Tac4598 - 3350KW - Instruction Manual

TECO Instruction Manual
TECO
Horizontal Wound Rotor Induction Motors.
3350kW, 6 Pole, 6.6kV, 50Hz.

Motor Serial Number:
E078002
Customer: Outotec
Customer Order No: 111553
End User:
San Bartolome Silver.
Ball Mill
TECO Reference – TAC4598
Teco Electric & Machinery Co. Ltd.

Taipei, Taiwan.
Drawing Number
IM4598/1 Rev 00.
TAC4598 / 1 Rev 00 - Installation and Maintenance Manual
Project: San Bartolome Silver – Ball Mill Motor.
Client: Outotec
Table of Content
Chapter 1: Motor Description............................................................................................4
Chapter 2: Technical Data .................................................................................................5
Chapter 3: Installation and Commissioning.....................................................................6

3.1. INSPECTION UPON RECEIPT..................................................................6
3.2. STORAGE....................................................................................................6
3.3. INSTALLATION. ........................................................................................9
3.4. MOUNTING. ...................................................................................................9
3.5. COUPLING & ALIGNMENT. ..................................................................10
Chapter 4: Operating Instructions ..................................................................................13

4.1. EXAMINATION BEFORE START..........................................................13
4.2. STARTING OPERATION.........................................................................15
Chapter 5: Routine Maintenance ......................................................................................18

5.1. IMPORTANCE OF DAILY INSPECTION. .............................................18
5.2. POINTS TO NOTE WHEN STARTING...................................................18
5.3. TEMPERATURE RISE..............................................................................18
5.4. VIBRATION. .............................................................................................19
5.5. NOISE.........................................................................................................20
5.6. ODOUR. .....................................................................................................20
5.7. MEASUREMENT OF THREE PHASE CURRENT.................................21
5.8. MOTOR APPEARANCE...........................................................................21
Chapter 6: Periodic Maintenance....................................................................................22

6.1 REGULAR INSPECTION & MAINTENANCE.......................................22
6.2. CLEANING OF COILS, DRYING & VARNISHING TREATMENT. ...25
6.3. VARNISH...................................................................................................26
6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION
INSPECTION AFTER LONG STORAGE................................................27
6.5. RECORDS OF OPERATION AND MAINTENANCE. ...........................28
6.6. POINTS TO NOTE ON DISASSEMBLY................................................29
Teco Electric and Machinery Company 2

Manual Number: IM4598 / 1 Rev.00
Client: Outotec
Chapter 7: Bearings............................................................................................................30
7.1. MAINTENANCE OF ROLLING BEARING............................................30
7.2. NOISE OF BEARING................................................................................32
7.3. VIBRATION. .............................................................................................32
7.4. REGULAR INSPECTION. ........................................................................33
Chapter 8: SLIP RING MAINTENANCE .......................................................................34

8.1. MAINTENANCE OF MOTORIZED BRUSH-LIFTING & SHORT
CIRCUITING DEVICE..............................................................................34
8.2. CONSTRUCTION OF MECHANISM......................................................34
8.3 INSPECTION .............................................................................................39
8.4 MAINTENANCE OF MAIN PARTS........................................................39
8.5 LUBRICATION .........................................................................................40
8.6. INTERLOCK CONTROL CIRCUIT DIAGRAM OF MOTORIZED BRUSH
LIFTING MECHANISM. ..........................................................................41
8.7 YEARLY INSPECTION............................................................................41
8.8 BRUSH REPLACEMENT.........................................................................42
Chapter 9: Repair and Overhauling................................................................................43
Chapter 10: Troubleshooting. ............................................................................................44

10.1. FAULT FINDING AND RECOGNITION ................................................44
Appendix..............................................................................................................................48

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Chapter 1: Motor Description
These motors are a Teco Type AEDT 6.6kV/3Ph/50Hz totally enclosed air cooled wound
rotor induction type suitable for direct couple horizontal foot mount operation. The motors
are of fabricated steel construction with external and internal cooling fans and a top mount
air to air heat exchanger. The bearings are grease lubricated anti friction bearings.
Please refer to the Appendix for all motor dimensions and performance data.
SAFETY WARNING
The following instruction address the more common situations encountered
in motor installation, operation and maintenance. For the TECO warranty
to remain valid, the motor must be installed and operated in strict
accordance with the outline drawing, motor nameplate and these
instructions and must not be altered or modified in any unauthorized
manner.
During the installation & operation of motors in heavy industrial
applications there is a danger of live electrical parts and rotating parts.
Therefore to prevent injury and/or damage the basic planning work for
transport, assembly, installation & operation needs to be carried out by
authorized and competent personnel. Points in this manual that are boxed
and headed “ATTENTION!”(see below) should be observed as they
indicate possible danger to personnel and/or the potential of equipment
damage.
ATTENTION!

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Chapter 2: Technical Data

OUTPUT............................................................. 3350kW
TYPE…………………………………………….. AEDT
FRAME………………………………………….. 800A
SERIAL NOS……………………………………… E078002
MOUNTING…………………………………….. IM1001
POLES…………………………………………… 6
FULL LOAD SPEED…………………………… 993 rpm
VOLTAGE………………………………………. 6,600
PHASES…………………………………………. 3
FREQUENCY…………………………………… 50Hz
STARTING METHOD………………………….. Direct on Line + Secondary Resistance
INSULATION CLASS………………………….. “F”
FULL LOAD CURRENT………………………. 343.5 amps
ROTOR CURRENT…………………………….. 650amps
ROTOR VOLTS……….………….……………… 3035v
PULL OUT TORQUE…………………………… 295 of FLT
EFFICIENCY
FULL LOAD……………………………………… 96.6%
¾ LOAD…………………………………………… 95.9%
½ LOAD…………………………………………… 94.6%
POWER FACTOR
FULL LOAD……………………………………… 88.3%
¾ LOAD…………………………………………… 85.4%
½ LOAD…………………………………………… 78.2%

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Chapter 3: Installation and Commissioning
3.1. INSPECTION UPON RECEIPT.
Check the following points upon receipt:

3.1.1. Is the nameplate rating identical to your order?
3.1.2. Do dimensions and colour comply with your specification?
3.1.3. Are the nameplate ratings for the heater, temperature detector etc. identical with
what you ordered?
3.1.4. Is there any damage due to transportation?
3.1.5. Are all accessories in good order?
3.1.6. If there are any specific requirements, please check if they conform with your
specification.
3.2. STORAGE.
When storing motor, the following procedures should be undertaken.
3.2.1. Place.
a. It should be dry, well-ventilated and not subject to direct sunlight, dust or corrosive
gas.
b. It should not be located close to a boiler or freezer.
c. It should be entirely free from vibration and have easy access.
d. Motor should be stored on pallets to prevent moisture ingress.
3.2.2 During storage, the insulation resistance should be kept above the specified values
as follows:-
a. Stator: Above 50MΩ measured with 1000VDC megger.
b. If the motor has absorbed moisture as evidenced by low insulation resistance, it
must be dried with external heat until it is thoroughly dry and the value of insulation
resistance exceeds the minimum requirements.
c. Measurement of insulation resistance should be performed once every month.
d. Anti-condensation heaters should always be connected.

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3.2.3 ATTENTION!
Insulation resistance test should be performed before making high voltage test.
a. Use 1000VDC megger to measure insulation resistance.
i. Stator: Over 50MΩ between windings.
ii. Stator: Over 50MΩ between windings and earth.
b. High Voltage Test

i. This test can be undertaken only after the values of insulation resistance in item
5.2.2 are assured.
ii. The value of testing voltage is (1000 + 2E) X 0.8 where E: rated voltage.
3.2.4 Care should be taken to keep parts such as the fitting surface, key, shaft extension
and axial centre hole free of any foreign matter. Grease should also be generously
applied to stop rust.
3.2.5 The shaft should also be rotated by hand a few revolutions once per month.
3.2.6 If practical, a test run should be performed once every three months.
3.2.7 Clean the motor thoroughly, and replenish grease before the machine is put back to
operation.
3.2.8 The ventilation system should be covered to avoid the entry of foreign matter or
insects. It should be thoroughly cleaned before use.
ATTENTION!
An accident could occur if the hoisting hook or eye bolts the motor is overloaded. They are
suitable for the motor weights only. Do not lift motor and load with motor lifting lug.

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3.2.9 Make sure the hoisting hook is correctly connected to eye bolts or lugs of motors
before hoisting. Also note that parts such as fan cowl, bracket, heat exchanger etc.
which have their own lifting facilities can only carry their own weight. They should
not be used for lifting the entire motor.
3.2.10 Points to note when hoisting:-

a. Do not twist steel wires.
b. Make sure eye bolts have been firmly screwed in.
c. Keep the sling vertical when moving/lifting motor.
Fig. 1
ATTENTION!
Motor is fitted with lifting points (arrowed). These points are designed to lift motor
weight only. Do not use other hooks or handles to lift motor.
Please keep the sling vertical when lifting / moving the motor.
Fig. 2

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3.3. INSTALLATION.
3.3.1. Site conditions for motor installation:

Standard site conditions for installation of motors are as follows:
a. Ambient temperature: -100C~370C.
b. Humidity: Relative humidity below 95% RH for totally enclosed type, and below
80% RH for semi enclosed type.
c. Elevation: Below 4400 metres.
d. Should the installation be in an industrial zone, it should be free of explosive gases
and liquids.
e. Foundation should be strong so as not to induce vibration.
3.3.2. Ventilation and Space.

a. Installation should be well ventilated.
b. The area should be large enough to facilitate heat dissipation and maintenance.
3.3.3. Foundation.
a. Use rigid and solid soleplate or common bed as foundation.
3.3.4. Power Source.

a. Voltage and frequency variation of the power source should always be within the
tolerance specified or performance will be poor and motor will overheat.
b. Voltage variations should be within 10%.
3.4. MOUNTING.
3.4.1. An adequate motor support (which is the responsibility of others) is very important.
It must have sufficient rigidity to maintain alignment between the motor and its
driven load. Inadequate or improperly designed motor supporting structures can
lead to serious vibration and alignment problems.

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3.5. COUPLING & ALIGNMENT.
ATTENTION!
The motor must not be coupled to the driven equipment by means other than direct
connection. The motor is not suitable for belt connection.
3.5.1. Installation.
a. Field application of a coupling to the motor shaft should follow the procedures
recommended by the coupling manufacturer. Under no circumstances may the
motor shaft be modified as to configuration or
diameter without the approval of Teco Australia. The motor shaft extension must
not be subjected to either extreme heat or cold during coupling installation. If it is
necessary to exert axial force on the shaft, either continuously or intermittently,
during coupling application, it must be properly restrained axially to prevent bearing
damage.
3.5.2. Alignment.
ATTENTION!
Alignment is critical, as misalignment will cause premature wear of the bearings
and shaft. Points to note for coupling installation are listed as follows.
In aligning the motor (and rotor) axially with the driven equipment, consideration should be
given to the axial shaft expansion and increase in shaft centreline height due to thermal
effects.
Shaft height growth (change in shaft centerline elevation) for TEFC machines can be
calculated as follows,
Growth=(0.0005) X (motor foot to shaft centreline dimension [in mm])
3.5.3 It is desirable, in normal operation that the motor operates, so that no axial force is
exerted on the coupling.
The motor shaft and the driven shaft should be aligned within the following
tolerances in both angular and parallel alignment.

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Units in mm
TIR Solid Flexible
Total Indicated Runout Coupling coupling
Dimension C Medium, Low speed up to 2500 RPM 0.04 0.05
High speed over 2500 RPM 0.03 0.03
Dimension A Medium, Low speed up to 2500 RPM 0.03 0.04
High speed over 2500 RPM 0.03 0.03
Table 1
3.5.4 Angular misalignment is the amount by which the centrelines of the driver and
driven shaft are skewed. It can be measured using a dial indicator set up as shown in
fig 3. The couplings are rotated together through 360 degrees so that the indicator
does not measure runout of the coupling hub face. The shaft should be forced
against either the in or out extreme of their end float while being rotated.
Fig. 3 Fig. 4
3.5.5 Parallel misalignment is the amount by which the centrelines of the driver and the
driven shafts are out of parallel. It can be measured using the dial indicator as
shown in fig. 4. Again the couplings are rotated together through 360 degrees so
that the indicator does not measure runout of the coupling hub outside diameter.
3.5.6 After the motor has been properly aligned with the driven equipment and the hold
down bolts have been installed and tightened, at least two dowel pins should be
installed diagonally opposite motor feet.

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3.6 PROTECTION DEVICES
3.6.1 Protection devices such as Resistance Temperature Detectors terminate in auxiliary

terminal boxes located on the motor. Other devices may terminate in their own
enclosures elsewhere on the motor. Information can be obtained by referring to the
relevant drawing. Refer to Table 2 for temperature settings.
The motor is provided with internal space heaters. The incoming supply to the
heaters must be as shown on the heater nameplate.
DEVICE TYPE LOCATION ALARM TRIP

RTD PLATINIUM 100Ω @ 0OC WINDING 1300C 1400C
RTD PLATINIUM 100Ω @ 0OC DE & NDE BEARING 900C 950C
Table 2

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Chapter 4: Operating Instructions
4.1. EXAMINATION BEFORE START.
4.1.1. After motor is installed the following points should be noted:-

a. Check all wiring is correct.
b. Is the cable size adequate?
c. Are all connections tight and properly insulated?
d. Check the rating of fuses, starter/contactor are correct & operating normally.
e. Check motor is correctly earthed.
f. Make sure starter/switches are set in correct position.
g. Check heater circuit if fitted is de-energised when motor is in operation.
h. Check bearings are filled with the correct quantity and grade of grease.
4.1.2. Measurement of insulation resistance.

a. Rated voltage above 1000V, measure with 1000VDC megger.
b. In accordance with IEEE-43 clause 9.3 standards, refer to following formula:
R∞ ( Rated Voltage(V) +1 ) x 10(MΩ)

1000
c. If a new winding has low insulation resistance moisture is generally the problem. Drying
the winding through the proper application of heat will normally increase the insulation
resistance to an acceptable level. Following are several accepted methods for applying
heat to a winding:
i. The motor is equipped with space heaters, which can be energised to heat the winding.
ii. Direct current (as from a welder) can be passed through the winding. The total current
should not exceed approximately 50% of rated full load current. The motor has six leads
(3 mains and 3 neutrals) and the three phases should be connected into one series circuit.
iii. Heated air can be either blown directly into the motor or into a temporary enclosure
surrounding the motor. The source of heated air should preferably be electrical as
opposed to fuelled (such as kerosene) where a malfunction of the fuel burner could
result in carbon entering the motor. Caution must be exercised, when heating the motor

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with any source of heat other than self-contained space heaters, to raise the winding
temperature at a gradual rate to allow any entrapped moisture to vaporise and
escape without rupturing the insulation. The entire heating cycle should extend over
15-20 hours.
iv. Insulation resistance measurements can be made while the winding is being heated.
However, they must be corrected to 400C for evaluation since the actual insulation
resistance will decrease with increasing temperature. As an approximation for a new
winding, the insulation resistance will approximately halve for each 100C increase
in insulation temperature above the dew point temperature.
d. Should the resistance fail to attain the specified value even after drying, careful
examination should be undertaken to eliminate all other possible causes.
4.1.3. Power Supply

a. Is the capacity of the power supply adequate?
b. Do voltage and frequency of supply match with those on the nameplate?
c. Voltage variation should be confined to within ±10% of the rated value and the
phase to phase voltages should be balanced.
4.1.4 Bearing Lubrication

Grease Lubricated Type.
ATTENTION:
The bearings are properly lubricated with the correct grade and quantity
of grease at the factory.
After long storage the grease should be renewed. Please refer to section 7 .
a. Refer to the section “Maintenance of Bearing” for maintenance procedures and
grease type.
4.1.5. Other Points to note

a. Make sure the transmission system, including belts, screws, bolts, nuts and set pins
are in good condition.
b. Dismantle all locks which fasten the moveable parts of the motor during
transportation, and turn the shaft by hand (if practical) to check if it moves freely

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c. Check if there is any evidence of foreign matter inside the motor before starting.
d. Make sure the items above are examined. Test the motor with or without load.
Record and check according to “Maintenance” at 15 minute intervals during the
first three hours of operation. Then conduct regular examinations after longer
intervals.
4.2. STARTING OPERATION.
4.2.1. Starting Load.

The initial test involves running the motor without load. Unless specified, a motor is
designed to start with light load which is then gradually increased to full load as the
motor accelerates to full speed.
4.2.2. Starting.
a. Motor can be restarted if the initial start fails. Three attempts are permissible when
the motor is at ambient temperature. Two starts in succession are permitted when
motor is at normal running temperature.
b. Motor can be started a maximum of two evenly spaced starts per hour when it is at
normal running temperature.
c. Should an additional start be necessary beyond the conditions stated above, the
following restrictions should be noted:
i. Let the motor cool down for 60 minutes before a full load restart.
ii. Let the motor cool down for 30 minutes before a no load restart.
iii. Two inching starts can be regarded as one normal start.
d. If the motor rotor fails to start turning after two seconds, shut off power supply
immediately. This can result from:
i. Too low a voltage at the motor terminals.
ii. The load is too large for motor rating.

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iii. The load has seized mechanically.
iv. Electrical connections incorrect.
v. Single phase power has been applied.
vi. Any combination of the above.
Note – Investigate thoroughly and take corrective action before attempting a restart.
4.2.3. Direction of Rotation.

a. The motor is bi-directional.
b. If direction of rotation must be changed, cut power and wait until the motor stops,
then interchange any two of the three phase leads.
4.2.4. Power Supply. Voltage/Current.

a. Check if the voltage and frequency of the power supply are identical to that shown
on the nameplate.
b. Voltage variation should be confined to within ±10% of nameplate voltage, and the
three phase voltages should be balanced.
c. Check if the phase currents of the motor, without load, are within ±5% of the
average values.
4.2.5. Frequency.
Frequency variation should be confined to within ±5% of the nameplate frequency.
The aggregate variation of voltage and frequency should be confined to within
±10% of the absolute value of the rating.
4.2.6. Run Up Time.

ATTENTION!
Run Up time is longer for motors connected to a load with a large inertia. However,
if the run up time exceeds what is normal or there is abnormal noise, motor should
be examined to establish the cause before attempting a restart.

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4.3 CAUTION POINTS TO NOTE:
4.3.1 Bearings:
a. The motor is fitted with grease lubricated bearings. Following initial start up
bearing temperatures should be closely monitored. The rate of rise in bearing
temperature is more indicative of impending trouble than is the actual temperature.
b. When the rate of bearing temperature rise is less than 10C per half hour, the bearing
temperature is considered to be stabilised.
c. If the total bearing temperature exceeds 1000C, the motor should be shut down
immediately.
.
4.3.2 Vibration:
a. The ideal values for the motor are below 2.8mm/sec. If vibration exceeds these
levels, an examination of the motor should be made to determine the cause.
4.3.3 Starting:
a. If the motor acceleration time exceeds the ramp time, shut off the power
immediately.
Investigate thoroughly and take corrective action before attempting to restart.
b. It should be recognised that each start of an induction motor subjects the motor to
current greater than full load current with resulting heating of the stator and rotor
windings. Each start can produce more heat than is produced and dissipated by the
motor under full load.
c. The starting duty for which the motor is designed must not be exceeded if long
motor life is expected. Abnormally low terminal voltage and/or excessive load
torque during motor start up can cause lengthened acceleration times during which
rotor ventilation is reduced. This can cause rotor damage or lead to shortened rotor
life.

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Chapter 5: Routine Maintenance

5.1. IMPORTANCE OF DAILY INSPECTION.
5.1.1. Normally electric motors do not fail suddenly. It happens over time, and regular
inspection will detect a problem before a serious situation develops. If operators in
the plant are alert, faults can be detected early and action taken to eliminate trouble.
Daily inspection, can be performed without interrupting the factory’s normal

operation.
5.1.2 Do not overlook any minor irregularities. If necessary, stop the machine
immediately to check and repair. Essentially, inspections should be performed by
the operator daily. But a maintenance technician should also check the machine
once a week together with the operator.
5.2. POINTS TO NOTE WHEN STARTING.

5.2.1 Check power supply to see if voltage and frequency are normal.
5.2.2 Is starter set at starting position?
5.2.3 Are there sparks during start?
5.2.4 Is the motor accelerating normally?
5.3. TEMPERATURE RISE.

5.3.1 The temperature of a motor is often determined initially by touching the frame with
a human hand (see ATTENTION point page 19). Care must be exercised. If the
temperature is found higher than usual, use an alcohol thermometer to check it is
overheated. If it is, please check the following possibilities.
5.3.2 Main causes of high temperature:
a. Motor Conditions
i. Voltage and frequency variation of the power source is in excess of
tolerance.
ii. Unbalanced three phase voltage; open circuit or poor contact.
iii. Insufficient or excessive lubrication.
iv. Abnormal frequency of starts.
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v. Single-phasing due to open or short circuits.
vi. Damaged starter or improper operation.
vii. Blocked ventilation ducts.
viii. Motors cooling vents blocked.
b. Due to load or mechanical conditions:

i. Overload.
ii. Defective transmission coupling.
iii. Poor installation causing overload.
iv. High ambient temperature or radiant heat emitted from load or surroundings.
ATTENTION!
DO NOT MAKE FINAL CONCLUSION WITH A SENSE OF TOUCH.
Often the temperature of a motor is determined by touch. However, human hands
can only tolerate temperatures below 600C. Most motors safely operate at
temperatures greater than this, therefore the sense of touch should only apply for
preliminary examinations, final conclusions should be made by measuring with a
thermometer.
5.4. VIBRATION.
5.4.1 Main causes inducing vibration:
i. Unbalanced load.
i. Misalignment of couplings.
ii. Unbalanced belt-sheaves.
iii. Improper couplings with belts or chains.
iv. Unsuitable foundation or poor installation.
v. Unbalanced motor rotor.
vi. Serious abrasion to motor or load machine drive bearing.
vii. Defective brake coupling.
5.4.2 No matter what causes the vibration, if it is not eliminated, the following faults may
develop:
i. Bearing damage.
ii. Deformation of shaft.
iii. Loose parts or couplings.

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5.5. NOISE.
5.5.1 Points to note
i. Not all noise is the result of a fault or abnormality. For instance, wind
and slight electromagnetic sounds are perfectly normal. They will remain at
the same level no matter how long the motor is in operation. Generally the
louder the noise, the larger the vibration amplitude will be.
5.5.2 Bearing Sound.
i. Bearing noise is a guide to the condition of the motor bearings without
dismantling the motor.
ii. Normal bearing sound in general is continuous, not intermittent. The sound
may tend to increase with the age of the bearings, but its increase is gradual
and hardly noticeable by the ear.
iii. Abnormal bearing sound is intermittent, rarely continuous.
iv. Some motors will emit noise when unloaded or after greasing due to skating.
This is normal and temporary.
5.5.3. Abnormal bearing sound generally develops from the following
causes:
i. Foreign matter in grease.
ii. Scratches on the contact surface of the bearing.
iii. Rust on the contact surfaces of the bearing.
iv. Poor quality of grease.
v. Insufficient grease (the sound could be continuous).
5.5.4. Causes of abnormal electromagnetic sound:
i. Single phasing.
ii. Short circuit in windings.
iii. Unbalanced air gap resulted from serious bearing wear.
5.6. ODOUR.
5.6.1 Causes of motor odours:
i. Short circuit or over current causing overheating of varnish.
ii. Poor lubrication due to insufficient or contaminated grease.

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5.7. MEASUREMENT OF THREE PHASE CURRENT.

5.7.1 Causes & effects
When load current is above the rating on the nameplate, it means the motor may be
overloaded. However, the cause of over current is not confined to overloading, but
may be caused by poor coupling installation, transmission structure, excessive high
or low voltage, etc.
a. Causes of unbalanced three phase current and its effects
i. Unbalanced three phase voltage.

ii. Open circuit in power distribution lines.
iii. Poor switch contact.
iv.Open or short circuit in winding.
v. Open circuit at power transformer.
b. Effects:
i. Overheating of the windings causing fire or short circuit.
ii. Vibration of motor.
iii. Reduction of motor output torque.
c. Causes of wavering of ammeter indicator:

The characteristics of devices such as compressor or press are apt to cause
wavering of the indicator. Other causes are,
i. Poor contact of switches.
ii. Uneven mechanism.
iii. Unbalanced air gap due to serious bearing aberration.
iv.Broken conductors of squirrel cage rotor.
5.8. MOTOR APPEARANCE.

5.8.1 Reasons for Cleaning
a. Excessive dust or oil accumulation on the motor surface will reduce its cooling
efficiency.
b. Keeping the motor and equipment clean will improve appearance and longevity.

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Chapter 6: Periodic Maintenance
6.1 REGULAR INSPECTION & MAINTENANCE.

6.1.1 Major points in regular inspection and maintenance:
a. Routine inspection and maintenance are usually performed by operators with the
sense of touch, sight and smell, and if fitted, meters. But it is difficult to detect
trouble such as insulation deterioration etc. unless the motor is stopped and
checked.
b. Replacement of worn-out parts will increase longevity and prevent breakdown.
c. Regular inspection and maintenance is important in preventing breakdown and

lengthening service life.
d. Owing to the varied uses and environments motors are placed in, it is difficult to set
periods for regular inspection and maintenance. However, it has to be performed at
least once every 6 months. Generally, the inspection time is determined by the
following factors:
i. Ambient conditions.
ii. Start and stop frequency.
iii. Trouble with components affecting motor functions.
iv. Parts which wear (eg. bearings).
v. The important position of a motor in operation of a factory, mine etc. should be
fully recognised. Therefore, its condition should be monitored, especially when it
is operating in severe conditions.
6.1.2. Motor Windings.

a. For measurement of insulation resistance and tests to determine quality of insulation
resistance, please refer to measures stated in Section 4.1.2.
b. Inspection of coil end:
i. Grease and dust accumulated on coil may cause insulation deterioration and a
reduction in cooling efficiency.
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ii. Moisture.
iii. Discolouring. Overheating mainly causes this.
c. Wedge, is there any change from the original position?
d. Is the bind wire at coil end in correct position?
6.1.3. Bearings.
a. Please refer to sections 7.7 and 7.8 for bearing maintenance.
6.1.4. Cleaning the interior of the motor.

a. After a motor has been in operation for some time, accumulation of dust, carbon
powder and grease etc., on the inside is unavoidable, and can cause failure. The
inside should therefore, be regularly cleaned and examined to assure reliable
performance.
b. Points to note during cleaning:
i. If using compressed air or a blower.
• Compressed air should be free of moisture.
• Maintain air pressure at 4kg/cm2, since high pressure can cause
damage to coils.
ii. Vacuum – Recommended.
Vacuum cleaning can be used, both before and after other methods of cleaning, to
remove loose dirt and debris. It is a very effective way to remove loose surface
contamination from the winding. Vacuum cleaning tools should be non-metallic to
avoid any damage to the winding insulation.
iii. Wiping.
Surface contamination on the winding can be removed using a soft, lint-free cloth.
If the contamination is oily, the cloth can moistened (not dripping wet) with a safety
type petroleum solvent. In hazardous locations, a solvent such as inhibited methyl
chloroform may be used, but must be used sparingly and immediately removed.
While this solvent is non-flammable under ordinary conditions, it is toxic and
proper health and safety precautions should be followed while using it.

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ATTENTION!
Solvents of any type should never be used on windings provided with abrasion
protection. Abrasion protection is a grey, rubber-like coating applied to the winding
end-turns.
ATTENTION!
Adequate ventilation must always be provided in any area where solvents are being
used to avoid the danger of fire, explosion or health hazards. In confined areas (such
as pits), each operator should be provided with an air line respirator, a hose mask, or
self-contained breathing apparatus. Operators should wear goggles, aprons and
suitable gloves. Solvents and their vapours should never be exposed to open flames
or sparks and should always be stored in approved safety containers.
6.1.5. Clean the exterior of the motor.
i. ATTENTION!
The inlet air openings should not be allowed to accumulate any dirt, lint, etc. that
could restrict free air movement. Motors should never be cleaned or disturbed while
the motor is in operation.
ii. Totally enclosed air-to-water cooled motors require special consideration when
cleaning. The water cooler should be inspected and cleaned approximately every 24
months.
ATTENTION!
All of the tubes of the air-to-water heat exchanger should be cleaned using a
suitable tube brush having synthetic fibre bristles (no wire of any type).
6.1.6 Checking motor installation and coupling.

a. Installation:
i. Is foundation solid?
ii. Are all bolts and/or nuts tight and in good order?

Client: Outotec
b. Coupling:
i.Is coupling in good order?
ii.Are fasteners tight and in good order?
6.2. CLEANING OF COILS, DRYING & VARNISHING TREATMENT.
Age, constant heating and cooling and other factors may cause insulation
deterioration. Also, salt deposits or grease may lower insulation resistance.
Washing, drying and re-varnishing may be necessary if motor is flooded or showing
deterioration from age.
6.2.1 Cleaning:
a. If the coils are slightly contaminated, compressed air, cloth or a nylon brush can be
used to do the cleaning. However, when contamination is serious, thorough washing
has to be performed. The cleaning methods are as follows:
b. Cleaning with water:
i. This method is applicable to motors having been immersed in water or insulated
with no cotton yarn and paper materials.
ii. After washing, dry immediately.
iii. Cleaning with steam.
• If the motor has been immersed in sea-water or a chemical solution, clean with
steam after washing thoroughly.
• Steam pressure must be kept between 2 – 4 kg/cm2. High pressure may cause
insulation damage.
c. Steam temperature should be maintained between 500C – 800C.
d. After cleaning, dry immediately.
6.2.3 Drying Method.

a. Application:
i. Drying after cleaning.
ii. Motor has absorbed moisture.
b. Hot air method (using heater and blower).

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i. Parts to be dried are surrounded inside a steel plate leaving an inlet and an outlet for
hot air. Hot air will enter the inlet to dry parts (stator, rotor, etc.), and will leave via
the outlet carrying away moisture.
ii. The temperature within the area surrounded by the steel plate should be maintained
at 900C – 1000C.
c. Drying with infrared ray lamp:
i. Install the infrared ray lamp in a baking area surrounded with steel plate with
openings at the bottom.
ii. This method can cause partial overheating. So attention must be paid to the parts
heated and the temperature must be kept below 1000C.
d. Drying method with electric current:
i. The winding must have a minimum insulation resistance above 0.5MΩ measured
with 500VDC megger before using this method so as to avoid a short circuit.
ii. Lock the rotor (short the secondary winding of the wound rotor motor), apply rated
voltage of approximately 5% - 10% to the winding.
iii. Temperature control settings:
• Squirrel cage rotor induction motor: 700C – 800C for the stator.
e. Measurement of insulation resistance.
i. Measure the insulation resistance periodically during drying.
ii. At the initial stage of drying, insulation resistance may decline slightly. When it
returns to normal, the drying process is complete.
iii. When the current method is applied, be sure to turn off the power to measure
insulation resistance.
6.3. VARNISH.
i. Teco high voltage motors utilise vacuum pressure impregnation (VPI)
to encapsulate the winding. This ensures outstanding resistance to heat, moisture,
and chemicals and offers outstanding service life even under the most severe
environmental conditions.
ii. Should the system fail, the motor must be repaired by an experienced repair facility
with VPI equipment.

Client: Outotec
6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION
INSPECTION AFTER LONG STORAGE.
6.4.1 If the motor has been out of service in excess of three months, careful inspection
should be made before putting the motor into operation again.
6.4.2 When the motor is not in operation, the following precautionary measures should be
undertaken:
The place for storage should be dry and well-ventilated. If the motor has to be
placed at work site for some time, it should be completely covered and stored on
pallets to prevent dust and moisture contamination.
Inspection and maintenance prior to storage.
Please refer to “Regular Inspection and Maintenance” (Section 7.1).
6.4.3 Items to be examined prior to initial operation.

Cleaning:
Outside of motor.
Motor interior.
Measurement of insulation resistance:
Measurement of insulation resistance and standards to determine quality if
Insulation resistance, please refer to measures stated in Section 4.1.2. Measurement
of insulation resistance.
6.4.4 Drying: If the motor has absorbed moisture, it must be dried.
6.4.5 Examination of bearings.

Turn the motor shaft by hand (if practical) to see if it rotates smoothly and if there is
any unusual noise.
6.4.6 Replenishment of grease. (Refer to bearing maintenance Section 7).
6.4.7 Switches and starters.
Clean off dust and any foreign matter etc.
Check if the operation is normal.
Are the moving parts functioning smoothly?
Check if all bolts and nuts are tight and in good order.

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6.4.8 Examination and maintenance of standby motor.
Importance: The purpose of a standby motor is to substitute as an emergency motor
if the motor in operation breaks down.
It is important to always maintain the standby motor in top condition.
Maintenance should be performed strictly according to items and notes stated
previously.
6.5. RECORDS OF OPERATION AND MAINTENANCE.
6.5.1 Objective:
a. Fully understand the site conditions of the motor in operation and discover any
abnormalities in advance.
b. Prevent the neglect and act of maintenance.
c. Map pertinent maintenance plans after fully understanding the operation of motor.
d. Assess the life of parts to determine the quantity of spare parts to be kept.
e. To plan the number of spare motors and replace or repair the motors in operation
according to a schedule.
6.5.2 Records of operation.

a. A maintenance card in table form is acceptable.
b. Principle contents:
i. Serial number of machine
ii. Model
iii. Three phase voltage
iv. Three phase current
v. Temperature of a motor in operation
vi. Ambient temperature, humidity, weather, date and time
vii. Time of start and stop
viii. Special remarks
ix. Operator’s name

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6.6. POINTS TO NOTE ON DISASSEMBLY.

a. Disassemble according to the pre-set steps.
b. Necessary tools should be ready before disassembly.
c. Mark the disassembled parts so as to facilitate re-assembly.
d. Place parts, bolts and nuts etc, in a box to avoid misplacing.
e. Avoid damage to heavy parts during transportation.
f. Dust accumulation on coil-end, ducts etc., should be cleaned during disassembly.
g. Coat parts with light oil.
h. Note if there is any shaft deflection or bearing damage when re-assembling.
i. Disassemble and assemble bearing according to the bearing maintenance manual.

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Chapter 7: Bearings
7.1. MAINTENANCE OF ROLLING BEARING.

7.1.1. General.
Bearings play a very important role in motor performance. It is essential to keep
bearings in good order for the motor to operate at optimum performance. For this
reason, please maintain bearings according to this manual.
a. Grease replenishment is required, if the motor has been out of service for three
months or more.
b. Replenishment of grease is recommended when motor is running.
c. Clean the grease nipple and open the grease drain (if applicable) prior to greasing.
Restore after greasing.
d. A slight leakage of grease between the flinger and bearing cover is normal and
assists in totally sealing of bearing from ingress of dust and foreign matter.
7.1.2. Grease Lubricated Type.

Keeping the bearing lubricant in top condition is extremely important in the
maintenance of bearings. It is a prerequisite of extended bearing life to replenish
grease using the correct grade, quantity and time interval.
The reasons for grease replenishment are:
a. Assure the rolling contact surface has no metal to metal contact.
b. Form a lubrication membrane on the rolling contact surface to reduce noise.
c. Purge the motor of old and contaminated grease.
d. The presence of the correct grade and quantity of grease reduces corrosion, seals the
bearing and lowers vibration.
7.1.3. Grease replenishment period:

The life of grease varies depending on model, speed, temperature, operational
conditions etc. it is, therefore, impossible to determine the exact time interval for
replenishment. However, under normal conditions the greasing interval is shown in
Table 3.

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7.1.4. Type of grease:
SHELL Alvania grease R3 is standard for TECO motors except some special
models for which special grease will be shown on the nameplate. Please use
identical grease when servicing.
*Don’t mix different kinds of grease.
Bearing Number Lubrication Interval

Drive end NU238 1000 Hours
Non drive end NU230 & 6230 1000 Hours
Table 3.
Remarks:
a. Please refer to lubrication nameplate, if attached.
b. The data as shown in Table 1 are the maximum intervals under good
conditions, please consider site conditions.
7.1.5. Amount of grease replenishment:

Amount of grease replenishment depends on the type, size and construction and the
bearings. For the maximum quantity used in one replenishment of each bearing,
please refer to Table 4.
Bearing Number Replenishment Quantity
Drive end NU238 350 grams

Non drive end NU230 & 6230 360 grams
Table 4.
*Fill new grease until it displaces the old grease completely.
7.1.6. Key points to note in grease filling:

a. Filling method for grease exchange type bearing.
Use grease gun to pump grease through grease nipple into bearings. The old
contaminated grease is forced to drain out if discharge chute. Please
open the grease drain (if fitted) while greasing, and leave the motor running. Shut
outlet after the motor runs for 30 minutes.
The outlet is not visible on some models, grease should be pumped in until the
sound of bearing is normal. It is advisable to grease when the motor is operating as
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old grease is expelled more easily. Don’t grease motor when it is at a standstill. If
there is a draw-out device for grease, draw out the used grease after greasing.
7.1.7. Temperature of bearing.

Temperature of the bearing will rise slightly, but temporarily while greasing and
will return to normal a few minutes after greasing. Brief temperature variations are
of no concern.
7.1.8. Selection of grease gun.

There are two types of grease gun. High pressure lever type and hand press type. As
the hand press type has a lower force, grease replacement will take more time.
Greasing can be achieved quickly by using a lever type gun, however care should be
taken to adjust the pressure and rate to avoid excessive grease entry which may
enter the motor’s interior.
7.2. NOISE OF BEARING.

a. Normal noise.
Noise is congenital to movement of the bearing. Generally bearing noise that has a
continuous rhythm with no sudden change is normal.
b. Abnormal noise.
It is difficult to detect the early stages of bearing failure with the ear. It takes a lot of
experience and a sharp ear to detect abnormal noise. Any sudden change in bearing
noise should be investigated.
7.3. VIBRATION.
a. If the vibration of the bearing is unusually high, please test with vibroscope.
The vibration for these motors should be below 2.8mm/sec. If the values exceed this
figure, an investigation should be undertaken to find and rectify the problem.

Client: Outotec
7.4. REGULAR INSPECTION.
7.4.1. Regular monthly inspection.
a. Grease replenishment.
Please refer to Section 7.1.
7.4.2 Regular yearly inspection.

It is important to undertake regular inspection every year when the machine is out
of service for maintenance.
7.4.3 Inspection Notes.

a. Electric etching.
When there are dark spots on bearing surface or outside the face of outer ring and /
or inside face of bearing housing, please
check with microscope to see if they look like pock marks or fish scales which
could be the result of electric etching due to poor installation etc.
b. Precision of installation.
The degradation of the bearing may be the result of mis-alignment due to sinking
foundations etc, after the motor has been in use for a long period. Regularly check
and record the alignment of couplings, and make adjustments as necessary.
ATTENTION!
As the bearing is a high precision component, it is important to avoid ingress of dust
and foreign matter. A hammering or similar object must not be used during the
cleaning and installation of the bearing.

Client: Outotec
Chapter 8: SLIP RING MAINTENANCE
These motors are fitted with a motorized brush-lifting and slipring short circuiting
device. Regular maintenance is important for a long trouble free slipring life.
Abnormal sparking during start-up is the most common sign of incorrect slipring or
brush performance. Regular visual checks should be made of the sliprings and short
circuiting contacts for signs of burning or pitting.
Please read this section before operation.
8.1. MAINTENANCE OF MOTORIZED BRUSH-LIFTING & SHORT

CIRCUITING DEVICE.
8.1.1 Description:
The mechanism is a combined rotor short circuiting and brush-lifting device.
Once the motor has reached it’s operating speed and following the closing of the
installed LRS shorting contactor, the secondary winding of the machine is then
short circuited by the rotor short circuiting mechanism and then the carbon brushes
are lifted away from the contact surface of the slipring.
For details of the mechanism please refer to Figures #1, #2 & #3.
N.B. These motors should not be operated with the brushes in contact with the
sliprings for a prolonged period.
8.1.2 Installation:
Connect between the secondary external cables and terminals of the machine rotor
winding. Ensure that the limit switch terminals are connected in accordance with the
correct circuit diagram.
8.2. CONSTRUCTION OF MECHANISM.
8.2.1 Rotor Short Circuiting Mechanism.

(1) Thrust rollers make the short circuiting disc move forward in an axial direction
bringing the moving knife switches and the stationary knife switches together thus
short circuiting all three sliprings.
(2) Once this has been completed, the brush lifting wheels are then moved by the
shorting disc and continue on to lift the brushes off the slipring surface.
8.2.2 Automatically Operated Mechanism.

(1) The operating motor rotates the turning plate permitting the rocking handle to
move.
(2) Limit switches which control the operating motor limits the rotational position
of the turning plate.
(3) The operating motor is fitted with a brake and this restrains the rotational
position of the mechanism which is very important.
(4) The limit switches are actuated by cams respectively which control the rotation
of the operating motor.
(5) The mechanism can be manually operated for emergency use.

Client: Outotec
8.2.3. Manually Operated Brush Lifting Mechanism.
(1) Remove the outer cover.
(2) Release the nut and take out the geared half coupling.
(3) Before energizing the motor turn the handle in a CCW direction to the
“START” nameplate position.
(4) Once the motor is up to operational speed and the LRS shorting contactor has
closed, turn the handle in a CW direction to the “RUN” nameplate position.
(5) Restore the half coupling, tighten the nut and fit the outer cover.
(6) Do NOT operate the manual and motorized system simultaneously.
STARTING
RUNNING
DESCRIPTION OF TERMINAL NO.

1.2: TERMINALS OF STARTING
INTERLOCK
3.4: CHANGE OVER SWITCH
TERMINALS
5.6 ROTATION OF OPERATING
FIGURE #1 - MOTOR
7.8: RUNNUNG INDICATING
TERMINALS
000 DC MOTOR 542-1 HOLDER(1)

010 TURNING PIN ASSY 542-2 HOLDER(2)
114 COVER 560 BRUSH HOLDER ASSY
200-1 BEARING (UCFC205) 609 CONDUCT PLATE
200-2 BEARING (UCP205) 702-1 SHAFT SLEEVE(1)
234-1 BEARING STAND(1) 702-2 SHAFT SLEEVE(2)
234-2 BEARING STAND(2) 711-1 COUPLING(1)
301-1 SHAFT(1) 711-2 COUPLING(2)
301-2 SHAFT(2) 721-1 WORM GEAR(1)
501 BOX SEAT 721-2 WORM GEAR(2)
502 BOX COVER 722-1 WORM(1)
510 SLIP RING ASSY 722-2 WORM(2)
514 CONTACT SHEET 802 FIXED SEAT
515 CONTACT SEAT 817 SUPPORT
517 BRUSH SUPPORT 820-1 SUPPORT SEAT(1)
518 COLLECTING PLATE 820-2 SUPPORT SEAT(2)
521 SHORT RING 829 PROTUBERANT PLATE
525 TURNING PLATE ASSY 840 SPRING
527 TURNING WHEEL 850 LOCK NUT
531 CARBON BRUSH
537 BOX SEAT

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FIGURE #2

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FIGURE #3

Client: Outotec
TABLE #1 - REQUIREMENTS FOR OPERATION

The operation requirements are summarized in the following table:
Brush lifting Short-circuit
Starting position Reset to start-up Running position
mechanism operation
Open: Clearance Closed Open
The switches are
Short-circuit distance should be Under the condition that the switches has an
completely short-
switches maintained. effective contact area more than 1/3 of the
circuited.
total.
Brushes in contact Brushes are lifting. Brushes in contact
Brushes Brushes are lifted.
with slip ring. with slip ring.
Thrust rollers The ring and the thrust rollers are in contact
with each other only when the brush-lifter is
Positional
operated.
interrelation
between short-
circuit ring and
thrust roller
Short-circuit ring.
No.1
Starting
Closed Open Open Open
interlock
switch(NC)
No.2
Brush-lifting Closed Closed Closed Open
switch(NO)
Limit switches
No.3
Brush-
Open Closed Closed Closed
lowering
switch(NO)
No.4
Running Open Open Open Closed
switch(NC)
CCW CW
Operating motor
Rotation NO. (From operating (From operating motor NO.

motor shaft end) shaft end)
Brake Engaged Released Released Engaged

Client: Outotec
8.3 INSPECTION
8.3.1 After Motor Shutdown, Check the Following:
(1) All the short circuit switches are disengaged?
(2) All the carbon brushes are in contact with the slip ring surface?
(3) Thrust rollers work normally. They should be free from rattling?
(4) Secondary LRS is set at the starting position?
8.3.2 Before Operating the Motor:

In case the mechanism has been manually used, check the following:
(1) Mechanism is changed over so that can be automatically operated.
(a) Half coupling and nut are restored and the worm gear is connected to the
transmission shaft.
(b) Control circuits are energized.
(2) Automatic mechanism works normally in its operation while the motor is at
standstill.
(3) Check also if the brushes, short circuit switches and thrust rollers are in their
regular position for either engagement or disengagement respectively.
8.3.3 In Case the Thrust Rollers Have Been Replaced:

By manual operation, ascertain the following:
(1) There is no loose irregular contact between the thrust rollers and the short-circuit
ring.
(2) There are no loose joints after assembly.
8.3.4 Inspection After a Long Shutdown for Servicing:

(1) Make sure that all the components of the mechanism are free from dirt.
(2) Remove any dirt or contaminants from the sliding surface of the short circuiting
ring using emery paper. If any contaminants gets into the moving parts,
thoroughly clean them with dry compressed air. If air-dry solvent is used for
cleaning, remove any excess residual solvent using waste cloth. If defective
movement in the respective mechanism occurs, avoid operating the mechanism
with the operating motor. In such case, try to slightly hitting the ring in the axial
direction with a wooden hammer applying a force while manually turning the
motor rotor.
8.4 MAINTENANCE OF MAIN PARTS.
8.4.1 Short Circuit Ring Stopper:

(1) The stopper, which serves to position the short circuit ring axially, consists of a
steel ball, spring and a setscrew. The steel ball is positioned in the teeth grooves
of the shaft key with a suitable spring force.
(2) When the suitable force is not applied to the stopper due to wearing of the steel
ball or of the aged-spring, the ring is released in the axial direction and sometimes
comes into contact with the thrust rollers. In the case, ball bearings in the roller
may sometimes be damaged. In case the ring comes by further tightening the
setscrew so that the suitable force may be applied to the steel ball. When the steel
ball cannot be properly positioned, replace the steel ball or the spring.

Client: Outotec
8.4.2 Thrust Rollers:
(1) It is recommended that the thrust rollers be checked about once per year.
(2) Each roller has two ball bearings, which are replaceable. Replace the bearings
immediately when abnormality is observed in the roller.
(3) Rollers should be replaced when the surface was found seriously damaged or
deformed.
8.4.3 Short Circuit Knife Switches:

(1) Knife switches require normal contact surface and normal contact pressure.
(2) If damage is found on the contact surface, remove any burrs using a scraper and
emery paper so that the contact surface is smooth and burr free.
(3) When the contact face has been cleaned, wipe the surface with waste cloth using a
slight quantity of oil, and then clean it again with dry waste cloth.
(4) Deposited dirt or contaminants will impair the contact surface.
8.4.4 Brushes:
(1) If the brushes have been subjected to continuous contact with the slipring surface
inspect the following items:
(a) Slip ring surface and brushes for damage or wear.
(b) Brush props for deterioration of insulation.
(c) Brush holders for looseness.
(2) Worn brushes should be replaced in good time by new brushes of the same type.
For replacing the brushes, holders should not be slackened or displaced on the
brush props. After screwing on the new brushes, check that all brushes are lifted
at the same time from the slip rings by the brush lifting arm.
8.4.5 Limit Switches:

(1) It is recommended that the limit switches be checked about once per year.
(2) When abnormality is observed, adjustment or replacement of limit switches
should be undertaken.
8.5 LUBRICATION
The following steps should be undertaken every six months -
(1) Coat slightly with molybdenum-disulfide lubricant with inhibiting-corrosion (or
equal) on the sliding surface of the short circuiting ring and the motor shaft.
(2) Provide slightly with grease -
(a) On the positions where shown on the figures with circle G ( G ).
(b) Provide slightly with a low-electrical-resistance grease for electrical switching-
contacts application (such as ELECTRON G302 of Three Bond Co. or equal)
on the matching face of the short circuiting knife switches.

Client: Outotec
8.6. INTERLOCK CONTROL CIRCUIT DIAGRAM OF MOTORIZED BRUSH
LIFTING MECHANISM.
① ⑦ ③ ⑤
② ⑧ ④ ⑥
AC
Power
G R A B
(1) Main motor stopped and brushes in contact:

①② close, ③④ close.
⑤⑥ open, ⑦⑧ open.
Ⓖ Green light on.
Ⓡ Red light off.
A Brush lifter motor can be driven to lift brushes only.
(2) Main motor on operation and brush lifted:

①② open, ③④ open.
⑤⑥ close, ⑦⑧ close.
Ⓖ Green light off
Ⓡ Red light on.
B Brush lifter motor can be driven to push brushes to in-contact position.
(3) Contactor capacities of limit switches : AC 500V 5A.
8.7 YEARLY INSPECTION

Besides daily and monthly examination, an annual check should be made on the
following items: -
a. Roundness of slipring:
The roundness of slip-ring should be as follows :
Maximum RPM Allowable roundness u

4000 30
2000 60
≤1000 70
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If roundness exceeds above values, slipring must be machined.
8.8 BRUSH REPLACEMENT
Carbon brush should be replaced if it has worn to below ½ its original size.
8.8.1 Material of Brush.
The material used in the carbon brush affects the performance of the motor. The
materials selected by TECO are the most appropriate for this motor. The type of
material is listed on the nameplate of the motor. It is important to replace brushes
with correct grade. Replacement brush arms complete with brushes can be obtained
from TECO quoting motor type, output, pole speed and the motor Serial Number.
8.8.2. Fitting of New Brushes.
The fitting of a new brush should be carried out as follows :-
a. File the new brush until it assumes the appropriate contour of the slip-ring
which it contacts.
b. Place sand-paper (JIS R6252, No. 40…50) on the slip-ring with the abrasive
face of the paper against the brush. Rub the paper across the brush surface until
even contact is obtained (as shown in Fig. 2).
c. Repeat item b. with fine sand-paper (JIS R6252 No. 100…200) until the contact
surface between brush and slip-ring exceeds 80% of brush surface.
d. Finally, clean the contaminated slip-ring and brush with clean lint free cloth
vacuum cleaner (compressed air is not recommended and should not be used)

Client: Outotec
Chapter 9: Repair and Overhauling.
Considering the size and complex nature of this motor, any repairs or overhauling required
should only be undertaken by trained high voltage personnel using the correct equipment. .

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Chapter 10: Troubleshooting.
10.1. FAULT FINDING AND RECOGNITION
Kind of Fault Symptom Cause Remedy

Fail to Motionless Power-off Consult power
start without And soundless company
load Switch-off Switch-on
No fuse Install fuse
Broken wires Check wires and repair
Broken lead Check leads and repair
Faulty winding Check winding and
repair
Fuse blowing – Short circuit Check circuit
(Circuit Breaker Incorrect wiring Check wiring
trips off, slow Poor contact in circuit Check and repair
start with switches
electromagnetic Broken wiring Check and repair
noise Poor contact of starting Check and repair
switch
Incorrect connection of Check and repair
starting switch
Overload after Fuse blowing – Insufficient capacity of Replace fuse or
start Fail to restart fuse or breaker breaker
due to circuit Overload Lighten load
breaker tripping High load at low Check circuit capacity
voltage and reduce load

Client: Outotec

Overload after Start Overheating Overload or Lighten Load
of Motor Intermittent
Overload
Under-voltage Check circuit capacity
and power source
Over-voltage Check power source
Ventilation duct Remove the foreign
clogged matter in the duct
Ambient Lower ambient
temperature temperature
exceeds 450C
Friction between Repair
rotor and stator
Fuse blowing Install the specified
(Single phase fuse
rotating)
Poor contact of Check and repair
circuit switches
Poor contact of Check and repair
starting switch
Unbalanced three Check circuit or
phase voltage consult power
company
Speed falls Voltage drop Check circuit and
sharply power source
Sudden overload Check machine
Single phase Check circuit and
rotating repair
Switch overheat Insufficient Replace switch
capacity of switch
High load Lighten load

Client: Outotec

Overload after Start Bearing Overheat Misalignment Re-align
between motor and
load
Overspeed of Adjust bracket
bearing outer-ring
High bearing noise Replace damaged
bearing
Noise Electro-magnetic Occurrence from Check noise not
noise induced by first operation normal
electricity Sudden sharp noise Short circuit of
and smoking windings. Repair.
Bearing noise Not enough grease Add grease
Deterioration of Clean bearing and
grease re-grease
Excessive noise Replace the
damaged bearing
Mechanical noise Loose belt sheaf Adjust key and
caused by lock the screw
machinery Loose coupling Adjust the position
of couplings and
tighten
Loose screw Tighten screw
Fan rubbing Adjust fan position

Client: Outotec

Noise Mechanical noise Rubbing as a result Clean motor
caused by of ingress of interior and
machinery foreign matter ventilation ducts
Wind noise Noise induced by
air flowing through
ventilation ducts
Induced by Repair machine
conveyance
machine
Vibration Electro-magnetic Short circuit of Repair
vibration windings
Open circuit of Repair
rotor
Vibration Unbalanced rotor Repair
Unbalanced fan Repair
Mechanical Broken fan blade Replace fan
vibration Un-symmetrical Align central points
centres between
belt sheaf
Central points of Adjust the central
couplings do not lie points of couplings
on the same level on the same level
Improper mounting Lock the mounting
installation screw
Motor mounting Reinforce
bed is not strong mounting bed
Remarks:
i. Circuit switches: This includes knife switch, electromagnetic switch, fuse and other
connection switches etc.
ii. Starting switches: This includes Delta-Star starter, compensate starter, reactance
starter, resistor starter, starting controllers etc.
Client: Outotec
Appendix.
Outline Dimension Drawing..........................................................................................49
Main Terminal Box Drawing............... .........................................................................50
Secondary Terminal Box Drawing ...............................................................................51
RTD Terminal Box Drawing ........................................................................................52
Heater Terminal Box Drawing .....................................................................................53
Brush Lifting Terminal Box Drawing ..........................................................................54
Air Flow Switch terminal Box Drawing ……………………………………………..55
External Air Fan Motor Terminal Box Drawing ……………………………………..56


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Tac4598 - 3350KW - Instruction Manual

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Tac4598 - 3350KW - Instruction Manual

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TECO Instruction Manual

3350kW, 6 Pole, 6.6kV, 50Hz.

TECO Reference – TAC4598

Teco Electric & Machinery Co. Ltd.

Chapter 1: Motor Description............................................................................................4

Chapter 2: Technical Data .................................................................................................5

Chapter 3: Installation and Commissioning.....................................................................6

Chapter 4: Operating Instructions ..................................................................................13

Chapter 5: Routine Maintenance ......................................................................................18

Chapter 6: Periodic Maintenance....................................................................................22

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Chapter 8: SLIP RING MAINTENANCE .......................................................................34

Chapter 9: Repair and Overhauling................................................................................43

Chapter 10: Troubleshooting. ............................................................................................44

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Chapter 2: Technical Data

SERIAL NOS……………………………………… E078002

FULL LOAD SPEED…………………………… 993 rpm

STARTING METHOD………………………….. Direct on Line + Secondary Resistance

INSULATION CLASS………………………….. “F”

FULL LOAD CURRENT………………………. 343.5 amps

ROTOR CURRENT…………………………….. 650amps

ROTOR VOLTS……….………….……………… 3035v

PULL OUT TORQUE…………………………… 295 of FLT

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Chapter 3: Installation and Commissioning

3.1. INSPECTION UPON RECEIPT.

Check the following points upon receipt:

d. Anti-condensation heaters should always be connected.

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b. High Voltage Test

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3.2.10 Points to note when hoisting:-

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3.3.1. Site conditions for motor installation:

3.3.2. Ventilation and Space.

3.3.4. Power Source.

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3.6 PROTECTION DEVICES

3.6.1 Protection devices such as Resistance Temperature Detectors terminate in auxiliary

DEVICE TYPE LOCATION ALARM TRIP

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4.1.1. After motor is installed the following points should be noted:-

4.1.2. Measurement of insulation resistance.

R∞ ( Rated Voltage(V) +1 ) x 10(MΩ)

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4.1.3. Power Supply

4.1.4 Bearing Lubrication

4.1.5. Other Points to note

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4.2. STARTING OPERATION.

4.2.1. Starting Load.

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4.2.3. Direction of Rotation.

4.2.4. Power Supply. Voltage/Current.