Installation & Maintenance Manual Slip Ring Machines

October 2006 AMK 400-500

ABB SACE ABB


























This document has been carefully checked. However, if any errors are found, we ask the user to notify us as soon
as possible.
The specified data is only a description of this product and should not be interpreted as binding characteristics. In
the interest of our customers we continually improve our product to the latest technical development. Deviations
between products and product descriptions or these operating instructions can, therefore, occur.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure
to third parties without express authority is strictly forbidden.





Safety Instructions

AMA, AMB, AMC, AMH, AMK, AML, HXR


Safety and Ex-instructions-EN.doc ABB Electrical Machines 2003 1(2)
1 General
General safety regulations, specific agreements made for each work
site and safety precautions shown in this document must be
observed at all times.
2 Intended use
Electric machines have dangerous live and rotating parts and may
have hot surfaces. All operations serving transport, storage,
installation, connection, commissioning, operation and maintenance
shall be carried out by responsible skilled persons (in conformity
with EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling
may cause serious personal injury and damage to property. Danger!
These machines are intended for industrial and commercial
installations as components as defined in the Machinery Directive
(MD) 89/392/EEC. Commissioning is prohibited until conformity of
the end product with this directive has been established (follow
particular local safety and installation rules as e.g. EN 60204).
These machines comply with the harmonized series of standards
EN 60034 / DIN VDE 0530. Their use in hazardous areas is
prohibited unless they are expressly designed for such use (follow
additional instructions).
On no account, use degrees of protection IP 23 outdoors.
Air-cooled models are typically designed for ambient temperatures
of -20C up to +40C and altitudes of 1000 m above sea level.
Ambient temperature for air-/water-cooled models should be not
less than +5C (for sleeve-bearing machines, see manufacturer's
documentation). By all means, take note of deviating information on
the rating plate. Field conditions must conform to all rating plate
markings.
3 Transport, storage
Immediately report damage established after delivery to transport
company. Stop commissioning, if necessary. Lifting eyes are
dimensioned for the weight of the machine, do not apply extra loads.
Ensure the use of correct lifting eyes. If necessary, use suitable,
adequately dimensioned means of transport (e.g. rope guides).
Remove shipping braces (e.g. bearing locks, vibration dampers)
before commissioning. Store them for further use.
When storing machines, make sure of dry, dust and vibration free
location (danger of bearing damage at rest). Measure insulation
resistance before commissioning. At values of 1k per volt of
rated voltage, dry winding. Follow manufacturer's instructions.
4 Installation
Make sure of even support, solid foot or flange mounting and exact
alignment in case of direct coupling. Avoid resonances with
rotational frequency and double mains frequency as a result of
assembly. Turn rotor and listen for abnormal slip noises. Check
direction of rotation in uncoupled state.
Follow manufacturers instructions when mounting or removing
couplings or other drive elements and cover them with a touch
guard. For trial run without output elements, lock or remove the shaft
end key. Avoid excessive radial and axial bearing loads (note
manufacturer's documentation). The balance of the machine is
indicated as H = Half and F = Full key. With half-key models, the
coupling too, must be half-key balanced. In case of protruding,
visible part of the shaft end key, establish mechanical balance.
Make necessary ventilation and cooling system connections. The
ventilation must not be obstructed and the exhaust air, also of
neighbouring sets, not taken in directly.
5 Electrical connection
All operations must be carried out only by skilled persons on the
machine at rest. Before starting work, the following safety rules must
be strictly applied:
De-energize!
Provide safeguard against reclosing!
Verify safe isolation from supply!
Connect to earth and short!
Cover or provide barriers against neighbouring live parts!
De-energize auxiliary circuits (e.g. anti-condensation heating)!
Exceeding of limit values of zone A in EN 60034-1 / DIN VDE
0530-1 - voltage 5%, frequency 2%, waveform and symmetry -
leads to higher temperature rise and affects the electromagnetic
compatibility. Note rating plate markings and connection diagram in
the terminal box.
The connection must be so made that permanent safe electrical
connection is maintained. Use appropriate cable terminals. Establish
and maintain safe equipotential bonding.
The clearances between uninsulated live parts and between such
parts and earth must not be below the values of appropriate
standards and values possibly given in manufacturers
documentation.
No presence of foreign bodies, dirt or moisture is allowed in the
terminal box. Close unused cable entrance holes and the box itself
in a dust- and watertight manner. Lock the key when the machine is
run without coupling. For machines with accessories, check
satisfactory functioning of these before commissioning.
The proper installation (e.g. segregation of signal and power lines,
screened cables etc.) lies within the installer's responsibility.
6 Operation
Vibration severity in the "satisfactory" range (V
rms
4.5 mm/s)
according to ISO 3945 is acceptable in coupled-mode operation. In
case of deviations from normal operation - e.g. elevated temperature,
noises, vibrations - disconnect machine, if in doubt. Establish cause
and consult manufacturer, if necessary.
Do not defeat protective devices, not even in trial run. In case of
heavy dirt deposits, clean cooling system at regular intervals. Open
closed condensate drain holes from time to time.
Grease the bearings during commissioning before start-up.
Regrease antifriction bearings while the machine is running. Follow
instructions on lubrication plate. Use right kind of grease. In case of
sleeve-bearing machines, observe time-limit for oil-change and if
equipped with oil supply system make sure the system is working.
7 Maintenance and servicing
Follow manufacturer's operating instructions. For further details, see
the comprehensive Users Manual. Preserve these safety
instructions!
8 Frequency converter
In frequency converter applications motor frame external
earthing must be used for equalising the potential between the
motor frame and the driven machine, unless the two machines are
mounted on the same metallic base. For motor frame sizes above
IEC 280, use 0.75 x 70 mm flat conductor or at least two 50 mm
round conductors. The distance of the round conductors must be at
least 150 mm from each other.
This arrangement has no electrical safety function; the purpose is to
equalise the potentials. When the motor and the gearbox are
mounted on a common steel fundament, no potential equalisation is
required.


U1
V1
W1
PE
3 ~ M
Driven machinery
0.75 mm
70 mm
> 150 mm
min 50 mm
Cables/wires Plate/strip
Potential equalisation






To comply with EMC-requirements, use only cables and connectors
approved for this purpose. (See instruction for frequency
converters.)


Additional Safety Instructions for Electrical
Motors for Hazardous Areas

IEC 60079-0; Std. concerning General Requirements for
Explosive Atmospheres
IEC 60079-2; Std. concerning Ex p protection
IEC 60079-7; Std. concerning Ex e protection
Safety and Ex-instructions-EN.doc ABB Electrical Machines 2003 2(2)
Note
IEC 60079-15; Std. concerning Ex nA protection
IEC 1241-1-1 Std. concerning Dust Ignition Protection
These instructions must be followed to ensure safe and proper
installation, operation and maintenance of the motor. They should
be brought to the attention of anyone who installs, operates or
maintains this equipment. Ignoring the instruction may invalidate the
warranty.
BS 5000:16; Std. concerning Ex N protection
ABB machines (valid only for group II) can be installed in areas
corresponding to following marking:
Zone (IEC) Category (EN) Marking
1 2 EEx p, EEx pe ,EEx e
Warning
Motors for hazardous areas are specially designed to comply with
official regulations concerning the risk of explosion. If improperly
used, badly connected, or alter, no matter how minor, their reliability
could be in doubt.
Ex p, Ex pe ,Ex e
2 3 Ex nA ,Ex N, EEx nA

Atmosphere (EN);
G explosive atmosphere caused by gases
D explosive atmosphere caused by dust
Standards relating to the connection and use of electrical apparatus
in hazardous areas must be taken into consideration, especially
national standards for installation. Only trained personnel familiar
with these standards should handle this type of apparatus.
Reception check
- Immediately upon receipt check the machine for external
damage and if found, inform the forwarding agent without
delay.
Declaration of Conformity
- Check all rating plate data, especially voltage, winding
connection (star or delta), category, type of protection and
temperature marking.
All ABB machines comply with:
- The Low Voltage Directive 73/23/EEC amended by Directive
93/68/EEC
Notice following rules during any operations!
- EMC Directive 89/336/EEC, amended by Directives 92/31/EEC
and 93/68/EEC Warning !
- Certificate of Incorporation with respect to the Machinery
Directive 89/392/EEC, amended by Directives 91/368/EEC,
93/44/EEC and 93/68/EEC
Disconnect and lock out before working on the machine or the
driven equipment. Ensure no explosive atmosphere is present while
the work is in progress.
- All ABB Ex-machines, which have a CE-mark on the rating
plate comply with the ATEX Directive 94/9/EC Starting and Re-starting
- The maximum number of the sequential starts has been
declared in machines technical documents.
Validity
These instructions are valid for the following ABBs electrical motor
types, when the machine is used in explosive atmospheres. - The new starting sequence is allowed after the machine has
cooled to the ambient temperature (-> cold starts) or to
operating temperature (-> warm starts).
Non-sparking Ex nA, Ex N, EEx nA
- AMA Induction Machines, sizes 315 to 500
- AMB Induction Machines, sizes 560 to 710 Earthing and Equipotentialing
- HXR Induction Machines, sizes 315 to 560
- Check before starting that all earthing and equipotentialing
couplings are effectively connected.
- AMC Induction Machines, sizes 800 to 1000
Increased safety EEx e, Ex e
- Do not remove any earthing or equipotentialing cables, which
has been assembled by the manufacturer.
- AMA Induction Machines, sizes 315 to 500
- AMB Induction Machines, sizes 560 to 710
- HXR Induction Machines, sizes 315 to 560
Clearances, creepage distances and separations
- AMC Induction Machines, sizes 800 to 1000
- Do not make any removal or adjustment in terminal boxes,
which could decrease clearances or creepage distances
between any parts.
Pressurisation EEx pe, Ex pe, EEx p, Ex p
- AMA Induction Machines, sizes 315 to 500
- AMB Induction Machines, sizes 560 to 710
- Do not install any new equipment to terminal boxes without
asking for advises from ABB.
- HXR Induction Machines, sizes 315 to 560
- AMC Induction Machines, sizes 800 to 1000
- Be sure that air gap between rotor and stator is measured after
any maintenance for the rotor or bearings. The air gap shall be
the same in any point between stator and rotor.
Dust Ignition Protection (DIP)
- AMA Induction Machines, sizes 315 to 500
- AMB Induction Machines, sizes 560 to 710
- HXR Induction Machines, sizes 315 to 560
- Centralise the fan to the centre of the fanhood or the air guide
after any maintenance. The clearance shall be at least 1% of
the maximum diameter of the fan and in accordance with
standards.
- AMC Induction Machines, sizes 800 to 1000
(Additional information may be required for some machine types
used in special applications or with special design.)
Conformity Connections in terminal boxes
- All connections in main terminal boxes must be made with Ex-
approved connectors, which are delivered with the machine by
the manufacturer. In other cases ask an advice from ABB.
As well as conforming to the standards relating to mechanical and
electrical characteristics, motors designed for explosive
atmospheres must also conform to the following IEC or CENELEC
standards: - All connections, in auxiliary terminal boxes, as marked
intrinsically safe circuits (Ex i) must be connected to proper
safety barriers.
EN 50014; General norm concerning explosion-proof
material.
EN 50016; Std. concerning EEx p protection
Note !
EN 50019; Std. concerning EEx e protection
If there are any conflicts between this instruction and user manual,
this document is prevailing.
EN 50021; Std. concerning EEx nA protection
EN 50281-1-1 Std. concerning Dust Ignition Protection
ABB
User`s Manual, AMK 400-500
Chapter 1 - Introduction

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 3
Chapter 1 - Introduction
1 General ....................................................................................................................................................4
2 Documentation........................................................................................................................................4
2.1 About this manual ........................................................................................................................4
2.2 Documentation of the machine ....................................................................................................4
2.3 Documentation of starting, speed control and other equipment....................................................4
3 Machine...................................................................................................................................................4
3.1 Serial number of the machine ......................................................................................................4
3.2 Rating and lubrication plate .........................................................................................................4
3.3 Direction of rotation.....................................................................................................................5
3.4 Mounting and machine definitions ..............................................................................................5
3.5 Normal operating conditions........................................................................................................5
3.6 Intended use .................................................................................................................................5
3.7 AMK machines type ....................................................................................................................5
4 Limitation of liability ..............................................................................................................................6

User`s Manual, AMK 400-500
Chapter 1 - Introduction ABB

4 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 1 - Introduction
1 General
This Users Manual applies to slip ring machines of
the type AMK made by ABB Induction Machines.
The information may sometimes be of a general
nature and applicable to the various machines.
Where a conflict exists between the contents
herein and the actual machinery supplied, the user
must either make an informed engineering
judgement as to a course of action or, if any doubt
exists, contact ABB.
This document and parts thereof must not be
reproduced, copied, imparted to a third party or
used for any unauthorized purpose without the
express written permission of ABB.
Note! To avoid accidents, safety measures
and devices required at the installation site
must be in accordance with the instructions and
regulations stipulated for safety at work. This
applies to general safety regulations of the
country in question, specific agreements made
for each work site and safety instructions
included in this manual.
2 Documentation
2.1 About this manual
The manual is based on 12 Chapters:
- Chapters 1-9: Machine related information
from transport and storage to maintenance
and repair.
- Chapter 10: Checklists to help operating the
machine. Lists should be kept for reference
during maintenance and trouble-shooting.
- Chapter 11: Trouble-shooting sheets to help
inspectioning and trouble-shooting the
machine.
- Chapter 12: Machine related drawings and
additional information e.g. bearing
construction and foundation instruction.
2.2 Documentation of the machine
The manual is delivered with each machine and is
located in a plastic cover on the machine frame.
Each machine is supplied with a final dimension
drawing and electrical connection diagram
showing information on the following (as
applicable):
- Mounting and outline dimensions
- Weight and load on foundation
- Location of lifting eyes
- Instrumentation
- Bearing oil requirements
- Main and auxiliary connections.
Note! Some customer specific items may not
be included in this manual or the machine
delivery. Additional documentation should be
requested.
2.3 Documentation of starting, speed
control and other equipment
This manual does not include any information
about starting or speed control equipment (e.g.
liquid coupling, control rheostat, cascade drive).
This information is performed according to each
equipment manual.
3 Machine
3.1 Serial number of the machine
Each machine is identified with a serial number.
It is stamped on the rating plate and machine
frame.
3.2 Rating and lubrication plate
A rating plate is fixed to the machine frame. It
shows the most important electrical data and
identification information (Figure 1).
ABB
User`s Manual, AMK 400-500
Chapter 1 - Introduction

10
11
12
13
14
15
16
17
18
2
3
1
4
5
6
7
8
9
60034-1

1 Type designation 10 Serial number
2 Year of manufacture 11 Output in kW
3 Duty 12 Stator voltage
4 Type of connection 13 Frequency
5 Insulation class 14 Rotating speed
6 Machine weight in kg 15 Stator current
7 Degree of protection 16 Power factor (coso)
8 Type of cooling 17 Rotor voltage
9 Mounting arrangement 18 Rotor current
Fig. 1. Standard rating plate (IEC version).
A lubrication plate is also fixed to the machine
frame. It shows the type of the bearings and
lubrication information.
3.3 Direction of rotation
Arrow plate on the machine frame indicates the
direction of rotation. The machine should be
operated only in the direction(s) of the arrow.
(Figure 2).


Clockwise Counter-clockwise Bi-directional
Fig. 2. Arrow plates.
3.4 Mounting and machine definitions
In this manual mounting arrangements and
machine ends are presented as in Figure 3.
D
N
N
D
D-end (DE, D) = Drive End
N-end (NDE, N) = Non-Drive End
IM 1001 IM 4011
horizontal foot mounting vertical flange mounting
Fig. 3. Mounting arrangements and machine
ends.
3.5 Normal operating conditions
Each machine is individually designed and
manufactured to operate in normal or abnormal
operation conditions according to IEC or NEMA
standard, customer specification and internal
standards of ABB.
Normal operating conditions:
- Max ambient temperature +40C (+104 F).
- Max operating height 1000 m (3280 ft) above
sea level.
- Foundation shall be free from external
vibration.
- Surrounding air shall be free of dust, salt and
corrosive gases.
The deviating ambient temperature and operating
height is stamped on the rating plate. Other
deviations agreed between the Customer and ABB
are informed on the sales documentation.
3.6 Intended use
Electric machines have dangerous live and
rotating parts and may have hot surfaces. All
operations serving transport, storage, installation,
connection, commissioning, operation and
maintenance shall be carried out by responsible
skilled persons (in conformity with EN 50 110-1 /
DIN VDE 0105 / IEC 60364). Improper handling
may cause serious personal injury and damage to
property.
These machines are intended for industrial and
commercial installations as components as
defined in the Machinery Directive (MD)
89/392/EEC. Commissioning is prohibited until
conformity of the end product with this directive has
been established (follow particular local safety
and installation rules as e.g. EN 60204).
These machines comply with the harmonized
series of standards EN 60034 / DIN VDE 0530.
Their use in hazardous areas is prohibited unless
they are expressly designed for such use (follow
additional instructions).
3.7 AMK machines type
AMK machines are based on a modular
construction. They are available in horizontal and
vertical mounting types and the standard shaft
heights are 400, 450 and 500 mm (respectively in
inches). Machines are weather protected or totally
enclosed equipped with air-to-air or air-to-water
heat exchanger (Figures 4, 5 and 6).
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 5
User`s Manual, AMK 400-500
Chapter 1 - Introduction ABB

The purpose of the slip ring gear is to allow the
machine to start with an adjustable and
controllable amount of current and/or torque and
run the machine with the rotor winding short
circuited without brush wear.

4 Limitation of liability
In no event shall ABB be liable for direct,
indirect, special, incidental or consequential
damages of any nature or kind arising from the
use of this document or any hardware described in
this document.
Fig. 4. Weather protected machine IC01 IP23 /
WP-I, IC01 IPW24 / WP-II.

ABB`s warranty covers manufacturing or material
defect. It does not cover the damage caused by
improper storage conditions, incorrect installation
or operating against specifications. General
conditions are defined according to Orgalime S92
specification.
Fig. 5. Air-to-water cooled machine IC81W
IP55 / TEWAC.
Note! ABB`s warranty is not valid, if
operation conditions, supply or load are
changed inappropriately during machines
lifetime.

Warranty will remain valid only if proposed
amendments in the construction or repair work
to the machine are accepted by an approval
from the ABB office / supplier factory.
Local ABB office may hold different warranty
details, which are specified in the sales terms,
conditions or warranty terms.
Fig. 6. Air-to-air cooled machine IC611 IP55 /
TEAAC.
AMK machines cover the power range 180-2500
kW at 50 Hz, 250-4000 HP at 60 Hz and the
speed range 500-1500 rpm and 600-1800 rpm
respectively. Adjustable speed is also available.
The voltage range cover from 380-11500 V (AC).
If you have any questions, please contact your
local ABB representative or the factory:
ABB SACE S.p.A.
Via dellIndustria, 18
20010 Vittuone (MILAN)
The slip ring unit, that locates always at the N-
end, is equipped with a permanent contact or brush
lifting type slip ring unit. The permanent contact
type unit has a similar heat exchanger or
protective cover as that of the machine. The brush
lifting type unit is always totally enclosed and does
not require any heat exchanger.
ITALY
Tel. +39 02 9034.1
Fax +39 02 9034.7272
Internet: www.abb.com/motors&drives
6 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 2 - Transport and Storage

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 7
Chapter 2 - Transport and Storage
1 Protective measures prior to transport.....................................................................................................8
2 Packages and lifting ................................................................................................................................8
2.1 Unpacked machine.......................................................................................................................8
2.2 Machine on pallet.........................................................................................................................9
2.3 Machine in ocean freight package ...............................................................................................9
3 Checks.....................................................................................................................................................9
3.1 Check on arrival...........................................................................................................................9
3.2 Check on unpacking.....................................................................................................................9
4 Storage ....................................................................................................................................................9
4.1 Storage conditions........................................................................................................................9
4.2 Short term storage (less than 2 months).......................................................................................9
4.3 Long term storage (over 2 months)............................................................................................10
4.3.1 Antifriction bearings.......................................................................................................10
4.3.2 Sleeve bearings...............................................................................................................10
4.4 Inspections, records....................................................................................................................11
4.5 Care after installation.................................................................................................................11



User`s Manual, AMK 400-500
Chapter 2 - Transport and Storage ABB

Chapter 2 - Transport and Storage
1 Protective measures prior to
transport
The following protective measures are made
before delivery at the factory:
- Machines with cylindrical roller and sleeve
bearings are provided with a bearing locking
device.
- Ball and roller bearings are greased with
ESSO/EXXON UNIREX N3 or MOBILUX
EP2.
8 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
- Sleeve bearings are bathed in oil and drained
after that. Oil tubes are plugged.
- Air-to-water coolers are drained and water
tubes are plugged.
- Blank metal surfaces (e.g. shaft extensions)
are protected with an anti-corrosive coating.
2 Packages and lifting
Before the machine is lifted, ensure that suitable
lifting equipment is available and personnel is
familiar with lifting work. The weight of the
machine is shown on the rating plate, dimension
drawing and packing list.
Note! Each machine has strong lifting eye(s)
to carry the load of the machine. Do not apply
extra load or confuse them to other lifting lugs
that are only to help service personnel to
dismantle/ assemble the machine.
2.1 Unpacked machine
The machine should always be lifted by crane
from the lifting eye(s) on the frame of the
machine (Figures 1 and 2). The machine should
never be lifted by forklift truck from the bottom.

Fig. 1. Lifting of the horizontal machines.

Fig. 2. Lifting of the vertical machines.
Note! Machines with upper cover, fan cover
or slip ring unit should be lifted with a proper
lifting beam or lifting triangle to prevent
damaging these constructions.
Vertical mounting rib cooled machines may
have turnable lifting eyes for lifting and turning
the machine. Turning from vertical to
horizo l position, or vice versa, is sh nta own in
Figure Avoid damaging the painting 3. or any
parts during the procedure. Remove/install the
bearing locking device when the machine is in
vertical position.
ABB
User`s Manual, AMK 400-500
Chapter 2 - Transport and Storage

a) b)
c)
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 9
d)

Fig. 3. Machine with turnable lifting eyes: lifting
and turning.
2.2 Machine on pallet
The machine on a pallet should be lifted by crane
from the lifting eye(s) (Figures 1 and 2) on the
frame of the machine or by forklift truck from the
bottom of the pallet. The machine is fixed to the
ith
2.3 Machine in ocean freight package
by forklift truck
pallet w bolts.
The package should be lifted
from the bottom or by crane with lifting slings.
The sling positions are painted to the package
(Figure 4).
PACKAGE NO.
SLING POSITION
METAL STRAP
PACKING LIST
CENTER OF GRAVITY
ADDRESS
SHIPPING INSTRUCTION
WEIGHTS
DIMENSIONS

Fig. 4. Ocean freight package.
3 Checks
3.1 Check on arrival
When the transport company delivers the machine
to the customer, the responsibility for the
handling passes to the customer or other party. If
damage has occurred during transportation do at
least the following:
- Photograph all damage, including damage in
the transportation box.
- Report any transport damage within one
week after arrival, if the transport insurance
is to be claimed. Check evidence of careless
handling and report immediately to the
transport company and the supplier. Use
Checklist 1 in Chapter Checklists.
3.2 Check on unpacking
After the package has been removed, check that
the machine is not damaged and all accessories
to the supplier,
if there is any damage, suspect of damage or if
ng. Use Checklist 1 in
4 Storage
riginal containers in a proper
warehouse.
uld be clean, dry and
aximum
v
ecklist 2 in Chapter
utdoors or in
ins. Leave space
boards.
ally that the heater is operating.
are included. Report immediately
components are missi
Chapter Checklists.
4.1 Storage conditions
Machines with their associated control enclosures
are stored in their o
The storage warehouse sho
ventilated. Corrosive gases, dust, shocks or
vibration are not allowed. Protect the machine
also against insects and vermin such as termites
and rodents.
The storage temperature should be from 10C to
50C (from 50F to 120F) with a m
relati e humidity of 75 %.
4.2 Short term storage (less than 2
months)
A machine that is not installed immediately
should not be left without supervision or
protective precautions. Obey the following
paragraphs and Ch
Checklists.
If the machine is temporarily left o
an open hall, cover it with tarpaul
for ventilation between the machine or machine
package and tarpaulins. Protect the machine or
package also against ground damp by placing it
on battens or
If relative humidity is higher than 75 %, turn the
anti-condensation heater on. To prevent
condensation of moisture, keep the machine 5C
(9F) above the dew point of the ambient air.
Check periodic
User`s Manual, AMK 400-500
Chapter 2 - Transport and Storage ABB

10 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
If anti-condensation heater is not fitted, apply an
alternative method of heating. Instead of heating,
the machine can be protected from humidity by
using moisture absorbing material, such as Silica-Gel.
by placing rubber blocks (fit
the measures described with short
g insulation resistance of
rotating machines).
ons)
every three months. If any corrosion is
t
oden box. Protect
them against water, insects and vermin.
with cylindrical roller
If shocks or vibration is present or may occur later,
isolate the machine
for the purpose) under the feet.
4.3 Long term storage (over 2 months)
In addition to
term storage, the following should be applied.
1. Measure the insulation resistance every three
months. The lowest rated value for insulation
resistance test at 40C (104F) is 40 MO
[megaohms] (IEEE 43-1974, Recommended
practice for testin
2. Measure the winding temperature (Pt-100)
every three months.
3. Check the condition of anti-corrosive coating
on blank metal surfaces (e.g. shaft extensi
observed, remove it with a fine emery cloth
and perform the treatment again.
4. Check the condition of painted surfaces every
three months. If rust is observed, remove i
and apply a coat of paint again.
5. Arrange small ventilation openings when the
machine is stored in a wo
4.3.1 Antifriction bearings
Apply also the following measures:
1. Turn the rotor 10 revolutions every two
months to keep the antifriction bearings in
good condition (before turning, remove
possible bearing locking device).
2. Check the bearing locking periodically
(horizontal machines
bearing and vertical machines may be provided
with a locking device to protect the bearings
against damage during transport and storage).
Tighten the shaft end locking screw to the
required degree depending on the axially
locating bearing type (Tables 1 and 2). A too
tight fixing can damage the bearing.
Table 1. Tightening torque for horizontal machines
(lubricated screw). Axially locating
bearing = deep groove ball bearing
carries the locking force.
Axially locating bearing Tightening torque [Nm]
type
6317 50
6319 60
6322 120
6324 140
6326 160
6330 240
6334 300
6034 140
Table 2. Tightening torque for vertical machines
(lubricated screw). Axially locating bearing
= angular contact ball bearing carries the
locking force.
Axially locating bearing
type
Tightening torque [Nm]
7317 30
7319 30
7322 60
7324 60
7326 90
7330 160
7334 350
4.3.2 Sleeve bearings
Apply also the following measures:
1. If the storing period is longer than two
months, spray Tectyl 511 or other anti-
corrosion film-forming oil to the bearing
through the filling hole.
2. Dismount the upper cover of bearing housing
every six months. Check the anti-corrosion
oil layer of the shaft and the inside of the
bearing. Repeat the anti-corrosion protection.
3. If the storing period is longer than two years,
the bearing has to be taken apart and treated
separately. If the environment is humid, a
package of Silica-Gel can be placed in the
bearing case.
4. After storage it is recommended that the
bearings are opened according to the
dismantling notes, and the bearing journal
and lining are inspected before
ABB
User`s Manual, AMK 400-500
Chapter 2 - Transport and Storage

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 11
commissioning. Remove any corrosion with
e emery cloth. If the shaft has left
nts on the lower liner-half, replace it
new one.
a fin
impri
with a
5.
(machi ith sleeve bearings are provided
with a g device to protect t earings
against age during transport and storage).
Tighte shaft end locking sc to the
requir gree depending on axially
locatin ring type (Table 3). o tight
fixing ca age the bearing.
Table 3. ning torque (lubrica screw).
locating bearing carries the locking
Axially locating bearing Tightening torque [Nm]
Check the bearing
nes w
locking periodically
lockin he b
dam
n the rew
ed de the
g bea A to
n dam
Tighte
Axially
ted
force.
type
RENK ZMNLB 7 100
REN 250 K EFZLB 9
RENK EFZLB 11 300
RENK EFZLB 14 600
4.4 Inspections, records
The conservation period, used methods and
measures with dates should be recorded.
e feet of the
4.5 Care after installation
If the machine is not in operation for a long time
after installation, the measures described earlier
apply. If external vibration is present, the shaft
coupling should be opened and suitable rubber
blocks should be placed under th
machine.
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment ABB

12 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 3 Installation and Alig
1 General......................................................................
2 Design of foundation ................................................
2.1 Horizontal foot mounted machines............................................................................................ 13
2.2 Vertical flange mounted machines ............................................................................................ 13
3 Installation of horizontal foot mounted machines................................................................................. 14
3.1 Scope of delivery....................................................................................................................... 14
3.2 General preparations.................................................................................................................. 14
3.3 Machine preparations ................................................................................................................ 14
3.4 Foundation and grouting hole preparations ............................................................................... 14
3.5 Foundation plate or sole plate preparations ............................................................................... 14
3.6 Erection onto the foundation ..................................................................................................... 15
3.7 Grouting..................................................................................................................................... 15
3.8 Final installation........................................................................................................................ 15
4 Installation of vertical flange mounted machines.................................................................................. 15
4.1 General preparations.................................................................................................................. 15
4.2 Machine preparations ................................................................................................................ 15
4.3 Erection onto the mounting flange ............................................................................................ 15
5 Alignment of horizontal foot mounted machines.................................................................................. 15
5.1 General ...................................................................................................................................... 15
5.2 Rough levelling ......................................................................................................................... 16
5.3 Rough adjusting......................................................................................................................... 16
5.4 Correction for thermal growth................................................................................................... 16
5.4.1 Growth upwards ............................................................................................................. 16
5.4.2 Axial growth................................................................................................................... 16
5.5 Alignment check........................................................................................................................ 16
5.5.1 Run-out at the coupling halves....................................................................................... 16
5.5.2 Radial and axial misalignment ....................................................................................... 17
5.6 Doweling of the machine feet.................................................................................................... 17
6 Alignment of vertical flange mounted machines .................................................................................. 17
6.1 General ...................................................................................................................................... 17
6.2 Axial thermal growth and coupling type ................................................................................... 17
6.3 Alignment check........................................................................................................................ 18
6.3.1 Run-out at the coupling halves....................................................................................... 18
6.3.2 Radial and axial misalignment ....................................................................................... 18
7 Acceptable misalignment...................................................................................................................... 18
8 Belt drive .............................................................................................................................................. 19
nment
............................................................................ 13
............................................................................ 13
ABB
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment

Chapter 3 Installation and Alignment
1 General
2.1 Horizontal foot mounted machines
Calcul a
respon
operat
undert
When
capacit
parts, i
2
The fo tio
free sp
ensure
monito
away f
Care has to
equipm
air. The incom
have the same
be flat
resonan
designe
foundation to
20% range o
correctly designed steel construction is also
acceptable. Anchorage to the foundation, provision
of air, water, oil and cable channels as well as
location of grouting holes should be considered
prior to construction.
The foundation and the mounting bolts must be
dimensioned to withstand a sudden mechanical
torque, which occurs when starting the machine or
at short circuit. The short circuit force is a
gradually damped sine wave type vibration that
changes direction. The machine has to be tightly
bolted to the foundation, in order for the machine
to be as vibration free as possible.
ation nd design of the foundation is not
The stress imposed on the foundation for
included in the ABB undertaking and the
custom
horizontal foot mounted machine can be
er or the third party is therefore
calculated with the aid of the following formulas
sible for it. Furthermore, the grouting
and Figure 1:
ion is also normally outside ABB
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 13
aking and responsibility. SI:
a machine is purchased, available lifting
y, lifting height, roads for transport, spare
nstallation tools etc. should be checked.
Design of foundation
unda n design should assure safe running
conditions with maximum accessibility. Sufficient
ace should be left around the machine to
easy access for maintenance and
ring. The cooling air should flow to and
rom the machine without obstruction.
be taken that other machines or
ent near do not heat the machine's cooling
ing cooling air of the machine must
temperature as surrounding air.
The foundation must be strong and rigid. It shall
and free from external vibration. To avoid
ce vibrations with the machine it shall be
d so that the natural frequency of
gether with machine is not within
f running speed frequency.
Concrete foundation is preferred, however, a
T 8
A
m g F = 5 . 0 where
]

]
]
]
F = stress on foundation per side [N
g = acceleration due to gravity [m/s2]
m = weight of the machine [kg
T = rated torque of the machine [Nm
A = distance between mounting holes [m
US:
T 8
2E
W F = 5 . 0 where
f]
f]
t]
t]
F = stress on foundation per side [lb
W = weight of the machine [lb
T = rated torque of the machine [lbf x f
2E = distance between mounting holes [f
8T
A (IEC)
2E (NEMA)

Fig. 1. Dimensions A and 2E.
The foundation shall be designed to permit 2 mm
(0.8 inch) shim plates under the feet of the
machine. That is to ensure an adjusting margin
and facilitate the installation of a replacement
machine with different shaft height compared to
the original machine.
Position of the grouting holes and height of the
foundation must agree with corresponding
dimensions on the provided dimensional drawing.
2.2 Vertical flange mounted machines
Vertical flange mounted machines are equipped
with a mounting flange. The flange of the
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment ABB

14 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
machine will always be mounted to the opposite
flange on foundation.
the coupli
Mechanic
A mounting adapter is recommended to enable an
easy coupling connection and inspection during
operation.
3 Installation of horizontal foot
does not
bolts, foundation
plate set or sole plate set. These are delivered
ete
ati is used,
.
o be
used between the machine feet and the
0.5,
curate and
precise alignment within the specified
- Remove the anti-corrosive coating on shaft
end and machine feet with white spirit. Install
ng half as described in Chapter
al and Electrical Connections.
- Check that the drain plugs at the lowest part
of both ends of the machine are in open
position (half of the plug inside and half
3.4 Foundation and grouting hole
count:
The upper part of the f dation has to
swept or vacuum cleaned.
ust have roug
ip. For the sa
ashed and rinsed. O
by chipping aw
- A steel wire is attached on the foundation to
nter line of the machine.
al position of the m ne should also
r sole plate
To assemble the foundation plate or sole plate set,
the machine must be suspended above the floor.
Proceed as follows (Appendix 1):
1. Screw greased leveling screw (6) to the
foundation plates (1) or sole plates (1).
2. Wrap a layer of tape (not in the foundation
plate or sole plate delivery) around the upper
part of the anchor bolts (2) according to
Appendix 1. The tape prevents th part of the
t fr he concrete and
l fter the concrete
ge (3) and the lower nut (4)
e
(1) under the machine foot with the mounting
the foundation plate or sole plate with white
mounted machines
3.1 Scope of delivery
As a standard the machine delivery
include shim plates, mounting
according to special order. The following
Paragraphs include the installation procedure of
foundation or sole plate set onto a concr
found on. If a rigid steel foundation
proceed straight to Paragraph Alignment
3.2 General preparations
Before starting of the installation procedure, take
the following aspects into account.
- Reserve 2 mm (0.8 inch) shim plates t
foundation.
- Reserve sheet steel material for shimming
under the feet of the machine. Possible
adjustments require shim thickness of 1,
0.2, 0.1 and 0.05 mm (40, 20, 8, 4 and 2 mil).
- Reserve adjusting screws or hydraulic jacks
for axial and horizontal adjustment.
- Reserve dial indicator gauges or preferably a
laser optical analyzer to achieve ac
tolerances.
- Provide sun and rain protection to eliminate
measuring errors during installation.
3.3 Machine preparations
Prepare the machine for installation as follows:
- Remove the bearing locking device. Store it for
future transportation and storage.
- Fill appropriate oil through the filling holes
into the sleeve bearings. A simple lever arm is
needed for turning the rotor during alignment.
outside).
preparations
To prepare the foundation take the following
aspects into ac
- oun be
- Walls of the grouting holes m h
surfaces to give a good gr me
reason they must be w il
or grease must be removed ay
slices of the concrete surfaces.
indicate the ce The
axi achi be
marked.
3.5 Foundation plate o
preparations
is
bol om getting stuck in t
enab es it to be retightened a
has set.
3. Fit the anchor bolt (2) in the foundation
plates (1) or sole plates (1) so that the top of
the anchor bolts is 1...2 mm (40...80 mil)
above the upper surface of the nuts (4).
4. Fit the anchor flan
to the anchor bolts (2). Bridge the anchor flange
(3) to the bolts by welding and tighten the nuts.
If the bridging cannot be done, lock the anchor
flange between two nuts.
5. Mount the foundation plate (1) or sole plat
bolt (8) and washer (9). Before that, clean the
anti-corrosive coating on the upper surface of
ABB
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 15
spirit. Center the mounting bolt (8) in the
hole of the machine by wrapping e.g. paper,
cardboard or tape around the upper part of
t and the plate (1). Fasten the plate
tig
Pl
le sliding plate
(n plate or sole plate
de ng plate. The sliding
ine is
still suspended above the floor, machine feet,
tes as well as
anchor bolts are cleaned with white spirit. To
, they must be
unpainted.
2 mm (80
machine into the foundation is a
, which
al months of
anchor bolts are grouted into the concrete. The
e grouting
compound or a poor attachment to the concrete
spects into account.
other
eq ntal adjustment.
pecified
ction to eliminate
follows:
e anti-corrosive coating on shaft
spirit.
n d in
Ch nical and Electrical
are in open
ure is started, the

4
the bolt.
6. Place the 2 mm (0.8 inch) shim (7) between
the foo
htly against the foot with a mounting bolt (8).
7. ace the leveling plate (5) under the
velling screw (6) and a thin
ot in the foundation
livery) under the levelli
plate is made of steel and it helps to move the
machine sideways and in axial direction.
8. Check that the space between the plate (1) and
the anchor bolts (2) is tight. If concrete
penetrates through this interstice up to the
nuts, the retightening cannot be done.
When the assembly is done and the mach
sides and bottom surfaces of the pla
ensure that the anchor bolts and plates are
satisfactorily attached to the concrete
After the previous steps the machine is ready to
be erected onto the foundation.
3.6 Erection onto the foundation
The machine is lifted and placed onto the
foundation. A rough horizontal alignment is made
with the aid of the previously installed steel wire
and the marking of the axial location. A vertical
alignment is made with the levelling screws.
Required positioning accuracy is within
mil).
3.7 Grouting
Grouting of the
very important part of the installation. Problems
can arise if materials are of poor quality
5 A
may show up early or after sever
operation.
After the settings and alignment checks, the
instructions of the grouting compound supplier
must be followed. Cracks in th
foundation cannot be accepted.
3.8 Final installation
Retighten the anchor bolt nuts after the concrete
has set. Lock the nuts by bridging or hitting
sufficiently hard with a center punch.
4 Installation of vertical flange
mounted machines
.1 General preparations
Before starting of the installation procedure, take
the following a
- Reserve a recoil hammer and
uipment for horizo
- Reserve dial indicator gauges or preferably a
laser optical analyzer to achieve accurate and
precise alignment within the s
tolerances.
- Provide sun and rain prote
measuring errors during installation.
- Clean the mounting flange of the foundation.
4.2 Machine preparations
Prepare the machine for installation as
- Remove the bearing locking device. Store it
for future use.
- Remove th
end and machine flange with white
I stall the coupling half as describe
apter Mecha
Connections.
- Check that the two drain plugs at the lower
end shield of the machine
position (half of the plug inside and half
outside).
After the previous steps the machine is ready to
be erected onto the mounting flange of the
foundation.
4.3 Erection onto the mounting flange
The machine is lifted and placed onto the mounting
flange. The mounting bolts are tightened lightly.
lignment of horizontal foot
mounted machines
5.1 General
When a machine is aligned with another machine,
the radial as well as the angular deviation between the
two shafts have to be minimized.
Before the alignment proced
coupling halves have to be installed. Refer to the
Chapter Mechanical and Electrical Connections
for installation of the coupling half of the
machine. In order to move freely during
alignment, the coupling halves must be bolted
together loosely.
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment ABB

5.2 Rough levelling
To facilitate the alignment in the vertical plane
and enable the mounting of earlier mentioned
shim plates, jack
16 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ing screws are fitted to the feet of

the machine (Figure 2). Do not ever tight the
mounting bolts against jacking screws, use always
shim plates. The level is checked for example
with a spirit level. The machine must stand on all
four feet (feet shall be plain parallel within 0.1
mm (4.0 mil) or better).
JACKING SCREW

Fig. 2. Vertical positioning.
5.3 Rough adjusting
To facilitate the alignment in offset and axial
directions, place the bracket plates with adjusting
screws at corners (Figure 3).
BRACKET WITH ADJUSTING SCREW

Fig. 3. Positioning of bracket plates.
Bracket plates are placed against the foundation
edge and tied down with an expansion bolt
(Figure 4).
Move the machine by using the four axial
adjusting screws until the shaft centerline and the
driven machine centerline are aligned roughly and
the desired distance between the coupling halves
is reached. Leave all adjusting screws only lightly
tightened.
BRACKET WITH ADJUSTING SCREW
EXPANSION BOLT

Fig. 4. Mounting of the bracket plate.

Tempe influence and
during the
alignment. The machine temperature is lower
compensating
owth of the electrical machine
e
[mm]
o = 10 10 K
]
he formula:


-6
K
-1

e length [mm]

Chapter Checklists the alignment check is done
xact,
der ent
in the systems). The
o give a background of the
5.4 Correction for thermal growth
ratures have a considerable
should therefore be considered
during erection than under operating conditions.
Therefore it may be necessary to use
alignment. This depends on the operating
temperature of the driven machine, coupling type,
distance between machines, etc.
5.4.1 Growth upwards
The thermal gr
upwards can be approximately calculated
according to the formula:
AH = o AT H wher
AH = thermal growth
-6 -1
AT = 30 K (AM_ machines), 40 K (HXR
machines)
H = shaft height [mm
5.4.2 Axial growth
The expected thermal growth of the rotor in
proportion to the stator frame, in case of fixed
bearing in the N-end, can be approximately
calculated according to t
AL = o AT L where
AL = thermal growth [mm]
o = 12 10
AT = 50 K (AM_ machines), 100 K (HXR
machines)
L = fram
5.5 Alignment check
In the following Paragraphs and Checklist 3 in
with dial gauges, although there are more e
mo n and common used measuring equipm
market (e.g. laser optical
reason for that is t
alignment theory.
The alignment check results should always be
recorded in a log.
5.5.1 Run-out at the coupling halves
Alignment check is started by measuring the run-out
at the coupling halves. This measurement will show
possible inaccuracy of the shaft / coupling half
systems.
ABB
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment

Measure the run-out at the cou
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 17
pling half of the
machine in respect to the bearing housing of the
machine (Figure 5). Respectively, check the run-
out at the coupling half of the driven machine in
respect to the bearing housing of the driven
machine. A simple lever arm is needed to turn a
rotor of a sleeve bearing machine (fill the bearing
with oil before turning). Admissible run-out error
is s 0.02 mm (0.8 mil).

Fig. 5. Measuring the run-out at the coupling
ts verify that the
shaft/coupling systems are in acceptable condition,
mount the gauge to the coupling flanges by means
of suitable fastening devices (eliminate the
possibility of sag). The following measurement will
show possible alignment or installation
inaccuracies.
All readings for radial and axial misalignment are
determined in the gauge positions: top, bottom
right and left, i.e. every 90, while both shafts are
simultaneously turned (Figure 6). Finally ch k
coupling
halves.
half.
5.5.2 Radial and axial misalignment
If the run-out measuremen
ec
the axial distance between the two

Fig. 6. Measuring the radial and axial
misalignment and distance between the
two coupling halves.
Correct the possible misalignment by adding or
removing shim plates or turning the adjusting
screws until the acceptable tolerances are reached.
Refer to the values presented in Paragraph 7,
Acceptable misalignment.
After the acceptable tolerances are reached, th
g required
9 Nm,
M30 1138 Nm, M36 1991 Nm, M39 2570 Nm,
are needed,
er.
Now the machine is ready for doweling the feet of
5.6 Doweling of the machine feet
m owel hole per foot of t
r uitable
to the holes to ensure th
easier the possible n
m igned with another mach
e angular deviation betw
minimized.
l g o the
nd Electrical Connection
e coupling half of th
e freely during
must be bolted
al growth and coupling
type
e considered during the
lower
e itions.
etween machines, etc. e
mountin bolts are tightened to the
degree (M20 334 Nm, M24 569 Nm, M27 83
M42 3178 Nm, M48 4601 Nm). Coupling halves
are disconnected to wait for a test run according to
Chapter Commissioning and Start-up.
After the test run is made and machine/driven
machine system has been running within the
permissible vibration until normal operating
temperatures are reached, the machine is stopped
and alignment is checked. If corrections
proceed them as presented earli
the machine and completing the installation and
alignment procedure.
The achine has one d he
machine at the D-end. by Deepen the holes
drilling to the steel foundation. After that the
holes a e tapered with a scraper tool. S
pins are fit tapered ted e
exact alignment and ew
installations.
6 Alignment of vertical flange
mounted machines
6.1 General
When a achine is al ine,
the radial as well as th een
the two shafts have to be
Before the alignment procedure is starte
coup in halves have to be installed. Refer t
d, the
Chapter Mechanical a s
for installation of th e
machine. In order to mov
alignment, the coupling halves
together loosely.
When the mating surfaces of the flanges on
machine and on foundation are compatible, the
alignment is easier to perform than the alignment
of a foot mounted machine.
6.2 Axial therm
Temperatures have a considerable influence and
should therefore b
alignment. The machine temperature is
during rection than under operating cond
Therefore it may be necessary to use compensating
alignment. This depends on the operating
temperature of the driven machine, coupling type,
distance b
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment ABB

6.3 Alignment check
In the following Paragraphs and Checklist 3 in
Chapter Checklists the alignment check is done
with dial gauges, although there are more exact,
modern and common used measuring equipment in
the market (e.g. laser optical systems). The reason
for that is to give a background of the alignment
theory.
18 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
The alignment check results should always be
recorded in a log.
6.3.1 Run-out at the coupling halves
Alignment check is started by measuring the run-
out at the coupling halves. This measurement will
show possible inaccuracy of the shaf coupling half
systems.
Measure the run-out at the coupling halve of the
of the
e run-
t/
machine in respect to the bearing housing
machine (Figure 7). Respectively, check th
out at the coupling halve of the driven machine in
respect to the bearing housing of the driven
machine. Admissible run-out error is s 0.02 mm
(0.8 mil).

Fig. 7. Measuring the run-out at the coupling
flange.
6.3.2 Radial and axial misalignment
If the run-out measurements verify that the shaft/
coupling systems are in acceptable condition,
mount the gauge to the coupling flanges by means
of suitable fastening devices (eliminate the
possibility of sag). The following measurement
will show possible alignment or installation
All readin
determined ns: top, bottom
inaccuracies.
gs for radial and axial misalignment are
in the gauge positio
right and left, i.e. every 90, while both shafts are
simultaneously turned (Figure 8). Finally check
the axial distance between the two coupling
halves.

Fig. 8. Measuring the radial and axial
en the
he
unt
degree M27 839 Nm,
6 1991 Nm, M39 2570 Nm,
4601 Nm). Coupling halves
chine/driven
a s 0.02 mm (0.8 mil)
b (coupling 100...250 mm)
misalignment and distance betwe
two coupling halves.
Correct the possible misalignment with a recoil
hammer by hitting the shield of the machine
lightly to the needed direction until the acceptable
tolerances are reached. Refer to the values
presented in Paragraph 7, Acceptable
misalignment.
After the acceptable tolerances are reached, t
mo ing bolts are tightened to the required
(M20 334 Nm, M24 569 Nm,
M30 1138 Nm, M3
M42 3178 Nm, M48
are disconnected to wait for a test run according to
Chapter Commissioning and Start-up.
After the test run is made and ma
machine system has been running within the
permissible vibration until normal operating
temperatures are reached, the machine is stopped
and alignment is checked. If corrections are needed,
proceed them as presented earlier.
7 Acceptable misalignment
Maximum permissible radial misalignment and
axial displacement (Figure 9):
r, a
Rigid flange coupling r,
Gear coupling r, a s 0.05 mm (2 mil)
Flexible coupling r, a s 0.10 mm (4 mil)
flange diameter
Rigid flange coupling b s 0.01 mm (0.4 mil)
Gear coupling b s 0.03 mm (1 mil)
Flexible coupling b s 0.05 mm (2 mil)
b (coupling flange diameter 250...500 mm)
Rigid flange coupling b s 0.02 mm (0.8 mil)
Gear coupling b s 0.05 mm (2 mil)
Flexible coupling b s 0.10 mm (4 mil)
ABB
User`s Manual, AMK 400-500
Chapter 3 - Installation and Alignment

b a
r
a


Radial misalignment r
Gap (angular displacement) b
g the run-out at the coupling.
bove.
urers indicate what the coupling can
The alignment of the machine must be performed
with great caution. Remember to log all
measurements, used devices and methods for
future checks.
8 Belt drive
Machines designed for belt drives are always
equipped with cylindrical roller bearing in the D-
end.
Axial displacement a
Fig. 9. Measurin
Note! Do not exceed the radial force specified
in the order definitions.
The normal accepted misalignments are as a
A definite tolerance is impossible to state because
too many factors have an influence.
Because the tolerances given by the coupling
manufact
If a belt d
and the dr ctly aligned.
rive is used, make sure that the driving
iven pulleys are corre
Note! Suitability of the shaft-end and the
bearings for the belt drive must be checked
allways before use.

survive, do not use them for judgement of how
accurate the alignment should be. Too large
tolerances will cause vibration and lead to
bearing/machine damage. Therefore it is
recommended to aim at as narrow tolerances as
recommended.
Note! IC611 AMK-machines are normally
not suitable for belt drive operation.

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 19
User`s Manual, AMK 400-500
Chapter 4 - Mechanical and Electrical Connections ABB

20 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 4 - Mechanical and Ele
1 General.................................................................................................................................................. 21
2 Mechanical connections.......................................................................................................
2. e coupling half ................
...............................
............................... ................................................................... 21
2.2 Couplin .............. 21
bearings .....
....................................................................................... 21
....................................................................................... 22
....................................................................................... 22
..................................
.......... .... 22
...................................................................................... 22
ith freq
............
............ ......................................... 23
.................................................................................... 23
in cables .................................................................... 23
machi . 24
uxiliary terminal box and connection of acce .. 24
3.6 Earth connections ...................................................................................................................... 24
3.7 Connection of external blower motor ............................................................................................ 24

ctrical Connections
................. 21
............................................................................. 21
............................................................................ 21
.........
1 Assembly of th ......
2.1.1 Balancing.............
2.1.2 Assembly.............
g type ..............................................................................................................
2.2.1 Machines with antifriction .......................................................................... 21
2.2.2 Machines with sleeve bearings
2.3 Air connections...................................
2.4 Water connections ..............................
2.5 Oil supply system....... ............................................................................. 22
........................................................................ 3 Electrical connections.....................................
3.1 Safety...................................................
3.2 EMC requirements for machines fed w
3.2.1 Main cable................................
3.2.2 Earthing of main cable .............
3.2.3 Auxiliary cables .........................
3.3 Main terminal box and connection of ma
3.4 Connection of secondary cables (AMK
3.5 A
uency converter ................................................ 22
.......................................................................... 23
.................................
nes only) ..........................................................
ssories ............................................................

ABB
User`s Manual, AMK 400-500
Chapter 4 - Mechanical and Electrical Connections

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 21
Chapter 4 - Mechanical and Electrical Connections
1 General
Mecha
after installa
Mechanical c
coupli
supply system
include conne
earthin
motor.
4 in Ch
nical and electrical connections are made
tion and alignment procedure.
onnections include connection of
ng halve, air ducts, water tubes or oil
as applicable. Electrical connections
ction of main and auxiliary cables,
g cables and possible external blower
Follow the next Paragraphs and Checklist
apter Checklists as applicable.
Note! Additional installation holes or threads
shoul e d nev r be drilled trough the frame.
2 ch
2.1 em
2.1.1
As a standard
ith half key. The way of balancing is stamped to
the shaft end as H = half key and F = full key. The
oupling half must be balanced respectively.
2.1.2 Assembly
When assembling the coupling half, take the
following instructions into account:
- Clean the shaft extension from anti-corrosive
coating and check measurements of extension
and coupling against the provided drawings.
Ensure also that the keyways in the coupling
and the shaft extension are clean, free from
burrs and truly parallel.
- Coat the shaft extension and hub bore with a
thin layer of cylinder oil. Never coat mating
surfaces with molybdenum diosulphide
(Molykote) or similar products.
- The weight of the coupling half can be
considerable. Suitable lifting gear may be
needed.
- The coupling must be covered with a touch
guard.
- Follow the coupling suppliers instructions.
Me anical connections
Ass bly of the coupling half
Balancing
the rotor is dynamically balanced
w
c
Note! No additional forces should be caused
to the bearings during the coupling half
assembly.
2.2 Coupling type
2.2.1 Machines with antifriction bearings
When the machine is equipped with antifriction
bearings, it must be connected to the driven
machine with flexible coupling (pin couplings, gear
couplings).
Make sure that continuous free axial movement is
possible between the coupling halves in order to
permit thermal expansion of the machine shaft
without damaging the bearings. The expected
axial thermal growth of the rotor can be
calculated as defined in Chapter Installation and
Alignment.
Vertical machine may be designed to carry some
load from the shaft of the driven machine. Then
the coupling halves have to be locked against
slipping in the axial direction e.g. by a lock plate
on the end of the shaft.
2.2.2 Machines with sleeve bearings
Sleeve bearing construction allows the rotor to
move axially between mechanical end float
limits. Standard bearings can not withstand any
axial force from the driven machine. Therefore all
axial force must be carried by the driven machine
and coupling must be of limited axial float type.
Sleeve bearing is equipped with a pointer for
running center which is marked with a groove on
the shaft. There are also grooves on the shaft for
rotor mechanical end float limits. The pointer
must always be within the limits (Figure 1).
Notice that the running center is not necessarily
the same as the magnetic center (fan may pull the
rotor from the magnetic center).
User`s Manual, AMK 400-500
Chapter 4 - Mechanical and Electrical Connections ABB

POINTER
22 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ROTOR END FLOAT LIMITS
OUTER SEAL

Fig. 1. Markings on shaft and running center
pointer.
2.3 Air connections
Machines designed for cooling air flow to and / or
f
fl awing.
Connect the ducts and seal the joints with
appropriate gaskets. After connection, perform a
with an air-to-water heat
aks.
ystem
hat case the
fitted before
a minimum angle of 10 which
the bearing sump. This can result in
Install the oil supply system near the machine in
equal distance from each bearing. Test the oil
supply system first by using rinsing oil. After this,
en connect
system and
bearings with appropriate oil. After connection,
perform a check for possible leaks. Prior to
starting the machine, oil supply has to be turned
on.
3
3.1 Safety
be carried out only by
skilled persons on the machine at rest. The
olation from supply!
- Connect to earth and short!
0530-1 - voltage 5%, frequency
2%, waveform and symmetry - leads to higher
uninsulated live parts and
between such parts and earth must not be below
0
d
cy converter is
installed with screened cables specified below.
For information on other equivalent cables, please
contact your local ABB representative.
rom the machine with ducts have connection
anges specified in the dimensional dr
check for possible leaks and obstructions.
2.4 Water connections
Machines equipped
exchanger have flanges specified in standards
DIN 633 or ANSI B 16.5. Connect the flanges
and seal the joint with appropriate gasket. After
connection, perform a check for possible le
2.5 Oil supply s
Sleeve bearing machines may be designed to have
a forced lubrication system. In t
bearings are equipped with flanges to connect all
necessary oil pipes. Running of the machine
without connection to the oil supply system
prevents the bearings to have an appropriate
lubrication. That results immediately in a bearing
damage.
Start the connection by cleaning all oil pipes and
rinsing them with rinsing oil. A pressure gauge
and a flow indicator are often provided at the oil
inlet. These are normally already
delivery.
Install the outlet pipes downwards from the
bearings at
corresponds to 160 to 170 mm/m (2 - 2 in/ft).
The oil level will increase if the oil is flowing too
slowly from
oil leaks or disturbances in the flow.
remove the oil filter and clean it. Th
the pipes and fill the oil supply
Electrical connections
Electrical connections must
following safety rules must be strictly applied:
- De-energize!
- Provide safeguard against reclosing!
- Verify safe is
- Cover or provide barriers against
neighbouring live parts!
- De-energize auxiliary circuits (e.g. anti-
condensation heating)!
Exceeding of limit values of zone A in EN 60034-
1 / DIN VDE
temperature rise and affects the electromagnetic
compatibility. Note rating plate markings and
connection diagram in the terminal box.
The clearances between
the following values: 8 mm at UN s 550 V, 1
mm at UN s 725 V, 36 mm at UN s 3.3 kV, 60
mm at UN s 6.6 kV and 100 mm at UN s 11 kV.
Connection must be made in such a way that
permanent safe electrical connection is maintained.
Appropriate cable terminals must be used. The
proper installation (segregation of signal an
power lines, earthing, screened cables etc.) lies
within the installer's responsibility.
3.2 EMC requirements for machines fed
with frequency converter
Compliance with the EMC directive (89/336/
EEC, as amended by 93/68/EEC) requires that the
AC machine fed with frequen
ABB
User`s Manual, AMK 400-500
Chapter 4 - Mechanical and Electrical Connections

3.2.1 Main cable
The main cable installed between the machine
and the frequency converter must be a
symmetrical three conductor screened cable in
order to fulfil the radiated emission requirements
stated in the generic emission standard for
industrial environment EN 50081-2. The cable
types MCCMK and AMCCMK from NOKIA
KAAPELI and VUSO and VO-YMvK-as from
DRAKA KABEL have been tested and approved
by ABB for low voltage (<1 kV) frequency
r
other man s can be used as well.
ble
STEM
cable transits for shielded installations.
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 23
converte applications. Equivalent cables from
ufacturer
3.2.2 Earthing of main ca
EMC directive requires high frequency earthing
of the main cable. This is achieved by a 360
earthing of the cable screens at the cable entries
both in the machine and in the converter. The
earthing at the machine is implemented for
example by means of the EMC ROX SY
Note! 360 high frequency earthing of cable
entries is done in order to suppress
electromagnetic disturbances. In addition,
cable screens have to be connected to
protective earth (PE) in order to meet safety
regulations.
3.2.3 Auxiliary cables
The auxiliary cables must as well be screened to
meet the EMC requirements. Special cable glands
must be used for the 360 high frequency earthing
of the cable screens at the cable entries.
3.3 Main terminal box and connection
of main cables
The inside of main terminal box must be free of
terminal box is equipped with a drain
plug at the lowest part of the end plate. The plug
west part of
size of input cables have to be adequate for
the maximum load current and in accordance with
be of
dirt, moisture and foreign bodies. The box itself,
cable glands and unused cable entrance holes
must be closed in a dust- and watertight manner.
The main
should be in open position (half of the plug inside
and half outside) during transportation and storage.
During operation the plug should be kept in shut
position but opened from time to time. If the box
is turned after delivery the drain plug functioning
must be checked and positioned at lo
the box.
Before the connection of cables can be started, the
connection diagrams delivered with the machine
have to be studied carefully. It is important to
verify that the supply voltage and the frequency are
the same as the values indicated on the rating plate
of the machine.
The
local standards. The cable terminals have to
appropriate type and of correct size.
Note! Prior to connection work, it is
important to check that the incoming cables are
separated and earthed properly.
The stator terminals are marked with letters U, V
T2 and
al terminal
(NEMA).
nected U, V and
and L3, the
ckwise direction

and W according to IEC 34-8 or with T1,
T3 according to NEMA MG-1. A neutr
th T0 is marked with N (IEC) or wi
When the supply cables are con
W and the phase sequence is L1, L2
machine will rotate in clo
(looking at the D-end).
Figure 2 presents standard medium voltage
terminal boxes according to IEC and NEMA
standards.

Fig. 2. Main terminal boxes: IEC medium voltage
(upper) and NEMA medium voltage.
Main terminal boxes can be turned in 90 degrees
steps. Before turning, check that the length of the
cables is sufficient.
User`s Manual, AMK 400-500
Chapter 4 - Mechanical and Electrical Connections ABB

Main cable phases with lugs are tightened to
stator terminals with connecting nuts. Tightening
Before the connection of accessories can be
started, the connection diagrams delivered with
the machine have to be studied carefully. The
connection and f
torque presented in Table 1 should be applied.
Table 1. Tightening torque of the connecting nut.
The size and material of
the connecting nut
Tightening torque [Nm]
M12 (Steel) 7583
M16 (Bronze) 40
3.4 Connection of secondary cables
(AMK machines only)
unctioning of accessories must be
checked before commissioning.
rrespondingly
labelled.
Terminals of accessories, which are normally
under voltage when the machine is switched off
(e.g. space heaters), must be co
Note! Circuit may be live!
3.6 Earth connections
e frame does typically not
cause any harm to the product e.g. bearings. Mark
The slip ring housing serves as a te
the secondary cables. It has the s
rminal box for
ame degree of
hat is
d
t
w
B
c
h ied carefully.
box and
connection of accessories
li h
termin ands (Figure 3). The
maximum size and voltage of the cables is limited
The machine frame, main terminal box and
associated equipment must be connected to the
earth with suitable cable blocks. Earth connection
and the power supply have to be such that
harmful or dangerous potential can not be created
to the machine frame. Voltage under 250 mV
between the shaft and th
protection as that of the machine. The cables can
be connected from either the right or left hand
side.
The cable entry flange is according to DIN 42962
and up to four 100 mm diameter cables can be
connected per side. The connection is made to
rotor terminals on the termination plate, t
esigned to fit up to 6 cable lugs / phase. The
erminals are marked K, L and M in accordance
ith IEC Publications 34-8.
efore the connection of cables can be started, the
onnection diagrams delivered with the machine
ave to be stud
the machine and terminal boxes with earth symbol
according to relevant national standards.
Note! Warranty is not valid if bearing is
destroyed due to wrong earthing or cabling.
3.7 Connection of external blower motor
The external blower motor is normally three
phase asynchronous motor. The motor rating plate
shows the voltage and frequency. The direction of
rotation is indicated by an arrow plate on the
flange of the machine.
3.5 Auxiliary terminal
Auxiliary terminal box(es) are attached to the
frame of the machine according to accessories
and customer needs.
Auxi ary terminal boxes are equipped wit
al blocks and cable gl Note! Check the direction of rotation of the
external blower motor before starting the
to 2,5 mm
2
and 750 V. Cable glands are in
accordance with DIN 46320 Teil 1.
machine.
If the motor is running in wrong direction, the
phase sequence must be changed.
Fig 3. Auxiliary terminal box.
24 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 25
Chapter 5 Commissioning an
1 e. .........
........................................................
1 ia for human saf ......................
for dry winding .........................
ng the insulation r stance of stator ............................................................26
1.5 Measuring the insulation resistance of rotor winding (AMK machines only) ...........................27
................ ............................27
2 .....................................................................................................................27
3 Protections.................................................................................................................. 27
nt .....................................................................................27
...........
(RTD)
..........
4.2 Bearing temperature control..........................
(RTD)
..........
..........
..........
..........
..........
he first ...........29
s with antifriction bearings ...............................................................................29
ve bearin
............. ..30

d Start-up
Insulation resistanc
1.1 General..
....................................... .............................................................................26
.............................................................................26
.............................................................................26
.............................................................................26
winding...
.2 Criter ety ........
1.3 Criteria
1.4 Measuri
.......
esi
1.6 Measuring value..............................
Drying the windings.........
...............................................
...........................
4 Alarm and trip limits of the control equipme
4.1 Stator winding temperature control ......
4.1.1 Resistance temperature detectors
4.1.2 Thermistors (PTC)...................
............................................................................27
.............................................................................27
.............................................................................28
.............................................................................28
.............................................................................28
.............................................................................28
.............................................................................28
.............................................................................28
.............................................................................29
.............................................................................29
start .........................................................
4.2.1 Resistance temperature detectors
4.3 Tripping ..............................................
5 Test start.........................................................
5.1 Starting of AMK machines .................
5.2 Checks before test start .......................
6 The first start ..................................................
6.1 Supervision and maintenance during t
6.1.1 Machine
6.1.2 Horizontal machines with slee
6.2 Vibrations ..........................................

gs......................................................................29
.........................................................................

User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up ABB

Chapter 5 Commissioning and Start-up
1 Insulation resistance
26 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
1.1
Before ac
after a long
scope
asu
machin he
winding.
The in
information a h
the ins
machin
normal
conditi m
extremely m
resistance bec
.2 Criteria for human safety
or safe (human safe) starting of the machine,
inimum acceptable insulation resistance of the
indings at temperature 40C (104F) can be
etermined by using the following formula:
R
40C
= 1 + U
N

where:
R
40C
= insulation resistance [megaohms, MO]
U
N
= rated supply voltage of the machine [kV]
1.3 Criteria for dry winding
To judge if a winding has got moist, higher
insulation resistance limits than those defining the
safe starting conditions (human safety) must be
considered. For a clean and dry winding the
insulation resistance value is typically very high - in
the order of thousands of megaohms. Depending
on the winding type, the insulation resistance value
may be very sensitive to moisture inside the
machine. As a thumb rule 1000 MO is
recommended to be applied as the minimum
accepted insulation resistance value prior starting a
machine.
- Measured insulation resistance values are
compared with values given in the test report.
Usually the star point connection or delta
connection of high voltage machine can not be
opened. Then the indicator should be connected
between the whole winding and the frame of the
machine, the frame earthed. (Figure 1).
General
moist it shall be dried carefully independent on the
In general, if a machine is suspected to have got
measured insulation resistance value.
a m hine is started up for the first time,
period of standstill or within the
The insulation resistance value will decrease when
of general maintenance work, the winding
the winding temperature rises. The resistance is
insulation resistance shall be measured. For
halved for every 10...15 K temperature rise.
squirrel cage machines this includes the
me ring of the stator winding. For slip ring
1.4 Measuring the insulation resistance
es t measuring includes also the rotor
of stator winding
sulation resistance measurements provide
measured with an insulation resistance indicator.
The insulation resistance of the stator winding is
bout t e humidity and dirtiness of
Required notes and measures:
ulation. Consequently, necessary measures
for cleaning and drying can be determined. New
- All power supply cables are disconnected.
es and machines with new windings have
- The frame of the machine and the stator
ly very high resistance insulation.
winding phases not been tested are earthed.
However, unsuitable transportation or storage
ons ight subject the machine to such
- All resistance temperature detectors (RTD)
oist conditions that the insulation
are earthed.
omes far too low.
- Measurement device is checked.
- Winding temperatures are measured.
1
F
m
w
d
M
O

Fig. 1. Measuring the insulation resistance of the
whole stator winding.
If it is possible to open the star point connection,
the indicator should be connected between one
winding phase and the frame of the machine at a
time, all other phases and the frame earthed
(Figure 2).
ABB
User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up

MO

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 27
Fig. 2. Measuring the insulation resistance of an
individual stator winding phase.
Note! After measurement the winding phases
must be earthed for discharging them.
1.5 Measuring the insulation resistance
of rotor winding (AMK machines
The frame of the machine and the stator
- The shaft and rotor winding phases not bee
ding temperatures are measured
as a reference value for the rotor
ding temperature).
are
co port.
ne winding
a time, all
only)
The insulation resistance of the rotor winding is
measured with an insulation resistance indicator.
Required notes and measures:
- All power supply cables are disconnected.
- The slip ring unit connection cables are
disconnected.
-
winding are earthed.
n
tested are earthed.
- The carbon brush connections are checked.
- Measurement device is checked.
- Stator win
(considered
win
- Measured insulation resistance values
mpared with values given in the test re
The indicator is connected between o
phase and the shaft of the machine at
other phases and the shaft earthed (Figure 3).
M
O

Fig. 3. Measuring the insulation resistance of an
Note! After measurement the winding phases
must be earthed for discharging them.
1.6 Measuring value
one decade
or more lower than the value measured in the
ation
resistance value measured in the factory.
the windings see
Chapter "Maintenance".
s
s
nce with the instructions and
uipment
es, e.g.
too
The machine parameter values for relay settings
are informed in the document Performance data
of machine, which is delivered after order.
The insulation resistance of new machine is
normally very high. As a thumb rule it can be
taken that if the measured value is
factory, check the winding for excess moisture or
dirt, as well as the calibration of the measuring
device. The test report contains the insul
2 Drying the windings
If the windings have been affected by damp to an
extent that the insulation resistance is too low, dry
the windings. For drying
3 Protections
The machine has to be protected against variou
disturbances that might damage it. Protection
must be in accorda
regulations for each country.
Protective relays are used to protect the eq
from different disturbances and stress
overloading in operation, or in starting (like
long or too many consecutive or stall startings),
supply disturbances or faults, switching errors and
insulation faults like earth faults. The scope of relay
protection in practice depends on the actual
application characteristics, local network and other
protective means, which may be needed.
Note! ABB is not responsible for relay
settings at site.
4 Alarm and trip limits of the
control equipment
Sta
ble based on the test results and
empirical operating temperature behaviour of the
4.1 tor winding temperature control
4.1.1 Resistance temperature detectors
(RTD)
With Pt-100 and other corresponding elements,
alarm and trip limit temperatures should be set as
low as possi
individual rotor winding phase.
User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up ABB

28 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
machine. Alarm limit can be set e.g. 10 and trip
limit 20 K higher than the winding temperature of
the machine at max load at highest ambient
temperature.
Recommended settings:
1 function: trip 120-140C (250-285F)
2 functions: alarm 120-140C (250-285F)
The maximum recommended settings defined to
p
1 function: trip 160C (320F)

4.1.2 Thermistors (PTC)
g function can be
is
arm and trip signals
s
ature behaviour of the
2 functions: alarm 85C (185F)
trip 90C (195F)
The limits can be set 20C (70F) higher, when
appropriate high temperature grease is used. See
Chapter Maintenance.
Sleeve bearings
ion:
2 function

T gher, when
appropriate high temperature oil is used. See
fter the
installation and alignment procedure is finished,
cklist 5 in Chapter
Checklists.
5.1 Starting of AMK machines
tor phase. Selection
of starter is done according to required starting
rting is not
ken into
account in settings.
trip 130-150C (265-300F)
rotect the windings are:
2 functions: alarm 160C (320F)
trip 180C (355F)
If the machine is equipped with three thermistors,
the operating temperature of the thermistors is
150C (300F). The operatin
chosen to be alarm or trip signal. If the machine
equipped with six thermistors, the operating
temperatures are 150C (300F) and 170C
(340F). In that case both al
can be used.
4.2 Bearing temperature control
4.2.1 Resistance temperature detector
(RTD)
With Pt-100 and other corresponding elements,
alarm and trip limit temperatures should be set as
low as possible based on the test results and
empirical operating temper
bearings. The maximum recommended settings
for normal operating with standard lubricants are:
Antifriction bearings
1 function: trip 90C (195F)
1 funct trip 90C (195F)
s: alarm 85C (185F)
trip 90C (195F)
he limits can be set 10C (50F) hi
Chapter Maintenance.
4.3 Tripping
In case of tripping, the reason must always be
found out and eliminated before the machine is
restarted. Use Trouble-Shooting 1 and 2 for
finding out the reason.
5 Test start
Test start is a standard procedure a
mechanical and electrical connections (except the
coupling connection) are made, commissioning
procedure is gone through and protective devices
are active. See Che
Slip ring machine type AMK can not be started
without a starter. Starter is typically a variable
resistance connected to each ro
torque and current. Typically starting is done with
nominal current and nominal torque.
During starting the starter resistance is decreased
and speed for breakdown torque is shifted towards
higher speed. The speed of the machine is always
between actual breakdown torque speed and
synchronous speed. Operation between slip=1 and
breakdown torque or stall during sta
allowed.
Normal protective relays are designed for use with
squirrel cage machines and this must be ta
Note! Failure in starting the machine without
checking the adjustments of the complete slip
ri gear can result in serious damage! Al ng so
co ections to the starter and functions with nn it
shall is equipped be checked! If the machine
with brush lifting device, read the Chapter
Slip Ring Unit with Brush Lifting Device.
Brush lifting device must be in starting
posit e starting the machine. ion befor
ABB
User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 29
5.2 Checks before test start
Before the test start can be done, the following
checks and measures must be made:
eservoir and possible oil
ed with recommended oil

is not assembled, the
shaft end key is locked or removed.
of coo water is
n. h and the
The first start should last only about one second.
on of rotation of the
After the initial test start, the machine can be run
s of the
r heck the
bearings eviations from normal
described in previous
ve been m st start is
the coupling e machine.
ing and functioning of
ain ce formed on
the maintenance card or in a computer file. The
ea i es, placed
to be checked frequently to ensure that they
operating
conditions of the machine.
- Sleeve bearing oil r
supply system are fill
to correct level. Oil supply system is turned
on.
- The rotor is turned and bearings are listened
for abnormal slip noises (to turn a sleeve
bearing rotor a simple lever arm is needed).
- If the coupling half
- In case water led machines the
turned o The tig tness of flanges
cooling unit is checked.
During that time check the directi
machine and possible external blower motor and
ensure that no obstacles are deterring free running
of the machine. In case of sleeve bearings, check
that stationary parts do not touch the rotating
parts.
Check that the brushes on the slip rings are not
sparking.
for a longer time. Check the temperature
stato winding phases and bearings. C
lubrication of antifriction bearings and oil level or
pressure and flow if the machine has sleeve
. In case of d
operation, e.g. elevated temperature, noise or
vibration, disconnect the machine. Establish cause
and consult manufacturer if necessary. Do not ever
defeat protective devices.
6 The first start
When all procedures
Chapters ha ade and the te
made, connect and start th
6.1 Supervision and maintenance
during the first start
Factors essential for the operation of the machine
need to be checked regularly. These factors
include machine load, cool
the bearings.
Record all m tenan and service per
temperature r dings g ven by the prob
in the windings and possibly in the bearings, need
remain below the maximum limits. Compare the
load current with the value given on the rating
plate of the machine to check the
Note! When RTDs or equivalent are not
available surface temperature at bearing area
shall be measured if possible. Bearing
temperature is approximately surface
temperature +10C (50F).
6.1.1 Machines with antifriction bearings
bearing housing.
initially
g for several
ub against the rotating parts. Pay also
ts still represents the best
m
T
t
b
c
I is
a
n 18 psi 4
psi). This gives the right flow of oil to the
bearing. Too high oil flow can cause oil leakages
to the machine or environment. The rate of oil
flow is given in the dimension drawing.
In case of a newly installed machine or a machine
which has been out of service for a longer time,
inject new grease immediately after the start-up.
New grease must be injected when the machine is
running until the old grease or excess new grease
is discharged through the lubrication valve in the
bottom of the
The temperature of the bearings will
increase because of the excess grease. After few
hours the excess grease will be discharged
through the lubrication valve and the temperature
of the bearing will return to normal.
Measure the SPM-values from the SPM-nipples
after the machine has been runnin
hours and record them for future use as reference
values.
6.1.2 Horizontal machines with sleeve
bearings
After the start-up, check that the stationary parts
do not r
attention to the oil tightness of all connections. A
bearing inspection after running on load for some
hours during commissioning or after changing
shells or segmen
easure to prevent damage.
he rotation of the lubrication ring is verified
hrough the inspection window on top of the
earing. Check the temperature and the oil level
ontinuously in the beginning.
n force lubricated machines, the oil pressure
djusted with the pressure valve and orifice. The
ormal pressure is 125 kPa 25 kPa (
User`s Manual, AMK 400-500
Chapter 5 - Commissioning and Start-up ABB

30 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Note! The lubrication system should be
constructed so that the pressure inside the
bearing is equal to atmospheric pressure.
Pressure from the oil pipes (inlet and/or outlet)
will cause oil leakages to the machine or
environment.
6.2 Vibrations
If noticeable vibration is detected, measure the
vibration from the bearing cover or the end shield
from both ends. Compare the measurements to the
values written in the commissioning report or in
the prescribed standard. It is useful to analyse the
d
t

ifferent frequencies of the vibration, speed and

wice the net frequency. See Chapter
Maintenance.

ABB
User`s Manual, AMK 400-500
Chapter 6 - Operation

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 31
C
1 ....................................................................
2 Number of starts.......................................................
3 Supervision...............................................................
3.1 Bearings ........................................................
3.2 Cooling ......................................................................................................................................32
3.3 Slip ring unit ..............................................................................................................................32
3.4 Miscellaneous ............................................................................................................................33
4 Follow-up..............................................................................................................................................33



hapter 6 - Operation
General . .............................................................................32
.............................................................................32
.............................................................................32
.............................................................................32
User`s Manual, AMK 400-500
Chapter 6 - Operation ABB

32 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 6 - Operation
1 General
- Measure the vibration levels. Vibration
To ensure trouble free running a machine must be
severities in the "satisfactory" range (V s
looked
deviati
temper
rotective devices.
Number of starts
heck always before starting that no shut-down
ve been forgotten and that the cooling
system and bearing lubrication are functioning.
The recommended maximum number of start-ups
is 1000 a year. Depending on the machine
characteristics and starting conditions, even higher
values are allowed. Too many and too heavy
frequent starts can cause abnormally high
temperatures and stresses accelerating ageing and
resulting in abnormally short lifetime.
3 Supervision
The operating personnel shall inspect the machine
frequently. The purpose of the inspection is to
thoroughly familiarize personnel with the
equipment. This is imperative if abnormal
occurrences are to be detected.
The following inspections must be done in
conjunction with Checklist 6 in Chapter
Checklists.
3.1 Bearings
- Check the bearing temperature.
- Look after that antifriction bearings are re-
greased according to instructions on lubrication
plate. The possible grease collector box
should be emptied every third relubrication
time.
- Check the sleeve bearing oil level and
functioning of the oil ring (through a sight
glass on top of the bearing). Observe time-
limit for oil-change and if equipped with oil
supply system make sure the system is working.
Check that there is no oil leakage.
antifriction bearings).
- Feel the bearing for abnormal noises or
surface temperatures.
after and carefully supervised. In case of
4.5 mm/s) according to ISO 3945 are
ons from normal operation - e.g. elevated
acceptable in coupled-mode operation.
ature, noise, vibration - disconnect
- Measure the SPM-values and compare them
machin
manufacturer if necessary. Do not ever defeat
development of trend (machines with
e, if in doubt. Establish cause and consult
with earlier measurements to observe the
p
2
C
means ha
rms
Note! When RTDs or equivalent are not
available surface temperature at bearing area
shall be measured if possible. Bearing
temperature is approximately surface
temperature +10C (50F).
3.2 Cooling
- Check the temperature of the stator winding.
- Observe if the flow of cooling air is normal.
- Observe if the flow of cooling water is
normal.
Note! The cooling air must be clean and free
of corrosive materials. If the cooling air
contains dust, clean the cooling surfaces (ribs,
tubes etc.) of the machine and cooling unit
regularly.
Even if the cooling water filter is used, some
fouling of the cooling coil will occure. Clean
the coil regularly.
3.3 Slip ring unit
- Follow the wear of the carbon brushes and
change them before the wear limit is reached.
- Check that the brushes are not sparking.
- Ensure that the ring surfaces are smooth. If not,
the slip rings must be turned on a lathe. Under
ideal conditions an even layer of brown patina
will form on the slip rings during the first few
hours of operation.
ABB
User`s Manual, AMK 400-500
Chapter 6 - Operation

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 33
- Change or clean the cooling air filter of
ring unit regularly.
the slip
- Clean the slip ring housing, slip ring gear, slip
ring assembly and possible heat
exchanger/upper cover regularly. See Chapter
nstructions. If the machin
h lifting type slip ring unit,
ng,
e
r
surface temperatures.
- Check that the drain plugs are in open
position (half of the plug inside and half
outside). Remove possible jam.
4 Follow-up
During the first period of operation (24 hours)
every 24 hours.
D
d
m
r
Maintenance for i
is equipped with brus
e
Normal supervision of operation includes logging of
operating data such as load, temperature etc. The
comments and data are used as a basis for
maintenance.
follow the instructions presented in Chapter
Slip Ring Unit with Brush Lifting Device.
- Check the tightness of the slip ring housi
water, grease, dust should not enter insid
housing.

s
3.4 Miscellaneous
- Measure the vibration levels on the machine
frame and coverings.
- Check the machine for abnormal noises o
- Observe alarms and fault indications.

upervision should be intensive. Read the
temperature of winding and bearings every hour.
Check also load, current, cooling, lubrication and
vibration.
During the next period of operation (first week)
supervision should be done
uring normal use machine checking must be
one in conjunction with the regular inspections, the
aintenance of the driven machine or during the
elubrication.
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

34 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 7 - Maintenance
1 Bearings and lubrication................................
1.1 Antifriction bearings..........................
1.1.1 Bearing constructions...............
1.1.2 Lubrication technique..............
1.1.3 Lubrication intervals and recom
...........
............
.........
.......... .................................................... 35
mend
...........
nning
..........
bearings..............................................
olutions............................................................................................................ 38
mended oils .............................
........... ..... 39
....................................................................................... 40
ctions..........................................
...........
............
.......................... 41
ing unit ........................................................................................ 41
filter .................................................................................. 41
4.1.2 Cleaning of the slip ring unit .......................................................................................... 41
4.1.3 Checking and changing of brushes................................................................................. 41
4.2 Brush lifting type slip ring unit.................................................................................................. 42
5 External blower motors......................................................................................................................... 42
6 Windings............................................................................................................................................... 42
6.1 Need and scope of maintenance ................................................................................................ 42
6.2 The maintenance program......................................................................................................... 42
6.3 Exterior inspection..................................................................................................................... 42
6.4 Maintenance tests ...................................................................................................................... 42
6.4.1 Insulation Resistance Test .............................................................................................. 42
6.4.2 Voltage Test ................................................................................................................... 44
6.4.3 Tan delta-measurements................................................................................................. 44
6.5 Inspection .................................................................................................................................. 44
6.5.1 Observations................................................................................................................... 44
6.5.2 Conclusions of the actions.............................................................................................. 45
6.6 Cleaning the windings ............................................................................................................... 45
6.6.1 Cleaning methods........................................................................................................... 45
6.6.2 Cleaning agents .............................................................................................................. 46
6.6.3 Drying ............................................................................................................................ 46
6.7 Varnishing of the windings........................................................................................................ 47
6.8 Other maintenance operations ................................................................................................... 48
6.9 Maintenance of old windings .................................................................................................... 48
6.10 Work safety principles with winding maintenance.................................................................... 49
7 Maintenance painting............................................................................................................................ 52
7.1 General ...................................................................................................................................... 52
7.2 Touch-up painting ..................................................................................................................... 52
7.2.1 Surface preparation ........................................................................................................ 52
7.2.2 Application conditions...................................................................................................... 52
7.2.3 Application..................................................................................................................... 52
7.2.4 Repainting ...................................................................................................................... 52
7.2.5 Standards of the painting system and surface preparation.............................................. 52
8 Cleaning................................................................................................................................................ 53
9 Overhaul ............................................................................................................................................... 53
............................................................................ 35
............................................................................ 35
............................................................................. 35
.........................
ed greases............................................................ 35
............................................................................ 37
............................................................................ 37
............................................................................. 37
............................................................................ 38
1.1.4 Miscibility of greases ..............
1.1.5 Control of the bearings when ru
1.1.6 Monitoring running quality .....
1.2 Sleeve
1.2.1 Bearing s
1.2.2 Recom ............................................................................ 39
....................................................................... 1.2.3 Maintenance ............................
1.2.4 Monitoring running quality .....
1.2.5 Inspe ............................................................................ 40
............................................................................ 40
............................................................................ 40
2 Heat exchangers.............................................
3 Filters of an upper cover ...............................
4 Slip ring unit ...............................................................................................................
4.1 Permanent contact type slip r
4.1.1 Changing of the carbon dust
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 35
Chapter 7 - Maintenance
1
After filling the free space in the bearing,
Bearings and lubrication
excessive grease will be discharged out from the
1.1 Antifr
1.1.1 Beari
Deep groove
standard co
machin
the D-
radial forces
equipped with
end and singl
the N-end. C
The D b
machines whe
in both ends
toward N
adjusti
The b
downw
growth will h
considered w
movin
1.1.2 Lubri
Bearin
greasing nipp
Grease is pe
bearing th
iction bearings
opening in the bottom of the bearing construction.
ng constructions
The greasing nipples must be cleaned well before
ball bearings in both ends is a
bearings. The grease pump gun should be filled
nstruction for horizontal AMK
up completely, leaving no air bubbles in the
es. Cylindrical roller bearings are used in
end if
grease. The grease must be free from impurities
the machine is loaded with great
and water.
. Vertical machines are normally
deep groove ball bearing in the D-
The lubrication must be done while the machine
e-row angular contact ball bearing in
is running normally. Otherwise the grease will not
omplete bearing identification code
penetrate to the bearing equally.
is stamped on the lubrication plate and dimensional
in draw g. Different constructions are presented in
Chapter Appendices.
-end earing is axially fixed in horizontal
n deep groove ball bearings are used
. The thermal growth will happen
s the -end. If a cylindrical roller bearing is
used in the D-end, then the N-end bearing is axially
fixed and the thermal growth will happen towards
the D-end. This should be considered when
ng the coupling.
earing in the N-end is axially fixed
ards in vertical machines. The thermal
appen in the D-end. This should be
hen adjusting the coupling and
g the machine.
cation technique
gs are lubricated by injecting grease to
les at both ends of the machine.
netrated to the inner side of the
rough the grease passage.
lubricating to prevent dirt from entering the
Note! Inject new grease until old grease or
excessive new grease is discharged out from the
bearing.
In special case the lubrication can be done while
the machine is not running. Then the
recommended amount of grease is injected to the
bearing 3 times. The machine is started for couple
of seconds between injections.
1.1.3 Lubrication intervals and
recommended greases
Lubrication interval and the amount of grease are
stamped on the lubrication plate. Standard
intervals and amounts can be read from Tables 1
and 2.
Note! Re-lubrication must be done at least once
a year, ignoring the running hours.
Table 1. Relubrication intervals and amount of grease for horizontal machines.
Bearin Amount of Lubrication intervals in running hours at different speeds [rpm] g
Type grease [g] 1800-1500 1200-1000 900-750 600-500
6324 70 4400 8800 8800 8800
6326 80 4400 8800 8800 8800
6330 100 3300 6600 8800 8800
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

36 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Table 2. Lubrication intervals and amount of grease for vertical machines.
Bearing Amount of Lubrication intervals in running hours at different speeds [rpm]
type grease [g] 1800-1500 1200-1000 900-750 600-500
6324 70 2200 4400 4400 4400
6326 80 2200 4400 4400 4400
6330 100 1600 3300 4400 4400
7324 70 2200 4400 4400 6600
7326 80 2200 4400 4400 6600
7330 100 2200 3300 4400 6600

Note! Although the bearings are lubricated at
the manufacturers work, relubricate new
bearings immediately after start-up to ensure a
long life time. AMK machines are lubricated in
the factory with ESSO UNIREX N3 or
MOBILUX EP2, if nothing else is specified.
The lubrication interval on the lubrication plate is
based on the bearing running temperature of 70C
ing temperature is noticeably under

p to 85 C (185F). Recommended types
of high temperature greases are listed in Table 4.
(158F). Size and type of bearings with running
speed and mounting arrangement of the machine
have also been taken in consideration. The
lubrication interval should be halved for every 15
K increase in the bearing temperature.
Recommended types of standard greases are
Table 3. Recommended standard greases.
listed in Table 3.
If the bear
70C (158F), the lubrication interval can be
lengthened to some extent. Other environmental
conditions need also to be taken into
consideration.
With high temperature grease the lubrication
intervals presented in Tables 1 and 2 can be
applied u
If the ambient temperature may stay below -
20C (-4F), use grease that is suitable for whole
operating temperature range.
Manufacturer Quality Thickener Base oil
Temperature
range [C]
Kinem. visc.
of base oil
[mm2/s, cSt
at 40C]
Kinem. Visc.
of base oil
[mm2/s, cSt
at 100C]
Drop
point
[C]
Consis-
tency
[NLGI
scale]
ESSO UNIREX N2 Li-comp. Mineral -30 to +165 112 12 300 2
ESSO UNIREX N3 Li-comp. Mineral -30 to +165 112 12 300 3
MOBIL OIL Mobilith SHC 100 Li-comp. Synthetic -50 to +180 100 11 280 2
SHELL Syntix 100 Li-comp. Synthetic -40 to +140 150 21 260 2
SHELL Alvania Grease G3 Li/Ca Mineral -20 to +150 100 11 185 3
NESTE Rasva 606 Li-comp. Synthetic -40 to +150 160 20 >250 1.5
NESTE Rasva 600 Li-comp. Synthetic -35 to +140 120 12 >250 1.5
ELF Rolexa 3 Li/Ca Mineral -30 to +120 110 10 >180 3
ELF Statermelf EP 2 Polyurea Synthetic -40 to +180 84 12 240 2
OPTIMOL Longtime PD2 Li -30 to +140 85 9.5 >180 2
TEBOIL Syntec Grease Li-comp. Synthetic -40 to +140 150 20.0 >260 2
STATOIL Uniway LiX 42 PA Li-comp. PAO -35 to +150 100 18.0 >260 2
CHEVRON SRI 2 Polyurea Mineral -30 to +150 100 11.0 243 2
KLBER Klberplex BEM 41-132 Li-comp. Sy n. nt./Mi -30 to +150 120 14 >220 2
FAG Arcanol L 135 V Li Mi n./Synt. -40 to +140 85 12.5 190 2
FAG L 30 Li-comp. Synthetic -50 to +200 162 19.8 >250 2
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 37
Table 4. Recommended high temperature greases.
Manufacturer Quality Thickener Base oil
Temperature
range [C]
Kinem. visc.
of base oil
[mm2/s, cSt
at 40C]
Kinem. visc.
of base oil
[mm2/s, cSt
at 100C]
Drop
point
[C]
Consis-
tency
[NLGI
scale]
MOBIL OIL Mobilgrease HP 103 Li-comp. Mineral -30 to +175 100 11 260 3
KLBER Asonic HQ 72-102 Polyurea Synthetic -40 to +180 100 12 >240 2
SHELL Syntix 100 Li-comp. Synthetic -40 to +140 150 21 260 2
CASTROL LMX Li-comp. Mineral -40 to +150 180 260 2
CHEVRON SRI 2 Polyurea Mineral -30 to +150 100 11.0 243 2
SKF LGHQ 3 Li-comp. Mineral -20 to +150 110 13 300 3

1
I
g
g
m ically.
Then the maximum operating temperature of the
grease mix can be so low compared to the original

sodium base greases. However, mixtures of
l which
is less than either of the component greases,
a the lub roper n
necessarily impaired.
1 Control o rings w
running
O of d ng d is
m the shock nerated cts
d d surfa rolled. Measuri
d for this k easurin er t
r quence of ock pul ed
sm ularities. Th rve and k pulse
di s represent beari g damage developmen
a ow it can th pul
m device
Material fatigue pos se fo
d n of a g condit
sh lse va co an
life time are largely affe by
s load, lubri her exte l fact
w also determin ock pul e of
bearing.
After commissioning, and when the machine is
smoothly running on-load, register the "initial
) of the bearings using a shock
pulse tester (e.g. SPM-instrument type T30) or a
initial SV measurement should be
taken as a reference value for further
r evaluation of the
measuring results, a slide rule has been included
in the SPM instrument.
n b re lle
t hol e ape in
bearing hous he m is zinc-coa
unning quality
possib detect bearing lure b
monito is to det ine ty l defe
time a d ct is o lled
k the vi ion si . The
of these peaks dep s on th sitio
aring ct (inne r oute g or a
ement, etc.) and t bearing ometr
.
ing d t freque peak nerally
r part he quency
(0-2 kHz , usually h harm cs. The
depen n the be ng spe nly f
peeds l er than 6 r/min.
The decisive quantity is the rms value of the
vibration velocity measured on the bearing
housing (according to ISO 3945). Alarm and
shutdown limits for automatic control system and
.1.4 Miscibility of greases
t is important to consider the miscibility of
reases if it is necessary to change from one
rease to another. If incompatible greases are
ixed, the consistency can change dramat
grease, that bearing damage cannot be ruled out.
Greases having the same thickener and similar
base oils can generally be mixed without any
detrimental consequences, e.g. a lithium base
grease can be mixed with another lithium base
grease. Calcium and lithium base greases are
generally miscible with each other but not with
compatib e greases may have a consistency
lthough ricating p ties are ot
.1.5 f the bea hen
ne way etecting beari amages to
easure pulse ge by impa as
amage ces are over ng
evices ind of m g regist he
apid se minor sh ses caus by
all irreg
agram
e cu
n
shoc
t
nd h be followed wi a shock se
easuring .
is not the only sible cau r
eterioratio bearin ion and high
ock pu lue readings. Bearing
cted
ndition
installatio
d
n,
peed, cation and ot rna ors,
hich e the sh se valu a
shock values" (SV
similar device. Fit the measuring probe to the
nipple provided on the end shield. After a certain
running-in period, the SV measurement could
decrease, i.e. the bearing condition can improve.
Therefore, the
measurements. Measurements should be taken
periodically with same speed, load, measuring
points and lubrication conditions, never directly
after relubrication.
Compare the new readings with the previously
measured values to see if there is any reason to
replace the bearing soon. Fo
Measuring
hreaded
ipples are
es that hav
ings. T
olts that a
a cone-sh
aterial
insta
ends
d in
the
ted
steel.
1.1.6 Monitoring r
Another ility to fai y
vibration ring erm pica ct
frequencies. Every efe verro it
causes a pea
repetition
in brat
end
gnal
e po

n
of the be defe r o r rin
rolling el he ge y
and speed
The bear efec ncy s ge
appear in the lowe
spectrum
of t
wit
fre
oni )
frequency ds o ari ed, o or
rotation s ow 000
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

38 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
for manual measurements should be set as low as
possible based on the test results and empirical
op aviour w the driven ne.
Recommended settings:
A mm
SH N mm
erating beh ith machi
LARM V
RMS
= 4.5 /s
UTDOW V
RMS
= 7.1 /s
Note! The contr stem sh abl ol sy ould be e to
separate occasio shock in nal pulses the
en ment th not viron at are related to the
machinery system in question, thus making it
possible to set the limits to correct level
without repeated alarms or shutdowns.
In order to have a comparison with the measured
values, the vibration amplitude S

can be
calculated as follows (supposing that vibration is
sinusoidal):

. S
V V V 2
rms rms rms
f f 2 e t
where
S

= vibration amplitude [mm]

f = speed frequency [Hz]
A conversion nomograph with limit values is
shown in Figure 1.
= = ~ 2 0 225

The sleeve bearing type used in AMK machines is
a side flange bearing (see Chapter Appendices).
The bearings can be self or force lubricated. The
complete bearing type is stamped on the bearing
plate of the bearing itself.
The bearings are rigidly mounted to the end
shields of the machine. The bearing in the D-end
is usually the locating bearing (code B in the type
designation). This means that the thermal growth
will happen towards t
Fig. 1. Conversion nomograph with limit values.
ear f a the
t req rat
normal ope of th e. This is why it is
hard to inguish e peak om normal
.
heckli apt eck
Slee
1.2.1 Bearing solutions
he N-end.
The b
range as
ing defect
he low f
ration
requencies
uency vib
e machin
re in
ions cau
same
sed by
often dist thes s fr
machinery noise
Use C st 7 in Ch er Ch lists.
1.2 ve bearings
The bearing in the N-end is insulated. This means
that the inside spherical housing surfaces are lined
with nonconducting PTFE film in order to avoid
bearing currents (Figure 2).

Fig. 2. Insulation films of the sleeve bearing.
The retention stopper in housing, which prevents
the bearing shell from dislocating, is surrounded
by a nonconducting sleeve. The shaft seals and as
well as the temperature sensor connection are
made of nonconducting material. Bearings are
provided with connections for oil feed, oil drain,
thermometer and oil level sight glass.
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 39
1.2.2 Recommended oils
Note! Sleeve bearings are delivered without
oil. The oil reservoir and possible oil supply
system must be filled with recommended oil
before start-up. There is enough oil in the
bearing if half of the oil sight glass is covered.
T
v
5
T
ISO viscosity
he oil used in the bearings must have a viscosity
alue as defined in ISO 3448 class or SSU. Table
presents the typival oil viscosity values.
able 5. Typical oil viscosity related to rotational
speed.
Rotation
speed [rpm]
SSU viscosity
grade number
grade number
1500 107 SSU/100F ISO VG 22
1000 1200 214 SSU/100F ISO VG 46
900 315 SSU/100F ISO VG 68

Note! The type of oil that has to be used for
lubricating the bearing is given on the
l drawing of ubrication plate and dimensional
the machine.
Table 6 lists the recommended mineral based oils
to lubricate the bearings.
Table 6. Recommended oils.
Manufacturer Quality
BP Energol CS
CASTROL Perfecto T
DEA Astron HL
ESSO Terresso
FUCHS Renolin DTA
GULF Harmony
KLBER Lamora HLP
MOBIL DTE
NESTE Paine
SHELL Tellus Oil S
TEBOIL Larita Oil
TOTAL Azolla ZS
Bearing manufacturer has tested some synthetic
oils with good results. With these oils it is
possible to run the bearing at higher operating
temperatures and the alarm and trip limits can be
set higher respectively.
Note! ontact the machine manufacturer for C
approved synthetic oils and permission to use
them with the machine.
1.2.3 Maintenance
Bearing housings has to be kept clean on the
ed by
deposits of dust or dirt.
During the first 24 operating hours, the oil flow,
l of vibration are
inspected every hour. Changing of a possible oil
In case of sleeve bearings with separate oil supply
ture or excessive
contamination due to external influences. The
gh the oil drain hole
which is located centrally in the bottom of the
bearing. Filling is effected through the bore of the
sight glass which can be removed using an
adjustable face spanner.
When changing out the oil, special care should be
taken to rinse out contamination and to remove oil
sump residues (if possible, the oil should be
drained while the bearing is still warm). If
unusual alterations of the oil or extra-ordinary
residues are noted, it is paramount investigate
and, if possible, to remove the causes for this
put If
chemical detergents are used they have to be
To check the quality of oil, oil analyses should be
performed regularly. An oil analysis performed
by mineral oil companies may form the basis for
decisions as to whether the oil in the bearing is
still suitable for use.
outside, since the radiation of heat is reduc
possible leaks and the leve
filter must be done after 1000, 2000 and 3000
operating hours. Changing of oil and cleaning of
an oil filter must be performed after 8000
operating hours.
system, oil is changed every 20000 operating
hours.
Shorter intervals are required in case of frequent
starts and stops, high oil tempera
general condition of the oil will provide
information in this respect.
The housing is drained throu
to
before ting the bearing into operation again.
completely removed when the cleaning process is
finished.
For filling and re-filling use the same quality of
oil as specified for the application. The dimension
drawing should be referred for the relevant
indications.
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

1.2.4 Monitoring running q
40 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
uality
A po
m
f
A
s
set as low as possible based on the test results and
of the
v
(according ISO 10816). Recommended
settin
A V /s
SHUT N V s
ssibility to detect bearing failure by vibration
onitoring is to determine the typical defect
requencies.
larm and shutdown limits for automatic control
ystem and for manual measurements should be
empirical operating behaviour with the driven
machine.
The decisive quantity is the rms value
vibration elocity measured on the bearing housing
to
gs:
LARM
RMS
= 4.5 mm
DOW
RMS
= 7.1 mm/
N ont uld b ote! The c rol system sho e able to
sep occasi ulses arate onal shock p in the
environment that are not related to the
machinery system in question, thus making it
possible to set the limits to correct level
without repeated alarms or shutdowns.
R maximum settings for relative
shaft vibration are:
.1 mm/s
SHUTDOWN V
RMS
= 11.2 mm/s
In order to have a comparison with the measured
values, on amplitude be
calculated a ws (supposing th
sinusoidal
ecommended
ALARM V
RMS
= 7
the vibrati S can
s follo at vibration is
):

. 225 S
V
f f
=

~ 2
2
2
0
rms rms

where
= vibr litude [mm]
f = speed frequency [Hz]
A convers mograph with li is
shown in Fi
Bearing d quencies are in th nge
as low frequency vibrations caused by normal
Inspections are carried out as a part of the
preventive maintenance work. Inspections are
a
i
l
For an inspection it is sufficient to remove the top
e the bottom part may be
he bearing and the work
ter Checklists.
noise damper and air duct must
be removed before cleaning. Dust and dirt can be
should not be used, because they are too
hard and can damage the tubes.
and tightness of
connections.
ore be cleaned at reqular
intervals, depending on the property of the water.
3 Filters of an upper cover
customers specification. By special
order, the upper cover is equipped with a
filters frequently.
V V
=
rms
e t
S

ation amp
ion no mit values
gure 1.
efect fre e same ra
operation of the machine. This is why it is often
hard to distinguish these peaks from normal
machinery noise.
1.2.5 Inspections
lso necessary if the bearing temperature
ncreases clearly by several degrees or if the
ubricating oil alters strikingly.
part of the bearing whil
left on the machine. T
place are cleaned thoroughly before
disassembling.
Use Checklist 7 in Chap
2 Heat exchangers
Air-to-air cooled machines are equipped with tube
type heat exchanger, which is placed on top of the
machine (also on top of permanent contact type
slip ring unit), does not have to be dismantled for
cleaning. Possible
removed using a soft round brass wire brush,
which is pushed through each tube. Steel wire
brushes
Air-to-water cooled machines are equipped with a
cooling coil. During the initial period of
operation, the coil should be inspected frequently.
Check the water flow
Even if water filter is used, some fouling of the
cooling surface and the tube wall will occure.
This fouling reduces the cooling capacity. The
cooling coil should theref
Measures should be taken to repair any damage,
due to corrosion, that may have occurred in the
tubes or the water chambers.
Drain the coil thoroughly. Remove the headings,
chambers and mark up the location of the
chamber to secure a correct mounting. Clean the
inside of the tubes by using the brush and flush
with water. Remove the old gasket and clean the
inside of the chamber.
Upper cover of the standard weather protected
machine can be delivered with or without filters
according to
differential pressure switch for monitoring the
condition of the filters. The filter should be
changed immediately after alarm. It is also higly
recommended that the operating personnel
manually inspect the
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

How often the filters are changed depends upon
the cleanliness of the air in the surrounding
environment. If surrounding air is sufficiently
clean, the filters can be changed during operation.
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 41
Note! Remove the filters from the machine
before cleaning them.
Filters are washable. A stream of water or
cleaning solution can easily reach and flush out
collected dirt.
4 Slip ring unit
The slip ring housing should be kept clean, the
doors closed and inspected at regular intervals. It
tenance work is not recommended to any main
when the machine is running.
Note! If gaskets of the slip ring housing have
to be changed or lubricated, do not use any
silicone based material e.g. silicone rubber,
silicone plastic or silicone grease.
4 ing
unit
The slip ring unit of the permanent contact type is
st (4, 6 and 8
nterval of the
filter in respect to carbon brush wear is shown in
.1 Permanent contact type slip r
4.1.1 Changing of the carbon dust filter
equipped with filter for carbon du
pole machines only). The cleaning i
Figure 3.
AMK 400 - 500, max. cleaning interval of the slipring housing
carbon dust filter, parameter brush wear in mm/10 h
45
0
5
10
6 12 18 24 30
15
C
l
e
a
n
i
20 g

i
n
t
e
r
v
25
30

h
35
40
36
Number of brushes
n
a
l

/

1
0

Wear 1mm/10 h
Wear 3 mm/10 h
Wear 4 mm/10 h
Wear 2 mm/10 h
h

leaning the filter.
ng gear and brush
ay with dry air, or wiped off with
thylated
rter intervals
e contact area needs not to be taken
as been reached.
Wear 5 mm/10
Fig. 3 Interval for c
4.1.2 Cleaning of the slip ring unit
Carbon dust as result of brush wear should be
cleaned from all insulated slip ri
pin parts at regular intervals. The cleaning
interval is about one month, depending on the
number of carbon brushes and the operating
conditions. The dust can be brushed off with a dry
brush, blown aw
a clean cloth slightly moistened with me
spirit.
It is recommended to clean at sho
during the initial operating period of the motor
until a suitable cleaning frequency interval is
established. Neglect in complying with these
maintenance requirements may result in dust
bridge formation and tracking between live parts.
4.1.3 Checking and changing of brushes
All carbon brushes and brush-holders must be
inspected at regular intervals.
The brushes must slide on the surface of the slip
rings with their entire cross sectional area with a
pressure of 2 N/cm. Helically grooved slip rings
have a brush contacting surface of about 60% of
the brush cross sectional area. However this
reduction of th
into account, i.e., the brush pressure is applied onto
the whole brush crossection area. The contact
surfaces should be completely clean, shiny, and
smooth. The slip rings should be free of oil and
grease, and after a few hours operation, an even
layer of brown patina should form on them. Worn
brushes must be changed before the top plate
begins to bear on the brush-holder guide, or before
the wear mark on the brushes h
Note! New brushes must be of the same
quality as those originally supplied with the
motor, and should be fitted one at a time for
each slip ring.
If the slip rings are turned on a lathe, the brush-
der gap of
about 2 mm between the slip rings and the brush-
hol s will require resetting to give a
holder.
Note! Remove all brushes before cleaning.
Brushes should never come into contact with
the cleaning solvent or the solvent vapour.
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

42 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
4.2 Brush lifting type slip ring unit
Follow the instructions presented in Chapter Slip
Ring Unit with Brush Lifting Device.
5
The external blower motors are maintenance free
is performed according to motor`s
nual
The windings of rotating electrical machines are
s
s
a
T achine often
depends on the insulation durability.
y be
preven at least slowed down with
all AC-
machines usually require only minor
- Maintenance of the windings should be


ple maintenance
scheme. Users should, however, plan the
External blower motors
units, e.g. the bearings of external blower motors
are greased for life. A spare external blower
motor is recommended. The maintenance of the
blower motor
ma .
6 Windings
6.1 Need and scope of maintenance
ubject to electrical, mechanical and thermal
tresses. The windings and insulation gradually
ge and deteriorate due to these stresses.
herefore, the service life of the m
Man processes leading to damages can
ted or
appropriate maintenance. Windings in sm
maintenance. The guidelines and instructions in
this section of the manual are valid for the
maintenance of windings in all large AC-
machines.
6.2 The maintenance program
Principles:
arranged according to other machine
maintenance.
- Maintenance is done only when necessary.
An important machine should be serviced more
often than a less important one. This also applies
to windings that become contaminated rapidly,
and to heavy drives.
Table 7 is an example of a sim
maintenance program according to their
machines, conditions, and processes.
Maintenance
Table 7. Maintenance scheme.
Type of machine Inspection interval
1 Heavy drives Periodic bearing inspection. Check the temperatures and vibration. Clean the outer surface if
necessary.

Once a year.
Open, inspect, clean, tighten supports, re-varnish if necessary.
2 Form wound LV and HV machines
Every third bearing inspection. Check the temperatures and vibration. Clean the outer surface if
necessary.
Every three to five years (when
changing the bearings).
Open, inspect, clean, tighten supports, re-varnish if necessary.
6.3 Exterior inspection
The correct temperature of the windings is
ensured by keeping the exterior surfaces of the
machine clean and by monitoring the temperature
of the cooling agent. If the cooling agent is too
cold, water may condensate on the cold water -
radiator, and the mixture of cold and warm air
might produce mist. This can wet the winding and
deteriorate the insulation resistance. The
operating temperatures must be monitored with
resistance temperature detectors. Significant
detectors
windings.
Make sure that the changes are not caused by the
drifting of the measuring channel.
6
ABB Service in many countries offers a complete
The insulation resistance values supply
in
c
i
c
Method: When the nominal voltage of the tested
machine is less than or equal to 3 kV, the test
voltage is usually between 500 and 1000 V DC. If
temperature differences among the
could be a sign of a damage in the
.4 Maintenance tests
service package with several tests.
6.4.1 Insulation Resistance Test
Purpose:
formation on wetness and degrees of
ontamination in the insulation. With this
nformation, one can prepare the necessary
leaning and drying actions.
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

the minal voltage of the tested machin no e is
higher than 3 kV, the test voltage is usually
between 1000 and 2500 V DC. The insulation
resistance values are noted at fifteen seconds and
one minute or at one minute and ten minutes.

Winding t
Degrees
0.01
0 10 20 30 40
The Polarization Index (PI) is gi
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 43
empera
Celsius
50 60 110
ven by the
P
ture,
C
0.1
1
10
100
70 80 90 100
relation:
I =
R
R
or
R
R
1 10 min mi
(
s 15 1
n
min
)
Effect of Temperature: The insulation resistance
usually decreases sharply due to the temperature
erature, one
can determine the coefficient K
t
from the graph
below. By multiplying this coefficient K
t
with the
measured insulation resistance of the winding R
m
,
the corresponding insulation resistance at a
st , R40C, is determined:
(1) R
40C
= K
t
R
m

Fig. 4. Correlation between the insulation resistance and the ure.
Table 8. Temperature values in d ius (C) and degrees Fahre
C 0 10 20 30 40 50 60 70 80 90 100 110
rise. This is shown by the coefficient K
t
in Figure
4. By measuring the winding temp
andard 40C
temperat
egrees Cels nheit (F).
F 32 50 68 22 140 158 176 194 212 230 86 104 1

The polarization index is less dependent on the
temperature than the insulation resistance. When
the winding temperature is below 50C (122F), it
may be considered independent of temperature.
High temperatures can cause unpredictable
changes in the polarization index, so it should not
be used above 50C (122F).
Effects of dirt and humidity: The dirt and
humidity accumulating in the winding normally
reduce the insulation resistance and the
polarization index as well as their dependence on
temperature. Thus, the line from Figure 4
becomes less steep. Windings with open creepage
distances (e.g. from squirrel cage) are very
Acceptable values: There are several rules of
insulation
resistance value with which the machine can be
gh, conducting dirt
collecting on one spot of the creepage surface
sensitive to the effects of dirt and humidity.
thumb for determining the lowest
safely started. The probability of insulation failure
increases as the insulation resistance deteriorates,
but an absolutely safe value of insulation
resistance does not exist. Although the insulation
resistance value may be hi
risks failure. In the US. [1], the following
equation is used for determining the minimum
acceptable insulation resistance at 40C:
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

(2) R
40C
= 1 + U [MO]
where U = main voltage [kV]
44 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
This value is compared with that determined from
Eq. (1) and insulation measurements. Insulation
resistance values for machines serviced at ABB
Service are determined using a standard
temperature of 80C instead of 40C as shown in
the following equation:
(3) R
80C
= 1 + U [MO]
where U = main voltage [kV]
The polarization index values usually range
between 1 and 4. When the windings are humid
and dirty, the PI is approximately 1.
As a thumb rule the following minimum values
may be applied to the PI:
- for class A machines PI = 1,5
where PI = .
- for class B-F machines PI = 2,5

R
R
s
1
15
min

The PI is seldom used anymore because it
h t
insulation resistance high (thousands of MO).
a standstill, the insulation resistance is more
i rtan an th larization in .
6.4.2 Voltage t
voltage test is used to check for electrically
spots in the windings that may lead to
occasionally gives misleading values. For
instance, some very low PI values have been
measured with modern epoxy-mica insulations
althoug he windings have been dry and the
When estimating a machine's ability to start after
mpo t th e po dex
Tes
A
weak
insulation failure during servicing. It is carried out
with greater maintenance work and repairs. DC or
AC voltage is used for the over voltage test. DC
voltage tests, although seldom performed, use 1,6
times the root-mean-square value of the AC
voltage. AC voltage tests use the following test
voltages:
- for service and repair
1,2 x U + 400 [V]
- for periodical tests
1,5 x U [V]
where U = main voltage (V).
Note! The higher voltage test is always used
for modern epoxy-mica insulations.
6.4.3 Tan delta-measurements
Tan delta, representing the dielectric and
discharge energy losses, is measured in steps of
0.2 x U up to the main voltage U. The rate of rise
of tan delta as a function of voltage describes the
average partial discharge level both inside and on
the surface of the insulation. This makes it
difficult to determine the condition inside the
insulation. It is emphasized that tan delta
measurements can not estimate the age or predict
failure of the insulation.
6.5 Inspection
6.5.1 Observations
.
s should be recorded on the
enclosed maintenance form.
When examining the contamination, particular
ten sho e to op reepage
surfaces, as the insulation resistance is easily
ec th ac a er
Accumulating dirt blocking coil gaps and air
up
Winding inspections reveal information about:
- the rate of contamination; presence of dirt
and humidity
- radiator condensation and leakage
- stability of bracings, vibration marks, and
cracking
- marks of overheating
All inspection
at tion uld b paid the en c
aff ted by e dirt cumul ting th e.
ducts diminishes the cooling capacity of the
machine. As a result, the winding temperature
increases, and the ageing may speed
considerably.
Mechanical strain, vibration, and shocks may
produce cracks on the edges of the supports,
tyings, and around slot ends. Loose supports and
slot wedges are signs of further deterioration.
Abrasion marks and powder near the supports,
tyings, and at the slot ends, must be checked.
Complete loosening of the slot wedges and bent
coils are serious problems that must be rectified
immediately.
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 45
Hair cracks and fractu in met res al parts such as
supporting bolts and squirrel cage windings are
, ey take longer to
develop a failure.
f an approaching failure.
In rare cases, conductors are corroded.
Marks of the electrical effects (apart from
lly hidden inside
the slot and conductor insulations.
squirrel-cage
ning may also be
due to the gases in the environment), and it
o
b
due start.
es cause
aterials
also signs of deterioration but th
Humidity in the winding is often shown by the
marks it leaves behind: rust on iron, drop marks,
dripping, and wetting marks on dirt layers. Bush-
like patterns, often charred and left behind by the
tracking currents, warn o
tracking current marks), are usua
Short period overtemperatures can leave marks all
over the machine. Copper in the
windings grows darker (darke
xidizes. Core laminations of the rotor become
lue (over 350C [662F]) if the temperature rises
to a jam or an exceedingly heavy
Prolonged period overtemperatur
premature ageing. The insulating m
become brittle and darken in the early stages,
especially varnishes containing cellulose. As a
result, the windings split, disintegrate, and
fracture.
6.5.2 Conclusions of the actions
According to the observations the following
conclusions can be drawn for necessary actions
(table 9):
Table 9. Observations and actions.
Observation Action
D of contamination egree
a lo ed
conductive dirt, low insulation resistance
y, low insulation resistance

cleaning, and drying, if necessary
ing, if necessary
t of dirt, cooling ducts about to be plugg
humidit

cleaning, and dry
drying
Finishing varnish
embrittlement, loose insulation layer
ish and re-varnish

*
mat, worn, cracked
coming off
Supporting parts
loose slot wedges
vibration marks
bent coils
Ageing
darkening, slight embrittlement

cleaning and re-varnishing
remove old varn

tightening *)
tightening, strengthen and re-varnish *)
strengthen or redo winding *
cleaning and re-varnishing
redo windings
) A statement from an expert is needed.
6.6 Cleaning the windings
Accumulating dirt in the open creepage surfaces
should be removed. This is especially important
when re-varnishing the windings because a new
varnish coat will trap any existing dirt beneath the
new coat.
6.6.1 Cleaning methods
lowing and vac
lowing and vacu if dirt is dry
and can be removed easily. Vacuuming is
bute
insulation
gs, a special brush may be more
unts of the cleaning agent.
Dip wash
B uuming
B uming are used the
recommended, since blowing tends to redistri
the dirt or move it deeper between the
layers.
Wiping
Wiping is used when spray-wash is not possible.
Surfaces easily reached are wiped clean with a
cloth dampened with detergent. In cramped areas
of the windin
effective.
Spray wash
A spray wash is carried out with an airless high-
pressure spray or a conventional spray. The high-
pressure spray is more effective in removing dirt.
The detergent used should remove the dirt
without softening or damaging the insulation. Use
excessive amo
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

46 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
A dip wash can be used if the detergent does not
soften or damage the insulation. Since the dirt is
not removed mechanically in this method, a very
effective cleaning and scouring agent is needed. A
long dipping time may be required.
structions
given above for wiping, dip wash, or spray wash.
After washing, the windings are rinsed with pure
f ary (see
Sect
6 s
S e n
ta
Before any cleaning agent is used, its damaging
e winding surface should be
checke st can be performed as
f
U with the cleaning agent, rub the
s c r five minutes. Make sure
th s completely wet during
th rubbing, try to remove the
fi varnish by thumb nail. For comparison,
do the surface. If
th asily, the
clean
g, water or
used when
dirt. These detergents should not leave
s on the surfaces.
such as acetone and
on aliphatic hydrocarbons are
White spirit is the most common organic solvent.
of white spirit can be improved by
adding 1.1.1-trichlorethane to the solvent,
s is no
longer recommended.
The windings must be dried after a wash
(especially a water wash and rinse) or if they have
become humid in use or during a standstill.
The rate of temperature rise of the winding should
not exceed 5 K (9F) per hour, and the final
C (220F). A
dden temperature rise or a too high final
formed in the
dings, which in turn can
destroy the windings. During the drying process,
nitored periodically,
d be measured
e should be dismantled and the
n uld be
t very wet, the
winding can be dried by passing a current through
ied by passing current through
a welding
r or a similar device.
Water wash
A water wash involves rinsing with water to
prevent the detergents from penetrating into
places where they can not be removed. A water
wash is done if needed following the in
The detergents used are described in Section
6.6.2.
water several times. It is recommended to use
distilled or deionized water for the last rinse.
recommended. Several manufacturers of cleaning
solvent mixtures are presently developing such
halogen-free cleaning agents to replace the
chlorinated solvent mixtures used in the past.
Drying a ter the water wash is necess
ion 6.6.3).
.6.2 Cleaning agent
om features of the detergents are described i
ble 10.
ffect on the old
d. A suitable te
ollows:
sing a cloth wet
urfa e to be tested fo
at
is time. After
the surface remain
nishing
same thing to a dry part of the
su e rface layer is soft or removed e
ing agent is too strong.
For minimal environmental loadin
water-detergent mixtures should be
possible. If the dirt contains water soluble agents,
water must be used.
Substances that improve the cleaning power
should be added to the water to dissolve grease-
containing
electrically conductive residue
Water soluble solvents
isopropyl alcohol can also be used to improve the
cleaning effect. Note that such solvents increase
the flammability of the mixture.
If organic solvents must be used, cleaning agents
based
It is a good solvent for greases but quite
inefficient for pitch-like dirt on the windings
(produced by coal and burning residues of diesel
oil and humidity). White spirit is also flammable
(flash point 30...40C [86...104F]). The cleaning
capacity
however, the use of chlorinated solvent
6.6.3 Drying
temperature should not exceed 105
su
emperature can cause steam to be t
cavities of the win
the temperature should be mo
and the insulation resistance shoul
at regular intervals.
A very wet machin
w
checked. If the machine is no
i ding dried in the oven. Every part sho
it.
If the winding is dr
it, the source of electricity could be
generato
Note! When an electric current is used for
drying the windings, the rotor must be first
removed from the machine. Direct current or
alternate current can be used. Current cannot
exceed 25 % of the value of the nominal
current, which is indicated on the rating plate
on the machine.
When drying in an oven, the temperature rise and
the maximum temperature should be monitored
carefully. The oven temperature should be 90C
(194F) for 12 to 16 hours and then 105C
(220F) for six to eight hours.
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 47
Effective drying is achieved with the proper
balance of heat and ventilation. The air inside the
machine should be circulated in the most effective
way.
Drying in an oven with good ventilation is the
nique. Unfortunately, this is
resistance tests. At the beginning of the
tion
resistance increases until it reaches a stable value.
ing of the windings
ish or a resin coat that
is sprayed or brushed on the insulation. It is a
esistance somewhat and makes cleaning
easier. In new machines finishing varnish
k or peel off to certain extent. This can
- the old finishing varnish flakes, cracks or
this new coat of varnish.
Old finishing varnish that can come off easily
d.
than
most effective tech
not usually possible at the machine's operating
site. Therefore, either hot-air-blow or heating the
windings with current should be used. Adequate
fresh-air exchange is essential, whatever heating
method is used.
The drying of the windings should be followed by
insulation
drying treatment, the insulation resistance
decreases due to the temperature rise. As the
drying continues, however, the insula
6.7 Varnish
A finishing varnish is a varn
protective layer that seals the windings, improves
tracking r
treatment is made optionally.
The finishing varnish may after long operating
time crac
be corrected by giving the windings a new coat of
finishing varnish. Re-varnishing is necessary
when:
peels off,
- the surface of the winding is rough (dirt
sticks to it easily)
- the materials on the surface of the insulation
or tyings have moved.
The windings should be cleaned with utmost care
before a new coat of varnish is given so that no
dirt will be left under
should be remove
Varnish is usually applied with a spray (one or
two coats suffices). If the windings are still warm
after drying, the temperature should be less
40C (104F). One should try to apply the varnish
between the coils and other parts that are not
easily reached. Thick coats of varnish should be
avoided as they dry slowly. Rotating parts should
be left to dry at least 24 hours at room
temperature before bringing them into use.
Solvent fumes from the varnishes are generally
poisonous and flammable, so safety at work
should be taken into account (see Section 6.10).
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

Table 10. Features of the detergents for the winding.
Commutator (insulations consisting
shellack

)
2 2
Silicone rubber

lo
Pitched diesel grime,
fats, oils
1
3
2
Class of flammable liquids
I
n
c
o
m
b
u
s
t
i
b
l
e
W
a
t
e
r
(
h
o
t
)
W
a
t
e
r
I
s
o
p
r
o
p
y
l
W
h
i
t
e

s
p
i
r
A
c
e
t
o
n
e
X
y
l
e
1
.
1
.
1
-
t
r
i
c
h
l
W
h
i
t
e

s
1
.
1
.
1
t
r
i
c
h
l
48 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
3 3 3 2 1 2
3 3 3 3 3 3 3 3

Epoxy, polyester resin
Red finishing varnish
(epoxy, alkyd)
Impregnating varnish
Black g
finnishing va
Shellack
Aspahlt-varnish
3 3 3 3 2 2 2 2
3 3 3 3 1 2 2 3
ssy
3 3 2 2 1
rnish
2 2 2 1 1
3 3 2 2 1
1-3 2 2 3 3 3 1
3
2 1 2 2 2 2 2
2 2 3 3 3 3 3
3 1 3 1 1 2 3
Salts
Greasy woodpulp
Greasy coaldust
Normal dust
Allowed concentration in air, ppm
cm
3
/ m
3
4
0
0
2
0
0
1
0
0
0
1
0
0
2
0
0
2
0
0
I
n
c
o
m
b
u
s
t
i
b
l
e
I I
I I I
I
I
n
c
o
m
b
u
s
t
i
b
l
e

N
o
t

r
e
c
o
m
m
e
n
d
e
d
I
I



















N
o
t

r
e
c
o
m
m
e
n
d
e
d
1
:
2
0

(
v
o
l
u
m
e
)
1
:
1

(
v
o
l
u
m
e
)

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6.8 Other maintenance operations
Some examples of repair maintenance are:
- impregnation
- tightening of the slot wedges
- tightening of the supporting parts.
Determine from the manufacturer if these
operations are necessary. If they are, obtain a
detailed plan to carry them out.
6.9 Maintenance of old windings
The old finishing varnish type may be unknown.
When choosing the cleaning solvent, make sure not
to damage the old coat of varnish (see Section
6.5.2). Test:
Rub the surface with a cloth moistened with the
solvent for a couple of minutes. If the varnish
does not dissolve, stick to the fabric, or become
soft when tested with a fingernail, the solvent
may be used.
Finishing varnish and surface materials may be
brittle and the insulations at the coil overhangs
may be soft and fragile, so avoid hard pressing or
rubbing when cleaning. Finishing varnish that
comes off on its own should be removed. Re-
varnishing is then generally needed.
When re-tightening the slot wedges, make sure
that they are not too tight as the old insulation
might get damaged. It is best to fix the slot
wedges with an adhesive resin.
When re-varnishing, ask the manufacturer about
the impregnation process and the choice of
finishing varnish. The type of finishing varnish
can be determined by testing a small sample on
the old surface and checking the adhesion and
quality. For example, epoxy finishing varnish
usually adheres well to old bitumen varnish,
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 49
increasing the resistance of the surface to oil and
solvents. Sometimes, it is best to use the original
finishing varnish when re-varnishing.
When drying, the construction of winding
insulation should be taken into account so that the
insulation does not get damaged. Insulations
consisting of cellulose and micafolium should be
dried slowly. The water vapour should be allowed
to escape without causing a high pressure on the
insulation, making it swell or break; the highest
drying temperature range is 100C-110C (212F-
230F).
6.10 Work safety principles with winding
maintenance
Winding maintenance involves:
- handling hazardous solvents, varnishes, and
resins,
- dealing with flammable solvents and
varnishes,
- testing at high voltage (HV).
Some dangerous substances are:
- white spirit: solvent
- 1.1.1-trichloroethane: solvent
- finishing varnish: solvent and resin
- adhesive resin: epoxy resin
There are special instructions for handling
dangerous substances during maintenance work.
Important handling instructions can also be found
on warning labels of the packing.
Some general safety measures are as follows:
- Avoid breathing air fumes; ensure proper air
circulation at the work site or use respiration
masks.
- Wear gloves and suitable protective clothing
to protect the skin. One should always use
protective creams.
- Spray-varnish equipment, the frame of the
machine, and the windings should be earthed
during spray-varnishing.
- Do not smoke, eat, or drink at the work site.
- Take necessary precautions when working in
pits and cramped places.
- Only people trained to do high voltage work
can carry out a voltage test.
LITERATURE
1) IEEE Std. 43-1974, IEEE Recommended
Practice for Testing Insulation Resistance of
Rotating Machines.
2) IEEE Std. 432-1976, IEEE Guide for Insulation
Maintenance for Rotating Electrical Machinery.
User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

50 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN

TEST RECORD Machine, type ................................. No: ................................
Annual inspection Use ......... ................... ........................ No: .............
Inspection every 4 years Voltage/output ................................. kW V ................................
Random inspection Running hours ................................. h
Distribution ................................................ Date/inspected by ........................./..........................
1. Seals OK Observations: .............................................................
2. Fixing air guiding plates etc. OK Observations: .............................................................
3. Contamination Stator Rotor Explanations End Air Cooling
windings windings ducts radiators D N
Total a mount of dirt
Grease, oil
Dry dirt,dust
Dampness, rust

OK Observations D N
4. Windings
4.1 AC stator
Support
Coils
Connecting cables
Core laminations
4.2 Asynchr. rotor
Ends of squir. cage windings
Keys of squir. cage ring
Core laminations
5. Fan
6. Cooling system
Visible radiator parts
Inner radiator parts
Flow-switch
7.Elect. connections
Main connection
Control gear

ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 51
8. Electrical test
Insulation resistanc R
15
= . . MO R
60
= .................. MO e to earth ................
Winding temperature ........... ....... .
Voltage test 1 min Test voltage .......................... ......
Operation test of protection Voltage ...................... kV DC voltage AC voltage

QUANTITY ESTIMATION
= clean
out plug)
ntiful (ducts p gged)
BASIS
12 = risen ba
2 = loosening 13 = battered
= cracking 14 = knocking: doubtful
= breaking
= dust, caused by vibration
17 = condensation
g 18 = loose ribs
brittlement 19 = abrasion
er marks 20 = noise from the bearing
racking 21 = another noise. What kind of?
22 = other flaws. What sort of?
0
1 = slight
2 = plentiful (ducts ab to
3 = very ple lu
ESTIMATION
1 = dropping rs
3
4
5
15 = corrosion
16 = leakages
6 = swelling
7 = darkenin
8 = em
9 = wat
10 = t
11 = hair cracks

User`s Manual, AMK 400-500
Chapter 7 - Maintenance ABB

52 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
7 Maintenance painting
37
n
red by touch-up painting.
aintenance when the
rust grade is Ri4 or
last clean steel surfaces to
1) in accordance with the
system, it is recommended
t system.
e preparation
ove
grease and oil using an al
lsions. Wash the su
ter.
e paint. Remove rust by
eaning to minimum St 2 - t
est result is achieved by blast cleaning. (SFS-
ISO 8501-1). Level off the edges between the old
paint film and cleaned up areas. When using blast
cleaning, be sure that there are no cracks in the
remaining paint film and do not cause damage for
the sealings.
The surface preparation is in accordance with the
following standards:
- SSPC-Vis 1-82
- SFS-ISO 8501-1:1994 (SS 05 59 00) St 2, Sa 1
SSPC = Steel Structures Painting Council
SO = International Standards Organisation
SFS = Finnish Standards Association
If the entire surface has to be overcoated, abrade
the old topcoat to a rough finish and remove all
dust and other cleaning residues.
7.2.2 Application conditions
Surface must be dry. The temperature of the
ambient air, surface or paint should not fall below
+10C / 50F during application and drying.
Relative humidity should not exceed 80%. The
surface temperature of the steel should remain at
least 3C / 5F above the dew point.
y brush or
rdener
components
ld be the same
m. If the film
thickness exceed 200 um, application should be
done with 2 layer and both layers should have the
same thickness.
The topcoat is not necessity but it can be used if
outward appearance is important. The standard
colour is blue (RALASEA C, TVT B-062,
Munsell 8B 4,5 / 3,25, NSC 4822-B05G).
Surface treatment:
omponent high-solids, modified epoxy
paint (e.g. TEMASTIC ST 200), 100
2-component high-solids, modified epoxy
inium paint (e.g. TEMASTIC ST 200) (only
sary), 100 200 um
xy or polyurethane topcoat (not
When the rusted area exceed 8 %, the entire
coating must be renewed. Remove the old paint
film and blast clean to Sa 2.5. Recoating in
accordance with the original paint system.
7.2.5 Standards of the painting system
and surface preparation
TP26 - EPUR 180/ 2 - Fe St2
Steel, cast iron and parts made of hot-rolled steel:
SFS 4596: E 180-320/ 1-2 - Fe St2
SFS 4596: EPUR 180-320/ 2-3 - Fe St2
Parts made of cold rolled sheet or light metal:
SFS 4962: E 180-320/ 1-2 - Fe St2
SFS 4962: EPUR 320/ 2-3 - Fe St2
- EPUR 320: epoxy undercoating,
polyurethane finish nominal film
thickness 320 um
- Fe: surface material
- St2: wire brushing to the degree 2
7.1 General
7.2.3 Application
Touch-up painting is sufficient for maintenance
Touch-up painting should be done b
when the rusted area is less than 8% of the
painted surface that means that the rust grade is
airless spray. Mix first the base and the ha
separately before mixing the
Ri1 Ri3 (ISO 4628 and SFS 62). Damages
caused by transport or installatio may also be
together. Total film thickness shou
as for the original paint syste
repai
Repainting is necessary for m
rusted area is 8% or more (the
Ri5).
7.2 Touch-up painting
If it is not possible to b
Sa 2.5 (SFS-ISO 8501-
original paint to use
2-c
the following pain
7.2.1 Surfac
20
Remove any water-
alum
solid impurities. Rem
soluble salts, kaline
if neces
solution or emu rfaces
a thoroughly with w
2-component epo
Remove all loos power
tool or wirebrush cl he 7.2.4 Repainting
b
aluminium
0 um.
necessity).
ABB
User`s Manual, AMK 400-500
Chapter 7 - Maintenance

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 53
- Sa2.5: sand blasting to the degree 2.
ISO 12944-5 / paint system 5.13 and 7.03.
5
8 Cleaning
loyed. Therefore,
electrical machines should only be cleaned with
cleaning methods should only be used
for the main cleaning, after thorough application
ethod. Standard
equired with
very gummy oil.
smantling /reassembly work is to
Before beginning the cleaning work, the machine
should be partially dismantled (as far as
practical). Components of austenic steel can be
destroyed by stress corrosion if halogenous
cleaning solvents are emp
non-halogenous solvents. Mechanical dry
cleaning should be used first, "to get the worst
off". Wet
of a mechanical cleaning m
cleaning agent, industrial benzene, should be used
for ordinary dirt and xylene may be r
9 Overhaul
When carried out at set intervals, every 2-4 years
are recommended, overhauls allow supervision of
wear, early recognition of any sign of damage and
replacement of defective parts in time. The extent
of overhaul will be mostly determined by the
observations made during operation. All
inspection and di
be performed by suitably trained personnel. The
first overhaul should be performed after 500 starts
or 8000 hours of operation whichever occurs first,
but not later than 2 years of operation.

User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly ABB

54 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
C ter 8 Dismantling a hap nd Re
............
.........
...........
assembly
1 In general ......................................................
2 Dismantling .....................................................
3 Reassembly....................................................

............................................................................ 55
............................................................................ 55
............................................................................ 58
ABB
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 55
Chapter 8 Dismantling and Reassembly
1 In general
This chapter presents the procedure to dismantle
a
carried
nd reassemble the machine. Operations must be
out by skilled persons with knowledge to
follow the applicable part of the instructions for
the extent of maintenance work in question.
Constructional drawings in Chapter Appendices
help to follow the work items.
Note! Before any action the incoming cables
shall be separated from electric power network
and grounded. All auxiliary cables shall be
disconnected. (mark each cable and wire before
disconnecting them). Follow all necessary
safety precautions according to the regulations
governing the work.
Notice that for certain maintenance work e.g.
change of the slip ring gear, only partial
dismantling of the slip ring housing & accessories
is needed.
Note! Some customer specific items may not
be included in this manual or the machine
delivery. Additional documentation should be
requested.
2 Dismantling
1. Separate and ground the main supply cables,
secondary rotor cables and all auxiliary
cables from electric power network. Remove
possible pipes, hoses, instrument cables and
grounding cables.
2. Depending of the extent of the dismantling
work remove also top-mounted attachments,
hold-down bolts, dowel pins and dismount
the coupling half.
Item 3 for air-to-air cooled vertical machines
only
3. Place the lifting hooks to the lifting points of
the air duct between the outer fan cover and
heat exchanger of the machine. Remove the
mounting screws and lift the air duct up.
Remove also the air duct between the outer
Items 4-6 for vertical machines only
4. Place the lifting hooks to the lifting points of
the heat exchanger (upper cover) of the slip
ring unit (permanent contact type slip ring
unit only). Remove the mounting screws of
the heat exchanger and lift it up. Perform the
same procedure for the heat exchanger of the
main machine (upper cover).
5. Place the lifting hooks to the lifting points of
the machine frame. Remove the mounting
screws of the machine and lift it up.
fan cover and heat exchanger of the slip ring
unit (machines with permanent contact type
slip ring unit only).
Note! Use a lifting beam to avoid damaging
the slip ring unit. See Chapter Transport and
Storage for lifting instructions.
6. Turn the vertical machine to horizontal
position. Use one hoist for lifting and
another for tilting.
Note! If it is difficult to remove the motor
from its site, partial maintenance may be
possible to be done also in vertical attitude. If
the bearings are to be changed, the rotor shall
be hold up by some special device.
Items 7, 8 and 9 are for air-to-air cooled
horizontal machines only.
7. Remove the D-end SPM nipple (machines
with antifriction bearings only). Place the
lifting hooks to the lifting points of the
external fan cover. Remove the mounting
screws and lift the cover up.
8. Remove the outer circlip and gently
withdraw the fan from the shaft. Remove
also the key and the inner circlip.
9. Place the lifting hooks to the lifting points of
the air duct (between the heat exchangers of
the machine and slip ring unit. Remove the
mounting screws and lift the air duct up.
Item 10 for horizontal machines only.
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly ABB

10. Place the lifting hooks to the lifting points of
the heat exchanger (upper cover) of the slip
21. Place the liftin
cover. Remove th
ring unit (permanent contact type only).
Remove the mounting screws and lift the heat
exchanger up. Perform the same procedure for
f the machine (upper
If the motor is equipped with brush lifting type
s
p
L
w
1
1 hooks to the slip ring
housing, open the retaining bolts, and
14. Open the spring assemblies of the brush

1 ect the rotor cables from the slip
ring bolts.
ol to the balancing
disk of the slip ring assembly and gently
17.
19. oks to the support plate.
Items 20-21 for air-to-air cooled vertical
20.
g hooks to the external fan
e mounting screws and lift
the cover up.
Now the machine has no heat exchangers (upper
covers) or slip ring unit and it is ready for
conti
Item hines equipped with
antifriction bearings.
When dismantling and reassembling the machine,

betw
the N
is to
the b
of in
the heat exchanger o
cover).
11. Disconnect the connecting copper busbars
from the brush rocker and the termination
bushing inside the slip ring housing.
Items 12-19 for machines with permanent
contact type slip ring unit only.
lip ring unit, follow the dismantling instructions
resented in Chapter Slip Ring Unit with Brush
ifting Device. After that, continue the dismantling
ork from item 22.
2. Remove the mounting screws of the fan of
the slip ring unit and dismantle the fan.
3. Place the lifting
remove the slip ring housing. Removing of
the slip ring housing may not be necessary,
if only the slip ring assembly has to be
changed.
56 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
holders and lift the carbon brushes up. Brush
holders can also be removed if that is
needed.
5. Disconn
16. Mount a withdrawal to
withdraw the slip ring assembly from the
shaft.
Disconnect and remove auxiliary cables
between the machine frame and the slip ring
support plate.
18. Remove the two semi-circular shaft sealing
plates on the support plate.
Place the lifting ho
Open the four distance bolts and remove the
support plate.
machines only.
Remove the outer circlip of the external fan
and gently withdraw the fan from the shaft.
Remove also the key and the inner circlip.
nuing the dismantling work.
s 22-30 for mac
pay attention to the optional bearing insulation
een the bearing housing and bearing shield at
-end (Fig. 1). The purpose of the insulation
stop possible shaft currents flowing trough
earings. The grease filling tube is also made
sulated material.

Fig. 1. The insulation of the antifriction bearing.
mach
Diffe tructions are shown in
Chapter Appendices.
2

2 se valve and
pull the valve out by using M12 threads.
26.
les to pull out
27. jack.
29. he
ly). Pull
away the inner cover.
Dismantle first the axially free bearing (horizontal
ines = N-end, vertical machines = D-end.
rent bearing cons
2. Remove the grease filling tube and possible
Pt-100, thermocouple or vibration probe of
the bearing.
3. Remove the circlip of the grea
24. Loosen the outer bearing cover and pull it
away.
25. Raise the shaft end by only a few tenths of a
mm by using a jack.
Remove the end shield (the end shield is
drawn out by gently tapping the rim of the
shield). Use the threaded ho
the shield.
Let down the rotor and remove the
28. Pull out the bearing. Use an adequate
bearing withdrawal tool set which will apply
pressure only on the inner bearing ring.
Remove the springs which preload t
bearing (axially free bearings on
ABB
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 57
No e! The bearing must be protected from t
dust and moisture by wrapping it up in e.g.
waxed paper if the bearing is going to be
reused. Reusing is not recommended.
Item for machines equipped with sleeve
Clea
thoro first the
D-end bearing and repeat the same procedure for
30. Drain off the bearing oil.
carrier (11).
35. top part of the housing carefully
(just enough to open the housing joint
36. embly position of the upper
lly in a way not
rings of the shaft seals (9
41. Remove the housing bottom part (1). After
that remove the end shield (15) with the
machine seal (14). Use the threaded holes to
pull out the shield (bearing sizes EFZL_ 11
and EFZL_ 14 only).
42. Remove the end shield (15) with the housing
bottom part (1) and the machine seal (14).
(bearing size EFZL_ 9 only).
evenly). Swing the top part out of the
machine end shield and lift it off.
Mark the ass
bearing shell (4) and take it off carefully.
37. Unscrew the bolts of the oil ring (6) and
handle the two halves carefu
s 30-43
bearings (Figure 2 and Chapter Appendices).
n the working place and the bearings
ughly before dismantling. Dismantle
to affect their true geometric shape.
38. Open the garter sp
and 10) by turning left on the lock and
remove the shaft seals.
39. Raise the shaft end by only a few tenths of a
mm just enough to relieve the lower bearing
shell (3). Use a jack.
40. Swing the lower bearing shell (3) up and lift it
up.
the N-end bearing.
31. Disconnect possible oil pipe connections and
remove possible Pt-100 or thermocouple and
vibration probe of the bearing.
32. Remove the seal
33. Remove the fastening screws of the machine
seal (14) (bearing size EFZL_ 9 only).
34. Unscrew the flange bolts of the top part of
the housing (2) on the machine end shield
(15) and the joint bolts (7) on the bottom
part (1).
Raise the
Use the threaded holes to pull out the shield
43. Let down the rotor and remove the jack.
I
II

1 H 12 l
2 H 8 Oil ring sight glass 13 l
3 Lower shell 9 Inboard shaft seal 14
15
11 Seal carrier 16 Oil o
Fig 2. Sleeve bearing.
ove the mounting
ousing bottom part 7 Joint bolt
ousing top part
Oil level gauge I for temperature contro
Retention pin II for temperature contro
Machine seal in oil sump
Machine shield III for oil outlet
utlet
4 Upper shell 10 Outboard shaft seal
6 Loose oil ring
Items 44-48 for all AMK machines 44. Remove the circlip of the fan and gently
withdraw the fan from the shaft. Remove
also the key. Then rem
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly ABB

58 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
screws of the inner air guide and dismantle
it.
5. Remove the rotor by using a special
supporting tool. Do not allow th
4
e rotor to
touch the stator.
or end ring.
xing bolts on both
Prior parts
are in acceptable condition. Dirtiness must be
If a
desig
rating plate achine.
1.
stator down to the frame with a crane.
Tighten the mounting screws. Use suitable
locking agent to lock the screws.
2. Turn the frame to horizontal position.
Connect the stator connection and all
auxiliary cables.
3. Turn the frame to horizontal position. Install
the rotor with a special supporting tool. Do
not allow the rotor to touch the stator.
4. Attach the air guide.
5. Heat up the hub of the fan to max 100C
(212F) and mount the fan with a key on the
shaft. A thin layer of suitable lubrication and
assembly paste is needed between the hub
and shaft.
Items 6-17 for antifriction bearings only.
r c position.
bearing a th
hich must b t.
bearing c rs w
(se ap tenance
ase types).
(221F) by
using an induction heater.
8.
bly paste
all
9. with a
site side.
over fully with new
11. ll the grease valve.
13.
ication and assembly
end
on its position and tighten the screws evenly
opposite side. Use suitable sealing agent on
the mating surfaces.
15. Fit and attach the outer bearing cover. Fill
the cover fully with new appropriate grease.
Tighten the screws.
16. Install the grease valve and attach the
circlip.
Items 17-26 for D-end sleeve bearing only.
17. Attach the bottom part of the bearing
housing to the end shield.
18. Place the machinery seal, lubrication ring
and the springs holding shaft seals hanging
on the shaft in appropriate places.
or as mu
earing sh ld
side.
21. Put the bottom bearing shell on its place, let
22.
46. Disconnect the stator connection and all
auxiliary cables. Check that the cables can
move freely.
47. Turn the frame N-end upwards and attach
the lifting eyes and crane to the threaded
holes on the stat
48. Remove the two stator fi
sides of the frame and possible other fixing
bolts on top of the frame. Lift the stator from
the frame.
3 Reassembly
to reassembly, check and verify that all
cleaned and worn out parts replaced.
new bearing must be fitted, its type
nation must be exactly the same as on the
of the m
Turn the frame N-end upwards. Move the
Lubricate the shaft surface with a thin layer
of suitable lubrication and assem
6. Place the inner bea ing overs in
19. Lift the rot ch as the air gap allows.
Axially free s re equipped wi
sition and
springs, w e attached at this po
20. Lift the b ie on its po
in
ith ne
tighten the screws evenly opposite
Fill the ove fully w
ppropr e Ch ter Main a iate grease
for appropriate gre
7. Heat up the bearings to 110C
and fit the bearings on the shaft. Fill them
fully with new appropriate grease.
Remember the absolute cleanness with
bearing parts and grease. Reusing of an old
bearing is not recommended.
Lubricate the bearing housing bore
thin layer of suitable lubrication and
assembly paste and lift the bearing shield of
the axially fixed end on its position. Tighten
the screws evenly oppo
10. Fit and attach the outer bearing cover. Use
suitable sealing agent on the mating
surfaces. Fill the c
appropriate grease. Tighten the screws.
Insta
12. Attach the circlip.
Place a new O-ring onto the bearing housing
bore of the end shield (axially free end). A thin
layer of suitable lubr
paste is needed between the housing and the
bearing. If the machine is equipped with
insulated end shield, measure and ensure the
insulation resistance over the bearing
housing and the end shield.
14. Lift the bearing shield of the axially free
the shaft down on the bearing and install the
shaft seals.
Put the upper bearing shell on its place.
ABB
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly

23.
ring housing (Figure 3).
Apply luting agent on the bottom part of the
bea

Fig. 3. Applying luting agent.
Attach the upper part of the bearing housing.
Attach the d
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 59
24.
25. ust seal.
appropriate oil to
correct level (to the middle of oil sight
only.
g is insulated (the
Item
unit.
If the
slip r e instructions presented in
ap
tin
conti
s reassembled, the slip
ho
e
ring
circu
chan
instru ented in Chapters "Maintenance
ce.
26. Fill the bearing with
glass).
Item 27 for the N-end sleeve bearing
27. Perform the same procedures as described in
items 17 to 26 for the D-end bearing. Notice
that the N-end bearin
inside spherical housing surfaces are lined
with nonconducting PTFE housing).
s 28-39 for reassembly of the slip ring
machine is equipped with brush lifting type
ing unit, follow th
Ch ter Manual for Slip Ring Unit with Brush
Lif g Device. After the applicable items
nue the reassebly from item 41.
Before the slip ring unit i
ring using, heat-exchanger, slip ring gear, brush
rock r and other parts must be cleaned. If the slip
unit is equipped with internal cooling air
it filter, the filter has to be cleaned or
ged if needed. Follow the cleaning
ctions pres
and Slip Ring Unit with Brush Lifting Devi
No e! If gaskets of the slip ring housing have t
to be changed or lubricated, do not use any
silicone based material e.g. silicone rubber,
silicone plastic or silicone grease.
28. olts and the
en the hub of the
29.
31.
e it with a
32. hub
roughness must be
machined and polished. If the condition is
e slip ring assembly in
Mount the four distance b
support plate. With air-to-air cooled vertical
machines the external fan cover is mounted
before the support plate. Th
external fan is heated to max 100C (212F)
and the fan is mounted with the key on the
shaft. A thin layer of suitable lubrication and
assembly paste is needed between the hub
and shaft.
Attach the two semi-circular shaft sealing
plates on the support plate.
30. Connect auxiliary cables between the
machine frame and the support plate.
Clean the shaft end at N-end. Polish it if the
surface is not smooth. Lubricat
thin layer of suitable lubrication and
assembly paste. The run-out at the shaft end
should be < 0.02 mm.
Check the condition of the slip ring and
hole surfaces. Possible
acceptable, heat th
oven until the temperature has reached
+130 C (+265 F).
Note! Heating the slip ring assembly by other
means is not permitted, as it will destroy the
insulation.
33. . The outer end
34. ables to the slip ring
35. shes down to the brush
2 mm distance to the slip ring
r, in
mit)
37.
rmination
39. slip
ring housing.
Item
40. seals of the heat exchangers
Mount the slip ring assembly
of slip ring hub should be in line with the
end face of the shaft. Allow the slip ring
assembly to cool down.
Connect the rotor c
bolts. If necessary bend the cables gently
while heating them with warm air.
Place the carbon bru
holders and close the spring assemblies. If
the brush holders have been removed, adjust
them to
surface. Check that all brushes are simila
acceptable condition (check the wear li
and can move freely inside the brush
holders.
36. Mount the slip ring housing.
Connect the connecting copper busbars to
the brush rocker and to the te
bushing.
38. Mount the slip ring unit fan.
Connect the electrical connections of the
40 for horizontal machines only.
Change the
(upper covers) and mount them.
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly ABB

60 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Items 41-45 for air-to-air cooled horizontal
ines only. mach
41. Clean the shaft surface and lubricate it with
a layer of suitable lubrication and assembly
paste. Attach the inner circlip.
42. Heat up the hub of the fan to max 100C
(212F) and mount the fan with a key on the
shaft. Attach the outer circlip.
43. Mount the external fan cover.
44. Mount the D-end SPM nipple (machines
ith ly).
exchanger of the machine and slip ring unit.
46.
and flange. Turn the machine to
for
47.
48. angers
(upper covers) and mount them.
Item
only
49.
eat-exchanger of the machine. If
the machine is equipped with an other air
unit, mount the

Item
50.
s.
52. ngs with appropriate
5 e instructions presented in
w antifriction bearings on
45. Mount the air duct (between the heat
Items 46-48 for vertical machines only.
Place the lifting hooks to lifting points of the
frame
vertical position by using one hoist
lifting and one for tilting.
Put the machine on the foundation and
attach the mounting bolts.
Change the seals of the heat exch
49 for air-to-air cooled vertical machines
.
Mount the air duct between the external fan
cover and h
duct between the external fan cover and heat
exchanger of the slip ring
duct.
s 50-53 for all AMK machines.
Place the auxiliary devices in their positions
and connect their cable
51. Connect all pipes, hoses, instrument cables
and/or grounding cables between heat
exchangers (upper covers) and machine
frame.
Lubricate the beari
lubricants as presented in Chapter
Maintenance.
3. Follow th
Chapters Installation and Alignment,
Mechanical and Electrical Connections and
Commissioning and Start-up
ABB
User`s Manual, AMK 400-500
Chapter 8 - Dismantling and Reassembly

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 61
SCHEDULE FOR REGULAR CHECKINGS PERIOD
Daily Monthly Yearly Durin
comple
overha
g
te
ul
Power X
Curre X nt
P.F. X
Excitation current X
Winding temperatures X
Bearing temperatures X
Cooling air temperatures X
Oil pressures X
Bearing vibration X
Heat exchangers X
Contamination X
Clea machine nliness of inner parts of the X
Cleanliness of diodes and diode bridges X
Cond s, lockings ition and support of winding X
Possible shifting of the slot wedges X
Cond finishing varnish X ition of the winding insulation and
Possible shifting or loosening of the field windings X
Insulating resistances of the windings X
Condition of the fan X
Lockings in connection with the rotating parts X
Painting and protection against corrosion X
Checking the seals preventing the ingress of dirt X
Checking the performances of control and regulation equipment
as well as protective relays
X
Checking of rust caused by vibration on stator core X
Checking the condition of the rotor winding supports X
Checking the solderings and possible broken bars of the rotor
damper winding
X
Bearings and bearing seals X

User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device ABB

62 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 9 Slip Ring Unit with Brush Lifting Device
1 General...........................................................................................................................................
1.1 Rated values of the slip ring gear .........................................................................................
.2 Purpose .................................................................................................................... ................ 63
3 The main parts of the slip ring gear.............................................................................................. 63
4 Operating functions of the slip ring gear ................................................................................... 63
1.4.1 Starting position ............................................................................................................. 63
Change from starting position to running position 63
Running position ............................................................................................................ 63
opping the motor ......................................................................................................... 63
2 Inspection of the motor upon delivery.................................................................................................. 64
..................................................................................................................................... 64
the actuating motor................................................................................................. 64
tor ............................................................................................................................. 64
ifting mechanism..................................................................................................................... 64
shes .................................................................................................................... ................ 64
circuit ring........................................................................................................................ 64
tric movement limits of the actuating motor....................................................................... 64
in normal use................................................................................................................... 64
rushes, brush holders............................................................................................................... 64
rings............................................................................................... 64
64
rcuit ring.......................................................................................... 65
............................................ ............... .............. 65
6 Dismantling of the slip ring gear .......................................................................................................... 65
ear ........................................................................................................... 66
ce ............................................................................ 66
device.............................................................. 66
.................................. ............... .............. ............... 67
ng and shifting claw position 67
er and the brushes............................................................................... 6
ing the mechanical end limit ........................................................................................... 67
..................... 68
......................................... ............... .............. ............... 68
tor .................................................................................................. 68
9.3 Adjusting the actuator motor ..................................................................................................... 68
..................................... ............... .................................. 69
............ ............... .............. ............... 69
....... 63
..... 63
1 ..
1.
1.
1.4.2
1.4.3
.........................................................
1.4.4 St
3 Commissioning
3.1 Connecting
4 Starting of the mo
4.1 L
4.2 Bru
4.3 Short
..
4.4 Elec
5 Maintenance
5.1 B
5.2 Contact surfaces of the slip
5.3 Contact parts.............................................................................................................
5.4 Moveability of the short ci
.................
5.5 Carbon dust............................. ... ... ....................
7 Assembling of the slip ring g
8 Instructions for adjusting of the brush lifting devi
8.1 Initial position of adjusting of the brush lifting
8.2 Aligning the fork .............................. ... ... .....
8.3 Adjusting the short circuit ri
8.4 Adjusting the brush rock
........................................................
7
8.5 Adjust
9 The actuator motor...........................................................................................................
9.1 General ...................................... ... ... .....
9.2 Connecting the actuator mo
10 Spare parts ................................................ ... ...
11 Appendices .............................................................

... ... .....
ABB
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 63
Chapter 9 Slip Ring Unit with Brush Lifting Device
1
1.1
This slip ring
rated rotor cu
voltage U2 <
amoun
with t
brush w
The sl
parts: tin
Appe
er
emb
short
carries
the ac r
and of
and ro
connec
starter re
1.4 Operating functions of the slip ring
gear
1.4.1 Starting position
The motor shall always be started with the
brushes (3, A15) down, touching the slip rings (6-
8, A12), and the short circuit ring (1, A12) in
open position (pos1, A17).
1.4.2 Change from starting position to
running position
When the motor during start has reached its
running speed, the actuator motor (2, A11) is
powered getting the short circuiting and brush
General
mechanism (6, A11) will close the short circuit
Rated values of the slip ring gear
ring (1, A12) to the slip ring assembly (9, A11)
gear is used for motors having the
rotor winding and then lift the brushes (3, A15)
rrent I2 < 1000 A and the rated rotor
away from the slip rings.
2500 V.
1.2 Purpose
the D-end of the motor, then the fork changes
The p
direction of its movement (pos2, A17), moving
urpose of the slip ring gear with brush
towards the slip ring assembly, thus moving the
lifting and short circuiting device is to allow the
motor
short circuit ring (1, A12) to close (pos3, A17) the
to start with an adjustable and controllable
short circuiting contact parts (3, A12) and (5,
t of current and/or torque and run the motor
A12). After closing the contacts between the short
he rotor winding short circuited without
circuit ring and slip ring assembly (9, A11) the
ear.
brush lifting mechanism lifts by the lever (8, A13)
1.3
and the wire (14, A13) the brushes (3, A15) away
The main parts of the slip ring gear
from the slip rings. After that the fork returns
ip rin gear consists of the following main
motor to give 2-5 mm clearance to the bearings
g
(pos4, A17) a few mm towards the D-end of the
actua g motor (2, Appendix 11 in Chapter
(detail 1, A17) on the ends of the fork. Then the
ndices), lifting mechanism (6, A11), brush
actuator motor is normally automatically switched
rock with collecting rings (10, A11), slip ring
off and the movements of the lifting mechanism
ass ly (9, A11), and housing (1-8, A10). The
are stopped (pos5, A17) to the running position.
actuating motor is situated outside of the slip ring
housing, and it manoeuvres the brush lifting and
circuiting mechanism. The brush rocker
br the ush holders and brushes. Normally
tuato motor is automatically switched on
f synchronized with the starter functions.
The slip ring assembly is shrunk on to the shaft,
tates with the rotor. The slip rings are
ted to the rotor winding with cables going
through a hole in the shaft, thus enabling
connection between the rotor circuit and the
sistors.
lifting gear in function. First the lifting
short circuiting the slip rings (6-8, A12), and the
First the fork (15, A13) moves a few mm towards
Note! In the running position the starter
resistors shall be short circuited, and the short
circuiting shall be happened before the brushes
are lifted up from the slip rings.

Note! When the starter resistors are short
circuited, the voltage drop in the starter and in
the cables between the slip ring gear and starter
shall not exceed 5 volts at the rated rotor
current I2 of the motor. This means that, if the
cables are dimensioned for a current density of
1 ... 1.5 A/mm, the distance between the
motor and the starter should be < 20 m.
1.4.3 Running position
In running position the bearings (3, A17) on the
ends of the fork will be situated in the groove of
the short circuit ring (2, A17) in such a way that
the bearings will have a minimum clearance of 2
mm to the short circuit ring (detail 1, A17).
1.4.4 Stopping the motor
When the motor has to be stopped, the lifting
mechanism will in reverse order move the brushes
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device ABB

64 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
(3, A15) down, and then the short circuit ring (1,
A12) back to starting position (pos1, A17).
Note! Starter functions shall always be
syncronized with the slip ring gear functions
according to the starter instructions.
2 Inspection of the motor upon
ecked for visual damages.
Any detected damage should be photographed,
pplier of the motor.
1) has to be electrically connected
and its adjustments checked. When the cables are
n
of the actuator can and shall be checked without
e,
the following items shall be thoroughly checked.
sition, and the brushes (3, A15)
down.
shall be in starting
at the brushes are
not sparking. If sparking is found, reasons for it
ing
The short circuit ring (1, A12) shall be in open
position, i.e., in the position where the contact
females (3, A12) of the short circuit ring do not
delivery
The slip ring housing and the actuator motor
housing have to be ch
and reported to the su
3 Commissioning
3.1 Connecting the actuating motor
Before starting the AMK motor, the actuating
motor (2, A1
connected according to the manual, the functio
starting the AMK motor.
4 Starting of the motor
Note! Failure in starting the motor without
checking the adjustments of the components of
the complete slip ring gear can result in serious
damage! Also connections to the starter and
functions with it shall be checked!
Before the AMK motor is started the first tim
4.1 Lifting mechanism
The lifting mechanism (6, A11) shall be in the
starting position, i.e., the short circuit ring (1,
A12) in open po
4.2 Brushes
All nine brushes (3, A15)
position, i.e., down and in good contact with the
slip rings (6-8, A12).
Check during the first starts, th
shall be checked and clarified before continu
the use.
4.3 Short circuit ring
make any contact with the contact pins (5, A12)
of the slip ring assembly (9, A11).
4.4 Electric movement limits of the
actuating motor
The electric movement limits (6-15, A18), i.e., the
h
roc
I
t
a es are in good
condition without burning marks.
5.2
C
s
g
o
r
s
s
gs or
place, if needed.
adjustments of the limit switches of the actuating
motor (2, A11) must be checked so that the lifting
mechanism (6, A11) will stop at proper positions.
5 Maintenance in normal use
The slip ring gear and slip ring housing shall be
checked at regular service intervals.
5.1 Brushes, brush holders
The brushes (3, A15), (1, A16) will normally
wear in use, and shall be replaced before they are
worn out. The brushes shall be checked at regular
intervals, and must be replaced latest when the
wear has reached the wear limit mark (25, A16).
When the brushes are replaced the brush rocker
must be re-adjusted (see Adjusting the brus
ker and brushes).
t has to be checked also at regular intervals, that
he brushes can freely move in the brush holders
nd that the brush contact surfac
Contact surfaces of the slip rings
heck at regular intervals, that the contact
urfaces of the slip rings are smooth without
rooves, burning marks etc. The contact surfaces
f the rings shall be clean, any dirt has to be
emoved. Formation of patina on the contact
urfaces is desirable, but often it can be thin on
teel rings.
5.3 Contact parts
It shall be checked at regular intervals, that the
contact surfaces of the contact pins (3, A12) of
the short circuit ring (1, A12) and of the contact
females (5, A12) of the slip ring assembly (9,
A11) are in good condition without burnin
dirt on the surfaces. Clean or re
ABB
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 65
5.4 Moveability of the short circuit ring
It shall be checked at regular intervals, that the
s
s
o ce shall be
cleaned from dirt and excessive carbon dust. The
sliding surfaces can be greased, when needed,
lyi
example Rocol A.S. Paste or Spray from Rocol
e and it
he insulating
ck the brushes
the
ting
-8, A10) have
motor from the
electrical mains supply.
3. Disconnect the connecting copper
A10) from the brush rocker
(10, A11), and the termination bushing
shaft (5, A11) between the
actuator motor (2, A11) and the lifting
both pins of the lower cardan joint).
Then move the shaft (5, A11) towards
the actuator motor, off the joint, to the
side of the joint and away from the
actuator motor.
lts, and remove the
actuator motor (2, A11) and the
7. Disconnect the wire (8, A11) from the
rush
11) by detaching the
spring (7, A11), and loosening the brush
opening two bolts.
) in
s far away as
possible from the slip rings (6-8, A12).
h rocker (10,
otor.
hort circuiting ring can easily move on its sliding
urface (hub extension of the slip ring assembly
r shaft of the rotor). Sliding surfa
app ng a thin film of MoS2 lubricant for
Ltd, Leeds England.
5.5 Carbon dust
Carbon dust is electrically very conductiv
can make conductive layers on t
surfaces. Carbon dust can also blo
into the brush holders. Therefore especially
slip ring assembly (9, A11) and the brush lif
device (6, A11) shall be kept clean. Also no
foreign particles or dust may enter the slip ring
housing (1-8, A10). Carbon dust may be removed
at regular intervals with air jet, and vacuum
cleaner; no detergents may be used.
6 Dismantling of the slip ring
gear
In order to access the N-end of the AMK motor
(1, A11), for example to change the antifriction
bearing at the N-end, the slip ring assembly (9,
A11), the lifting mechanism (6, A11), the brush
rocker (10, A11) and the housing (1
to be removed.
Removal is carried out as follows:
1. Disconnect the AMK
2. Remove the electrical connections of the
slip ring housing (6, A10).
busbars (7,
(6, A10).
4. Remove the
mechanism (6, A11) by opening the
locking screw (23, A14) of the lower
cardan joint (18, A13) (on some models
5. Open the retaining bo
intermediate flange (4, A2).
6. Open the retaining bolts, and remove the
slip ring housing (1-7, A10).
lifting mechanism (6, A11) and the b
rocker unit (10, A
rocker locking screws (20, A16).
8. Remove the lifting mechanism (6, A11)
from the support plate (11, A11) by
9. Lock the brush lifting arms (23, A16
brushes up position, i.e. where the
brushes (3, A15) are lifted a
10. Carefully remove the brus
A11) from the support plate (11, A11) by
opening three connecting bolts.
11. Place a spring and ball mounting tool on
the hub (AMK 400 and 450) or shaft
(AMK 500), and carefully push the short
circuit ring (1, A12) towards the D-end
of the AMK m
Note! There are spring (13, A3) tensioned
balls (12, A3) underneath the short circuit ring
(1, A3). Open carefully.
12. Remove the ball(s) (12, A12) and the
spring(s) (13, A12) underneath the short
ugh the slip ring hub (15, A12).
awal tool to the balancing
disk (16, A12) of the slip ring assembly
d
the four distance bolts (13, A11).
circuit ring (1, A12).
13. Disconnect the rotor cables (11, A12)
from the slip ring bolts (9, A12), and
bend them carefully while heating them
with warm air, as to let them pass
thro
14. Mount a withdr
and gently withdraw the slip ring
assembly from the shaft.
15. Remove the short circuit ring (1, A12).
16. Remove the support plate (11, A11) an
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device ABB

66 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
7 Assembling of the slip ring
gear
3. Mount the short circuit ring (1, A12) on
1. Mount the four distance bolts (13, A2)
and the support plate (11, A11).
2. Bend the rotor cables (11, A12) gently
while heating them with warm air as to
let them pass through the slip ring hub
(15, A12).
the rotor.
4. Heat the slip ring assembly (9, A11) in
oven until the slip ring assembly has
reached +130 C (+265 F).
Note! Heating the slip ring assembly by other
means is not permitted, as it will destroy the
insulation.
5. Mount the slip ring assembly (9, A11).
The outer end of slip ring hub (15, A12)
the
to
own.
12) in appropriate holes. If
tool.
d be careful not
to move the ring as to let the ball(s)
lm of MoS2
lubricant for example Rocol A.S. Paste
ush rocker (10, A11) after
having locked the brushes (3, A15) in th
14. Mount the shaft (5, A11) between the
nd the
actuator motor (2, A11).
18. Re-mount the shaft (5, A11) between the
o
the brush rocker (10, A11), and to the
ns of the
slip ring housing (6, A10).
2
8
the brush lifting device
g
claw (12, A13) open.
- Locking nuts of the brush lifting arms (3
should be in line with the end face of
shaft. Allow the slip ring assembly
cool d

21.
6. Connect the rotor cables (11, A12) to the
slip ring bolts (9, A12). If necessary
bend the cables gently while heating
them with warm air.
7. Place the spring(s) (13, A12) and ball(s)
(12, A
necessary, use an mounting
8. Place the short circuit ring (1, A12) over
the ball(s) (12, A12), an
escape. The sliding surfaces shall be
greased applying a thin fi
The
or Spray from Rocol Ltd, Leeds
England.
9. Mount the br
e
- L
brushes up position.
10. Unlock the brush lifting arms (23, A16)
and put the brushes into holders.
11. Mount the lifting mechanism (6, A11).
12. Mount the wire (8, A11) to the lifting
mechanism and to the brush rocker (10,
A11).
13. Mount the intermediate flange (4, A11)
and the actuator motor (2, A11).
lifting mechanism (6, A11) and the
actuator motor (2, A11).
15. Adjust the lifting mechanism (6, A11)
(see below).
16. Remove the shaft (5, A11) between the
lifting mechanism (6, A11) a
17. Mount the slip ring housing (1-7, A10).
lifting mechanism (6, A11) and the
actuator motor (2, A11).
19. Connect the copper busbars (7, A10) t
termination bushing (6, A10).
20. Connect the electrical connectio
Check the adjustment of the lifting
mechanism (6, A11), the brushes (3,
A15), and the actuator motor (2, A11)
(see below).
2. Connect the AMK motor to the electric
mains supply.
Instructions for adjusting of
8.1 Initial position of adjusting of the
brush lifting device
brush lifting device (6, A11) shall be in the
following position when adjustment is
undertaken:
- Locking washers (10, A13) of the shiftin
ocking nuts/bolts (2, A13) of the control
fork (15, A13) open.
pcs.) (20, A16) loosened.
- Mechanical end limit (5, A13) not tightened,
i.e. the screw (9, A13) loose.
ABB
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 67
- ctuator crank (3, A11) mounted to actua
, A11).
A to
(2
) to its
ircuit ring (1, A12) by hand
L
b
8.3 Adjusting the short circuit ring and
1) clockwise (CW).
e closest position
should be as small as possible, i.e. the
, A13)
and locking nut on the shifting claw (12,
.
e short
circuit (run) position, the circuit open
e
correct.
r (8, A13) in its
outermost position, i.e. the wire (14,
tensioned. This should
correspond with position 5 in appendix
5) so that there
is a 2-3 mm gap between the brushes and
.
The adjustment is done by loosening the
e brush holder
lever (18, A16).
f each set
of brushes.
counter-clockwise (CCW) and ensure
otor.
1. Turn the actuator crank (3, A11)
it
uit
her
, A17) is in the
of the bearings
it (5, A13) by

circuit open position (pos2, A17).
r 8.
8.2 Aligning the fork
- Move the short circuiting ring (1, A12
middle horizontal position (pos. 3, A17) by
turning the actuator crank (3, A11).
- Pull the short c
towards the open position, i.e. towards the
motor D-end.
Align the fork bearings (1, A13) to the short
circuit ring (1, A12) so that both of the bearings
are in contact with same side of the short circuit
ring.
ock the fork (15, A13) position by locking the
olts and locking nuts (2, A13).
shifting claw position
1. Start by moving the short circuit ring (1,
A12) in to the short circuit position
(pos4, A17) by turning the actuator
crank (3, A1
2. The axial distance between the short
circuit ring (2, A17) and the hub
insulator (6, A17) in th
8.5
ball (5, A17) should be in the groove of
short circuit ring (2, A17). Correct the
position by turning the screw (11
A13).
3. After the correct position is reached, turn
the actuator crank (3, A11) to move the
fork (15, A13) back and forth at least
two times in order to ensure that the right
position is reached also after a few
operations
4. Tighten the nut of the adjusting screw
(44, A14), and lock the washers (29 and
45, A14).
5. Note that when the shifting claw (12,
A13) is correctly adjusted in th

t
(start) position will automatically b
4 Adjusting the brush rocker and the
brushes
1. Turn the actuator crank (3, A11)
clockwise (CW) until the eccentric (7,
A13) has pushed the leve
A13) and spring (13, A13) are
maximally
17.
2. Adjust the brushes (3, A1
the surface of the slip rings (6-8, A12)
locking nut (20, A16), lifting or lowering
the lifting arm (23, A16) as to move the
brushes by means of th
3. Tighten the three locking nuts (20, A16)
in order to lock the position o
4. Turn the actuator crank (3, A11)
that the brushes (3, A15) touch the slip
rings (6-8, A12) before the short circuit
ring (1, A12) starts to move towards the
D-end of the m
Adjusting the mechanical end limit
clockwise (CW) until the short circu
ring (1, A12) reaches its short circ
position (pos4, A17).
2. Turn the actuator crank (3, A11) furt
CW until the bearing (3
middle of the groove of the short circuit
ring (2, A17). In this position (pos5,
A17) there should be an approximate 2-5
mm clearance on all sides
(detail 1, A17).
3. Turn the mechanical end limit (5, A13)
so that it will be in a position 1 mm from
the end limit bolt (3, A13). Lock the
mechanical end lim
ightening the screw (9, A13)
thoroughly.
4. Turn the actuator crank (3, A11)
counter-clockwise (CCW) until the
short-circuit ring (2, A17) reaches its
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device ABB

68 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
5. Turn the actuator crank (3, A11) further
CCW until there is an approximate 1 mm
clearance between the mechanical end
olt (4
A13).
of the
bearings (3, A17) towards the short
9 The actuator motor
ctuator motor (10, A10) (1, A18) is situated
outside the slip ring housing, and is mounted on a
0 VAC / 50 Hz /
1 phase, which is connected to terminals 2 or 3,
nd
lead is
s of the
cams can be changed by finding the screw (14,
m, signal lamps on the control
board etc.
2. Connect the neutral lead of 230VAC/ 50
e lead of 230VAC/ 50 Hz for
closing short circuit ring, and lifting
ort circuit ring, and lowerin
brushes, i.e. moving towards starting
position, to terminal 2 (A18).

o terminals 4 and 6 (A18).
) in to Remote position.
pos3, A17).
s5, A17) is reached. Note
that the bearings (3, A17) are moving
elow, i.e. when the
cams are rotating CW.
4. Adjust the electric limit switch S2 and
the limit switch,
push down and turn the screw in
e (CCW) until the
starting position (pos1, A17) is reached.
, A18) to assure that the
switches will be activated from below,
before
limit (5, A13) and the end limit b ,
6. There should now be an approximate 2-5
mm clearance on both sides
circuit ring (detail 2, A17). If not, re-start
from point 1.
9.1 General
The a
special intermediate flange (9, A10) (4, A18). The
actuator motor is powered by 23
depe ing on the required function. The neutral
connected to terminal 1.

3.
There are four micro-switches (6-9, A18) inside
the actuator motor, two on each side, thus
corresponding to four rotating disks with
actuating cams (10-13, A18). The position
A18) with the same color as the cam, pushing it
with a screw driver, and turning. The cams shall
always operate the switches from below the
switch.
The cams are used to adjust the rotating of the
motor S2 and S3 as well as giving signals S7 and
S8 (terminals 4 to 6, and 7 to 9, A9) to the
operating syste
9.2 Connecting the actuator motor
1. Open the cover (2, A18) of the actuator
motor (1, A18).
Hz to terminal 1 (A18).
3. Connect liv
brushes, i.e. moving towards running
position, to terminal 3 (A18).
4. Connect live lead of 230VAC/ 50 Hz for
opening sh g
i
5. Connect leads to indicate starting
position t
6. Connect leads to indicate running
position to terminals 7 and 9 (A18).
7. Close the cover (2, A18) of the actuator
motor (1, A18).
8. Turn the Manual-Remote-Switch (18,
A18
9.3 Adjusting the actuator motor
1. Open the cover (2, A18) of the actuator
motor (1, A18).
2. Turn the actuator crank (5, A18) until the
short circuiting ring (1, A12) is in its
middle position (
Turn the actuator crank (5, A18)
clockwise (CW) until the running
position (po
towards the AMK motor D-end when
this position is reached. During the
motion observe the cams (10-11, A18) of
the electric limit switches S2 and S8 (6-
7, A18) to assure that the switches will
be activated from b
S8 (6-7, A18) to switch off 1 mm before
the mechanical end limit switch (5, A13)
reaches its end position. To move the
cam (10-11, A18) of
corresponding color (14, A18) in the
cam in the desired direction. The cam is
automatically locked when the pressure
on the screw is loosened.
5. Turn the actuator crank (5, A18)
counter-clockwis
Note that the bearings (3, A17) are
moving away from the AMK motor D-
end when this position is reached.
During the motion observe the cams (12-
13, A18) of the electric limit switches S3
and S7 (8-9
.e. when the cams are rotating CCW.
6. Adjust the electric limit switch S3 and
S7 (8-9, A18) to switch off 1 mm
ABB
User`s Manual, AMK 400-500
Chapter 9 - Slip Ring Unit with Brush Lifting Device

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 69
the mechanical end limit (5, A13)
reaches its end position. To move the
cam (12-13, A18) of the limit switch,
push down and turn the screw in
corresponding color (14, A18) in the
cam in the desired direction. The cam is
8. Connect 230VAC/ 50Hz to terminals 1 and
t the function is towards
osition (short circuit ring
30VAC/ 50Hz to
terminals 1 and 2.
chapter Connecting the Actuator
Motor.
13. Close the cover (2, A18) of the actuator
te position.
The following components can be obtained from
- Actuating motor (2-3, A11)
, A11)
- Set of Slip Ring Short Circuiting Parts (2-5,
(1, 3-5, A15)
following
additional information has to be submitted:
ly
Appendix 18 Electrical Connections
automatically locked when the pressure
on the screw is loosened.
7. Remove the crank (5, A18).
3.
9. Check tha
running p
closing, brushes moving up) by pushing
the lower actuator drive button (15,
A18). Check that the actuating motor
will stop properly.
10. Remove 230VAC/ 50Hz from terminals
1 and 3, and connect 2
Check that the direction of rotation is towards
starting position (brushes moving down, short
circuit ring opening) by pushing the upper
actuator drive button (17, A18). Check that the
actuating motor will stop properly.
11. Connect terminals 1-3 according to the
12. Check the electrical connections of the
actuator motor, and switch on the
electricity.
motor (1, A18).
14. Turn the Manual-Remote-Switch (18,
A18) in to Remo
10 Spare parts
the manufacturer as spare parts:
- Lifting Mechanism (6
- Slip Ring Assembly (9, A11)
17, A12)
- Brush Rocker complete, including Brush
Holders, and Brushes
- Set of 9 Brushes (1, A16)
When ordering spare parts the
Motor type and serial number. For instance: AMK
400L4L BALFT, No. 4532123
11 Appendices
Appendix 10 Housing Details
Appendix 11 Slip Ring Gear
Appendix 12 Slip Ring Assemb
Appendix 13 Brush Lifting Mechanism
Appendix 14 Brush Lifting Mechanism, Parts
Appendix 15 Brush Rocker
Appendix 16 Brush Bolt
Appendix 17 Theory of Operation
User`s Manual, AMK 400-500
Chapter 10 - Checklists ABB

70 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Ch
1 Unpac ...................... 71
2 Stora 72
3 ...................... .................... 73
ns........................................................................................................ 75
................. ................... 77


apter 10 Checklists
king and Damages ........................................
ge....................................................................
Installation and Alignment...........
................................................................
......................................................................................
.......................................................................
4 Mechanical and Electrical Connectio
5 Test Run............................................ ........................................................................
6 Inspection...............................................................
7 Maintenance...........................................................
....................................................................................... 78
....................................................................................... 79
ABB
User`s Manual, AMK 400-500
Chapter 10 - Checklists

For files
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P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 71
Unpacking and Damages
Customer
Checklist 1


Machine type Machine serial no.


Arrival date of the machine Signature of
the consignee

Damage(s): Action(s) taken in response to damage(s):
Machine Accessories Photographed Registered

Package Reported to supplier

Other............................................... Reported to insurance company

Dispatched by: To carrier

Airfreight Railway
Lorry/Truck Post/Mail
Shipped by the m/s .................................
Other........................................................


Missing parts / damages found during customer inspection:












After unpacking, store spare parts and installation tools for future use.

User`s Manual, AMK 400-500
Chapter 10 - Checklists ABB

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72 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Storage Checklist 2
Customer

Machine type Machine serial no.


Storage period Person responsible
for storage

Storage: Outdoors Indoors

In packing case Protected by Warm Cool
waterproof cover

Measures taken during storage:
Case is provided with External heating is used Space heaters
ventilation openigs are used
Rotor is turned 10 revolutions Anti-co e coating is Absorbing rrosiv
every two m h ont s checked ery 3 months material is used ev
(antifriction beari ly) ngs on Painted rfaces are checked Climate is su
The inside of sleeve bearing is every 3 months non-corrosive
treated with anti-corrosive oil Storage lace is vibration-free p
Bearing locking is checked
Brushes are lifted up (machine type AMK)
In case the standstill period is longer than year:
- Check and repeat the oil treatment for sleeve bearings.
In case the standstill period is longer than 2 years:
- Dismantle the sleeve bearing and treat the bearing parts with anti-corrosive oil separately.


Comments:




Protective measures must be taken before operating the machine if it is stored for a long period.
The customer is responsible for the storage and the required protective measures.
The machine must be stored on a level surface in a vibration-free area. If storage is outdoors, the machine must
be protected against environmental effects.
If long-time storage under humid conditions is anticipated, connection of space heaters, efficient coverage, and
other protective measures must be arranged.
ABB
User`s Manual, AMK 400-500
Chapter 10 - Checklists

For files
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P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 73
Installatio cklist 3 (1/2) n and Alignment Che
Customer

Machine type Machine serial no.


Measures:

Foundation according to drawing................................................................

ent checked accordi Alignm ng to instructions.

Foundation bolts are tightened with torque wrench.

Assembly of coupling half checked.

Bearings filled with lub ic p .............................................. .. r ant - ty e .. ............

Bearings filled with lubricant - q a ............................................... .. u ntity .. ...........

pipes checked, Assembly of oil and coolant flanges tightened.

Cooling water test run. Check fo l Possible leakages a ir r eakage. re repa ed.

Stator terminal box mounted correctly.

Rotor rotates without scrapings/sound (transport locking device dismantled).


Comments:













User`s Manual, AMK 400-500
Chapter 10 - Checklists ABB

Installation and Alignment hecklist 3 (2/2) C
Customer

Machine type Machine serial no.

Radial misalignment
1
, b
1
, c
1
and d
1
are readings from the dial indicator "R" at the points a = top, b = bottom, c = right, d = left (4 turns, each of 90 angle). The
red in the formula to obtain the values of radial misalignment (table 1).
T
M ing points 1st measurement 2nd measurement Example
a
readings are ente
able 1
easur
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74 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Vertical

T p a
1
a
2
25 28 o
B 31 28 ottom b
1
b
2

D rence a
1
-b
1
a
2
-b
2
-6 0 iffe

-3 0 V
m lignment
ertical
isa
2
1 1
b a

2
2 2
b a
+ Left hand coupling Left-hand coupling is higher than the right-hand one
- Left-hand coupling is lower than the right-hand one raised by 0,03 mm.
orizontal H
R
1 2
ight c c 38 28
Left d
1
d
2
18 28
D
1 1 2 2
ifference c -d c -d 20 0
V
m
ertical
isalignment
2
1 1
d c
2
2 2
d c

10 0
+ Left-hand coupling displaced to right of right-hand coupling Left hand coupling
- Left-hand coupling displaced to left of right-hand coupling moved to left by 0.1 mm.
Check f
m
or
easuring error
Schematic for table 1 25+31
1
28+28
28+28 38 18 +
= =

1 1
1 1
d c
b a
+
+
= 1 =
2 2
2
d c
b a
+
+
2

Axial gap and
T rst reading from the top indicator AI is
designated by e
1
and that from the bottom indicator AII by h
1
. The values for vertical and horizontal misalignment can be determined as shown
in table 2; axial displacement (in example 0.2 mm) during the measurement does not effect the results. Use a feeler gauge in case the gap is too
s gauge.
T
M ing points Dial AI Dial AII Example
misalignment
he axial gap is determined by taking readings from the two dial indicators AI and AII, whereby the fi
mall to use a dial
able 2
easur
Vertical gap
T e
1
g
1
50 42 op
Bottom f
1
h
1
62 50

Gap ( ) ( f e g h
1 1 1 1
2
)

( ) ( 62 50 42 50
2
)

+ The gap is greater at the top The gap is greater by
- The gap is greater at the bottom 0.1 mm at the top.
H rizontal gap o
Left i
1
l
1
40 36
Right k
1
m
1
48 40
Gap ( ) ( k i l m
1 1 1 1
2
) ( ) ( ) 48 40 36 40
2

+ The gap is greater at the left The gap is greater by Schematic for table 2
- The gap is greater at the right 0.06 mm at the left.
ABB
User`s Manual, AMK 400-500
Chapter 10 - Checklists

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P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 75
Mechanical and Electrical C Checklist 4 (1/2 onnections )
Customer

Machine type achine serial no. M


Safety:

The incoming cables are separated from the electric power network.

The cables are grounded.

Electrical data:

Machine Electric network power

Voltage........................... ............V/VAC Voltage........... ......................V/VAC ...... ...

Frequency........................................Hz F ency....... .....................Hz requ ....

Space heater
for machine: ...........V/VAC, ..........W
*) Space heater for
....V/VAC, .... slip ring unit: ..... ....W
External blower
VAC, ..............W/HP
*) Brush lifting vice
motor.V/VAC 1 or 3 phase motor: .................V/
de
*) Machine type AMK.
Insulation test: (See chapter: Winding Maintenance for Electrical Machines.)

Stator windin red with..... VDC, Win perature....................C/F g megge ........ V/ ding tem
Insulation value (after 1 min)......... ..... MO, R (40C/104F) = ................ MO
Insulation value (afte min)............. M R (40C 4F) = ....... MO r 10 O, /10 ......
Main protection settings:
Overcurrent level ........................................ ... Overload level .. .................................... .. ..
Differe ......................... ................................. ntial protection level ..... Ground fault level ..
Negati ..... e .................................... ve sequence level ............................ Acceleration tim
Other protection level(s) ....................................
The supply network is p ided with rov :
Under voltage protection ............... ......................... ............... .................... , set at..... .... ... ......
Current transformers, ratio............................................................................ ....................... ..
Vo tag ...................................... .................... l e transformers, ratio........ .............................. .....
User`s Manual, AMK 400-500
Chapter 10 - Checklists ABB

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76 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Mechanical and Electrical Connections Checklist 4 (2/2)
Monitoring equipment
Temperature monitoring Alarm (C/F) Trip (C/F)
In stator winding

In bearing

In.......................................................


ow or pressure monitoring Fl : (m
3
/s or Pa) Alarm Trip
(ft
3
/s or psi)
Lubricating oil min

Lubricating oil max

Cooling water (machine type AM_ )

Filter guard (machine type AM_ )

Vibration monitoring:





Comments:














ABB
User`s Manual, AMK 400-500
Chapter 10 - Checklists

For files
To From Date Page

Issued by Register no. Continues on page


P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 77
Test Run Checklist 5
Customer

Machine type Machine serial no.


ame of Date N
supervisor

Connections:
The auxiliary devices have been checked.
ked (machine t K).
hing is rem .
The rheostats are connected and the slip ring unit is chec ype AM
All connections are checked and supply cables eart oved

First start
Direction of rotation: clockwise counter- ockwise (as seen fr m drive-end) cl o
Noise: normal abnormal
Second start (to full speed)
Run: normal abnormal
Noise: normal abnormal
Vibration: normal abnormal
Sparking: normal abnormal
Run OK operation stops (why ?).................. ................................ ....... ... ..
........................................................................................................ .............................. . ..... ..

ime Bearing temp. Winding temperature Stator Vibr. (mm/s, um) Load T
or D-end N-end U / T1 V / T2 W /T3 Curr. Power n/sec,mil) (W) (i
Date (C/F) (C/F) (C/F) (C/F) (C/F) (A) factor D-end N-end (HP)













User`s Manual, AMK 400-500
Chapter 10 - Checklists ABB

For files
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78 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Inspection Checklist 6
Customer

Machine type Machine serial no.



Number of starts during week ........................ Operating hours during week .........................


Comments:








Loggings of operational data and rem o ept for refere arks sh uld be k nce during maintenance work, trouble
epa rs. Copi shooting and r i es of loggings are not to be sent to ABB.

Year............. , Week............. Mon Tues Wed Thurs Fri Sat Sun
Point of ins Date pection
Load pow (W er /HP)
Load curre nt (A)
Fault indi e cation (Y s/No)
Bearing temperature (C/F) DE
Bearing temperature (C/F) NDE
Oil level (No mal/Abnormal) r
Oil leakage (Yes/No)
Winding peratur U/T1 (C/F) tem e
Winding peratur V/T2 (C/F) tem e
Winding peratur W/T3 (C/F) tem e
Coolant flow (m
3
/h m)

/Gp

Water leakage (mach.type AM_) (Yes/No)
Vibration el (No mal/Abnormal) lev r
Noise (No mal/Abnormal) r
Slip ring sparking (No mal/Abnormal)
achine type AMK.)
r
(M


ABB
User`s Manual, AMK 400-500
Chapter 10 - Checklists

For files
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P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 79
Maintenance Checklist 7
Customer

Machine type Machine serial no.


Maintenance interval...........h, Operating hours ............, Number of starts......................
Bearings: Lubricant change Lubricant type.................................
Quantity...........................................
Oil filter change Oil filter type....................................
Flanges and pipes checked
Comments:


Cooling: Flanges and pipes checked Cleaned
Air filter checked Exchanged
Air cooler checked Cleaned
Water cooler fins (machine type AM_) Cleaned
Cooling ribs are cleaned (machine type HXR).
Comments:


Electr. part: Connection of high-voltage cables checked
Connection of control c ch ables ecked
Space heate d r checke
ed an Machine d i pected open ns
unit check *) Slip ring ed Carb ns chec ed Exchanged o k
*) Machine type AMK.
Comments:


Mech. part: checked Couplings
n bolts ch Foundatio ecked
n checked Foundat io
ine checked in Mach general
Machine opened and c ked hec
Bearings opened and c ecked h

Comments:



User`s Manual, AMK 400-500
Chapter 11 - Trouble Shooting ABB

80 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Chapter 11 - Trouble Shooting
1 Starting.......................................................................................................................................................... 81
Temperature.................................................................................................................................................. 82
3 .............................. 83
Bearings ....................... 85


2
Bearings (Antifriction Bearings).....................................................................................
(Sleeve Bearings)....................................................................................................
ABB
User`s Manual, AMK 400-500
Chapter 11- Trouble Shooting

Starting
Customer
Trouble Shooting 1

Machine type Machine serial no


The thermal overload
relay has tripped
Starting time is
too long
Load inertia is
too high
Check, that the load inertia is same
which has been reported with the
order to ABB Company 1)
Load torque
is too high
Check the starting
method of the
driven machine 2)
The setting of the
momentary overcurrent
tripping is not correct
The maximum momentary value of the
starting current may be as high as 2.5
times the indicated r.m.s value
The momentary over-
current protection
relay has tripped
Check, why the fuse has blown and
repair the fault. Change the fuse.
MACHINE DOES
NOT START
One phase is
missing
The fuse has
blown
Starting equipment is
malfunctional
Check the starting
equipment 3)


1) If the load inertia is higher than has been reported, please contact your local ABB representative.
2) Driven machines may have different starting methods. Many of them can be started without load. For
example compressors and blowers can be started with closed suction vanes. In refiners the pulp feeding
can be started after starting the machine. It is possible that the machine does not start loaded, if it has been
designed to start without load. In this case the machine can be damaged.
3) The machine manufacturer does not deliver the starting equipment. Please contact your local ABB
representative.
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 81
User`s Manual, AMK 400-500
Chapter 11 - Trouble Shooting ABB

Tempera rouble Shooting 2 ture T
Customer

Machine type Machine serial no


Another machine
is too near
Air duct is
blocked
Water-pipes
are blocked
Open and
adjust
Open and
adjust
Water circulation
is not working
Air in the
water-pipes
Cooling-water pump
is not working
Repair
the fault
Cooling circuits should
not disturb each another
Adjust sufficient ventilation
for the motor 1)
Bleed air from
the water-pipes
through bleeder
screw
HIGH WINDING TEMPERATURE
Ambient temp.
is too hot
Cooling air is too hot
Cooling-water temperature is too hot
(machine type AM_)
Adjust sufficient
condensation for
cooling-water
One phase is
missing
The fuse has
blown
82 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Stop the running
and check, why the
fuse has blown
Repair the fault
Overload
External blower
is not working
External blower
is rotating in the
wrong direction
Change direction
The motor fan is
rotating in the
wrong direction
of rotation
Check voltage
current and
eliminate overload
Blower motor's
protection has
tripped
Repair the fault
The fan must
be changed
Cooling-water is
too hot
Dirt on the machine
frame (machine
type HXR)
Clean
the frame

1) For example machines can be partitioned off. If the room temperature is too high, the air-conditioning must be
improved.

ABB
User`s Manual, AMK 400-500
Chapter 11- Trouble Shooting

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 83
Bearings (Ant le Shooting 3 (page 1/4 ifriction Bearings) Troub )
Customer

Machine type Machine serial no

COMMON SYMPTOMS

A Overheated bearing E Unsatisfactory equipment performance
B Noisy bearing F Bearing is loose on the shaft
C Replacements are too frequent G Shaft is difficult to turn
D Vibration

A B C D E F G
Typical conditions Reason for condition Practical solution
- - - -
Inadequate
lubrication
Grease or oil is breaking down
because it is the wrong type for
operating conditions.
Consult lubricant manufacturer to
determine proper type of lubricant. Check
miscibility if grease or oil has been
changed from one type to another.
- - - -
Insufficient
lubrication
Insufficient grease in the
housing.
Fill housing 1/3 to 1/2 with grease.

Low oil level. Lubricant is being
lost through the seal.
Oil level should be just below the center of
the lowest rolling element in the bearing.
- -
Excessive
lubrication
Housing is fully packed with
grease or the oil level is too high.
This causes excessive lubricant
churing, high operating
temperature or oil leakage.
Purge bearing until the housing is 1/2
filled with grease. For oil lubricated
bearings, reduce the oil level to just below
the center of the lowest rolling element.
- - - - -
Insufficient bearing
clearance
Bearing has inadequate internal
clearance for conditions where
external heat is conducted
through the shaft. This causes
the inner ring to expand
excessively.
Check weather overheated bearing had
clearance according to the rating plate of
the machine. If so, then change to bearing
with increased radial clearance. If not,
order according to rating plate.
Check with bearing manufacturer if the
bearing designation has become illegible.
- - - - -
Foreign matter
acting as an
abrasive.
Dirt, sand, carbon or other
contaminants are entering the
bearing housing.
Clean the bearing housing. Replace worn
seals or improve the seal design to obtain
adequate bearing protection.
- - - - -
Foreign matter
acting as a
corrosive.
Water, acids, paints or other
corrosives are entering the
bearing housing.
Install a protective shield and/or flinger to
guard against foreign matter. Improve
seals.
- - - - -
Foreign matter in
bearing housing.
Chips, dirt etc. were not
removed from housing before
Carefully clean and install lubricant.
assembling the bearing unit.
- - - -
Preloaded bearings "Two locating bearings" on one
shaft. Insufficient axial float in
bearing construction caused by
excessive shaft expansion.
Improve the possibility of shaft expansion
by machining the outer bearing cover.
- - - - -
Outer ring spins in
housing
Unbalanced load. Rebalance the machine.
User`s Manual, AMK 400-500
Chapter 11 - Trouble Shooting ABB

84 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
Bearings (Antifriction Bearings) rouble Shooting 3 (page 2/4) T
Customer

Machine type Machine serial no


- - -
Noisy bearing Flat spot on rolling element due Visually check the rolling ele
to skidding.
ments and
a rolling element has
ake sure that the requisite
minimum load is applied to the bearing.
replace the bearing if
flat spot. M
- - - - -
Linear or/and Incorrect linear or angular
ore
more
Correct alignment by shimming the
Ensure that the shafts
Be sure to
angular
misalignment of
shaft.
alignment of two or m
coupled shafts with two or
bearings.
electrical machine.
are coupled in a straight line.
use full support shims.
- - - -
ent is
dented. ring. when
ing
Rolling elem Incorrect mounting method.
Hammer blows on bea
Replace the bearing with a new one.
Newer hammer any part of a bearing
mounting. Always heat up the bear
before mounting.
- - -
clearance in the Use a bearing with recommended internal Vibrations Excessive
bearing causing vibration. clearance.
- - -
Vibrations g. Equipment is vibratin Check the balance of the rotating parts.
Rebalance the equipment.
Check the stiffness of the foundation.
Stiffen the foundation.
-
Bearing is
discolored.
ther
bearing assembly components,
Use a torch to remove a bearing only
under extreme circumstances. Avoid high
Distortion of the shaft and o
probably due to heat. heat concentration at any one point to
avoid distortion. Replace discolored
bearings.
- -
Bearing noisy ration
chine is idle.
or wear Bearing is exposed to vib
while the ma
Carefully examine the bearing f
spots corresponding to the spacing of
rolling elements. For standby equipment
ball bearings are better suited than roller
bearings to withstand vibration.



REFERENCE:......................... ............. ..........
SKF, Maintenance Han
................
dbook
..................................... .................................................
ABB
User`s Manual, AMK 400-500
Chapter 11- Trouble Shooting

Bearings (Sleeve Bearings) Trouble Shooting 3 (page 3/4)
Customer

Machine type Machine serial no


HIGH G TEMPERATU
Oil temper
too high
Axial forces
Faulty assembled
bearing
Damaged
linings
Has bearing been
disassembled?
Indu
curre
Complete seizure
of bearing
Repair bearing journal
Replace lining
Renewed commissioning
ir
sulati
R
BEARIN RE
ature
Impurities in
the oil?
ctive bearing
nts?
Repa
in
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 85
Faulty
instrument?
bearing
on
epair the cooler
Con
next page
tinued to
(4/4)
Faulty oil
cooler
Check if bearing is
designed to carry
axial loads
Lubrica
insuffic
tion
ient
Change oil
Open and
adjust
Faulty oil
viscosity
Ch
fr
pla
eck viscosity
om lubrication
te
Faulty
coupling
Too high
axial force
No
Yes


User`s Manual, AMK 400-500
Chapter 11 - Trouble Shooting ABB

Bearings (Sleeve Bearings) rouble Shooting 3 (page 4/4) T
Customer

Machine type Machine serial no


Low oil
level
Check maintenance
status
Add oil
Oil pump not
reliable?
Motor protection
trips?
Find the fault
and action
Low oil
flow
Oil filter
clogged
Replace filter
Reduction valve
shut?
Latest
adjustment?
Adjust flow
Too low oil
temperature
Faulty oil
heater
Unsuitable oil
quality
Check with ABB
Company the
recommendation
Change oil
quality
Oil worn out
Check the status of
oil change
Replace the oil
Oil ring working
unreliable
Previous bearing
disassembly?
Disassemble and
adjust
Oil leaks ?
Continuing from
previous page (3/4).
UNSTABLE BEARING
TEMPERATURE
Oil worn out Replace the oil
Low oil level Add oil
Open bearing
and adjust
Impurities in
the oil
Replace the oil
OIL LEAKS
Damaged
shaft seals
Replace the seals
Air-lock seals
out of action
Repair and clean
Too high oil level Correct oil level
Problem in oil
flow return
Incorrect inclination
of the return pipe?
Check maintenance
status
Find the fault
and action
Oil ring working
unreliable
Over pressure
inside bearing
Remove the cause for
defective pressure
Too high oil flow Correct oil flow

86 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 87
Chapter 12 - Appendices
1 Housing Details............................................................................................................................................. 88
2 Bearing construction for axially locked deep groove ball bearing................................................................ 89
3 Bearing construction for axially free deep groove ball bearing .................................................................... 90
4 Bearing construction for cylindrical roller bearing ....................................................................................... 91
5 Bearing construction for angular contact ball bearing (vertical machines) ................................................... 92
6 Bearing construction for angular contact ball bearing back to back mounting (for axial thrust) .................. 93
7 Sleeve bearings ............................................................................................................................................. 94
8 Sectional drawing of horizontal mounting machine with permanent contact type slip ring unit .................. 95
9 Sectional drawing of vertical mounting machine with permanent contact type slip ring unit....................... 96
10 Star- and delta connections ........................................................................................................................... 97
11 Housing Details............................................................................................................................................. 97
12 Slip Ring Gear............................................................................................................................................... 99
13 Slip Ring Assembly..................................................................................................................................... 100
14 Brush Lifting Mechanism ........................................................................................................................... 101
15 Brush Lifting Mechanism, Parts.................................................................................................................. 102
16 Brush Rocker............................................................................................................................................... 103
17 Brush Bolt ................................................................................................................................................... 104
18 Theory of Operation.................................................................................................................................... 105
19 Electrical Connections ................................................................................................................................ 106



User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 1
Fig. 1 Fig. 2 Fig. 3

Levelling spindle Sole plates/Bedplate Sole plates/Bedplate
with foundation with foundation
anchor bolts through-bolt

1 Sole plate/bedplate
r bolt
ugh-
le
8 Anchor plate
9 Concrete foundation
10 Grouting
11 Synthetic filling comp.
12 Elastic filling comp.
13 Fastening nut

2 Shims
3 Fastening bolt
4 Dowel pin

5 Foundation ancho
6 Foundation thro
bolt
1 Sole plate/bedplate

7 Levelling element

9 Slide plate

10 Synthetic bonding
agent



7 Levelling spind
88 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 2



1 Ball bearing 6 Cirlip
2 Inner bearing cover 8 Outer bearing cover
4 Cov Alle er plate 10 n screw
5 grease valve Labyrinth packing 11


NOTE! The screws are locked with loctite
Bearing construction for axially locked deep groove ball bearing

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 89
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 3





pipe 1 Ball bearing 7 Grease
2 Inner bearing cover 8 Outer bearing cover
9 Spring
4 Cover plate 10 Allen screw
5 Grease valve 11 Labyrinth packing
6 Cirlip


NOTE! The screws are locked with loctite.
Bearing construction for axially free deep groove ball bearing


90 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 4





OLLER BEARING G COVER 1 CYLIND. R 4 OUTER BEARIN
2 INNER BEARING COVER 5 CIRCLIP
3 GREASE VALVE GON SCREW 6 HEXA

a) Screws (item 6) are locked with locking agent.
b) Seal the surface between parts with sealing compound.
Bearing construction for ylindrical roller bearing

c
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 91
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 5



1 Angular contact ball bearing 10 Allen screw
2 Inner bearing cover 11 Cover
4 Cov pla 12 rin er te Oil g
5 Gre e v 13 xag as alve He on screw
6 Circ 14 se lip Ba plate
8 Outher bearing cover

NOTE! The screws are locked with loctite
Bearing construction for angular contact ball bearing (vertical machines)
92 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices


Appendix 6



1 Ball bearing 6 Cirlip
2 Inner bearing cover 8 Outer bearing cover
4 Cover plate 10 Allen screw
5 grease valve 11 Labyrinth packing


NOTE! The screws are locked with loctite
Bearing construction for angular contact ball bearing back to back mounting (for axial thrust)
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 93
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 7


AXIALLY LOCATING BEARING AXIALLY FREE BEARING


1 BEARING HOUSING 6 OIL SIGHT GLASS
2 B L 7 L RING SIGHT GLASS / OIL FILL PLUG EARING SHEL OI
3 O 8 IL RING OIL DRAIN PLUG
4 L EAL 9 OMETER BORE POSITION ABYRINTH S THERM
5 M AL 1 HELL ACHINERY SE 0 INSULATED S

Sleeve bearings
94 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 8


1 ROTOR 6 D-END SHIELD
2 STATOR 7 N-END SHIELD
3 INNER FAN 8 O-RING
4 AIR GUIDE 9 SLIP RING UNIT
5 COOLING UNIT/UPPER COVER

ec wing of horizontal mounting machine with er ring unit S tional dra p manent contact type slip
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 95
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 9



1 STATOR 6 COOLING UNIT
2 ROTOR 7 D-END SHIELD
3 END SHIELD STATOR LOCKING PIN 8 N-END SHIELD
4 AIR GUIDE 9 SLIP RING UNIT
5 INNER FAN 10 O-RING

Sectional drawing of vertical mounting machine with permanent contact type slip ring unit
96 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 10

Star- and del connections ta

P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 97
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 11

Housing Details
98 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 12


Slip Ring Gear
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 99
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 13



Slip Ring Assembly
100 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 14






Brush Lifting Mechanism
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 101
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 15






Brush Lifting Mechanism, Parts
102 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 16




Brush Rocker
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 103
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 17





Brush Bolt

104 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
ABB
User`s Manual, AMK 400-500
Chapter 12 Appendices

Appendix 18

Theory of Operation
P34AMK039510 EN Copyright 2006, ABB SACE S.p.A 105
User`s Manual, AMK 400-500
Chapter 12- Appendices ABB

Appendix 19


Electrical Connections
106 Copyright 2006, ABB SACE S.p.A P34AMK039510 EN
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