Totally enclosed fan-cooled (TEFC)three-phase motors with squirrel cage

for low voltage, with antifriction bearings.

Installation and Maintenance Manual Premium RangeTC Cast Iron RangeTA Aluminum Range

BROOK CROMPTON ELECTRIC MOTORS

Installation And Maintenance Procedure

All 3 phase induction motors aremanufactured in accordance with strictquality control procedures, haveexcellent functional and performancecharacteristics, and are of robustconstruction. To obtain optimumperformance and service life fromthese motors please follow theinstructions listed below.

1. SAFETY WARNINGThese Electric Motors are designed foroperation in Industrial applications andin normal service there is possibledanger from rotating parts and/or liveterminals. It is essential that thesemotors are only installed and servicesby qualified personnel in order to avoidinjury or death and/or damage toequipment or buildings.If there are any safety concernsregarding these motors please contactyour nearest sales office for advice orassistance.If there are any doubts about safety donot install the motor and do not attemptto operate it.We cannot be held responsible fordamage as a result of installation orservice by unqualified personnel.

2. ACCEPTANCE INSPECTIONUpon receiving the motors please carryout the following:(a) Check that the description on thepacking slip agrees with yourorder specifications.(b) Check that the rating, speed, etc.are in accordance with yourrequirements.(c) Check for any damage, rust, dirt,foreign substance, etc. All motorsshould be received with a plastic shaftcover to protect the shaft duringstorage and transport.(d) Check that the direction of rotation,if specified, is correct. If the motor hasa low noise uni-directional fan adirection arrow is fitted to the motor.

3. PRE-COMMISSIONINGSatisfactory operation of an electricmotor depends on its location. Pleaseensure that the following factors havebeen taken into consideration.(a) Ambient TemperatureThe ambient temperature range inwhich a standard motor will operatewithout any problems is -15°C to+40°C. If motors are required tooperate outside this temperature range,and were not specifically ordered andsupplied for such conditions, pleasecontact the nearest sales office foradvice before proceeding.(b) VentilationPlease ensure that the motor isinstalled in a suitably ventilated area.

Ensure that there is a free area in frontof the air intake of at least a quarter ofthe shaft height. The exhausted airmust not be re-circulated back over themotor, as this will reduce theeffectiveness of the cooling system.(c) DustIf the air contains a high concentrationof dust which is permitted toaccumulate on the external surfaces ofthe motor, it may result in the motoroverheating. If the dust is a problem itmay warrant the use of a specialmotor.(d) Hazardous AreaEnsure that the motor is certified foruse in the area of operation.Hazardous areas require speciallycertified motors.(e) VibrationEnsure that the motor is installed on asolid floor, foundation, or rigid base,free from any external vibration.(f) MountingMotors are designed for horizontalmounting and frames 254T and aboveare provided with suitably positionedcondensation drain holes. All motors inframes up to and including 447T aremechanically suitable for mounting inany position subject to the drain holesbeing suitably positioned. Where it isrequired to mount larger frame sizesother than horizontal please contactyour nearest sales office.(g) EnclosureAll motors are Totally Enclosed FanCooled and have an enclosure rating ofIP55 as a minimum. Motors with higherprotection are available, but werecommend that IP56 and IP66 motorsare supplied and used with spaceheaters to prevent the build up ofcondensation

4. FITTING COUPLINGS ANDALIGNMENTExtreme care must be exercised inlining up couplings as mis-alignmentcan be detrimental to the shaft andbearings. For direct drives, werecommend that flexible couplings areused. Please ensure that the alignmentinstructions given by the couplingmanufacturer are followed. Werecommend that couplings and pulleysare bored out with an H7 tolerance. Donot at any time use force in the fittingof couplings, pulleys etc. Care mustalso be taken to ensure that the motorbearings are not subjected to end-thrust caused by the two halves of the couplingbeing squeezed too tightly together.Please ensure that all couplings, belts,pulleys etc are properly andpermanently guarded againstaccidental contact while the motor isrunning.Care should be taken to ensure fixingbolts are correctly tightened. It is

recommended that a flat washer and aspring washer are used to prevent toomuch stress on the foot or flange of amotor, and to prevent fixing bolts frombecoming loose. Normal hand tools shouldbe used and bolts should only be tighteneduntil the spring washer is fully compressedbetween the flat washer and the bolthead.Electrical connections also need to bedone correctly to ensure solidconnections and avoid hot joints. All fixingbolts and electrical connections should bechecked and tightened if necessary after100 to 200 hours of operation.Recommended tightening torques forelectrical terminals in Nm.

5. BELTS DRIVESPlease ensure that the V-Belts are ofthe same manufacture and have thesame dimensions. Also ensure that thebelts are correctly tensioned inaccordance with the manufacturersrecommendations. If the V-Belts arenot tensioned correctly it can causebelt and pulley wear and / or shaft andbearing damage. When replacing belts,it is recommended that all belts bereplaced at the same time. It is notgenerally recommended to use twopole motors for belt drive applications.Please refer such requirements to thenearest sales office.

6. COMMISSIONINGBefore starting the motor, pleaseensure that the following checks havebeen carried out:(a) Safety / LiftingAll motors 182T frame and above arefitted with lifting eyebolts as standard.These eyebolts are only intended forlifting the motor, not equipmentattached to the motor such as gearbox,pump etc.(b) WiringPlease refer to the motor nameplate forthe method of connection. All motorsare supplied with a connection diagramon the inside of the terminal box lid oron the motor nameplate. Ensure themotor is connected in the correctmanner for the starter.(c) ConnectionAll motors are provided with a spaciousterminal box. All terminal boxes can berotated in 90° steps.(d) Earth ConnectionAll motors are provided with twoearthing points, ensuring reliable andpermanent connection of the motor tothe earth with the protective conductor.The internal connection is located

Stud diameterMin.Max.

M51.82.5

M63.04.0

M88.09.0

M101017

M122030

M166073

1

Installation And Maintenance Procedure

adjacent to the supply terminals insidethe terminal box. The externalconnection is mounted on the statorframes for all frame size.(e) Insulation ResistanceCheck the insulation resistance betweenphase and earth, and between phaseswith a 500 volt or 1000 volt megger for 60 seconds. The reading must not be lessthan 5 megohms after a long period ofstorage or standing idle in a moistenvironment. It is recommended thatmotors are dried out or run on no loadat approximately 20% of rated volts toensure that any internal moisture isdried out.(f) StartingWhen a motor is operated for the firsttime it is recommended that it is rununcoupled from the load to ensure thatthe direction or rotation is correct andthat there is no undue noise orvibration. Before running the motormake sure that any loose items suchas shaft keys are removed or fixed sothat they cannot "fly off" when themotor is switched on.All motors are balanced in the factorywith a half key. Motors can be runwithout the key fitted, or with the fullkey fitted, however this may cause asmall amount of vibration.(g) ReversingTo reverse the direction of rotationinterchange any 2 of the 3 supplyleads. In the case of incorrect rotationof a motor fitted with unidirectional fanplease contact your nearest salesoffice.(h) Frequency of StartingStandard motors are capable of 2starts in succession, of 3 secondsduration each start, with the motor atnormal running temperature. Standardmotors are also suitable for 6 evenlyspaced starts per hour. If startingfrequency in excess of the above isrequired please contact your nearestsales office.

7. BEARINGSThe bearings in all motors arelubricated with lithium based grease.Motors running in high or low ambienttemperatures may require specialbearings and almost certainly specialgrease. As standard the motors aresupplied with the following bearings:(a) Frames 143T - 215TThese motors have C3 internalclearance double shielded "sealed forlife" ball bearings. These bearings arenot designed to be regreaseable.(b) Frames 254T - 447TThese motors have open bearings witha C3 internal clearance. Greasenipples are fitted and the motors areregreaseable as standard. Thesemotors are fitted with a grease reliefplug which must be removed to allow

the old grease to purge duringregreasing. It is recommended that themotor should be run for 2 hours withthe plug removed when the newgrease is added. We recommend thatthe motors are checked every threemonths and regreased if necessary.Please refer to the separate bearingand regreasing page.We recommend that these motors areregreased whilst they are running. It isessential that the grease nipples arealways cleaned before each lubricationto ensure dirt does not enter thebearings.Recommended grease for normalapplications are :Frames 160/254T - 315/449T Lithium based grease TC EPACT model only, PC Premium model polyurea grease. Mixing different greases is notrecommended, as not all greases arecompatible with each other.If the motor is subject to any axialthrust, please contact your nearestsales office, as special thrust bearingsmay be necessary.For motors without grease relieffacilities the old grease must becleaned out from time to time byremoving the bearing cap and \ orendshield. The bearing and housingmust then be repacked with greaseand reassembled. Do not overfill thebearing housing - it should not be morethan a quarter full of grease afterreassembly. The bearing details andregreasing information are shown onthe bearing and regreasing page.

8. MAINTENANCEWe recommend that if a motor is usedcontinuously that it is removed forinspection and dismantled every 5years. Items that should be checkedand recorded are:(a) Insulation resistance andtemperature at which it is measured.(Expect the insulation level to be low ifthe motor is hot)(b) Inspection of the bearings andcheck for discoloration of the grease.(c) Tightness of " V-Belts" andalignment of couplings.(d) Ensure that the holding down boltsare tight and the base plate orfoundations are rigid.(e) Cleanliness inside and outside themotor.

9. FAULT FINDINGPlease see separate fault finding page 3.

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Fault Finding - Three Phase Induction Motors

Motor will not start

Supply or starter trips out atstart

Motor starts but has no torque.Motor does not reach full speedor takes a long time to accelerate

Motor overheating

No load amps in excess of fullload amps.

1. Fault with supply.2. Motor or load locked up.3. Wrong connection in controlcircuit.1. Wrong or loose connections.2. Motor overloaded.

3. Inertia of load too high.4. Low voltage due to volt dropin cables.5. Overload or circuit breakerincorrectly set or sized.1. Incorrect connection.2. Delta wound motor connected in star.3. Star/Delta starter staying instar.4. Inertia of load too high.5. Motor overloaded.6. Low voltage due to drop incables.1. Motor overloaded.2. Ineffective cooling.Temperature of air.Look for build up of dirt3. Excessive ambient.4. Wrong connections.5. Delta wound motor in star.6. Motor ‘Single Phasing”.7. Wrong voltage or frequency.8. Supply voltage unbalanced.1. Incorrect connection.2. Star wound motor connected Delta.3. Voltage in excess of nameplate.4. Motor supplied for a different voltage or frequency.

1. Check for correct voltage atmotor terminals.2. Make sure motor and loadare free to turn.3. Check to ensure contactorsoperate.1. Check all lugs are properlycrimped or soldered, and connections are tight.2. Check load performancedata against motor performance data.3. Measure voltage at motorterminals while motor starting.4. Check settings of overloadand circuit breaker and allowfor starting current.

1. Check connection diagramand nameplate data.2. Check load performancedata against motor performance data.3. Measure voltage at motorterminals while motor starting.

1. Check load performancedata.2. Check fan and air flow.

3. Check connection diagramand nameplate data.4. Check volts and amps on allthree phases.5. Check nameplate6. Check phase to phase voltage accurately.

1&2. Check connection diagram

3. Measure voltage at motorterminals.4. Compare supply voltage andfrequency to nameplate.

1.. Fit new fuses, reset circuitbreakers, etc.2. Remove clamps, locks etc.3. Sort out control circuit.

1. Fix up connections.

2. Change motor for correctsize.3. Change cables for correctsize.4. Correct setting of overloador breaker or change.

1. Sort out and correct connections.2. Check timer and startercontrol circuit.3. Change motor for correctsize.

4. Change cables for correctsize.1. Fix problem with load or fit alarger motor.2. Clean motor. Sort out cool-ing of air temp. and flow.

3. Sort out connections.4. Restore supply to all phases5. Correct voltage or frequency6. Balance supply or acceptunbalance

1&2. Sort out and correct connections at motor terminals.

3. Correct supply voltage.

4. Change motor for correctvoltage and frequency.

3

Fault Finding - Three Phase Induction Motors

Mechanical noise or vibration.Noisy bearings. Bearingsoverheating

Motor amps in excess of nameplate full load amps onload.

Excessive electrical noise

Unbalanced amps in differentphases when motor loadedMotor runs in wrong direction

1. Thrust from load ormisalignment..

2. Damaged bearings, toomuch grease, no grease, or foreign matter in grease.3. Rotor pulling or foreign matter in air gap.4. Out of balance load, coupling or pulley.5. Excessive belt pull.6. Motor foundations not rigid

1. Motor overloaded2. Low voltage supply3. Wrong voltage and frequency.4. Wrong connections.5. Motor “Single Phasing”.6. Supply voltage unbalanced7. Motor speed not matched toload.1. Wrong connections2. Wrong voltage.3. Motor “Single Phasing”1. Unbalanced power supply.

1. Wrong connections.

1. Check gaps between cou-pling halves and alignment.2&3. Turn shaft slowly by handand feel for roughness or stiffness. Check for bent shaftor fan rubbing.

4. Run motor disconnectedfrom load and then with pulleyor coupling removed.5. Run motor without belts.6. Check design and construction foundations.performance data.1. Check load and performance data.2. Measure voltage at motorterminals.3. Check nameplate data.

4. Check nameplate data..5&6 Check volts and amps inall three phases.

7. Measure motor speed andcheck load requirements.1. Check connections.2. Check voltage with nameplate.3. Check volts and amps on allthree phases.1. Measure phase to phase voltage accurately.1. Watch shaft rotation.

1. Re-align couplings.

2&3. Clean bearing housing,change bearings and repackwith fresh grease.

4. Fix up out of balance items.

5. Loosen belt tension.6. Increase strength of foundations.

1. Fix problem with load or fitlarger motor.2. Fix problem, maybe withlarger cables.3. Correct voltage or frequency

4. Sort out and correct.5&6 Restore balanced supplyto all three phases.

7. Change motor for correctmotor speed.1. Fix connections.2. Correct voltage.3. Restore supply to all phases1. Balance supply or acceptunbalance1. Swap any two phases ofsupply.

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Parts Lists

63 - 132 / 143T - 215TParts Description

1 Endshield D.E. with seal2 Bearing D.E. 3 Terminal Box.4 Rotor Lamination Pack5 Stator frame6 Stator Lamination Pack7 Eyebolt8 Wave Washer N.D.E. 9 Endshield N.D.E. with seal10 Bearing N.D.E.11 Fan Cowl12 Fan

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160 - 315 / 254T - 449TParts Description

1 Outer bearing cap D.E. with seal2 Endshield D.E.3 Bearing D.E.4 Inner bearing cap D.E.5 Eyebolt6 Terminal box7 Rotor lamination pack8 Stator lamination pack9 Stator frame10 Inner bearing cap N.D.E.11 Endshield N.D.E.12 Fan13 Fan Cowl14 Bearing N.D.E. 15 Outer bearing cap N.D.E. with seal

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Connection Diagrams

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Brook Crompton264 Attwell DriveToronto, Ontario M9W 5B2Tel: 416 675-3844Fax: 416 675-6885Internet: www.brookcromptonna.com

Printed in Canada15/09/04 - 2004.T.OI Issue 1

© Copyright 2002. Brook Crompton. All rights reserved

CALL TOLL FREE - NORTH AMERICA:1-800-463-89171-800-463-8917

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www.brookcromptonna.com

Customer Service

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Every care has been taken to ensure the accuracy

of the information contained in this publication, but,

due to a policy of continuous development and

improvement the right is reserved to supply

products which may differ slightly from those

illustrated and described in this publication