Duty Voltage Type of Enclosure Frequency Connection Full load Current Makers Name/Type Frame Size S.No. RPM Bearings Class of insulation
ETHIOPIA MARITIME TRAINING INSTITUTE CHAPTER -
Frame size Say, the frame size is given as D112 S4 D denotes Manufacturers Code ( CG) 112 is the height of shaft centre from base in mm. Suffix S denotes a Short rotor. (M and L will denote Medium and Long rotors.) Suffix 4 denotes no. of poles for which the motor is wound. Also conveys that the sync speed of this motor, when connected to 50Hz is 1500 RPM.
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Class of Insulation Class A Max.Temp 105C Class E Do 120C Class B Do 130C Class H Do 155C Class F Do 180C Class C Do >180C
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Enclosures Drip Proof Splash Proof Totally Enclosed - TE Totally Enclosed Fan Cooled - TEFC Totally Enclosed Pipe Ventilated - TEV
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Ingress Protection Mating surfaces of end shields,bearing caps and terminal boxes are suitably constructed to prevent entry of dust and moisture. Degree of ingress protection is classified as IP 40, IP 50 etc. The first digit is for dust and the second is for moisture classification. An example - IP 54 is dust & waterproof IP 55 is dust & Hose proof IP56 is dust & splash proof Motors in weather deck are of IP 56 type
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General Failures of motors Insulation Breakdown, causing burn-outs, due to a. Over voltage b. Over current c. Over temperature d. Loss of ventilation e. Absorption of moisture/contaminants Single Phasing Open or short-ckt.of one phase winding Failure of mechanical components viz. a. Worn out Bearings b. Cracked Endshields c. Loose Bed bolts d. Unbalanced components (Rotor, Fan)
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Causes of failures Environmental Stress Electrical Stress Mechanical Stress Thermal Stress usually caused by one of, or combination of the stresses above
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Environmental Stress Pollution Dust/Dirt accumulation in T.B.s Corrosion of hardware used for connections High Humidity Results in moisture accumulation in T.B.s High ambient Temperature causes accelerated ageing of insulation Climate Rain/Water washing
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Electrical Stress Overvoltage Switching/Lightning surges Overcurrent Motors running above rated load and due to undervoltage conditions High Contact resistance improper cable terminations Single Phasing Tracking in T.B.s
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Overload Protection
POWER SUPPLY MODERN OVERLOAD RELAYS PROTECT TH E MOTOR
AGAINST 'OVERLOADING' AND 'SINGLE-PH ASING' R Y B O/L RELAY IS TH E FIRST ONE TO ACT IN TH E CONTROL EVENT OF A FAULT AND PROVIDES TH E PRIMARY VOLTAGE PROTECTION FOR TH E MOTOR FUSES Q1 BACK-UP PROTECTION TH REE BI-METAL ELEMENTS, EACH CARRYING TH E LINE CURRENT, H EAT UP AND WH EN TH E LINE CURRENT EXCEEDS TH E RATED FULL LOAD CURRENT, CONTACTOR CONTACTOR BEND AND OPEN A CONTACT IN TH E CIRCUIT OF C1 COIL TH E CONTACTOR COIL TH EREBY DISCONNECTING TH E MOTOR FROM TH E POWER SUPPLY.
O/L RELAY IN CASE TH E 0/L RELAY FAILS TO OPERATE IN TH E
WITH SINGLE PH ASING O/L CONTACT EVENT OF OVERLOAD (OR) IF A SH ORT-CIRCUIT, (DIFFERENTIAL PROTECTION) F1 OR A LOCKED ROTOR CONDITION TAKES PLACE, PRIMARY PROTECTION TH E MAIN FUSE(S) BLOW AND SAFEGUARD TH E U1 V1 W1 MOTOR AGAINST EXCESSIVE CURRENT. FUSES, TH EREFORE, PROVIDE TH E BACK-UP PROTECTION.
M FUSES MAY BE REPLACED BY CIRCUIT BREAKERS WITH
SH OR T CIRCUIT PROTECTION. ~
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Single-Phasing
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Motor Protections Overload protection Single Phase protection Locked rotor or Overcurrent protection Ground Fault protection Winding Temp protection Differential protection Under Voltage Protection Over voltage protection Degree of Protection provided depends on Size, Cost and importance of application
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Mechanical Stress Vibration Loose bed bolts, unbalanced components (rotor, fans) Loose contacts/overtightening Broken/Cracked insulators,terminal bars,studs etc. Improper end terminations Straining of cables due to cramped housing/glanding Defective Bearings ETHIOPIA MARITIME TRAINING INSTITUTE CHAPTER - Bearings used in Motors Sleeve Bearings - For Large Motors Ball Bearings normally for Drive end Roller Bearings normally for Non Drive end Angular Contact Bearings for Vertical Motors
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Effect of Bearing wear Motors have small and equal air gaps between stator and rotor. Excessive bearing wear will cause the rotor to rub against the stator, resulting in damage to the magnetic core and windings. Excessive bearing wear causes unequal magnetic attraction of the rotor, thus creating additional load on the bearings, heating of the bearings and set up vibrations of the motor.
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Seizure of Bearings Can occur if the motor shaft is heated. As it heats, the shaft becomes larger and the bearing has to shift in the end shield by the same amount. In ball bearings with close axial clearance, if the outer race of the bearings fits too tightly in the endshield housing, the balls will be jammed between the races as the shaft becomes heated. As a result, the bearings become stiff and may even stop rotating. This fault is eliminated by relieving the fit of the bearing race in the endshield bearing housing.
ETHIOPIA MARITIME TRAINING INSTITUTE CHAPTER -
Lubrication of Bearings Oil is used for lubrication of Sleeve Bearings Grease, recommended by manufacturer, is used for lubricating Ball and Roller Bearings. Over-greasing is as harmful as lack of grease. Excessive friction taking place between the grease (in fully packed bearing housing) and rotating parts of the bearing, heats the bearing and causes the grease to become thin and to leak from the housing. Pack grease only to half the bearing housing, just sufficient for lubrication.
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Bearing Inspection & Renewal Before opening up a bearing, the space around the motor to be clean & dry. Remove endshields taking care not to damage the winding overhangs. Use bearing pullers of the correct size. Clean bearings ( if to be reused) in a solvent and dry them using clean and dry compressed air. Lightly lubricate taking care not to overfill. Ensure shaft is clean and apply a light coat of grease. Tap the bearing in place applying light, uniform force on the inner race of the bearing as close as possible. While replacing, use bearing of correct size and clearance.
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Routine Inspection General Cleanliness Clogging of fins, blocking of ventilation Feel (By touch) for any unusual temp of Bearings, rotor or stator Listen for any unusual sound from bearings or vibrations due to loose bed-bolts. Look for any unusual variations in the motor current (where local ammeters are provided) and for Condition of earthing leads.
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Routine Testing of Motors Insulation resistance Winding resistance No load current Protective devices
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IR/Continuity/Resistance Checks
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Replacement of motors Important Points to be considered a. Frame Size b. RPM c. Winding d. Ingress protection e. Class of Insulation f. Duty g. HP
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Rewinding of Motors Datas to be gathered from the old coil or original data sheets Gauge of the wire used Pitch of the coil Number of turns Details of end connections Insulation used Method of execution Prepare former for the coil Wind coil(s). use the correct type of insulation and shape them to fit into the slots Embed the coils in the slots Wedge the coils tightly in their slots. Prepare the end connections Bring out the lead wires to the terminal block
Tests to be carried out after rewinding
Insulation Resistance Winding resistance High Voltage Withstand Test (By applying 2KV for one minute)
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