................................................27
4.7.2.1 Connection diagrams according to IEC60034-8 ................................................................. 27
4.7.2.1.1 Stator connection diagrams ............................................................................27
4.7.2.2 Connection diagrams according to NEMA MG1 .................................................................. 28
4.7.2.2.1 Stator connection diagrams ............................................................................28
4.7.2.3 Rotation direction ............................................................................................................... 28
4.7.2.4 Accessory connection diagrams ......................................................................................... 28
4.8 MECHANICAL ASPECTS ............................................................................................................... 29
4.8.1 Base ...................................................................................................................................................29
4.8.2 Base loads ..........................................................................................................................................29
4.8.3 Motor mounting ..................................................................................................................................29
4.8.3.1 Motor with solid shaft and flange ........................................................................................ 29
4.8.3.2 Motor with hollow shaft and flange ...................................................................................... 29
4.8.4 Anchor plate set ..................................................................................................................................29
4.8.5 Natural frequency of the base ..............................................................................................................30
4.8.6 Leveling ..............................................................................................................................................30
4.8.7 Alignment ............................................................................................................................................30
4.8.8 Hollow shaft motor alignment ..............................................................................................................31
4.8.9 Doweling .............................................................................................................................................31
4.8.10 Couplings ...........................................................................................................................................31
4.8.10.1 Direct coupling ................................................................................................................... 32
4.8.10.2 Gear coupling ..................................................................................................................... 32
4.8.10.3 Belt drive ............................................................................................................................ 32
4.8.10.4 Coupling for hollow shaft motors ........................................................................................ 32
4.9 HYDRAULIC UNIT .......................................................................................................................... 32
5 STARTING ........................................................................................................ 33
5.1 DIRECT ON-LINE STARTING ......................................................................................................... 33
5.2 DIRECT ONLINE STARTING FREQUENCY ..................................................................................... 33
5.3 LOCKED ROTOR CURRENT .......................................................................................................... 33
5.4 STARTING WITH REDUCED CURRENT ......................................................................................... 33
6 COMMISSIONING ............................................................................................. 34
6.1 PRELIMINARY INSPECTION .......................................................................................................... 34
6.2 FIRST STARTING ........................................................................................................................... 34
6.2.1 Starting procedure ..............................................................................................................................34
6.3 OPERATION ................................................................................................................................... 35
6.3.1 General ...............................................................................................................................................35
6.3.2 Temperatures......................................................................................................................................35
6.3.3 Bearings .............................................................................................................................................35
6.3.3.1 High-pressure oil injection system ....................................................................................... 35
6.3.4 Radiators ............................................................................................................................................35
6.3.5 Vibration .............................................................................................................................................36
6.3.6 Shaft vibration limits ............................................................................................................................36
6.3.7 Shutdown ...........................................................................................................................................36
7 MAINTENANCE ................................................................................................. 37
7.1 GENERAL ....................................................................................................................................... 37
7.2 GENERAL CLEANING .................................................................................................................... 37
7.3 WINDING MAINTENANCE .............................................................................................................. 37
7.3.1 Winding inspection ..............................................................................................................................37
7.3.2 Winding cleaning .................................................................................................................................37
7.3.3 Inspections .........................................................................................................................................37
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7.3.4 Reimpregnation .................................................................................................................................. 37
7.3.5 Insulation Resistance .......................................................................................................................... 38
7.4 COOLING SYSTEM MAINTENANCE ............................................................................................... 38
7.5 RADIATOR MAINTENANCE ............................................................................................................ 38
7.6 VIBRATION...................................................................................................................................... 38
7.7 ANTI-REVERSION RATCHET MAINTENANCE ................................................................................ 38
7.8 SHAFT GROUNDING DEVICE ......................................................................................................... 38
7.9 BEARING MAINTENANCE .............................................................................................................. 39
7.9.1 Grease-lubricated rolling bearings ....................................................................................................... 39
7.9.1.1 Instructions for lubrication .................................................................................................... 39
7.9.1.2 Procedures for rolling bearing relubrication .......................................................................... 39
7.9.1.3 Rolling bearing relubrication with drawer device for grease removal ..................................... 39
7.9.1.4 Type and amount of grease ................................................................................................. 39
7.9.1.5 Alternative greases .............................................................................................................. 40
7.9.1.6 Procedure for changing the grease ...................................................................................... 41
7.9.1.7 Low temperature greases .................................................................................................... 41
7.9.1.8 Grease compatibility ............................................................................................................ 41
7.9.1.9 Disassembly – vertical bearings ........................................................................................... 41
7.9.1.9.1 Before disassembling ...................................................................................... 41
7.9.1.9.2 Lower bearing disassembly ............................................................................. 42
7.9.1.9.3 Upper bearing disassembly ............................................................................. 42
7.9.1.10 Bearing assembly ................................................................................................................ 42
7.9.2 Oil-lubricated rolling bearing ................................................................................................................ 42
7.9.2.1 Lubrication instructions........................................................................................................ 43
7.9.2.2 Oil type................................................................................................................................ 43
7.9.2.3 Oil change ........................................................................................................................... 43
7.9.2.4 Bearing operation ................................................................................................................ 43
7.9.2.5 Bearing disassembly ........................................................................................................... 44
7.9.2.6 Bearing assembly ................................................................................................................ 45
7.9.3 Rolling bearing replacement ................................................................................................................ 45
7.9.4 Sleeve bearings .................................................................................................................................. 45
7.9.4.1 Bearing data........................................................................................................................ 45
7.9.4.2 Bearing installation and operation ........................................................................................ 45
7.9.4.3 Cooling by water circulation ................................................................................................. 45
7.9.4.4 Oil change ........................................................................................................................... 45
7.9.4.5 Sealing ................................................................................................................................ 46
7.9.4.6 Sleeve bearing operation ..................................................................................................... 46
7.9.4.7 Sleeve bearing maintenance ................................................................................................ 46
7.9.4.8 Bearing disassembly and assembly ..................................................................................... 46
7.9.4.8.1 Thrust bearing (upper) ..................................................................................... 46
7.9.4.8.2 Guide bearing (lower) ...................................................................................... 47
7.9.5 Bearing protection .............................................................................................................................. 47
7.9.5.1 Protection settings .............................................................................................................. 47
7.9.5.2 Disassembly/assembly of the sleeve bearing temperature sensors ....................................... 47
8 MOTOR DISASSEMBLY AND ASSEMBLY .......................................................... 48
8.1 PARTS LIST .................................................................................................................................... 48
8.2 DISASSEMBLY ............................................................................................................................... 48
8.3 ASSEMBLY ..................................................................................................................................... 48
8.4 AIR-GAP MEASUREMENT .............................................................................................................. 48
8.5 TIGHTENING TORQUE ................................................................................................................... 49
8.6 SPARE PARTS ................................................................................................................................ 50
9 MAINTENANCE PLAN ....................................................................................... 51
10 ABNORMALITIES, CAUSES AND SOLUTIONS ................................................... 52
11 DECLARATION OF CONFORMITY ..................................................................... 54
12 ENVIRONMENTAL INFORMATION ..................................................................... 55
12.1 PACKAGE ....................................................................................................................................... 55
12.2 PRODUCT ....................................................................................................................................... 55
12.3 HAZARDOUS WASTE ..................................................................................................................... 55
13 SERVICE NETWORK ........................................................................................ 55
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14 WARRANTY TERM ............................................................................................ 56
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1 INTRODUCTION
This manual contains information regarding low and high-voltage, three-phase induction motors.
Motors with special features can be supplied with specific documents (drawings, connection diagram, characteristic curves
etc.). Those documents, together with this manual, must be thoroughly evaluated before proceeding with the installation,
operation or maintenance of the motor.
In order to use a frequency inverter, it is mandatory to follow the instructions contained in the specific technical
documentation of the motor and in the manual of the frequency inverter.
If any additional explanation about motors with major special features is necessary, consult WEG. All procedures and
standards contained in this manual must be observed in order to ensure proper operation of the motor and the safety of the
personnel involved in its operation. Following these procedures is also important to ensure the validity of the motor warranty.
Thus, we recommend the careful reading of this manual before the installation and operation of the motor. If any further
information is still necessary, consult WEG.
1.1 SAFETY WARNINGS IN THE MANUAL
In this manual, the following safety warnings are used:
DANGER
Failure to observe the procedures recommend in this warning may result in death, serious injuries and
extensive equipment damage.
ATTENTION
Failure to observe the procedures recommend in this warning may result in equipment damage.
NOTE
This provides important information for correct understanding and proper operation of the product.
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Thus, the operation with open terminal boxes,
ATTENTION
ATTENTION
2 GENERAL INSTRUCTIONS
All the personnel involved with the assembly, operation or maintenance of electrical installations must be permanently
informed and updated on the standards and safety instructions that guide the job and are advised to strictly comply with
them. Before beginning any job, the person in charge must make sure that all points have been duly observed and warn the
respective personnel about the danger inherent to the task to be performed.
Improper application, inadequate handled or maintenance of the motor, may cause serious injuries and/or material damages.
Therefore, it is highly recommended that these services be always performed by qualified personnel.
2.1 QUALIFIED PERSONNEL
The term qualified personnel means those who, because
of their training, experience, education level, and
knowledge of the applicable standards, specifications,
accident prevention, safety standards and operating
conditions, have been authorized by the persons in charge
to execute the necessary tasks, and who are able to
recognize and avoid any possible danger.
Such qualified personnel must also know and be able to
provide first aid procedures if necessary.
The entire start-up, maintenance and repair tasks must
only be performed by qualified personnel.
2.2 SAFETY INSTRUCTIONS
DANGER
During normal operation of this equipment, a
hazard associated with energized or rotating
components with high voltage or elevated
temperatures exists.
unprotected couplings, improper handling, or
failure to comply with the operating
standards, may cause severe personal
injuries and material damages.
When devices and equipment are used
outside the industrial environment, the user
must ensure the safety of the equipment by
adopting proper protection and safety
measures during installation (for example,
keep people away, avoid contact of children,
etc.).
Those responsible for the safety of the installation must
ensure that:
Only qualified personnel install and operate the
equipment;
They have this manual and all other documents
supplied with the motor at hand, as well as that they
perform the tasks in strict compliance with the service
instructions, relevant standards and specific product
documentation;
Qualified personnel must also observe:
All the technical data regarding the allowed applications
(operating conditions, connections and installation
environment), included in the catalog, in the purchase
order documents, in the operating instructions, in
manuals and all other documentation;
The specific regulations and conditions for the loca
l
installation;
The use of suitable tools and equipment for handling
and transportation;
That the protective devices of the individual
components are removed shortly before installation.
Individual parts must be stored in vibration-free
environments, avoiding falls and ensuring their protection
against aggressive agents and/or that they do not
jeopardize people.
2.3 STANDARDS
The motors are specified, designed, manufactured and
tested according to the standards described in Table 2.1.
The applicable standards are specified in the commercial
contract, which may indicate other national or international
standards, depending on the application or installation
location.
Specification IEC60034-1 / NBR 17094
Dimensions IEC60072 / NBR 15623 MG1-4,11
Tests IEC60034-2 / NBR 5383 MG1-12
Levels of
protection
Cooling IEC60034-6 / NBR IEC 60034-6 MG1-6
Mounting IEC60034-7 / NBR IEC 60034-7 MG1-4
Noise IEC60034-9 / NBR IEC 60034-9 MG1-9
Mechanical
Vibration
Terminal
marking
Mechanical
Tolerances
Balancing ISO1940 MG1-7
Table 2.1: Applicable standards
IEC60034-5 / NBR IEC 60034-5 MG1-5
IEC60034-14 / NBR IEC 60034-14 MG1-7
IEC / NBR NEMA
IEC60034-8 / NBR 15367 MG1-2
ISO286 / NBR6158 MG1-4
MG1-
1,10,20
Failure to comply with installation and safety
standards may void the product warranty.
Firefighting equipment and first aid notices
must be available in visible and easily
accessible locations at the work site.
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2.4 ENVIRONMENTAL CONDITIONS
ATTENTION
°C, antifreeze
The motor was designed according to the specific
environmental conditions (temperature and altitude) of
your application, and are described on the nameplate and
in the datasheet of the motor.
For the use of water-cooled motors in
ambient temperatures below +5
additives must be added to the water.
2.5 OPERATING CONDITIONS
In order for the product warranty to be valid, the motor
must be operated according to nominal data indicated on
its nameplate, observing all applicable standards and
information contained in this manual.
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2.6 VOLTAGE AND FREQUENCY
It is very important to ensure a proper power supply for
the motor. The conductors and the entire protection
system must ensure the quality of the power supply at the
motor terminals within the limits, in accordance with the
IEC60034-1 standard:
Voltage: may vary within a range of ±10% of the rated
value;
Frequency: may vary within a range of -5% to +3% of
the rated value.
Figure 2.1: Voltage and frequency variation limits
Figure 2.1 legend:
1. Voltage
2. Zone A
3. Frequency
4. Zone B (outside zone A)
5. Voltage with rated characteristics
The motor must be able to perform its main function
continuously in Zone A, but it may not fully meet its
performance characteristics at rated voltage and
frequency (refer to the point with rated characteristics in
Figure 2.1), when it may present some deviations. The
temperature rises may be above those at rated voltage
and frequency.
The motor must be able to perform its main function in
Zone B, but regarding the performance characteristics at
rated voltage and frequency, it may present deviations
greater than those of Zone A. The temperature rises may
be higher than those observed at rated voltage and
frequency, and they will most likely be higher than those in
Zone A.
Prolonged operation in the periphery of Zone B is not
recommended.
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ATTENTION
Any damage must be photographed,
documented and reported immediately to the
ATTENTION
Parts supplied in additional packages must be
lifting
ATTENTION
or transport the motor, the
Lifting equipment and devices must be able
3 RECEIVING, HANDLING AND STORAGE
3.1 RECEIVING
All motors were tested and are in perfect operating
conditions. The machined surfaces are protected against
corrosion. The package must be inspected upon receipt
for occasional damages during transportation.
3.2 HANDLING
Vertical motors must be handled as shown in Figure
3.1;
Use the motor top lifting lugs for vertical movements, so
that the lifting chains or cables are also in the vertical
position, avoiding too much stress on the lifting lugs.
carrier, the insurer and WEG. The noncommunication of this damage will void the
warranty.
checked upon receipt.
When lifting the package (or container), the proper
hoisting points, the weight indicated on the package or
on the nameplate and the operating capacity and
conditions of the hoisting equipment must be observed;
Motors packed in wooden crates must always be lifted
by their own lifting lugs or by a proper forklift; they must
never be lifted by the package;
The package can never be overturned. Place it on the
floor carefully (without impact) in order to avoid damage
to the bearing;
Do not remove the grease for protection against
corrosion from the shaft end, or the closing plugs
present in the terminal box holes. These protections
must remain in place until the moment of the final
assembly.
A complete visual inspection of the motor must be
arried out after removing the package;
c
The shaft locking system must be removed just before
the installation and stored to be used in future
transportation of the motor.
Figure 3.1: Motor handling
NOTES
Observe the indicated weight. Do not lift
the motor causing jolts or put it down
abruptly on the floor, because this can
cause damage to the bearings;
In order to lift the motor, use only the
lugs provided for that purpose. If
necessary, use a crossbeam to protect
parts of the motor.
The lifting lugs on the heat exchanger, end
shields, bearings, radiator, terminal box,
etc. are designed to handle these
components only separately;
Never use the shaft to lift the motor;
The frame lifting lugs are intended to lift
only the motor. Never use them to lift the
motor-driven machine set.
14 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
In order to move
shaft must be locked with the locking
device supplied with the motor.
to withstand the motor weight.
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3.2.1 Motor positioning
ATTENTIO
recommendations may cause damage to the
ATTENTION
Any damage to the paint
ATTENTION
To assure that the motor warranty be valid, it
Vertical motors are supplied with lifting lugs at the drive
end DE and non-drive end NDE.
Some motors are transported in the horizontal position
and need to be moved to the original position. Figure 3.2
shows how to move motors from the horizontal position to
the vertical position and vice versa.
Figure 3.2: Motor positioning
In order to position vertical motors, proceed according to
the following recommendations:
1. Lift the motor using the side lifting lugs and two
hoists;
2. Lower the motor drive end (DE) and lift the non-drive
end (NDE) at the same time until balance is reached;
3. Loosen the DE cables and turn the motor 180º in
order to enable the connection of these cables to the
other lifting lugs of the NDE;
4. Connect the loose cables to the NDE lifting lugs and
lift them until the motor reaches the vertical position.
Failure to comply with these
equipment, personal injuries or both.
N
3.3 STORAGE
If the Motor is not installed immediately after reception, it
must remain inside the package and stored in a location
protected against moisture, vapors, sudden changes in
temperature, rodents and insects.
The motor must be stored in vibration-free locations in
order to avoid bearing damage.
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Space heaters must remain powered during
storage in order to avoid moisture
condensation inside the motor.
protection of the machined parts must be
repaired.
or corrosion
3.3.1 Outdoor storage
The motor must be stored in a dry location, free of
flooding and vibrations.
Repair any damages on the package before storing the
motor, which is needed to ensure proper storage
conditions.
Place the motor on platforms or foundations that ensure
protection against humidity from the ground and prevent it
from sinking into the soil. Free air circulation underneath
the motor must be assured.
The cover used to protect the motor against the bad
weather must not be in contact with its surfaces. In order
to ensure free air circulation between the motor and such
covers, place wooden blocks as spacers.
3.3.2 Extended storage
When the motor is stored for a long period of time (two
months or more) before start-up, it is exposed to
external agents, such as temperature variations,
moisture, aggressive agents, etc.
The empty spaces inside the motor – such as rolling
bearings, terminal boxes, and windings – are exposed to
humidity, which can cause condensation, and,
depending on the degree of air contamination,
aggressive substances may also penetrate these empty
spaces.
Consequently, after long periods of storage, the winding
insulation resistance may drop below the acceptable
values, internal components, such as rolling bearings,
may oxidize, and the lubricant power of the lubricant
agent in the bearings may be adversely affected.
All of these influences increase the risk of damages
before starting the motor.
is necessary to make sure that all preventive
measures described in this manual, such as
constructive aspects, maintenance,
packaging, storage, and periodical
inspections, are followed and recorded.
The extended storage instructions are valid for motors
that remain stored for long periods (two months or more)
before start-up or motors already installed that are in a
prolonged stoppage, considering the same period.
3.3.2.1 Storage location
In order to ensure the best storage conditions for the
motor during long periods, the chosen location must
strictly meet the criteria described in sections 1.1.1.1.1
and 3.3.2.1.2.
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ATTENTION
ATTENTION
3.3.2.1.1 Indoor storage
In order to ensure better storage conditions for the motor,
the storage site must comply strictly with the criteria
described below:
The storage site must be closed, covered, dry, free of
air contaminants (moisture, vapor, dust, particles and
aggressive fumes) and free of flooding;
The site should be protected against sudden
temperature variations, humidity, rodents and insects;
Vibration-free location, to avoid damaging to the motor
bearings;
The floor must be of leveled concrete with resistant
structure to support the motor weight;
Must have system to fire detection and extinguishing;
Be provided with electricity for supplying the space
eaters with power failure detection system;
h
Exclusive site to store electrical machines (do not mix
with other equipment and/or products that could
prejudice the correct motor storage);
Site with facilities of cargo handling services, suitable to
allow the motor handling and removal;
There must be no gas present, such as chlorine, sulfur
dioxide or acids;
The site must have ventilation system with air filter;
Ambient temperature between 5°C and 50°C, and
should not present sudden temperature variation;
Relative air humidity <50%;
Must have prevention against dirt and dust deposition;
The motor should be stored on a suitable metal base
that prevents the absorption of moisture from the floor.
If any of these requirements is not met in the storage site,
WEG suggests that additional protections be added to the
motor package during the storage period, as follows:
A closed wooden crate or the like with an electrical
installation that allows the energization of the space
heaters;
If there is a risk of infestation and fungus formation, the
package must be protected in the storage place by
spraying it or painting it with appropriate chemicals;
The package preparation must be prepared carefully b
an experienced person.
y
3.3.2.1.2 Outdoor storage
Outdoor storage of the motor is not
recommended.
In case outdoor storage is unavoidable, the motor must be
packed in specific packaging for such conditions, as
follows:
For outdoor storage (exposed to the weather), besides
the packaging recommended for indoor storage, the
package must be covered with protection against dust,
moisture and other odd materials, using resistant
canvas or plastic.
The package must be placed on platforms or
foundations that ensure protection against dirt and
moisture and prevent it from sinking into the soil;
After the package is covered, a shelter must be erec
to protect it against direct rain, snow and excessive sun
heat.
ted
In case the motor remains stored for long
periods (two months or more), it is
recommended to inspect it regularly as
specified in the section
during storage
Maintenance plan
of this manual.
3.3.2.2 Separate parts
If parts are supplied separately (terminal boxes, heat
exchanger, end shields, etc.), these parts must be
mounted on motor to store it;
Spare parts must be stored in an adequate place, as
specified in sections
manual.
The relative humidity inside the package must not
exceed 50%.
Rolling bearings must not be subject to shocks, falls or
storage with vibration or humidity, which can cause
marks on the internal tracks or on the balls, reducing
their useful life.
1.1.1.1.1
and 3.3.2.1.2 of this
3.3.3 Preservation during the storage
3.3.3.1 Space heater
Space heaters must remain powered during storage to
avoid moisture condensation inside the motor and ensure
that the winding insulation resistance remains within
acceptable levels.
The space heaters drive circuit must be unique and the
voltage and current of this circuit must be measured and
recorded monthly.
It is recommended that a signal be installed near the
motor to indicate that the space heaters are energized.
3.3.3.2 Insulation resistance
During the storage period, the insulation resistance of the
motor windings must be measured and recorded every
two months, and before the motor installation or eventually
if there is any change in the preservation process (E.g.
prolonged lack of electricity).
The measurement procedures and the criteria for
acceptance of the results shall be according to IEEE-43
Standard.
Any insulation resistance reduction must be investigated.
3.3.3.3 Exposed machined surfaces
All exposed machined surfaces (e.g., shaft end and
flanges) are protected at the factory with a temporary
protective agent (rust inhibitor).
This protection coating must be reapplied at least every
six months or when removed and/or damaged.
Recommended Product:
Supplier
: Fuchs
Protective agent Anticorit BW
3.3.3.4 Sealing
The rubber seals, gaskets, plugs and cable glands of the
motor shall be inspected annually and replaced, if
necessary.
16 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
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3.3.3.5 Bearings
ATTENTION
complete turns
ATTENTION
complete turns
ATTENTION
The shaft
in the
ATTENTION
3.3.3.5.1 Grease-lubricated rolling bearing
The rolling bearings are lubricated at the factory for the
motor tests.
In order to keep the bearings in good
condition during the storage period,
shaft locking device must be removed
every two months, and the motor rotor
must be rotated at least 10
at 30 rpm
preserve the internal parts of the bearings.
Before putting the motor into operation, the
rolling bearings must be lubricated;
If the motor remains stored for a period
exceeding two years, the rolling bearings must
be disassembled, washed, inspected and
relubricated.
the
to circulate the grease and
3.3.3.5.2 Oil-lubricated rolling bearing
Depending on the motor mounting position and on the
lubrication type, the motor can be transported with or
without oil in the bearings;
The motor storage must be done in its original
operating position and with oil in the bearings, when
specified;
The oil level must be respected, remaining in the
middle of the sight glass.
In order to keep the bearings in good
condition during the storage period,
shaft-locking device must be removed
every two months, and the motor rotor
must be rotated at least 10
at 30 rpm
the internal parts of the bearings.
Before putting the motor into operation, the rolling
bearings must be relubricated.
If the motor remains stored for a period exceeding 2
years, the rolling bearings must be disassembled,
washed, inspected and relubricated.
the
to circulate the oil and preserve
3.3.3.5.3 Sleeve bearing
Depending on the machine mounting position and the
lubrication type, the machine can be transported with or
without oil in the bearings.
The machine storage must be done in its original
operating position and with oil in the bearings, when so
specified.
The oil level must be respected, remaining in the middle of
the sight glass.
In order to keep the bearings in good conditions during
the storage period, the following preservation procedures
must be performed:
Close all the threaded holes with plugs;
Check if all the flanges (e.g., oil inlet and outlet
closed. If not, they must be closed with blind covers;
) are
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The oil level must be respected, remaining in the mi
of the oil sight glass;
Every two months, the shaft-locking device must be
removed, and the motor rotor must be rotated at least 10
complete turns at 30 rpm to circulate the oil and preserve
the internal parts of the bearings.
If the motor has a radial locking device, used
for transport, it must be replaced according
to item 4.2.3, so that the motor shaft tuning
can be performed.
NOTES
For bearings that have a high-pressure oil
injection system (jacking), this system must
be activated before rotating the machine
rotor.
For bearings without oil tank (dry crankcase),
the oil circulation system must be activated
before rotating the machine shaft.
machine rotation direction.
After six months of storage, the following procedure must
be used for protecting both the bearing internally and the
contact surfaces against corrosion:
Close all the threaded holes with plugs;
Seal the gaps between the shaft and the bearing seal
on the shaft by applying water-proof adhesive tape;
Check if all the flanges (e.g., oil inlet and outlet) are
closed. If not, they must be closed with blind covers;
Remove the upper sight glass from the bearing and
apply the corrosion inhibitor spray (TECTYL 511 or
equivalent) inside the bearing;
Close the bearing with the upper sight glass.
ach six months of storage, repeat the procedure
E
described above.
If the storage period exceeds two years, the bearing oil
must be replaced.
rotation must always be done
ddle
3.3.3.6 Terminal boxes
When the insulation resistance of the motor windings is
measured, the main terminal box and the other terminal
boxes must also be inspected, observing the following
aspects:
The inside must be dry, clean and free of any dust
accumulation;
The contact elements cannot present corrosion;
The seals must be in proper condition;
The cable inlets must be correctly sealed.
If any of these items are not in proper
condition, proceeds the adequate
maintenance and, if necessary, replace
damaged parts.
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ATTENTION
The pressurized radiator
products, such as ammonia compounds and
3.3.3.7 Air-water heat exchanger
To ensure better conditions or the radiator storage for
long-term storage, the following criteria must be strictly
met:
Remove the flanged connections from the radiator to
gain access to it;
Drain the water inside the radiator tubes and heads
completely;
Blow hot air in one of the nozzles from 15 to 20 minutes
in order to eliminate humidity inside of radiator. For this
procedure, the radiator tubes shall be horizontally
placed, and the inlet and outlet water flanges placed in
such a way that the water are eliminated;
After dried, the nozzles shall be covered with blind
flanges with new sealing gaskets in order to assure a
perfect sealing;
Install a pressure gauge on one of the blind flanges
a globe valve on the other;
Pressurize the cooler with inert gas (Nitrogen or other)
at a pressure of 1.2 bar abs;
This pressure shall be checked monthly during the
radiator term storage, which shall not be exposed to
temperatures exceeding 50°C;
Considering that the storage procedure is followed, the
radiator seals must be replaced every 3 years, as
recommended by the radiator supplier.
with care. Use a warning plate informing that
the equipment is pressurized and should not
be exposed to temperatures exceeding
50°C.
must be handled
and
3.3.3.9 Inspections and records during storage
The stored motor must be inspected periodically and
inspection records must be filed.
The following items must be inspected:
1. Check the motor for physical damages and repair it, if
necessary;
2. Inspection of the cleanliness conditions;
3. Check for signs of water condensation inside the
motor;
4. Check of the protective coating conditions of the
exposed machined parts;
5. Check the paint conditions, and repair if necessary;
6. Check for aggressive agents signs;
7. Check the operation of the space heaters;
8. Measure and record the ambient temperature and
relative humidity around the motor;
9. Measure and record the temperature, insulation
resistance and polarization index of the stator winding;
10. Make sure that the storage location complies with the
criteria described in section 3.3.2.1.
3.3.3.10 Predictive / preventive maintenance
WEG recommends that, every 3 years of storage, the
stored motor be sent to a WEG Authorized Repair Shop or
to WEG own factory, in order to perform a complete
predictive maintenance.
The complete predictive maintenance procedure
comprises disassembling the complete motor for
inspection and, after assembly, performing a routine test in
the laboratory.
NOTE
During short operation stoppages, instead of
draining the water, it is preferable to keep its
circulation at low speeds through the heat
exchanger, thus ensuring that harmful
hydrogen sulfide, are taken out of the
radiator and not deposited inside.
3.3.3.8 Cleanliness and conservation of the motor during storage
The motor should be free of oil, water, dust and dirt.
The motor outside must be cleaned with compressed
air under reduced pressure;
Remove the removable rust signs with a clean cloth
soaked in petroleum solvent.
Check that the bearings and lubrication hollows are free
of dust and dirt and if the bearing plugs are properly
tightened.
Risks, marks or rust on the shaft-end should be carefully
removed.
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Inspect the humidity and temperature
Check the
function of the signal system (if
Check
the rust inhibitor
on the exposed
If the storage period
exceeds 2
If the storage period exceeds 2
3.3.3.11 Maintenance plan during storage
During the storage period, the motor maintenance must be performed and recorded according to the plan described in
Table 3.1.
Monthly
Inspect the cleanliness conditions
conditions
Inspect for insect infestation signs
Inspect for damage
Check the internal relative humidity
Replace the desiccant in the package (if any)
Check the operating conditions
Measure the circuit voltage and frequency
any)
Perform external cleaning
Check the painting conditions
machined parts
Reapply the rust inhibitor
Inspect the rubber seals and gaskets
Complete predictive maintenance
Measure the winding temperature
Measure the insulation resistance
Measure the polarization index
TERMINAL BOX AND GROUNDING TERMINALS
Clean the interior of the terminal boxes
Inspect the seals and gaskets
Rotate the shaft
Relubricate the bearing
Disassemble and clean the bearing
Rotate the shaft
Apply corrosion inhibitor spray
Clean the bearings
Change the oil
Table 3.1: Storage plan
2
months
STORAGE LOCATION
X
X
X
X
X
X
X
X
X
X
X
X
X
PACKAGE
SPACE HEATER
X
WHOLE MOTOR
WINDINGS
X
X
X
ROLLING BEARINGS
X
SLEEVE BEARINGS
X
6
months
Whenever necessary.
X
X
2
years
X
Before
start-up
X
X
X
X
X
X
X
X
X
According to section 3.3.3.10
years.
years.
Notes
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AT
The
3.3.4 Preparation for commissioning
3.3.4.1 Cleaning
The internal and external parts of the motor must be
free of oil, water, dust and dirt.
Remove the rust inhibitor from the exposed surfaces
with a cloth damped in a petroleum-based solvent;
Make sure that the bearings and cavities used for
lubrication are free of dirt and that the cavity plugs are
correctly sealed and tightened. Oxidation and marks on
the bearing seats and on the shaft must be carefully
removed.
3.3.4.2 Bearing inspection
TENTION
If the motor storage period exceeds six months,
the sleeve bearings must be disassembled,
inspected and cleaned, before starting the
motor operation.
sleeve bearings without oil tank (dry
crankcase), regardless of the motor storage
period, should necessarily be disassembled,
inspected and cleaned before starting the motor
operation.
Reassemble the sleeve bearings and carry out
lubrication.
Contact WEG to perform this procedure.
3.3.4.3 Bearing lubrication
Use the lubricant specified for bearing lubrication.
Information on the bearings and lubricants are indicated
on the bearing nameplates, and the lubrication must be
done as described in section 1.1 of this manual, always
considering the type of bearing.
3.3.4.4 Insulation resistance verification
Before putting the motor into operation, the insulation
resistance must be measured according to section 3.3.3.2
of this manual.
3.3.4.5 Air-water heat exchanger
When starting the motor, ensure that the water
circulates freely through the radiator;
The radiator bolts should be tightened with torques of
40 to 50Nm;
Make sure that there is no water leakage. Check the
radiator gaskets, and replace if necessary;
Check the heat exchanger sealing rubbers, and replace
them if necessary.
3.3.4.6 Others
Follow the other procedures described in section 6 of this
manual before putting the motor into operation.
20 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 21
4 INSTALLATION
ATTENTION
The
whenever the motor is removed from its base
The shaft end is protected at the factory with
ATTENTION
4.1 INSTALLATION SITE
Electric motors must be installed in easily accessible
places, allowing periodic inspections, on-site maintenance
and, if necessary, removal for external services.
The following environmental conditions must be ensured:
Clean and well-ventilated location;
The installation of other equipment or walls must not
block or hinder the motor ventilation;
The area around and above the motor must be
sufficient for maintenance or handling;
The environment must be in accordance with the motor
protection degree.
4.2 SHAFT LOCK
4.2.1 Axial lock
The motor leaves the factory with a lock on the shaft to
prevent damages to the bearings during transportation.
This lock must be removed prior to motor installation.
shaft-locking device must be installed
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4.2.3
Procedure for replacing the radial locking device
1. Remove the fastening screws from the locking device
on bearing cap;
2. Remove the screws that attach the two parts of the
split device;
3. Remove the locking device as show in Figure 4.2 ;
Figure 4.2: Radial locking device
4. Identify the external bearing seal, supplied loose;
5. Fit the seal on bearing, following the disassembling
reverse procedure of the locking device.
Radial locking device
(uncoupled) in order to prevent damages to
the bearings during transportation.
a temporary protective agent (rust inhibitor).
During the motor installation, it is necessary
to remove this product from the grounding
brush (if any) contact track on the shaft.
4.2.2 Radial lock
Depending on the bearing type, a locking device may be
installed in the upper bearing for radial shaft locking during
transportation. This device is identified on the motor with
an adhesive label, as shown in Figure 4.1.
Figure 4.1: Adhesive label
It is imperative that before starting the motor this device is
removed and replaced with the original bearing seal which
is supplied loose.
Figure 4.3: Bearing seal
NOTE
Store the radial locking device for use in
future transport of the motor.
4.3 ROTATION DIRECTION
The motor rotation direction is indicated by a plate affixed
to the frame on the drive end and in the motor specific
documentation.
Motors supplied with a single rotation
direction must not operate in the opposite
direction.
In order to operate the motor in the direction
opposite to the specified, consult WEG.
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In order to measure the insulation resistance,
The winding being tested must be connected
procedures may
ATTENTION
obtained in previous tests on the same motor
ATTENTION
After measuring the insulation resistance,
The testing voltage to measure the insulation
Vdc and for the other accessories, 100 Vdc.
4.4 INSULATION RESISTANCE
4.4.1 Safety Instructions
MΩ MΩ
DANGER
the motor must be turned off and stopped.
to the frame and grounded until all residual
electrostatic charges are removed.
Capacitors (if any) must also be grounded
before disconnecting and separating the
terminals to measure the insulation
resistance.
Failure to comply with these
result in personal injury.
4.4.2 General considerations
When the motor is not immediately put into operation, it
must be protected against moisture, high temperatures,
and dirt, thus avoiding impacts on the insulation
resistance.
The winding insulation resistance must be measured
before putting the motor into operation.
If the environment is too humid, the insulation resistance
must be measured periodically during storage. It is difficult
to establish fixed rules for the actual value of winding
insulation resistance, as it varies according to the
environmental conditions (temperature, humidity), machine
cleanliness conditions (dust, oil, grease, dirt) and quality
and condition of the insulating material used.
The evaluation of the periodical follow-up records is useful
to conclude whether the motor is able to operate.
4.4.3 Measurement on the stator windings
The insulation resistance must be measured with a
megohmmeter. The testing voltage for the motor
windings must be in accordance with Table 4.1 and
IEEE43 standard.
Table 4.1: Voltage for the winding Insulation resistance test
Winding rated
voltage (V)
< 1000 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
> 12000 5000 - 10000
Before measuring the stator winding insulation resistance:
Disconnect all connections to the stator terminals;
Disconnect and insulate all CTs and PTs (if any);
Ground the motor frame;
Measure the winding temperature;
Ground all temperature sensors;
Check the humidity.
The insulation resistance measurement of the stator
windings must be done in the main terminal box.
The megohmmeter must be connected between the
motor frame and the winding.
The frame must be grounded and the three phases of the
stator winding must remain connected to the neutral point,
according to Figure 4.4.
Insulation resistance test -
continuous voltage (V)
Figure 4.4: Megohmmeter connection
Whenever possible, each phase must be isolated and
tested separately. The separate test allows the
comparison between the phases. When a phase is tested,
the other two phases must be grounded to the same
ground of the frame, according to Figure 4.5
MΩ
Figure 4.5: Connection of the megohmmeter to separate
phases
.
If the total winding measurement presents a value below
the recommended, the neutral connections must be
opened and the insulation resistance of each phase must
be measured separately.
Much higher values may be frequently
obtained from motors in operation for long
periods of time. Comparison with values
- under similar load, temperature and
humidity conditions – may be an excellent
parameter to evaluate the winding insulation
conditions, instead of using the value
obtained in a single test as the basis.
Significant or sudden reductions are
considered suspicious.
4.4.4 Additional Information
ground the tested winding in order to
discharge it.
resistance of the space heater must be 500
It is not recommended to measure the
insulation resistance of thermal protectors.
4.4.5 Polarization Index
The polarization index is defined by the ratio between the
insulation resistance measured in 10 minutes and the
insulation resistance measured in 1 minute. This
measurement procedure is always carried out at relatively
constant temperatures.
22 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 23
The polarization index allows the assessment of the motor
In order to avoid accidents, the winding must
be grounded immediately after measuring the
ATTENTION
Winding t
emperatur
e ºC
insulation conditions.
DANGER
insulation resistance.
4.4.6 Conversion of the measured values
The insulation resistance must be referred at 40°C. If the
measurement is performed at a different temperature, it is
necessary to correct the reading to 40°C by using a curve
of the insulation resistance variation as a function of the
temperature, obtained at the motor itself. If this curve is
not available, the approximate correction provided by the
curve in Figure 4.6, according to NBR 5383 / IEEE43
standard, may be used.
40ºC
Coefficient of insulation resistance variation Kt
To convert the insulation resistance
measured (Rt) for 40 ºC, multiply by the
temperature coefficient (Kt)
R
= Rt x Kt
40ºC
Figure 4.6: Insulation resistance variation coefficient according
to the temperature
40ºC
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4.4.7 Insulation assessment
Table 4.2 and Table 4.3 present guiding limits of insulation
resistance and polarization index for the assessment of
the motor insulation conditions.
Table 4.2: Insulation resistance guiding limits on electrical
Insulation resistance value Insulation assessment
2 MΩ or lower
< 50 MΩ Dangerous
50...100 MΩ Fair
100...500 MΩ
500...1000 MΩ
> 1000 MΩ Excellent
machines
Unacceptable
Good
Very Good
Table 4.3: Polarization index (ratio between 10 minutes and 1
Polarization Index Insulation assessment
1 or lower Unacceptable
< 1.5 Dangerous
1.5 to 2.0 Fair
2.0 to 3.0 Good
3.0 to 4.0 Very Good
> 4.0 Excellent
minute)
If the measured insulation resistance,
referred to 40 ºC, is below 100 MΩ or the
polarization index is below 2, than before
putting the motor into operation, consult
WEG.
4.5 PROTECTIONS
Motors used in continuous duty must be protected
against overloads by means of a motor integral device, or
an independent protection device, which is generally a
thermal relay with rated or adjustable current equal to or
below the value obtained by multiplying the full load motor
supply current by:
1.25 for motors with service factor equal to or above
1.15;
1.15 for motors with service factor equal to 1.0.
Motors also have protection devices against overheating
(in cases of overloads, locked rotor, low voltage, lack of
motor ventilation).
4.5.1 Thermal protections
The over-temperature protections devices are installed on
the main stator, bearings and other parts that require
temperature monitoring and thermal protection.
These sensors must be connected to an external
temperature monitoring and protection system.
The type of temperature sensor, the connection terminals
and the setting temperatures for alarm and shutdown are
given in the motor CONNECTION DIAGRAM.
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B
Ambient temperature
°C 40 40 40
T = temperature rise (temperature
Difference between the hottest spot
Total: temperature of the hottest point
°C
130 155 180
ATTENTION
Temperature rise
Class B
120 130
Class F
130 155
Winding
- class H
Class H
155 180
Bearings
-
110 120
ATTENTION
The
values may be determined
ATTENTION
The motor protection devices are listed
in the
4.5.1.1 Temperature limits for the windings
The temperature of the hottest spot of the winding must
be kept below the limit of the insulation thermal class. The
total temperature is obtained by the sum of the ambient
temperature and the temperature rise (T), plus the
difference between the average temperature of the
winding and the hottest spot of the winding.
The ambient temperature must not exceed 40 °C, in
accordance with NBR IEC60034-1 standard. Above this
temperature, the working conditions are considered
special and the motor specific documentation must be
consulted.
Table 4.4 shows the numerical values and the
composition of the acceptable temperature at the hottest
spot on the winding.
Table 4.4: Insulation class
Insulation class
F H
4.5.1.2 Alarm and trip temperatures
The motor alarm and trip temperatures must be set at the
lowest possible value. These temperatures can be
determined based on the factory tests or through the
motor operating temperature. The alarm temperature can
be set 10 ºC above the machine operating temperature at
full load, always considering the highest ambient
temperature on site. The adjusted trip temperatures must
not exceed the maximum admissible temperatures for the
stator winding insulation class and for the bearings
(considering the lubrication type and system), according
to Table 4.5.
Winding - class F
Table 4.5: Maximum temperature settings
(∆t)
Maximum temperature
Alarm Trip
(ºC)
measurement method by resistance
variation)
and the average temperature
If the motor operates with winding
temperatures above the limits of the
insulation thermal class, the lifespan of the
insulation, and hence that of the motor, will
be significantly reduced, or it may even result
in the motor burnout.
°C 80 105 125
°C 10 10 15
alarm and trip
as a result of experience, but they must not
exceed the values indicated in Table 4.5.
WEG drawing – Connection diagram.
Not using these devices is the sole
responsibility of the user and, in case of
damage to the motor, it will void the
warranty.
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ATTENTION
The protection devices of the cooling system
The
. For further details, refer to the
ATTENTION
This data must be observed for the proper
ATTENTION
4.5.1.3 Temperature and ohmic resistance of the PT100 thermoresistance
Table 4.6 shows the temperature as a function of the ohmic resistance measured across PT100 RTDs.
Table 4.6: Temperature X Resistance (Pt100)
º C 0 1 2 3 4 5 6 7 8 9
0
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120
130
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
Formula: Ω - 100 = °C
0.386
4.5.1.4 Space heater
When the motor is equipped with a space heater to
prevent internal water condensation during long periods
out of operation, it must be assured that the space heater
is energized shortly after turning the motor off, and that it
is de-energized before the motor is put into operation.
The values of the space heater supply voltage and power
are informed in the connection diagram and in the specific
plate affixed to the motor.
4.5.2 Water leak sensor
Motors with air-water heat exchangers are supplied with a
water leak sensor intended to detect accidental water
leaks from the radiator into the motor. This sensor must
be connected to the control panel, according to the motor
connection diagram. The signal of this sensor must be
used to activate the alarm.
When this protection actuates, the heat exchanger must
be inspected and, if any water leak is detected, the motor
must be shut down and the problem corrected.
4.6 COOLING
The motor cooling system type may vary according to its
application.
Only the correct installation of the motor and of the cooling
system can ensure its continuous operation without
overheating.
4.6.1 Air-water heat exchange cooling
In motors with air-water heat exchanger, the internal air, in
a closed circuit, is cooled by the radiator, which is a
surface heat transmitter designed to dissipate heat.
Clean water with the following characteristics must be
used as coolant:
pH: 6 to 9;
Chlorides: maximum 25.0 mg/l;
Sulphates: maximum 3.0 mg/l;
Manganese: maximum 0.5 mg/l;
Suspended solids: maximum 30.0 mg/l;
Ammonia: without ammonia dashes.
4.6.1.1 Radiators for application with seawater
(if any) must be monitored periodically.
air and/or water inlets and outlets (if any)
must not be obstructed, because this could
cause overheating and even lead to the
motor burnout
motor dimensional drawing.
Data of the radiators that compose the airwater heat exchanger are informed on their
nameplate and on the motor dimensional
drawing.
operation of the motor cooling system, thus
preventing overheating.
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In the case of
radiator
s for applications with
The
ATTENTION
Analyze
The
ATTENTION
ATTENTION
Sacrificial a
nodes
seawater, the materials in contact with the
water (pipes and plates) must be corrosion
resistant. Furthermore, the radiators may be
fitted with sacrificial anodes (e.g., zinc or
magnesium), as shown in Figure 4.7, which
are corroded during the heat exchanger
operation, protecting the radiator heads.
In order to maintain the integrity of the
radiator heads, these anodes must be
replaced periodically according to their
corrosion level.
Figure 4.7: Radiator with sacrificial anodes
NOTE
type, quantity and position of the
sacrificial anodes may vary according to the
application.
4.6.2 Independent ventilation cooling
The
independent fans
asynchronous motors with integral terminal boxes. The
characteristic data (frequency, voltage, etc.) are on the
nameplate of these motors, and the rotation direction is
indicated by a plate affixed to the fan housing or close to
it.
The
air filters
the motor, must be regularly inspected according to the
section “Maintenance Plan” of this manual. The filters must
be in perfect condition to ensure the correct operation of
the cooling system and the continuous protection of the
motor sensitive internal parts.
NOTE
It is necessary to check the rotation direction
of the independent ventilation motors before
putting them into operation.
If the rotation direction is opposite to the
specified, invert the connection of two of
their power supply phases.
(if any), which prevent the ingress of dirt into
are driven by three-phase
4.7 ELECTRICAL ASPECTS
4.7.1 Electrical connections
supplied with the motor carefully before
beginning the connection of the main cables
and those of the accessories. For the
electrical connection of auxiliary equipment,
refer to their specific manuals.
4.7.1.1 Main electrical connections
The location of stator terminal box is identified in the
specific motor DIMENSIONAL DRAWING.
The location of stator terminal box is identified in the
specific motor DIMENSIONAL DRAWING.
Make sure the cross section and insulation of the main
connection cables are suitable for the motor current and
voltage. The motor must rotate in the rotation direction
specified on the nameplate and on the sign arrow affixed
to the motor drive end.
NOTE
rotation direction is, by convention,
determined looking to the shaft end at the
motor drive end.
Motors with a single rotation direction must
only rotate in the indicated direction.
In order to operate the motor in the rotation
direction opposite to the specified, consult
WEG.
Before making the connections between the
motor and the power supply, it is necessary
to perform a careful measurement of the
winding insulation resistance.
In order to connect the motor main power supply cables,
unscrew the cover of the stator terminal box, cut the
sealing rings (standard motors without cable gland)
according to the diameter of the cables to be used and
insert the cables in the sealing rings. Cut the power supply
cables to the necessary length, strip the ends and mount
the cable lugs that will be used.
4.7.1.2 Grounding
The motor frame and the main terminal box must be
grounded before connecting the motor to the supply
system. Connect the metallic sheath of the cables (if any)
to the common grounding conductor. Cut the grounding
conductor to the proper length and connect it to the
terminal in the terminal box and/or on the frame.
Fasten all connections firmly.
the electrical connection diagram
26 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Do not use washers made of steel or other
materials with low electrical conductivity to
fasten the cable lugs.
Page 27
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3 TERMINALS
6 TERMINALS
6 TERMINALS
- DAHLANDER
3 TERMINALS +
9 TERMINALS
12
TERMINALS
4.7.2 Connection diagrams
4.7.2.1 Connection diagrams according to IEC60034-8
The following connection diagrams show the terminal identification in the terminal box and the possible connections for the
motors.
4.7.2.1.1 Stator connection diagrams
NEUTRAL
ΔΔ
Δ
12 TERMINALS -
Δ Y
YY
LOWER SPEED
(part winding)
Δ
Y
YY
HIGHER
SPEED
ΔΔ
Y
LOWER SPEED
YY
YY
LOWER
SPEED
Δ
Δ
HIGHER
SPEED
Y
FOR Y START
FOR Δ START
Y FOR START
ONLY
FOR RATED SPEED
NOTE
When two or more motor connecting cables are used in parallel in order
to divide the electric current, the identification of these cables is made
with an additional suffix separated by a hyphen, according to
Figure
4.8.
Figure 4.8: Parallel connections
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3 TERMINALS
6 TERMINALS
6 TERMINALS
- DAHLANDER
3 TERMINALS +
9 TERMINALS
12 TERMINALS
ΔΔ
Δ
YY
Y
ΔΔ
YY Δ Y
4.7.2.2 Connection diagrams according to NEMA MG1
4.7.2.2.1 Stator connection diagrams
NEUTRAL
FOR Y START
Δ Y
12 TERMINALS -
FOR Δ START
(part winding)
Y FOR START
ONLY
Δ
LOWER SPEED
FOR RATED SPEED
YY
HIGHER
SPEED
Y
LOWER
SPEED
YY
LOWER
SPEED
Δ
HIGHER
SPEED
NOTE
When two or more motor connecting cables are used in parallel in
order to divide the electric current, the identification of these cables is
made with an additional suffix separated by a hyphen, according to
Figure
4.9.
4.7.2.3 Rotation direction
The rotation direction is indicated on the nameplate and must be observed looking to the shaft end at the motor drive
end. The rotation direction must be checked before coupling the motor to the driven machine;
Motors with terminal identification and connections as described in this manual have clockwise rotation direction,
according to IEC60034-8 standard;
In order to invert the rotation direction, it is necessary to swap any two phases;
Motors with a single rotation direction, as indicated on the nameplate and on sign plate affixed to the frame, have
unidirectional fan and must be operated only in the specified rotation direction. In order to invert the rotation direction of
unidirectional motors, consult WEG.
4.7.2.4 Accessory connection diagrams
For the correct installation of the accessories, refer to the drawing in the specific CONNECTION DIAGRAM of the motor.
Figure 4.9: Parallel connections
28 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 29
4.8 MECHANICAL ASPECTS
ATTENTION
Place shims of different thicknesses between
The user is responsible for dimensioning and
ATTENTION
The user is
except when
4.8.1 Base
The base or structure where the motor will be installed
must be sufficiently rigid, flat, free of external vibration
and capable to withstand the mechanical loads to
which it will be submitted;
If the dimensioning of the base is not carefully executed,
this may cause vibration in the base, on the motor and
the driven machine;
The base structural design must be done based on the
dimensional drawing, on the information about
foundation mechanical loads, and on the motor
anchoring method.
the motor supporting surfaces and the base
in order to allow a precise alignment.
NOTE
building the foundation where the motor will
be installed.
4.8.2 Base loads
The foundation loads are informed in the motor
documentation.
4.8.3 Motor mounting
Mount the motor securely, and align it correctly with the
driven machine, according to the mounting types
described next:
1.
Motor mounted directly on the driven machine:
two units must be firmly coupled, and the driven
machine must be installed on a proper base;
2.
Motor mounted on a metal base:
rigid enough and free of vibration.
Improper mounting can generate excessive
vibration, causing early wear of the bearings
and even breaking the shaft.
4.8.3.1 Motor with solid shaft and flange
In order to mount the motor on the driven machine,
proceed as follows:
1. Lift the motor by the upper lifting lugs, and rotate it to
position the grease fittings, pipes and terminal boxes
properly;
2. Clean the flanges to be coupled;
3. Remove the motor shaft locking device;
4. Move the motor towards the driven machine, fitting
the motor flange on the machine flange;
5. Insert the bolts for fixing the flanges and tighten them
with adequate torque;
6. Couple the motor shaft to the driven machine;
7. Rotate the shaft of the set to ensure that it rotates
freely:
the
The base must be
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8. Align the equipment according to the procedure
described in this manual;
9. Tighten all the fastening bolts of the flanges, avoiding
their bending or loosening;
10. Rotate the shaft of the set again.
4.8.3.2 Motor with hollow shaft and flange
First the motor must be fastened to its base and the
driven machine shaft inserted through the motor hollow
shaft.
In some cases, it may be necessary that the motors be
lifted and lowered onto the driven machine shaft.
Those procedures must be done with the necessary
precautions in order to avoid damaging the motor shaft or
the driven machine shaft.
Proceed as follows:
. Remove the protection cover of the upper coupling,
1
and lift the motor with the hoist to install it on the
base;
2. Lower the motor slowly and carefully, fitting it on the
base;
3. Position the motor in order to allow access to the
terminal boxes and for the lubrication of the bearings.
Install the fastening bolts and tighten them;
4. Insert the pump shaft into the motor hollow shaft;
5. Align the motor shaft with the driven machine shaft,
according to the procedure described in this manual;
6. Fasten the pump shaft to the coupling and adjust the
fastening nut of the pump shaft;
7. Rotate the shaft manually to make sure it rotates
freely and that the shafts are perfectly aligned, always
observing the rotation direction of the anti-reversion
ratchet (if any);
8. After aligning, tighten all the flange bolts evenly;
9. Rotate the shaft again manually to make sure it
rotates freely.
10. Reinstall the cover of the upper coupling.
4.8.4 Anchor plate set
The anchor plate set, when used, is composed of the
anchor plate, leveling bolts, leveling shims, alignment bolts
and anchor bolts.
NOTES
When WEG supplies the anchor plate for
fastening and aligning the motor, the
dimensional and installation details of the
anchor plate are supplied in the specific
dimensional drawing of the motor.
responsible for mounting, leveling
and grouting the anchor plates (
otherwise specified by commercial
agreement).
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Dry tightening
Tightening torque with
M30 710 470
M36 1230 820
M42 1970 1300
M48 2960 1950
ATTENTION
At least 75% of the
ATTENTION
Paral
lel misalignment
Radial measurement
The anchor bolts must be fastened according to Table
4.7.
Table 4.7: Tightening torque of the anchor bolts
Type Ø
torque [Nm]
Molycote [Nm]
4.8.7 Alignment
The motor must be correctly aligned with the driven
machine.
Incorrect alignment can damage the
bearings, generate excessive vibration and
After positioning the motor, perform the final leveling
using the vertical leveling bolts and the leveling shims.
Protect all the threaded holes to prevent
The alignment must be done according to the coupling
manufacturer recommendations.
The motor and driven machine shafts must be aligned in
the axial and radial directions, as shown in Figure 4.10
and Figure 4.11.
even break the shaft.
grout from penetrating the threads during
the grouting of the anchor plate and anchor
bolts.
4.8.5 Natural frequency of the base
In order to ensure a safe operation, the motor must be
precisely aligned with the coupled equipment and both
must be properly balanced.
As a requirement, the motor installation base must be flat
and meet the requirements of DIN 4024-1 standard.
In order to verify if the criteria of the standard are being
met, the following potential vibration excitation
frequencies generated by the motor and coupled
machine must be checked:
The motor rotation frequency;
The double of the rotation frequency;
The double of the motor electric frequency.
According to DIN 4024-1 standard, the natural
frequencies of the base or foundation must be away from
these potential excitation frequencies, as specified next:
The first natural frequency of the base or foundatio
n
(first order natural frequency of the base) must be out
of the range from 0.8 to 1.25 times any of the potential
excitation frequencies above;
The other natural frequencies of the base or foundation
must be out of the range from 0.9 to 1.1 times any of
the potential excitation frequencies above.
4.8.6
Leveling
The motor must rest on a surface with flatness of up to
0.08 mm/m.
Verify whether the motor is perfectly leveled, both in the
vertical and horizontal planes. Make the proper
adjustments by placing shims under the motor. The
motor leveling must be checked with proper equipment.
Figure 4.10 shows the parallel misalignment of the two
shaft ends and the practical way to measure it by using
suitable dial gauges.
The measurement is performed in four points 90° away
from each other with the two half-couplings rotating
together in order to eliminate effects of support surface
irregularities on the dial gauge tip. Choosing the upper
vertical point as 0°, half of the difference between the dial
gauge measurements at the 0° and 180° points
represents the vertical coaxial error. In case of deviation,
it must be corrected by adding or removing leveling
shims. Half of the difference between the dial gauge
measurements at the 90º and 270º points represents the
horizontal coaxial error.
These measurements indicate when it is necessary to lift
or lower the motor, or move it to the right or to the left on
the drive end in order to eliminate the coaxial error.
Half of the maximum difference among the dial gauge
measurements in a complete rotation represents the
maximum eccentricity found.
The misalignment in a complete shaft rotation, with rigid
NOTE
motor foot support
surfaces must rest on the motor base.
or semiflexible coupling, cannot exceed 0.03 mm.
When flexible couplings are used, greater values than
those indicated above are acceptable, provided that they
do not exceed the value allowed by the coupling
manufacturer.
It is recommended to keep a safety margin for these
values.
30 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Figure 4.10: Parallel alignment
Page 31
Angular
misalignment
1
2
3
4
5
6
Axial measurement
Figure 4.11: Angular alignment
Figure 4.11 shows the angular misalignment and a
practical form to measure it.
The measurement is done in four points 90° away from
each other, with the two half-couplings rotating together
in order to eliminate effects of support surface
irregularities on the dial gauge tip. Choosing the upper
vertical point as 0°, half of the difference between the dial
gauge measurements at the 0° and 180° points
represents the vertical misalignment. In case of deviation,
it must be corrected by adding or removing alignment
shims.
Half the difference between the dial gauge measurements
at the 90° and 270° points represents the horizontal
misalignment, which must be properly corrected by
displacing the motor in the lateral/angular direction.
Half of the maximum difference among the dial gauge
measurements in a complete rotation represents the
maximum angular misalignment found.
The misalignment in a complete shaft rotation, with rigid
or semi flexible coupling, cannot exceed 0.03 mm.
When flexible couplings are used, greater values than
those indicated above are acceptable, provided that they
do not exceed the value allowed by the coupling
manufacturer.
It is recommended to keep a safety margin for these
values.
the
In the alignment/leveling, the influence of
temperature on the motor and the driven machine must
be taken into account. Different expansions of the parts
may change the alignment/leveling conditions during
operation.
4.8.8 Hollow shaft motor alignment
Motors with hollow shaft require an exact alignment of
the motor shaft with the driven machine shaft. The pump
shaft works as a pendulum supported by the upper
coupling and the motor bearing.
1. Fix the dial gauge by its magnetic base to the pump
shaft and align it with the base surface (motor shaft),
setting the dial gauge to zero (Figure 4.12);
2. Remove the upper cover and rotate both motor and
pump shafts;
3. Read the dial gauge at 90 degrees from the starting
point;
4. An acceptable alignment occurs when the dial gauge
reading does not exceed 0.05 mm;
5. Use shims between the motor flange surface and the
base to correct the alignment, if necessary.
Small misalignments can be corrected by inserting shims
between the faces of the motor and driven machine
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flanges. These shims can also compensate flanges that
are not flat.
Figure 4.12: Alignment of motors with hollow shaft
Figure 4.12 legend:
1. Upper bearing
2. Lower guide bearing
3. Dial gauge
4. Motor hollow shaft
5. Flange
6. Pump shaft
4.8.9 Doweling
After aligning the set and having assured a perfect
alignment (both, hot and cold), the motor must be
doweled to the anchor plate or to the base, as shown in
Figure 4.13.
Figure 4.13 legend:
1. Dowel pin (optional supply)
2. Nut (optional supply)
3. Washer (optional supply)
4.8.10 Couplings
Only proper couplings, which convey only torque without
generating transversal forces, must be used.
For both flexible and rigid couplings, the shaft centers of
the coupled machines must be in a single line.
Flexible couplings mitigate the effects of residual
misalignments and prevent transmission of vibration
between the coupled machines, which does not occur
when rigid couplings are used.
The coupling must be mounted or removed with the aid
of proper devices and never by means of rudimentary
tools, such as hammers, sledgehammers, etc.
Figure 4.13: Dowel pin set
NOTE
For the doweling, the motor has a pre-hole
with Ø9 mm, which must be first expanded
to Ø11.5 mm, and then reamed to Ø12 mm
with a taper of 1:50.
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ATTENTION
ins, nuts, washers and leveling shims
The user is responsible for the motor
ATTENTION
A
ATTENTION
Always use properly balanced pulleys.
Corre
ct
Incorre
ct
Dowel p
may be supplied with the motor, when
requested in the purchase order.
NOTES
4.8.10.3 Belt drive
Incorrect
installation (unless otherwise specified by
commercial agreement).
WEG is not liable for damages to the motor,
associated equipment and installation
occurred because of:
Transmission of excessive vibration;
Poor installations;
Faulty alignment;
Improper storage conditions;
Noncompliance with the instructions
before start-up;
Incorrect electrical connections.
4.8.10.1 Direct coupling
Because of issues about cost, space economy, problems
with belt sliding and more safety against accidents, direct
coupling must be used whenever possible. Also, direct
coupling is preferable in case of transmission with
reduction gearing.
lign the shaft ends carefully, and, whenever
possible, use flexible coupling, leaving a
minimum clearance (E) of 3 mm between the
couplings, as shown in Figure 4.14.
Figure 4.15: Belt drive
When a reduction or increase in speed is required, the
belt transmission is the most indicated.
In order to avoid unnecessary stress on the bearings, the
shafts and the pulleys must be perfectly aligned.
Belts that operate obliquely transmit alternating jolts to
the rotor and will be able to damage the bearings.
Belt slippage can be prevented by applying a resin like
material, such as pitch for instance.
The belt tension must be just enough to prevent slippage
during operation.
Avoid using too small pulleys, since they cause flexion of
the motor shaft because of the belt traction force that,
which increases as the diameter of the pulley decreases.
NOTE
Belts too tensioned increase the load on the
shaft end, causing vibration and fatigue, or
even the break of the shaft.
Consult WEG for the correct sizing of the
pulley.
Figure 4.14: Axial clearance of the coupling (E)
4.8.10.2 Gear coupling
Gear couplings badly aligned generate vibration in the
transmission itself and in the motor. Therefore, caution
must be taken so that the shafts be perfectly aligned,
rigorously parallel in case of spur gear transmissions and
in a correct angle in case of transmissions by bevel or
helical gears.
The gear teeth meshing can be controlled with the
insertion of a paper strip, on which the trace of all teeth
shows up after a gear turn.
NOTE
Avoid
extra key lengths, because they increase the
unbalancing mass and increase the motor
vibration.
4.8.10.4 Coupling for hollow shaft motors
Vertical hollow shaft motors are generally designed to
drive deep water pumps or turbine pumps. The type of
coupling is specified by the manufacturer of the pump
according to the application. Remove the motor top
cover to access the coupling.
4.9 HYDRAULIC UNIT
For further information on installation, operation and
maintenance of the hydraulic unit (if any), refer to the
motor dimensional drawing and the specific manual of
this equipment.
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Page 33
5 STARTING
5.1 DIRECT ON-LINE STARTING
It is the simplest and most economically feasible method;
however, it must only be used when the starting current
does not affect the power grid.
Bear in mind that the starting current of motors may reach
6 to 7 times the rated current value. Therefore, it must be
ensured that this current (Ip) will not affect the supply of
other consumers because of the high voltage drop in the
power grid.
This requirement is met in one of the three situations:
a) When the power grid is "strong" enough and the
motor current is negligible in relation to the grid
capacity.
b) The motor is always started without load, which
reduces the starting time and, in turn, the duration of
the starting current and the momentary voltage drop,
which is acceptable for the other consumers of the
grid;
c) When DOL starting is duly authorized by the local
electric utility company.
When the motor starting current is high, the following
detrimental consequences may occur:
a) The high voltage drop in the power supply system may
cause interference in equipment installed in this
system;
b) The protection system (cables, contactors) must be
oversized, increasing the installation costs.
NOTE
In some cases, there is an imposition of the
electric utility companies that limits the
voltage drop of the grid.
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5.2 DIRECT ONLINE STARTING
FREQUENCY
Since induction motors have a high starting current, the
time spent to accelerate loads with high inertia results in a
quick rise of the motor temperature. If the intervals
between successive starts are too short, the temperature
of the windings will rise quickly, reducing their useful life or
even burning them. The NBR 17094 and IEC60034-1
standards establishes a minimum starting duty to which
the motors must be able to comply:
a) Two successive starts: the first one with the motor
cold, i.e., with its windings at ambient temperature,
and the second one right afterwards, but only after
the motor has decelerated to a full stop;
b) One start with the motor hot, i.e., with the windings at
continuous duty temperature.
The first condition simulates the case in which the first
motor start is aborted, for instance, by the trip of the
motor protection, when a second motor start is permitted
right afterwards.
The second condition simulates the case of an accidental
motor shutdown under normal operation, for instance, by
power outage, when the motor restart is allowed right after
the power is reestablished.
NOTE
Special starting conditions must be checked
in the specific motor documentation before
starting the procedure.
5.3 LOCKED ROTOR CURRENT
The motor nameplate indicates the value of I
the relation between the starting current and the rated
current of the motor.
, which is
P/In
5.4 STARTING WITH REDUCED
CURRENT
If direct online starting is not possible, the following
starting systems can be used in order to reduce the motor
starting current.
Star-delta starter;
Series-parallel starter;
Autotransformer starter;
Static starter or soft-starter;
Frequency inverter.
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ATTENTION
ATTENTION
6 COMMISSIONING
When the motor is started for the first time or after a prolonged standstill, several aspects must be considered besides the
regular operation procedures.
Avoid any contact with electric circuits;
Even low-voltage circuits may be life threatening;
In any electromagnetic circuit, overvoltages may occur under certain operating conditions;
Do not open an electromagnetic circuit suddenly, because the presence of an inductive discharge voltage
may break the insulation or injure the operator;
In order to open those circuits, disconnect switches or circuit breakers must be used.
6.1 PRELIMINARY INSPECTION
Before the first motor start or after long periods out of
operation, the following items must be inspected:
1. Check if all the motor fastening bolts are tightened;
2. Measure the winding insulation resistances , making
sure they are within the specified values;
3. Check if the motor is clean and if the packages,
measuring instruments and alignment devices were
removed from the motor operating area;
4. Check if coupling connecting components are in
perfect operating conditions, duly tightened and
greased, where necessary;
5. Check if the motor is correctly aligned;
6. Check if the bearings are properly lubricated. The
lubricant must be of the type specified on the
nameplate;
7. Check the oil level of oil-lubricated bearings. Bearings
with forced lubrication must have the oil pressure and
flow as specified on their nameplate;
8. Inspect the cable connections of accessories (thermal
protectors, grounding, space heaters, etc.);
9. Check if all electrical connections comply with the
motor connection diagram;
10. Check if the motor is properly grounded;
11. The cables connected to the stator and rotor main
terminals must be properly tightened in order to
prevent their short-circuit or loosening;
12. Inspect the cooling system. In water-cooled motors,
inspect the operation of the radiator water supply
system. In motors with independent ventilation, check
the rotation direction of the fans;
13. Motor air inlets and outlets (if any) must be
unobstructed;
14. The moving parts of the motor must be protected to
prevent accidents;
15. The terminal box covers must be correctly fastened;
16. Check if the power supply voltage and frequency
comply with the data on the motor nameplate;
17. Inspect the operation of the anti-reversion devices (if
any).
18. Check if the radial locking device on the upper
bearing (if any) has been replaced, as per item 4.2.3;
6.2 FIRST STARTING
6.2.1 Starting procedure
After all preliminary inspections have been carried out,
proceed according to the directions presented next in
order to perform the first start of the uncoupled motor:
1. Turn off the space heater;
2. Set the protections in the control panel;
3. In oil-lubricated bearings, check the oil level;
4. In bearings with forced-lubrication, start the oil
circulation system and check the level, flow and
pressure of the oil, making sure that they comply with
the data on the nameplate.
5. If the system has oil flow detection equipment, it must
be waited until the flow return signal from the oil
circulation system of both bearings is received, which
makes sure that the oil has reached the bearings;
6. Start the industrial water cooling system checking the
required flow and pressure (motors with air-water
heat exchanger);
7. Turn on the fans (motors with forced ventilation);
8. Switch on the high-pressure oil injection system (if
any), keeping it on as informed in the motor technical
documentation until the bearings get the lubrication
by self-pumping;
9. Rotate the motor shaft slowly in order to check that
no part is being dragged or any abnormal noises are
occurring;
10. After the previous steps have been adequately
completed, it is possible to proceed with the motor
starting sequence;
11. Start the motor with no load, making sure it rotates
smoothly without strange noises;
12. Check the rotation direction with the motor
uncoupled;
13. In order to invert the rotation direction, just invert the
connections of any two phases;
In order to invert the rotation direction of
motors with single direction, it is necessary to
consult WEG.
34 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
14. Keep the motor rotating at rated speed and write
down the bearing temperatures at 1-minute intervals
until they become constant. Any sudden increase in
bearing temperature indicates lubrication or friction
surface abnormality;
15. Monitor the temperature, the oil level of the bearings,
and the vibration levels. If there is a significant
Page 35
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ATTENTION
The noncompliance with the procedures
ATTENTION
The high
variation of any value, interrupt the motor starting,
identify possible causes and make the necessary
corrections;
16. When the bearing temperatures stabilize, it is possible
to proceed to the other motor operation steps.
described in section 6.2 may impair the
motor performance, cause damages and
even lead to its burnout, voiding the
warranty.
6.3 OPERATION
The operating procedures vary considerably depending
on the motor application and the type of control
equipment used.
The general procedures are described in this manual. For
the control system operating procedures, refer to the
specific manual of this equipment.
6.3.1 General
After a first successful starting test, couple the motor to
the driven load, and then the starting procedure can be
reinitiated, as follows:
Start the motor coupled to the load until its
temperature stabilizes and check for unusual noises,
abnormal vibrations or excessive heating. If significant
vibration variations occur regarding the initial operation
condition until the condition after reaching thermal
stability, then it is necessary to check the alignment
and the leveling.
Measure the current consumption and compare it to
the value given on the nameplate.
In continuous duty, without load variation, the
measured current must not exceed the value indicated
on the nameplate multiplied by the service factor;
All the instruments and devices for measurement and
ontrol must be permanently monitored to detect
c
occasional alterations, determine their causes and
make the proper corrections.
6.3.2 Temperatures
The temperatures of the bearings, stator winding and
cooling system must be monitored while the motor is
operating.
These temperatures must stabilize within 4 to 8 hours
of operation.
The stator winding temperature depends on the
machine load; therefore, the driven load must also be
monitored during the motor.
6.3.3 Bearings
The system start, as well as the first hours of operation,
must be monitored carefully.
Before putting the motor into operation, verify:
If the high-pressure oil injection system (if any) is ON;
If the external lubrication system (if any) is ON;
If the used lubricant complies with the specificatio
ns;
In case of overheating, the motor must be shut down
i
mmediately for the inspection of bearings and
temperature sensors, and the correction of possible
causes;
The motor must operate for several hours until bearing
temperatures stabilize within the specified limits;
After the bearing temperatures stabilize, check if there
are no leaks through the plugs, gaskets or shaft end.
6.3.3.1 High-pressure oil injection system
In bearings which have the option for shaft lifting when
starting or stopping by means of oil pressure, the
activation of this system is done by means of an external
oil pump, and the following procedure must be observed:
-pressure oil injection system must be
switched on before putting the motor into
operation and during the shutdown procedure,
as informed in the motor technical
documentation.
6.3.4 Radiators
During the operation of motors with air-water heat
exchanger, it is necessary:
Controlling the temperature at the radiator inlet and
outlet and, if necessary, correcting the water flow;
Adjusting the water pressure just to overcome the
resistance in the pipes and in the radiator;
In order to control the motor operation, it is
recommended to install thermometers at the radiator
air and water inlets and outlets and record these
temperatures at certain time intervals;
When installing the thermometers, recording or
signaling instruments (siren, lights) can also be installed
in certain places.
Verification of the radiator performance
For operation control purposes, it is recommended
that water and air temperatures at the radiator inlets
and outlets be measured and recorded periodically;
The radiator performance is expressed by the
temperature difference between cold water and cold
air during normal operation. This difference must be
checked periodically. If an increase in this difference is
observed after a long period of normal operation, verify
the need for radiator cleaning.
The accumulation of air inside the radiator can lead to
a performance reduction or to its damage. In this case,
a deaeration of the radiator and the pipes may solve
the problem;
The water pressure differential can be considered an
indicator of the need for cleaning the radiator.
It is also recommended to measure and record the
difference between the water pressure before and after
the radiator. Periodically, the values measured must be
compared to the original value, and an increase of the
pressure differential indicates the need for cleaning the
radiator.
The lubricant characteristics;
The oil level (oil-lubricated bearings);
If the bearing alarm and trip temperatures are set;
During the first start, it is important to pay atten
tion to
unusual vibrations or noises;
If the bearing is not working silently and smoothly, the
motor must be shut down immediately;
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 35
Page 36
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Vibration Levels (mm/s RMS)
Alarm 4.5 4.5 5.5
Alarm 3.5 4.5 5.5
ATTENTION
Shaft Vibration (μm peak
-to-
peak)
280 and
355 to
ATTENTION
ATTENTION
The terminal boxes of motors equipped with
6.3.5 Vibration
The motors are balanced at the factory in compliance
with the vibration limits established by IEC60034-14,
NEMA MG1 – Part 7 and NBR 11390 standards (except
when the purchase contract specifies different values).
The vibration measurements are carried out on the NDE
and DE bearings, in the vertical, horizontal and axial
directions. When the customer sends the half coupling to
WEG, the motor is balanced with the half coupling
mounted on the shaft. Otherwise, according to the
standards above, the motor is balanced with half-key
(i.e., the key slot is filled with a bar of the same width,
thickness and height of the key slot during the balancing
operation).
The maximum vibration levels attended by WEG for
motors in operation are informed in Table 6.1. These
values are generic and for guidance, and the specific
application conditions must always be taken into
account:
Rated speed
(rpm)
600 ≤ n ≤ 1800
1800 < n ≤ 3600
Table 6.1: Vibration (RMS)
Frame < 355 355 to 560 > 630
Tripping 7.0 7.0 8.0
Tripping 5.5 6.5 7.5
The main vibration causes are:
Misalignment between the motor and the driven
equipment;
Improper fastening of the motor to the base, with
“loose shims” under one or more motor feet, and
loose fastening bolts;
Improper or insufficiently rigid base;
External vibrations proceeding from other equipment.
Operating the motor with vibration levels
above the values contained in Table 6.1 may
impair its useful life and/or performance.
6.3.6 Shaft vibration limits
In motors equipped with or prepared for the installation of
proximity sensors (normally used on sleeve bearings), the
surfaces of the shaft are prepared with special finishing in
the areas adjacent to the bearings, in order to assure the
correct measurement of the shaft vibration.
The shaft vibration measured in these motors must
comply with the IEC 60034-14 or NEMA MG 1 standard.
The alarm and trip values of Table 6.2 represent the
acceptable shaft vibration values for coupled electrical
machines according to the ISO7919-3 standard.
These values are generic and for guidance, and the
specific application conditions must always be taken into
account, especially the diametrical clearance between the
shaft and the bearing.
Rated Speed
(rpm)
1800
3600
Table 6.2: Shaft vibration
Frame
Alarm 110 130 150
Tripping 140 160 190
Alarm 85 100 120
Tripping 100 120 150
315
450
> 450
Operating the motor with shaft vibration
values within the alarm or tripping range may
cause damages to the bearing shell.
The main causes for increase in shaft vibration are:
Coupling unbalance issues or other problems that may
also generate machine vibration;
Shaft shape problems in the measurement region,
minimized during manufacturing;
Residual magnetism or voltage on the shaft surface
where the measurement is done;
Scratches, dents or variations on the shaft finishing in
the measurement region.
6.3.7 Shutdown
In order to shut down the motor, proceed as follows:
Reduce the load of the driven equipment, if possible;
Open the main circuit breaker;
Switch on the high-pressure oil injection system (if
any);
After the motor stops completely:
Switch off the high-pressure oil injection system (if
any);
Switch off the oil circulation system of the bearings (if
any);
Switch off the hydraulic unit (if any);
Shut down the industrial water system (if any);
Switch off the forced ventilation system (if any);
Switch on the space heaters. They must be kept ON
ntil the next motor operation.
u
DANGER
Even after switching the motor off, while the
rotor is rotating, there is danger to life by
touching any of the motor active parts.
capacitors must not be opened before their
full discharge.
Discharge time of the capacitors: five
minutes after shutting down the motor.
36 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 37
7 MAINTENANCE
ATTENTION
The frequency of such inspections depends
7.1 GENERAL
A proper maintenance program for electric motors
includes the following recommendations:
Keep the motor and the associated equipment clean;
Measure the winding insulation resistance periodically;
Measure the temperature of windings, bearings and
cooling system periodically;
Check the wear, operation of the lubrication system and
useful life of the bearings;
Measure the motor vibration levels;
Inspect the cooling system;
Inspect associated equipment;
Inspect all the motor accessories, protections and
onnections, ensuring that they are operating properly;
c
Noncompliance with the recommendations
of section 7.1 may cause undesired
stoppages of the equipment.
on the local application conditions.
Every time that it becomes necessary to
transport the motor, the shaft must be
properly locked to prevent damages to the
bearings. Use the device supplied with the
motor to lock the shaft.
If the motor requires reconditioning or
replacement of any damaged part, consult
WEG.
7.2 GENERAL CLEANING
Keep the frame clean, without external accumulation of
oil or dust, in order to facilitate the heat exchange with
the environment;
The inside of the motor must also be kept clean, free of
dust, debris and oils;
For cleaning, use brushes or clean cotton cloths. If the
dust is not abrasive, the cleaning must be done with an
industrial vacuum cleaner, “aspiring” the dirt from the
fan cover and the dust accumulated on the fan blades
and on the frame;
Debris impregnated with oil or moisture can be
removed with a cloth soaked in appropriate solvents;
Clean the terminal boxes when necessary. Terminals
and connectors must be kept clean, free of rust and in
perfect operating conditions. Avoid the presence of
grease or verdigris in the connection parts.
7.3 WINDING MAINTENANCE
To obtain more satisfactory operation and a longer life of
the motor, the windings should be inspected and cleaned
annually.
7.3.1 Winding inspection
Yearly, the windings must be submitted to a complete
visual inspection, recording and repairing all and every
damage or defect observed.
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The winding insulation resistance measurements must be
done at regular intervals, especially during humid weather
and after prolonged motor stoppages.
Low values or sudden variations in the insulation
resistance must be investigated.
The windings must be submitted to complete visual
inspections at frequent intervals, recording and repairing
all and every damage or defect observed.
The winding insulation resistance can be increased up to
an adequate value in the points where it is low (as a result
of excessive dust and moisture) by means of the dust
removal and by drying the winding moisture.
7.3.2 Winding cleaning
In order to obtain a more satisfactory operation and a
longer useful life of the insulated windings, it is
recommended to keep them free of dirt, oil, metal dust,
contaminants, etc.
Therefore, it is necessary to inspect and clean the
windings periodically, according to the recommendations
of the "Maintenance Plan" of this manual. If reimpregnation
is necessary, consult WEG.
The windings may be cleaned with an industrial vacuum
cleaner with a non-metallic crevice tool or just a dry cloth.
For extreme dirt conditions, it may be necessary to use a
proper liquid solvent for cleaning. This cleaning must be
quick to prevent prolonged exposure of the windings to
the solvent effects.
After being cleaned with solvents, the windings must be
completely dried.
Measure the insulation resistance and the polarization
index in order to assess the winding insulation conditions.
Winding drying time after cleaning varies depending on the
weather conditions such as temperature, humidity, etc.
DANGER
Most solvents currently used are highly
toxic and/or flammable.
Solvents must not be used in the straight
parts of the coils of high-voltage motors,
because they may affect the protection
against corona effect.
7.3.3 Inspections
The following inspections must be carried out after the
windings are carefully cleaned:
Check the insulations of the winding and connections;
Check if spacers, bindings, slot wedges, bandages and
supports are properly fixed;
Check for breaks, faulty welds, short-circuit between
turns and against the frame in the coils and
connections. In case any fault is detected, consult
WEG.
Ensure that all cables are properly connected and that
terminal fixation components are duly tightened.
Retighten, if necessary.
7.3.4 Reimpregnation
If any layer of resin on the windings is damaged during
cleaning or inspection, such parts must be corrected with
adequate material (in this case, consult WEG).
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 37
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ATTENTION
AT
7.3.5 Insulation Resistance
The insulation resistance must be measured after the
completion of all of the maintenance procedures.
Before putting the motor back into
operation, it is essential to measure the
winding insulation resistance and ensure
that the measured values meet the
specifications.
7.4 COOLING SYSTEM
MAINTENANCE
In motors with air-air heat exchanger (IC611), the
cooling pipes and noise attenuator (if any) must kept
clean and unobstructed to ensure a perfect heat
exchange. In order to remove the dirt accumulated in
the pipes, a rod with a round brush at the end may be
used. Noise attenuators (if any) can be cleaned with dry
compressed air.
In case of air-water heat exchangers (IC81W), periodic
cleaning in the radiator pipes is necessary to remove all
and any incrustation, according item 7.5.
In open motors (IC01), the air filters should be cleaned
with dry compressed air. If dust is difficult to remove,
wash the filter with cold water and neutral detergent
and dry it in horizontal position. Replace the filters, if
necessary.
TENTION
It is recommended to close the openings of
the external air circuit, if the motor is out of
operation for long terms.
5. Reassemble the heads, replacing the gaskets, if
necessary.
Sacrificial anodes
S
acrificial anodes are used in radiators that operate with
seawater. The regular inspection must be carried out,
according to the maintenance plan. If excessive corrosion
is found in the sacrificial anode, the frequency of
inspection must be increased in order to determine the
corrosion period and establish a plan for proper
replacement intervals.
7.6 VIBRATION
Any evidence of increase in the unbalance or vibration of
the motor must be investigated immediately.
7.7 ANTI-REVERSION RATCHET
MAINTENANCE
The ratchet anti-reversion condition (if any) must be
inspected according to the maintenance plan described in
Erro! Fonte de referência não encontrada..
Remove the motor top cover and check the wear of the
pins and gear teeth of the ratchet. If excessive wear is
detected, these parts must be replaced.
7.8 SHAFT GROUNDING DEVICE
The shaft grounding brush (if any) avoids the circulation of
electric current through the bearings, which is detrimental
to their operation. The brush is put in contact with the
shaft and connected by a cable to the motor frame, which
must be grounded. Make sure that the brush holder
fastening and its connection to the frame have been made
correctly.
7.5 RADIATOR MAINTENANCE
The degree of dirt in the radiator can be detected by the
increase of the temperature at the air outlet. When the
temperature of the cold air, under the same operating
conditions, exceeds the specified value, it can be
assumed that the pipes are dirty.
If corrosion is found in the radiator, it is necessary to
provide adequate protection against corrosion (i.e., zinc
anodes, cover with plastic, epoxy or other similar
products), in order to prevent further damage to the parts
already affected.
The external surface of all the radiator parts must always
be kept in good conditions.
Instructions for removal and maintenance of the
radiator
In order to remove the radiator for maintenance, use the
following procedure:
1. Close all the water inlet and outlet valves after stopping
the ventilation;
2. Drain the water through the radiator drain plugs;
3. Remove the heads, keeping the bolts, nuts, washers
and seals (gaskets) in a safe place;
4. Brush the inside of the pipes carefully with nylon
brushes in order to remove residues. If damages to the
radiator tubes are found during the cleaning, they must
be repaired;
38 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Drying oil is used to protect the motor shaft against rust
during transportation. In order to ensure the proper
operation of the grounding brush, this oil, as well as any
residue between the shaft and the brush, must be
removed before starting the motor. The brush must be
constantly monitored during operation, and it must be
replaced by another one of the same quality (granulation)
at the end of its useful life.
Figure 7.1: Shaft grounding brush
Shaft
Page 39
7.9 BEARING MAINTENANCE
The
are informed
The bearings shall be relubricated annually
Bearing operating
ATTENTION
The injection of all the grease with the
ATTENTION
7.9.1 Grease-lubricated rolling bearings
The informed lubrication intervals, consider a 70 °C
working temperature of the rolling bearing;
Based on the operating temperature ranges listed in
Table 7.1, apply the following correction factors for the
rolling bearing lubrication intervals:
NOTE
rolling bearing data, amount and type of
grease, and lubrication intervals
on a bearing nameplate affixed to the motor.
or according to the lubrication interval
stated on the bearings nameplate,
whichever occurs first.
Table 7.1: Reduction factor for lubrication intervals
temperature
Below 60 ºC 1.59
Between 70 and 80 ºC 0.63
Between 80 and 90 ºC 0.40
Between 90 and 100 ºC 0.25
Between 100 and 110 ºC 0.16
Reduction factor
7.9.1.1 Instructions for lubrication
The lubrication system was designed in such a way that
during the lubrication of the rolling bearings, all the old
grease is removed from the rolling bearing races and
expelled through a drain which enables the exit of the
grease, but prevents the ingress of dust or other harmful
contaminants.
This drain also prevents damage to the rolling bearings by
excessive lubrication.
It is recommended to make the lubrication with the motor
in operation in order to ensure the renewal of the grease in
the rolling bearing housing.
If that is not possible due to the presence of rotating parts
near the grease nipple (pulleys, etc.) which may put the
operator at risk, follow the procedures below:
With the motor stopped, inject approximately half of
total intended amount of grease and operate the motor
for approximately one minute at full speed;
Stop the motor and inject the rest of the grease.
motor stopped may lead to the penetration
of part of the lubricant into the motor
through the internal seal of the rolling
bearing cap;
It is important to clean the grease nipples
prior to lubrication in order to prevent
foreign materials from being dragged into
the rolling bearing. For lubrication, use only
manual grease gun.
the
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7.9.1.2 Procedures for rolling bearing relubrication
1. Remove the drain plug;
2. Clean with a cotton cloth around the hole of the
grease nipple;
3. With the rotor operating, inject the grease with a
manual grease gun until grease starts coming out from
the drain or until the proper amount of grease,
informed in
encontrada.
4. keep the motor running long enough so that the
grease excess passes through the drain;
5. Inspect the bearing temperature to make sure there
was no significant change;
6. Put the drain plug back in place.
Erro! Fonte de referência não
, has been injected.
7.9.1.3 Rolling bearing relubrication with drawer device for grease removal
In order to relubricate the bearings, the old grease is
removed by means of the device with a drawer installed
on each bearing.
Lubrication procedure:
1. Before starting the lubrication of the bearing, clean the
grease nipple with a cotton cloth;
2. Remove the rod with drawer to remove the old grease,
clean the drawer and put it back in place;
3. With the motor running, inject the amount of grease
specified on the rolling bearing nameplate by means of
a manual grease gun;
4. The excess of grease comes out through the bearing
lower drain and is deposited in the drawer;
5. Leave the motor running long enough for the grease
excess to drain;
6. Remove the excess of grease, by pulling the drawer
rod and cleaning the drawer. This procedure must be
repeated as many times as necessary until the drawer
no longer retains grease;
7. Inspect the bearing temperature to ensure that there
was no significant change.
7.9.1.4 Type and amount of grease
The relubrication of the bearings must always be done
with the
nameplate and in the documentation of the motor.
original grease
WEG does not recommend the use of
greases different from the motor original
grease.
It is important to perform a correct lubrication, i.e., to
apply the correct grease and in the proper quantity,
because either poor or excessive lubrication will damage
the rolling bearings.
Excessive amount of grease cause temperature increase,
due to the great resistance it offers to the movement of
the bearing rotating parts. Consequently, due to the
heating, the grease can completely lose its lubricating
characteristics.
, specified on the bearing
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 39
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Limit s
peed
of the
g
rease [rpm]
Petrobras
7.9.1.5 Alternative greases
If it is not possible to use the original grease, the
alternative greases listed in Table 7.2 can be used, under
the following conditions:
1. The motor speed must not exceed the limit speed of
the grease, according to the type of rolling bearing, as
informed in Table 7.3;
2. The lubrication interval must be corrected by
multiplying the interval informed on the bearing
nameplate by the multiplication factor informed in
Table 7.2;
3. Use the correct procedure to change the grease,
according to section 1.1.1.1 of this manual.
Table 7.2: Options and characteristics of the alternative
greases for regular applications
Constant
Manufacturer Grease
Exxon Mobil
Shell
Petrobras
Shell
SKF
UNIREX N3
(Lithium Complex
Soap)
ALVANIA RL3
(Lithium Soap)
LUBRAX
INDUSTRIAL GMA-2
(Lithium Soap)
STAMINA RL2
(Diurea Soap)
LGHP 2
(
Polyurea Soap)
operating
temperature
(°C)
(-30 to +150) 0.90
(-30 to +120) 0.85
(0 to +130) 0.85
(-20 to +180) 0.94
(-40 to +150) 0.94
Multiplication
factor
Table 7.3 shows the most common rolling bearings used in vertical motors, the quantity of grease and the speed limit for
using alternative greases.
Table 7.3: Application of alternative greases
Rolling
bearing
Grease
quantity
(g)
Shell STAMINA
RL2
SKF LGHP 2 Esso UNIREX N3
Vertical motors
Shell ALVANIA
RL3
LUBRAX Industrial
GMA-2
6215 15 3600 3600 3600 3000 3000
6217 20 1800 1800 1800 1800 1800
6220 30 1800 1800 1800 1800 1800
6222 40 1800 1800 1800 1800 1800
6224 45 1800 1800 1800 1800 1800
6228 55 1800 1800 1800 1800 1500
6232 70 1800 1800 1800 1500 1200
6236 85 1800 1800 1500 1500 1200
6240 105 1800 1800 1200 1200 1000
6048 100 1500 1500 1200 1200 1000
6052 130 1500 1500 1200 1000 900
6064 290 1200 1200 1000 900 750
7216 20 3600 3600 3600 3000 1800
7218 25 1800 1800 1800 1800 1800
7222 40 1800 1800 1800 1800 1800
7224 45 1800 1800 1800 1800 1800
7228 55 1800 1800 1800 1800 1500
7322 60 1800 1800 1800 1800 1500
7324 70 1800 1800 1800 1800 1500
7326 80 1800 1800 1800 1500 1200
7328 95 1800 1800 1800 1500 1200
7330 105 1800 1800 1500 1500 1200
7332 115 1800 1800 1500 1200 1200
7332 DT 230 1800 1800 1500 1200 1200
7334 DT 260 1800 1800 1500 1200 1000
7338 DT 310 1500 1500 1200 1200 1000
40 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 41
7.9.1.6 Procedure for changing the grease
ATTENTION
This
ATTENTION
or for
Constant
temperature
MOBILITH SHC
ATTENTION
In order to replace the
POLYREX EM103
grease by one
of the alternative greases, the bearings must be opened to
remove the old grease and then filled with the new grease.
If it is not possible to open the bearings, the old grease
must be purged by applying new grease until it begins to
appear in the exit drawer with the motor running.
In order to replace the
STABURAGS N12MF
grease by
one of the alternative greases, you must first open the
bearings, completely remove the old grease, and then fill it
with new grease.
Since there is no grease compatible with
STABURAGS N12MF
, other grease must
not be injected in the attempt to purge it.
procedure will not expel completely the old
grease and they will mix, which may cause
damage to the bearings.
When the bearing is opened, inject the new
grease through the grease nipple to expel
the old grease found in the grease inlet
tube, and apply the new grease in the
rolling bearing, to the inner and outer
bearing caps, filling 3/4 of the empty
spaces. In case of double bearings (ball
bearing + roller bearing), also fill 3/4 of the
empty spaces between the intermediate
rings.
Never clean the rolling bearing with cottonbased cloths, because they may release
some lint, working as solid particles.
NOTE
WEG is not liable for the grease change
any damages arising from this change.
7.9.1.7 Low temperature greases
Table 7.4: Grease for application at low temperatures
Manufacturer
Exxon Mobil
Grease
100
(Lithium Soap and
Synthetic Oil)
operating
(°C)
(-50 to +150)
Application
Low
temperature
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7.9.1.8 Grease compatibility
You can say that greases are compatible when the
properties of the mixture are within the property ranges of
the greases individually.
In general, greases with the same type of soap are
compatible; however, depending on the proportion of the
mixture, there might be incompatibility. Therefore, it is not
recommended to mix different types of grease without
consulting the grease supplier or WEG.
Some thickeners and basic oils cannot be mixed, because
they do not form a homogeneous mixture. In this case,
one cannot rule the possibility of hardening or softening of
the grease, or reduction of the dropping point of the
resulting mixture.
Greases with different types of base must
never be mixed.
For example: Lithium-based greases must
never be mixed with sodium or calciumbased greases.
7.9.1.9 Disassembly – vertical bearings
Figure 7.2 legend:
1. Temperature sensor
2. Grease nipple
3. Grease collecting drawer
4. Screw
5. Protection disc
6. Labyrinth taconite seal
7. Screw
8. Outer bearing cap
9. Screw
10. Grease flinger
11. Lower end shield
12. Rolling bearing
13. Spring
14. Inner bearing cap
7.9.1.9.1 Before disassembling
Remove the extension tubes from the grease inlet and
outlet;
Thoroughly clean the external part of the bearing;
Remove the grounding brush (if any);
Remove the temperature sensors.
Figure 7.2: Lower bearing
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ATTENTION
necessary to be careful not to damage the
ATTENTION
The breather hose (6) must not
7.9.1.9.2 Lower bearing disassembly
In order to disassemble the bearing, proceed according to
the following guidelines:
1. Place the motor in the horizontal position;
2. Remove the screws (4), protection disc (5) and the
labyrinth taconite seal (6);
3. Remove the screws (7) from the outer and inner
bearing caps (8 and 14);
4. Remove the outer bearing cap (8);
5. Remove the screw (9) that fixes the grease flinger (10);
6. Remove the grease flinger (10);
7. Remove the lower end shield (11);
8. Remove the rolling bearing (12);
9. Remove the inner bearing cap (14), if necessary.
During the bearing disassembly, it is
balls, rollers or shaft surface;
Keep the disassembled parts in a safe
and clean place.
7.9.1.10 Bearing assembly
Clean the bearings completely and inspect the
disassembled parts and the inside of the bearing caps;
Make sure the rolling bearing, shaft and bearing cap
surfaces are perfectly smooth;
Fill up to ¾ of the inner and outer bearing cap depo
with the recommended grease (Figure 7.4) and lubricate
the rolling bearing with enough grease before
assembling it;
Before assembling the rolling bearing on the shaft, heat
it up to a temperature between 50 ºC and 100 ºC;
For the complete assembly of the bearing, follow the
disassembly instructions in the reverse order.
sits
Figure 7.3: Upper bearing
Figure 7.3 legend:
1. Grease nipple
2. Grease inlet tube
3. Temperature sensor
4. Grease collecting drawer
5. Grease outlet tube
6. Screw
7. Outer bearing cap
8. Spring
9. KMT nut
10. Spacer ring
11. Screw
12. Screw
13. Bearing hub
14. Upper end shield
15. Rolling bearing
16. Intermediate ring
17. Grease flinger
18. Guiding ring
19. Inner bearing cap
7.9.1.9.3 Upper bearing disassembly
In order to disassemble the bearing, proceed according to
the following guidelines:
1. Support the motor shaft with a hydraulic jack;
2. Remove the screws (6) from the outer bearing cap of
the rolling bearing (7);
3. Remove the outer bearing cap (7);
4. Remove the KMT nut (9);
5. Remove the screws (11 and 12) and remove the
bearing hub;
6. Remove the upper end shield (14);
7. Move the intermediate ring and the inner bearing cap
away from the bearing in order to obtain space to
place the device to remove the rolling bearing;
8. Remove the rolling bearing (15);
9. Remove the grease flinger (17), the intermediate ring
and the inner bearing cap, if necessary.
Figure 7.4: Outer bearing cap
7.9.2 Oil-lubricated rolling bearing
Figure 7.5 legend:
1. Oil inlet
2. Oil sight glass
3. Oil outlet
4. Temperature sensor
5. Cooling water inlet and outlet (optional use)
6. Breather hose
Figure 7.5: Oil-lubricated rolling bearing
curvature that can accumulate oil inside.
present any
42 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 43
7.9.2.1 Lubrication instructions
The use of a larger amount of oil will not
Never use hydraulic oil or mix it with the
Bearing
operating
Bearing oil change
ATTENTION
The oil level must be inspected daily and
Oil drainage:
oil, remove the oil outlet plug (3) and drain the oil
completely.
To fill the bearing with oil:
Close the oil outlet with the plug (3);
Remove the plug from the oil inlet or from the filter (1);
Fill it with the specified oil up to the level indicated in the
oil sight glass.
When it is necessary to change the bearing
NOTES
1. All threaded holes that are not used
must be closed with plugs and no fitting
may present leaks;
2. The oil level is reached when the
lubricant can be seen approximately in
the middle of the sight glass;
3.
damage the bearing; but it can cause
leaks through the shaft seals;
4.
bearing lubricant oil.
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7.9.2.4 Bearing operation
The system start, as well as the first hours of
operation, must be monitored carefully.
Before starting, check:
If the used oil complies with the specification on the
nameplate;
The lubricant characteristics;
The oil level;
The alarm and trip temperatures set for the bearing.
During the first start, it is necessary to stay alert for
unusual vibrations or noises. If the bearing does not
operate in a silent and smooth way, the motor must be
shut down immediately.
The motor must operate for some hours until the bearing
temperatures stabilize. In case of overheating of the
bearings, the motor must be shut down for inspection of
the bearings and temperature sensors.
Check if there is no oil leak through the plugs, gaskets or
shaft end.
7.9.2.2 Oil type
The type and quantity of
lubricant oil
to be used are
specified on the nameplate affixed to the motor.
7.9.2.3 Oil change
The bearing oil change must be done according to the
intervals, which depend on the bearing operating
temperature, shown in Table 7.5:
Between 75 and 80 ºC 16,000 hours
Between 80 and 85 ºC 12,000 hours
Between 85 and 90 ºC 8,000 hours
Between 90 and 95 ºC 6,000 hours
Between 95 and 100 ºC 4,000 hours
The lifespan of the bearings depends on their operating
conditions, on the motor operating conditions and on the
maintenance procedures.
Proceed according to the following directions:
The oil selected for the application must have the
proper viscosity for the bearing operating temperature.
The type of oil recommended by WEG already
considers these criteria;
Insufficient quantity of oil may damage the bearing;
The minimum recommended oil level is reached when
the lubricant can be seen in the lower part of the oil
sight glass with the motor stopped.
Table 7.5: Oil change intervals
temperature
Below 75 ºC 20,000 hours
intervals
must remain in the middle of the oil sight
glass.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 43
Page 44
www.weg.net
ATTENTION
7.9.2.5 Bearing disassembly
130
270
120
110
110
110
200
100
90
80
210
20
150
30
60
10
140
280
Figure 7.6: Upper bearing
Figure 7.6 legend:
10. Oil tank
20. Bearing hub
30. Oil flinger
60. Oil drip pan
80. Seal fastening ring
90. Socket screw
100. Teflon seal
110. Gasket
120. Rolling bearing
130. Upper intermediate ring
140. Fastening nut
150. Socket screw
200. Lower intermediate ring
210. Socket screw
270. Shaft
280. Socket screw
Before disassembling the upper bearing:
Support the rotor on the shaft end with a hydraulic jack;
Drain the oil completely from the bearing;
Clean the external part of the bearing thoroughly;
Remove the temperature sensors.
Upper bearing disassembly
n order to disassemble the bearing, proceed carefully as
I
the following guidelines, keeping all the parts in a safe
place.
Remove the upper bearing cover;
Remove the KMT nut (140);
Remove the intermediate ring (130);
Remove the screws (150) and remove the bearing hub;
Remove the rolling bearing (120);
Reinstall the upper intermediate ring (130), fasten it
directly to the lower intermediate ring (200) and, using a
rolling bearing puller, extract the set formed by the
upper ring (130), lower ring (200) and rolling bearing
(120).
Figure 7.7: Lower bearing
Figure 7.7 legend:
10. Oil tank
20. Oil flinger
30. Oil guide
40. Bearing hub
50. Rolling bearing
60. Socket screw
70. Oil injector nozzle
80. Seal fastening ring
100. Socket screw
110. Gasket
130. Socket screw
180. Segmented ring
190. Teflon seal
200. Seal fastening ring
210. Oil guide
250. Labyrinth taconite seal
Before disassembling the lower bearing:
Drain the oil completely from the bearing;
Put the motor in the horizontal position;
Clean the external part of the bearing thoroughly;
Remove the grounding brush (if any);
Remove the temperature sensors.
Lower bearing disassembly
n order to disassemble the bearing, proceed carefully as
I
the following guidelines, keeping all the parts in a safe
place.
Remove the screws (8) that fasten the labyrinth taconite
seal (250);
Remove the labyrinth taconite seal (250);
Remove the oil tank (10);
Remove the segmented ring (180);
Remove the oil flinger (20);
Remove the rolling bearing hub (40);
Remove the rolling bearing (50);
During the bearing disassembly, it is
necessary to be careful not to damage
the balls, rollers or shaft surface;
Keep the disassembled parts in a safe
and clean place.
44 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 45
7.9.2.6 Bearing assembly
ATTENTION
Under no circumstances can water leak into
Bearing
operating
Bearing oil change
The oil level must be inspected daily
ATTENTION
The care with the lubrication will determine
Clean the rolling bearing and the oil tanks thoroughly,
and inspect all the parts before the bearing assembly.
Make sure the rolling bearing contact surfaces are
smooth and free of signs of scratches or corrosion;
Before mounting the rolling bearing on the shaft, heat it
up to a temperature between 50 to 100 ºC;
For the complete assembly of the bearing, follow the
disassembly instructions in the reverse order.
During the bearing assembly, apply sealant
(e.g.
) in order to seal the surfaces of
Curil T
the oil tank.
7.9.3 Rolling bearing replacement
The disassembly of rolling bearings must be done with an
appropriate tool (rolling bearing puller).
The arms of the puller must be placed on the lateral
surface of the bearing inner ring to be disassembled or on
an adjacent part.
www.weg.net
NOTE
the oil tank, because this will contaminate
the lubricant.
7.9.4.4 Oil change
Self-lubricated bearings
The bearing oil change must be done according to the
intervals, which depend on the bearing operating
temperatures, shown in Table 7.6:
Between 75 and 80 ºC 16,000 hours
Between 80 and 85 ºC 12,000 hours
Between 85 and 90 ºC 8,000 hours
Between 90 and 95 ºC 6,000 hours
Between 95 and 100 ºC 4,000 hours
Bearings with external oil circulation
The oil of the bearings must be changed every 20,000
hours of operation or whenever the lubricant presents
modifications in its characteristics. The oil viscosity and pH
must be checked periodically.
Table 7.6: Oil change intervals
temperature
Below 75 ºC 20,000 hours
intervals
Figure 7.8: Tool for rolling bearing extraction
7.9.4 Sleeve bearings
7.9.4.1 Bearing data
The characteristic data, such as oil flow, quantity and
type, are indicated on the bearing nameplate and must be
strictly observed; otherwise, overheating and damages to
the bearings may occur.
The hydraulic installation (for bearings with forced
lubrication) and the oil supply for the motor bearings are
responsibilities of the user.
7.9.4.2 Bearing installation and operation
For information on the bill of materials, assembly and
disassembly instructions, and maintenance details, refer to
the specific installation and operation manual of the
bearings.
7.9.4.3 Cooling by water circulation
The sleeve bearings with cooling by water circulation have
a serpentine inside the oil tank through which the water
circulates.
In order to assure an efficient bearing cooling, the
circulating water must have at the bearing inlet a
temperature lower or equal to the ambient, so that the
cooling takes place.
The water pressure must be 0.1 bar and the flow equal to
0.7 l/s. The pH must be neutral.
NOTE
, and it
must remain in the middle of the oil sight
glass.
The bearings must be lubricated with the specified oil,
respecting the flow rate informed on their nameplate;
All threaded holes that are not used must be closed with
plugs and no fitting may present leaks.
The oil level is reached when the lubricant can be seen
approximately in the middle of the sight glass. The use of
a larger amount of oil will not damage the bearing, but it
can cause leaks through the shaft seals.
the useful life of the bearings and the safety
in the motor operation. Therefore, the
following recommendations must be
observed:
The selected lubricant oil must be the
one with proper viscosity for the
operating temperature of the bearings;
That must be observed at every oil
change or during periodical
maintenances;
Never use or mix hydraulic oil with the
lubricant oil of the bearings;
Lack of lubricant, due to incomplete
illing or non-monitoring of the level, can
f
damage the bearing shells;
The minimum oil level is reached when
he lubricant can be seen in the lower
t
part of the sight glass with the motor
stopped.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 45
Page 46
www.weg.net
ATTENTION
7.9.4.5 Sealing
Make visual inspections of the sealing, making sure that
the dragging marks of the seal on the shaft do not
compromise its integrity, checking for cracks and broken
parts. Cracked or broken parts must be replaced.
In case of bearing maintenance, in order to assemble the
seal, it is necessary to carefully clean the seal contact
surfaces and its enclosure, and cover the sealing with a
non-hardening component (i.e.
). The two halves of
Curil T
the labyrinth taconite seal must be joined by a garter
spring.
The drain holes located in the lower half of the seal must
be cleaned and unobstructed.
Improper installation can damage the sealing and cause oil
leakage.
For further information about the dismounting
and mounting of sleeve bearing seals, refer to
the specific manual of this equipment.
7.9.4.6 Sleeve bearing operation
The system start, as well as the first hours of
operation, must be monitored carefully.
Before starting, check:
If the oil inlet and outlet tubes (if any) are, clean. Clean
the tubes by pickling, if necessary;
If the used oil complies with the specification on the
nameplate;
The lubricant characteristics;
The oil level;
The alarm and trip temperatures set for the bearing.
During the first start, it is necessary to stay alert for
unusual vibrations or noises. If the bearing does not
operate in a silent and smooth way, the motor must be
shut down immediately.
The motor must operate for several hours until the bearing
temperatures stabilize. In case of overheating of the
bearings, the motor must be shut down for inspection of
the bearings and temperature sensors.
Check if there is no oil leak through the plugs, gaskets or
shaft end.
7.9.4.7 Sleeve bearing maintenance
The sleeve bearing maintenance includes:
Periodic checking of the oil level and its lubricating
conditions;
Checking the bearing noise and vibration levels;
Monitoring of the operating temperatures and
retightening of the fastening and mounting screws;
In order to facilitate the heat exchange with the
environment, the frame must be kept clean, without
external dust or oil accumulation;
The NDE bearing is electrically insulated. The spherical
seat surfaces of the bearing shell on the frame are
covered with insulating material. Never remove this
cover;
The anti-rotation pin is also insulated, and the sea
made of non-conducting material;
Temperature control devices that are in contact with
bearing shell must also be properly insulated.
ls are
the
7.9.4.8 Bearing disassembly and assembly
NOTE
If the supplied bearings are manufactured by
WEG, refer to the specific bearing manual
supplied with the motor, containing the
assembly, disassembly and maintenance
information.
7.9.4.8.1 Thrust bearing (upper)
The upper thrust bearing function is to withstand the
weight of the motor and the axial thrust for which it was
designed. Its main elements are the stationary axial pads
and the rotating pivots (see Figure 7.9).
The pivots receive the load through the thrust pads.
14
10 9
7
Figure 7.9 legend:
1.
Lower flange
2.
Base ring of the pads
3.
Axial segment
4.
Axial pad
5.
Bearing housing
6.
Serpentine (optional)
7.
Fittings for cooling water
8.
Stand pipe
9.
Runner
10.
Bearing shell
11.
Bearing cover
12.
Vertical guide plate
13.
Seal box
14.
Seal fastening ring
15.
Floating seal
13
15
12 2
3
Figure 7.9: Upper thrust bearing
8
4
Before disassembling:
Support the rotor at the shaft end with a hydraulic jack;
Drain the oil thoroughly from the bearing;
Clean the external part of the bearing thoroughly;
Remove the temperature sensors.
Disassembly
Support the rotor at the shaft end with a hydraulic jack;
Remove the screws that fix the bearing upper cover and
remove it;
Disassemble the bearing following the manufacturer
manual instruction.
Assembly
n order to assemble the bearing, follow the disassembly
I
procedures in the reverse order.
11
5
6
1
46 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 47
7.9.4.8.2 Guide bearing (lower)
ATTENTION
The following temperatures must be set on
Alarm 110 ºC
The alarm temperature must be set 10 ºC
ATTENTION
Pt100 and the adapters must not exceed
The lower guide bearing function is to provide the radial
location of the motor shaft without load or axial
displacement limitation.
11
6
9
8
2
3
7
10
Figure 7.10 legend:
1.
Bearing housing
2.
Serpentine
3.
Fittings for cooling water
4.
Stand pipe
5.
Stand pipe seal
6.
Runner
7.
Bearing shell
8.
Thermoresistance (optional)
9.
Cover
10.
Radial segment
11.
Double seal
Figure 7.10: Lower guide bearing
5
4
1
Before disassembling:
Drain the oil thoroughly from the bearing;
Thoroughly clean the external part of the bearing;
Remove the temperature sensors;
Remove the grounding brush (if any);
Uncouple the motor and place it in the horizontal
position.
Disassembly
Remove the screws that fix the bearing lower cover an
remove it;
Disassemble the bearing following the manufacturer
manual instruction.
Assembly
In order to assemble the bearing, follow the disassembly
procedures in the reverse order.
7.9.5 Bearing protection
7.9.5.1 Protection settings
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7.9.5.2 Disassembly/assembly of the sleeve bearing temperature sensors
Figure 7.11 legend:
1.
Reduction nipple
2.
Insulating adapter
3.
Locknut
4.
Bulb
5.
Flexible metal tube
6.
Pt-100 temperature sensor
7.
Non-insulated bearing
8.
Insulated bearing
Disassembly instructions:
If it is necessary to remove the Pt100 for bearing
maintenance, proceed according to the following
instructions:
Remove the Pt100 carefully, locking the locknut (3), and
unscrewing just the Pt100 from the bulb (4);
Parts (2) and (3) must not be disassembled.
Assembly instructions:
d
Insert the Pt100 into the bearing;
Restrain the locknut (3) with a wrench;
Screw it in the bulb (4), adjusting it so that the tip of the
Pt100 touches the outer surface of the bearing.
Figure 7.11: Pt100 on the bearings
Before assembling the Pt100 on the
bearing, check if it does not contain marks
of knock or any other damage that may
compromise its operation.
NOTES
The assembly of the Pt100 on non-
insulated bearings must be done directly
on the bearing, without the insulating
adapter (2);
The tightening torque to assemble the
the bearing protection system:
above the operating temperature, not
exceeding the limit of 110 ºC.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 47
– Trip 120 ºC
10Nm.
Page 48
www.weg.net
ATTENTION
All the repair, disassembly and assembly services must be performed
The disassembly and assembly sequence
Always use proper tools and devices.
8 MOTOR DISASSEMBLY AND ASSEMBLY
only by properly qualified and trained
professionals; otherwise, equipment damage and personal injury may occur. If any further explanations are
necessary, consult WEG.
s depend on the motor model.
Any damaged part (cracks, dents on machined parts, faulty threads)
must be replaced, avoiding restorations.
8.1 PARTS LIST
5
17
12
10
1
14
3
16
2
5. In order to prevent damages to the rotor, provide a
support for the shaft on both drive and non-drive ends;
6. In order to disassemble the bearings, follow the
procedures described in this manual, according to the
bearing type;
7. Use a proper device to remove the rotor from the
motor, taking extreme care not to drag the rotor
against the stator laminated core or coil heads, thus
preventing damages.
8.3 ASSEMBLY
In order to assemble the motor, follow the disassembly
15
6
7
procedures in the reverse order.
8.4 AIR-GAP MEASUREMENT
4
9
11
13
Figure 8.1: Overview of a typical motor with solid shaft and oil-
lubricated rolling bearings
8
18
After disassembling and assembling the motor, it is
necessary to measure the air gap in order to check the
concentricity between rotor and stator.
The difference between the air-gap measured in two
points diametrically opposed must be less than 10% of
the average air gap.
Figure 8.1 legend:
1. Frame
2. Stator
3. Rotor
4. Internal fan
5. External fan
6. Fan cover
7. Grounding terminal
8. Shaft
9. D-end shield
10. ND-end shield
11. DE bearing
12. NDE bearing
13. Key
14. Terminal box support
15. Accessory terminal box
16. Stator terminal box
17. Ventilation box
18. Fastening bolts
8.2 DISASSEMBLY
The following precautions must be taken when
disassembling the motor:
1. Before disassembling the motor, disconnect the water
cooling and lubrication pipes (if any);
2. Disconnect the motor electrical connections and those
of the accessories;
3. Remove the heat exchanger and the noise suppressor
(if any);
4. Remove the bearing temperature sensors and the
grounding brush;
48 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 49
8.5 TIGHTENING TORQUE
Material /
% Yield
Mol
ycote
Molycote
Pitch
M3 0,5 1,2 0,8 1 0,69
M4 0,7 2,7 1,8 2,4 1,6
M5 0,8 5,4 3,6 4,8 3,2
M6 1 9,3 6,3 8,2 5,5
M8 1,25 22,4 15 20 13
M10 1,5 44 30 39 26
M12 1,75 77 52 67 45
M14 2 123 82 107 72
M16 2 188 126 165 110
M18 2,5 263 176 230 154
M20 2,5 368 246 322 215
M22 2,5 500 332 437 290
M24 3 637 425 557 372
M27 3 926 615 810 538
M30 3,5 1260 838 1102 734
M33 3,5 1704 1130 1490 990
M36 4 2195 1459 1920 1277
M42 4,5 3507 2328 3070 2037
M48 5 5258 3488 4600 3052
Material /
% Yield
Molycote
Molycote
Pitch
M3 0,5 0,6 0,5 0,48 0,32
M4 0,7 1,5 1 1,1 0,76
M5 0,8 3 2 2,2 1,5
M6 1 5,2 3,4 3,8 2,6
M8 1,25 12,3 8,3 9,2 6,2
M10 1,5 24 16 18,2 12,2
M12 1,75 42 28 32 21
M14 2 68 45 51 34
M16 2 104 69 78 52
M18 2,5 145 98 108 72
M20 2,5 202 135 152 101
M22 2,5 274 183 206 137
M24 3 350 233 263 175
M27 3 510 338 382 254
M30 3,5 693 461 520 346
M33 3,5 937 622 703 466
M36 4 1207 802 905 602
M42 4,5 1929 1280 1447 960
M48 5 2892 1918 2170 1440
The resistance class is normally indicated
The Table 8.1 and Table 8.2 shows the tightening torques
of the screws recommended for assembling the motor.
Table 8.1: Screw tightening torque for metal/metal parts
Resistance
class
Strength
Lubricant Dry
Diam
(mm)
Carbon Steel /
8.8 or above
60%
1000
Screws tightening torque (Nm)
Stainless steel /
A2 – 70 or above
70%
Dry
1000
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Table 8.2: Screw tightening torque for metal/isolated parts
Resistance
class
Strength
Lubricant Dry
Diam
(mm)
Carbon Steel /
8.8 or above
33%
1000
Screws tightening torque (Nm)
Stainless steel /
A2 – 70 or above
33%
Dry
1000
NOTE
the head of the hex bolts.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 49
on
Page 50
www.weg.net
Motor model
MGA, MGP, MGD, MGT
MGF MGW MGL, MGI
MGR W60
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
8.6 SPARE PARTS
Table 8.3 shows the necessary spare parts, which must be kept in stock for the maintenance procedures recommended in
the maintenance plan, and the optional spare parts, which can be requested to meet any replacement needs.
Table 8.3: Necessary and optional spare parts list
Spare parts
Temperature sensor for front and rear bearing
Space heater
Filter felt (if any)
Grounding Brush
Front and rear bearing for the fan motor (if applicable)
Lubricant for bearings
Vibration sensor for front and rear bearing (if applicable)
Vibration signal converter for front and rear bearing (if applicable)
Air temperature sensor (if applicable)
Water temperature sensor (if applicable)
Set of water leakage sensor (if applicable)
Repeater relay for water leak sensor (if applicable)
Water regulating valve (if applicable)
Motor for fan motor
Bearing
Teflon seal
Internal bearing cap
External bearing cap
Grease valve
Ring with labyrinth
Cylindrical pressure spring
Rolling bearing
(One piece for each bearing)
Protective ring against water ingress
Set of bearing shell
Floating labyrinth seal
Mechanical seal
Loose oil ring
Sleeve bearing (One piece
for each bearing)
Oil regulating valve (if applicable)
▲ Required spare parts
• Optional spare parts
• Recommended
▲ Highly Recommended
• • • • • •
• • • • • •
• •
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
• • • • • •
• • • • • •
50 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
NOTES
When placing an order for spare parts, inform the motor type and serial number, as specified on
motor nameplate.
Spare parts should be stored in a clean, dry, well-ventilated environment and, if possible, at a
constant temperature.
Page 51
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3
6
3
Verification
of the fastening of the stator
Measurement of the winding insulation
x
x
Control of noise, vibration, oil flow, leaks and
Inspection of the bearing shell and shaft
journal
According to the period indicated on
Inspection of the radiator sacrificial anodes (if
Replacement
of the gaskets of the radiator
Inspection, cleaning and replacement, if
Retightening of electrical and grounding
9 MAINTENANCE PLAN
The maintenance plan described in Table 9.1 is only referential, and the intervals between each maintenance intervention
may vary according to the motor location and operating conditions.
For the associated equipment, such as the water supply unit or control and protection system, it is necessary to refer to their
specific manuals.
Table 9.1: Maintenance plan
MOTOR PART Weekly Monthly
months
months
Annual
STATOR
Visual inspection of the stator.
Cleanliness control.
Inspection of the slot wedges.
terminals.
resistance.
ROTOR
Visual inspection.
Cleaning control.
Inspection of the shaft (wear, incrustations).
BEARINGS
temperature.
x
Lubricant quality control.
(sleeve bearing).
Lubricant change.
AIR-WATER HEAT EXCHANGER
Inspection of the radiators.
Cleaning of the radiators.
any).
heads.
x
AIR-AIR HEAT EXCHANGER
Cleaning of the ventilation ducts.
Inspection of the ventilation.
x
x
AIR FILTER(S)
necessary.
PROTECTION AND CONTROL EQUIPMENT
Record of the values.
x
Operation test.
Disassembly and operation test.
COUPLING
Inspection of the alignment.
Inspection of the fastening.
Inspection of the anti-reversion ratchet (if any).
WHOLE MOTOR
Inspection of noise and vibration.
Drainage of condensed water.
x
x
Retightening of the screws.
Cleaning of the terminal boxes.
connections.
years
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
the bearing nameplate.
Increase the inspection frequency in
case of excessive corrosion.
Every 2 months.
Check after the first week of operation.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 51
Page 52
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The instructions of
At least two power cables are interrupted,
Check the control panel, the power cables,
Do not apply load to the driven machine
Measure the power supply voltage, and set
Check the sizing of the installation
The stator current oscillates
Measure the power supply voltage and set it
Interruption
of the parallel wires or phases of
The noise normally decreases when the
10 ABNORMALITIES, CAUSES AND SOLUTIONS
NOTE
of questions, consult WEG.
ABNORMALITY POSSIBLE CAUSES CORRECTION
Neither coupled nor
uncoupled does the motor
Motor starts with no load, but
fails when load is applied It
starts very slowly and does
not reach the rated speed
under load with double the
slip frequency. Motor
presents a humming noise
Very high no load current
Hot spots in the stator
start
during starting
winding
Table 10.1 present only a basic list of abnormalities, causes and corrective actions. In case
Table 10.1: Basic list of abnormalities, causes and corrective actions
without voltage
Rotor is locked
Bearing damaged
Load torque is too high during the start
Power supply voltage is too low
Very high voltage drop in the power cables
Rotor with faulty or interrupted bar
A power cable was interrupted after the start
Rotor winding is interrupted
Power supply voltage is too high
Short-circuit between turns
the stator winding
Faulty connection
and the terminals
Unlock the rotor
Replace the bearing
during the start
it to the correct value
(transformer, cable section, relays, circuit
breakers, etc.)
Check and repair the rotor winding
Check the power cables
Check and repair the rotor winding
to the correct value
Rewind
Redo the connection
hot spots in the rotor
Abnormal noise during
operation with load
When coupled, there is noise;
when uncoupled, the noise
disappears
Interruptions in the rotor winding
Mechanical causes
Electrical causes
Defect in the coupling parts or in the driven
machine
Defect in the gear coupling
Unaligned/unleveled base
Faulty balancing of the components or of
the driven machine
Defective coupling
Wrong rotation direction of the motor
Repair the rotor winding or replace it
speed reduces, see also:
when uncoupled”
The noise disappears when the motor is
switched off. Consult WEG
Check the power transmission, the coupling
and the alignment
Align the drive set
Align/level the motor and the driven machine
Perform new balancing
Repair or replace the coupling
Invert the connection of two phases
“noisy operation
52 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 53
ABNORMALITY POSSIBLE CAUSES CORRECTION
Measure the stator current; reduce the load.
High number of starts or moment of inertia
Do not exceed 110% of the rated voltage,
Voltage too low
, therefore, the current is
very
Check the supply voltage and the voltage
Interruption in a power cable or in a winding
Measure the current in all the phases and, if
Check t
he air-gap, operating conditions
The operating condition does not correspond
Keep the operating condition according to
Unbalance in the power
supply (
blown
fuse
,
Check if there is voltage unbalance or
Rotation direction
is not compatible with the
Check the fan
regarding
to the motor
rotation
Noise remains during deceleration after
Interruption in one phase of the stator
The rotor balancing conditions become
Check the shaft warping or
rolling
bearing
Stator winding becomes
very hot under load
Noisy operation when
uncoupled
Fans with inverted rotation direction
Insufficient cooling due to dirty air channels
Overload
too high
Voltage too high, therefore, the iron losses
increase
high
phase
Rotor drags against the stator
to the nameplate data
wrong command)
Dirty windings
Air ducts clogged
Dirty air filter
fan used
Unbalance
winding
Fastening screws are loose
worse after the assembly of the coupling
Resonance in the foundation
Motor frame is deformed
Bent shaft
Air-gap is not even
www.weg.net
Correct the rotation direction of the fans
Open and clean the air passage channels
Analyze the motor application
Reduce the number of starts
except when otherwise specified on the
nameplate
drop in the motor
necessary, correct it
(vibration etc.), bearing conditions
the nameplate or reduce the load
operation with two phases and correct it
Clean
Clean the filter element
direction
disconnecting the voltage
Perform new balancing
Measure the current of all connecting cables
Retighten and lock the screws
Balance the coupling
Adjust the foundation
Check flatness of the base
The shaft may be warped
Check the rotor balancing and eccentricity
wear
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 53
Page 54
www.weg.net
11 DECLARATION OF CONFORMITY
54 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 55
12 ENVIRONMENTAL
INFORMATION
12.1 PACKAGE
Electric motors are supplied in cardboard, polymer, wood
or metallic material packages. These materials are
recyclable or reusable and must be properly disposed
according to the current regulations of each country. All
the wood used in the packaging of WEG motors comes
from reforestation and receives anti-fungal treatment.
12.2 PRODUCT
Electric motors, under the constructive aspect, are
manufactured mainly with ferrous metals (steel, cast iron),
nonferrous metals (copper, aluminum) and plastic.
The electric motor, in general, is a product that has a long
useful life; however, when it must be disposed, WEG
recommends that the materials of the packaging and of
the product be properly separated and sent for recycling.
The non-recyclable materials must be properly disposed
according to the environmental regulations, i.e., in
industrial landfills, co-processed in cement kilns or
incinerated. The service providers for recycling, disposal in
industrial landfills, co-processing or incineration of waste
must be properly licensed by the environmental agency of
each state to carry out these activities.
12.3 HAZARDOUS WASTE
Grease and oil waste used to lubricate the bearings
should be disposed, according to the instructions of the
relevant environmental agencies, because its improper
disposal can cause impacts to the environment.
www.weg.net
13 SERVICE NETWORK
To consult the Service Network, access the website
www.weg.net.
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 55
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14 WARRANTY TERM
These products, when operated under the conditions stipulated by WEG in the operating manual for such product,
are warranted against defects in workmanship and materials for twelve (12) months from start-up date or eighteen
(18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication, neglect
(including without limitation, inadequate maintenance, accident, improper installation, modification, adjustment,
repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation
expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do not
give Warranty extension, unless otherwise expressed in writing by WEG.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed
or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG
nor to assume for WEG any other liability in connection with any of its products.
In case this happens without WEG's authorization, Warranty is automatically cancelled.
LIABILITY
xcept as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
E
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any claims
for consequential damages or labor costs, by reason of any breach of the express warranty described therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled
"Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or
negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or
repair of any product described in this quotation and sold or furnished by the company to the purchaser.
56 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
WEG Group - Energy Business Unit
Jaraguá do Sul - SC - Brazil
Phone: 55 (47) 3276-4000
energia@weg.net
www.weg.net
Page 57
www.weg.net
NOTES
11371757 Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical l 57
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58 l Installation, operation and maintenance manual – Squirrel cage motor – M line – Vertical 11371757
Page 59
ARGENTINA
WEG EQUIPAMIENTOS ELECTRICOS S.A.
Sgo. Pampiglione 4849
Parque Industrial San Francisco
2400 - San Francisco
Phone: +54 (3564) 421484
www.weg.net/ar
AUSTRALIA
WEG AUSTRALIA PTY. LTD.
14 Lakeview Drive, Scoresby 3179,
Victoria
Phone: +03 9765 4600
www.weg.net/au
AUSTRIA
WATT DRIVE ANTRIEBSTECHNIK GMBH *
Wöllersdorfer Straße 68
2753, Markt Piesting
Phone: + 43 2633 4040
www.wattdrive.com
LENZE ANTRIEBSTECHNIK GES.M.B.H *
Ipf - Landesstrasse 1
A-4481 Asten
Phone: +43 (0) 7224 / 210-0
www.lenze.at
BELGIUM
WEG BENELUX S.A.*
Rue de l’Industrie 30 D,
1400 Nivelles
Phone: +32 67 888420
www.weg.net/be
BRAZIL
WEG EQUIPAMENTOS ELÉTRICOS S.A.
Av. Pref. Waldemar Grubba, 3000,
CEP 89256-900 Jaraguá do Sul – SC
Phone: +55 47 3276-4000
www.weg.net/br
CHILE
WEG CHILE S.A.
Los Canteros 8600,
La Reina - Santiago
Phone: +56 2 2784 8900
www.weg.net/cl
CHINA
WEG (NANTONG) ELECTRIC MOTOR
MANUFACTURING CO. LTD.
No. 128# - Xinkai South Road, Nantong
Economic & Technical Development Zone,
Nantong, Jiangsu Province
Phone: +86 513 8598 9333
www.weg.net/cn
COLOMBIA
WEG COLOMBIA LTDA
Calle 46A N82 – 54
Portería II - Bodega 6 y 7
San Cayetano II - Bogotá
Phone: +57 1 416 0166
www.weg.net/co
DENMARK
WEG SCANDINAVIA DENMARK *
Sales Office of WEG Scandinavia AB
Verkstadgatan 9 - 434 22 Kumgsbacka,
Sweden
Phone: +46 300 73400
www.weg.net/se
FRANCE
WEG FRANCE SAS *
ZI de Chenes - Le Loup13 / 38297 Saint
Quentin Fallavier,
Rue du Mo¬rellon - BP 738/
Rhône Alpes, 38 > Isère
Phone: + 33 47499 1135
www.weg.net/fr
GREECE
MANGRINOX*
14, Grevenon ST.
GR 11855 - Athens, Greece
Phone: + 30 210 3423201-3
www.weg.net/gr
GERMANY
WEG GERMANY GmbH*
Industriegebiet Türnich 3 Geigerstraße 7
50169 Kerpen-Türnich
Phone: + 49 2237 92910
www.weg.net/de
GHANA
ZEST ELECTRIC MOTORS (PTY) LTD.
15, Third Close Street Airport Residential Area,
Accra
Phone: +233 3027 66490
www.zestghana.com.gh
HUNGARY
AGISYS AGITATORS & TRANSMISSIONS
LTD.*
Tó str. 2. Torokbalint, H-2045 Phone: + 36
(23) 501 150
www.agisys.hu
INDIA
WEG ELECTRIC (INDIA) PVT. LTD.
#38, Ground Floor, 1st Main Road,
Lower Palace, Orchards,
Bangalore, 560 003
Phone: +91 804128 2007
www.weg.net/in
ITALY
WEG ITALIA S.R.L.*
Via Viganò de Vizzi, 93/95
20092 Cinisello Balsamo, Milano Phone: + 39
2 6129 3535
www.weg.net/it
FERRARI S.R.L.*
Via Cremona 25 26015
Soresina (CR), Cremona
Phone: + 39 (374) 340-404
www.ferrarisrl.it
STIAVELLI IRIO S.P.A.*
Via Pantano - Blocco 16 - Capalle 50010 ,
Campi Bisenzio (FI)
Phone: + 39 (55) 898.448
www.stiavelli.com
JAPAN
WEG ELECTRIC MOTORS JAPAN CO., LTD.
Yokohama Sky Building 20F, 2-19-12
Takashima, Nishi-ku, Yokohama City,
Kanagawa, Japan 220-0011
Phone: + 81 45 5503030
www.weg.net/jp
MEXICO
WEG MEXICO, S.A. DE C.V.
Carretera Jorobas-Tula
Km. 3.5, Manzana 5, Lote 1 Fraccionamiento
Parque Industrial
Huehuetoca
Estado de México - C.P. 54680
Phone: +52 55 53214275
www.weg.net/mx
NETHERLANDS
WEG NETHERLANDS *
Sales Office of WEG Benelux S.A. Hanzepoort
23C, 7575 DB Oldenzaal
Phone: +31 541 571090
www.weg.net/nl
PORTUGAL
WEG EURO - INDÚSTRIA ELÉCTRICA, S.A.*
Rua Eng. Frederico Ulrich,
Sector V, 4470-605 Maia,
Apartado 6074, 4471-908 Maia, Porto
Phone: +351 229 477 705
www.weg.net/pt
RUSSIA
WEG ELECTRIC CIS LTD *
Russia, 194292, St. Petersburg, Pro¬spekt
Kultury 44, Office 419
Phone: +7 812 3632172
www.weg.net/ru
SOUTH AFRICA
ZEST ELECTRIC MOTORS (PTY) LTD.
47 Galaxy Avenue, Linbro Business
Park Gauteng Private Bag X10011
Sandton, 2146, Johannesburg
Phone: +27 11 7236000
www.zest.co.za
SPAIN
WEG IBERIA INDUSTRIAL S.L
C/ Tierra de Barros, 5-7
28823 Coslada, Madrid
Phone: +34 91 6553008
www.weg.net/es
SINGAPORE
WEG SINGAPORE PTE LTD
159, Kampong Ampat, #06-02A KA PLACE.
368328
Phone: +65 68581081
www.weg.net/sg
SWEDEN
WEG SCANDINAVIA AB *
Box 27, 435 21 Mölnlycke
Visit: Designvägen 5, 435 33
Mölnlycke, Göteborg
Phone: +46 31 888000
www.weg.net/se
SWITZERLAND
BIBUS AG
Allmendstrasse 26, 8320 – Fehraltorf
Phone: + 41 44 877 58 11
www.bibus-holding.ch
UNITED ARAB EMIRATES
The Galleries, Block No. 3, 8th Floor,
Office No. 801 - Downtown Jebel Ali
262508, Dubai
Phone: +971 (4) 8130800
www.weg.net/ae
UNITED KINGDOM
WEG ELECTRIC MOTORS (U.K.) LTD.*
Broad Ground Road - Lakeside Redditch,
Worcestershire B98 8YP
Phone: + 44 1527 513800
www.weg.net/uk
ERIKS *
Amber Way, B62 8WG Halesowen
West Midlands
Phone: + 44 (0)121 508 6000
BRAMMER GROUP *
PLC43-45 Broad St, Teddington
TW11 8QZ
Phone: + 44 20 8614 1040
USA
WEG ELECTRIC CORP.
6655 Sugarloaf Parkway, Duluth, GA 30097
Phone: +1 678 2492000
www.weg.net/us
VENEZUELA
WEG INDUSTRIAS VENEZUELA C.A.
Centro corporativo La Viña Plaza,
Cruce de la Avenida Carabobo con la calle
Uzlar de la Urbanización La Viña / Jurisdicción
de la Parroquia San José - Valencia
Oficinas 06-16 y 6-17, de la planta tipo 2, Nivel
5, Carabobo
Phone: (58) 241 8210582
www.weg.net/ve
*
* European Union Importers
.*
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