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—INSTALLATION, OPERATION, MAINTENANCE AND SAFETY MANUAL
Low voltage motors
Installation, operation,
maintenance and safety manual
34 3GZF500730-85 REV H EN 05-2022
35
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4 Motor weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Motors with other than deep groove ball bearings . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Insulation resistance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Balancing and fitting coupling halves and pulleys . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6 Mounting and alignment of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.7 Radial forces and belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.8 Motors with drain plugs for condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.9 Cabling and electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.9.1 Connections for different starting methods . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.9.2 Connections of auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.10 Terminals and direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Low voltage motors in variable speed operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2 Winding insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2.1 Selection of winding insulation for ABB converters . . . . . . . . . . . . . . . . . . . . . . 45
6.2.2 Selection of winding insulation with all other converters . . . . . . . . . . . . . . . . . . 45
6.3 Thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Bearing currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.1 Elimination of bearing currents with ABB converters . . . . . . . . . . . . . . . . . . . . .46
6.4.2 Elimination of bearing currents with all other converters . . . . . . . . . . . . . . . . . . .46
6.5 Cabling, grounding and EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6 Operating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7 Motors in variable speed applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7.2 Motor loadability with AC_8_ _ – Series of converters with DTC control . . . . . . . . . .47
6.7.3 Motor loadability with AC_5_ _ – series of converter . . . . . . . . . . . . . . . . . . . . . .48
6.7.4 Motor loadability with other voltage source PWM-type converters . . . . . . . . . . . . .48
6.7.5 Short time overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.8 Rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.9 Commissioning the variable speed application . . . . . . . . . . . . . . . . . . . . . . . . . . 48
—
Contents
3GZF500730-85 REV H EN 05-2022
36 3GZF500730-85 REV H EN 05-2022
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1.1 Standby motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.1 Motors with permanently greased bearings . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.2.2 Motors with regreasable bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.2.3 Lubrication intervals and amounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2.4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8 After Sales Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Dismantling, re-assembly and rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9 Environmental requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
37
—
1 Introduction
3GZF500730-85 REV H EN 05-2022
The conformity of the end product according to
Directive 2006/42/EC (Machinery) has to be
established by the commissioning party
when the motor is fitted to the machinery.
These instructions are valid for the following
ABB electrical machine types, in both motor
and generator operation:
• series MT*, MXMA,
• series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*,
M2C*/M3C*, M2F*/M3F*, M2L*/M3L*, M2M*/
M3M*, M2Q*, M2R*/M3R*, M2V*/M3V*
• in IEC frame sizes 56-500
• in NEMA frame sizes 58*, 50**
There is a separate manual for e.g. Ex motors
‘Low voltage motors for explosive atmospheres:
Installation, operation and maintenance and
safety manual (3GZF500730-47).
Additional information is required for some
machine types due to special application
and/or design considerations.
Additional manual is available for the
following motors:
• roller table motors
• water cooled motors
• smoke extraction motors
• brake motors
• motors for high ambient temperatures
• motors in marine applications for mounting
on open deck
• of ships or offshore units
1.1 Declaration of Conformity
1.2 Validity
These instructions must be followed to ensure safe and proper installation, operation and
maintenance of the motor. They should be brought to the attention of anyone who installs,
operates or maintains the motor or associated equipment. The motor is intended for
installation and use by qualified personnel, familiar with health and safety requirements and
national legislation. Ignoring these instructions may invalidate all applicable warranties.
38 3GZF500730-85 REV H EN 05-2022
The motor is intended for installation and use
by qualified personnel, familiar with health and
safety requirements and national legislation.
Safety equipment necessary for the prevention of
accidents at the installation and operating site must
be provided in accordance with local regulations.
WARNING
Emergency stop controls must be
equipped with restart lockouts. After
emergency stop a new start command
can take effect only after the restart
lockout has been intentionally reset.
Points to be observed:
1. Do not step on the motor.
2. The temperature of the outer casing of the
motor may be hot to the touch during normal
operation and especially after shut-down.
3. Some special motor applications may require
additional instructions (e.g. when supplied
by frequency converter).
4. Observe rotating parts of the motor.
5. Do not open terminal boxes while energized.
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2 Safety considerations
3GZF500730-85 REV H EN 05-2022 39
—
3 Handling
Immediately upon receipt, check the motor for
external damage (e.g. shaft-ends, flanges and
painted surfaces) and, if found, inform the forwarding agent without delay.
Check all rating plate data, especially voltage and
winding connections (star or delta). The type of
The motor should always be stored indoors
(above –20 °C), in dry, vibration-free and dust-free
conditions. During transportation, shocks, falls
and humidity should be avoided. In other conditions, please contact ABB.
Unprotected machined surfaces (shaft-ends and
flanges) should be treated against corrosion.
It is recommended that shafts are rotated periodically (once per quarter) by hand to prevent
grease migration.
bearing is specified on the rating plate of all motors except the smallest frame sizes.
In the case of a variable speed drive application
check the maximum loadability allowed according
to frequency stamped on the motor’s second rating plate.
Anti-condensation heaters, if fitted, are recommended to be used to avoid water condensing in
the motor.
The motor must not be subject to any external vibrations at standstill so as to avoid causing damage to the bearings.
Motors fitted with cylindrical-roller and/or angular contact bearings must be fitted with locking
devices during transport.
3.1 Reception
3.2 Transportation and storage
40 3GZF500730-85 REV H EN 05-2022
All ABB motors above 25 kg are equipped with lifting lugs or eyebolts.
Only the main lifting lugs or eyebolts of the motor
should be used for lifting the motor. They must
not be used to lift the motor when it is attached
to other equipment.
Lifting lugs for auxiliaries (e.g. brakes, separate
cooling fans) or terminal boxes must not be used
for lifting the motor. Because of different output,
mounting arrangements and auxiliary equipment,
motors with the same frame may have a different
center of gravity.
Damaged lifting lugs must not be used. Check
that eyebolts or integrated lifting lugs are undamaged before lifting.
The total motor weight can vary within the same
frame size (center height) depending on different
output, mounting arrangement and auxiliaries.
The following table shows estimated maximum
weights for machines in their basic versions as a
function of frame material.
The actual weight of all ABB’s motors, except the
smallest frame sizes (56 and 63), is shown on the
rating plate.
—
Table 3.1: Minimum cross-sectional area of protective conductors
Frame size Aluminum, Weight kg Cast iron, Weight kg Add. for brake
56 4.5 – –
63 6 – –
71 8 13 5
80 14 20 8
90 20 30 10
100 32 40 16
112 36 50 20
132 93 90 30
160 149 130 30
180 162 190 45
200 245 275 55
225 300 360 75
250 386 405 75
280 425 800 –
315 – 1 700 –
355 – 2 700 –
400 – 3 500 –
450 – 4 500 –
5000 – 2 800 –
If the motor is equipped with a separate fan, contact ABB for the weight.
Lifting eyebolts must be tightened before lifting.
If needed, the position of the eyebolt can be adjusted using suitable washers as spacers.
Ensure that proper lifting equipment is used and that
the sizes of the hooks are suitable for the lifting lugs.
Care must be taken not to damage auxiliary
equipment and cables connected to the motor.
Remove eventual transport jigs fixing the motor
to the pallet.
Specific lifting instructions are available from ABB.
WARNING
During lifting, mounting or maintenance
work, all necessary safety considerations
shall be in place and special attention to
be taken that nobody will be subject
to lifted load.
3.3 Lifting
3.4 Motor weight
3GZF500730-85 REV H EN 05-2022 41
—
4 Installation and commissioning
All rating plate values must be carefully checked
to ensure that the motor protection and connection will be properly done.
When starting the motor for the first time or after
it has been in storage more than 6 months, apply
the specified quantity of grease.
See section “7.2.2 Motors with re-greasable bearings” for more details.
When fitted in a vertical position with the shaft
pointing downwards, the motor must have a protective cover to prevent foreign objects and fluid
from falling into the ventilation openings. This
task can also be achieved by a separate cover not
fixed to the motor. In this case, the motor must
have a warning label.
Remove transport locking if employed. Turn the
shaft of the motor by hand to check free rotation,
if possible.
Motors equipped with cylindrical roller bearings:
Running the motor with no radial force applied to
the shaft may damage the roller bearing due to
“sliding”,
Motors equipped with angular contact ball bearing:
Running the motor with no axial force applied in
the right direction in relation to the shaft may
damage the angular contact bearing.
WARNING
For motors with angular contact bearings
the axial force must not by any means
change direction.
The type of bearing is specified on the rating plate.
4.1 General
4.2 Motors with other than deep groove ball bearings
WARNING
Disconnect and lock out before working
on the motor or the driven equipment.
42 3GZF500730-85 REV H EN 05-2022
Measure insulation resistance (IR) before commissioning, after long periods of standstill or
storage when winding dampness may be suspected. IR shall be measured directly on the motor terminals with the supply cables disconnected
in order to avoid them affecting the result.
Insulation resistance should be used as a trend indicator to determine changes in the insulation
system. In new machines the IR is usually thousands of Mohms and thus following the change of
IR is important so as to know the condition of the
insulation system. Typically, the IR should not be
below 10 MΩ and in no case below 1 MΩ (measured with 500 or 1000 VDC and corrected to 25
°C). The insulation resistance value is halved for
each 20 °C increase in temperature.
Figure 1, in chapter 11, can be used for the insulation correction to the desired temperature.
The end user has full responsibility for
preparation of the foundation.
Metal foundations should be painted to
avoid corrosion.
Foundations must be even and sufficiently rigid
to withstand possible short circuit forces. They
must be designed and dimensioned to avoid the
transfer of vibration to the motor and vibration
caused by resonance. See figure below.
WARNING
To avoid risk of electrical shock, the motor
frame must be grounded and the windings
should be discharged against the frame
immediately after each measurement.
If the reference resistance value is not attained,
the winding is too damp and must be oven dried.
The oven temperature should be 90 °C for 12-16
hours followed by 105 °C for 6-8 hours.
If fitted drain hole plugs must be removed and
closing valves must be opened during heating. After heating, make sure the plugs are refitted. Even
if the drain plugs are fitted, it is recommended to
disassemble the end shields and terminal box
covers for the drying process.
Windings drenched in seawater normally need to
be rewound.
4.3 Insulation resistance check
4.4 Foundation
Note! Height difference shall
not exceed ± 0,1mm referred
to any other motor foot
Ruler
Foot location
3GZF500730-85 REV H EN 05-2022 43
As standard, balancing of the motor has been carried out using half key.
Coupling halves or pulleys must be balanced after
machining the keyways. Balancing must be done
in accordance with the balancing method specified for the motor.
Belts must be tightened according to the instructions of the supplier of the driven equipment.
However, do not exceed the maximum belt forces
(i.e. radial bearing loading) stated in the relevant
product catalogs.
Ensure that there is enough space for free airflow
around the motor. It is recommended to have a
clearance between the fan cover and the wall etc. of
at least ½ of the air intake of the fan cover. Additional
information may be found from the product catalog
or from the dimension drawings available on our web
pages: www.abb.com/motors&generators.
Correct alignment is essential to avoid bearing,
vibration and possible shaft failures.
Mount the motor on the foundation using the
appropriate bolts or studs and place shim plates
between the foundation and the feet.
Align the motor using appropriate methods.
If applicable, drill locating holes and fix the
locating pins into position.
Mounting accuracy of coupling half: check that
clearance b is less than 0.05 mm and that the difference a1 to a2 is also less than 0.05 mm. See figure 2.
Re-check the alignment after final tightening of
the bolts or studs.
Do not exceed permissible loading values for
bearings as stated in the product catalogs.
Check that the motor has sufficient airflow.
Ensure that no nearby objects or direct sunshine
radiate additional heat to the motor.
For flange mounted motors (e.g. B5, B35, V1),
make sure that the construction allows sufficient
air flow on the outer surface of the flange.
Coupling halves and pulleys must be fitted on the
shaft by using suitable equipment and tools
which do not damage the bearings and seals.
Never fit a coupling half or pulley by hammering
or removing it by using a lever pressed against
the body of the motor.
WARNING
Excessive belt tension will damage
bearings and can cause shaft damage.
4.5 Balancing and fitting coupling halves and pulleys
4.7 Radial forces and belt drives
4.6 Mounting and alignment of the motor
44 3GZF500730-85 REV H EN 05-2022
Check that drain holes and plugs face downwards. In vertical position mounted motors,
the drain plugs may be in horizontal position.
The terminal box on standard single speed motors normally contains six winding terminals and
at least one earth terminal.
In addition to the main winding and earthing terminals, the terminal box can also contain connections for thermistors, heating elements or other
auxiliary devices.
Suitable cable lugs must be used for the connection of all main cables. Cables for auxiliaries can
be connected into their terminal blocks as such.
Motors are intended for fixed installation only.
Unless otherwise specified, cable entry threads
are metric. The IP class of the cable gland must be
at least the same as those of the terminal boxes.
Certified conduit hub or cable connector has to
be used at the time of installation.
Cables should be mechanically protected
and clamped close to the terminal box to
fulfill the appropriate requirements of IEC/
EN 60079-0 and local installation standards.
Unused cable entries must be closed with blanking elements according to the IP class of the terminal box.
The degree of protection and diameter are specified in the documents relating to the cable gland.
WARNING
Use appropriate cable glands and seals in
the cable entries according to the type
and diameter of the cable.
Earthing must be carried out according to local
regulations before the motor is connected to the
supply voltage.
Motors with sealable plastic drain plugs are delivered in an open position. In very dusty environments, all drain holes should be closed.
The earth terminal on the frame has to be connected to PE (protective earth) with a cable as
shown in Table 5 of IEC/EN 60034-1:
—
Table 4.1: Minimum cross-sectional
area of protective conductors
Cross-sectional area
of phase conductors
of the installation, S, [mm2]
Minimum crosssectional area of the
corresponding protective
conductor, S, [mm2]
4 4
6 6
10 10
16 16
25 25
35 25
50 25
70 35
95 50
120 70
150 70
185 95
240 120
300 150
400 185
In addition, earthing or bonding connection facilities on the outside of electrical apparatus must
provide effective connection of a conductor with
a cross-sectional area of at least 4 mm2.
The cable connection between the network and
motor terminals must meet the requirements
stated in the national standards for installation
or in the standard IEC/EN 60204-1 according to
the rated current indicated on the rating plate.
4.8 Motors with drain plugs for condensation
4.9 Cabling and electrical connections
3GZF500730-85 REV H EN 05-2022 45
When the ambient temperature exceeds
+50 °C, cables having permissible
operating temperature of +90 °C as
minimum shall be used. Also all other
conversion factors depending on the
installation conditions shall be taken
into account while sizing the cables.
Ensure that the motor protection corresponds
to the environment and weather conditions.
For example, make sure that water cannot enter
the motor or the terminal boxes.
The seals of terminal boxes must be placed
correctly in the slots provided to ensure the correct
IP class. A leak could lead to penetration of dust or
water, creating a risk of flashover to live elements.
4.9.1 Connections for different starting methods
The terminal box on standard single speed
motors normally contains six winding terminals
and at least one earth terminal. This enables the
use of DOL- or Y/D –starting.
For two-speed and special motors, the supply
connection must follow the instructions inside
the terminal box or in the motor manual.
The voltage and connection are stamped on the
rating plate.
Direct-on-line starting (DOL):
Y or D winding connections may be used.
For example, 690 VY, 400 VD indicates
Y-connection for 690 V and D-connection for 400 V.
Star/Delta (Wye/Delta) starting (Y/D):
The supply voltage must be equal to the rated
voltage of the motor when using a D-connection.
Remove all connection links from the terminal block.
Other starting methods and severe starting
conditions:
In cases where other starting methods e.g.
converter or soft starter will be used in the duty
types of S1 and S2, it is considered that the device
is “isolated from the power system when the
electrical machine is running” as in the standard
IEC 60079-0 and thermal protection is optional.
4.9.2 Connections of auxiliaries
If a motor is equipped with thermistors or other
RTDs (Pt100, thermal relays, etc.) and auxiliary
devices, it is recommended they be used and
connected by appropriate means. For certain
applications, it is mandatory to use thermal
protection. More detailed information can be
found in the documents delivered with the
motor. Connection diagrams for auxiliary
elements and connection parts can be found
inside the terminal box.
The maximum measuring voltage for the
thermistors is 2.5 V. The maximum measuring
current for Pt100 is 5 mA. Using a higher
measuring voltage or current may cause errors
in readings or a damaged temperature detector.
The insulation of thermal sensors fulfills
the requirements of basic insulation.
The shaft rotates clockwise when viewing the
shaft face at the motor drive end, and the line
phase sequence – L1, L2, L3 – is connected to
the terminals as shown in figure 3.
To alter the direction of rotation, interchange
any two connections on the supply cables.
If the motor has a unidirectional fan, ensure
that it rotates in the same direction as the
arrow marked on the motor.
4.10 Terminals and direction of rotation
46 3GZF500730-85 REV H EN 05-2022
—
5 Operation
The motors are designed for the following conditions unless otherwise stated on the rating plate:
• Motors are to be installed in fixed installations
only.
• Normal ambient temperature range is from
–20 °C to +40 °C.
• Maximum altitude is 1000 m above sea level.
• The variation of the supply voltage and
frequency may not exceed the limits mentioned
in relevant standards. Tolerance for supply
voltage is ±5 %, and for frequency ±2 %
according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values
are not supposed to occur at the same time.
The motor can only be used in applications for
which it is intended. The rated nominal values and
operation conditions are shown on the motor rating plates. In addition, all requirements of this
manual and other related instructions and standards must be followed.
If these limits are exceeded, motor data and construction data must be checked. Please contact
ABB for further information.
WARNING
Ignoring any instructions or maintenance
of the apparatus may jeopardize safety
and thus prevent the use of the motor.
5.1 General
3GZF500730-85 REV H EN 05-2022 47
—
6 Low voltage motors in variable
speed operation
This part of the manual provides additional
instructions for motors used in frequency
converter supplies. The motor is intended to
operate from a single frequency converter supply
and not motors running in parallel from one
frequency converter. Instructions given by the
converter manufacturer shall be followed.
Variable speed drives create higher voltage
stresses than the sinusoidal supply on the
winding of the motor. Therefore, the winding
insulation of the motor as well as the filter at
the converter output must be dimensioned
according following instructions.
6.2.1 Selection of winding insulation for
ABB converters
In the case of ABB e.g. AC_8_ _-series and
AC_5_ _-series single drives with a diode
Most of the motors covered by this manual are
equipped with PTC thermistors or other type of
RTD’s in the stator windings. It is recommended
to connect those to the frequency converter.
Read more in chapter 4.9.2.
Additional information may be required by ABB
to decide on the suitability for some motor types
used in special applications or with special
design modifications.
supply unit (uncontrolled DC voltage),
the selection of winding insulation and
filters can be made according to table 6.1.
6.2.2 Selection of winding insulation
with all other converters
The voltage stresses must be limited below
accepted limits. Please contact the system
supplier to ensure the safety of the application.
The influence of possible filters must be taken
into account while dimensioning the motor.
6.1 Introduction
6.2 Winding insulation
6.3 Thermal protection
48 3GZF500730-85 REV H EN 05-2022
Insulated bearings or bearing constructions,
common mode filters and suitable cabling and
grounding methods must be used according to
the following instructions and using table 6.1.
—
Table 6.1 Selection of winding
insulation for ABB converters
PN < 100 kW PN ≥ 100 kW or
IEC315 ≤ Frame size ≤ IEC355
PN ≥ 350 kW or
IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor
+ Insulated N-bearing
Standard motor
+ Insulated N-bearing
+ Common mode filter
500V > UN ≤ 600V Standard motor
+ dU/dt –filter (reactor)
OR
Reinforced insulation
Standard motor
+ dU/dt –filter (reactor)
+ Insulated N-bearing
OR
Reinforced insulation
+ Insulated N-bearing
Standard motor
+ Insulated N-bearing
+ dU/dt –filter (reactor)
+ Common mode filter
OR
Reinforced insulation
+ Insulated N-bearing
+ Common mode filter
500V > UN ≤ 600V
(cable length > 150 m)
Standard motor Standard motor
+ Insulated N-bearing
Standard motor
+ Insulated N-bearing
+ Common mode filter
600V > UN ≤ 690V Reinforced insulation
+ dU/dt –filter (reactor)
Reinforced insulation
+ dU/dt –filter (reactor)
+ Insulated N-bearing
Reinforced insulation
+ Insulated N-bearing
+ dU/dt –filter (reactor)
+ Common mode filter
600V > UN ≤ 690V
(cable length > 150 m)
Reinforced insulation Reinforced insulation
+ Insulated N-bearing
Reinforced insulation
+ Insulated N-bearing
+ Common mode filter
6.4.1 Elimination of bearing currents with
ABB converters
In case of ABB frequency converter e.g. AC_8_ _-
and AC_5_ _-series with a diode supply unit, the
methods according to table 6.1 must be used to
avoid harmful bearing currents in motors.
Insulated bearings which have aluminum
oxide coated inner and/or outer bores or
ceramic rolling elements are recommended.
Aluminum oxide coatings shall also be
treated with a sealant to prevent dirt and
humidity penetrating into the porous
coating. For the exact type of bearing
insulation, see the motor’s rating plate.
Changing the bearing type or insulation
method without ABB’s permission
is prohibited.
6.4.2 Elimination of bearing currents with all
other converters
The user is responsible for protecting the motor
and driven equipment from harmful bearing
currents. Instructions described in chapter 6.4.1
can be used as guideline, but their effectiveness
cannot be guaranteed in all cases.
6.4 Bearing currents
3GZF500730-85 REV H EN 05-2022 49
To provide proper grounding and to ensure compliance with any applicable EMC requirements,
motors above 30 kW shall be cabled by shielded
symmetrical cables and EMC glands, i.e. cable
glands providing 360° bonding.
Symmetrical and shielded cables are highly
recommended also for smaller motors. Make the
360° grounding arrangement at all the cable
entries as described in the instructions for the
glands. Twist the cable shields into bundles and
connect to the nearest ground terminal/bus bar
inside the terminal box, converter cabinet, etc.
Proper cable glands providing 360°
bonding must be used at all termination
points such as motor, converter, possible
safety switch, etc.
6.7.1 General
With ABB’s frequency converters, the motors can be
dimensioned by using ABB’s DriveSize dimensioning program. The tool is downloadable from the
ABB website (www.abb.com/motors&generators).
For application supplied by other converters,
the motors must be dimensioned manually.
For more information, please contact ABB.
The loadability curves (or load capacity curves)
are based on nominal supply voltage. Operation
in under or over voltage conditions may influence
on the performance of the application.
For speeds higher than the nominal speed stated on
the motor’s rating plate or in the respective product
catalog, ensure that either the highest permissible
rotational speed of the motor or the critical speed
of the whole application is not exceeded.
For motors of frame size IEC 280 and above,
additional potential equalization between the
motor frame and the driven equipment is needed,
unless both are mounted on a common steel
base. In this case, the high frequency conductivity
of the connection provided by the steel base
should be checked by, for example, measuring the
potential difference between the components.
More information about grounding and cabling of
variable speed drives can be found in the manual
“Grounding and cabling of the drive system”
(Code: 3AFY 61201998).
6.7.2 Motor loadability with AC_8_ _ – Series
of converters with DTC control
The loadability curves presented in Figures 5a – 5d
are valid for ABB AC_8_ _-series converters with
uncontrolled DC-voltage and DTC-control. The
figures show the approximate maximum continuous output torque of the motors as a function of
supply frequency. The output torque is given as a
percentage of the nominal torque of the motor.
The values are indicative and exact values are
available on request.
6.5 Cabling, grounding and EMC
6.7 Motors in variable speed applications
6.6 Operating speed
50 3GZF500730-85 REV H EN 05-2022
The maximum speed of the motor and
application may not be exceeded!
6.7.3 Motor loadability with AC_5_ _ – series
of converter
The loadability curves presented in Figures 6a – 6d
are valid for AC_5_ _ -series converters.
The figures show the approximate maximum
continuous output torque of the motors as a
function of supply frequency. The output torque
is given as a percentage of the nominal torque
of the motor. The values are indicative and exact
values are available on request.
The maximum speed of the motor and
application may not be exceeded!
6.7.4 Motor loadability with other voltage
source PWM-type converters
For other converters, with uncontrolled
DC voltage and minimum switching frequency
of 3 kHz (200…500 V), the dimensioning
instructions as mentioned in chapter 6.7.3 can be
used as guidelines. However, it shall be noted that
the actual thermal loadability can also be lower.
Please contact the manufacturer of the converter
or the system supplier.
The actual thermal loadability of a motor
may be lower than shown by guideline
curves.
6.7.5 Short time overloads
ABB motors can usually be temporarily
overloaded as well as used in intermittent duties.
The most convenient method to dimension such
applications is to use the DriveSize tool.
The usage of ABB’s motors in variable speed
applications do not usually require additional
rating plates. The parameters required for
commissioning the converter can be found
from the main rating plate. In some special
applications, however, the motors can be
equipped with additional rating plates for
variable speed applications.
Those include the following information:
• speed range
• power range
• voltage and current range
• type of torque (constant or quadratic)
• and converter type and required minimum
switching frequency.
6.8 Rating plates
The commissioning of the variable speed application must be done according to the instructions
of the frequency converter and local laws and regulations. The requirements and limitations set by
the application must also be taken into account.
All parameters needed for setting the converter
must be taken from the motor rating plates.
The most often needed parameters are:
• nominal voltage
• nominal current
• nominal frequency
• nominal speed
• nominal power
In case of missing or inaccurate
information, do not operate the motor
before ensuring correct settings!
ABB recommends using all the suitable protective features provided by the converter to improve the safety
of the application. Converters usually provide features such as (names and availability of features depend on manufacturer and model of the converter):
• minimum speed
• maximum speed
• acceleration and deceleration times
• maximum current
• maximum torque
• stall protection
6.9 Commissioning the variable speed application
3GZF500730-85 REV H EN 05-2022 51
—
7 Maintenance
1. Inspect the motor at regular intervals, at least
once a year. The frequency of checks depends
on, for example, the humidity level of the
ambient air and on the local weather conditions.
This can initially be determined experimentally
and must then be strictly adhered to.
2. Keep the motor clean and ensure free
ventilation airflow. If the motor is used in a
dusty environment, the ventilation system
must be regularly checked and cleaned.
3. Check the condition of shaft seals (e.g. V-ring
or radial seal) and replace if necessary.
4. Check the condition of connections and
mounting and assembly bolts.
5. Check the bearing condition by listening for
any unusual noise, vibration measurement,
bearing temperature, inspection of spent
grease or SPM bearing monitoring. Pay special
attention to bearings when their calculated
rated life time is coming to an end.
When signs of wear are noticed, dismantle the
motor, check the parts and replace if necessary.
When bearings are changed, replacement bearings must be of the same type as those originally
fitted. The shaft seals have to be replaced with
seals of the same quality and characteristics as
the originals when changing bearings.
In the case of the IP 55 motor and when the motor
has been delivered with a plug closed, it is advisable
to periodically open the drain plugs in order to ensure that the way out for condensation is not blocked
and allows condensation to escape from the motor.
This operation must be done when the motor is at
a standstill and has been made safe to work on.
7.1.1 Standby motors
If the motor is in standby for a longer period of
time on a ship or in other vibrating environment
the following measures have to be taken:
1. The shaft must be rotated regularly every
2 weeks (to be reported) by means of starting
up of the system. In case a start-up is not
possible, for any reason, at least the shaft has
to be turned by hand in order to achieve a
different position once a week. Vibrations
caused by other vessel's equipment will cause
bearing pitting which should be minimized by
regular operation/hand turning.
2. The bearing must be greased while rotating
the shaft every year (to be reported). If the
motor has been provided with roller bearing
at the driven end, the transport lock must be
removed before rotating the shaft. The
transport locking must be remounted in case
of transportation.
3. All vibrations must be avoided to prevent a
bearing from failing. All instructions in the
motor instruction manual for commissioning
and maintenance have to be followed.
The warranty will not cover the winding and
bearing damages if these instructions have
not been followed.
7.1 General inspection
WARNING
Voltage may be connected at standstill
inside the terminal box for heating
elements or direct winding heating.
52 3GZF500730-85 REV H EN 05-2022
WARNING
Beware of all rotating parts!
WARNING
Grease can cause skin irritation and eye
inflammation. Follow all safety
precautions specified by the
manufacturer of the grease.
Bearing types are specified in the respective
product catalogs and on the rating plate of all
motors, except smaller frame sizes.
Reliability is a vital issue for bearing lubrication
intervals. ABB uses mainly the L1 -principle
(i.e. that 99 % of the motors are certain to make
the life time) for lubrication.
7.2.1 Motors with permanently greased bearings
Bearings are usually permanently greased bearings of 1Z, 2Z, 2RS or equivalent.
As a guide, adequate lubrication for sizes up to
250 can be achieved for the following duration,
according to L1
. For duties with higher ambient
temperatures, please contact ABB. The informative formula to change the L1 values roughly to
L10 values: L10 = 2.0 x L1
.
Duty hours for permanently greased bearings at
ambient temperatures of 25 °C and 40 °C are:
—
Table 7.1
Frame size Poles Duty hours
at 25 °C
Duty hours
at 40 °C
56 2 52 000 33 000
56 4–8 65 000 41 000
63 2 49 000 31 000
63 4–8 63 000 40 000
71 2 67 000 42 000
71 4–8 100 000 56 000
80–90 2 100 000 65 000
80–90 4–8 100 000 96 000
100–112 2 89 000 56 000
100–112 4–8 100 000 89 000
132 2 67 000 42 000
132 4–8 100 000 77 000
160 2 60 000 38 000
160 4–8 100 000 74 000
180 2 55 000 34 000
180 4–8 100 000 70 000
200 2 41 000 25 000
200 4–8 95 000 60 000
225 2 36 000 23 000
225 4–8 88 000 56 000
250 2 31 000 20 000
250 4–8 80 000 50 000
Data is valid up to 60 Hz.
7.2.2 Motors with regreasable bearings
Lubrication information plate and general lubrication advice.
If the motor is equipped with a lubrication information plate, follow the given values.
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on
the lubrication information plate.
During the first start or after a bearing lubrication a temporary temperature rise may appear,
approximately 10 to 20 hours.
Some motors may be equipped with a collector
for old grease. Follow the special instructions
given for the equipment.
A. Manual lubrication
Regreasing while the motor is running
• Remove grease outlet plug or open closing
valve if fitted.
• Be sure that the lubrication channel is open.
• Inject the specified amount of grease into
the bearing.
• Let the motor run for 1-2 hours to ensure that
all excess grease is forced out of the bearing.
Close the grease outlet plug or closing valve,
if fitted.
Regreasing while the motor is at a standstill
If it is not possible to re-grease the bearings
while the motors are running, lubrication can be
carried out while the motor is at a standstill.
• In this case, use only half the amount of grease
and then run the motor for a few minutes at full
speed.
• When the motor has stopped, apply the rest of
the specified amount of grease to the bearing.
• After 1–2 running hours, close the grease outlet
plug or closing valve, if fitted.
B. Automatic lubrication
The grease outlet plug must be removed permanently with automatic lubrication or open closing
valve, if fitted.
ABB recommends only the use of electromechanical systems.
The amount of grease per lubrication interval
stated in the table should be multiplied by three
if a central lubrication system is used. When using
a smaller automatic re-grease unit (one or two
cartridges per motor) the normal amount of
grease can be used.
7.2 Lubrication
53
When 2-pole motors are automatically re-greased,
the note concerning lubricant recommendations
for 2-pole motors in the Lubricants chapter should
be followed.
The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and the grease manufacturer’s recommendations should check.
Calculation example of amount of grease for
automatic lubrication system
Central lubrication system: Motor IEC M3_P 315_
4-pole in 50 Hz network, re-lubrication interval
according to Table is 7600 h/55 g (DE) and
7600 h/40 g (NDE):
(DE) RLI = 55 g/7600 h*3*24 = 0,52 g/day
(NDE) RLI = 40 g/7600 h*3*24 = 0,38 g/day
Calculation example of amount of grease for
single automation lubrication unit (cartridge)
(DE) RLI = 55 g/7600 h*24 = 0,17 g/day
(NDE) RLI = 40 g/7600 h*24 = 0,13 g/day
RLI = Re-lubrication interval, DE = Drive end,
NDE = Non drive end
7.2.3 Lubrication intervals and amounts
Lubrication intervals for vertical motors are
half of the values shown in the table below.
As a guide, adequate lubrication can be achieved for
the following duration, according to L1
. For duties with
higher ambient temperatures please contact ABB. The
informative formula to change the L1 values roughly
to L10 values is L10 = 2.0 x L1
, with manual lubrication.
The lubrication intervals are based on a bearing
operating temperature of 80 °C (ambient temperature +25 °C).
An increase in the ambient temperature
raises the temperature of the bearings
correspondingly. The interval values should
be halved for a 15 °C increase in bearing
temperature and may be doubled for a
15 °C decrease in bearing temperature.
Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy
load will require shorter lubrication intervals.
WARNING
The maximum operating temperature of
the grease and bearings, +110 °C, must
not be exceeded. The designed maximum
speed of the motor must not be exceeded.
3GZF500730-85 REV H EN 05-2022
—
Table 7.2
Frame
size
Amount
of grease
g/bearing
kW 3600
r/min
3000
r/min
kW 1800
r/min
1500
r/min
kW 1000
r/min
kW 500-900
r/min
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 – – – – – – –
2801) 60 – – – all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 – – – – – – –
280 40 – – – all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 – – – – – – –
315 55 – – – all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 – – – – – – –
355 70 – – – all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 – – – – – – –
400 85 – – – all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 – – – – – – –
450 95 – – – all 2 500 3 900 all 7 700 all 8 700
5008 40 all 3 000 5 300 – – – – – – –
5008 85 – – – all 6400 9 500 all 17 200 all 19 400
5010 40 all 1 300 2 400 – – – – – – –
5010 85 – – – all 4 900 7 200 all 13 200 all 14 800
5012 85 – – – all 2 700 3 900 all 7 100 all 8 000
54 3GZF500730-85 REV H EN 05-2022
Frame
size
Amount
of grease
g/bearing
kW 3600
r/min
3000
r/min
kW 1800
r/min
1500
r/min
kW 1000
r/min
kW 500-900
r/min
Roller bearings, lubrication intervals in duty hours
160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 – – – – – – –
2801) 70 – – – all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 – – – – – – –
280 40 – – – all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 – – – – – – –
315 55 – – – all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 – – – – – – –
355 70 – – – all 2 000 2 800 all 4 800 all 5 400
400 40 all – 1 300 – – – – – – –
400 85 – – – all 1 600 2 400 all 4 300 all 4 800
450 40 all – 1 300 – – – – – – –
450 95 – – – all 1 300 2 000 all 3 800 all 4 400
5008 40 all – 2 700 – – – – – – –
5008 85 – – – all 3 200 4 700 all 8 600 all 9 700
5010 40 all – 1 200 – – – – – – –
5010 85 – – – all 2 500 3 600 all 6 600 all 7 400
5012 85 all – – all 1 300 1 900 all 3 500 all 4 000
1) M3AA
7.2.4 Lubricants
WARNING
Do not mix different types of grease.
Incompatible lubricants may cause
bearing damage.
When re-greasing, use only special ball bearing
grease with the following properties:
• good quality grease with lithium complex soap
and with mineral- or PAO-oil
• base oil viscosity 100-160 cST at 40 °C
• consistency NLGI grade 1.5 - 3 *)
• temperature range –30 °C - +120 °C, continuously
*) A stiffer end of scale is recommended for vertical mounted motors or in hot conditions.
The above mentioned grease specification is valid
if the ambient temperature is above –30 °C or below +55 °C, and the bearing temperature is below
110 °C; otherwise, consult ABB regarding suitable
grease.
Grease with the correct properties is available
from all major lubricant manufacturers.
Admixtures are recommended, but a written
guarantee must be obtained from the lubricant
manufacturer, especially concerning EP admixtures, that admixtures do not damage bearings or
the properties of lubricants at the operating temperature range.
WARNING
In general, lubricants containing EP
admixtures are not recommended. In
some cases it can cause harm in the
bearing, therefore its use has to be
evaluated case by case together with
lubricant suppliers.
The following high performance greases can be used:
• Mobil Unirex N2 or N3 (lithium complex base)
• Mobil Mobilith SHC 100 (lithium complex base)
• Shell Gadus S5 V 100 2 (lithium complex base)
• Klüber Klüberplex BEM 41-132 (special lithium base)
• FAG Arcanol TEMP110 (lithium complex base)
• Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
• Total Multis Complex S2 A (lithium complex base)
Always use high speed grease for high
speed 2-pole motors where the speed
factor is higher than 480,000 (calculated
as Dm x n where Dm = average bearing
diameter, mm; n = rotational speed, r/min).
The following greases can be used for high speed
cast iron motors but not mixed with lithium complex greases:
• Klüber Klüber Quiet BQH 72-102 (polyurea base)
• Lubcon Turmogrease PU703 (polyurea base)
If other lubricants are used, check with the manufacturer that the qualities correspond to those of the
above mentioned lubricants. The lubrication intervals
are based on the listed high performance greases
above. Using other greases can reduce the interval.
3GZF500730-85 REV H EN 05-2022 55
—
8 After Sales Support
Unless otherwise stated, spare parts must be
original parts or approved by ABB.
When ordering spare parts, the motor serial
number, full type designation and product code,
as stated on the rating plate, must be specified.
Rewinding should always be carried out by
qualified repair shops.
Smoke venting and other special motors should
not be rewound without first contacting ABB.
Special care should be taken with the bearings.
These must be removed using pullers and fitted
by heating or using special tools.
Bearing replacement is described in detail in a
separate instruction leaflet available from the
ABB Sales Office.
Any directions placed on the motor, such as labels,
must be followed. The bearing types indicated on
the rating plate must not be changed.
8.1 Spare parts
8.2 Dismantling, re-assembly and rewinding
8.3 Bearings
56 3GZF500730-85 REV H EN 05-2022
Most of ABB’s motors have a sound pressure level
not exceeding 82 dB (A) (± 3 dB) at 50 Hz.
Values for specific motors can be found in the relevant product catalogs. At 60 Hz sinusoidal supply,
the values are approximately 4 dB(A) higher compared to 50 Hz values stated in the product catalogs.
For sound pressure levels at frequency converter
supplies, please contact ABB.
When motor(s) need to be scrapped or recycled,
appropriate means, local regulations and laws
must be followed.
—
9 Environmental requirements
3GZF500730-85 REV H EN 05-2022 57
These instructions do not cover all details or variations in equipment nor provide information for
every possible condition to be met in connection
with installation, operation or maintenance.
Should additional information be required,
please contact the nearest ABB Sales Office.
Motor troubleshooting chart
Your motor service and any troubleshooting
must be handled by qualified persons who
have the proper tools and equipment.
—
10 Troubleshooting
—
Table 10.1: Troubleshooting
TROUBLE CAUSE WHAT TO DO
Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with
motor rating plate and load factor.
Improper line connections Check connections against diagram supplied
with motor.
Open circuit in winding or
control switch
Indicated by humming sound when switch is
closed. Check for loose wiring connections and
ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator Contact ABB
or
Ensure that the supply is disconnected and
grounding for work done, disconnect the cables
and measure the insulation resistance.
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained.
Check connection.
Open circuit Fuses blown. Check overload relay, stator and
push buttons.
Motor runs and
then dies down
Power failure Check for loose connections to line, fuses and
control.
Motor does not
accelerate up to
nominal speed
Not applied properly Consult equipment supplier for proper type.
Voltage too low at motor terminals
because of line drop
Use higher voltage or transformer terminals or
reduce load.
Check connections. Check conductors for
proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may
be required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
58 3GZF500730-85 REV H EN 05-2022
TROUBLE CAUSE WHAT TO DO
Motor takes too long
to accelerate and/or
draws high current
Excessive load Reduce load.
Low voltage during start Check for high resistance. Make sure that an
adequate cable size is used.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation
direction
Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats
while running
Overload Reduce load.
Frame or ventilation openings may be full of
dirt and prevent proper ventilation of motor
Open vent holes and check for a continuous
stream of air from the motor.
Motor may have one phase open Check to make sure that all leads and cables are
well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of rotor
and coupling (half key - full key)
Rebalance coupling or rotor.
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft shoulder Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease
in bearing.
Deterioration of grease or lubricant
contaminated
Remove old grease, wash bearings thoroughly
in kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not
be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
3GZF500730-85 REV H EN 05-2022 59
—
11 Figures
100
50
10
5
1.0
0.5
0.1
0.05
-10 0 10 20 30 40 50 60 70 80 90 100
1)
a1 b
a2
Key
X-axis: Winding temperature, Celsius
Degrees
Y-axis: Insulation Resistance
Temperature Coefficient, ktc
1) To correct observed insulation
resistance, Ri
, to 40 °C multiply it by the
temperature coefficient ktc . Ri 40 °C = Ri
x
—
Figure 1. Diagram
illustrating the
insulation resistance
dependence from
the temperature and
how to correct the
measured insulation
resistance to the
temperature of 40 °C.
—
Figure 2. Mounting of
half-coupling or pulley
—
Figure 1.
—
Figure 2.
60 3GZF500730-85 REV H EN 05-2022
1
2
3
Y
X
1.00 1.02
0.90
0.98
1.10
0.93
0.95
1.05
1.03
0.95
1.09
Key
X axis frequency p.u.
Y axis voltage p.u.
1 zone A
2 zone B (outside zone A)
3 rating point
—
Figure 3. Connection
of terminals for
main supply
—
Figure 4. Voltage and
frequency deviation
in zones A and B
—
Figure 3.
—
Figure 4.
3GZF500730-85 REV H EN 05-2022 61
Guideline loadability curves with converters with DTC control
—
Figure 5a. Conventer
with DTC control, 50
Hz, temperature rise B
—
Figure 5b. Conventer
with DTC control, 60
Hz, temperature rise B
—
Figure 5c. Conventer
with DTC control, 50
Hz, temperature rise F
—
Figure 5d. Conventer
with DTC control, 60
Hz, temperature rise F
—
Figure 5a.
—
Figure 5b.
—
Figure 5c.
—
Figure 5d.
62 3GZF500730-85 REV H EN 05-2022
Guideline loadability curves with other voltage source PWM type
—
Figure 6a. Other
voltage source PWM
type converter, 50 Hz,
temperature rise B
—
Figure 6b. Other
voltage source PWM
type converter, 60 Hz,
temperature rise B
—
Figure 6c. Other
voltage source PWM
type converter, 50 Hz,
temperature rise F
—
Figure 6d. Other
voltage source PWM
type converter, 60 Hz,
temperature rise F
—
Figure 6a.
—
Figure 6b.
—
Figure 6c.
—
Figure 6d.
3GZF500730-85 REV H EN 05-2022 63
3GZF500730-85 Rev H EN 06-2022
—
abb.com/motors&generators
© Copyright 2022 ABB. All rights reserved.
Specifications subject to change without notice.
—
LOW VOLTAGE WATER COOLED MOTORS
Additional manual
Additional Manual for LOW VOLTAGE water cooled motors .............................................................................. EN 5
Zusätzliches Handbuch für Wassergekühlte NIEDERSPANNUNGS-Motoren .................................................. DE 9
Manuel supplémentaire pour les Moteurs BASSE TENSION à refroidissement par eau ............................... FR 13
Manual adicional para Motores refrigerados por agua de BAJA TENSIÓN ..................................................... ES 17
Supplemento al manuale per motori a bassa tensione raffreddati ad acqua ................................................. IT 21
Manual för vattenkylda lågspänningsmotorer ..................................................................................................... SV 25
Lisäopas vesijäähdytteiset pienjännitemoottorit ................................................................................................ FI 29
2 9AKK104378 ML 10-2020
3
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condensation drain holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water leakage detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
—
Contents
9AKK104378 ML 10-2020
4 9AKK104378 ML 10-2020
5
—
Validity
—
Handling
This additional installation, operation, and maintenance manual is valid for water cooled motors
(M3LP 280–500) and is to be read together with
the main manual (Low Voltage Motors/Manual).
Additional information may be required for some
machines due to special application and/or
design considerations.
Use
Normally, water cooled motors are manufactured
to specific customer requirements. However,
these instructions refer to ’standard’ water
cooled motor versions.
Should the motor be used or stored in
environments with the risk of sub-zero
temperatures, freezing of the water inside the
motor must be prevented. This can be done either
by emptying the water jacket or by using antifreeze additives.
Before emptying the water jacket, protect it with
a corrosion-protective emulsion, e.g. Esso Cutwell
40, Shell Dromus Oil BS, or equivalent, in
accordance with the instructions given by the
emulsion manufacturer. If the motor has been
standing for a long period of time with no water,
ensure that water can circulate freely before using
the motor again. Remove possible rust blockages
by dissolving them with oxalic acid:
1. Empty the frame of water.
2. Fill the frame with water mixed with oxalic acid
(100 g/ liter).
3. Let the acid take effect for approximately
10 minutes.
4. Empty the frame and wash it with pressurized
water.
5. Repeat the treatment if necessary.
If the motor is equipped with a separate bearing
fan, ensure that there is free ventilation airflow.
Installation of a motor with a bearing fan in a
closed flange construction (i.e. flange-mounted
motor) is not recommended.
Cleaning of motor cooling system helps to restore
system efficiency. ABB recommends using regular
flushing and cyclonic or magnetic filters, which
should be regularly maintained. Flushing can be
done as described above.
Check that water in the system is neutral or near
neutral pH after flushing.
6 3GZF500730-85 REV G EN 08-2018
—
Water cooling
In motors type M3LP, waste heat is drawn off by
water circulating inside the motor housing. The
water circulates around the motor in a jacket inside the housing and flows out through an outlet.
Motor frame sizes 280–315 have one water inlet
and one outlet with R ½\" or R 1\" threads in Dand ND-end (fig 1).
Motor frame sizes 355–500 have one water inlet
and one outlet with R 1\" threads in ND-end (fig 1).
Note! Read the cooling water instruction plate
as well as the markings for inlet and outlet pipes
on the motor!
Requirements for cooling water in motor
sizes 280–315
Water with a proportion of chloride up to
3000 mg/l can be used if the ingress of
oxygen into cooling water is prevented and
the cooling water temperature does not
exceed 30 °C. The highest allowed pressure
for cooling water is 5 bar.
Requirements for cooling water in motor
sizes 355–500
Cooling water must be tap water quality. Sea
water or water with a proportion of chloride
above 120 mg/l should not be used. The
highest allowed pressure for cooling water is
5 bar, with a recommended maximum input
water temperature of 40 °C. Steel frame
water- cooled construction is only to be used
with a closed fresh water circulation. The
cooling water circulates in ducts integrated in
the machine frame. The material of the frame
and ducts is carbon steel according to the
standard EN 10025-S235JR. This material is
prone to corrosion in saline and foul water.
The corrosion products and fouling deposits
might block the water flow in the ducts. This
is why it is important to use pure water in the
cooling system.
Standard values for the cooling water to be
used in the cooling system:
• pH 6.5–9.5
• Alkalinity (CaCO3) > 1 mmol/l
• Chloride (Cl) < 120 mg/l
• Conductivity < 1500 μS/cm
In most cases, normal tap water, i.e. water for
domestic consumption, meets all these
requirements.
The cooling water can also be inhibited with
an agent protecting the cooling system
against corrosion, fouling, and, when
necessary, against freezing. All materials in
contact with the cooling water (pipes, heat
exchanger, etc.) must be taken into account
when selecting a suitable inhibitor.
Use only suitable and high-class connection
parts and seals to connect the machine to the
water circuit.
NOTE!
Only closed-circuit water systems can be used in compliance with the requirements specified in the following section. Open water systems can be used in
types M3LP 280–315 when cooling water with a proportion of chloride below
120 mg/l is used. Water with a proportion of chloride up to 3000 mg/l can be
used if the ingress of oxygen into cooling water is prevented and the cooling
water temperature does not exceed 30 °C.
—
Connection
9AKK104378 ML 10-2020
9AKK104378 ML 10-2020 7
In environments with risk of sub-zero temperatures, a glycol/water mixture can be used with
40/60 mixture (glycol/water), with a recommended minimum environment temperature of
-20 °C.
The lower the cooling water input temperature,
the better the cooling of the motor.
For some cases a higher input temperature can
be allowed when requested and checked by the
manufacturer.
The outlet water temperature rise is from 7–15 K.
The minimum pressure and amount of cooling
water for the basic construction of a water
cooled motor is shown in the following table.
Please check the requirements for pressure and
the amount of cooling water in the case of special constructions.
(If the amount of water varies, its temperature
rise will be inversely proportional to the flow rate.)
Motor type
M3LP
Frame type
Number of
inlets
Cooling
water flow
rate
(l/min)
Water
pressure
min. (bar)
Water
temp. rise
(K)
Heat transfer of thermal loss in
(approx.) ratio air/water at room
temperature
Temperature of inlet cooling water
25 °C 40 °C
Water-space
of st. frame
(l)
280 SM_ 1 20 2,0 7-12 10/90 30/70 1,2
315 KH_ 1 30 2,0 7-12 10/90 30/70 3,5
315 LK_ 1 30 2,0 7-12 10/90 30/70 4,7
355 ML_ 1 30 2,0 10-15 10/90 30/70 28
355 LK_ 1 35 2,0 10-15 10/90 30/70 35
400 L_ 1 40 2,0 10-15 10/90 30/70 50
450 L_ 1 50 2,0 10-15 10/90 30/70 65
500 L_ 1 60 2,0 10-15 10/90 30/70 71
8 9AKK104378 ML 10-2020
Filling or draining cooling water
When filling, open the air plug on top of the motor (fig. 1). Let the cooling water flow into the
motor until it comes out of the air gap. Close the
air gap with a plug and seal the joint with sealing tape or strip. Filling must be done carefully
so that no air is left in the motor’s cooling channels. Check for possible leaks after the piping
and joints have been connected.
When emptying, open the emptying plug underneath the motor and the air plug on top of the
motor. In motor sizes 280–315 emptying can be
done with pressurized air. After emptying, the
plugs must be re-fitted and the seals of the
joints must be checked.
It is of special importance with water cooled
motors that the condensation drain holes are located in the correct position (fig. 1). Check that
the condensation drain holes face downwards,
especially when the mounting arrangement differs from standard.
—
Condensation drain holes
As an option, there is the possibility to order the
motors with a float type leakage detector (fig.
2). The leakage detector has a magnetic float
switch. The magnetic float switch is positioned
on a non-magnetic guide tube. When a specified
water level is reached, the magnetic field produced by the magnet in the float actuates a reed
switch (sealed contact) inside the guide tube.
This closes the electric circuit that transmits the
alarm signal to the control board.
Vertical mounting of the motor has only one
leakage detector, while horizontal mounting has
two. The detectors are connected in the lowest
part of the motor and vertically installed according to the mounting arrangement of the motor.
The maximum deviation from the vertical axis
line is ±30°.
Electrical connection of float switch
max. voltage
230 V DC/AC
max. current 1 A switch capacity
100 VA
—
Water leakage detector
9
—
Gültigkeit
—
Handhabung
Dieses zusätzliche Installations-, Betriebs- und
Wartungshandbuch gilt für wassergekühlte
Motoren (M3LP 280–500) und muss zusammen mit
dem Haupthandbuch (Niederspannungsmotoren/
Handbuch) gelesen werden. Aufgrund spezieller
Anwendungs- und/oder Konstruktionshinweise
können für manche Maschinen zusätzliche
Informationen erforderlich sein.
Verwendung
Normalerweise werden wassergekühlte Motoren
nach spezifischen Kundenanforderungen
hergestellt. Diese Anleitung bezieht sich jedoch
auf „standardmäßige“ wassergekühlte
Motorversionen.
Sollte der Motor in Regionen mit einem Risiko von
Minustemperaturen eingesetzt oder gelagert
werden, muss das Einfrieren des Wassers im
Inneren des Motors verhindert werden. Dies kann
entweder durch Entleeren des Wassermantels
oder durch Verwendung von FrostschutzAdditiven erfolgen.
Vor dem Entleeren des Wassermantels ist dieser,
gemäß den Anweisungen des EmulsionHerstellers, mit einer korrosionssicheren
Emulsion zu schützen, z. B. Esso Cutwell 40, Shell
Dromus Oil BS oder gleichwertig. Wenn der Motor
über einen längeren Zeitraum ohne Wasser steht,
stellen Sie sicher, dass Wasser frei zirkulieren
kann, bevor Sie den Motor wieder in Betrieb
setzen. Entfernen Sie mögliche Rostschutzmittel,
indem Sie sie mit Oxalsäure auflösen:
1. Leeren Sie das Wasser aus dem Rahmen.
2. Füllen Sie den Rahmen mit Wasser, das mit
Oxalsäure gemischt ist (100 g/Liter).
3. Lassen Sie die Säure für ca. 10 Minuten
einwirken.
4. Entleeren Sie den Rahmen und reinigen Sie
ihn mit Druckwasser.
5. Wiederholen Sie die Behandlung ggf.
Wenn der Motor mit einem separaten Lagerlüfter
ausgestattet ist, stellen Sie sicher, dass ein freier
Belüftungsluftstrom vorhanden ist. Der Einbau
eines Motors mit einem Lagerlüfter
in geschlossener Flanschbauweise
(z. B. flanschmontierter Motor) wird nicht
empfohlen.
Die Reinigung des Motorkühlsystems unterstützt
die Wiederherstellung der Systemeffizienz.
ABB empfiehlt die Verwendung von normalen
Spül-, Zyklon- oder Magnetfiltern, die regelmäßig
zu warten sind. Die Spülung kann wie oben
beschrieben erfolgen.
Prüfen Sie, ob das Wasser im System nach dem
Spülen einen neutralen oder nahezu neutralen
pH-Wert aufweist.
10 3GZF500730-85 REV G EN 08-2018
—
Wasserkühlung
In den Motoren vom Typ M3LP wird durch im
Motorgehäuse zirkulierendes Wasser Abwärme
abgezogen. Das Wasser zirkuliert durch einen
Mantel im Gehäuse um den Motor und strömt
durch einen Auslass aus.
Die Motorbaugrößen 280-315 haben einen
Wassereinlass und einen Auslass mit R ½- oder
R 1-Zollgewinde an der D- und ND-Seite (Abb. 1).
Die Motorbaugrößen 355-500 haben einen
Wassereinlass und einen Auslass mit
R 1-Zollgewinde im ND-Ende (Abb. 1).
Hinweis! Lesen Sie das KühlwasserHinweisschild sowie die Markierungen für
Einlass- und Auslassleitungen am Motor!
Anforderungen an das Kühlwasser in den
Motorgrößen 280–315.
Es kann Wasser mit einem Chloridanteil bis
zu 3000 mg/l verwendet werden, wenn das
Eintreten von Sauerstoff in das Kühlwasser
verhindert wird und die Kühlwassertemperatur
30 °C nicht überschreitet. Der höchste zulässige
Druck für das Kühlwasser beträgt 5 bar.
Anforderungen an das Kühlwasser in den
Motorgrößen 355–500.
Kühlwasser muss Leitungswasserqualität
aufweisen. Es darf kein Seewasser oder Wasser
mit einem Anteil von Chlorid über 120mg/l
verwendet werden. Der höchste zulässige
Druck für das Kühlwasser beträgt 5 bar, mit einer
maximalen Eingangswassertemperatur von
40 °C. Die Konstruktion mit StahlrahmenWasserkühlung darf nur in einem geschlossenen
Frischwasserkreislauf verwendet werden.
Das Kühlwasser zirkuliert in im Maschinenrahmen
integrierten Kanälen. Das Material des Rahmens
und der Kanäle ist Kohlenstoffstahl gemäß Norm
EN 10025-S235JR. Dieses Material ist in
Salzwasser und Abwasser anfällig für Korrosion.
Die Korrosionsprodukte und
Schmutzablagerungen können den
Wasserdurchfluss in den Kanälen blockieren.
Daher ist es wichtig Reinwasser im Kühlsystem
zu verwenden.
Standardwerte für das im Kühlsystem verwendete
Kühlwasser:
• pH-Wert 6,5–9,5
• Alkalität (CaCO3) > 1 mmol/l
• Chlorid (Cl) < 120 mg/l
• Leitfähigkeit < 1500 μS/cm
In den meisten Fällen erfüllt normales
Leitungswasser, d. h. Wasser für den
Haushaltsgebrauch, alle diese Anforderungen.
Das Kühlwasser kann auch mit einem Mittel
inhibiert werden, das das Kühlsystem vor
Korrosion, Verunreinigung und ggf. vor Einfrieren
schützt. Bei der Auswahl eines geeigneten
Inhibitors sind alle Materialien, die mit dem
Kühlwasser (Rohre, Wärmetauscher usw.)
in Berührung kommen, zu berücksichtigen.
Verwenden Sie zum Anschließen der Maschine
an den Wasserkreis nur geeignete und
hochwertige Anschlussteile und Dichtungen.
HINWEIS!
Nur geschlossene Wassersysteme dürfen in Übereinstimmung mit den
im folgenden Abschnitt genannten Anforderungen eingesetzt werden.
Offene Wassersysteme können für die Typen M3LP 280–315 verwendet
werden, wenn Kühlwasser mit einem Chloridanteil unter 120 mg/l verwendet
wird. Es kann Wasser mit einem Chloridanteil bis zu 3000 mg/l verwendet
werden, wenn das Eintreten von Sauerstoff in das Kühlwasser verhindert
wird und die Kühlwassertemperatur 30 °C nicht überschreitet.
—
Anschluss
9AKK104378 ML 10-2020
9AKK104378 ML 10-2020 11
In frostgefährdeten Regionen kann ein Glykol/
Wasser-Gemisch im Verhältnis 40/60 (Glykol/
Wasser) bei einer empfohlenen minimalen
Umgebungstemperatur von -20 °C verwendet
werden.
Je niedriger die Kühlwassereinlasstemperatur
ist, desto besser wird der Motor gekühlt.
In einigen Fällen kann bei Bedarf und nach
Rücksprache mit dem Hersteller eine höhere
Eingangstemperatur zugelassen werden.
Der Temperaturanstieg des Austrittswassers
liegt zwischen 7–15 K.
Der Mindestdruck und die Mindestmenge an
Kühlwasser für den Grundaufbau eines
wassergekühlten Motors sind in der folgenden
Tabelle dargestellt. Bei Sonderkonstruktionen
bitte die Druckanforderungen und die Menge
des Kühlwassers überprüfen.
(Wenn die Wassermenge variiert, ist ihr
Temperaturanstieg umgekehrt proportional zur
Durchflussmenge.)
Motortyp
M3LP
Rahmentyp
Anzahl
der
Einlässe
Kühlwasserdurchfluss
(l/min)
Wasserdruck
min. (bar)
Wassertemp.
Anstieg (K)
Wärmeübertragung Wärmeverlust
im (ca.) Verhältnis Luft/Wasser bei
Raumtemperatur
Temperatur des Einlasskühlwassers
25 °C 40 °C
Wasserraum
des
St.-Rahmens
(l)
280 SM_ 1 20 2,0 7-12 10/90 30/70 1,2
315 KH_ 1 30 2,0 7-12 10/90 30/70 3,5
315 LK_ 1 30 2,0 7-12 10/90 30/70 4,7
355 ML_ 1 30 2,0 10-15 10/90 30/70 28
355 LK_ 1 35 2,0 10-15 10/90 30/70 35
400 L_ 1 40 2,0 10-15 10/90 30/70 50
450 L_ 1 50 2,0 10-15 10/90 30/70 65
500 L_ 1 60 2,0 10-15 10/90 30/70 71
12 9AKK104378 ML 10-2020 9AKK104378 ML 10-2020
Kühlwasser einfüllen oder ablassen
Öffnen Sie beim Auffüllen den Luftstopfen oben
auf dem Motor (Abb. 1). Lassen Sie das
Kühlwasser in den Motor strömen, bis es aus
dem Luftspalt austritt. Schließen Sie den
Luftspalt mit einem Stopfen und dichten Sie die
Verbindung mit Dichtungsband oder Band ab.
Die Befüllung muss vorsichtig erfolgen, damit
keine Luft in den Kühlkanälen des Motors
eingeschlossen wird. Nach dem Anschließen die
Rohrleitungen und Verbindungen auf mögliche
Undichtigkeiten prüfen.
Öffnen Sie während des Entleerens den
Entleerungsstopfen unter dem Motor und den
Luftstopfen oben auf dem Motor. Für die
Motorgrößen 280–315 kann die Entleerung mit
Druckluft erfolgen. Nach dem Entleeren müssen
die Stopfen wieder eingesetzt und die
Dichtungen der Verbindungen überprüft
werden.
Bei wassergekühlten Motoren ist es besonders
wichtig, dass sich die Kondenswasserbohrungen an der richtigen Position befinden
(Abb. 1). Es ist sicherzustellen, dass die
Kondenswasserbohrungen nach unten zeigen,
insbesondere wenn die Montageanordnung vom
Standard abweicht.
—
Kondenswasserbohrungen
Optional besteht die Möglichkeit, die Motoren
mit einem Schwimmer-Leckagedetektor zu
bestellen (Abb. 2). Der Leckagedetektor verfügt
über einen magnetischen Schwimmerschalter.
Der magnetische Schwimmerschalter ist auf
einem nicht magnetischen Führungsrohr
angeordnet. Wenn ein angegebener
Wasserstand erreicht wird, betätigt das
Magnetfeld, das durch den Magnet im
Schwimmer erzeugt wird, einen Reed-Schalter
(Dichtungskontakt) im Führungsrohr. Dadurch
wird der Stromkreis geschlossen, der das
Alarmsignal an die Steuerplatine sendet.
Die vertikale Montage des Motors hat nur einen
Leckagedetektor, während die horizontale
Montage zwei hat. Die Detektoren werden im
tiefsten Teil des Motors angeschlossen und
vertikal entsprechend der Montageanordnung
des Motors installiert. Die maximale
Abweichung von der vertikalen Achsenlinie
beträgt ±30 °.
Elektrischer Anschluss des Schwimmerschalters
max.
Spannung
230 V DC/AC
max. Strom 1 A Schaltleistung
100 VA
—
Wasserleckdetektor
13
—
Validité
—
Manutention
Ce manuel d’installation, d’exploitation et de
maintenance supplémentaire est valable pour
les moteurs à refroidissement par eau
(M3LP 280–500) et doit être lu en parallèle
du manuel principal (Moteurs basse tension /
manuel). Des informations supplémentaires
peuvent être requises pour certaines machines
en raison d’applications et/ou de conceptions
spécifiques.
Utilisation
Les moteurs à refroidissement par eau sont
fabriqués conformément aux exigences
spécifiques du client. Cependant, ces instructions
se réfèrent aux versions « standard » de moteur
à refroidissement par eau.
Si le moteur est utilisé ou stocké dans des
environnements présentant un risque de
températures inférieures à zéro, il faut éviter que
l’eau à l’intérieur du moteur ne gèle. Pour ce faire,
vidangez le circuit d’eau ou utilisez des additifs
antigel.
Avant de vider le circuit d’eau, protégez-le avec
une émulsion anticorrosion, par exemple Esso
Cutwell 40, Shell Dromus Oil BS, ou équivalent,
conformément aux instructions du fabricant
de l’émulsion. Si le moteur reste immobile
pendant de longues périodes sans eau, assurezvous que l’eau peut circuler librement avant
d’utiliser à nouveau le moteur. Éliminez les
éventuels blocages par dépôt de rouille en les
dissolvant avec de l’acide oxalique :
1. Videz le circuit d’eau.
2. Remplissez le circuit d’eau mélangée à de
l’acide oxalique (100 g / litre).
3. Laissez l’acide faire effet pendant environ
10 minutes.
4. Videz le circuit et nettoyez-le avec de l’eau sous
pression.
5. Si nécessaire, répétez le traitement.
Si le moteur est équipé d’un ventilateur
de roulement séparé, assurez-vous qu’il est
correctement ventilé. L’installation d’un moteur
avec un ventilateur de roulement dans une
structure à bride fermée (c’est-à-dire un moteur
à bride) n’est pas recommandée.
Le nettoyage du système de refroidissement
du moteur permet de restaurer l’efficacité
du système. ABB recommande d’utiliser des
filtres de rinçage, d’aspiration ou magnétiques
normaux qui feront l’objet d’un entretien régulier.
Le rinçage peut s’effectuer comme décrit
ci-dessus.
Vérifiez que l’eau dans le système est neutre
ou proche du pH neutre après le rinçage.
14 3GZF500730-85 REV G EN 08-2018
—
Refroidissement par eau
Dans les moteurs de type M3LP, la chaleur
résiduelle est dissipée par la circulation d’eau
à l’intérieur de la carcasse du moteur.
L’eau circule autour du moteur dans un circuit
à l’intérieur de la carcasse et s’écoule à travers
une sortie.
Les moteurs 280 à 315 sont équipés d’une
entrée et d’une sortie d’eau avec filetages
R ½\" ou R 1\" côté D et ND (fig. 1).
Les moteurs 355 à 500 sont équipés d’une
entrée et d’une sortie d’eau avec filetages
R 1\" côté ND (fig. 1).
Remarque ! Lisez la plaque d’instructions
de l’eau de refroidissement ainsi que les
marquages des tuyaux d’entrée et de sortie
sur le moteur.
Exigences relatives à l’eau de refroidissement
dans les moteurs 280 à 315
De l’eau avec une proportion de chlorure jusqu’à
3 000 mg/l peut être utilisée si la pénétration
d’oxygène dans l’eau de refroidissement est
empêchée et que la température de l’eau de
refroidissement ne dépasse pas 30 °C.
La pression maximale autorisée pour l’eau
de refroidissement est de 5 bar.
Exigences relatives à l’eau de refroidissement
dans les moteurs 355 à 500
L’eau de refroidissement doit être d’une qualité
équivalente à l’eau du robinet. Il ne faut pas
utiliser d’eau de mer ou d’eau dont la proportion
de chlorure est supérieure à 120 mg/l. La pression
maximale autorisée pour l’eau de refroidissement
est de 5 bar, avec une température maximale
recommandée de l’eau d’entrée de 40 °C.
La structure à refroidissement par eau du cadre
en acier doit être utilisée uniquement avec une
circulation fermée d’eau froide. L’eau de
refroidissement circule dans des conduites
intégrées dans la carcasse de la machine.
Les conduites et circuits sont en acier au carbone
conformément à la norme EN 10025-S235JR.
Ce matériau est sensible à la corrosion dans l’eau
salée et sale. Les résidus de corrosion et les
dépôts de saletés peuvent bloquer le débit d’eau
dans les conduites. C’est pourquoi il est
important d’utiliser de l’eau pure dans le système
de refroidissement.
Valeurs standard de l’eau de refroidissement
à utiliser dans le système de refroidissement :
• pH 6,5 à 9,5
• Alcalinité (CaCO3) > 1 mmol/l
• Chlorure (Cl) < 120 mg/l
• Conductivité < 1 500 μS/cm
Dans la plupart des cas, l’eau du robinet normale,
c’est-à-dire l’eau destinée à une consommation
domestique, répond à toutes ces exigences.
L’eau de refroidissement peut également être
inhibée avec un agent protégeant le système
de refroidissement contre la corrosion,
l’encrassement et, si nécessaire, contre le gel.
Tous les matériaux en contact avec l’eau de
refroidissement (tuyaux, échangeur thermique,
etc.) doivent être pris en compte lors du choix
d’un agent inhibiteur adapté.
N’utilisez que des pièces de raccordement
adaptées et de haute qualité pour raccorder
la machine au circuit d’eau.
REMARQUE !
Seuls les systèmes d’eau en circuit fermé peuvent être utilisés conformément
aux exigences spécifiées dans la section suivante. Les systèmes à eau en circuit
ouvert peuvent être utilisés dans les types M3LP 280 à 315 lorsque l’eau de
refroidissement avec une proportion de chlorure inférieure à 120 mg/l est
utilisée. L’eau avec une proportion de chlorure jusqu’à 3 000 mg/l peut être
utilisée si la pénétration d’oxygène dans l’eau de refroidissement est empêchée
et que la température de l’eau de refroidissement ne dépasse pas 30 °C.
—
Raccord
9AKK104378 ML 10-2020
9AKK104378 ML 10-2020 15
Dans les environnements présentant un risque
de températures inférieures à zéro, un mélange
glycol / eau peut être utilisé avec un mélange
40 / 60 (glycol / eau), avec une température
minimale recommandée de l’environnement
de -20 °C.
Plus la température d’entrée de l’eau de
refroidissement est basse, meilleur est le
refroidissement du moteur.
Dans certains cas, une température d’entrée
plus élevée peut être autorisée lorsqu’elle est
demandée et vérifiée par le fabricant.
L’élévation de la température de l’eau de sortie
va de 7 à 15 K.
La pression et la quantité minimales d’eau
de refroidissement pour la structure de base
d’un moteur à refroidissement par eau sont
indiquées dans le tableau suivant. Veuillez
vérifier les exigences en matière de pression
et de quantité d’eau de refroidissement en cas
de structures spéciales.
(Si la quantité d’eau varie, son échauffement
sera inversement proportionnel au débit.)
Type de
moteur
M3LP
Type de
carcasse
Nombre
d’entrées
Débit d’eau
de refroidissement
(l/min)
Pression
de l’eau
min. (bar)
Augmentation
de la température de l’eau
(K)
Transfert de chaleur de la perte
thermique dans le rapport
(approximatif) air / eau
à température ambiante
Température de l’eau de
refroidissement d’entrée
25 °C 40 °C
Contenance
en eau dans
le circuit (l)
280 SM_ 1 20 2,0 7-12 10/90 30/70 1,2
315 KH_ 1 30 2,0 7-12 10/90 30/70 3,5
315 LK_ 1 30 2,0 7-12 10/90 30/70 4,7
355 ML_ 1 30 2,0 10-15 10/90 30/70 28
355 LK_ 1 35 2,0 10-15 10/90 30/70 35
400 L_ 1 40 2,0 10-15 10/90 30/70 50
450 L_ 1 50 2,0 10-15 10/90 30/70 65
500 L_ 1 60 2,0 10-15 10/90 30/70 71
16 9AKK104378 ML 10-2020
Remplissage ou vidange de l’eau de
refroidissement
Lors du remplissage, ouvrez le bouchon d’air
situé sur le dessus du moteur (fig. 1). Laissez
l’eau de refroidissement s’écouler dans le circuit
jusqu’à ce qu’elle sorte de l’espace d’air. Fermez
l’espace d’air à l’aide d’un bouchon et scellez le
joint avec un ruban d’étanchéité ou une bande.
Le remplissage doit être effectué avec soin de
façon à ce qu’il n’y ait plus d’air dans le circuit de
refroidissement du moteur. Détectez toute fuite
éventuelle une fois que les tuyaux et les joints
ont été raccordés.
Lors de la vidange, ouvrez le bouchon de
vidange situé sous le moteur et le bouchon d’air
situé sur le dessus du moteur. La vidange des
moteurs 280 à 315 peut être réalisée avec de l’air
sous pression. Après la vidange, les bouchons
doivent être remis en place et les joints doivent
être vérifiés.
Il est particulièrement important avec les
moteurs à refroidissement par eau que les trous
de purge de condensation soient dans la bonne
position (fig. 1). Vérifiez que les trous de purge
de condensation sont orientés vers le bas,
en particulier lorsque la disposition de montage
n’est pas standard.
—
Trous de purge de condensation
En option, il est possible de commander les
moteurs avec un détecteur de fuite de type
flotteur (fig. 2). Le détecteur de fuite est doté
d’un commutateur de flotteur magnétique.
Le commutateur de flotteur magnétique est
positionné sur un tube de guidage non
magnétique. Lorsqu’un niveau d’eau spécifié est
atteint, le champ magnétique produit par
l’aimant dans le flotteur actionne un
commutateur à ampoule (contact fermé)
à l’intérieur du tube de guidage. Cela ferme
le circuit électrique qui transmet le signal
d’alarme au tableau de commande.
La version avec montage vertical du moteur ne
comporte qu’un seul détecteur de fuite, tandis
que la version avec montage horizontal en
a deux. Les détecteurs sont connectés dans la
partie inférieure du moteur et installés
verticalement selon la disposition de montage
du moteur. L’écart maximal par rapport à la ligne
d’axe vertical est de ±30°.
Raccordement électrique du commutateur
de flotteur
tension max.
230 V DC/AC
courant max. 1 A capacité de
commutation
100 VA
—
Détecteur de fuite d’eau
17
—
Validez
—
Manipulación
Este manual adicional de instalación,
funcionamiento y mantenimiento es válido
para los motores refrigerados por agua
(M3LP 280–500) y debe leerse junto con
el manual principal (Motores de baja tensión/
Manual). Es posible que algunas máquinas
requieran información adicional debido a sus
consideraciones especiales de aplicación
y/o diseño.
Uso
Normalmente, los motores refrigerados por agua
se fabrican según los requisitos específicos del
cliente. No obstante, estas instrucciones hacen
referencia a las versiones «estándar» con motor
refrigerado por agua.
Si el motor se utiliza o almacena en entornos con
riesgo de temperaturas bajo cero, se deberá
evitar que el agua se congele dentro del motor.
Esto puede realizarse vaciando la camisa de agua
o usando aditivos anticongelantes.
Antes de vaciar la camisa de agua, protéjala con
una emulsión anticorrosiva, por ejemplo, Esso
Cutwell 40, Shell Dromus Oil BS o equivalente,
conforme a las instrucciones proporcionadas por
el fabricante de la emulsión. Si el motor ha estado
parado por un largo período de tiempo sin agua,
asegúrese de que el agua pueda circular
libremente antes de usar de nuevo el motor.
Elimine las posibles obstrucciones de óxido
disolviéndolas con ácido oxálico:
1. Vacíe la carcasa de agua.
2. Llene la carcasa de agua mezclada con ácido
oxálico (100 g/litro).
3. Deje que el ácido haga efecto durante unos
10 minutos.
4. Vacíe la carcasa y lávela con agua a presión.
5. Repita el procedimiento en caso necesario.
Si el motor está equipado con un ventilador de
rodamiento separado, asegúrese de que el aire
pueda fluir libremente. No se recomienda instalar
un motor con ventilador de rodamiento en una
estructura de brida cerrada (p. ej.: un motor
montado en brida).
La limpieza del sistema de refrigeración del
motor ayuda a restaurar la eficiencia del sistema.
ABB recomienda hacer lavados regulares y usar
filtros ciclónicos o magnéticos, cuyo
mantenimiento debe realizarse con regularidad.
El lavado puede realizarse de la forma descrita
anteriormente.
Compruebe que el agua del sistema sea neutra
o tenga un pH casi neutro después del lavado.
18 3GZF500730-85 REV G EN 08-2018
—
Refrigeración por agua
En los motores del tipo M3LP, el calor residual se
extrae mediante el agua que circula dentro de la
carcasa del motor. El agua circula alrededor del
motor por una camisa dentro de la carcasa y
fluye hacia el exterior por una salida.
Los motores con carcasa de tamaño 280–315
tienen una entrada de agua y una salida con
roscas R ½\" o R 1\" en el lado acople y no
acople(fig. 1).
Los motores con carcasa de tamaño 355–500
tienen una entrada de agua y una salida con
roscas R 1\" en el lado no acople (fig. 1).
¡Atención! ¡Lea la placa de instrucciones del
agua de refrigeración y los marcados de los
tubos de entrada y salida del motor!
Requisitos para el agua de refrigeración
en motores de tamaños 280–315
Puede utilizarse agua con una proporción de
cloruro de hasta 3000 mg/l si se evita la entrada
de oxígeno en el agua de refrigeración y si la
temperatura de esta no supera los 30 °C.
La presión máxima permitida para el agua
de refrigeración es de 5 bares.
Requisitos para el agua de refrigeración
en motores de tamaño 355–500
La calidad del agua de refrigeración debe ser
equivalente a la del agua del grifo. No se debe
utilizar agua del mar ni agua con una proporción
de cloruro superior a 120 mg/l. La presión
máxima permitida para el agua de refrigeración
es de 5 bares y la temperatura máxima
recomendada para el agua de entrada es de
40 °C. La estructura con carcasa de acero
refrigerada por agua solo permite la circulación
de agua dulce en circuito cerrado. El agua de
refrigeración circula por conductos integrados en
la carcasa de la máquina. El material de la carcasa
y los conductos son de acero al carbono según la
norma EN 10025-S235JR. Este material es
propenso a la corrosión en aguas salinas y sucias.
Los productos corroídos y los depósitos de
suciedad pueden obstaculizar el flujo del agua en
los conductos. Por esta razón es importante
utilizar agua pura en el sistema de refrigeración.
Valores estándar del agua de refrigeración que
debe utilizarse en el sistema de refrigeración:
• pH 6,5–9,5
• Alcalinidad (CaCO3) > 1 mmol/l
• Cloruro (Cl) < 120 mg/l
• Conductividad < 1500 μS/cm
En la mayoría de los casos, el agua de grifo
normal, es decir, el agua para consumo doméstico
cumple todos estos requisitos.
El agua de refrigeración puede inhibirse también
con un agente que proteja el sistema de
refrigeración contra la corrosión, la suciedad y,
en caso necesario, contra la congelación. Deberán
tenerse en cuenta todos los materiales en
contacto con el agua de refrigeración (tuberías,
intercambiador de calor, etc.) al seleccionar un
inhibidor adecuado.
Use solamente juntas y piezas de conexión
adecuadas y de alta calidad para conectar la
máquina al circuito de agua.
¡ATENCIÓN!
Solo pueden utilizarse sistemas de agua de circuito cerrado de acuerdo con
los requisitos especificados en la sección siguiente. Los sistemas de agua
abiertos pueden utilizarse en los motores de tipo M3LP 280–315 cuando
se utiliza agua de refrigeración con una proporción de cloruro inferior
a 120 mg/l. Puede utilizarse agua con una proporción de cloruro de hasta
3000 mg/l si se evita la entrada de oxígeno en el agua de refrigeración
y si la temperatura de esta no supera los 30 °C.
—
Conexión
9AKK104378 ML 10-2020
