GEI–M1036-B

GE Energy

IEC 90-315 Frame

AC Small Industrial
Motors

2011/03/22
 GEI-M1036-B

Table of Contents

I. General Information................................................................................................................................................. 3
A. How to Properly Use this Instruction Manual.................................................................................. 3
B. Safe Motor Operation Information....................................................................................................... 3
C. Safety Symbol Table ................................................................................................................................... 4
D. Description of Labels and Nameplates ............................................................................................. 5
E. Model and Serial Numbers....................................................................................................................... 5
F. Relevant Industry Standards................................................................................................................... 5
II. Receiving ....................................................................................................................................................................... 5
A. Temporary Storage..................................................................................................................................... 5
B. Extended Storage ........................................................................................................................................ 6
C. Handling........................................................................................................................................................... 6
D. Unpacking....................................................................................................................................................... 6
III. Installation.................................................................................................................................................................... 6
A. Zone 2 Hazardous Locations.................................................................................................................. 6
B. Mounting.......................................................................................................................................................... 6
C. Sleeve Bearing Endplay............................................................................................................................. 8
D. Power Supply and Connections ............................................................................................................ 8
E. Allowable Voltage and Frequency......................................................................................................10
F. Position of the Terminal (Conduit) Box..............................................................................................10
IV. Operation…………………………………………… ..................................................................................................................10
A. Steps Prior to Starting..............................................................................................................................10
B. Initial Start.....................................................................................................................................................11
C. Jogging and Repeated Starts...............................................................................................................11
V. Maintenance..............................................................................................................................................................11
A. General ...........................................................................................................................................................11
B. General Cleanliness ..................................................................................................................................12
C. Insulation and Windings .........................................................................................................................12
D. Vacuum and Compressed Air Cleaning...........................................................................................12
E. Cleaning with Water and Detergent..................................................................................................12
F. Cleaning with Solvents.............................................................................................................................12
G. Anit-Friction Bearings and Lubrication............................................................................................13
H. Recommended Frequency of Regreasing.......................................................................................13
I. Sleeve Bearings ............................................................................................................................................14
VI. Operational Difficulties..........................................................................................................................................15
VII. Failure ...........................................................................................................................................................................16
VIII. Repair............................................................................................................................................................................16
IX. Renewal Parts ...........................................................................................................................................................16
X. Tightening Torque for Metric Hardware........................................................................................................17
XI. Motor Lubrication Guide.......................................................................................................................................21

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 GEI-M1036-B

I. GENERAL INFORMATION

A. How to Properly Use this Instruction Manual

This installation and maintenance manual has been written to assist the user with proper procedures when
handling, installing, operating and maintaining the equipment. All of the safety warnings and instructions in this
book must be followed to prevent injury to personnel.

This manual must be kept for future reference during installation, operation and maintenance.

B. Safe Motor Operation

WARNINGS: High voltage and rotating parts can cause serious or fatal injuries. Qualified personnel
should perform installation, operation and maintenance of electrical machinery. For equipment covered
by this instruction book, it is important to observe safety precautions to protect personnel from possible
injury. Be sure to keep the installation and maintenance information for future reference. All warnings and cautions must
be followed.

Installation
• Avoid contact with energized circuits and rotating parts.
• Avoid bypassing or rendering inoperative any safeguards or protective devices.
• Avoid use of automatic-reset thermal protection where unexpected starting of equipment might be hazardous to
personnel.
• Avoid long contact with capacitors until safe discharge procedures have been followed.
• Be sure the shaft key is captive before the motor is energized.
• Avoid long exposure in close proximity to machinery with high noise levels.
• When the motor is coupled to equipment, customer should ensure that system vibrations are within acceptable limit
(per ISO 10816-1) to avoid the failure of motor.
• Use proper care and procedures in handling, lifting, operating and maintaining the equipment.
• Use proper protective gear when handling, lifting, installing, operating and maintaining the equipment.
• If eyebolts are used for lifting motors, they must be securely tightened, and the direction of the lift must not exceed a
15° angle with the shank of the eyebolt. Do not use eyebolts in an ambient below 0°F. At temperature below 0° F, the
eyebolt could fail resulting in injury to personnel and/or damage to equipment. Drop-forged eyebolts per American
Scoiety of Testing Materials A489 or equivalent must be used.
• Do not use the shaft as a means for lifting.
• Do not lift both the motor and driven equipment with the motor lifting means.
• Do not stand on or place objects on the motor.

Maintenance
Safe maintenance practices performed by qualified personnel are imperative. Before starting maintenance procedures,
be positive that:
• Equipment connected to the shaft will not cause mechanical rotation.
• Main motor windings and all accessory devices associated with the work area are disconnected from electrical power
sources.
• The motor has been given time to cool.

Failure to properly earth the frame of the motor can cause serious injury to personnel. Earthing should be in accordance with IEC Standards and consistent with
sound practice.

These instructions do not purport to cover all details in equipment nor to provide for every possible contingency to be met in connection with installation,
operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s
purposes the matter should be referred to the General Electric Company.

This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the
installation, testing, operating and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part, nor shall its contents
be disclosed to any third party without the written approval of GE Energy.

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 GEI-M1036-B

C. Safety Symbol Legend

Below is a safety symbol table that identifies the safety symbols that will appear in this manual and on the
equipment.

The use of a lightning bolt within an

arrowhead symbol, enclosed in a yellow This symbol identifies any terminal
triangle, indicates warning of which is intended for connection to
dangerous electrical voltage that could an external earthing conductor for
cause an electric shock to a person. protection against electric shock in
case of a fault.
The use of an exclamation point within
a yellow triangle indicates to the user
that important installation, operating The use of a small case “i” enclosed
and maintenance instructions must be in a square indicates a general note.
followed.

The use of wavy lines, enclosed in a Indicates a procedure or condition

yellow triangle, indicates that the motor WARNING: that, if not strictly observed, could
can be hot and should not be touched result in personal injuries or death.
without taking proper precautions.

Indicates a procedure or condition

CAUTION: that, if not strictly observed, could
This symbol instructs one to read the result in minor injuries to personnel.
manufacturer’s instruction manual
before installation, operation and
maintenance.
This symbol represents the need to
wear hearing protection.

 Copyright 2010 General Electric Company

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 GEI-M1036-B

D. Description of Labels and F. Relevant Standards

Nameplates
Motors shipped with this installation instruction have been
designed and built to the following standards to the latest
Motor rating and identification data are furnished on labels
revision:
and nameplates. Labels provide basic motor characteristics.
NEMA MG-1
Nameplates provide a permanent record of motor
IEC and/or BS/EN 60034-1
characteristics, plant identification and date of manufacture.
IEC and/or BS/EN 60034-5
Below is an example of a label that is attached to the shipping
IEC and/or BS/EN 60034-6
package.
IEC and/or BS/EN 60034-7
IEC and/or BS/EN 60034-8
9262MC02 IEC and/or BS/EN 60034-9
MOD : 5KFS112XAA120 IEC and/or BS/EN 60034-12
KW : 3.7 IEC and/or BS/EN 60034-14
RPM : 2950 IEC and/or BS/EN 60072-1
VOL : 400
Motors that have the IECEx designation have also been
ENCL : TEFC CE designed to meet the requirements of the following standards:
FR : 112M
MASS : 53.2 KG IEC and/or BS/EN 60079-0
SERIAL# JCFT244B06 S/O 9262MC02 IEC and/or BS/EN 60079-15

II. RECEIVING
Figure 1: Packing Label
Each shipment should be carefully inspected upon arrival.
MOD – GE model number
Motor rating and identification data are furnished on a
KW = Motor power rating
packing label for verification purposes. Any damage should
RPM = Motor speed at full load
be reported promptly to the carrier and a claim filed. The
VOL – Motor voltage
nearest GE Energy sales office may provide additional
ENCL = GE enclosure code
guidance.
FR = IEC frame size
MASS = Motor mass
SERIAL = Motor serial number A. Temporary Storage
(Up to 6 Months)
E. Model and Serial Numbers
In the event the motor will not be put into service
As discussed in section D, every motor that is manufactured immediately, certain precautions should be taken to protect
by GE Energy will be provided with a model and serial the motor while in storage. It is recommended the motor
number, which are permanently marked on the motor be placed under cover in a clean, dry location.
nameplate and shipping pack. These numbers identify basic
motor characteristics and pertinent data. When contacting During storage, windings should be protected from
a GE Energy Service Shop or representative, please refer to excessive moisture by some safe and reliable method of
the model and serial number. In the note section of this heating, such as space heaters, to keep the temperature of
book, space has been provided for you to record these windings above the temperature of the surrounding air. It is
numbers. recommended the motor in storage be inspected at periodic
intervals, the windings meggered and a log kept of pertinent
Data and information regarding an individual motor model
data. (Refer to the OPERATION section.) Any significant
can be obtained from the Data Pack for the motor or
drop in insulation resistance should be investigated.
through EliteNet or by contacting your local GE Energy
representative.
Precautions are taken by the factory to guard against
corrosion. The machined parts are coated to prevent rust
during shipment. If the equipment is to be stored, examine
the machined parts carefully for rust and moisture and
recoat where necessary.

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 GEI-M1036-B

Motors with oil-lubricated or oil-mist lubricated bearings are III. INSTALLATION

normally operated and tested in the factory with a rust-
inhibiting oil in the lubrication system. A rust-inhibiting film
WARNING: Installation should be in
remains on critical bearing surfaces during transit and for
accordance with the ‘USA-National
up to six months in storage. However, when the machine is
received, it is recommended that the bearing oil reservoirs Electric Code’ or ‘BS/EN 60204-1’ and
on sleeve bearing motors be filled to the proper oil level with ‘BS/EN 60204-11’ and consistent with
a good grade of rust-inhibiting oil. Rotate the shaft of two- sound local practices.
bearing machines (10 to 25 revolutions) until the journals Coupling, belt and chain guards should be installed
are thoroughly coated with oil. as needed to protect against accidental contact with
moving parts. Motors accessible to personnel
The bearings of grease-lubricated motors are greased at the should be further guarded by screening, guard rails,
factory with the grease cavity approximately 50% full. etc., to prevent them from coming in contact with
Rotate the shaft of all grease-lubricated motors 10-20 the equipment.
revolutions at two-month intervals.
A. Zone 2 Hazardous Locations
If the purchaser has specified the machine be packaged for
long-term storage, the foregoing recommendations do not All motors marked with an IECEx or ATEX designation are
apply and the packing should be left intact during the period suitable for Zone 2 locations. Before the motor is install in
of storage. the hazardous location, the marking must be reviewed for
the intended location. If the motor marking does not meet
B. Extended Storage the intent of the location do not install or operate the motor.
Refer to BS/EN 60079-0 and BS/EN 60079-15.
In the event the motor is to be stored longer than six
Motor marking for IECEx will have a nameplate with the
months, please refer to GE instruction manual GEK-97427.
IECEx logo, IECEx certification number, and IECEx marking
codes. An example of the IEC EX marking is as follows;
C. Handling
WARNING: Lifting lugs on the motor are
Ex nA IIC T3 Gc
designed for handling only the motor.
Where symbol:
They are not to be used to lift the motor 1) Ex indicates the motor corresponds to one or
plus additional equipment such as more types of protection.
Pumps ,compressors or other driven equipment. In 2) nA indicates non-sparking
the case of assemblies on a common base, lugs or 3) IIC is a code to indicate the type of explosive gas
eyebolts provided on the motor are not to be used to atmosphere.
lift the assembly and base, but rather, the assembly 4) T3 is a code for the maximum surface
should be lifted by a sling around the base or by temperature.
other lifting means provided on the base. In the case 5) Gc is a code for the motor protection level.
of unbalanced loads (such as couplings or other
attachments), additional slings or other effective Refer to B/EN 60079-0 and BS/EN 60079-15 for the meaning
and understanding of all symbols and codes.
means should be used to prevent tipping.

D. Unpacking B. Mounting

If the motor or motor parts have been exposed to low 1. Mount motors securely on a firm, flat base. Grout-in
temperatures, unpack it only after it has reached the larger motors, if necessary. Grease lubricated motors can
temperature of the room in which it will be unpacked or be wall or ceiling mounted with the shaft horizontal. Grease
located. Otherwise the windings will be exposed to lubricated motors in IEC 90-200 frame ratings can be wall
condensing moisture. mounted with the shaft vertical. The standard transition
and/or sliding bases are only suitable for floor mounting.
For other mounting positions, please refer to your local GE
representative. Oil lubricated sleeving-bearing motors shall
always be mounted with the shaft horizontal. The endshield
shall be located with the oil ring sight gage in the twelve
o’clock position.

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 GEI-M1036-B

Table 1
Bolt Recommended Torque
Size in N-m (Lb-ft)
WARNING: Remove drain plugs
Metric Minimum Maximum
from the frame or end shields
M6 7 (5) 11 (8)
of enclosed motors used
M8 20 (15) 26 (19)
outdoors or in other high M10 43 (32) 50 (37)
moisture areas M12 73 (54) 88 (65)
M16 176 (130) 217 (160)
M20 312 (230) 393 (290)
2. Align motor accurately. For direct drive, use flexible M24 569 (420) 691 (510)
couplings if possible. For drive recommendations, consult
drive or equipment manufacturers or GE. 4. For belt drive applications; make certain that the
required minimum diameter of the belt pulley and the belt
3. For base assembly and motor mounting, the tension are properly related to the pulley diameter as an
mounting bolts must be carefully tightened to prevent excessive pull may cause bearing trouble and shaft failures.
changes in alignment and possible damage to the Tighten belts only enough to prevent slippage. Belt speeds
equipment. It is recommended that a washer be used under should not exceed 25 meters per second (5000 feet per
each nut or bolt head to get a secure hold on the motor feet. minute). When V-belts are used, sheave ratios greater than
As an alternative, flanged nuts or bolts may be used. The 5:1 and center-to-center distances less than the large
recommended tightening torques for medium carbon steel sheave should not be used. The dimensions of the belt pulley
bolts, identified by class 8.8 (ISO 898) on the head are listed are to be determined according to the kind of belt,
below in Table 1. transmission and capacity to be transmitted. Vent holes
have to be kept free and required minimum distances are to
be observed in order not to obstruct the flow of cooling air.
In addition, make sure that the discharged hot air is not
circulated into the motor.

5. On motors with dual mounting holes use the holes

indicated per Figure 2A and 2B.

Figure 2A - Mounting

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 GEI-M1036-B

Figure 2B: Mounting

C. Sleeve Bearing Endplay
On sleeve-bearing motors the feet should be located
at a correct distance from the load so that the motor’s rotor
is in the approximate mid-point of its end play. The mid-
position of the rotor’s endplay is indicated with a mark on
the motor’s shaft. Locate this mark flush with the bearing
housing.

D. Power Supply and Connections

For IEC frame 90-315 Motors, and rated 690 Volts and less,
the terminal box cable entry holes are fitted with one plastic
& one metal plug, refer Figure 3A.
Figure 3A: Terminal Box
• If both cable entry holes are to be used, replace both
plugs with proper cable glands to retain ingress 1. All terminal box connections are tight per the
protection. connection diagram with tightening torques as given below
in Table 2.
• If only one hole is to be used, replace only the plastic
plug with a proper cable gland & use the metal plug Table 2 (per DIN 46200)
to retain ingress protection. Tightening Torque
Stud Thread Size N-m (Lb-ft)
These terminal boxes require the removal of the terminal M4 1.2 (0.9)
box cover before removing the gland plate. For reassembly,
M5 2 (1.5)
the gland plate must be attached first, followed by the
terminal box cover. M6 3 (2.2)
M8 6 (4.4)
The terminal box hole size, threading, number of holes, and M10 10 (7.4)
relative location are all specified on the motor’s outline. M12 15.5 (11.4)
The motor shall be earthed by attaching an earth strap from M16 30 (22)
a known earth point to the bronze earthing bolt in the
terminal box and/or on the motor frame. 2. The earthing conductor that is routed
Stator winding connections should be made as shown on inside the terminal box, should be located to ensure that
the connection diagram supplied in the Data Pack or as sufficient clearances are maintained from the live motor &
shown on the motor. supply parts.
Before the terminal box cover is closed be sure that:

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 GEI-M1036-B

Ensure adequate clearance and creepage distances of Table 4

leads/terminals are maintained in accordance with Table 3 Tightening torques (N-m)
below and any applicable local standards. Dome Hex Plastic Hex Metal
Table 3 Plug sizes
Plastic Plugs Plugs
Clearance Creepage Plugs
Voltage Rating
(mm) (mm) M12 X 1.5 1.0 1.5 4.0
Less than 601 10 12.5 M16 X 1.5 1.5 2.5 5.5
M20 X 1.5 2.0 3.5 8.0
601 to 1000 16 22 M25 X 1.5 2.5 4.0 12.0
1001 to 2500 18 25 M32 X 1.5 3.5 6.0 13.5
2501 to 5000 36 50 M40 X 1.5 3.5 8.5 15.0
5001 to 6901 56 80 M50 X 1.5 4.0 10.5 18.0
M63 X 1.5 5.0 12.0 20.5
Note: Exposed live terminals shall be enclosed in at least an
IP54 enclosure to meet BS/EN 60079-15 Table 5
Metric Cable Glands
Note: Motor and power supply terminals shall be in direct Recommended Maximum
contact with the terminal board links. Do not place any Tightening torques Tightening
hardware between the link and a motor or power supply (N-m) torques (N-m)
terminal. Refer to Figure 3B for the proper connection of
terminals and links. Cooper Crouse
Hinds
Metric Hummel / Seal Con Unar
1. Nut
2. Motor terminal lug Hole sizes m- Arm-
3. Link (used to short two oure oured
studs) d
4. Power supply terminal lug Metal
5. Plain washer Plastic Metal Metal
Cable
6. Spring washer Cable Cable Cable
7. Nut Glan
Glands Glands Glands
8. Terminal board base ds
M12 X 1.5 1.5 4.0 --- ---
M16 X 1.5 2.5 6.0 25.0 32.5
Figure 3B: Terminal Board Link Configuration M20 X 1.5 3.5 9.0 25.0 32.5
M25 X 1.5 4.0 12.0 30.0 47.5
M32 X 1.5 6.0 15.0 32.0 55.0
3. The interior of the terminal box shall be clean M40 X 1.5 9.0 15.5 32.0 65.0
and free from foreign materials.
M50 X 1.5 11.0 22.0 60.0 80.0
4. Cable openings not used should be closed
M63 X 1.5 12.5 28.0 60.0 95.0
and the closing screws should be fixed tightly.
M75 X 1.5 --- --- 80.0 110.0
5. To meet requirements of IEC 60079-0 and
IEC 60079-15 (Zone 2) all terminal box plugs shall be tighten M80 X 2.0 --- --- 100.0 150.0
to the values stated in Table 4. M85 X 2.0 --- --- 100.0 150.0
6. To meet requirements of IEC 60079-0 and M90 X 2.0 --- --- 120.0 225.0
IEC 60079-15 (Zone 2) all Cable glands shall be tighten to the M100 X 2.0 --- --- 120.0 225.0
values stated in Table 5 or Table 6. Note: If different kinds of cable glands are used, use the
recommended torque value from the cable gland manufacturer.
7. The gasket in the terminal box cover should A lower tightening torque maybe used but the terminal box may
no longer meet IP55.
be clean and tightly sealed to the cover.
8. The condition of all gaskets should be in
accordance to protective regulations.

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 GEI-M1036-B

Table 6
NPT Sizes WARNING: Motor and control
Recommended overload protection and earthing
Maximum Tightening
Tightening should be in accordance with the
Cable torques (N-m)
torques (N-m) ‘USA -National Electric Code’ or ‘BS/EN 60204-1’
Gland
Cooper Crouse Hinds and/or ‘BS/EN 60204-11’ and consistent with sound
for Hummel / Seal
Unarmoure local practices.
NPT Con Armoured
d
Hole
Sizes Plastic Metal Metal IV. OPERATION
Metal Cable
Cable Cable Cable
Glands A. Steps Prior to Starting
Glands Glands Glands
3/8” 2.5 5.5 --- ---
WARNING: If the motor has been in
½” 3.5 10.0 25.0 32.5
a damp location, dry it out
¾” 4.5 12.5 25.0 32.5
thoroughly before operating. Before
1” 6.0 15.0 30.0 47.5
1-1/4” 6.0 17.0 32.0 55.0 energizing the motor for the first
1-1/2” 9.0 22.0 32.0 65.0 time or after an extended shut down,
2” --- --- 60.0 80.0 it is advisable to check the insulation resistance,
2-1/2” --- --- 60.0 95.0 power supply and mechanical freedom of the
3” --- --- 80.0 110.0 motor.
3-1/2” --- --- 100.0 150.0
4” --- --- 120.0 225.0 WARNING: Customer should close
the terminal box cover and secure
Before starting the motor, make sure all safety regulations the gland plate (if applicable) to the
are strictly met. This is also important for motor service and box before the power supply is
for disconnection. When the motor is put into service, check energized.
operating current against nameplate current.
In accordance with established standards, the
CAUTION: Do not exceed the value of recommended minimum insulation resistance for the stator
nameplate current multiplied by the winding when measured with a 500 volt DC direct indicating
motor service factor. ohmmeter with self-contained power supply (megger), shall
not be less than 5 mega-ohms for a motor rated under 1000
volts, and not less than 100 mega-ohms for a motor rated
E. Allowable Voltage and Frequency over 1000 volts. If the insulation resistance is lower than
this value, it is advisable to eliminate the moisture in one of
The power supply must agree with the nameplate voltage the following ways.
and frequency. The motor will operate (but with 1. Dry the winding in an air-circulating oven
characteristics somewhat different from nameplate values)
with the air surrounding the winding at 110°C, +5/-15°C
on line voltage within + 5% of the nameplate value and
until the part has been above 90°C for at least four hours.
frequency within + 2% and a combined variation not to
exceed + 5%. Then the air temperature may be raised to 150°C, +5°C/-
15°C. Continue to heat until the insulation resistance is
constant for a one-half-hour period.
F. Position of the Terminal (Conduit) Box
When mounting conditions permit, the terminal box may be 2. Enclose the motor with canvas or similar
rotated so that power supply cables can enter the box at covering, leave a hole at the top for moisture to escape.
the top, bottom or either side. For oversize terminal boxes, Insert heating units or lamps and leave them on until the
such as those required for stress cones or surge protection insulation resistance is constant for a one-half hour period.
equipment, the mounting height of the motor may have to
be increased for accessibility 3. With the rotor locked mechanically and using
. approximately 10% of rated voltage, pass a current through
the stator windings. Increase the current gradually until the
winding temperature reaches 90°C. Do not exceed this
temperature. Maintain a temperature of 90°C until the
insulation resistance becomes constant for a one-half hour
period.

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 GEI-M1036-B

B. Initial Start investigation of lineup conditions, and if necessary, the

bearing and oil ring assembly.
WARNING: Be sure the motor is not 8. For anti-friction bearings check motor
running and the power supply is operation under load for an initial period of at least one hour
disconnected. to observe whether any unusual noise or hot spots develop.
9 In the event of excessive vibration or unusual
1. For sleeve-bearing motors, flush out all noise disconnect the motor from the load and check the
sleeve bearings with kerosene to remove any dust or grit mounting and alignment.
which may have accumulated during storage. Do not flush
out anti-friction bearings. The bearing grease supplied is 10. Space heaters should be de-energized
sufficient for initial operation. during motor operation.
11. Check the operating current against the
Make sure that the oil plugs are tight and fill
nameplate value. Do not exceed the value of nameplate
the oil wells with the oil recommended in the “Bearing
current multiplied by the motor service factor (if any) under
Maintenance” section of this book to center of the oil level
steady continuous load.
sight gages. The oil level should be checked only when the
machine is not running. C. Jogging and Repeated Starts
2. Whenever possible, examine the interior of CAUTION: Repeated starts and/or jogs of
the motor for loose objects or debris which may have
induction motors greatly reduce the life of
accumulated and remove any foreign material.
the winding insulation.
3. If possible, turn the rotor by hand to be sure The heat produced by each acceleration or jog is
that it rotates freely. much more than that dissipated by the motor
under full load. If it is necessary to repeatedly start
4. Check all connections with the connection or jog a motor, it is advisable to check the
diagram. Check all accessible factory made connections for application with the local GE Energy sales office.
tightness to make sure none has become loose during
shipment.
V. MAINTENANCE
5. When the driven motor is likely to be
damaged by the wrong direction of rotation, it is best to WARNING: Before initiating
uncouple the motor from its load during the initial start and maintenance procedures, discon-
make certain it rotates in the correct direction. If it is nect all power sources to the motor
necessary to change rotation, interchange any two line and accessories. For motors
leads. equipped with surge capacitors, do not handle the
capacitors until they are discharged by a conductor
Some motors are designed for unidirectional
rotation. Rotation of these motors must be in accordance simultaneously touching all terminals and leads,
with the rotation indicated on the motor nameplate and the including earth. This discharge conductor should
outline furnished with the equipment. Connection plates on be insulated for handling. Replace all normal
the motor have been furnished to assist in obtaining the earthing connections prior to operating.
proper rotation.
6. After inspecting the motor carefully, make A. General
the initial start by following the regular sequence of starting
operations in the control instructions. If the motor is dismantled during maintenance, sealing
compounds (if any) shall be removed from machined rabbet
7. For sleeve-bearing machines, after starting (spigot). When reassembling the motor, all machined
see that the oil rings are operating properly and that oil is surfaces forming metal-to-metal joints are sealed with
being fed to the shaft. watertight sealing compound (Tite-Seal, GE Spec.
A50CD427A or equivalent).
The temperature of the sleeve bearings, as
measured by bearing temperature detectors, should not Inspect the motor at regular intervals, depending on service.
exceed 93°C (200°F). Keep the motor clean and the ventilation openings clear.

At initial start, the rate of rise of the bearing In addition to the daily observation of the overall condition, it
temperature is more indicative of trouble than is total is recommended that a general inspection
temperature. When starting a machine for the first time, the routine be set up to check periodically the following items:
bearing temperature should be observed for a minimum of 1. General cleanliness
2 hours. If at any time the rate of temperature rise exceeds 2. Insulation and windings
2°C/minute, shut down the motor immediately and make an 3. Lubrication and bearings

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E. Cleaning with Water and

B. General Cleanliness Detergent
This method is very effective in cleaning windings when
The interior and exterior of the motor should be kept free used with a low-pressure steam jenny maximum steam flow
from dirt, oil and grease and conducting dust. Paper, textile 30 psi and 90°C.
or dusts may build up and block off ventilation. Any of these
contaminants can lead to early motor failure. CAUTION: To minimize possible damage
to varnish and insulation, a fairly neutral
C. Insulation and Windings non-conductive type of detergent such as
To obtain a long life and satisfactory operation of insulated DuBois Flow should be used. A pint of detergent to
windings, they should be kept clean from dirt, oil, metal 76 liters (20 gallons) of water is recommended.
particles and other contaminants. A variety of satisfactory
and acceptable methods are available for keeping If a steam jenny is not available, the cleaning solution may
equipment clean. The choice of method will depend greatly be applied with warm water by a spray gun. After the
on time, availability of equipment and on the insulation cleaning operation, the windings should be rinsed with
system. However, vacuum and/or compressed air cleaning water or low-pressure steam.
with non-metallic hose tips should precede cleaning with
water and detergent or with solvents. Tightly adhering dirt It is advisable to dry the windings. Refer to the Insulation
will require removal by gentle brushing or wiping. Resistance section in IV. above, for instructions on how to
proceed.
WARNING: To prevent injury to the eyes
and respiratory organs, safety glasses
F. Cleaning with Solvents
and suitable ventilation or other
protective equipment should be used.
WARNING: Many cleaning fluids are
flammable and/or toxic. To prevent injury
D. Vacuum and Compressed to personnel and property, care should be
taken to avoid flames, sparks, etc. Safety glasses
Air Cleaning
should be used and contact with the skin should be
Compressed air should be used to remove loose dirt and avoided. The area should be well ventilated or
dust from air passages such as air ducts. Suction should be protective equipment should be used.
used to remove dirt from the windings and to avoid
damaging the coils. Although cleaning with water and detergent is the preferred
method, solvent cleaning may be used when heat-drying
CAUTION: Care must be taken to make facilities are not available. Mineral spirits are recommended
sure the air is dry and that air pressure of for use as the cleaning solvent. Solvent cleaning of silicon-
not more than 21 x 103kg/m2 (30 psi) insulated windings (Class H insulated motors), leads and
is used. space heaters is not recommended.

WARNING: Mineral spirits should be used

WARNING: Operator must not use
only in a well-ventilated area that is free
compressed air to remove dirt or dust
from open flames. Avoid prolonged
from his person or clothing.
exposure to vapor.

Windings cleaned with solvent should be dried thoroughly

by circulation or dry air before voltage is applied.

12
 GEI-M1036-B

G. Anti-Friction Bearings and H. Recommended Frequency for

Lubrication Maintaining Grease lubrication
(Details: Table 9 & 10)

The grease used as a lubricant in grease-lubricated anti- WARNING: lubrication maintenance

friction ball bearings does not lose its lubricating ability should be performed with the motor
suddenly, but over a period of time. For a given bearing stationary and disconnected from
construction and assembly, the lubricating ability of a the power source. Extreme caution
grease over time depends primarily on the type of grease, must be exercised to avoid contact
the size of the bearing, the speed at which the bearing with rotating parts or electrical wiring if the motor
rotates and the severity of operating conditions. As a result, must be lubricated while running. Failure to
it is not possible to accurately predetermine when new
observe these precautions may result in damage to
grease must be added. But, good results can be obtained if
the general recommendations, as stated in this manual, are the equipment, injury to personnel, or both.
followed.
1. Run the motor until warm.
The primary function of grease is to supply the essential 2. Stop the motor and disconnect it from the
lubrication oil from the sponge-like reservoir or its soap power supply.
structure. Grease-lubricated anti-friction ball bearings 3. Clean dirt and debris from around the inlet
consume only a small amount of lubricant. This lubricant lubrication fitting and the grease relief plug.
must always be present to avoid rapid wear and bearing 4. Remove the relief plug and clean the opening
failure. However, excessive or too frequent lubrication may and relief tube of hardened grease. This may be
also damage the motor. accomplished with a twisted wire brush or sturdy pipe
cleaner.
Ball bearing motors are adequately lubricated at the factory.
5. Insert brush into relief hole. While the motor
Motors with grease fittings should be lubricated in
is still warm, add grease with a hand-operated grease gun
accordance with these instructions to provide maximum
until fresh grease appears on the end of the brush or until
bearing life.
grease has been added up to the amount listed in Table 10.
6. Leave the relief plug temporarily off. Start
To obtain optimum results, Exxon Mobil Polyrex EM (General
the motor and run for 10 to 20 minutes to expel any excess
Electric Specification D6A2C23) polyurea grease should be
grease.
used for lubrication, unless special grease is specified on the
7. Stop the motor. Replace the relief plug.
motor. Greasing frequency should be in accordance with
8. Restart the motor and resume operation.
Table 9 and recommended quantity of grease is given in
Table 10. If in doubt, refer to GE Energy.
CAUTION: Failure to observe the
CAUTION: Failure to use polyurea base foregoing instructions for regreasing may
(NLGI Grade 2) or known compatible result in grease leakage and/or bearing
grease could result in premature bearing damage. To avoid damage to equipment,
Failure. bearings and grease must be kept free of dirt.

Since this method of greasing bearings tends to purge the

housing of used grease over a period of time, removal of all
The procedure below must be followed for safe and grease should be required infrequently. A GE Energy
effective re-greasing. Authorized Service Shop can clean the bearing cavity and
replace the bearings and grease when the motor is
removed from service for maintenance or reconditioning.

NOTE: Warranty may be voided if

internal maintenance or repairs are not
performed by a GE Energy Authorized
Service Shop

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 GEI-M1036-B

I. Sleeve Bearings
(1) For the opposite drive end the fan cover
Motors with sleeve bearings have a removable top half must be removed first. Use the lifting eye on the fan cover
bearing housing cover. By removing this cover each bearing to support and move the fan cover during dis-assembly.
and the oil in the reservoir can be inspected without There are 5 socket head cap screws that secure the fan
disturbing the line-up. cover. These must be removed.

Prior to operation of the motor, both oil reservoirs should (2) For Zollern bearings remove the three
be filled to the center of the oil level gage. The oil should socket head cap screws on the outer flange of the upper
be maintained at this level (determined with the motor at half of the bearing housing which secure it to the endshield.
stand still) during operation of the motor. Oil is added For RENK bearings remove the cover plate that is bolted to
through the oil sight gauge hole above each bearing or the upper half of the bearing housing and endshield. The
through the inlet pipe provided. name Zollern or Renk will be embossed in the bearing
housing.
1. Oil
(3) Remove the four socket head screws
For motors operating between -10°C and 50°C, use a good that secure the top half of the bearing housing to the
grade of mineral oil having a viscosity of ISO 32. Consult GE bottom half.
Energy sales office regarding special lubricants for unusual (4) Remove the upper half of the bearing
operating conditions. housing.

2. Cleaning Sleeve Bearings (5) Remove the four socket head screws on
the bearing.
Sleeve bearings housings are provided with liberal settling
chambers into which dust, dirt, and oil sludge (6) Remove the upper half of the bearing.
collect. The only cleaning necessary is to remove the drain
plug from beneath the oil level indicator or bearing housing (7) Jack up the shaft a few mils to remove
as the case may be. After draining, seal the threads of the the weight of the rotor from the lower bearing surface.
drain plug with an oil sealing compound and refill the oil
reservoir. (8) Remove the split line screws from the oil
ring and remove the split parts.
Whenever the motor is disassembled for general cleaning,
the bearing housing may be washed out with a suitable (9) Rotate the lower half bearing around the
solvent. In washing the bearing housing the bearing and shaft and remove.
bearing housing assembly should be disassembled only to
the extent that is absolutely necessary. Dry the bearing b. Cleanliness is important when working with bearings.
lining and shaft with a film of oil before reassembling. Before reassembling a bearing, all bearing and machine
surfaces should be thoroughly cleaned with a suitable
3. Sleeve Bearing Replacement solvent. Examine all machined fits for burrs. Remove all oil-
sealing compound from sealing surfaces.
Extreme care is required in the Prior to actual reassembly, the following precautions should
disassembly of a bearing to prevent be observed:
(1) Inspect the bearing housing and related
nicking or burring of the bearing or
parts for foreign matter. Clean, if necessary.
machined surfaces. In addition, the surfaces of the (2) Inspect the journals and polish them
journal and the bearing must be protected from with crocus clothe if any scratches are detected. Do not
damage when exposed during the process of allow any metal dust to fall into the housing when polishing
disassembly. the journals.
(3) Spread a thin coat of oil over the journal
and bearing surfaces before reassembling.
Remove all bearing sensors prior to (4) The sealing surfaces of the bearing
disassembly of the bearing. should be coated with a sealing compound such as No. 3
Permatex.
(5) To replace the bearing, reverse the
a. The drive end and opposite drive end sleeve bearing disassembly procedure.
may be replaced by the following procedure:

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 GEI-M1036-B

VI. OPERATIONAL DIFFICULTIES

Some operating difficulties may occur, and their causes are given in Table 7 and should be corrected as soon as possible.

TROUBLE SHOOTING CHART

Table 7

Affected Parts Difficulty What to Check

Windings Overheating • Calibration of measuring instrument
• Excessive Current
• Unbalanced AC current
• Improper or restricted ventilation
• Excessive ambient temperature
• Short circuited coil or windings
• Dirty windings
• Unbalanced voltage
Bearings Overheating • Calibration of measuring instrument
• Misalignment
• Excessive end thrust or radial loading
• Shaft currents
• Excessive or insufficient grease
• Worn out or dirty grease
Motor Excessive Vibration • Unbalance
• Misalignment
• Improper or settled foundation
• Non-uniform air gap
• Rubbing parts
• Bent shaft
• Unbalanced stator current
• Damaged bearing
Insulation Low insulation resistance • Moisture, dirt, metal particles, oil, or other contaminants on
or insulation failure the insulated windings
• Wrong voltage
• Excessive temperature
• Voltage surges
• Mechanical damage
• Excessive vibration with resultant mechanical damage

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 GEI-M1036-B

VII. FAILURE VIII. REPAIR

WARNING: An extreme overload or If a motor is marked with IECEx or ATEX designation and
electrical failure may result in repairs are required, the motor must be repaired by
heating or arcing which can cause operators trained in the understanding of BS/EN 60079-1
the insulation to give off noxious and BS/EN 60079-15 standards. The motor has been
fumes. All power should be removed from the designed to meet the rigid requirements of these standards.
motor circuit as a precaution even though the Repair or alteration of the motor may result in the motor no
circuit has overload protection. Personnel should longer meeting the requirements of these standards. If
not approach the motor until adequate ventilation major repairs are undertaken (such as rewinding a stator),
of the area has purged the air of fumes. When proper facilities should be made available and suitable
precautions observed.
covers of a motor are removed after a failure, care
Recommended tightening torques for various parts is listed
should be observed to avoid breathing fumes from in Tables 8A, 8B, 8C and 8D below.
inside the motor. Preferably, time should be
allowed for the motor to cool before attempting WARNING: When burning off old
any examination or repair. insulation materials or when
welding near insulation during
WARNING: Water should not be rewinding, adequate ventilation must be provided
applied to any electrically energized to avoid exposing personnel to noxious fumes.
equipment because electric shock Combustion of exhaust must be complete and
could result in serious or fatal injury adequately vented to the outside atmosphere in
In case of fire, disconnect all power and use a compliance with acceptable standards.
carbon dioxide extinguisher to quench the flame.
Before operating any motor after a suspected Exposure of personnel to air-borne inorganic fibers
failure, it should be inspected for damage. must be avoided by adequate ventilation or by
wetting the remaining insulation components
following the burning of the organic materials.

IX. RENEWAL PARTS

The use of only GE Energy renewal parts is recommended.

When ordering, specify the model number and the serial
number of motor (complete nameplate data is desirable).
Specify quantity and describe the part.

For information and service, refer to the nearest GE Energy

Sales Office or a GE Energy Authorized Service Shop.

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 GEI-M1036-B

X. TIGHTENING TORQUE FOR METRIC HARDWARE

General Notes related to fasteners:

1. Medium carbon steel Metric fasteners are per ISO-898-1 & ISO-898-2.
2. Stainless steel Metric fasteners are per ISO-3506-1 & ISO-3506-2.
3. Threaded holes in parts for Metric fasteners are per ISO-965-1.

Table 8A: Tightening Torque Range

Medium Carbon Steel Metric Hardware Property class 8.8 (Unless specified in below table)
Frames 90 to 280

Screw/Bolt Size Torque Torque

Typical Application
Metric (Inch-lbs) (N-m)
M5 Only for Bearing cap 20 - 30 2.3 - 3.4
M6 Only for Bearing cap 40 - 60 4.5 - 6.8
M8 Only for Bearing cap 90 – 130 10 – 15
All parts except bearing cap
M6 80 - 120 9 – 14
and fan cover bolt
M8 All parts except bearing cap 180 - 270 20 – 30
M10 All parts except bearing cap 345 – 515 39 – 58
M12 All parts except bearing cap 670 – 1000 76 - 113
M16 All parts except bearing cap 1550 – 2330 175 – 263
M20 All parts except bearing cap 2900 -4350 330 - 490
Only for Fan cover bolt (Frame
M6-Gr10.9 100 - 145 11 – 16
IEC 90-180)

Table 8B: Tightening Torque Range

Stainless Steel Metric Hardware Property Class 50
Frames 90 to 280

Screw/Bolt Size Torque Torque

Typical Application
Metric (Inch-lbs) (N-m)
M5 Only for Bearing cap 20 - 30 2.3 - 3.4
M6 Only for Bearing cap 40 - 60 4.5 - 6.8
M8 Only for Bearing cap 90 – 130 10. - 15
M6 All parts except bearing cap 60 - 74 6.8 – 8.4
M8 All parts except bearing cap 130 - 168 15 – 19
M10 All parts except bearing cap 250 – 320 28 – 36
M12 All parts except bearing cap 500 – 620 56 – 70
M16 All parts except bearing cap 1120 – 1440 126 – 163
M20 All parts except bearing cap 2100 -2700 237 – 305

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 GEI-M1036-B

Table 8C: Tightening Torque Range

Medium Carbon Steel SAE Hardware Grade 5 (Unless specified in below table)
Frame 315

Torque Torque
Screw/Bolt Size Typical Application
(Inch-lbs) (N-m)
1/4 in (Low
Accessory Terminal Box Cover 72 – 96 8 – 11
Carbon Steel)
3/8 in Fan Cover Access Plate 276 – 396 31 – 45
3/8 in (Low
Main Terminal Box Cover 276 – 396 31 – 45
Carbon Steel)
3/8 in (Low
Terminal Box to Frame 276 – 396 31 – 45
Carbon Steel)
3/8 in Bearing cap 276 – 396 31 – 45
1/2 in Fan to Shaft 684 – 936 77 – 106
1/2 in Fan Cover to Frame 684 – 936 77 – 106
3/4 in Endshield to Frame 2400 – 3190 271 - 361

Table 8D: Tightening Torque Range for Stainless Steel SAE Hardware
Property Class 50
Frames 90 to 280

Torque Torque
Screw/Bolt Size Typical Application
(Inch-lbs) (N-m)
1/4 in (Low
Accessory Terminal Box Cover 44 – 62 5.5 – 7
Carbon Steel)
3/8 in Fan Cover Access Plate 190 – 230 22 – 26
3/8 in (Low
Main Terminal Box Cover 190 – 230 22 – 26
Carbon Steel)
3/8 in (Low
Terminal Box to Frame 190 – 230 22 – 26
Carbon Steel)
3/8 in Bearing cap 190 – 230 22 – 26
1/2 in Fan to Shaft 440 – 500 50 – 57
1/2 in Fan Cover to Frame 440 – 500 50 – 57
3/4 in Endshield to Frame 1300 – 1500 152 - 174

18
 GEI-M1036-B

19
 GEI-M1036-B

Typical 315/500 Frame TEFC Construction - Ball Bearing

Typical 315/500 Frame TEFC Construction - Sleeve Bearing

20
 GEI-M1036-B

XI. Lubrication Guide

(Excerpt from: GEK-72836E)

Table 9: Motor Lubrication Guide

Type of kW Lubrication Interval (Yrs.)

Service Typical Examples Range Horizontal Vertical
Easy Valves, door openers, portable floor 0.75 – 5.6 10 9
sanders, motor operating 7.5 – 29.8 7 3
infrequently (one hour per day) 37 – 75 4 1.5
146 – 261 3 9 months
298 – 596 1 ---
Standard Machine tools, air-conditioning 0.75 – 5.6 7 3
apparatus, conveyors (one or two 7.5 – 29.8 4 1
shafts), garage compressors, 37 – 75 1.5 6 months
refrigeration machinery, laundry 146 – 261 1 3 months
machinery, oil well pumps, water 298 – 596 6 months ---
pumps, woodworking machinery
Severe Motor for fans, MG- sets, etc., that 0.75 – 5.6 4 1.5
run 24 hours per day, 365 days per 7.5 – 29.8 1.5 6 months
year; coal and mining machinery; 37 – 75 9 months 3 months
motors subject to severe vibration; 146 – 261 6 months 1.5 months
steel mill machinery 298 – 596 3 months ---
Very Dirty, vibrating applications; where 0.75 – 5.6 9 months 6 months
Severe end of shaft is hot (pumps and fans); 7.5 – 29.8 4 months 3 months
high ambient temperature 37 – 75 4 months 2 months
146 – 261 3 months 1 month
298 – 596 2 months ---

Table 10: Number of Grease Gun Pumps

Number of Pumps Number of Pumps
Bearing Size on 16 Oz. Gun 24 Oz. Gun Bearing Size on 16 Oz. Gun 24 Oz. Gun
Motor Nameplate Motor
(Approx. 473 mL) (Approx. 710 mL) (Approx. 473 mL) (Approx. 710 mL)
Nameplate

6205 5 3 6312 40 27
6206 6 4 6314 50 35
6208 10 7 6315 65 45
6210 25 17 6316 60 40
6213 35 23 6318; NU 318 75 50
6220 58 39 6320; NU 320 95 65
6309 20 13 6321 153 102
6310 25 17 NU324 246 164

NOTE: A standard 10,000 PSI (68.950 kPa) 16 ounce (473 mL) grease gun delivers approximately 0.04
oz. (1.18 mL) of grease with each pump, and a 24 oz. (710 mL) gun delivers approximately 0.06 oz.
(1.77 mL) of grease. The number of pumps listed represents approximately 20% of the total grease
cavity volume in the end shield.

21