28851en

ECOFAN APS axial-flow fan

Fittings 6 and 3
Installation, operation and maintenance instructions

ECOFAN APS Axial-flow Fan

Installation, operation and maintenance instructions

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

1 Introduction appropriate directives pertaining to the plant in

question at the time) are complied with before filling in
Correct installation, start-up, operation control and the Declaration of Conformity and labelling the unit
regular maintenance ensure efficient and economical with appropriate CE markings.
performance of the fan minimizing possible
malfunctions and downtime.
4 Packaging and storage
A standard structure axial-flow fan is strictly
not suitable for: 4.1 Packaging
• pumping water, Small axial-flow fans are covered with plastic and
loaded onto pallets. Larger fans are loaded on
• transferring solid or long materials or materials that specially constructed wooden bases and covered with
may stick to the impeller, plastic.
• conditions involving explosive gases or dust,
• cold conditions involving temperatures below -
40°C,
• hot conditions involving temperatures above
+50°C,
• demanding, chemically corrosive conditions.

2 Sound level
Sound level data is provided in the dimensional
calculations in octave bands.

2.1 Purpose
Standard-construction fans have been designed to
transfer gas that is free from impurities and that has a
temperature below +50°C and humidity below 100%.
The maximum rotation speed of and the operating
temperature for the fan are shown on the type plate.
Specially constructed fans are designed individually
together with the customer for specific purposes. 4.2 1.1. Storage
Any accessories, such as flexible connections, are
delivered unassembled. Fans must be stored away
3 Safety instructions from dust, rain and direct sunlight. Bearings and
motors must be protected from humidity and
3.1 Operation-specific safety vibrations. The fan should be checked on receipt for
any defects that may have arisen during
instructions transportation.
Instructions for safe use and maintenance of the fan
have been provided for each operation.

3.2 CE marking
Axial-flow fans by Koja Ltd. are delivered semi-
manufactured (standard delivery) and must not start
to be used as such and not before an appropriate
Declaration of Conformity has been issued for the
plant in question.
Koja Ltd. designs and manufactures fans taking
essential safety requirements into consideration and
provides a Manufacturer’s Declaration for the fans that
it delivers. Other safety declarations for fan
components (the motor, if included as part of the Koja
delivery) are delivered with the fan on request. The
person in charge of assembling the machinery, plant
or system must ensure that directive requirements (all

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

5 Transportation and lifting

Fans are transported on pallets.
Fans should be lifted using lifting lugs or loop lifting THE FAN MUST
straps placed around the body of the fan. Care must
be taken to ensure that the lifting belt stays in place NOT BE LIFTED BY
and that the fan cannot turn within the loop. THE IMPELLER!

6 Axial-flow fan structure

6.1 Fitting 6: Direct drive with flange motor

1. Casing
2. Guide vanes
3. Access door
4. Blade
5. Hub
6. Hub boss
7. Hub cap
8. Terminal screw
9. Flange motor

Pedestal B3 V6 V8
motor

Flange B14 V3 V1
motor,
large
flange
Flange B14 V19 V18
motor,
small
flange

Flange-mounted motors (installation positions B5 and B14) are mounted on the fan’s mounting flange, which
is a structural part of the guide vanes.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

6.2 Fitting 6: Direct drive with pedestal motor

1. Casing
2. Guide vanes
3. Access door
4. Blade
5. Hub
6. Hub boss
7. Hub cap
8. Terminal screw
9. Pedestal motor
10. Motor bed

The pedestal motors on direct drive axial-flow fans

are mounted on a motor bed fixed in place with screws.
The model of the motor bed may vary depending on
the size of the motor and the fan.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

6.3 Fitting 3: V-belt drive

1. Casing
2. Bearings
3. Grease nipples
4. Blade
5. Hub
6. Hub boss
7. Hub cap
8. Terminal screw
9. Motor
10. Motor/belt guard
11. Motor bed
12. Adjustment and locking nuts
13. Guide vanes
The bearings of V-belt drive fans are mounted and
fastened using screw fittings on the bearing bed. The
bearing bed is part of the integrated welded support
vane structure. Bearings are protected by the shaft
seal and a protective casing. The motor and the belt
drive are protected using a common protective casing.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

7 Installation • the impeller is locked on the shaft,

• the screws fixing the bearings are tight, that the
7.1 Safety instructions bearings are lubricated and that the lubrication
system (if installed) operates correctly,
The fan must not be taken into use before the
following steps relating to the safe use and • the bearings have been disassembled, cleaned
and relubricated according to section 15.2, if
maintenance of the fan have been taken!
moisture has condensed inside the bearings
• Install the safety guards, such as the belt guard during storage, for example,
and the shaft guard.
• the fixing screws of the motor are tight, if the fan
• Connect the inlet and outlet openings to the duct has been stored in damp conditions for a lengthy
or attach a safety grid to them. period of time that the motor operation has been
• Wire the motor in a flexible way, arrange the tested according to the instructions provided,
electrical connections and install the safety switch • the V-belt drive is aligned, that the belts are
according to regulations. properly tensioned and that the belt pulleys are
• Attach any safety instructions and warning signs locked on the shaft, the impeller rotates freely and
to the fan. that there are no foreign objects or moisture inside
the fan casing.
The fan can also be installed directly to the duct with
7.2. Installation checks flange mounting (rigid installation). If mounting feet are
Before closing the inlet and outlet openings, check used, the mounting base must be level (flexible
that: installation).
• the impeller rotates freely and that there are no
foreign objects or moisture inside the fan casing, 7.3 Motor mounting positions
• the fan moves freely when moved manually and The fan can be mounted in several different positions.
that the flexible connections allow the fan and the The plugging of motor drains may need to be changed
duct to move without too much tension (flexible to suit different mounting positions according to the
installation), motor manufacturer’s instructions. The illustration
• the mounting and fixing of the fan to the base plate, below shows the different possible installations and
vibration dampers and duct have been carried out the corresponding motor mounting positions for a
according to installation instructions and that fixing direct drive and a V-belt drive axial-flow fan.
screws are tight,

Pedestal B3 V6 V8
motor B3 V5 V6

Flange B14 V3 V1
motor,
large
flange
B6 B7
Flange B14 V19 V18
B8
motor,
small B8
flange

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

7.4 Installation feet and vibration

dampers
The fan can be mounted horizontally or vertically using
mounting feet. The mounting feet are fixed to the fan
flange with bolts and have openings for vibration
dampers to be fixed.

Ød

a b d e Weight
Model Kg/damper
mm mm mm mm kg
4WL 3/8 18 2 x 12 6 10 -3 0,010
4WL 3/10 20 2 x 10 6 10 2-6 0,010
4WL 3/20 25 2 x 12 6 10 3 - 10 0,017 e
4WL 4/30 30 2 x 16 8 12 5 - 15 0,030 d
4WL 8/40 30 2 x 20 10 16 7 - 20 0,055
4WL 8/80 35 2 x 20 10 16 20 - 60 0,075
b
4WL 10/120 46 2 x 40 12 18 50 - 100 0,245
4WL 10/120 60 2 x 40 12 18 100 - 200 0,440 a
4WL 10/120 70 2 x 40 16 20 150 - 300 0,640
4WL 10/120 90 2 x 40 16 20 300 - 600 1,190

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

7.5 Flexible connections

7.5.1 Installation
The connections are installed between the inlet and
outlet openings and the duct.
• Install the duct at an appropriate distance from the
fan opening, see
• Make sure that all screws are in place before
tightening any of them.
• Finally, check that the connection is flexible in all
directions so that the fan can move freely on
vibration dampers and that the guide plate does
not come into contact with the fan or the duct.

spacing Ø D2
inner Ø D1+1

outer Ø D3
n pcs, even
spacing

1. Flexible connection flange

2. Flexible connection
3. Steel rim
4. Tightening lock

Size D1 D2 L s d1 n ~D3 l A M
40 400 450 100±5 3 12 8 492 105 1262 45
45 450 500 100±5 3 12 8 542 105 1419 45
50 500 560 130±10 3 12 12 612 140 1576 55
56 560 620 130±10 3 12 12 672 140 1766 55
63 630 690 130±10 3 12 12 742 140 1986 55
71 710 770 130±10 3 12 16 822 140 2238 55
80 800 860 130±10 3 12 16 912 140 2520 55
90 900 970 130±10 3 15 16 1032 140 2834 55
100 1000 1070 160±15 3 15 16 1132 170 3151 70
112 1120 1190 160±15 3 15 20 1252 170 3528 70
125 1250 1320 160±15 3 15 20 1382 170 3924 70
140 1400 1470 160±15 3 15 20 1532 170 4408 70
160 1600 1680 160±15 3 15 24 1732 170 5038 70
180 1800 1880 160±15 3 19 24 1932 170 5666 70
200 2000 2080 160±15 3 19 24 2132 170 6295 70

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

8 Disassembling and assembling the fan

8.1 Disassembly

Fan parts
1. Blade
2. Hub
3. Hub boss
4. Hub cap
5. Motor
6. Casing
7. Guide vanes

8.1.1 Direct drive fans with a flange motor 8.1.3 V-belt drive fans
• Disconnect the fan from the power supply. • Disconnect the fan from the power supply.
• Dismount the fan from the duct. • Dismount the fan from the duct.
• Detach the accessories and connections of the fan • Detach the accessories and connections of the fan
from the inlet and outlet openings. from the inlet and outlet openings.
• Remove the impeller from the shaft. • Remove the impeller from the shaft using an
extraction tool.
• Detach the safety guards. Remove the inlet and
outlet opening guards. • Detach the safety guards. Detach the guards of
the inlet and outlet openings and the motor.
• Detach any grease pipes and sensor wiring from
the motor. • Loosen the V-belts moving the motor bed adjuster
screws and remove the belts.
• Dismount the motor from the guidance vanes’
flange. • Dismount the motor from the motor bed.
• Dismount the bearings from the bearing bed.
8.1.2 Direct drive fans with a pedestal motor
• Detach the shaft seal from the bearing pedestal.
• Disconnect the fan from the power supply.
• Dismount the fan from the duct. 8.2. Assembly
• Detach the accessories and connections of the fan Assembly follows the same pattern as disassembly,
from the inlet and outlet openings. but in reverse. Push the impeller in place hydraulically
or using an extraction tool, not by force.
• Remove the impeller from the shaft using an
extraction tool.
• Detach the safety guards. Detach the inlet and
outlet opening guards.
• Detach any grease pipes and sensor wiring from
the motor.
• Dismount the motor from the motor bed.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

9 Start-up 10 Starting the fan

9.1. Safety instructions 10.1 Safety instructions

Before start-up, ensure that: Before starting the fan, ensure that this does not
• all guards, such as the belt guard, shaft guard and cause any damage within operating range of the
the inlet or outlet opening safety grid, have been fan. Also ensure that the power offtake of the fan
installed and properly fastened, does not exceed the motor rate.
• the motor has a safety switch and that the Check that:
electrical connection box has a cover to protect it, • the fan rotates in the right direction by starting the
• any instructions are attached to the fan and any fan briefly,
warning signs are in place, • the fan does not vibrate and that no strange loud
• operating and maintenance personnel have been noises can be heard,
properly trained. • the bearing temperatures are as per
recommended levels, see 12.3,
Before start-up, check that:
• the mounting and fixing of the fan to the base plate, • the belts run smoothly and that no strong
vibration dampers and duct have been carried out vibrations or jerking occur (V-belt drive),
according to installation instructions and that fixing • the lubrication system works (if installed).
screws are tight,
• the fixing screws of the motor are tight and, if the
fan has been stored in damp conditions for a
11 Stopping the fan
lengthy period of time, that the motor operation
has been tested according to the instructions 11.1 Safety instructions
provided, • The fan is stopped for down-time or maintenance
• the V-belt drive is aligned, that the belts are by disconnecting the power from the electric motor
properly tensioned and that the belt pulleys are using the safety switch.
locked on the shaft, • Ensure by removing all fuses, for example, that
• the impeller rotates freely and that there are no the fan cannot be accidentally switched on (fuses
foreign objects or moisture inside the fan casing, for both speeds for two-speed motors). The
impeller of large fans does not stop immediately
• the fan moves freely when moved by hand and but can rotate for several minutes after the power
that the flexible connections allow the fan and the has been disconnected. Make sure that the fan
duct to move without too much tension, has stopped completely and prevent the impeller
• the guide plates of the flexible connections are at from rotating due to possible airflows before
an equal distance from each other and from the starting the maintenance process.
duct on all sides,
• the access door is in place and that the screws
are tight.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

12 Operation control and Once the causes have been identified, immediate
maintenance action must be taken to resolve the problem!
Possible causes for excessive vibration include:
12.1 Safety instructions a) Unbalance of a rotating part
Arrange adequate free space around the fan for
Impeller
control and maintenance measures, by placing service
platforms at appropriate places, for example. Control • Uneven wear or corrosion, contamination and
and maintenance measures can be carried out by the loosening of dirt, uneven contamination of a fan
facility’s own maintenance personnel, provided that during down-time
they have received appropriate training, or by a • A change in the blade angle caused by mechanical
competent external maintenance company. impact or lifting
Check the following items at appropriate intervals • Deformation of structure caused by temperatures
(e.g., weekly) with the fan in operation. that are too high
• Loosening of mounting

12.2 Fan vibration level Belt pulley

The impellers of fans manufactured by Koja Ltd. are • Wear, contamination, loosening of balancing
balanced dynamically in accordance with piece, loosening of mounting
14694:2003(E) to quality class G 6.3 or above.
Belt
Koja Ltd. has classified its fans applying the
ISO14694:2003(E) standard as follows: • Wear, loosening, belt turned in groove, belt
stiffened during down-time or storage
• direct drive and belt drive axial-flow fans in
machine class BV3. Motor
• Operation control is performed by measuring the • Unbalance of ventilator and rotor
total vibration level (vrms, mm/s) from the fan b) Emerging bearing damage or insufficient
bearings. lubrication
• The total vibration level range allowed for axial- c) Resonance vibration of a fixed structural part
flow fans is shown in the table below. (fan part, part attached to the fan or duct)
d) Loose fixings: impeller/shaft, bearings/shaft,
bearings/pedestal, pedestal/base plate and
other screw fixings
e) The mounting of the fan on the base plate has
Installation Flexible Rigid altered, the weight is distributed unevenly on
Operation vibration dampers or the mounting base is
r.m.s. mm/s r.m.s. mm/s
unsteady or uneven
Test use at factory 3.5 2.8
Start-up 6.3 4.5 f) The operating point falls outside the normal
Alarm rate 11.8 7.1 operating range or, in the case of an AC
Stop rate 12.5 9.0 inverter drive, the rpm falls within the specific
frequency range of the vibration dampers or
some other part or structure
NOTE! The rates given can only be applied within
a frequency range of 10...1000 Hz. The vibration
stress range for other frequencies is defined
separately in each case.

If vibration values exceed the alarm rate, an

investigation to establish the causes of this must
be launched immediately.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

Correction 12.4 Vibration dampers (accessory)

a) Check the mountings of the rotating parts; Check that the dampers are undamaged and in good
clean, balance, replace (all belts must be working order and that the weight of the fan is
replaced). distributed on the dampers evenly.

b) Increase bearing lubrication or change the

bearings. 12.5 Belt drive (fitting 3)
c) Support vibrating parts. Check the belts and belt pulleys for signs of damage
and check the belt tension. Stretched and worn belts
d) Check fixings. vibrate and make a noise and their friction surface has
e) Correct the loading on vibration dampers and a glossy appearance. The groove sides and the
check fixings or support the mounting base. bottom of a worn belt pulley have a glossy appearance
and the belts sink deep into the grooves.
f) Change the operating point of the fan by
opening or closing the inlet damper, for
example. For AC inverter drives, the rpm 12.6 Flexible connections (accessory)
causing vibration must be exceeded quickly. Check that the flexible connections are undamaged
and that the fixing screws are tight. Also check that
the flexible connections allow the fan and the duct to
12.3 Bearings move without too much tension. Check that the flexible
Temperature connection guide plates do not come into contact with
each other or with the duct.
The operating temperature of bearings is affected by
the rotation speed, ambient conditions and properties
of the gas being transported. The maximum allowed 12.7 1.1. Fan safety equipment
operating temperature depends on the bearing
Check the belt drive and shaft guards and the possible
construction, the lubricant used and the lubrication
inlet or outlet opening safety grids and their fixings.
interval. Normally, the temperature of grease-
Also check that power cables are undamaged, that
lubricated bearings must not exceed +70°C.
the safety switch operates properly and that warning
Temporary temperatures of +100°C can be allowed
labels are in place.
when using a lubricant with an operating temperature
range of -30...+110°C.
The operating temperature is measured at the fan
and motor bearings using a surface thermometer.
Changes in temperatures must be monitored to gather
information about the condition of the bearings and
the appropriateness of lubrication.

Increases in temperature can be caused by:

• the presence of too much grease in the bearing,
• insufficient lubrication,
• the presence of moisture or contamination in the
bearings,
• insufficient bearing clearance,
• the belt drive being too tense,
• vibration caused by the impeller or another rotating
part,
• a defective bearing,
• a bend in the shaft.

Lubrication
The fan and motor bearings must be lubricated as per
the instructions provided on the type plate or provided
on delivery.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

13 Maintenance 13.2.1Adjusting impeller blade angles

APS axial-flow fan impeller blade angles can be
13.1 Safety instructions adjusted steplessly. The fan’s yield values can be
Make sure that there is adequate free space around influenced by adjusting the blade angles. Blade angle
the fan for maintenance by placing service platforms adjustments exceeding 2° require balancing of the
as appropriate, for example. Before carrying out any impeller. Blade angles have been set for each fan
maintenance, make sure that the fan cannot be started individually at the factory, to correspond to the
during maintenance by disconnecting the power feed dimension-specific optimum values.
with the safety switch, removing fuses from all phases The blade root has a scale indicating the blade
and by posting a written notice confirming the angles. The blades are made from pressure-moulded
maintenance process. aluminium. The hub structure is made from light metal
and the impeller blades are fitted between the two
¦¨ WARNING halves using fastening screws. The hub boss structure
is made from steel and has a groove for an extraction
The impellers of large fans do not stop immediately, tool.
but can rotate for several minutes after disconnecting
the current. Make sure that the fan has stopped
completely and prevent the impeller from rotating as a
result of possible airflows before carrying out any
maintenance.

NOTE! Before restarting the fan after

maintenance, make sure that the guards, such as
the belt guard, the shaft guard and the inlet or
outlet opening safety grid are installed and
properly fastened and that the instructions
attached to the fan and any possible warning
signs are in place.
Maintenance times and intervals are determined
according to the need for maintenance and repairs.
Maintenance and repairs can be performed by the
facility’s own repair personnel, provided that they have
received the appropriate training, or by a competent
external maintenance company. Spare parts referred
to in the instructions are available from Koja Ltd. and
from the manufacturers of the relevant parts. (Koja
Ltd. reserves the right to implement changes without 13.3 6.12 Fan bearings
prior notice.)
Lubricate the fan’s bearings according to the type plate
or the instructions accompanying the fan. Bearing
13.2 1.1. Impeller grease used in fans operating in normal conditions
must be completely changed every other year and
If the fan is used in an environment that contains flue
every year for hot gas fans. Change the grease by
gases or dusty air, any accumulation on the impeller
opening the bearing and removing the old grease
or unusual wear may cause balance problems. This
carefully and by applying new grease as per the
may lead to damage to the bearing or impeller. If the
instructions in section 8.3.
impeller needs to be replaced, the balance must be
checked in cases where the vibration level exceeds
acceptable values. Clean the impeller by washing it 13.4 6.13 Motor bearings
with water or by dry-brushing it with a soft brush.
Lubricate the motor bearings as per the type plate or
Determine cleaning intervals on the basis of check-
the relevant instructions.
ups or controls performed during operation. Remove
any dirt from the fan casing before starting the fan.
The fan casing may have a cleanout door to facilitate 13.4 6.14 Belt drive
cleaning.
Maintain and start up the belt drive as per sections
14.2.1 and 14.2.2.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

14 Actuators 14.2.3 Malfunctions and possible causes

Damage or fault
14.1 Electric motors
1. Broken belt
Start-up and maintenance as per the manufacturer’s
instructions. 2. Soft, elastic area on the belt
3. One or more belts shift in the grooves.
14.2 V-belt drive 4. The drive is noisy or vibrates.
Axial-flow fans with a V-belt drive are equipped with a 5. The side surfaces wear out quickly.
motor and belt guard that must be removed for
maintenance and/or repair and remounted before 6. The side surfaces are scratched or slightly torn.
restarting the fan. 7. The side surfaces are soft, burnt rubber is stuck in
the grooves.
14.2.1Start-up
8. The side surfaces are torn; cracks.
The V-belt drive has been aligned and tensioned at 9. The outer face is scratched and torn.
the factory and is ready for operation. The belts should
be retensioned approximately 30 minutes after start- 10. All belt surfaces are sticky, nodular particles of
up to match the maximum values shown in the table rubber are stuck on the belt and pulleys.
in section 14.2.7. Subsequently, no further tensioning 11. The belt surface is hard; there are cracks on the
should be required under normal circumstances. underside.

14.2.2 Maintenance
Check the wear of the V-belt drive pulleys and V-belts.
Groove gauges can be used to determine groove wear
easily and reliably. Gauges are available from V-belt
drive pulley manufacturers.
• Replace worn belt pulleys and V-belts. All multi-
belt drive belts must be replaced at the same time.
• Tighten belt pulley taper bush coupling screws.
• Check belt alignment and tension as per the
instructions in sections 12.5, 14.2.6 and 14.2.5.
• Clean the belt pulleys and belts as necessary.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

Malfunction Damage, fault

- Cause/Solution

Belts are loose

- replace the belts and tension as per instructions 1 3 4 5 7
Belts in grooves at different depths, worn pulleys
- replace the pulleys and belts 1 3 4 5
Belt forced into groove
- install new belts as per instructions 1 2 - - -
Hard particles in pulley grooves
- check the guards, replace the belts 1 2 - - -
Belts are not equally tensioned
- follow the installation instructions 1 2 3 4 7
Cracks or flaws in the grooves appear
- replace the pulleys and belts 6 - - - -
The belt touches fixed structures
- check the condition of and replace the belts as per instructions 3 4 9 - -
Abrasive dust is entering the drive
- check the guards, replace the belts and pulleys 5 - - - -
The drive is under-dimensioned
- redimension the drive 1 5 6 7 –
The pulley is too small
- replace the pulleys and belts 5 7 8 11 -
Short belt, high speed
- check the profile options and redimension the drive 7 8 - - -
The drive is idle with tensioned belts
- loosen the belts if the drive is likely to be idle for more than 2 months 4 - - - -
Lubricant or fuel on belts, belt wax used
- clean the drive, stop any leaks
- replace the belts 7 10 - - -
Belts have been exposed to sunlight during storage
- store the belts as per instructions 10 11 - - -

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

14.2.4 Uncoupling
Slacken the belts by moving the motor towards the • Slide the drive off the shaft.
fan by unscrewing the screws that secure the motor
• Fill the pullout holes with grease, for example, in
and turning the tensioning screws.
order to keep out dirt.
• Lift the belts from the pulleys.
• Remove grease and oil from the pulleys. Check
• Clean the pulleys. the grooves for rust.
• Remove the screws and insert one or two of them, • Adjust the shaft spacing so as to allow the belts to
depending on the bush type, into the pullout holes. be installed into the pulley grooves without the
The picture below shows the pullout holes with the need for force.
thread on the taper bush.
• Make sure that the pulleys are aligned and that
• Tighten the screws gradually one at a time until the shafts are parallel.
the bush becomes loose in the hub.
• Insert the belts into the grooves and tension the
drive.

14.2.5 Coupling
• Remove protective grease from the bush and the • Clean the shaft and fit the pulley and bush onto it.
pulley hub. When fitting the pulley, remember that the bush
will nip the shaft first and that the pulley will then
• Insert the bush into the pulley hub and align the
be drawn onto the bush slightly.
holes.
• Use a wrench to tighten the screws.
• Grease the coupling screws and turn them finger
tight. The picture below shows the coupling screw • Tap the bush gently with a metal drift and tighten
positions with the thread in the hub. the screws again. Repeat this procedure a few
times to make sure that the bush is firmly in place.

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

1. Shafts are 2. Shafts are not aligned 3. Shafts are in 4. Correct alignment.
not in parallel even if they appear to parallel but the Shafts are in parallel
be in parallel when pulleys are not and the pulleys are
viewed from above. aligned. aligned.

End view of
the same.

Straight edge
Dotted lines indicate correct alignment.

14.2.6 Tensioning
The high power transmission capacity of modern belts, Belt tension gauge
especially narrow V-belts, cannot be fully utilised
without correct tensioning. When using belt pulleys
with several grooves, the belt length must be made
equal by pressing all belts strongly and simultaneously
Belt deflection, mm Force, kp
from the direction indicated in the picture when the
belts are spanned loosely on the pulleys.
Belt tension can be adjusted by moving the motor.
Firstly, unscrew the four motor mounting screws and
then tension the belt by turning the tensioning screws.
Make sure that the pulleys are aligned and that the
shafts are parallel. When the belts are properly
Be
tensioned, tighten the motor mounting screws. lt s
pa
Retighten the belts after 30 minutes of operation as n
per section 14.2.7 or the values given in separate
instructions supplied with the fan.
rce
Fo

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ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

14.2.7 Tension gauge and tensioning values

1. Measure the span (t). 4. Compare the deflection force reading with the
values indicated in the table below. If the
2. Press perpendicularly in the middle of the span
measured value is lower than the
using a Gates tension gauge. The force should be
recommended minimum value, tension the
sufficient to make the belt deflect 1 mm over a
belt. If the measured value is higher than the
span of 100 mm. Read the depth of the deflection
recommended maximum value, the belt is too
on the lower scale at the level of the upper side of
tight. IMPORTANT:
the belt. A straight edge placed over the belt(s)
helps to get accurate readings. The gauge length 5. New belts may be tensioned as close to the
on the scale is 2 mm. recommended maximum deflection force
value as possible. Old (used) belts should be
3. Read the deflection force from the upper scale. A
tensioned above the recommended minimum
rubber O-ring slides down on the scale as the
deflection force value. During the run-in
gauge is compressed and stops at a certain point
phase, the belt may slacken rapidly. The belt
to give an accurate reading. The upper edge of
tension needs to be checked regularly once
the ring indicates the deflection force. Lift the ring
the run-in phase is over.
up before using the gauge again.

Belt profile Diameter of Recommended Single-spring tension gauge

smaller pulley deflection force*
mm N
min. max.

Quad-Power
56 7 11
60 - 63 8 13
67 - 71 9 14
XPZ/3VX 75 - 80 10 15
85 - 95 11 16
100 - 125 13 19 Deflection
132 - 200 16 24 force (read
from the
80 - 125 18 27 bottom up)
XPA
132 - 200 22 31
112 - 118 24 36
125 - 140 27 41
150 - 170 30 47
XPB/5VX
180 - 200 36 53
212 - 280 38 55
300 - 400 41 64 Pocket clip
180 - 236 50 75
XPC 250 - 355 65 95
375 - 530 80 110 Sliding O-
rings

Deflection distance
(read from the
bottom up)

Read the value on the bottom edge of the O-ring.

Slide the O-rings back down before using the
tension gauge again.

14.2.8 Storing V-belts

Store belts in a dry place. Prevent contact with hot
surfaces and exposure to direct sunlight. If possible,
hang belts in loose single or triple coils for storage. Do
not roll up the belts.

20 7/2004
 28851en
ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

15 Bearings Lubrication interval/

service hours
15.1 Start-up
Perform a test-run after lubricating and installing the
bearings. Observe bearing temperatures and running
sounds during the test run.

15.2 Lubricating bearings

Ball, roller and Carb bearings are lubricated. Bearings
are usually equipped with grease nipples and possibly
also with grease pipes on the upper surface of the
casing, through which grease is injected using a
grease gun. Lubricate bearings without grease nipples
by removing the top of the bearing housing. Manually
pack as much grease as possible between the bearing
rollers or balls, but fill only one third of the bearing
housing with grease, see section 8.4. Excessive
grease in the housing may cause a sharp rise in
temperature and may damage the bearings.

NOTE! Always clean the exterior of the bearing tfa = Spherical ball bearings
housing before lubrication to prevent dirt from tfc = Spherical roller bearings and cone bearings
entering the housing along with grease. Bearings
are initially lubricated using SKF Alfalub LGMT 2
or LGHT 3 grease.
Amount of grease
15.3 Lubrication intervals and grease Housing Amount of grease for Relubrication,
amounts markings first lubrication, g
g
Lubrication intervals depend on the rotation speed (n),
507 - 606 50 10
the bearing construction and the size (d = bearing
207
bore diameter), for example. As a rule, lubrication
508 - 607 60 10
intervals can be determined based on the set of curves
208
above.
509 65 10
E.g. bearing 22213 209
510 - 608 75 10
Rotation speed n = 1400 l/min 210
Bore diameter d = 5 x 13 x 65 mm. The bearing bore 511 - 609 100 15
diameter is 5 x the last two figures of the bearing type 211
number. Thus, the lubrication interval of a spherical 512 - 610 150 15
roller bearing is 1,000 service hours. 212
513 - 611 180 20
NOTE! The curves are valid, when the temperature 213
of the bearing’s outer ring does not exceed +70°C. 515 - 612 230 20
215
When the bearing temperature exceeds +70ÚC,
516 - 613 280 25
lubrication intervals must be halved for each
216
additional 15ÚC rise in temperature. Do not 517 330 25
exceed the maximum allowable operating 217
temperature for the grease. As temperatures drop 518 - 615 430 40
below +70ÚC, lubrication intervals may be longer 218
accordingly. The grease used is SKF LGMT2. 519 - 616 480 50
520 - 617 630 55
522 - 619 850 70
524 - 620 1000 80
526 1100 95
528 1400 110
530 1700 130
532 2000 150

7/2004 21
 28851en
ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

15.4 Replacing bearings

Fans manufactured by Koja Ltd. have spherical ball Uncoupling the bearing on the impeller side
or roller bearings or CARB bearings in vertical bearing • Remove the impeller and the drive from the shaft.
housings and they are fastened onto the shaft using a
clamping bush. There are two bearings, one of which • Uncouple the bearing as per the instructions
takes the axial load. This must be taken into account above.
when replacing both bearings at the same time. • Unfasten the coupling screws on the drive side
Uncoupling the bearing on the drive side bearing (mark the position of the bearing housing
before uncoupling).
• Clean any dirt off the bearing and the shaft and
mark the position of the bearing housing. • Slide the shaft out of the bearing.
• Support the shaft in place.
• Remove the drive guard and the drive from the Installation
shaft. • Clean the shaft and bearing bed.
• Remove the top half of the bearing. • Check the gasket rings and replace them if they
are defective.
• Pry the lockwasher bolt out of the nut groove and
loosen the nut a few turns. • Slide bearing parts onto the shaft as illustrated.
• Detach the inner ring by striking the sleeve or • Fit the lockwasher and the nut on the taper and
metal drift, which is pressed against the bush nut tighten the nut slightly.
or inner bearing ring. • Place bearing parts into the bottom part of the
• Remove the bearing housing from its bed and slide bearing housing and, if you have unfastened the
the bearing and its bottom part away from the bearing housing, install it according to the
shaft. markings you have made and fasten it onto the
bed.
• Drive the bearing onto the bush by tightening the
nut and lock it in place using the lockwasher.
• Pack the bearing housing with grease.
• Replace the top part of the bearing housing and
tighten the screws. The screw torque is shown in
the table.
Guide bearing
(guide rings) NOTE! The top and bottom parts of different
housings are not interchangeable.
Install the uncoupled parts in place, test-start the fan
and check the bearing temperature and sounds.

Free
bearing

22 7/2004
 28851en
ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

16 Disassembly and disposal 17 Spare parts

Disassemble the fan as per section 8 of the installation • Bearings
instructions. Dispose of the materials as per the
• Impeller
relevant regulations and instructions.
• Vibration dampers
The fan has been constructed using the
following materials: • Flexible connection
Casing, pedestal, base, inlet section as well as • Shaft
equipment and accessories
• Belts and belt pulleys
• steel or acid-resistant steel
• Motor
Impeller
• aluminium and steel
Bearings
• cast iron and special steel
Motor
• cast iron or aluminium, copper, steel and
special materials
Drive
• rubber, plastic and cast iron
Flexible connections
• steel, plastic, rubber, silicon and fibreglass
Vibration dampers
• rubber and steel

7/2004 23
 28851en
ECOFAN APS axial-flow fan
Fittings 6 and 3
Installation, operation and maintenance instructions

ECOFAN âåíòèëÿòîð
Öåíòðîáåæíûé APS Axial-flow
ECOFAN
Fan APS
Installation, operation and maintenance instructions

KOJA GROUP AT YOUR SERVICE Koja’s air handling units are used in public
buildings, business premises, offices and industrial
Koja Group is a versatile and advancing
buildings. Koja products meet high quality
enterprise with experience since 1935 of
requirements for tightness, hygiene and energy
providing customers with high-quality air
consumption. The comprehensive range of products
handling technology and building technology
together with versatile construction capacity enable
products and services.
the correct solution to be found for every site. Koja
KOJA LTD products include air handling units, heat recovery
equipment, air heaters, roof extractors and flue
Koja Ltd is an expert in air handling gas extractors, air curtains, an extensive
technology for industrial processes and selection of centrifugal and axial-flow fans and
buildings. Koja’s industrial fans operate air conditioning systems for ships.
reliably in numerous locations around the
world. Koja systems are installed for Koja’s production plants are situated in Tam-
example in power plant boilers, wood pere and in Jalasjärvi. Modern and flexible
processing industry processes and production techniques enable the continuous
conveyor systems. Koja fan systems are development of products and quality.
renowned for their wear-resistant structure, Koja Ltd has been granted ISO 9001:2000
reliability and economy of use. Quality Certificate.

KOJA OY
P.O. Box 351 • Lentokentänkatu 7 Ohrahuhdantie 2 A
FIN-33101 TAMPERE, FINLAND FIN-00680 HELSINKI, FINLAND
7/2004

Tel. +358 3 2825 111 Tel. +358 9 777 1750

24 Fax +358 3 2825 111 Fax +358 9 77717510
7/2004
 28851en

Low Voltage Motors

Installation, operation, maintenance and safety manual

List of Contents Page

1. Introduction .............................................................................................................................................. 5
1.1 Declaration of Conformity . ................................................................................................................. 5
1.2 Validity ............................................................................................................................................... 5

2. Handling . .................................................................................................................................................. 6
2.1 Reception check ................................................................................................................................ 6
2.2 Transportation and storage ................................................................................................................ 6
2.3 Lifting . ............................................................................................................................................... 6
2.4 Machine weight . ................................................................................................................................ 6

3. Installation and commissioning . ............................................................................................................ 7

3.1 General .............................................................................................................................................. 7
3.2 Insulation resistance check ................................................................................................................ 7
3.3 Foundation . ....................................................................................................................................... 7
3.4 Balancing and fitting coupling halves and pulleys ............................................................................... 8
3.5 Mounting and alignment of the motor . ............................................................................................... 8
3.6 Slide rails and belt drives . .................................................................................................................. 8
3.7 Machines with drain plugs for condensation . ..................................................................................... 8
3.8 Cabling and electrical connections ..................................................................................................... 8
3.8.1 Connections for different starting methods .............................................................................. 9
3.8.2 Connections of auxiliaries . ...................................................................................................... 9
3.9 Terminals and direction of rotation ...................................................................................................... 9

4. Operation ................................................................................................................................................ 10
4.1 Use .................................................................................................................................................. 10
4.2 Cooling ............................................................................................................................................ 10
4.3 Safety considerations . ..................................................................................................................... 10

Low voltage motor manual 01-2009 | ABB Motors and Generators EN-3
 28851en

5. Low voltage motors in variable speed operation ............................................................................... 11

5.1 Introduction . .................................................................................................................................... 11
5.2 Winding insulation ............................................................................................................................ 11
5.2.1 Phase to phase voltages ....................................................................................................... 11
5.2.1 Phase to ground voltages ..................................................................................................... 11
5.2.3 Selection of winding insulation for ACS550- and ACS800-converters ................................... 11
5.2.4 Selection of winding insulation with all other converters . ....................................................... 11
5.3 Thermal protection of windings ........................................................................................................ 11
5.4 Bearing currents .............................................................................................................................. 12
5.4.1 Elimination of bearing currents with ABB ACS550 and ACS800 converters . ......................... 12
5.4.2 Elimination of bearing currents with all other converters . ....................................................... 12
5.5 Cabling, grounding and EMC ........................................................................................................... 12
5.6 Operating speed .............................................................................................................................. 12
5.7 Dimensioning the motor for variable speed application ..................................................................... 12
5.7.1 General ................................................................................................................................. 12
5.7.2 Dimensioning with ABB ACS800 converters with DTC control .............................................. 12
5.7.3 Dimensioning with ABB ACS550 converters ......................................................................... 13
5.7.4 Dimensioning with other voltage source PWM-type converters ............................................. 13
5.7.5 Short time overloads ............................................................................................................. 13
5.8 Rating plates . .................................................................................................................................. 13
5.9 Commissioning the variable speed application ................................................................................. 13

6. Maintenance . ......................................................................................................................................... 14
6.1 General inspection ........................................................................................................................... 14
6.1.1 Standby motors .......................................................................................................................14
6.2 Lubrication ................................................................................................................................................ 14
6.2.1 Machines with permanently greased bearings ....................................................................... 14
6.2.2 Motors with regreasable bearings ......................................................................................... 15
6.2.3 Lubrication intervals and amounts ......................................................................................... 15
6.2.4 Lubricants . ........................................................................................................................... 17

7. After Sales Support ............................................................................................................................... 18

7.1 Spare parts ...................................................................................................................................... 18
7.2 Rewinding . ...................................................................................................................................... 18
7.3 Bearings .......................................................................................................................................... 18

8. Environmental requirements . ............................................................................................................... 18

8.1 Noise levels . .................................................................................................................................... 18

9. Troubleshooting ..................................................................................................................................... 19

EN-4 ABB Motors and Generators | Low voltage motor manual 01-2009
 28851en

1. Introduction
NOTE!
1.2 Validity
The instructions are valid for the following ABB electrical
These instructions must be followed to ensure safe
machine types, in both motor and generator operation.
and proper installation, operation and maintenance
of the machine. They should be brought to the series MT*, MXMA,
attention of anyone who installs, operates or series M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
maintains the machine or associated equipment. M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*,
The machine is intended for installation and use by M2R*/M3R*, M2V*/M3V*
qualified personnel, familiar with health and safety in frame sizes 56 - 450.
requirements and national legislation. Ignoring these
instructions may invalidate all applicable warranties. There is a separate manual for e.g. Ex motors ‘Low voltage
motors for hazardous areas: Installation, operation and
maintenance Manual’ (Low Voltage Motors/Manual for Ex-
motors).
1.1 Declaration of Conformity Additional information is required for some machine types
Declarations of Conformity with respect to the Low voltage due to special application and/or design considerations.
Directive 73/23/EEC amended by Directive 93/68 EEC are
Additional information is available for the following motors:
issued separately with individual machines.
– roller table motors
The Declaration of Conformity also satisfies the – water cooled motors
requirements of a Declaration of Incorporation with – open drip proof motors
respect to the Machinery Directive 98/37/EEC, – smoke venting motors
Art 4.2 Annex II, sub B – brake motors
– motors for high ambient temperatures

Low voltage motor manual 01-2009 | ABB Motors and Generators EN-5
 28851en

2. Handling Motors with the same frame may have a different center of
gravity because of different output, mounting arrangements
and auxiliary equipment.
2.1 Reception check
Damaged lifting lugs must not be used. Check that
Immediately upon receipt check the motor for external eyebolts or integrated lifting lugs are undamaged before
damage (e.g. shaft-ends and flanges and painted surfaces) lifting.
and if found, inform the forwarding agent without delay.
Lifting eyebolts must be tightened before lifting. If needed,
Check all rating plate data, especially voltage and winding the position of the eyebolt can be adjusted using suitable
connection (star or delta). The type of bearing is specified washers as spacers.
on the rating plate of all motors except the smallest frame
sizes. Ensure that proper lifting equipment is used and that the
sizes of the hooks are suitable for the lifting lugs.

2.2 Transportation and storage Care must be taken not to damage auxiliary equipment and
cables connected to the motor.
The motor should always be stored indoors (above
–20°C), in dry, vibration free and dust free conditions.
During transportation, shocks, falls and humidity should be 2.4 Machine weight
avoided. In other conditions, please contact ABB. The total machine weight can vary within the same
Unprotected machined surfaces (shaft-ends and flanges) frame size (center height) depending on different output,
should be treated against corrosion. mounting arrangement and auxiliaries.

It is recommended that shafts are rotated periodically by The following table shows estimated maximum weights
hand to prevent grease migration. for machines in their basic versions as a function of frame
material.
Anti-condensation heaters, if fitted, are recommended to
be used to avoid water condensing in the motor. The actual weight of all ABB’s motors, except the smallest
frame sizes (56 and 63) is shown on the rating plate.
The motor must not be subject to any external vibrations at
standstill so as to avoid causing damage to the bearings. Frame Aluminum Cast iron Steel
size Add.
Motors fitted with cylindrical-roller and/or angular contact Weight Weight Weight for brake
kg kg kg
bearings must be fitted with locking devices during
56 4.5 - -
transport.
63 6 - -
71 8 13 5
2.3 Lifting 80 12 20 8
90 17 30 10
All ABB motors above 25 kg are equipped with lifting lugs 100 25 40 16
or eyebolts. 112 36 50 20
132 63 90 30
Only the main lifting lugs or eyebolts of the motor should be 160 95 130 30
used for lifting the motor. They must not be used to lift the 180 135 190 45
motor when it is attached to other equipment. 200 200 275 55
225 265 360 75
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 250 305 405 75
fans) or terminal boxes must not be used for lifting the 280 390 800 600 -
motor. 315 - 1700 1000 -
355 - 2700 2200 -
400 - 3500 3000 -
450 - 4500 - -

EN-6 ABB Motors and Generators | Low voltage motor manual 01-2009
 28851en

3. Installation and commissioning

Insulation resistance, corrected to 25°C, must exceed the
WARNING reference value, i.e. 100 MΩ (measured with 500 or 1000 V
Disconnect and lock out before working on the DC). The insulation resistance value is halved for each 20°C
motor or the driven equipment. rise in ambient temperature.

WARNING
3.1 General The motor frame must be grounded and the
All rating plate values must be carefully checked to ensure windings should be discharged against the frame
that the motor protection and connection will be properly immediately after each measurement to avoid risk of
done. electrical shock.

WARNING If the reference resistance value is not attained, the

In case of motors mounted with the shaft upwards winding is too damp and must be oven dried. The oven
and water or liquids are expected to go down along temperature should be 90°C for 12-16 hours followed by
the shaft, the user must take in account to mount 105°C for 6-8 hours.
some means capable of preventing it.
Drain hole plugs, if fitted, must be removed and closing
valves, if fitted, must be opened during heating. After
heating, make sure the plugs are refitted. Even if the drain
Remove transport locking if employed. Turn shaft by hand plugs are fitted, it is recommended to disassemble the end
to check free rotation if possible. shields and terminal box covers for the drying process.

Windings drenched in seawater normally need to be

Motors equipped with roller bearings:
rewound.
Running the motor with no radial force applied to the shaft
may damage the roller bearing.
3.3 Foundation
Motors equipped with angular contact bearing: The end user has full responsibility for preparation of the
Running the motor with no axial force applied in the right foundation.
direction in relation to the shaft may damage the angular
contact bearing. Metal foundations should be painted to avoid corrosion.

Foundations must be even, see figure below, and

WARNING sufficiently rigid to withstand possible short circuit forces.
For machines with angular contact bearings the axial They must be designed and dimensioned to avoid the
force must not by any means change direction. transfer of vibration to the motor and vibration caused by
resonance.

The type of bearing is specified on the rating plate. Ruler

Motors equipped with regreasing nipples:

When starting the motor for the first time, or after long Note! Height difference shall
storage, apply the specified quantity of grease. not exceed ± 0,1mm referred
to any other motor foot
For details, see section “6.2.2 Motors with regreasable
bearings”.

3.2 Insulation resistance check

Measure insulation resistance before commissioning and Foot location
when winding dampness is suspected.

WARNING
Disconnect and lock out before working on the
motor or the driven equipment.

Low voltage motor manual 01-2009 | ABB Motors and Generators EN-7
 28851en

3.4 Balancing and fitting coupling 3.6 Slide rails and belt drives
halves and pulleys Fasten the motor to the slide rails as shown in Figure 2.
As standard, balancing of the motor has been carried out Place the slide rails horizontally on the same level.
using half key
Check that the motor shaft is parallel with the drive shaft.
When balancing with full key, the shaft is marked with
YELLOW tape, with the text “Balanced with full key”.

In case of balancing without key, the shaft is marked with Belts must be tensioned according to the instructions of
BLUE tape, with the text “Balanced without key”. the supplier of the driven equipment. However, do not
exceed the maximum belt forces (i.e. radial bearing loading)
Coupling halves or pulleys must be balanced after stated in the relevant product catalogues.
machining the keyways. Balancing must be done in
accordance with the balancing method specified for the
motor. WARNING
Excessive belt tension will damage bearings and can
Coupling halves and pulleys must be fitted on the shaft by cause shaft damage.
using suitable equipment and tools which do not damage
the bearings and seals.

Never fit a coupling half or pulley by hammering or by

removing it using a lever pressed against the body of the 3.7 Machines with drain plugs
motor.
for condensation
Check that drain holes and plugs face downwards.
3.5 Mounting and alignment
Machines with sealable plastic drain plugs are delivered in
of the motor open position. In very dusty environments, all drain holes
Ensure that there is enough space for free airflow around should be closed.
the motor. Minimum requirements for free space behind the
motor fan cover can be found from the product catalog or
from the dimension drawings available from the web: see 3.8 Cabling and electrical
www.abb.com/motors&generators. connections
Correct alignment is essential to avoid bearing, vibration The terminal box on standard single speed motors normally
and possible shaft failures. contains six winding terminals and at least one earth
terminal.
Mount the motor on the foundation using the appropriate
bolts or studs and place shim plates between the In addition to the main winding and earthing terminals, the
foundation and the feet. terminal box can also contain connections for thermistors,
heating elements or other auxiliary devices.
Align the motor using appropriate methods.
Suitable cable lugs must be used for the connection of all
If applicable, drill locating holes and fix the locating pins into
main cables. Cables for auxiliaries can be connected into
position.
their terminal blocks as such.
Mounting accuracy of coupling half: check that clearance
Machines are intended for fixed installation only. If not
b is less than 0.05 mm and that the difference a1 to a2 is
otherwise specified, cable entry threads are metric. The IP-
also less than 0.05 mm. See Figure 3.
class of the cable gland must be at least the same as those
Re-check the alignment after final tightening of the bolts or of the terminal boxes.
studs.
Unused cable entries must be closed with blanking
Do not exceed permissible loading values for bearings as elements according to the IP class of the terminal box.
stated in the product catalogues.
The degree of protection and diameter are specified in the
documents relating to the cable gland.

EN-8 ABB Motors and Generators | Low voltage motor manual 01-2009
 28851en

3.8.2 Connections of auxiliaries

WARNING If a motor is equipped with thermistors or other RTDs
Use appropriate cable glands and seals in the cable (Pt100, thermal relays, etc.) and auxiliary devices, it is
entries according to the type and diameter of the recommended they be used and connected by appropriate
cable. means. Connection diagrams for auxiliary elements and
connection parts can be found inside the terminal box.

Additional information on cables and glands suitable for Maximum measuring voltage for the thermistors is 2.5 V.
variable speed applications can be found from chapter 5.5. Maximum measuring current for Pt100 is 5 mA. Using a
higher measuring voltage or current may cause errors in
Earthing must be carried out according to local regulations readings or damage the system.
before the machine is connected to the supply voltage.
The insulations of the winding thermal sensors is of basic
Ensure that the motor protection corresponds to the type. While connecting the sensors to control systems etc,
environment and weather conditions; for example, make ensure adequate insulation or isolation, see IEC 60664.
sure that water cannot enter the motor or the terminal
boxes.
NOTE!
The seals of terminal boxes must be placed correctly in the Ensure the insulation level or isolation of thermistor
slots provided, to ensure the correct IP class. circuit, see IEC 60664.

3.8.1 Connections for different

starting methods 3.9 Terminals and direction
The terminal box on standard single speed motors normally
contains six winding terminals and at least one earth
of rotation
terminal. This enables the use of DOL- or Y/D –starting.
See Figure 1. The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence - L1, L2,
For two-speed and special motors, the supply connection L3 - is connected to the terminals as shown in Figure 1.
must follow the instructions inside the terminal box or in the
motor manual. To alter the direction of rotation, interchange any two
connections on the supply cables.
The voltage and connection are stamped on the rating
plate. If the motor has a unidirectional fan, ensure that it rotates in
the same direction as the arrow marked on the motor.
Direct-on-line starting (DOL):
Y or D winding connections may be used.

For example, 690 VY, 400 VD indicates Y-connection for

690 V and D-connection for 400 V.

Star/Delta starting (Y/D):

The supply voltage must be equal to the rated voltage of
the motor when using a D-connection.

Remove all connection links from the terminal block.

Other starting methods and severe starting

conditions:
In case other starting methods are used, such as a soft
starter, or if starting conditions are particularly difficult,
please consult ABB first.

Low voltage motor manual 01-2009 | ABB Motors and Generators EN-9
 28851en

4. Operation
4.1 Use 4.2 Cooling
The motors are designed for the following conditions unless Check that the motor has sufficient airflow. Ensure that no
otherwise stated on the rating plate. nearby objects or direct sunshine radiate additional heat to
the motor.
- Normal ambient temperature limits are -20°C to +40°C.
- Maximum altitude 1000 m above sea level. For flange mounted motors (e.g. B5, B35, V1), make sure
- Tolerance for supply voltage is ±5% and for frequency that the construction allows sufficient air flow on the outer
±2% according to EN / IEC 60034-1 (2004). surface of the flange.

The motor can only be used in applications it is intended

for. The rated nominal values and operational conditions 4.3 Safety considerations
are shown on the motor rating plates. In addition, all
The machine is intended for installation and use by qualified
requirements of this manual and other related instructions
personnel, familiar with health and safety requirements and
and standards must be followed.
national legislation.
If these limits are exceeded, motor data and construction
Safety equipment necessary for the prevention of accidents
data must be checked. Please contact ABB for further
at the installation and operating site must be provided in
information.
accordance with local regulations.

WARNING
WARNING
Ignoring any of given instructions or maintenance of
Do not carry out work on motor, connection cables
the apparatus may jeopardize the safety and thus
or accessories such as frequency converters,
prevents the use of the machine.
starters, brakes, thermistor cables or heating
elements when voltage is applied.

Points to observe

1. Do not step on the motor.

2. The temperature of the outer casing of the motor

may be too hot to touch during normal operation and
especially after shut-down.

3. Some special motor applications require special

instructions (e.g. using frequency converter supplies).

4. Be aware of rotating parts of the motor.

5. Do not open terminal boxes while energized.

EN-10 ABB Motors and Generators | Low voltage motor manual 01-2009
 28851en

5. Low voltage motors in variable speed operation

5.1 Introduction 5.2.3 Selection of winding insulation for

ACS800 and ACS550 converters
This part of the manual provides additional instructions for In the case of ABB ACS800-series and ACS550-series
motors used in frequency converter supply. Instructions single drives with a diode supply unit (uncontrolled DC
provided in this and respective manuals of selected voltage), the selection of winding insulation and filters can
frequency converter must be followed to ensure safety and be made according to table below:
availability of the motor.
Nominal supply Winding insulation and
Additional information may be required by ABB to decide
voltage UN of the filters required
on the suitability for some machine types used in special
converter
applications or with special design modifications.
UN ≤ 500 V ABB Standard insulation
UN ≤ 600 V ABB Standard insulation
5.2 Winding insulation + dU/dt filters
OR
Variable speed drives cause higher voltage stresses than
ABB Special insulation
the sinusoidal supply on the winding of the motor and
(variant code 405)
therefore the winding insulation of the motor as well as
UN ≤ 690 V ABB Special insulation
the filter at the converter output must be dimensioned
(variant code 405)
according following instructions.
AND
dU/dt-filters at converter
5.2.1 Phase to phase voltages output
The maximum allowed phase to phase voltage peaks at UN ≤ 690 V ABB Special insulation
the motor terminal as a function of the rise time of the pulse AND (variant code 405)
can be seen in Figure 1. cable length > 150 m
The highest curve “ABB Special Insulation” applies to For more information on resistor braking and converters
motors with a special winding insulation for frequency with controlled supply units, please contact ABB.
converter supply, variant code 405.
5.2.4 Selection of winding insulation
The “ABB Standard Insulation” applies to all other motors with all other converters
covered by this manual.
The voltage stresses must be limited below accepted limits.
5.2.2 Phase to ground voltages Please contact the system supplier to ensure the safety of
the application. The influence of possible filters must be
The allowed phase to ground voltage peaks at motor
taken into account while dimensioning the motor.
terminals are:

Standard Insulation 1300 V peak 5.3 Thermal protection

Special Insulation 1800 V peak Most of the motors covered by this manual are equipped
with PTC thermistors in the stator windings. It is
recommended to connect those to the frequency converter
by appropriate means. See also chapter 3.8.2.

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5.4 Bearing currents For motors of frame size IEC 280 and upward, additional
potential equalization between the motor frame and the
Insulated bearings or bearing constructions, common driven equipment is needed, unless both are mounted on
mode filters and suitable cabling and grounding methods a common steel base. In this case, the high frequency
must be used according to the following instructions: conductivity of the connection provided by the steel
base should be checked by, for example, measuring the
potential difference between the components.
5.4.1 Elimination of bearing currents with
ABB ACS800 and ACS550 converters More information about grounding and cabling of variable
In the case of the ABB ACS800 and ACS550-series speed drives can be found in the manual “Grounding and
frequency converter with a diode supply unit, the following cabling of the drive system” (Code: 3AFY 61201998).
methods must be used to avoid harmful bearing currents in
the motors: 5.6 Operating speed
Nominal Power (Pn) Preventive measures For speeds higher than the nominal speed stated on the
and / or Frame size (IEC) motor’s rating plate or in the respective product catalogue,
Pn < 100 kW No actions needed ensure that either the highest permissible rotational speed
Pn ≥ 100 kW Insulated non-drive end of the motor or the critical speed of the whole application is
OR bearing not exceeded.
IEC 315 ≤ Frame size
≤ IEC 355 5.7 Dimensioning the motor
Pn ≥ 350 kW
OR
Insulated non-drive end
bearing
for variable speed application
IEC 400 ≤ Frame size AND 5.7.1 General
≤ IEC 450 Common mode filter at
In case of ABB’s frequency converters, the motors can
the converter
be dimensioned by using ABB’s DriveSize dimensioning
Insulated bearings which have aluminum oxide coated program. The tool is downloadable from the ABB website
inner and/or outer bores or ceramic rolling elements, (www.abb.com/motors&generators).
are recommended. Aluminum oxide coatings shall also
be treated with a sealant to prevent dirt and humidity For application supplied by other converters, the motors
penetrating into the porous coating. For the exact type of must be dimensioned manually. For more information,
bearing insulation, see the motor’s rating plate. Changing please contact ABB.
the bearing type or insulation method without ABB’s The loadability curves (or load capacity curves) are based
permission is prohibited. on nominal supply voltage. Operation in under or over
voltage conditions may influence on the performance of the
5.4.2 Elimination of bearing currents application.
with all other converters
The user is responsible for protecting the motor and driven 5.7.2 Dimensioning with ABB ACS800
equipment from harmful bearing currents. Instructions converters with DTC control
described in Chapter 5.4.1 can be used as guideline, but The loadability curves presented in Figures 4a - 4d are valid
their effectiveness cannot be guaranteed in all cases. for ABB ACS800 converters with uncontrolled DC-voltage
and DTC-control. The figures show the approximate
5.5 Cabling, grounding and EMC maximum continuous output torque of the motors as a
function of supply frequency. The output torque is given
To provide proper grounding and to ensure compliance as a percentage of the nominal torque of the motor. The
with any applicable EMC requirements, motors above 30 values are indicative and exact values are available on
kW shall be cabled by shielded symmetrical cables and request.
EMC glands, i.e. cable glands providing 360° bonding.
Also for smaller motors symmetrical and shielded cables
are highly recommended. Make the 360° grounding NOTE!
arrangement at all the cable entries as described in the The maximum speed of the motor must not be
instructions for the glands. Twist the cable shields into exceeded!
bundles and connect to the nearest ground terminal/bus
bar inside the terminal box, converter cabinet, etc.

NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points, e.g. at motor,
converter, possible safety switch, etc.

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5.7.3 Dimensioning with ABB ACS550 5.8 Rating plates

converters
The usage of ABB’s motors in variable speed applications
The loadability curves presented in Figures 5a - 5d are
do not usually require additional rating plates and the
valid for ABB ACS550 series converters. The figures show
parameters required for commissioning the converter can
the approximate maximum continuous output torque of
be found from the main rating plate. However, in some
the motors as a function of supply frequency. The output
special applications the motors can be equipped with
torque is given as a percentage of the nominal torque of
additional rating plates for variable speed applications and
the motor. The values are indicative and exact values are
those include following information:
available on request.
- speed range
- power range
NOTE!
- voltage and current range
The maximum speed of the motor must not be
- type of torque (constant or quadratic)
exceeded!
- converter type and required minimum switching
frequency
5.7.4 Dimensioning with other voltage
source PWM-type converters 5.9 Commissioning the variable
For other converters, which have uncontrolled DC
voltage and minimum switching frequency of 3 kHz,
speed application
the dimensioning instructions of ACS550 can be used The commissioning of the variable speed application must
as guidelines, but it shall be noted, that the actual be done according to the instructions of the frequency
thermal loadability can also be lower. Please contact the converter and local laws and regulations. The requirements
manufacturer of the converter or the system supplier. and limitations set by the application must also be taken
into account.
NOTE! All parameters needed for setting the converter must be
The actual thermal loadability of a motor may be taken from the motor rating plates. The most often needed
lower than shown by guideline curves. parameters are:

- Motor nominal voltage

5.7.5 Short time overloads - Motor nominal current
ABB motors can usually be temporarily overloaded as well - Motor nominal frequency
as used in intermittent duties. The most convenient method - Motor nominal speed
to dimension such applications is to use the DriveSize tool. - Motor nominal power

Note: In case of missing or inaccurate information, do not

operate the motor before ensuring correct settings!

ABB recommends using all the suitable protective features

provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):

- Minimum speed
- Maximum speed
- Acceleration and deceleration times
- Maximum current
- Maximum Torque
- Stall protection

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6. Maintenance 6.1.1 Standby motors

If the motor is in standby for a longer period of time on
a ship or in other vibrating environment the following
measures have to be taken:
WARNING
Voltage may be connected at standstill inside the 1. The shaft must be rotated regularly every 2 weeks (to
terminal box for heating elements or direct winding be reported) by means of start up of the system. In case
heating. a start up is not possible, due to any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
WARNING
should be minimized by regular operation / hand turning.
The capacitor in single-phase motors can retain a
charge that appears across the motor terminals, even 2. The bearing must be greased while rotating the shaft
when the motor has reached standstill. every year (to be reported). If the motor has been
provided with roller bearing at the driven end the
transport lock to be removed before rotating the shaft.
The transport locking must be remounted in case of
WARNING transportation.
A motor with frequency converter supply may
energize even if the motor is at standstill. 3. All vibrations must be avoided to prevent a bearing from
failuring. All instructions in the motor instruction manual
for commissioning and maintenance have to be followed
additionally. The warranty will not cover the winding and
6.1 General inspection bearing damages if these instructions have not been
followed.
1. Inspect the motor at regular intervals, at least once a
year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local 6.2 Lubrication
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation WARNING
airflow. If the motor is used in a dusty environment, Beware of all rotating parts!
the ventilation system must be regularly checked and
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial WARNING
seal) and replace if necessary. Grease can cause skin irritation and eye
inflammation. Follow all safety precautions specified
4. Check the condition of connections and mounting and
by the manufacturer.
assembly bolts.
5. Check the bearing condition by listening for any unusual
noise, vibration measurement, bearing temperature,
Bearing types are specified in the respective product
inspection of spent grease or SPM bearing monitoring.
catalogs and on the rating plate of all motors except
Pay special attention to bearings when their calculated
smaller frame sizes.
rated life time is coming to an end.
Reliability is a vital issue for bearing lubrication intervals.
When signs of wear are noticed, dismantle the motor,
ABB uses mainly the L1-principle (i.e. that 99% of the
check the parts and replace if necessary. When bearings
motors are certain to make the life time) for lubrication.
are changed, replacement bearings must be of the same
type as those originally fitted. The shaft seals have to be
replaced with seals of the same quality and characteristics 6.2.1 Machines with permanently
as the originals when changing bearings.
greased bearings
In the case of the IP 55 motor and when the motor Bearings are usually permanently greased bearings of 1Z,
has been delivered with a plug closed, it is advisable to 2Z, 2RS or equivalent types.
periodically open the drain plugs in order to ensure that
the way out for condensation is not blocked and allows As a guide, adequate lubrication for sizes up to 250 can be
condensation to escape from the motor. This operation achieved for the following duration, according to L10.
must be done when the motor is at a standstill and has
been made safe to work on.

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Duty hours for permanently greased bearings at ambient – Let the motor run for 1-2 hours to ensure that all excess
temperatures of 25 and 40° C are: grease is forced out of the bearing. Close the grease
outlet plug or closing valve if fitted.
Lubrication intervals according to L10 principle
Regreasing while the motor is at a standstill
Duty hours Duty hours If it is not possible to regrease the bearings while the
Frame size Poles at 25° C at 40° C motors are running, lubrication can be carried out while the
56-63 2-8 40 000 40 000 machine is at a standstill.
71 2 40 000 40 000 – In this case use only half the quantity of grease and then
71 4-8 40 000 40 000 run the motor for a few minutes at full speed.
80-90 2 40 000 40 000 – When the motor has stopped, apply the rest of the
80-90 4-8 40 000 40 000 specified amount of grease to the bearing.
100-112 2 40 000 32 000 – After 1-2 running hours close the grease outlet plug or
100-112 4-8 40 000 40 000 closing valve if fitted.
132 2 40 000 27 000
B. Automatic lubrication
132 4-8 40 000 40 000
160 2 40 000 36 000 The grease outlet plug must be removed permanently with
160 4-8 40 000 40 000 automatic lubrication or open closing valve if fitted.
180 2 38 000 38 000 ABB recommends only the use of electromechanical
180 4-8 40 000 40 000 systems.
200 2 27 000 27 000
200 4-8 40 000 40 000 The amount of grease per lubrication interval stated in the
225 2 23 000 18 000 table should be multiplied by four if an automatic regreasing
225 4-8 40 000 40 000 system is used.
250 2 16 000 13 000 When 2-pole motors are automatically regreased, the note
250 4-8 40 000 39 000 concerning lubricant recommendations for 2-pole motors in
Data valid at 50 Hz, for 60 Hz reduce values for 20 %. the Lubricants chapter should be followed.

These values are valid for permitted load values given in

the product catalog. Depending on application and load
6.2.3 Lubrication intervals and amounts
conditions, see the applicable product catalog or contact As a guide, adequate lubrication for motors with
ABB. regreasable bearings can be achieved for the following
duration, according to L1. For duties with higher ambient
Operation hours for vertical motors are half of the above temperatures please contact ABB. The formula to change
values. the L1 values roughly to L10 values: L10 = 2.7 x L1.

Lubrication intervals for vertical machines are half of the

6.2.2 Motors with regreasable bearings values shown in the table below.
Lubrication information plate and general lubrication The lubrication intervals are based on an ambient
advice temperature +25°C. An increase in the ambient
If the machine is equipped with a lubrication information temperature raises the temperature of the bearings
plate, follow the given values. correspondingly. The values should be halved for a 15°C
increase and may be doubled for a 15°C decrease.
On the lubrication information plate, greasing intervals
regarding mounting, ambient temperature and rotational In variable speed operation (i.e. frequency converter supply)
speed are defined. it is necessary to measure the bearing temperature for
During the first start or after a bearing lubrication a the whole duty range and if exceeds 80°C, the lubrication
temporary temperature rise may appear, approximately 10 intervals should be halved for a 15°C increase in bearing
to 20 hours. temperature. If the motor is operated at high speeds, it is
also possible to utilize so called high speed greases, see
Some motors may be equipped with a collector for old chapter 6.2.4.
grease. Follow the special instructions given for the
equipment.
WARNING
A. Manual lubrication The maximum operating temperature of the grease
and bearings, +110°C, must not be exceeded.
Regreasing while the motor is running
The designed maximum speed of the motor must
– Remove grease outlet plug or open closing valve if fitted. not be exceeded.
– Be sure that the lubrication channel is open
– Inject the specified amount of grease into the bearing.

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 28851en

Lubrication intervals according to L1 principle

Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings

Lubrication intervals in duty hours

112 10 all 10000 13000 all 18000 21000 all 25000 all 28000
132 15 all 9000 11000 all 17000 19000 all 23000 all 26500
160 25 ≤ 18,5 9000 12000 ≤ 15 18000 21500 ≤ 11 24000 all 24000
160 25 > 18,5 7500 10000 > 15 15000 18000 > 11 22500 all 24000
180 30 ≤ 22 7000 9000 ≤ 22 15500 18500 ≤ 15 24000 all 24000
180 30 > 22 6000 8500 > 22 14000 17000 > 15 21000 all 24000
200 40 ≤ 37 5500 8000 ≤ 30 14500 17500 ≤ 22 23000 all 24000
200 40 > 37 3000 5500 > 30 10000 12000 > 22 16000 all 20000
225 50 ≤ 45 4000 6500 ≤ 45 13000 16500 ≤ 30 22000 all 24000
225 50 > 45 1500 2500 > 45 5000 6000 > 30 8000 all 10000
250 60 ≤ 55 2500 4000 ≤ 55 9000 11500 ≤ 37 15000 all 18000
250 60 > 55 1000 1500 > 55 3500 4500 > 37 6000 all 7000
2801) 60 all 2000 3500 - - - - - - -
2801) 60 - - - all 8000 10500 all 14000 all 17000
280 35 all 1900 3200 - - - -
280 40 - - all 7800 9600 all 13900 all 15000
315 35 all 1900 3200 - - - -
315 55 - -
all 5900 7600 all 11800 all 12900
355 35 all 1900 3200 - - - -
355 70 - -
all 4000 5600 all 9600 all 10700
400 40 all 1500 2700 - - - -
400 85 - - all 3200 4700 all 8600 all 9700
450 40 all 1500 2700 - - - -
450 95 - - all 2500 3900 all 7700 all 8700

Roller bearings

Lubrication intervals in duty hours

160 25 ≤ 18,5 4500 6000 ≤ 15 9000 10500 ≤ 11 12000 all 12000
160 25 > 18,5 3500 5000 > 15 7500 9000 > 11 11000 all 12000
180 30 ≤ 22 3500 4500 ≤ 22 7500 9000 ≤ 15 12000 all 12000
180 30 > 22 3000 4000 > 22 7000 8500 > 15 10500 all 12000
200 40 ≤ 37 2750 4000 ≤ 30 7000 8500 ≤ 22 11500 all 12000
200 40 > 37 1500 2500 > 30 5000 6000 > 22 8000 all 10000
225 50 ≤ 45 2000 3000 ≤ 45 6500 8000 ≤ 30 11000 all 12000
225 50 > 45 750 1250 > 45 2500 3000 > 30 4000 all 5000
250 60 ≤ 55 1000 2000 ≤ 55 4500 5500 ≤ 37 7500 all 9000
250 60 > 55 500 750 > 55 1500 2000 > 37 3000 all 3500
2801) 60 all 1000 1750 - - - - - - -
2801) 70 - - - all 4000 5250 all 7000 all 8500
280 35 all 900 1600 - - - -
280 40 - - all 4000 5300 all 7000 all 8500
315 35 all 900 1600 - - - -
315 55 - -
all 2900 3800 all 5900 all 6500
355 35 all 900 1600 - - - -
355 70 - -
all 2000 2800 all 4800 all 5400
400 40 all - 1300 - - - -
400 85 - - all 1600 2400 all 4300 all 4800
450 40 all - 1300 - - - -
450 95 - - all 1300 2000 all 3800 all 4400

1) M3AA

For motors M4BP 160 to 250 the interval may be increased by 30 %, up to a maximum of three calendar years.
The values in table above are valid also for sizes M4BP 280 to 355.

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6.2.4 Lubricants The following high performance greases can be used:

- Esso Unirex N2 or N3 (lithium complex base)

WARNING - Mobil Mobilith SHC 100 (lithium complex base)
Do not mix different types of grease. - Shell Gadus S5 V 100 2 (lithium complex base)
Incompatible lubricants may cause bearing damage. - Klüber Klüberplex BEM 41-132 (special lithium
base)
- FAG Arcanol TEMP110 (lithium complex base)
When regreasing, use only special ball bearing grease with - Lubcon Turmogrease L 802 EP PLUS
the following properties: (special lithium base)
– good quality grease with lithium complex soap and with - Total Multiplex S 2 A (lithium complex base)
mineral- or PAO-oil
– base oil viscosity 100-160 cST at 40°C NOTE!
– consistency NLGI grade 1.5 - 3 *) Always use high speed grease for high speed 2-pole
– temperature range -30°C - +120°C, continuously. machines where the speed factor is higher than
*) For vertical mounted motors or in hot conditions a stiffer 480,000 (calculated as Dm x n where Dm = average
end of scale is recommended. bearing diameter, mm; n = rotational speed, r/min).
The high speed grease is also used in motor types
The above mentioned grease specification is valid if the M2CA, M2FA, M2CG and M2FG, frame sizes 355 to
ambient temperature is above -30°C or below +55°C, and 400 2-pole machines.
the bearing temperature is below 110°C; otherwise consult
ABB regarding suitable grease.

Grease with the correct properties is available from all the The following greases can be used for high speed cast iron
major lubricant manufacturers. motors but not mixed with lithium complex greases:

Admixtures are recommended, but a written guarantee - Klüber Klüber Quiet BQH 72-102 (polyurea base)
must be obtained from the lubricant manufacturer, - Lubcon Turmogrease PU703 (polyurea base)
especially concerning EP admixtures, that admixtures do If other lubricants are used;
not damage bearings or the properties of lubricants at the
operating temperature range. Check with the manufacturer that the qualities correspond
to those of the above mentioned lubricants. The lubrication
interval are based on the listed high performance greases
WARNING above. Using other greases can reduce the interval.
Lubricants containing EP admixtures are not
recommended in high bearing temperatures in frame If the compatibility of the lubricant is uncertain, contact
sizes 280 to 450. ABB.

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7. After Sales Support

7.1 Spare parts

When ordering spare parts, the motor serial number, full
type designation and product code, as stated on the rating
plate, must be specified.

For more information, please visit our web site

www.abb.com/partsonline.

7.2 Rewinding
Rewinding should always be carried out by qualified repair
shops.

Smoke venting and other special motors should not be

rewound without first contacting ABB.

7.3 Bearings
Special care should be taken with the bearings. These
must be removed using pullers and fitted by heating or
using special tools for the purpose.

Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.

8. Environmental requirements

8.1 Noise levels

Most of ABB’s motors have a sound pressure level not
exceeding 82 dB(A) at 50 Hz .

Values for specific machines can be found in the relevant

product catalogues. At 60 Hz sinusoidal supply the values
are approximately 4 dB(A) higher compared to 50 Hz
values in product catalogues.

For sound pressure levels at frequency converter supply,

please contact ABB.

Sound pressure levels for all machines having separate

cooling systems and for series M2F*/M3F*, M2L*/M3L*,
M2R*/M3R*, M2BJ/M3BJ and M2LJ/M3LJ are indicated in
separate additional manuals.

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9. Troubleshooting
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be met in
connection with installation, operation or maintenance. Should additional information required, please contact the nearest
ABB Sales Office.

Motor troubleshooting chart

Your motor service and any troubleshooting must be handled by qualified persons who have proper tools and equipment.

TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate and
load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or control switch Indicated by humming sound when switch is closed. Check for loose
wiring connections.

Also ensure that all control contacts are closing.

Mechanical failure Check to see if motor and drive turn freely. Check bearings and
lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound. Remove end
Poor stator coil connection shields, locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown, check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, to fuses and to control.
then dies down
Motor does Not applied properly Consult equipment supplier for proper type.
not come up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load. Check
nominal speed because of line drop connections. Check conductors for proper size.
Starting load too high Check the start load of the motor.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as repairs
are usually temporary.
Open primary circuit Locate fault with testing device and repair.

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 28851en

TROUBLE CAUSE WHAT TO DO

Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Make sure that adequate cable
high current size is used.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation direction Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while Overload Reduce load.
running Frame or ventilation openings may Open vent holes and check for a continuous stream of air
be full of dirt and prevent proper from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well connected.
Grounded coil Motor must be rewound
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key - full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft shoulder Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene
contaminated and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than
half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.

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Figure 1. Connection diagram

Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figura 1. Diagrama de ligações
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio

Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figura 2. Transmissão por correias
Figur 2. Remdrift
Kuva 2. Hihnakäyttö

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Figure 3. Mounting of half-coupling or pulley

Bild 3. Anbau von Kupplungshälften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figura 3. Montagem de meio acoplamento ou poleia
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus

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Loadability curves with ACS800 converters with DTC control

Belastbarkeitskurven für ACS800-Frequenzumrichter mit DTC-Steuerung
Courbes de capacité de charge avec convertisseurs ACS800 et commande DTC
Curvas de capacidad de carga con convertidores ACS800 dotados de control DTC
Curve di caricabilità con convertitori ACS800 e controllo DTC
Curvas de capacidade de carga com conversores ACS800 com controlo de transmissão digital (DTC)
Lastbarhetskurvor för ACS800-omriktare med DTC-styrning
Kuormitettavuuskäyrät DTC-säädöllä varustetuille ACS800-taajuusmuuttajille

Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat 4a, 4b, 4c, 4d

Low voltage motors, nominal frequency of the motors 50/60 Hz, temperature rise B/F
Niederspannungsmotoren, Nennfrequenz der Motoren 50/60 Hz, Temperaturanstieg B/F
Moteurs à basse tension, fréquence nominale des moteurs de 50/60 Hz, augmentation de température B/F
Motores de baja tensión, frecuencia nominal de los motores 50/60 Hz, aumento de temperatura B/F
Motori a bassa tensione, frequenza nominale dei motori 50/60 Hz, incremento di temperatura B/F
Motores de baixa tensão, frequência nominal dos motores 50/60 Hz, aumento da temperatura B/F
Lågspänningsmotorer, märkfrekvens för motorerna 50/60 Hz, temperaturstegring B/F
Pienjännitemoottorit, moottorin nimellistaajuus 50/60 Hz, lämpötilan nousu B/F

4a ACS800/50 Hz, Temperature rise B 4b ACS800/60 Hz, Temperature rise B

T/TN (%) T/TN (%)

120 120
Separate cooling Separate cooling

100 100

80 80
Sizes Sizes
80-132 80-132

60 60
Sizes Sizes
160-450 160-450

40 40

0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Frequency (Hz) Frequency (Hz)

4c ACS800/50 Hz, Temperature rise F 4d ACS800/60 Hz, Temperature rise F

T/TN (%) T/TN (%)

120 120
Separate cooling Separate cooling

100 100
Sizes Sizes
80-132 80-132
80 80

Sizes Sizes
160-450 160-450
60 60

40 40

0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Frequency (Hz) Frequency (Hz)

Low voltage motor manual 01-2009 | ABB Motors and Generators 157
 28851en

Loadability curves with ACS550 converters

Belastbarkeitskurven für ACS550-Frequenzumrichter
Courbes de capacité de charge avec convertisseurs ACS550
Curvas de capacidad de carga con convertidores ACS550
Curve di caricabilità con convertitori ACS550
Curvas de capacidade de carga com conversores ACS550
Lastbarhetskurvor för ACS550-omriktare
Kuormitettavuuskäyrät ACS550-taajuusmuuttajille

Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat 5a, 5b, 5c, 5d

Low voltage motors, nominal frequency of the motors 50/60 Hz, temperature rise B/F
Niederspannungsmotoren, Nennfrequenz der Motoren 50/60 Hz, Temperaturanstieg B/F
Moteurs à basse tension, fréquence nominale des moteurs de 50/60 Hz, augmentation de température B/F
Motores de baja tensión, frecuencia nominal de los motores 50/60 Hz, aumento de temperatura B/F
Motori a bassa tensione, frequenza nominale dei motori 50/60 Hz, incremento di temperatura B/F
Motores de baixa tensão, frequência nominal dos motores 50/60 Hz, aumento da temperatura B/F
Lågspänningsmotorer, märkfrekvens för motorerna 50/60 Hz, temperaturstegring B/F
Pienjännitemoottorit, moottorin nimellistaajuus 50/60 Hz, lämpötilan nousu B/F

5a ACS550/50 Hz, Temperature rise B 5b ACS550/60 Hz, Temperature rise B

T/TN (%) T/TN (%)

120 120
Separate cooling Separate cooling

100 100

80 80

Sizes Sizes
80-132 80-132
60 60

Sizes Sizes
160-450 160-450
40 40

0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Frequency (Hz) Frequency (Hz)

5c ACS550/50 Hz, Temperature rise F 5d ACS550/60 Hz, Temperature rise F

T/TN (%) T/TN (%)

120 120
Separate cooling Separate cooling

100 100
Sizes Sizes
80-132 80-132
80 80

Sizes Sizes
160-450 160-450
60 60

40 40

0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Frequency (Hz) Frequency (Hz)

158 ABB Motors and Generators | Low voltage motor manual 01-2009
 28851en

Figure/Bild/Figure/Figura/Figura/Figura/Figur/Kuva 6.

Allowed phase to phase voltage peaks at motor terminal as a function of rise time.
..... ABB Special Insulation; ___ ABB Standard Insulation
Zulässige Phase-zu-Phase-Spannungsspitzen an Motorklemmen als Funktion der Anstiegszeit.
..... ABB Spezialisolierung; ___ABB Standardisolierung
Pics de tension phase-phase au niveau des bornes du moteur en tant que fonction de temps de hausse.
..... ABB Isolation spéciale ; ___ Isolation standard ABB
Picos de tensión permitidos entre fases en los bornes del motor en función del tiempo de aumento.
..... Aislamiento especial de ABB; ___ Aislamiento estándar de ABB
Picchi di tensione da fase a fase ammessi ai morsetti del motore in funzione del tempo di salita.
..... Isolamento speciale ABB; ___ Isolamento standard ABB
Fase permitida para picos de tensão de fase no terminal do motor como função do tempo de subida.
..... Isolamento especial da ABB; ___ Isolamento normal da ABB
Tillåtna fas till fas-spänningsstoppar vid motoranslutningarna som en funktion av stigtid.
..... ABB Specialisolering; ___ ABB Standardisolering
Pääjännitteiden suurimmat sallitut piikkiarvot nousunopeuden funktiona.
..... ABB:n erikoiseristys; ___ ABB:n vakioeristys

2,20

2,00

1,80
Peak voltage ULL, kV

1,60

1,40

1,20
ABB Special Insul.
1,00
ABB Standard Insul.
0,80
0,00 0,20 0,40 0,60 0,80 1,00 1,20
Rise time 10-90 %, µs