Series TA, TC, (2,3)JS, EC - 3-PHASE INDUCTION MOTORS OPERATING INSTRUCTIONS | ENGLISH
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Series TA, TC,
(2,3)JS, EC
3-PHASE INDUCTION MOTORS
OPERATING INSTRUCTIONS | ENGLISH
2
3-PHASE INDUCTION MOTORS
OPERATING INSTRUCTIONS | ENGLISH
BV 401
Version V_09, 01-03-2021
Changes and misprints reserved
www.EMK-motor.nl
3
Contents
1. Introduction............................................................................................................ 6
1.1. Validity ............................................................................................................ 6
1.2. Guide for the user ............................................................................................. 7
1.3. Declaration of Conformity ................................................................................... 8
2. Handling ................................................................................................................ 9
2.1. Reception check ................................................................................................ 9
2.2. Transportation and storage................................................................................. 9
2.3. Lifting .............................................................................................................. 9
2.4. Machine weight ............................................................................................... 10
3. Installation and commissioning ............................................................................... 11
3.1. General .......................................................................................................... 11
3.2. Insulation resistance check ............................................................................... 12
3.3. Foundation ..................................................................................................... 12
3.4. Mounting and alignment of the motor ................................................................ 12
3.5. Drain holes ..................................................................................................... 13
3.6. Permissible loads on the shaft end ..................................................................... 14
3.7. Balancing and fitting coupling halves and pulleys ................................................ 15
3.8. Slide rails and belt drives ................................................................................. 15
3.9. Earthing, cabling and electrical connections ........................................................ 16
3.10. Terminals and direction of rotation ................................................................. 18
4. Operation ............................................................................................................. 19
4.1. Conditions ...................................................................................................... 19
4.2. Cooling .......................................................................................................... 19
4.3. Safety considerations....................................................................................... 19
5. Maintenance ......................................................................................................... 21
5.1. General inspection ........................................................................................... 21
5.2. Lubrication ..................................................................................................... 22
6. Environmental requirements ................................................................................... 27
7. Troubleshooting .................................................................................................... 28
8. Parts list............................................................................................................... 30
9. Instructions for motors with star/delta switch ........................................................... 31
10. Terms and conditions of warranty ......................................................................... 32
410.1. Guarantee ................................................................................................... 32
10.2. Waste equipment ......................................................................................... 32
51. Introduction
1.1. Validity
The instructions are valid for the operation of the following types of EMK electrical machines in
frame sizes 56—355:
Series: MS1/MS2 (TM), MSB, MSD, MSC/MYC, MSV (TMV), MYV
Series: MY/MYT, ML, MC
Series: Y/Y2 (TM), YC, T1C (TM), T2C (TM/TCF), T3C (TM/ TCF), T4C, TCl/TCP, TG,
T1A, T2A, T3A, T4A
Series: JF, JC, JS, 2JF, 2JC, 2JS, 3JF, 3JC, 3JS
This manual is not valid for explosion-proof motors marked with the -symbol.
61.2. Guide for the user
The instructions in this manual should be followed to ensure safe and proper installation,
operation and maintenance of the machine. They should be brought to the attention of anyone
who installs, operates or maintains the machine or associated equipment. The machine 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.
Framed information is important for the user. An overview of the different types of frames:
ATTENTION!
In this frame remarks are given with extra information for the user. Information in this
frame draws attention to possible problems.
CAUTION!
Information in this frame means that machine can be damaged if instructions are not
followed carefully.
WARNING!
Information in this frame warns user for heavy damage to himself, or the machine, if
instructions are not followed carefully.
LIFE DANGER!
Information in this frame warns for direct life danger of the user or others if the instructions
are not followed carefully.
71.3. Declaration of Conformity 8
2. Handling
2.1. Reception check
Immediately upon receipt, check the motor for external damage (e.g. shaft-ends, flanges and
painted surfaces) and if found, contact EMK without delay. Check all rating plate data,
especially Voltage and winding connection (star or delta). The type of bearing is specified in
the motor catalogue.
2.2. Transportation and storage
The motor should always be stored indoors (above -10°C and max. +40°C), in dry, vibration
free and dust free conditions where the maximum relative humidity does not exceed 80% at
20°C. Dust, fumes and acrid vapours and other aggressive chemical fumes which can damage
the isolation or the cover should not enter the storage space.
The motor should be transported packaged, in roofed vehicles. Shocks, falls and humidity
should be avoided. Packaging should adequately protect the motor from mechanical damage
during transport. In other conditions, please contact EMK.
Unprotected machined surfaces (shaft-ends and flanges) should be treated against corrosion.
It is important to protect processed surfaces of motors in storage from atmospheric impact, by
covering them with thick grease or easily removable anti-corrosion paint.
It is recommended that shafts are rotated periodically by hand to prevent grease migration.
Anti-condensation heaters, if fitted, are recommended to be used to avoid water condensing in
the motor, they can be plugged into mains.
The motor must not be subject to any external vibrations at standstill so as to avoid causing
damage to the bearings. After storing a motor for a period of three years, its bearings should
be replaced for new ones, or the greasing should be replaced.
Motors fitted with cylindrical-roller and/or angular contact bearings must be fitted with locking
devices during transport.
2.3. Lifting
Motors with a weight of 25kg and more are equipped with lifting lugs or eyebolts.
Only the main lifting lugs or eyebolts of the motor should be used for lifting the motor. The
motor should not be lifted when it is attached to other equipment. Lifting lugs for auxiliaries
(e.g. brakes, separate cooling fans) or terminal boxes should not be used for lifting the motor.
Do not attach a rope to motor elements which stick out, such as the terminal box, mounting
feet, shaft, etc.
Motors with a same frame may have a different center of gravity because of different output,
mounting arrangements and auxiliary equipment. Damaged lifting lugs must not be used.
Check that eyebolts or integrated lifting lugs are undamaged before lifting.
9Lifting 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.
2.4. Machine weight
The total machine 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 EMK motors is shown in the catalogue.
Frame size Aluminium frame weight [kg] Cast Iron frame weight [kg]
56 4
63 5
71 7
80 11.2 17
90 17.6 27
100 27.3 38
112 35.7 50
132 64 84
160 97.5 147
180 128 195
200 156 270
225 320
250 427
280 667
315 1270
355 1850
103. Installation and commissioning
3.1. General
WARNING!
Disconnect and lock out before working on the motor or the driven equipment.
All rating plate values must be checked carefully to ensure that the motor protection and
connection will be properly done. The motor cannot be used without the covers foreseen in its
construction.
Before starting the motor, check:
whether the motor's rated voltage confirms with the network voltage
whether the motor hasn't been damaged during transportation or storage
whether the surrounding temperature in the location of the motor's installation does not
exceed +40°C, (for maritime motors,+45°C or +50°C, according to the maritime
association regulations)
whether free flow of cooling air, necessary for proper operation of the motor, will be
provided
CAUTION!
In case of motors mounted with the shaft upwards and water or liquids are expected to go
down along the shaft, the user must take in account to mount some means capable of
preventing it. Remove transport locking if employed. Turn shaft by hand to check free
rotation if possible.
Motors equipped with roller bearings:
Running the motor with no radial force applied to the shaft may damage the roller bearing.
Motors equipped with angular contact bearing:
Running the motor with no axial force applied in the right direction in relation to the shaft may
damage the angular contact bearing.
CAUTION!
For machines with angular contact bearings the axial force must not by any means change
direction.
Motors equipped with regreasing nipples:
When starting the motor for the first time, or after long storage, apply the specified quantity of
grease. For details, see section 5.2.2. Motors with regreasable bearings.
113.2. Insulation resistance check
Inspection of the insulation's condition should be done prior to starting the motor, if moistness
of the winding is suspected, or after a lengthy standstill or storage period (about 6 months).
WARNING!
Disconnect and lock out before working on the motor or the driven equipment.
LIFE DANGER!
During, and directly after measuring the insulation resistance, harmful voltage is present in
the terminals, therefore it is forbidden to touch them. The motor frame must be grounded
and in order to remove the threat of electrocution, it is necessary to discharge the winding.
The insulation resistance, corrected to 25°C, must exceed the reference value of 100 MΩ
(measured with 500 or 1000 V DC). The insulation resistance value is halved for each 20°C
rise in ambient temperature. 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.
Drain hole plugs, if fitted, must be removed. Valves, if fitted, 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.
3.3. Foundation
The end user has full responsibility for the preparation of a proper foundation. 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.
3.4. Mounting and alignment of the motor
The motor should be oriented in such a way so that it
IEC Minimal free space
is possible to have easy access for inspection and behind motor fan cover
operations relating with its maintenance. Ensure that ≤ 80 10 mm
there is enough space for free airflow around the
90 15 mm
motor. Minimum requirements for free space behind
100,112 20 mm
the motor fan cover should be achieved. See table on
the right. Correct alignment is essential to avoid 132-180 40 mm
bearing, vibration and possible shaft failures. Mount 200 30 mm
the motor on the foundation using appropriate bolts or 225 35 mm
studs and place shim plates between the foundation
250,280 45 mm
and the feet. Align the motor using appropriate
315 50 mm
methods. If applicable, drill locating holes and fix the
locating pins into position. Re-check the alignment after final tightening of the bolts or studs.
123.5. Drain holes
Every motor is supplied with drain holes and condensation plugs, located in the bearing
shields. Be aware that the drain holes should be located downwards when mounted, so that
moisture can flow out of the motor.
The drain holes can be used in 3 situations:
When opened, condensation moisture can be removed immediately, but be aware that
no moisture should be able to walk into the motor.
When closed, condensation moisture will not automatically be removed from the
motor. Therefore, maintenance should be applied from time to time, with the plug being
opened to allow the moisture to flow out of the motor.
As a combination it is possible to fit a hose plug with a hose so that there is an open
connection and the motor can drain moisture, but no direct moisture can come into the
motor.
As standard, the motors are supplied with closed drain holes. The other options are available
on request.
133.6. Permissible loads on the shaft end
3.6.1. TA, TC series
Radial load: Axial load:
Frame size Permissible Radial Load FR [kN] (x=xmax) Permissible Axial Load FP [kN]
2 Pole 4 Pole 6 Pole 8 Pole 2 Pole 4 Pole 6 Pole 8 Pole
TA 56 0.326 0.410 0.261 0.355
TA 63 0.327 0.411 0.470 0.260 0.353 0.423
TA 71 0.359 0.451 0.515 0.570 0.283 0.383 0.459 0.519
TA 80 0.595 0.749 0.854 0.944 0.465 0.629 0.753 0.859
TA 90S 0.643 0.811 0.935 1.015 0.496 0.671 0.806 0.913
TA 90L 0.657 0.830 0.956 1.035 0.493 0.669 0.803 0.907
TA 100 0.920 1.148 1.329 1.436 0.679 0.914 1.104 1.240
TA 112 1.269 1.596 1.833 2.015 0.951 1.286 1.541 1.758
TA 132S 1.878 2.374 2.728 2.985 1.414 1.919 2.305 2.615
TA 132M 1.845 2.334 2.681 3.052 1.395 1.895 2.276 2.606
TA 160M 2.346 2.945 3.393 3.778 1.789 2.415 2.910 3.339
TA 160L 2.358 2.956 3.398 3.846 1.763 2.379 2.860 3.320
TC 80 4.433 4.433 4.433 4.433 0.566 0.715 0.823 0.905
TC 90 5.253 5.253 5.253 5.253 0.614 0.778 0.895 0.980
TC 100 7.667 7.667 7.667 7.667 0.882 1.115 1.278 1.410
TC 112 10.133 10.133 10.133 10.133 1.136 1.438 1.654 1.824
TC 132 16.000 16.000 16.000 16.000 1.278 1.622 1.852 2.048
TC 160 21.200 21.200 21.200 21.200 1.403 1.769 2.028 2.239
TC 180 30.000 30.000 30.000 30.000 2.677 3.373 3.935 4.340
TC 200 34.700 34.700 34.700 34.700 3.733 4.712 5.394 5.950
TC 225 40.000 40.000 40.000 40.000 4.201 5.192 5.957 6.482
TC 250 45.300 45.300 45.300 45.300 4.641 5.847 6.707 7.366
TC 280 57.700 57.700 57.700 57.700 6.750 8.500 9.750 10.700
TC 315 64.700 79.300 79.300 79.300 6.800 10.350 11.800 12.350
TC 355 79.300 119.300 119.300 119.300 8.450 13.850 15.750 17.300
143.7. Balancing and fitting coupling halves and pulleys
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 standard balancing method specified for the motor. 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 by removing it using a lever pressed
against the body of the motor. Peak load on the shaft neck with transverse and axial force may
not exceed the limit values specified in section 3.6. Permissible loads on the shaft end. In belt
drives, avoid an excessive belt pull - it reduced the life of the bearings and overloads the shaft.
3.8. Slide rails and belt drives
A motor with feet can be mounted directly on anchor bolts or on slide-rails for belt tension
adjustment. Fasten the motor to the slide rails as shown in Figure 3.1). Place the slide rails
horizontally on the same level. Check that the motor shaft is parallel with the drive shaft. Belts
must be tensioned according to the instructions of the supplier of the driven equipment.
CAUTION!
Excessive belt tension will damage bearings and can cause shaft damage.
Figure 3.1 - Belt drive
For belt drives, it is recommended to use transmissions with wedge belts, which have:
smaller slide
quieter operation
lower belt tension
Lower belt tension results in a lower risk of damaging motor's bearing from the drive
side. Correct assembly and appropriately balanced coupling element have a
significant effect on the drive's vibrations and quite operation.
153.9. Earthing, cabling and electrical connections
The terminal box on standard single speed motors normally contains six winding terminals and
at least one earth terminal. The terminal box on standard multi speed motors normally
contains six or nine 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. Machines are intended for fixed installation only. If not 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. 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.
ATTENTION!
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 machine is connected
to the supply voltage. The earthing or the protective conductor should be connected to the
terminal marked with the earthing symbol located in the terminal box and / or on the
motor's frame.
Ensure that the motor protection corresponds to the environment and weather conditions;
Minimal earthing
for example, or protective
make lead profiles:
sure that water cannot enter the motor or the terminal boxes. The seals
of terminal boxes must be placed 2correctly in the slots provided, to ensure the correct IP
class. Live lead profile S [mm ] Earthing or protective conductor profile
[mm2]
S 25 S
25 S 50 25
S 50 0,5 S
In order to avoid unfortunate accidents while operating the motor, it is important to follow
these rules:
power cables must be properly secured from being damaged.
after failures (short circuit or eventually overheating of the winding) in order to ensure
that no eventual explosion of fumes - gasses trapped inside the motor occurs, it is
necessary, before performing electrical measurements, to carefully air out the motor’s
interior by dismantling the motor, including taking out the rotor from the stator
163.9.1. 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. See the connection
diagram below (figure 3.2). For multi-speed and special motors, the supply connection must
follow the instructions inside the terminal box or according an appropriate connection diagram
as supplied by EMK. The voltage and connection are stamped on the terminal box cover.
Figure 3.2 - Connection diagram
Direct-on-line starting (DOL):
Y or D winding connections may be used. For example, 600 VY, 400 VD indicates Y-connection
for 600 V and D-connection for 400 V.
Star/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.
3.9.2. Connections of auxiliaries
If a motor is equipped with thermistors or other RTDs (Pt100, thermal relays, etc.) and
auxiliary devices, they are recommended to be used and connected by appropriate means.
Maximum measuring voltage for the thermistors is 2,5V. Maximum measuring current for
PT100 is 5 mA. Using a higher measuring voltage or current may cause errors in readings or
damage the system.
173.10. Terminals and direction of rotation 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 3.2. 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. 18
4. Operation
4.1. Conditions
The motors are designed for the following conditions (unless otherwise stated on the
nameplate):
Normal ambient temperature limits are -20°C to +40°C
Maximum altitude 1000 m above sea level
Tolerance for supply voltage is ±5% and for frequency ±2% according to EN / IEC
60034-1
Relative air humidity: 95%
Motors in a basic version have a protection rating IP55 acc. to PN- IEC 60034-5. On
request, motors can be made with a protection rating up to IP66
Stator winding and the insulation material used correspond to the insulation class F. On
request, motors can be made with insulation class H
WARNING!
Ignoring any of given instructions or maintenance of the apparatus may jeopardize the
safety and thus prevents the use of the machine.
4.2. Cooling
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.
4.3. Safety considerations
The machine 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!
Do not carry out work on motor, connection cables or accessories such as frequency
converters, starters; brakes, thermistor cables or heating elements when voltage is applied.
Points to observe
1. Do not step on the motor
2. The motor cannot in any case be in operation without a functional earthing. The quality
of earthing or neutralization should be checked periodically for the reason that contacts
may loosen or get corroded
193. The temperature of the outer casing of the motor may be too hot to touch during
normal operation and especially after shut-down
4. Some special motor applications require special instructions (e.g. using inverter
supplies)
5. Be aware of rotating parts of the motor. The motor cannot be operated without the
cover of an external fan or without the cover of the coupling or the belt, fan or gear
transmission, with elements leading current exposed.
6. Do not open terminal boxes while energized
7. After failures (short circuit or eventually overheating of the winding) in order to ensure
that no eventual explosion of fumes - gasses trapped inside the motor occurs, it is
necessary, before performing electrical measurements, to carefully air out the motor's
interior by dismantling the motor, including taking out the rotor from the stator
8. Each location where the electric motion takes place should be equipped with a fire
extinguisher filled with non-conducting extinguishing agent.
9. Safety devices preventing accidents from occurring should be present in the location of
the installation, in accordance with local safety regulations
205. Maintenance
In order to maintain the motor in full technical efficiency, it is necessary to remove all defects
noticed during operation on an ongoing basis. Every working motor should be subjected to
periodic maintenance inspections. Time periods between maintenances, running and major
repairs, are dependent on the conditions of motor's work.
LIFE DANGER!
Voltage may be connected at standstill inside the terminal box for heating elements or
direct winding heating. Before attempting any regulating operations, inspections or repairs,
turn off all power supplies. Prior to taking off protective covers, prior to directly touching
moving parts or parts which can be under current, unplug the motor and all additional and
support circuits from the mains.
The capacitor in single-phase motors can retain a charge that appears across the motor
terminals, even when the motor has reached standstill.
A motor with frequency converter supply may energize even if the motor is at standstill.
5.1. General inspection
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, mounting and assembly bolts
5. Check the bearing condition by listening for any unusual noise, vibration measurement,
bearing temperature, inspection of spent grease or bearing monitor. 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 IP55 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.
215.2. Lubrication
WARNING!
Beware of all rotating parts! Grease can cause skin irritation and eye inflammation. Follow
all safety precautions specified by the manufacturer.
Bearing types are specified in the respective product catalogs.
Reliability is a vital issue for bearing lubrication intervals. EMK uses mainly the L1 principle
(i.e. that 99% of the motors are certain to make the life time) for lubrication.
5.2.1. Machines with permanently greased bearings
Bearings are usually permanently greased bearings of 1Z, 2Z, 2RS or equivalent types.
As a guide, adequate lubrication for sizes up to 200 can be achieved for the following duration,
according to L10. Duty hours for permanently greased bearings at ambient temperatures of 25
and 40°C are:
Lubrication intervals according to L10 principle
Frame size Poles Duty hours at 25°C Duty hours at 40°C
56 – 63 2–8 40000 40000
71 2–8 40000 40000
80 – 90 2–8 40000 40000
100 – 112 2 40000 32000
100 – 112 4–8 40000 40000
132 2 40000 27000
132 4–8 40000 40000
160 2 40000 36000
160 4–8 40000 40000
180 2 38000 38000
180 4–8 40000 40000
200 2 27000 27000
200 4–8 40000 40000
Data valid at 50 Hz, for 60 Hz reduce values for 20%
These values are valid for permitted load values given in the product catalogue. Depending on
application and load conditions, see the applicable product catalogue or contact EMK.
Operation hours for vertical motors are half of the above values.
5.2.2. Motors with regreasable bearings
During the first start or after a bearing lubrication a temporary temperature rise may appear,
approximately 10 to 20 hours.
22A. Manual lubrication
Regreasing while the motor is running:
Remove grease outlet plug
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
Regreasing while the motor is at a standstill:
If it is not possible to regrease the bearings while the motors are running, lubrication can be
carried out while the machine is at a standstill.
In this case use only half the quantity 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
B. Automatic lubrication
The grease outlet plug must be removed permanently with automatic lubrication.
EMK recommends only the use of electromechanical systems.
The amount of grease per lubrication interval stated in the table should be multiplied by four if
an automatic regressing system is used.
When 2-pole motors are automatically regreased, the note concerning lubricant
recommendations for 2-pole motors in the Lubricants chapter (chapter 5.2.4.) should be
followed.
5.2.3. Lubrication intervals and amounts
As a guide. adequate lubrication for motors with regreasable bearings can be achieved for the
following duration, according to L1. For duties with higher ambient temperatures please
contact EMK The formula to change the L1 values roughly to L10 values: L10 = 2.7 x L1.
Lubrication intervals for vertical machines are half of the values shown in the table below.
The lubrication intervals are based on an ambient temperature +25°C. An increase in the
ambient temperature raises the temperature of the bearings correspondingly. The values
should be halved for a 15°C increase and may be doubled for a 15°C decrease.
CAUTION!
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.
23Lubrication intervals according to L1 principle
Ball bearings – Lubrication interval in duty hours
Amount of
Frame 3000 1500 1000 500-900
grease kW kW kW kW
size rpm rpm rpm rpm
g/bearing
112 10 All 13000 All 21000 All 25000 All 28000
132 15 All 11000 All 19000 All 23000 All 26500
160 25 ≤18.5 12000 ≤15 21500 ≤11 24000 All 24000
160 25 >18.5 10000 >15 18000 >11 22500 All 24000
180 30 ≤22 9000 ≤22 18500 ≤15 24000 All 24000
180 30 >22 8500 >22 17000 >15 21000 All 24000
200 40 ≤37 8000 ≤30 17500 ≤22 23000 All 24000
200 40 >37 5500 >30 12000 >22 16000 All 20000
225 50 ≤45 6500 ≤45 16500 ≤30 22000 All 24000
225 50 >45 2500 >45 6000 >30 8000 All 10000
250 60 ≤55 4000 ≤55 11500 ≤37 15000 All 18000
250 60 >55 1500 >55 4500 >37 6000 All 7000
280 60 All 3500
280 60 All 10500 All 14000 All 17000
280 35 All 3200
280 40 All 9600 All 13900 All 15000
315 35 All 3200
315 55 All 7600 All 11800 All 12900
355 35 All 3200
355 70 All 5600 All 9600 All 10700
24Lubrication intervals according to L1 principle
Roller bearings – Lubrication interval in duty hours
Amount of
Frame 3000 1500 1000 500-900
grease kW kW kW kW
size rpm rpm rpm rpm
g/bearing
160 25 ≤18.5 6000 ≤15 10500 ≤11 12000 All 12000
160 25 >18.5 5000 >15 9000 >11 11000 All 12000
180 30 ≤22 4500 ≤22 9000 ≤15 12000 All 12000
180 30 >22 4000 >22 8500 >15 10500 All 12000
200 40 ≤37 4000 ≤30 8500 ≤22 11500 All 12000
200 40 >37 2500 >30 6000 >22 8000 All 10000
225 50 ≤45 3000 ≤45 8000 ≤30 11000 All 12000
225 50 >45 1250 >45 3000 >30 4000 All 5000
250 60 ≤55 2000 ≤55 5500 ≤37 7500 All 9000
250 60 >55 750 >55 2000 >37 3000 All 3500
280 60 All 1750
280 60 All 5250 All 7000 All 8500
280 35 All 1600
280 40 All 5300 All 7000 All 8500
315 35 All 1600
315 55 All 3800 All 5900 All 6500
355 35 All 1600
355 70 All 2800 All 4800 All 5400
255.2.4. Lubricants
CAUTION!
Do not mix different types of grease. Incompatible lubricants may cause bearing damage.
When regreasing, 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
*) For vertical mounted motors or in hot conditions a stiffer end of scale is recommended.
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. Grease with the correct
properties is available from all the 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.
CAUTION!
Lubricants containing EP admixtures are not recommended in high bearing temperatures in
frame sizes 280 to 450.
The following high performance greases can be used:
Esso Unirex N2 or N3 (lithium complex base)
Mobil Mobilith SHC 100 (lithium complex base)
Shell Albida EMS 2 (lithium complex base)
Klüber Klüberplex BEM 41-132 (special lithium base)
FAG Arcanol TEMP110 (lithium complex base)
Lubcon Turmogrease L802 EP PLUS
Total Multiplex S 2 A (lithium complex base)
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 (poyurea 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.
266. Environmental requirements
Noise levels
Most of the EMK-motors have a sound pressure level not exceeding 82 dB(A) at 50 Hz.
Values for specific machines can be found in the relevant product catalogues. At 60 Hz
sinusoidal supply the values are approximately 4 dB(A) higher compared to 50 Hz values in
product catalogues.
277. Troubleshooting
Motor troubleshooting chart
These instructions do not cover all details or variations in equipment nor provide for every
possible condition to be met in connection with installation, operation or maintenance. Your
motor service and any troubleshooting must be handled by qualified persons who have proper
tools and equipment.
Trouble Cause Solution
Motor none start Blown fuses Replace fuses with proper type and rating
Overload trips Check and reset overload in starter
Check to see that power supplied agrees with motor rating
Improper power supply
plate and load factor
Improper line connections Check connections against diagram supplied with motor
Indicated by humming sound when switch is closed. Check
Open circuit in winding or
for loose wiring connections. Also ensure that all control
control switch
contacts are closing
Check to see if motor and drive turn freely. Check
Mechanical failure
bearings and lubrication
Short circuited stator Indicated by blown fuses. Motor must be rewound
Poor stator coil connection Motor needs to be repaired by an expert
Rotor defective Motor needs to be repaired by an expert
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
Ensure the rating plate voltage is maintained. Check
Low voltage
connection
Fuses blown, check overload relay, stator and push
Open circuit
buttons
Motor runs and then
Power failure Check for loose connections to line, to fuses and to control
dies down
Motor does not Not applied properly Consult equipment supplier for proper type
come up to nominal
speed Voltage too low at motor Use higher voltage or transformer terminals or reduce
terminals because of line drop load. Check connections. Check conductors for proper size
Starting load too high Check the start load of the motor
Look for cracks near the rings. A new rotor may be
Broken rotor bars or loose rotor
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair
Motor takes too Excessive load Reduce load
long to accelerate
and/or draws high Check for high resistance. Make sure that adequate cable
Low voltage during start
current size is used
Defective squirrel cage rotor Motor needs to be repaired by an expert
Applied voltage too low Correct power supply
28Trouble Cause Solution
Wrong rotation
Wrong sequence of phases Reverse connections at motor or at switchboard
direction
Motor overheats Overload Reduce load
while running
Frame or ventilation openings
Open vent holes and check for a continuous stream of air
may be full of dirt and prevent
from the motor
proper ventilation of motor
Motor may have one phase
Check to make sure that all leads are well connected
open
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 Balance driven equipment
Defective bearings Replace bearings
Bearings not in line Motor needs to be repaired by an expert
Balancing weight shifted Rebalance motor
Contradiction between
balancing of rotor and coupling Rebalance coupling or motor
(half key-full key)
Polyphase motor running single
Check for open circuit
phase
Excessive end play Adjust bearing or add shim
Scraping noise Fan rubbing end shield of fan
Correct fan mounting
cover
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 Move pulley closer to motor bearing
shoulder
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 Remove old grease, wash bearings thoroughly in kerosene
lubricant contaminated and replace with new grease
Excess lubricant Reduce quantity of grease, bearing should not be more
than half full
Overload bearing Check alignment, side and end thrust
Broken ball or rough races Replace bearing, clean housing thoroughly first
298. Parts list # Description # Description 1 Screw 20 Preload washer 2 Gasket 21 Key 3 Oil seal 22 Rotor 4 Front shield 23 Bearing 5 B14 flange 24 NDE (Non Drive End) shield 6 B5 flange 25 Cooling fan 7 Terminal Box cover 26 Fan circlip 8 Terminal Box fixing screws 27 Fan cover 9 Terminal Box upper gasket 28 Fan cover fixing shim 10 Terminal board fixing nut 29 Fan cover fixing screws 11 Terminal bridge 30 End shield fixing nut 12 Terminal pin 31 Rivet 13 Terminal shim 32 Nameplate 14 Terminal board 33 Foot fixing nut 15 Terminal Box fixing screws 34 Foot fixing screws 16 Terminal Box base 35 Foot 17 Cable gland 36 Bearing fixation plate 18 Terminal Box bottom gasket 37 Bearing fixation bolt 19 Frame 30
9. Instructions for motors with star/delta switch
Safety instructions
Pull of the power plug before opening the housing of the switch!
Only qualified, skilled personnel are permitted to work on assembling and putting the
switch into operation. Only personnel familiar with the components are allowed to use
the switch in operation.
A detailed manual is available on request
3110. Terms and conditions of warranty 10.1. Guarantee The manufacturer issues a guarantee for correct operation of the motor and its components on condition that the user complies with the directions contained in this document. The period of guarantee amounts to 12 months of utilization. The guarantee does not cover damages resulting from utilization of the product not in compliance with its purpose, incorrect selection to operating conditions, errors committed while mounting the motor into a machine or equipment, incorrect current source connections and mechanical damages. Defects or malfunctioning in motor operation noticed during the guarantee period should be reported to EMK immediately. Any modifications or repairs whatsoever performed in the user’s own capacity without the consent of the manufacturer causes forfeiture of rights resulting from the guarantee. A complete overview of warranty conditions is available on request. 10.2. Waste equipment Information on Disposal for Users of Waste Electrical and Electronic Equipment: This product is marked according to the European 1000VAC Directive on Waste Electrical and Electronic Equipment (2002/96/EC) and further amendments. By ensuring this product is disposed of correctly, you will help to prevent potential negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling of this product. The symbol on the product, or the documents accompanying the product, indicates that this appliance may not be treated as household waste. It shall be handed over to the applicable collection point for used up electrical and electronic equipment for recycling purpose. For more information about recycling of this product, please contact your local authorities, your household waste disposal service or the shop where you purchased the product. 32
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