Electric MotorsInstructions for use and maintenance

Les Ateliers del’Avre

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CONTENTS

Page

Introduction . . . . . . . . . . . . . . . . . . . 01

Note regardingelectro-magneticcompatibility . . . . . . . . . . . . . . . . . . . 01

1. General safety warnings . . . . . . . . . 021.1 Danger . . . . . . . . . . . . . . . . . . . . . . . . 02

2. Storage and installation . . . . . . . . . . 042.1 Control . . . . . . . . . . . . . . . . . . . . . . . . 042.2 Storage procedure . . . . . . . . . . . . . . . 042.3 Installation . . . . . . . . . . . . . . . . . . . . . 04

3. Putting into operation . . . . . . . . . . . 073.1 Initial Controls . . . . . . . . . . . . . . . . . . 073.2 Control of Design Data . . . . . . . . . . . . 073.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . 083.4 Conditions of Use . . . . . . . . . . . . . . . 08

4. Maintenance . . . . . . . . . . . . . . . . . . . 094.1 Inspection . . . . . . . . . . . . . . . . . . . . . . 094.2 Lubrication . . . . . . . . . . . . . . . . . . . . . 094.3 Dismantling and Reassembling

the Motor . . . . . . . . . . . . . . . . . . . . . . 104.4 Replacing the Bearings . . . . . . . . . . . 104.5 Overhauls and Repairs . . . . . . . . . . . 10

5. Troubleshooting . . . . . . . . . . . . . . . . 11

Table . . . . . . . . . . . . . . . . . . . . . . . . . 14

Number: UM-3.1

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IntroductionThe electrical machines referred to in theseinstructions are intended as components foruse in industrial areas. The information con-tained in this documentation is designed foruse by quali�ed personnel who are familiarwith the current rules and regulations in force.They are not intended to replace any installa-tion regulations issued for safety purposes.

In terms of Directive 89/392/CEE low voltagemotors are to be considered as componentsto be installed on machines. Commissioningis forbidden until the �nal product has beenchecked for conformity.

Note regarding electro-magneticcompatibilityLow voltage induction motors, i�nstalledcorrectly and connected to the power sup-ply, respect all immunity and emission lim-its as set out in the regulations relating toelectro-magnetic compatibility (EMC“Generic Standard” for industrial environ-ments).In the case of supply by means of electron-ic impulse (inverters, soft starters etc.), allveri�cations and any modi�cations neces-sary to ensure that emission and immunitylimits stated within the regulations arerespected, are the responsibility of theinstaller.

Motors to be used in dangerous areas aredesigned in compliance with European stan-dards, using protection methods that are suit-able for guaranteeing safety in areas subject torisk of �re and explosion.Where these motors are used improperly ormodi�ed their safety may be impaired. See the“Safety Instructions” manual.

Motors for classi�ed areas

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1. General safety warnings

Rotating electric machines are dangerous.Consequently:- improper use- removal of protection and disconnection of pro-

tection devices- lack o�nspection and maintenance can cause

serious harm.The personnel must be informed of any dangercaused by contact with:

- live parts

- rotating parts

- hot surfaces. In normal working conditionsthe motor exceeds 50 °C.

The safety manager must ensure and guarantee that:- the machine is moved, installed, put in service

inspected, maintained and repaired only by qual-i�ed personnel, who should have:

- speci�c technical training and experience- knowledge of technical standards and applicable

laws- knowledge of general safety regulations as well as

national, local and installation regulations- ability to recognize and avoid all possible dangers.Work on the electric machine should be carriedout upon authorization of the safety managerafter having ensured that:a) the motor has been disconnected from the power

supply and that no parts of the motor includingauxiliary parts are live

b) discharge of the capacitor has been done forsingle phase motors

c) the motor is completely stopped and there is nodanger of accidental restarting

d) the right precautions against faulty braking opera-tions have been taken for self-braking motors

where thermal protection with automatic resetis used care must be taken to ensure automaticrestart cannot occur. Since the electric machinereferred to is intended to be used in industrial areas,additional protective measures must be takenand guaranteed by the person who is in charge ofinstallation where more stringent protectivemeasures are needed.

Cemp has its own program for theAuthorized Repair Shops to select the facilities,provide training courses, issue certi�cates ofparticipation, release logo and recognition sign tothe quali�ed companies.Wherever it is possible we recommend the usersto address our network of Authorized Repairers,which updated list can be found at the"Organization" page of our website:www.cemp.eu <www.cemp.eu>

1.1 Danger

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Standards and speci�cations

INTERNATIONAL EU I GB F D

Title IEC CENELEC CEI-EN BS NFC DIN/VDE

Electrical rotating machines/rated operationand characteristic data

IEC 60034-1 EN 60034-1 CEI-EN 60034-1(CEI 2-3)

BS 4999-1BS 4999-69

NFC 51-100NFC 51-111

VDE 0530-1

Methods for determining losses andef�ciency of rotating electrical machinery

IEC 60034-2 EN 60034-2 CEI-EN 60034-2(CEI 2-6)

BS 4999-34 NFC 51-112 VDE 0530-2

Protection types of rotating electricalmachines

IEC 60034-5 EN 60034-5 CEI-EN 60034-5(CEI 2-16)

BS 4999-20 NFC 51-115 VDE 0530-5

Cooling methods of rotating electricalmachines

IEC 60034-6 EN 60034-6 CEI-EN 60034-6(CEI 2-7)

BS 4999-21 IEC 34-6 DIN IEC 34-6

Construction types of rotating electricalmachines

IEC 60034-7 EN 60034-7 CEI-EN 60034-7(CEI 2-14)

BS 4999-22 NFC 51-117 DIN IEC 34-7

Terminal markings and direction of rotationfor electrical machines

IEC 60034-8 EN 60034-8 CEI 2-8 BS 4999-3 NFC 51-118 VDE 0530-8

Noise emission, limit values IEC 60034-9 EN 60034-9 CEI-EN 60034-9(CEI 2-24)

BS 4999-51 NFC 51-119 VDE 0530-9

Start-up behaviour of squirrel-cage motorsat 50 Hz up to 660V

IEC 60034-12 EN 60034-12 CEI-EN 60034-12(CEI 2-15)

BS 4999-112 IEC 34-12 VDE 0530 12

Vibration severity of rotating electricalmachines

IEC 60034-14 EN 60034-14 CEI-EN 60034-14(CEI 2-23)

BS 4999-50 NFC 51-111 DIN ISO 2373

Fixing dimensions and outputs for IM B3 IEC 60072 EN 50347 IEC 60072 BS 4999-10 NFC 51-104/110 DIN 42673

Fixing dimensions and outputs for IM B5,IM B14

IEC 60072 EN 50347 IEC 60072 BS 4999-10 NFC 51-104/110 DIN 42677

Cylindrical shaft ends for electricalmachines

IEC 60072 EN 50347 IEC 60072 BS 4999-10 NFC 51-111 DIN 748-3

Electrical equipment for hazardous areasGeneral provisions

IEC 60079-0 EN 60079-0 (CEI 31-8) BS 5501-1 NFC 23-514 VDE 0171-1

Electrical equipment for hazardous areasFlame-proof enclosure “d”

IEC 60079-1 EN 60079-1 (CEI 31-1) BS 5501-5 NFC 23-518 VDE 0171-5

Electrical equipment for hazardous areasIncreased safety “e”

IEC 60079-7 EN 60079-7 (CEI 31-7) BS 5501-6 NFC 23-519 VDE 0171-6

Checking and maintenance of electricalsystems in places in danger of explosiondue to the presence of gas

IEC 60079-17 EN 60079-17 CEI EN 60079-17 ---- ---- ----

Electrical systems in places in danger ofexplosion due to the presence of gas

IEC 60079-14 EN 60079-14 CEI EN 60079-14 ---- ---- ----

Classi�cation of dangerous places due ofthe presence of gas

IEC 60079-10 EN 60079-10 CEI EN 60079-10 ---- ---- ----

Checking and maintenance of electricalsystems in places in danger of explosiondue to the presence of dust

IEC 61241-17 EN 61241-17 CEI EN 61241-17 ---- ---- ----

Electrical systems in places in danger ofexplosion due to the presence of dust

IEC 61241-14 EN 61241-14 CEI EN 61241-14 ---- ---- ----

Classi�cation of dangerous places due ofthe presence of dust

IEC 61241-10 EN 61241-10 CEI EN 61241-10 ---- ---- ----

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2. Storage and installation

The motors are shipped ready for installation. Uponreceipt remove packaging and turn the shaft tocheck the motor has not been damaged, also checkall physical aspects of the machine for damage. Inthe case where the machine is damaged an immedi-ate noti�cation must be given in writing by the store-man and the representative of the carrier to Cempwithin 3 days.

2.2.1 Storage conditionsIf the motors are not used immediately, they shouldbe stored in a clean, dry temperate environment freeof vibrations and protected from the weather. (Ifstored below -15 °C, and before starting, the motortemperature must be restored to the permissibleworking temperature range (i.e. -15 °C 40 °C). Inthis case, it is necessary to specify these partic-ular storage conditions during the ordering stageso that proper precautions can be taken duringbuilding and packaging.

2.2.2 Checking bearingsWhen the motors are stored properly, bearingsneed, no maintenance. However, it is a good idea toturn the shaft by hand every three months. After stor-age of over one year motors with unshielded bear-ings (usually such motors have a lubricator and beara lubrication plate), it is advisable to check the con-dition of the lubrication and motor components.

2.2.3 Checking insulationBefore installation check the motor windings usingthe appropriate instruments to ensure the conditionof the insulation between phases and betweenphase and earth are of the corrects resistance val-ues.

Do not touch the terminals during and imme-diately after measuring as they are live.

If the insulation resistance value is less than 10megaohm, or after storage in a damp environment,the motors must be dried in an oven for about 8hours by gradually bringing the temperature up to100 °C. To ensure that the dampness has beencompletely expelled, the motors must be disman-tled.

2.2.4 Operating precautionsAll operations listed above must be carried out byquali�ed personnel. In case of �ame-proof motors itis necessary:- to be very careful that the �ame-proof character-

istics are not altered- to have the procedure described in point 2.2.2

carried out by authorized repair shops- to be aware that dismantling or opening of the

motor during the warranty period without authori-zation of Cemp may invalidate the warranty.

Work on the electric machine must becarried out when the machine has stopped andbeen disconnected from the power supply (includ-ing auxiliary parts, such as anticondensationheaters).

2.3.1 LiftingBefore using the lifting rings make sure they havebeen tightened.

The lifting rings are big enough to bear theweight of a single motor, therefore they must notbe used to lift the equipment connected to themotor.

In environments where the temperature is below -20°C, these lifting rings should be used with caution asthey could break at low temperatures and causedamage.

2.3.2 Assembly of connecting deviceFitting pulley, coupling or gear to the motor shaftmust be carried out with care to ensure no damageis caused to the bearing. Remove the protectivepaint �nish from the shaft and smear with oil then �tthe device, heating before �tting if possible to ensurean easy �t.

Any component that is assembled on the motor shaftmust be accurately balanced.

The motor is normally balanced using a half key andthe letter H is punched on the shaft.

Fitments not balanced properly can cause anom-alous vibrations during operation that jeopodises theproper working of the motor and drastically reducesits life.

2.3 Installation2.2 Storage procedure

2.1 Control

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2.3.3 Direct connectionUse couplings that have been made and balancedperfectly align the motor shaft and the operatingmachine precisely. Inaccurate alignment maycause vibrations and damage to the bearings orbreakage of the shaft end.

2.3.4 Connection by means of pulleyCheck that alignment with the pulley of the operatingmachine has been carried out perfectly. The tensionof the belts must be enough to avoid slipping.Excessive tension of the belts causes harmful radialloads on the motor shaft and bearings, reducingtheir life.

It is advisable to assemble the motor on belt-ten-sioning slides in order to regulate tension of the beltsexactly.

Connection with belts must be such as to avoidaccumulation of static charges in the moving beltswhich could cause sparks.

2.3.5 Connection to power supplyUse cables with suf�cient section to bear the maxi-mum current absorbed by the motor, avoiding over-heating and/or drops in voltage. Connect the cablesto terminals by following the instructions on the plateor on the diagram included in the terminal box.Check that terminal nuts are tightened.

Connections to the terminals must be madein order to guarantee safe distances between liveuncovered parts.

Earthing is through the screw located inside theterminal box. Flame-proof motors are provided witha second earth stud located on the motor casingoutside the terminal box. Earths must be of suf�-cient size and installed according to relevantstandards. The area of contact of connections mustbe cleaned and protected against corrosion.

When the cable inlet is made by means of a cablegland, it must be chosen properly in relation to thetype of plant and type of cable used. The cable glandmust be tightened so that the retaining rings createthe pressure necessary to:

a) prevent transmission of mechanical stress to themotor terminals

b) ensure the mechanical (IP degree) protection ofthe terminal box.

For �ame-proof motors the cable inlet must bemade by complying with the regulations in point 13of the standard IEC 60079-1. Apertures not usedmust be closed in accordance with speci�cations inpoint 13 of the same standard.When reassembling the terminal cover, make surethat if there is a seal, and it is in the right place.Flame-proof motors do not have a seal so beforereassembling the terminal box it is necessary toreplace the layer of grease. The terminal box covermust be tightened to ensure it is properly sealed.

2.3.6 Connection of auxiliary parts(Table B)a) thermal protection

Check which type of protection is installed beforemaking connections. If thermistors (PTC) areused, it is necessary to utilize a suitable relay. Donot apply a tension over 6V during the thermistorcontinuity test.

b) anti-condensation heatersIf the motor is �tted with anti-condensationheaters, their power supply must be separatedfrom that of the motor, using the terminals housedin the terminal box.

WARNING: the supply of the heater is alwaysmonophase and the voltage is different from that ofthe motor. Check that it corresponds to the one indi-cated on the plate.

c) auxiliary ventilationConnect the supply of the auxiliary ventilationmotor separately from that of the main motor.

WARNING: use a device that allows startingand operation of the main motor only when the aux-iliary fan is working.

d) all the above-mentioned operations must be car-ried out by following the instructions shown on theconnection diagram provided with the motor.

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2.3.7 Fixing to the baseThe bolts �xing the motor to the base must be �ttedwith washers that they ensure adequate load distri-bution.

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3. Putting into operation

It is the responsibility of the installer to esta-blish the motor's �tness to be used in a certainplant, after analysing the characteristics of dangerexisting in the installation area with respect to cur-rent provisions of the law and to those issued forsafety purposes.

Before starting the motor it is important to checkthat:a) installation has been carried out properlyb) the bearings have not been damaged during

installationc) the motor base is sturdy enough and the founda-

tion bolts have been tightenedd) the design data corresponds to those given on the

plate and in the technical documentation

The electric motor is a component made tobe mechanically connected to another machine (sin-gle or part of a plant). Consequently, it is the task ofthe person responsible for the installation to gua-rantee that during operation there is an adequatedegree of protection for people or things againstthe danger of accidental contact with movingparts.

Make sure that the motor is suited for use in the wor-king conditions foreseen and check the following:

3.2.1 Environmental conditionsa) ambient temperature: standard closed motors

can operate between -15 °C and + 40 °C.Standard motors for classi�ed areas (Ex-d, Ex-de, Ex-e, Ex-n) can operate between -20 °Cand + 40 °C.

b) altitude:normal motors have been designed to work bet-ween 0 and 1.000 m above sea level

c) protection against the presence of harmful agentslike: sand, corrosive substances, dust and/or�bre, water, mechanical stress and vibrations

d) mechanical protection:installation inside or outside considering theharmful effects of the weather, the combinedeffect of temperature and humidity and the forma-tion of condensation

e) adequate space around the motor particularly onthe fan side to allow proper ventilation

f) motors mounted in the vertical, shaft down requirea protective cowl over the fan inlet

g) any danger of explosion or �re.

3.2.2 Working conditionsa) The motor must only be assembled and operated

in the construction form indicated on commercialand technical documentation (e.g. acknowledge-ment, delivery note, invoice, data sheet or draw-ing).

b) operation type:the motors are normally for S1 duty continuousoperation.

c) load type:carefully evaluate machines with high moments ofinertia and the relative starting times.

d) for motors intended for operation in hazardousareas (Ex-d or Ex-e) the motor type and tempera-ture classi�cation must comply with the area rat-ing.When there is an “X” on the plate near the cer-ti�cate number, it is necessary to check on thecerti�cate which additional conditions arerequired for proper working.

e) for self-braking motors see the special applica-tions envisaged in the relative catalogue.

3.2.3 Electrical characteristicsa) voltage and frequency should correspond to

those on the plateb) motor power should be adequate as required by

the loadc) power supply protection against overloads and/or

short circuits should be adequate for the nominalcurrent and starting current

d) for connection to control circuits follow the con-nection diagram supplied with motor (Table A)

Abnormal working conditions must alwaysbe de�ned when placing order to ensure that thesite conditions are not prejudicial to the proper oper-ation of the machine.

3.2.4 Other checks before commissioning• Check that the motor rotates in the correct direc-

tion, and that when the inverter is activated thespeed limit is not exceeded.

• Check that the motor is protected as prescribed inthe standards.

• Where using a star/delta starter, to avoid the riskof overloading make sure that the switch overfrom star to delta only takes place when the start-ing current has been adequately reduced.

• Check that any auxiliary accessories are working.

3.2 Control of Design Data

3.1 Initial Controls

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3.3.1 Earthing connectionBefore starting the motor ensure that the groundingcable is connected.

3.3.2 Motors with auxiliary ventilationFor motors with forced ventilation by means of exter-nal ventilation make sure that the motor starter isinterlocked with the, contactor of the external venti-lator to ensure the fan is operational.

3.3.3 Start upWhen all previous checks have been made satisfac-torily, the motor may be started. Unless otherwisestated all motors can be direct on line started. If youintend to start the motor by means of staticstarters, rheostats or the star-delta system, theymust be chosen and set property to avoid incor-rect functioning of the motor.

3.4.1 Working featuresOnce the motor has started it is necessary to checkthat during operations the working conditions remainwithin the limits envisaged, and that the followingdoes not occur:a) overloadb) dangerous rise in environmental temperaturec) excessive drop in voltage

Every time there is a change in the working con-ditions, it is necessary to check that the complete�tness of the motor has been maintained for thenew operating conditions.For example:- variation in working cycle- the function of the motor has altered- moving of the motor to a different environment

(from outside to inside)- moving of the motor from a low temperature envi-

ronment to one with a higher temperature.

3.4.2 Restarting after long restBefore starting the motor after a long resting period,repeat the controls described in section 2.2.2 and2.2.3.Where supplied, heater must not be energisedwhen the motor is running .

3.4.3 Anomalous conditionsThe motor must be used solely for applications itwas designed for and must be utilized and controlledcomplying with the precautionary standards.

If the machine shows anomalous workingcharacteristics (greater absorption, increase intemperature, noisiness, vibrations), inform thepersonnel in charge of maintenance immediately.

3.4.4 Protection against overloadingIn terms of the IEC 60079-14 standard all motors areto be protected using a suitable switch, such as onewith a delayed trip that is triggered by the current, aswell as protection in case of a phase going down.The protective device is to be set at the nominal cur-rent shown on the plate. This device must be cho-sen so that the motor is protected thermally shouldthe rotor jam.

The windings connected in delta must be protectedin such a way that the switches or relays are con-nected in series with the winding phase. Switchesare to be chosen and set taking the nominal phasecurrent, that is, 0,58 times the motor’s nominal cur-rent, as the base value.

3.4 Conditions of Use

3.3 Starting

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4. MaintenanceAny operation on the motor must be car-

ried out with the machine stopped and disconnectedfrom the power supply (including auxiliary circuits,especially the anticondensation heaters).Maintenance of the original characteristics ofelectric machines over time must be ensured bya schedule o�nspection, maintenance and set-ting up managed by quali�ed technicians. Thetype and frequency of maintenance depends onenvironmental and working conditions. As a rule, itis recommended that the �rst inspection is madeafter about 500 hours of operations (or, within 1year), while subsequent inspections should followthe schedules established for lubrication and gene-ral inspection.

4.1.1 Normal workingCheck that the motor works normally without ano-malous noise or vibrations. I�t does not, locate thecause of the anomaly.

4.1.2 Cleaning the surfaceMake sure that the ventilation is not obstructed.Clean the motor by removing any dust or �bre depo-sits from the �ns and from the fan cover.

4.1.3 Checking the supply and earthing cableCheck that the supply cable does not show signs ofwear and that the connections are tight. Make surethat the earth and supply cables are not damaged.

4.1.4 Transmission elementsCheck that the transmission elements are in perfectcondition and that the screws and nuts are tight.

4.1.5 Protection against waterWhen the motor is installed in a very damp environ-ment or is subject to drips of water, check regularlythat the seal and retaining rings and any protectivedevices work ef�ciently. Ensure that there are noin�ltrations inside the casing or terminal box.

4.1.6 Drainage devicesThe motors furnished with drainage devices shouldbe checked and cleaned regularly so that such devi-ces continue to work properly.

4.1.7 Thermal protectionMake sure that thermal protections have not cut outand have been set properly.

The right selection and setting of thermal pro-tections for Ex-e motors is essential to guarantee thetemperature class and safety against the danger ofexplosion.

4.1.8 Unauthorized modi�cationsCheck that no modi�cations have been madethat alter the electric and mechanical operationof the motor.

4.1.9 PaintingWhen the motor is installed in an environment wherethere are corrosive agents it is recommended topaint the motor itself to protect the outer surfacesfrom corrosion if necessary.

4.1.10 Reconditioning operationsEvery irregularity or fault found during inspectionmust be �xed immediately.

4.2.1 Permanently lubricated bearingsMotors with shielded or sealed bearings (type ZZ or2RS) do not require lubrication. Therefore, if usedproperly, they do not require maintenance.

4.2.2 Bearings with lubricatorMotors with unshielded bearings are furnished withlubricators. The interval time between lubricationsdepends on the type of grease, environmental tem-perature, (any excessive working temperature) andtype of operation the motor carries out. The table Cshows the intervals foreseen for 70 °C as a workingtemperature of the bearings in normal operatingconditions. It is recommended to use a good qualitylithium based grease with great penetration capacityand high dropping point like. (Eg. SKF LGHP 2, SKFLGWA 2). If the velocity is different from the onegiven in the table, the intervals must be modi�ed ininverse proportion.

Eg. bearing 6314 at 1.800 RPM

1 = 1500 x 3550 h = 2950 h1800

Regardless of working hours, the grease must berenewed after 1 or 2 years or during a completeoverhaul. When the motor is furnished with a lubri-cation plate, refer to the dates shown on it.

4.2 Lubrication

4.1 Inspection

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All operations must be carried out bearing inmind health and safety regulations.

4.3.1 Consulting the catalogueBefore working on the motor it is advisable to con-sult the relevant catalogue and have all the toolsready.

4.3.2 Disconnection from power supplyBefore proceeding with dismantling, the motor mustbe disconnected from the power supply. Make surethat the power is off disconnect supply cables andauxiliary cables when there are any.

4.3.3 Placing on workstandIn order to work on the motor satisfactorily it shouldbe removed from its mounting and placed on a workbench.

4.3.4 Dismantling procedureTake off the fan cover by removing the �xing screws.Using an extractor remove the cooling fan. Removethe end shields and withdraw the rotor being carefulnot to damage the windings. Precautions must betaken with �ameproof motors so that the spigotson the frame and the end shields are not dama-ged. When the motor is dismantling and before it isreassembled it is necessary to protect the variouscomponents (particularly the bearings and windings)to avoid damage caused by dust or knocks.

4.3.5 Additions for self-braking motorsFor dismantling of self-braking motors follow theinstructions shown in the relative catalogue.

4.4.1 Dismantling of bearingsa) Bearings interference �t to shaft: remove the bear-

ings with the aid of a suitable extractor.b) Bearings interference �t to end shield: heat end

shield to a temperature between 140 and 160 °Cand then remove the bearings with the aid of asuitable extractor.

In both cases, check that the respective housingshave not been damaged. Then proceed with �ttingthe new bearings, these should be identical to thosebeing replaced.

4.4.2 Fitting new bearingsa) Bearings interference �t to shaft: heat the bear-

ings to 120-130 °C and push them quickly ontothe shafts. If required, use a mallet and a brasssleeve, this must rest on the inner race of thebearing. Alternatively, i�t is not possible to heatthe bearings, we recommend using a press and asuitable sleeve which must rest on the inner raceof the bearing.

b) Bearings interference �t to end shield: heat theend shield to a maximum temperature of 140 °C,then position the bearing in its housing, pushing ituntil it rests against the snap ring (Seeger).

4.4.3 Checking the bearingsa) Bearings interference �t to shaft: after assembly

has been completed the inner ring of the bearingmust rest against the relevant shaft shoulder.

b) Bearings interference �t to end shield: afterassembly has been completed the inner ring ofthe bearing must rest against the snap ring(Seeger).

4.4.4 Reassembling the motorBefore reassembling, clean the internal parts of themotor carefully and check that the components havenot been damaged. Renew the layer of grease whereneeded on the abutting spigots and proceed withthe reassembling.

4.5.1 Spare partsWhen needed, all motor components should bereplaced by original spare parts. To request spareparts use the nomenclature shown in the cataloguesand always give:- motor type

- serial number

- year built

4.5.2 Personnel quali�cation - Authorized repairshopsOverhauls and repairs must be carried out bytrained personnel who guarantee restoration ofthe motor to its original conditions, we recom-mend that you contact an authorised repairagent. For further information please contact oursales department.

4.5 Overhauls and Repairs

4.4 Replacing the bearings

4.3 Dismantling and Reassemblingthe Motor

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5. TroubleshootingProblem Possible Cause Solution

The motor does not start Fuses damaged due to overloading Replace the fuses with similar onesof the correct size.

Opening of the overload switch Check and reset the switches.

Insufficient power available Check that the power required is asshown on the motor’s plate.

Connections incorrect Check that the connections are asshown in the motor’s connectiondiagram.

Mechanical fault Check that the motor and themachine to which it is coupled turnfreely.Check the bearings and lubricant.

Short circuit on the stator The motor must be rewound.

Defective rotor Check whether the bars and therings are broken, if necessaryreplace the rotor.

One phase is down Check the connection cables.

Incorrect application Check the sizing with themanufacturer.

Overload Reduce the load.

Voltage too low Make sure that the motor is poweredat the voltage shown on the plate.

The motor does not reach itsnominal speed or theacceleration times are toolong and/or absorptionexcessive

Voltage drop on the line Check the connections.Check that the cables are of thecorrect size.

Excessive inertia Check the size of the motor.

Defective rotor Check the state of the rotor cage.Replace the rotor if necessary.

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Problem Possible Cause Solution

The motor overheats whenworking under load

Overloaded Reduce the load.

Cooling �ns and/or fan coverblocked by dirt

Clear the ventilation slots to ensurea continuous �ow of air over themotor.

One phase on the motor may bedown

Check that all the cables areconnected tightly and correctly.

One phase on the winding is earthed Check the winding and remove thefault.

Phase voltages asymmetrical Check the power supply and motor-voltages and rebalance the loads.

Duty too great Use the motor for the serviceindicated on the plate.

Incorrect rotation Incorrect phase sequence Invert two phases.

Functioning of the protectivedevice

The motor may have one phasedown

Check the power supply.

Wrong connection Follow the wiring diagram for theconnections and the performancedata shown on the plate.

Overloaded Compare against the data on theplate and reduce the load ifnecessary.

Abnormal vibrations Motor not aligned Align the motor with the machine itcontrols.

Base weak Reinforce the base.Check the bolts.

Coupling or pulley not balanced Balance the device.

Coupled machine unbalanced Balance the coupled machine.

Defective bearings Replace the bearings.

Motor balanced differently fromthe coupling (half key – full key)

Balance the coupling using the halfkey.

Three-phase motor working with 1phase down

Check the phases and reinstate thethree-phase system.

Excessive play on the bearings Either:- replace the bearings- replace the shield- add a shim to the bearing seating.

Irregular noise Fan touching the fan cover Eliminate contact.

Defective bearings Replace the bearings.

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Problem Possible Cause Solution

Bearings overheating Motor �tted incorrectly Check that the motor is adequatefor the type of �tting.

Belts over-tensioned Reduce the belt tension.

Pulleys too far from the shaftshoulder

Move the pulley nearer to theshoulder on the motor shaft.

Pulley diameter too small Use a bigger pulley.

Alignment incorrect Correct the alignment of the motorand the machine coupled to it.

Insuf�cient grease Keep the correct amount oflubricant in the bearings.

Lubricant ineffective orcontaminated

Remove the old grease, washcontaminated bearings carefullyandgrease with new lubricant.

Excessive lubricant Reduce the amount o�ubricant.The bearing must not be more thanhalf full.

Bearing overloaded Check the alignment and anyradialand/or axial thrust.

Bearing balls or race damaged Replace the bearing.

14

EN

GLI

SH

Connecting diagrams - Table A

Connection for single speed motors:

Y-ConnectionU2W2 V2

W1V1U1

L1 L2 L3

U1

W1 V1

Connection-∆

V1W1

U1

U1

W2 U2 V2

V1 W1

L1 L2 L3

Number of pole: 2, 4, 6, 8 .... - Synchronous speed at 50 Hz: 3000, 1500, 1000, 750 ....

Two separate windings for two speed motors:

Number of pole: 2/6, 2/8, 4/6, 6/8 .... - Synchronous speed at 50 Hz: 3000/1000, 3000/750, 1500/1000, 1000/750 ....

Low Speed

U1

W2 U2 V2

L1 L2 L3

V1 W1

U1

W1 V1

High Speed

U1

W2 U2 V2

L1 L2 L3

V1 W1

W2

V2 U2

Dahlander system for two speed motors, constant torque:

High Speed

U2

W2

V2

W1

V1

U1 V1 W1U1

W2 U2 V2

L1 L2 L3

Low Speed

V1W1

U1

U2

V2 W2

U1

W2 U2 V2

L1 L2 L3

V1 W1

Number of pole: 2/4, 4/8 - Synchronous speed at 50 Hz: 3000/1500, 1500/750

Dahlander system for two speed motors, quadratic torque:

High Speed

V1 W1U1

W2 U2 V2

L1 L2 L3

W2

V2 U2

U1W1V1

Low Speed U1

W1 V1

U2V2

W2

U1

W2 U2 V2

L1 L2 L3

V1 W1

Number of pole: 2/4, 4/8 - Synchronous speed at 50 Hz: 3000/1500, 1500/750

Connection for single-phase and special motors.

For single-phase motors and motors with special connections, refer to the diagrams provided with the motor.

15

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Lubrication intervals in hours for unshielded bearings - Table C

Use the data shown on the motor’s plate (see also catalogue 14).

BearingsAmount of Grease“in Grammes”

3000RPM

1500RPM

1000RPM

750RPM

6 2056 2066 3066 2086 308

6 309 / NU 3096 310 / NU 3106 310 / NU 310

6 311NU 311

6 312 / NU 3126 312 / NU 3126 313 / NU 3136 313 / NU 3136 314 / NU 3146 316 / NU 316

73163 316

6 317 / NU 3173318/7318

3 318NU 318

6320/73203 320

NU 320

456.5

10101212151717121515182033335837417041519051

4500400037502800280055002000

-1800

9502100

-2000

--

2900900

--------

950085008000600060008250

-600045002350

-5000

-450041004300315031507800265026501400236023601180

100001000010000

90009000

11000-

700075003750

-7000

-560053004600560056007800500050002650450045002360

100001000010000100001000011000

-7000

100005000

-7000

-64006200480080008000

13600710071003550630063003350

Additional terminals marking (IEC60034-8) - Table B

Marking No. terminals Additional terminal for:TP1 - TP2 (warning)TP3 - TP4 (switch off)

22

Thermistor PTC (* )

R1 - R2 - R3 (I sensor)R4 - R5 - R6 (II sensor)R7 - R8 - R9 (III sensor)

333

Thermistor PT 100 with 3 wires

R11 - R12 - R13 (DE)R21 - R22 - R23 (NDE)

33

Thermistor PT 100 on bearing

TB1 - TB2 (warning)TB3 - TB4 (switch off)

22

Normally closed bi-metallic switch (** )

TB8 - TB9 (switch off) 2 Normally closed brake bi-metallic switch (** )TM1 - TM2 (warning)TM3 - TM4 (switch off)

22

Normally open bi-metallic switch (** )

HE1- HE2 2 Space heatersU1 - U2 2 Single phase forced ventilationU - V - W 2 Three phase forced ventilationcolours according manufacturer diagram 9 EncoderCA1 - CA2 2 CapacitorPE 1 Earth cable(* ) U rated = 6V - max 30V - (** ) U rated = 250V

Nel redigere questa documen-tazione è stata posta ognicura al �ne di assicurare lacorrettezza delle informazio-ni contenute.

Tuttavia, anche in conse-guenza della politica di con-tinuo sviluppo e migliora-mento della qualità del pro-dotto perseguita daCemp, lasocietà si riserva il diritto ela facoltà di apportare modi-�che di qualsiasi genere, inqualsiasi momento e senzapreavviso, sia a questo docu-mento sia ai propri prodotti.

Le descrizioni e le caratteri-stiche tecniche della presen-te pubblicazione non sonoquindi impegnative e i datiriportati non costituiscono,in nessun caso, impegnocontrattuale.

Every care has been taken toensure the accuracy of theinformation contained in thispublication.

Due to Cemp’spolicy of con-tinuous development andimprovement, the companyreserves the right to supplyproducts which may differslightly from those illustra-ted and described in thispublication.

Descriptions and technicalfeatures listed in this bro-chure may not be consideredas binding. Under no circum-stances should data in thispublication be considered asa contractual obligation.

Dans la préparation de cettedocumentation nous avonspris le soin d’y intégrer lesinformations les plus exactespossibles.

Néanmoins, compte tenu denotre politique de dévelop-pement et d’améliorationcontinue des produits, laSociété Cemp se réserve ledroit et la faculté d’apportertoute modi�cation sur ladocumentation et sur les pro-duits, à tout moment et sanspréavis.

Les descriptifs et les caracté-ristiques techniques conte-nus dans ce cataloguen’engagent pas la Société.Par conséquent, ces donnéesne constituent en aucun casun engagement contractuel.

Die Ausführungen und tech-nischen Eigenschaften, die indieser Broschüre angegebensind, dürfen nicht als ver-bindlich angesehen werden.

In keinem Fall können jedochdie in diesem Dokument auf-geführten technischen Datenals rechtlich verbindlichangesehen werden.

Cemp behält sich das Rechtvor, ohne Mitteilung, jeglicheAbweichungen und Änderun-gen jederzeit vorzunehmen,sowohl in diesem Dokumentals auch bei den Produkten,die hier beschrieben sind.

La presente documentación seha redactado de manera muyatenta para poder asegurarque las informaciones quecontiene son correctas.

No obstante, como consecuen-cia de la política de continuodesarrollo y mejora de la cali-dad del producto que Cemppone en práctica, la sociedadse reserva el derecho y lafacultad de modi�car en loque fuera necesario, en cual-quier momento y sin que paraello medie preaviso alguno,tanto este documento comosus productos.

Por lo tanto, las descripcionesy las características técnicasindicadas en el presente docu-mento no son vinculantes, ylos datos que contiene noconstituyen en ningún caso,vínculo contractual.

ATAV s.a.r.l.Zone Artisanale L’Arbre Saint Germain27320 Marcilly la CampagnesTel. +33 (0)2 32 58 03 81Fax. +33 (0)2 32 32 12 98

www.atav.com

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