3 Phase TM
3 Phase TM
3 Phase TM
Maintenance Handbook
On
3 Phase Traction Motor of
AC Electric Locomotives
TARGET GROUP: TRS Maintenance Staff
CAMTECH/E/2010/3Ph-TM/1.0
March 2010
QUALITY POLICY
All the major electrical working horses of Indian Railways such as WAP5, WAP7 and
WAG9 locomotives are equipped with three phase AC technology with asynchronous induction
motors. These motors are very robust, reliable, low weight and economical in maintenance
compared to DC traction motors. Since this technology is comparatively new, need for a handbook
on maintenance of three phase traction motors has been felt.
CAMTECH has prepared this handbook to cover all essential aspects of maintenance and
overhauling of three phase traction motors. It describes constructional features, various
maintenance schedules, overhauling procedure along with special tools, cleaning agents,
lubricants etc.
I am sure the book will prove to be very useful for our maintenance staff in electric loco
sheds and workshops maintaining three phase locomotives.
Improved technology in the field of power electronics, IGBTs and microprocessor based
digital control systems have made the application of three phase induction motor possible in
traction applications. The asynchronous three phase induction motor is more suitable for traction
applications because of its high power density, greater reliability, higher operational speed and
lower maintenance. With the commercial availability of light weight, compact and high power
single phase to 3 phase converter three phase locomotives are now an ideal choice by the
Railways all over the world.
Traction motor is one of the most important equipment of electric locomotives which
provides driving power to the wheel. Its proper upkeep and maintenance is necessary to ensure
good reliability and availability of electric locomotives in service.
This handbook on maintenance of three phase traction motor has been prepared by
CAMTECH with the objective of making our maintenance personnel aware of correct
maintenance and overhaul techniques to be adopted in field.
It is clarified that this handbook does not supersede any existing provisions laid down by
RDSO or Railway Board. The handbook is for guidance only and it is not a statutory document.
I am sincerely thankful to Bharat Heavy Electricals Ltd. for their valuable inputs. I am also
thankful to all field personnel who helped us in preparing this handbook.
Technological upgradation and learning is a continuous process. Hence feel free to write us
for any addition/modification in this handbook. We shall highly appreciate your contribution in
this direction.
Foreword iii
Preface iv
Contents v
Correction Slip ` vi
1. GENERAL DESCRIPTION 01
1.1 INTRODUCTION 01
1.2 PRINCIPLE OF VVVF CONTROL 02
1.3 ADVANTAGES OF THREE PHASE TRACTION MOTOR 02
1.4 TECHNICAL DATA 03
1.5 BEARING DETAILS 03
1.6 CONSTRUCTIONAL FEATURES 03
3. OVERHAULING 08
3.1 REMOVAL OF TRACTION MOTOR 08
3.2 PRE-INSPECTION 12
3.3 INCOMING TESTING 13
3.4 DISASSEMBLY OF PINION 13
3.5 DISASSEMBLY OF TRACTION MOTOR 14
3.6 OVERHAULING OF STATOR 14
3.7 OVERHAULING OF ROTOR 16
3.8 OVERHAULING OF END COVERS AND BEARINGS 17
3.9 ASSEMBLY OF TRACTION MOTOR 18
3.10 ASSEMBLY OF PINION 18
3.11 RUN TEST 19
3.12 INSTALLATION 20
3.13 INSPECTION AND TESTING PROFORMA FOR OVERHAULING OF
THREE PHASE TRACTION MOTOR 6 FXA 7059/ 6 FRA 6068 24
3.14 CLEANING AGENTS 29
3.15 ADMISSIBLE LUBRICATING GREASES 30
3.16 SPECIAL TOOLS FOR TRACTION MOTOR 30
3.17 LIST OF MUST CHANGE ITEMS 31
REFERENCES 32
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be numbered as follows :
CAMTECH/E/2010/3Ph-TM/C.S. # XX date---------
Where XX is the serial number of the concerned correction slip (starting from 01
onwards).
CHAPTER 1
GENERAL DESCRIPTION
1.1 INTRODUCTION
There has always been a strong desire to utilize the time proven robust squirrel
cage induction motor for traction application because of its high power density, greater
reliability, higher operational speed and lower maintenance. It has become possible
due to improved technology in the field of power electronics, IGBTs and
microprocessor based digital control system. The high power single phase to 3-phase
converter system not only meets the weight and space constraints peculiar to
locomotive design but also is economically viable. Consequently, 3-phase locomotive
are now found suitable for commercial use in Railways all over the world.
The size of 3 phase traction motor for the same output power is much less
compared to DC motor. Resulting in low power to weight ratio.
Regenerative braking is possible in 3 phase locomotives from the full speed till
dead stop. Resulting in energy saving and higher operational efficiency.
It operates at near unity power factor throughout the speed range except at very
low speeds.
Due to lesser weight of traction motor, the unsprung masses are low. This reduces
the track forces and consequently minimizes wear on rails and disturbance to track
geometry.
The rotational force from the traction motor is transmitted to the gear box by a
drive coupling. The opposite end of rotor shaft is enclosed by end plate.
Following are the main parts of traction motor and its support assembly:
1.6.1 Stator
There are two end plates one at drive end and other at non drive end. The
openings for air inlet and outlet are integrated in the end plates. The plug in cartridge
for the rotary speed transmitter is fitted on the non drive end plate.
1.6.3 Rotor
The rotor is supported and guided at both ends on two grease lubricated
cylindrical roller bearings. Radial non contacting seals are provided to protect the
bearings from the loss of grease and penetration of dirt.
1.6.7 Pinion
CHAPTER 2
Following maintenance schedules shall be followed for traction motors type 6FRA
6068 & 6FXA 7059 as per RDSO letter no. EL/ 3.1.35/ 16 dtd. 30.03.2007.
IA 90 days 90 days
2.1 TI SCHEDULE
Examine all traction motors for signs of damage caused by ballast. Check air
outlets are not obstructed in any way.
Check traction power cables, speed sensor and temperature sensor cables are not
chafed or damaged in any way.
Check the condition of bearing by seeing the grease, which comes out from grease
inlet. Check the condition of grease too.
Check the condition of spheriblocks. Replace if required.
Measure inductance at TM power cable terminals of SR-1 and SR-2.
Check end shield bolts tightness.
Visually check TM support plate lugs for any damage/ crack.
Attend logbook/ PPIO bookings if any.
2.2 IA / IB SCHEDULE
2.3 IC SCHEDULE
Before greasing, open NDE speed sensor cover. Take grease sample for checking
ferrous content.
Check the condition of speed pulse generator unit on traction motor (NDE) for
any grease ingress.
Lubricate TM bearing with specified grease ( Kluber Isoflex Topaz L 152 ) DE-
50 storke ( 150 gms), NDE- 25 storkes ( 75 gms )
Check the suspension tube bearing grease (NDE) and do the greasing.
Open TM junction box at TM side and check the tightness of connection and
water ingress.
Check the condition of DE side stator winding for any abnormality from DE side
net.
CHAPTER 3
OVERHAULING
Overhauling of traction motor shall be carried out during every IOH/ POH.
Place and secure a dummy plate over the cooling air inlets on the traction motor
to avoid foreign particles and debris entering the traction motor and causing
damage to the motor internals.
pict4.jpg
pict5.jpg
pict6.jpg
pict7.jpg
Remove screws (5) and spring washers (6) securing the non-drive end bearing
cover (4) to the traction motor (7).
Remove the bearing cover (4). Pay attention to the pulse transmitter ring (3).
Remove screws (2) securing the pulse transmitter ring (3) to the support (1).
Remove the pulse transmitter ring (3).
1 2 3 4 5
Remove the screws (2) and spring washers (1) securing the pulse transmitter ring
support (3).
Remove the pulse transmitter ring support (3).
Remove the screws (6) and spring washers (5) securing the thrust collar (4).
Remove the thrust collar (4).
pict10.jpg
Inspect the condition of the traction motor mounting points on the bogie frame.
Inspect the condition of all cables. Ensure all cables and cable insulation is in
good condition and free from wear, cracks or other damage. If necessary, replace
any damaged or suspect cabling.
Ensure all cable tangs, plugs and sockets are in good condition and free from
oxidation, wear, cracks or other damage.
pict0.jpg
Visually inspect the support arm for cracks or damage. Pay particular attention to
the eye and traction motor mounting flange.
Measure the inside diameter of the eye bore (x). If greater than the specified,
replace the support arm.
Remove any burrs from the eye or mounting flange using a suitable honing stone.
Test the support arm for damage using a non-destructive method and replace if
required.
Check the distance between shaft face and pinion teeth back face (Advancement).
Clean pinion inside hole by Kerosene oil.
Provide a wooden lever across the pinion teeth and secure the lever against
turning.
Connect the SKF pressure pump and fit the special plug into the pinion.
Screw the special screw M24 into the shaft by using the pressure bearing. A
clearance of approx. 0.5 mm is required between pressure bearing and pinion face.
Increase the pressure of the pressure pump up to 130 MPa and maintain it for 15
minutes.
Increase the pressure further to 150 MPa and maintain it for 15 minutes.
Increase the pressure further to 180 MPa and wait until a ring of oil is visible at the
pinion shaft end towards the teeth. Now the pinion is free.
This pressure can be increased up to 200 MPa, if necessary.
Increase the pressure steadily and loosing the screw M24 at same time, until the
pressure collapsed and the pinion is totally released.
Disconnect the special plug and remove the wooden lever.
Remove the pinion.
Check the insulation resistance between phase and earth with 2.5 kV megger. It
should be min. 2.18 M Ohms.
Check visually the stator body, core and windings for any damage and flashing.
Check the tightness of each phase cable connection in terminal box.
Heat the stator in oven at 120C for 2 Hrs. and remove loose dust by vacuum
cleaner.
Check the insulation resistance between phase and earth with 2.5kV megger after
dry cleaning of stator. It should be min. 6.36 M ohm for 6FRA 6068 & 3.18 M
ohm for 6FXA 7059.
Spray liquid Xylol on stator inside out side, coil, core and terminal box etc. and
allow it to act for 5 to 10 minutes.
Again spray liquid Xylol.
Clean inside by nylon brush and outside by wire brush.
Blow the stator thoroughly with dry compressed air from inside and out side.
Repeat the cleaning process, if required.
Wipe the stator by calico cloth inside and out side.
Spray the liquid Xylol by air or by brush to out side rotor cage and in side hole etc.
Allow it to act for 5 to 10 minutes.
Clean racers by petrol.
Rub the nylon brush on cavities & holes. Blow the rotor thoroughly with dry
compressed air to remove dust/ dirt from core & holes.
Repeat the cleaning process, if required.
Wipe the rotor & racer by calico cloth.
3.8.1 Cleaning
M6 - 9.5 Nm
M8 - 23 Nm
M10 - 46 Nm
M12 - 80 Nm
M14 - 125 Nm
M16 - 195 Nm
M18 - 270 Nm
M20 - 380 Nm
3.12 INSTALLATION
support arm.
Apply a thin film of machine oil to
the spheriblock collar.
Position the support arm (3) in a
suitable press (1 , 4).
Support the eye using a suitable steel
tube (4). Ensure the tube (4) will not
interfere with the spheriblock (2)
during installation.
Position a suitable mandrel (1),
slightly smaller than the outer
diameter of the collar, over the spheriblock (2). Check that the mandrel (1) is
square with the yoke on the press and contacts around the entire perimeter of the
spheriblock collar.
Ensure the spheriblock (2) is square with the eye before pressing.
Press the spheri-block (2) into the eye until the face is flush.
pict17.jpg
Connect the three UIC plugs to the sockets, and then secure the signal cables (9)
in the clamp (8).
Install the access cover (7) beneath cable clamp (8) for the signal cables (9).
pict25.jpg
2.6 Check visually the winding for any damage after No damage
cleaning.
2.7 Check the winding resistance between phases with
Wheatstone bridge or multimeter at room
temperature.
a. Phase U and V
Record
b. Phase V and V
Record
c. Phase U and W
Record
2.8 Measure the diameter at core portion 380 mm for
(If any repairing is done for coils of stator) 6FRA 6068
510 mm for
6FXA 7059
2.9 Bake the stator in oven at 120 deg C for 24 hrs. Done
Check the winding resistance between phases with
Wheatstone bridge or multimeter at 120 deg C.
a. Phase U and V Record
b. Phase V and W Record
c. Phase U and W Record
Only cleaning agents free from Halogens may be used to clean the traction
motors. To prevent deterioration of silicone rubber components in the traction motor,
the hydrocarbon content of any cleaning solvents must not exceed 30%.
W: P3-KF special
6.5 kg/m3 water
R: P3-t225
7.5 kg/ m3 water
Henkel & Co. AG CH-4133 Pratte)n W: P3-Saxin
25 kg/ m3 water
R: P3-VR-740-N-
5 kg/ m3 water
20
Fa.Cetema
ljsselstraat 41
Cetemal 10 kg/ m3 water
NL-Oss
Postbus 19
The following greases are recommended for the roller bearings in traction
motors. Suitable greases of the lithium and mineral oil type are listed below. Only one
brand of grease should be used to lubricate the traction motor bearings.
Esso Beacon EP2
SKFLGMT2
SKFLGEP2
Mobilgrease 22
Mobilux EP2
Optimol Longtime PD2
Exxon Ronex MP
Exxon Unirex EP2
Exxon Unirex N2
Exxon Lidok EP2
BP Energrease LS-EP2
Shell Calithia EPT2
Suitable greases of the synthetic basic oil type are listed below. Different
brands and types of synthetic greases must not be mixed.
KlUber lsoflex Topas Li 52
KiUber lsoflex Topas NCA52
Synthetic and lithium/ mineral oil based greases must not be mixed.
1. Tool for WAG9/ WAP7 pinion mounting & extraction with high pressure (2500
bar) pump and jack.
2. Induction Heater (40kVA) for different sizes of bearing racers & labyrinth rings
for traction motor (cylindrical roller bearing NU2236E/ C4, NJ320, HJ320 &
NU224, NJ219, HJ219).
3. Pinion push-pull rod.
4. Ring Gauge
5. Shaft Gauge (plug gauge)
6. L nozzle set
7. Nozzle
8. Filler Gauge (0.5 mm to 10 mm)
9. Disc Micrometer (75 mm to 100 mm)
10. Lifting Chain (04 hooks)
3.17.1 Spheriblock
5. TM pinion (WAP7).
7. TM bellows.
REFERENCES
4. Field study and Literature collected from various electric loco sheds/
workshops.
OUR OBJECTIVE