Manual For Induction Motors and Generators

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Motors and Generators
Manual for induction motors and generators

2 MANUAL FOR INDUCTION MOTORS AND GENERATORS
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Safety instructions — AMA, AMB, AMD, AMG, AMH, AMI, AMK,
AMZ, AXR, HXR, M3BM, NMH, NMI, NMK, NXR
1. General
General safety regulations, specific agreements made for each work site and safety precautions shown in this
document must be observed at all times.
NOTE: If there are any conflicts between these safety instructions and the user manual, these
safety instructions prevail.
2. Intended use
Electric machines have dangerous live and rotating parts and may have hot surfaces. It is not allowed to
climb on the machine. All operations serving transport, storage, installation, connection, commissioning,
operation and maintenance shall be carried out by responsible skilled persons (in conformity with
EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling may cause serious personal injury and damage to
property. Danger!
These machines are intended for industrial and commercial installations as components as defined in the Machinery
Directive (MD) 2006/42. Commissioning is prohibited until conformity of the end product with this directive has
been established (follow particular local safety and installation rules as, for example, EN 60204).
These machines comply with the harmonized series of standards EN 60034 / DIN VDE 0530. Their use in explosive
atmosphere is prohibited unless they are expressly designed for such use (follow additional instructions).
On no account, use degrees of protection ≤ IP23 outdoors. Air-cooled models are typically designed for ambient
temperatures of -20°C up to +40°C and altitudes of ≤ 1000 m above sea level. Ambient temperature for air-/water-
cooled models should be not less than +5°C (for sleeve-bearing machines, see manufacturer's documentation). By
all means, take note of deviating information on the rating plate. Field conditions must conform to all rating plate
markings.
3. Transport, storage
Immediately report damage established after delivery to transport company. Stop commissioning, if necessary.
Lifting eyes are dimensioned for the weight of the machine, do not apply extra loads. Ensure the use of correct lifting
eyes. If necessary, use suitable, adequately dimensioned means of transport (for example, rope guides). Remove
shipping braces (for example, bearing locks, vibration dampers) before commissioning. Store them for further use.
When storing machines, make sure of dry, dust and vibration free location (danger of bearing damage at rest).
Measure insulation resistance before commissioning. At values of ≤ 1 kΩ per volt of rated voltage, dry winding. Follow
the manufacturer's instructions. Long term storage procedures must always be considered properly.
4. Installation
Take care of even support, solid foot or flange mounting, and exact alignment. Avoid resonances with rotational
frequency and double mains frequency as a result of assembly. Turn rotor and listen for abnormal slip noises. Check
direction of rotation in uncoupled state.
Follow the manufacturer's instructions when mounting or removing couplings or other drive elements and cover
them with a touch guard. For trial run in uncoupled state, lock or remove the shaft end key. Avoid excessive radial and
axial bearing loads (note manufacturer's documentation). The balance of the machine is indicated as H = Half and F
= Full key. In half key cases coupling must be half key balanced. In full key cases coupling must be balanced without a
key. In case of protruding, visible part of the shaft end key, establish mechanical balance.
Make necessary ventilation and cooling system connections. The ventilation must not be obstructed and the exhaust
air, also of neighbouring sets, not taken in directly.
SAFETY INSTRUCTIONS — AMA, AMB, AMD, AMG, AMH, AMI, AMK, AMZ, AXR, HXR, M3BM, NMH, NMI, NMK, NXR 3
5. Electrical connection
All operations must be carried out only by skilled persons on the machine at rest. Before starting work, the following
safety rules must be strictly applied:
• De-energize!
• Provide safeguard against reclosing!
• Verify safe isolation from supply!
• Connect to earth and short!
• Cover or provide barriers against neighbouring live parts!
• De-energize auxiliary circuits (for example, anti-condensation heating)!
Exceeding limit values of zone A in EN 60034-1 / DIN VDE 0530-1 — voltage ± 5%, frequency ± 2%, waveform and
symmetry — leads to higher temperature rise and affects electromagnetic compatibility. Note rating plate markings
and connection diagram in the terminal box.
The connection must be made so that permanent safe electrical connection is maintained. Use appropriate cable
terminals. Establish and maintain safe equipotential bonding.
The clearances between uninsulated live parts and between such parts and earth must not be below the values of
appropriate standards and values possibly given in manufacturer's documentation.
No presence of foreign bodies, dirt or moisture is allowed in the terminal box. Close unused cable entrance holes and
the box itself in a dust- and watertight manner. Lock the key when the machine is run without coupling. For machines
with accessories, check satisfactory functioning of these before commissioning.
Proper installation (for example, segregation of signal and power lines, screened cables etc.) lies within the installer's
responsibility.
When current transformers are fitted, the following applies to a netural terminal arrangement: Adequate precautions
must be taken to ensure that the secondary circuits of the current transformers are always connected to a load.
6. Operation
Vibration severity in the "satisfactory" range (Vrms ≤ 4.5 mm/s) according to ISO 3945 is acceptable in coupled-
mode operation. (Piston engine generators according to ISO 8528-9). In case of deviations from normal operation -
for example, elevated temperature, noises, vibrations - disconnect machine, if in doubt. Establish cause and consult
manufacturer, if necessary.
Do not defeat protective devices, not even in trial run. In case of heavy dirt deposits, clean cooling system at regular
intervals. Open blocked condensate drain holes from time to time.
Grease the bearings during commissioning before start-up. Regrease antifriction bearings while the machine is
running. Follow instructions on lubrication plate. Use right kind of grease. In case of sleeve-bearing machines,
observe time-limit for oil-change and if equipped with oil supply system make sure the system is working.
7. Maintenance and servicing

Follow the manufacturer's operating instructions. For further details, see the comprehensive User’s Manual. Preserve
these safety instructions!
8. Frequency converter
In frequency converter applications motor frame external earthing must be used for equalising the potential between
the motor frame and the driven machine, unless the two machines are mounted on the same metallic base. For motor
frame sizes over IEC 280, use 0.75 x 70 mm flat conductor or at least two 50 mm² round conductors. The distance of
the round conductors must be at least 150 mm from each other.
This arrangement has no electrical safety function; the purpose is to equalise the potentials. When the motor and the
gearbox are mounted on a common steel fundament, no potential equalisation is required.
1. Potential equalisation
2. Driven machinery
3. Plate/strip
4. Cables/wires.
To comply with EMC-requirements, use only cables, connectors and cable lead in approved for this purpose. (See
instruction for frequency converters.)
Additional safety instructions for permanent magnet synchronous

machines
Electrical connection and operation

When the machine shaft is rotating, a permanent magnet synchronous machine induces voltage to the terminals.
The induced voltage is proportional to the rotational speed, and can be hazardous even at low speeds. Prevent any
rotation of the shaft before opening the terminal box and/or working at the unprotected terminals.
WARNING: The terminals of a machine with frequency converter supply may be energized even when
the machine is at a standstill.
WARNING: Beware of reverse-power when working at the supply system.
WARNING: Do not exceed the maximum allowed speed of the machine. See product specific manuals.
Maintenance and servicing

Permanent magnet synchronous machines must only be serviced by repair shops qualified and authorised by ABB.
For more information concerning service of permanent magnet synchronous machines, please contact ABB.
WARNING: Only qualified personnel familiar with the relevant safety requirements are allowed to open
and maintain permanent magnet synchronous machines.
WARNING: It is not allowed to remove the rotor of a permanent magnet synchronous machine without
the special tools designed for this purpose.
WARNING: Magnetic stray fields, caused by an open or disassembled permanent magnet synchronous
machine or by a separate rotor of such a machine, may disturb or damage other electrical
or electromagnetic equipment and components, such as cardiac pacemakers, credit cards
and equivalent.
WARNING: Loose metallic parts and waste must be prevented from entering the interior of the
permanent magnet synchronous machine as well as getting into contact with the rotor.
WARNING: Before closing an opened permanent magnet synchronous machine, all parts which does
not belong to the machine and wastes must be removed from the interior of the machine.
NOTE: Beware of magnetic stray fields and possible induced voltages when rotating the separate
rotor of a permanent magnet synchronous machine as they may cause damage to
surrounding equipment, for example lathes or balancing machines.
Additional safety instructions for electrical motors for explosive

atmospheres
NOTE: 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 this equipment. Ignoring these instructions may invalidate
the warranty.
WARNING: Motors for explosive atmospheres are specially designed to comply with official
regulations concerning the risk of explosion. If the motors are used improperly, connected
badly, or altered, no matter how minimally, their reliability can be in doubt.
Standards relating to the connection and use of electrical apparatus in explosive
atmospheres must be taken into consideration, especially national standards
for installation (see standards EN 60079-14, EN 60079-17, GOST-R 52350.14,
GOST IEC 60079-14, GOST 31610.17, GOST IEC 60079-17, GB3836.15, IEC 60079-14,
IEC 60079-17). All repairs and overhauls must be carried out according to standards
IEC 60079-19, EN 60079-19, GOST 31610.19 and GB 3836.13. Only trained personnel familiar
with these standards should handle this type of apparatus.
Declaration of conformity
All ABB Ex-machines intended for explosive atmospheres comply with the ATEX Directive 2014/34/EU and have a CE-
mark on the rating plate.
Validity
These instructions are valid for the following ABB electric motor types when the motors are used in explosive
atmospheres.
Non-sparking Ex nA, Class I Div 2, Class I Zone 2, and increased safety Ex ec
• AMA induction machines, sizes 315 to 500

• AMI induction machines, sizes 400 to 1120
• AMZ synchronous machines, sizes 710 to 2500
• AXR induction machines, sizes 315 to 500
• HXR induction machines, sizes 315 to 560
• NMH induction machines, size 423.
Increased safety Ex e, Ex eb

• AMH induction machines, size 423
• NMH induction machines, size 423.
Flame proof Ex db, Ex db eb
• AMD induction machines, sizes 355 to 500.

Pressurized enclosure Ex e px, Ex e pz, Ex nA pz, Ex px, Ex pz, and Ex eb pxb, Ex eb pzc, Ex ec pzc, Ex pxb, Ex pzc

• AMZ synchronous machines, sizes 710 to 2500
• HXR induction machines, sizes 315 to 560.
Dust ignition protection Ex t (DIP, Ex tD), Class II Div 2, Class II Zone 22, Class III

• AMD induction machines, sizes 355 to 500.
(Additional information may be required for some machine types used in special applications or with special design.)
Conformity with standards

As well as conforming to the standards relating to mechanical and electrical characteristics, motors designed for
explosive atmospheres must also conform to the following international/national standards.
Standards concerning general requirements for explosive atmospheres:
• EN 60079-0
• IEC 60079-0
• GB 3836.1
• GOST 31610.0
Std. concerning Ex db protection:
• EN 60079-1
• IEC 60079-1
• GB 3836.2
• GOST IEC 60079-1
Std. concerning Ex p protection:
• EN 60079-2
• IEC 60079-2
• GB 3836.5
• GOST IEC 60079-2
Std. concerning Ex e protection:
• EN 60079-7
• IEC 60079-7
• GB 3836.3
• GOST 31610.7
Std. concerning Ex nA protection:
• EN 60079-15
• IEC 60079-15
• GB 3836.8
• GOST 31610.15
Std. concerning combustible dust protection:
• EN 61241-1; EN 60079-31
• IEC 61241-1; IEC 60079-31
• GB 12476.1
• GOST-R IEC 61241-0; GOST-R IEC 61241-1-1; GOST IEC 60079-31
National Electric Code (NEC):
• NFPA 70
Canadian Electrical Code, Part II (CE Code):
• C 22-2
TR CU Technical Regulation in Customs Union (Russia, Belarus, Armenia, Kyrgyzstan and Kazakhstan):
• TR CU 012/2011
• TR CU 004/2011.
ABB machines can be installed in areas corresponding to the following markings:
Zone (IEC) Category (EN) Marking

1 2 Ex e, Ex e px, Ex eb, Ex eb
pxb, Ex px, Ex pxb, Ex db,
Ex db eb
2 3 Ex nA, Ex nA pz, Ex e pz, Ex
eb pzc, Ex ec, Ex ec pzc, Ex
pz, Ex pzc
Some AMD machines can also be installed in group I (Mine) areas. Forr more details, see the hazardous area
certificate of the machine.
Atmosphere (EN)
G - explosive atmospheres caused by gases
D - explosive atmospheres caused by dust.
Arrival inspection
• Immediately upon receipt check the machine for external damage. In case of damages, inform the forwarding
agent without delay.
• Confirm all rating plate data, especially voltage, winding connection (star or delta), category, type of protection
and temperature marking.
Note the following rules during any operation!
WARNING: Disconnect power and lock out the power switch before working on the machine or
the driven equipment. Ensure that no explosive atmosphere is present while work is in
progress.
Special conditions
• The special conditions mentioned in the certificates of the motors and separately certified apparatus must be
conformed to. Letter “x” in the certificate number typically indicates that special conditions are included.
WARNING: Substitution of components may impair suitability for Class I Division 2 and other Ex
protection types.
Starting and re-starting
• The maximum number of allowed sequential starts has been declared in the machine’s technical documents.
• A new starting sequence is allowed after the machine has cooled to ambient temperature (cold starts) or to
operating temperature (warm starts).
Earthing and equipotentialing
• Check before starting that all earthing and equipotentialing cables have been effectively connected.
• Do not remove any earthing or equipotentialing cables that have been installed by the manufacturer.
Clearances, creepage distances and separations
• Do not make any removals or adjustments in terminal boxes; this could decrease clearances or creepage
distances between parts.
• Do not install any new equipment to terminal boxes without asking for advice from ABB.
• Be sure that the air gap between rotor and stator is measured after any maintenance on the rotor or bearings.
The air gap shall be the same at any point between stator and rotor.
• Centralize the fan to the center of the fan cover or the air guide after any maintenance activity. The clearance
must be at least 1% of the maximum diameter of the fan and in accordance with standards.
Connections in terminal boxes
• All connections in main terminal boxes must be made with Ex-approved connectors, which are delivered with
the machine by the manufacturer. In case of any other connectors, ask for advice from ABB.
• All connections in auxiliary terminal boxes, marked as intrinsically safe circuits (Ex i), must be connected to
proper safety barriers.
• Energy-limited circuits (Ex nL) and intrinsically safe circuits (Ex i) have to be separated from other electrical
circuits with a separator plate or a 50 mm greepage distance. For more information, see the connection
diagram and terminal box drawings of the motor.
Space heaters
• If an anti-condensation heater, without self-regulation, is turned on immediately after the motor is shut down,
take suitable measures to control the inside motor housing temperature. The anti-condensation heaters can
only operate in a temperature-controlled environment.
• The anti-condensation heaters must be interlocked in such a way that they can only be energized when the
motor is de-energized.
Pre-start ventilation
• Ex ec, Ex eb, Ex nA and Ex e machines may, or in some cases have to, be equipped with a provision for pre-start
ventilation.
• Before starting, check the need to purge the machine enclosure to make sure that the enclosure is free of
flammable gases. Based on risk assessment, the customer and/or the local authorities make the decision on
whether to use pre-start ventilation or not.
Motors in Gas Group IIC or Dust Group III
WARNING: To minimize the risk of hazards caused by electrostatic charges, clean the motors only with
a damp cloth or by non-frictional means.
Flame paths (AMD machines)
• AMD machines cannot be modified, and the flameproof joints cannot be repaired in any way. This applies to
the components of the sub-assemblies related to the protection mode or to the surface temperature (frame
and end shileds, covers, flame seals, input devices to the terminal boxes, winding, etc.). When substantial
modification is absolutely necessary, the standard requires new certification by a Notified Body. For details,
see EN 60079-19 / IEC 60079-19.
• The gaps of the flame paths are less than the maximum gaps given in the tables of EN 60079-1, IEC 60079-1.
• The width of flameproof joints exceeds the minimum widths given in the tables of EN 60079-1, IEC 60079-1.
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Contents
Safety instructions — AMA, AMB, AMD, AMG, AMH, AMI, AMK, AMZ, AXR, HXR, M3BM, NMH, NMI, NMK, NXR..............2
1. General..................................................................................................................................................................................2
2. Intended use....................................................................................................................................................................... 2
3. Transport, storage............................................................................................................................................................ 2
4. Installation.......................................................................................................................................................................... 2
5. Electrical connection.........................................................................................................................................................3
6. Operation............................................................................................................................................................................ 3
7. Maintenance and servicing.............................................................................................................................................. 3
8. Frequency converter......................................................................................................................................................... 3
Additional safety instructions for permanent magnet synchronous machines.......................................................4
Electrical connection and operation..................................................................................................................................4
Maintenance and servicing.................................................................................................................................................. 4
Additional safety instructions for electrical motors for explosive atmospheres.................................................... 6
Declaration of conformity....................................................................................................................................................6
Validity...................................................................................................................................................................................... 6
Conformity with standards..................................................................................................................................................7
Arrival inspection................................................................................................................................................................... 8
Note the following rules during any operation!............................................................................................................. 8
Chapter 1 Introduction............................................................................................................................................................14
1.1 General information........................................................................................................................................................ 14
1.2 Important note................................................................................................................................................................ 14
1.3 Limitation of liability...................................................................................................................................................... 14
1.4 Documentation................................................................................................................................................................ 15
1.4.1 Documentation of the machine.................................................................................................................15
1.4.2 Information not included in documentation.......................................................................................... 15
1.4.3 Units used in this User’s Manual.............................................................................................................. 15
1.5 Identification of the machine.......................................................................................................................................15
1.5.1 Serial number of the machine....................................................................................................................15
1.5.2 Rating plate................................................................................................................................................... 16
Chapter 2 Transport and unpacking..................................................................................................................................... 18

2.1 Protective measures prior to transport.....................................................................................................................18
2.1.1 General.............................................................................................................................................................18
2.1.2 Bearing plate................................................................................................................................................. 18
2.2 Lifting the machine........................................................................................................................................................20
2.2.1 Lifting a machine in a seaworthy package............................................................................................. 21
2.2.2 Lifting a machine on a pallet.....................................................................................................................21
2.2.3 Lifting an unpacked machine.................................................................................................................... 22
2.2.4 Lifting additional equipment.................................................................................................................... 22
2.3 Turning a vertically mounted machine...................................................................................................................... 24
2.4 Checks upon arrival and unpacking........................................................................................................................... 25
2.4.1 Check upon arrival....................................................................................................................................... 25
2.4.2 Check upon unpacking............................................................................................................................... 25
2.5 Installation instructions for main terminal box and cooler parts........................................................................25
2.5.1 Installation of main terminal box............................................................................................................. 26
2.5.2 Installation of cooler parts........................................................................................................................ 26
2.6 Storage..............................................................................................................................................................................26
2.6.1 Short term storage (less than 2 months)...............................................................................................26
2.6.2 Long term storage (more than 2 months)............................................................................................. 27
2.6.3 Rolling bearings............................................................................................................................................28
2.6.4 Sleeve bearings............................................................................................................................................ 29
2.6.5 Openings........................................................................................................................................................29
2.7 Inspections, records.......................................................................................................................................................29
Chapter 3 Installation and alignment................................................................................................................................... 30

3.1 General.............................................................................................................................................................................. 30
3.2 Foundation design......................................................................................................................................................... 30
3.2.1 General............................................................................................................................................................30
3.2.2 Forces to the foundation...........................................................................................................................30
3.2.3 Flanges for vertically mounted machines............................................................................................... 31
CONTENTS 11
3.3 Machine preparations before installation................................................................................................................. 31

3.3.1 Insulation resistance measurements....................................................................................................... 31
3.3.2 Disassembly of the transport locking device.........................................................................................31
3.3.3 Coupling type................................................................................................................................................32
3.3.4 Assembly of the coupling half.................................................................................................................. 33
3.3.5 Belt drive........................................................................................................................................................ 33
3.3.6 Drain plugs.................................................................................................................................................... 34
3.4 Installation on concrete foundation.......................................................................................................................... 34
3.4.1 Scope of delivery..........................................................................................................................................34
3.4.2 General preparations.................................................................................................................................. 34
3.4.3 Foundation preparations........................................................................................................................... 34
3.4.4 Erection of machines..................................................................................................................................36
3.4.5 Alignment...................................................................................................................................................... 36
3.4.6 Grouting.........................................................................................................................................................36
3.4.7 Final installation and inspection.............................................................................................................. 36
3.5 Installation on steel foundation.................................................................................................................................. 37
3.5.1 Scope of delivery.......................................................................................................................................... 37
3.5.2 Check of foundation....................................................................................................................................37
3.5.3 Erection of machines.................................................................................................................................. 37
3.5.4 Alignment.......................................................................................................................................................37
3.5.5 Final installation and inspection.............................................................................................................. 37
3.5.6 Installation of flange mounted machines on steel foundation......................................................... 38
3.6 Alignment......................................................................................................................................................................... 38
3.6.1 General............................................................................................................................................................38
3.6.2 Rough levelling............................................................................................................................................. 39
3.6.3 Rough adjustment....................................................................................................................................... 39
3.6.4 Correction for thermal expansion............................................................................................................41
3.6.5 Final alignment.............................................................................................................................................42
3.7 Care after installation....................................................................................................................................................45
Chapter 4 Mechanical and electrical connections.............................................................................................................. 46

4.1 General.............................................................................................................................................................................. 46
4.2 Mechanical connections................................................................................................................................................46
4.2.1 Cooling air connections..............................................................................................................................46
4.2.2 Cooling water connections....................................................................................................................... 46
4.2.3 Sleeve bearing oil supply........................................................................................................................... 47
4.2.4 Connection of purging air pipe................................................................................................................47
4.2.5 Mounting of vibration transducers......................................................................................................... 48
4.2.6 Provision for purging air........................................................................................................................... 48
4.2.7 Roller bearing oil mist supply................................................................................................................... 50
4.3 Electrical connections.................................................................................................................................................... 51
4.3.1 General information.....................................................................................................................................51
4.3.2 Safety.............................................................................................................................................................. 51
4.3.3 Insulation resistance measurements.......................................................................................................51
4.3.4 Main terminal box options........................................................................................................................ 51
4.3.5 Insulation distances of main power connections.................................................................................52
4.3.6 Main power cables...................................................................................................................................... 52
4.3.7 Secondary cables for slip ring connections........................................................................................... 53
4.3.8 Auxiliary terminal box................................................................................................................................. 53
4.3.9 Earth connections....................................................................................................................................... 54
4.3.10 Requirements for machines fed by frequency converters............................................................... 54
Chapter 5 Commissioning and start-up...............................................................................................................................55

5.1 General...............................................................................................................................................................................55
5.2 Check of mechanical installation................................................................................................................................ 55
5.3 Insulation resistance measurements......................................................................................................................... 55
5.4 Check of electrical installation.................................................................................................................................... 55
5.5 Control and protection equipment............................................................................................................................ 56
5.5.1 General............................................................................................................................................................56
5.5.2 Stator winding temperature..................................................................................................................... 56
5.5.3 Bearing temperature control.....................................................................................................................57
5.5.4 Protection equipment.................................................................................................................................57
5.6 First test start.................................................................................................................................................................57
5.6.1 General............................................................................................................................................................57
5.6.2 Precautions before first test start...........................................................................................................57
5.6.3 Starting.......................................................................................................................................................... 58
5.7 Running the machine the first time........................................................................................................................... 59
5.7.1 Supervision during the first run............................................................................................................... 59
5.7.2 Checks during running of the machine...................................................................................................59
5.7.3 Bearings......................................................................................................................................................... 60
5.7.4 Vibrations.......................................................................................................................................................61
5.7.5 Temperature levels...................................................................................................................................... 61
5.7.6 Heat exchangers...........................................................................................................................................61

5.7.7 Slip rings.........................................................................................................................................................61
5.8 Shut down........................................................................................................................................................................ 61
Chapter 6 Operation................................................................................................................................................................63
6.1 General.............................................................................................................................................................................. 63
6.2 Normal operating conditions...................................................................................................................................... 63
6.3 Number of starts............................................................................................................................................................63
6.4 Supervision...................................................................................................................................................................... 64
6.4.1 Bearings......................................................................................................................................................... 64
6.4.2 Vibrations...................................................................................................................................................... 64
6.4.3 Temperatures............................................................................................................................................... 64
6.4.4 Heat exchanger............................................................................................................................................64
6.4.5 Slip ring unit.................................................................................................................................................64
6.5 Follow-up..........................................................................................................................................................................64
6.6 Shut down........................................................................................................................................................................65
Chapter 7 Maintenance........................................................................................................................................................... 66
7.1 Preventive maintenance................................................................................................................................................ 66
7.2 Safety precautions......................................................................................................................................................... 66
7.3 Maintenance program....................................................................................................................................................67
7.3.1 Recommended maintenance program.................................................................................................... 68
7.4 Maintenance of general constructions...................................................................................................................... 72
7.4.1 The tightness of fastenings.......................................................................................................................72
7.4.2 Vibration and noise..................................................................................................................................... 73
7.4.3 Bearing housing vibrations........................................................................................................................73
7.4.4 Shaft vibrations............................................................................................................................................75
7.5 Maintenance of bearings and lubrication system................................................................................................... 75
7.5.1 Sleeve bearings............................................................................................................................................. 75
7.5.2 Lubrication of sleeve bearings..................................................................................................................76
7.5.3 Rolling bearings............................................................................................................................................ 77
7.5.4 Bearing insulation and bearing insulation resistance check..............................................................80
7.6 Maintenance of stator and rotor windings.............................................................................................................. 82
7.6.1 Particular safety instructions for winding maintenance..................................................................... 83
7.6.2 The timing of the maintenance................................................................................................................ 83
7.6.3 The correct operating temperature.........................................................................................................83
7.6.4 Insulation resistance test.......................................................................................................................... 84
7.6.5 Insulation resistance measurement for auxiliaries.............................................................................. 87
7.6.6 The polarization index................................................................................................................................ 87
7.6.7 Other maintenance operations................................................................................................................ 88
7.7 Maintenance of slip rings and brush gear................................................................................................................ 88
7.7.1 Care of slip rings..........................................................................................................................................88
7.7.2 Care of brush gear...................................................................................................................................... 88
7.8 Maintenance of cooling units...................................................................................................................................... 89
7.8.1 Maintenance instructions for machines with open air cooling..........................................................89
7.8.2 Maintenance instructions for air-to-water heat exchangers............................................................. 90
7.8.3 Maintenance instructions for air-to-air heat exchangers................................................................... 90
7.8.4 Maintenance of external blower motors................................................................................................ 91
7.9 Repairs, disassembly and assembly........................................................................................................................... 91
Chapter 8 Trouble shooting................................................................................................................................................... 92

8.1 Trouble shooting.............................................................................................................................................................92
8.1.1 Mechanical performance.............................................................................................................................92
8.1.2 Lubrication system and bearings.............................................................................................................92
8.1.3 Thermal performance..................................................................................................................................96
8.2 Oil leakage of sleeve bearings.................................................................................................................................... 99
8.2.1 Oil.................................................................................................................................................................. 100
8.2.2 Sleeve bearings.......................................................................................................................................... 100
8.2.3 Bearing verification................................................................................................................................... 100
8.2.4 Oil container and piping.......................................................................................................................... 100
8.2.5 Oil container and piping verification.....................................................................................................101
8.2.6 Use.................................................................................................................................................................101
8.2.7 Use verification...........................................................................................................................................102
8.3 Electrical performance, control and protection.................................................................................................... 104
8.3.1 Protection trips.......................................................................................................................................... 105
8.3.2 Pt-100 resistance temperature detectors............................................................................................105
8.4 Slip rings and brushes................................................................................................................................................ 106
8.4.1 Brush wear.................................................................................................................................................. 106
8.4.2 Brush sparking........................................................................................................................................... 107
8.5 Thermal performance and cooling system.............................................................................................................107
CONTENTS 13
Chapter 9 Life cycle services for motors and generators...............................................................................................108

9.1 Motors and Generators Service.................................................................................................................................108
9.1.1 Service products.........................................................................................................................................108
9.1.2 Support and warranties............................................................................................................................108
9.1.3 Contact information for Motors and Generators Service................................................................. 108
9.2 Spare parts for rotating electrical machines......................................................................................................... 109
9.2.1 General spare part considerations.........................................................................................................109
9.2.2 Periodical part replacements.................................................................................................................. 109
9.2.3 Need of spare parts.................................................................................................................................. 109
9.2.4 Selection of the most suitable spare part package........................................................................... 110
9.2.5 Typical recommended spare parts in different sets..........................................................................110
9.2.6 Order information...................................................................................................................................... 113
Chapter 10 Recycling............................................................................................................................................................. 114

10.1 Introduction.................................................................................................................................................................. 114
10.2 Average material content..........................................................................................................................................114
10.3 Recycling of packaging material............................................................................................................................. 114
10.4 Dismantling of the machine.....................................................................................................................................114
10.5 Separation of different materials........................................................................................................................... 114
10.5.1 Frame, bearing housing, covers and fan.............................................................................................114
10.5.2 Components with electrical insulation................................................................................................115
10.5.3 Permanent magnets................................................................................................................................ 115
10.5.4 Hazardous waste......................................................................................................................................115
10.5.5 Land fill waste...........................................................................................................................................115
Commissioning report.......................................................................................................................................................... 116

Transportation.................................................................................................................................................................... 117
Storage................................................................................................................................................................................. 118
Mechanical installation......................................................................................................................................................119
Lubrication check...............................................................................................................................................................120
Self lubrication.................................................................................................................................................... 120
Flood lubrication................................................................................................................................................ 120
Grease lubricated bearings:............................................................................................................................. 120
Electrical installation..........................................................................................................................................................121
Insulation resistance test..................................................................................................................................121
Accessories resistance test.............................................................................................................................. 121
Machine protection settings........................................................................................................................................... 122
Test run................................................................................................................................................................................ 123
First start (a few seconds only)...................................................................................................................... 123
Second start (uncoupled, if possible)............................................................................................................123
Test run (with load)...........................................................................................................................................................124
Machine approval............................................................................................................................................................... 125
Fax cover sheet.................................................................................................................................................................. 126
Typical position of plates.....................................................................................................................................................127
Typical main power cable connections.............................................................................................................................. 129

—
Chapter 1 Introduction
Introduction
1.1 General information

This User’s Manual contains information on the transport, storage, installation, commissioning, operating and
maintenance of rotating electrical machines manufactured by ABB.
This manual provides information regarding all aspects of operation, maintenance and supervision of the machine.
Careful study of the contents of this manual and other machine related documentation before any actions are taken
is necessary to ensure proper functionality and a long lifetime of the machine.
NOTE: Some customer specific items may not be included in this User’s Manual. Additional
documentation will be found in the project documentation.
Actions described in this manual are only to be performed by trained personnel with previous experience in similar
tasks, and authorized by the user.
This document and parts thereof must not be reproduced or copied without the express written permission of ABB,
and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
ABB constantly strives to improve the quality of the information provided in this User’s Manual, and will welcome
any improvement suggestions. For contact information, see Chapter 9.1.3 Contact information for Motors and
Generators Service.
NOTE: These instructions must 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 this equipment. Ignoring the instruction invalidates the
warranty.
1.2 Important note

The information in this document may sometimes be of a general nature and applicable to various machines
produced by ABB.
Where a conflict exists between the contents herein and the actual machinery supplied, the user must make an
engineering judgment as to what to do. If any doubt exists, contact ABB.
The safety precautions presented in the Safety Instructions must be observed at all times.
Safety is dependent on the awareness, concern and prudence of all those who operate and service machines. While it
is important that all safety procedures be observed, care near machinery is essential - always be on your guard.
NOTE: To avoid accidents, safety measures and devices required at the installation site must be
in accordance with the instructions and regulations stipulated for safety at work. This
applies to general safety regulations of the country in question, specific agreements made
for each work site and safety instructions included in this manual and separate safety
instructions delivered with the machine.
1.3 Limitation of liability

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind
arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from
use of any software or hardware described in this document.
The warranty issued covers manufacturing and material defects. The warranty does not cover any damage caused
to the machine, personal or third party by improper storage, incorrect installation or operating of the machine. The
warranty conditions are in more detail defined according to Orgalime S2000 terms and conditions.
NOTE: The warranty issued is not valid, if the operation conditions of the machine are changed or
any changes in the construction of the machine, or repair work to the machine have been
made without prior written approval from the ABB factory, which supplied the machine.
INTRODUCTION 15
NOTE: Local ABB sales offices may hold different warranty details, which are specified in the sales
terms, conditions or warranty terms.
For contact information, please see the back page of this User’s Manual. Please remember to provide the serial
number of the machine when discussing machine specific issues.
1.4 Documentation
1.4.1 Documentation of the machine

It is recommended that the documentation of the machines is studied carefully before any actions are taken. This
manual and safety instructions are delivered with each machine and is located in a plastic cover attached on the
machine frame.
NOTE: The documentation is delivered to the ordering customer. For additional copies of these
documents, please contact your local ABB office or the After Sales department, see Chapter
9.1.3 Contact information for Motors and Generators Service.
In addition to this manual, each machine is supplied with a Dimension Drawing, an Electrical Connection Diagram and
a Data Sheet indicating the following:
• Mounting and outline dimensions of the machine
• Machine weight and load on the foundation
• Location of lifting eyes of the machine
• Instrumentation and location of accessories
• Bearing oil and lubricant requirements
• Main and auxiliary connections.
NOTE: Some customer specific items may not be included in this User’s Manual. Additional
documentation will be found in the project documentation. In case of conflict between this
manual and the additional documentation of the machine, additional documentation will
prevail.
1.4.2 Information not included in documentation

This User’s Manual does not include any information about any starting, protection or speed control equipment. This
information is provided in the user’s manuals for respective equipment.
1.4.3 Units used in this User’s Manual

The measurement units used in this User’s Manual are based on the SI (metric) system and the US system.
1.5 Identification of the machine
1.5.1 Serial number of the machine

Each machine is identified with a 7-digit serial number. It is stamped on the rating plate of the machine as well as on
the machine frame.
The serial number must be provided in any future correspondence regarding a machine, as it is the only unique
information used for identifying the machine in question.
1.5.2 Rating plate

A stainless steel rating plate is attached permanently to the machine frame, and it must not be removed. For the
location of the rating plate, see Appendix Typical position of plates.
The rating plate indicates manufacturing, identification, electrical and mechanical information, see Figure 1 Rating
plate for direct on line machines manufactured according to IEC (Ex-machine according to ATEX Directive).
Figure 1 Rating plate for direct on line machines manufactured according to IEC (Ex-machine according to ATEX
Directive)
Figure 2 Rating plate for frequency converter machines manufactured according to IEC
INTRODUCTION 17
Figure 3 Rating plate for direct on line machines manufactured according to NEMA
1. Type designation
2. Manufacturing year
3. Duty
4. Type of connection
5. Insulation class
6. Machine weight [kg] or [lbs]
7. Degree of protection [IP class]
8. Type of cooling [IC code]
9. Mounting arrangement [IM code] (IEC)
10. Additional info
11. Manufacturer
12. Serial number
13. Output [kW] or [HP]
14. Stator voltage [V]
15. Frequency [Hz]
16. Rotating speed [rpm]
17. Stator current [A]
18. Power factor [cosf]
19. CSA marking
20. Standard
21. Designation for locked-rotor kVA/ HP (NEMA)
22. Ambient temperature [°C] (NEMA)
23. Service factor (NEMA).
—
Chapter 2 Transport and unpacking
Transport and unpacking
2.1 Protective measures prior to transport
2.1.1 General
The following protective measures are taken before delivery of the machine from the factory. The same protective
measures should be taken, whenever the machine is moved:
• Some machines, and all machines with sleeve or roller bearings, have transport locking devices installed.
Following bullet for bearing type: Rolling bearing
• Ball and roller bearings are greased with lubricant indicated on the bearing plate, which is attached to the
machine frame, see Chapter 2.1.2 Bearing plate.
Following bullet for bearing type: Sleeve bearing
• Sleeve bearings are flooded with oil and drained. All oil in- and outlets, as well as oil tubes are plugged. This
gives sufficient protection against corrosion.
Following bullet for cooling method: Air-to-water
• Air-to-water coolers are drained and the cooler in- and outlets are plugged.
• Machined metal surfaces, such as the shaft extension, are protected against corrosion with an anti-corrosive
coating.
• In order to protect the machine properly against water, salt spray, moisture, rust and vibration damages during
loading, sea transport and unloading of the machine, the machine should be delivered in a seaworthy package.
Following bullet for mounting: Vertical machine
• The D-end bearing and a possible ND-end bearing are greased with a lubricant indicated on the bearing plate
attached to the machine frame.
• If the ND-end bearing is oil-filled (self-lubricated):
Any time the machine is transported, the lubrication oil must first be drained from the bearing, or it could
ingress through the seals to the inside of the machine from the ND-bearing.
2.1.2 Bearing plate

A stainless steel bearing plate is attached to the machine frame. For the location of the bearing plate, see Appendix
Typical position of plates.
The bearing plate indicates the type of the bearings and lubrication to be used, see Figure 4 Bearing plate for grease
lubricated rolling bearings and Figure 5 Bearing plate for sleeve bearings.
TRANSPORT AND UNPACKING 19
Following figure for bearing type: Rolling bearing
Figure 4 Bearing plate for grease lubricated rolling bearings
1. Bearing type of D-end

2. Bearing type of ND-end
3. Lubrication interval
4. Quantity of grease for D-end bearing
5. Quantity of grease for ND-end bearing
6. Additional information
7. Type of grease delivered from factory.
Following figure for bearing type: Sleeve bearing
Figure 5 Bearing plate for sleeve bearings
1. Bearing type for D-end.

2. Bearing type for ND-end.
3. Oil change interval.
4. Viscosity class.
5. Oil quantity for D-end bearing (for self lubricated).
6. Oil quantity for ND-end bearing (for self lubricated).
7. Method of lubrication for D-end bearing. Oil flow and pressure for flood lubricated bearing.
8. Method of lubrication for ND-end bearing. Oil flow and pressure for flood lubricated bearing.
9. Rotor end float (axial play).
NOTE: The information given on the bearing plate must imperatively be followed. Failure to do so
will void the warranty for the bearings.
2.2 Lifting the machine

Before the machine is lifted, ensure that suitable lifting equipment is available and that the personnel is familiar with
lifting work. The weight of the machine is shown on the rating plate, dimension drawing and packing list.
NOTE: Use only the lifting lugs or eyes intended for lifting the complete machine. Do not use any
small additional lifting lugs or eyes available, as they are there only for service purposes.
NOTE: The center of gravity of machines with the same frame may vary due to different outputs,
mounting arrangements and auxiliary equipment.
NOTE: Check that eyebolts or the lifting lugs integrated with the machine frame are undamaged
before lifting. Damaged lifting lugs must not be used.
NOTE: Lifting eyebolts must be tightened before lifting. If needed the position of the eyebolt
must be adjusted with suitable washers.
NOTE: When lifting the machine from the bottom, use only lifting spots marked with
ISO 7000-0625- standard mark see Figure 6 Sling here - mark (ISO 7000-0625).
Figure 6 Sling here - mark (ISO 7000-0625)
2.2.1 Lifting a machine in a seaworthy package

The seaworthy package is normally a wooden box, which is covered with lamina paper on the inside. The seaworthy
package should be lifted by forklift from the bottom, or by crane with lifting slings. The sling positions are painted on
the package.
Figure 7 Lifting of horizontal and vertical machines in seaworthy packages when lifting by crane from the eyebolts
of the machine
2.2.2 Lifting a machine on a pallet

A machine mounted on a pallet should be lifted by crane from the lifting eyes of the machine, see Figure 8 Lifting of
horizontal and vertical machines on pallets when lifting by crane from the eyebolts of the machine, or by forklift from
the bottom of the pallet. The machine is fixed to the pallet with bolts.
Figure 8 Lifting of horizontal and vertical machines on pallets when lifting by crane from the eyebolts of the
machine
2.2.3 Lifting an unpacked machine

Suitable lifting equipment must be used! The machine should always be lifted by crane from the lifting eyes on the
frame of the machine, see Figure 9 Lifting of unpacked machines. The machine should never be lifted by forklift from
the bottom or the feet of the machine.
Figure 9 Lifting of unpacked machines
2.2.4 Lifting additional equipment

2.2.4.1 Cooler top, air-to-water

The design of an individual cooler top can be found in project specific documentation. The following instructions
must be followed if there is no sign on the cooler top instructing lifting in some other way.
When an air-to-water cooler needs to be lifted after the machine has been in operation, the water cooler must be
drained before lifting.
If the cooler top has been delivered as separate parts, assemble the parts according to the cooler supplier’s drawings
and manual included in project specific documentation.
When lifting the cooler top only, remove the cooler top roof first, if removable. Use lifting lugs as shown in Figure 10
Lifting the roof of the cooler top, 4 lifting points, max. α = 90 °, Figure 11 Lifting the cooler top, 4 lifting points, max. α
= 90 °, and Figure 12 Air-to-air cooler top example.
Figure 10 Lifting the roof of the cooler top, 4 lifting points, max. α = 90 °
Figure 11 Lifting the cooler top, 4 lifting points, max. α = 90 °

Figure 12 Air-to-air cooler top example
Use lifting eyes marked with 1 only for lifting the cooler top roof, if the roof is removable. Lifting eyes for lifting the
actual cooler top are located under the top roof and will be visible after removing the top roof, in case it is removable.
Use lifting eyes marked with 2 for lifting the removable air guides or silencers of the cooler top.
2.2.4.2 Main terminal box and neutral terminal box

Figure 13 Main terminal box is an example of how the main terminal box should be lifted. The number of lifting eyes
is two or four depending on the size of the terminal box, with max. α = 60 °. The lifting sling is not included in the
delivery.
Figure 13 Main terminal box
Following chapter for mounting type: Vertical
2.3 Turning a vertically mounted machine

Vertically mounted machines may be necessary to turn from vertical to horizontal position, e.g. when changing the
bearings, and vice versa. This is shown in Figure 14 Machine with turnable lifting eyes: lifting and turning. Avoid
damaging the painting or any parts during the procedure. Remove or install the bearing locking device only when the
machine is in vertical position.
NOTE: In AMI 710-1120 the cooler top must be removed first.

Figure 14 Machine with turnable lifting eyes: lifting and turning
2.4 Checks upon arrival and unpacking
2.4.1 Check upon arrival

The machine and the package must be inspected immediately upon arrival. Any transport damage must be
photographed and reported immediately, i.e. within less than one (1) week after arrival, if the transport insurance is
to be claimed. It is, therefore, important that evidence of careless handling is checked and reported immediately to
the transport company and the supplier. Use checklists in Appendix Commissioning report.
A machine, which is not to be installed immediately upon arrival, must not be left without supervision or without
protective precautions. For more details, see Chapter 2.6 Storage.
2.4.2 Check upon unpacking

Place the machine so that it does not hinder the handling of any other goods and on a flat, vibration-free surface.
After the package has been removed, check that the machine is not damaged and that all accessories are included.
Tick off the accessories on the packing list which is enclosed. If there is any suspected damage or if accessories
are missing, take photographs thereof and report this immediately to the supplier. Use checklists in Appendix
Commissioning report.
For correct recycling and disposal of the packaging material, see Chapter 10.3 Recycling of packaging material.
2.5 Installation instructions for main terminal box and cooler parts
These instructions are applied, when the machine is delivered on site with disassembled main components, such as
the main terminal box or cooler parts. Refer to the Dimension Drawing included in the project documentation for the
correct positions of the parts. All bolts, nuts and washers are included in the delivery.
Mechanical assembly should be done only by experienced personnel. Electrically active parts such as stator cables
should be installed by skilled persons only.
Safety instructions must be observed at all times, for more information see Safety Instructions.
To ensure that the warranty terms agreed in the purchase order contract of the project are not invalidated, these
instructions should be followed carefully.
2.5.1 Installation of main terminal box

The main terminal box is delivered with the machine in a separate box/slide package. The installation of the main
terminal box is performed according to these guidelines.
1. Open the package and lift the main terminal box with a suitable lifting device (for example a crane) from the
lifting eyes of the main terminal box.
2. Check that all connection parts are free of dust and dirt.
3. Prepare the delivered bolts and washers for installation.
4. Lift the main terminal box directly onto the machine frame at the position where the main terminal box has
to be connected. (See Dimension Drawing included in the project documentation. See Chapter 2.2.4.2 Main
terminal box and neutral terminal box for lifting instructions.)
5. For NEMA main terminal box only: pull the stator cables through the ceiling membrane.
6. Connect the main terminal box with the screws delivered with the machine frame. Make sure that the isolation
sealing is available to the connection surface of the machine housing.
7. Tighten all screws with max. 200 Nm. (See Chapter 7.4.1 The tightness of fastenings.)
For NEMA main terminal box only: After connecting the main terminal box mechanically to the machine housing, the
stator cables are connected to the terminals:
1. Check the markings of the stator cables and the terminals.
2. Connect the stator cables to the corresponding terminals according to the cable markings (U1, V1, W1 or L1, L2,
L3). See the Electrical Connection Diagram for more information.
3. Tighten the preinstalled screws with max. 80 Nm. (See Appendix Typical main power cable connections.)
2.5.2 Installation of cooler parts

If the cooler or parts of the cooling system (for example silencer, air lead channel) are delivered separately, they have
to be installed on site according to the following instructions.
1. Open the package of the cooler/cooler parts and lift the part(s) using a suitable lifting device (for example a
crane) from the lifting eyes of the package.
2. Check that all connection parts are free of dust and dirt.
3. Check the correct installation positions from the Dimension Drawing delivered with the project documentation.
4. Check that all connection parts, bolts, washers and nuts are included in the delivery.
5. Lift the cooler part to its correct position and connect it with the delivered installation parts. Make sure that all
sealing parts are installed at correct locations. See lifting instructions in Chapter 2.2.4.1 Cooler top, air-to-water
and Chapter 2.2.4.2 Main terminal box and neutral terminal box.
6. Tighten all screws with max. 80 Nm. (See Chapter 7.4.1 The tightness of fastenings.)
2.6 Storage
2.6.1 Short term storage (less than 2 months)

The machine should be stored in a proper warehouse with a controllable environment. A good warehouse or storage
place has:
• A stable temperature, preferably in the range from 10ºC (50°F) to 50ºC (120°F). If the anti-condensation heaters
are energized, and the surrounding air is above 50ºC (120°F), it must be confirmed that the machine is not
overheated.
• Low relative air humidity, preferably below 75%. The temperature of the machine should be kept above the
dew point, as to prevent moisture from condensing inside the machine. If the machine is equipped with anti-
condensation heaters, they should be energized. The operation of the anti-condensation heaters must be
verified periodically. If the machine is not equipped with anti-condensation heaters, an alternative method of
heating the machine and preventing moisture from condensing in the machine must be used.
• A stable support free from excessive vibrations and shocks. If vibrations are suspected to be too high, the
machine should be isolated by placing suitable rubber blocks under the machine feet.
• Air which is ventilated, clean and a free from dust and corrosive gases.
• Protection against harmful insects and vermin.
If the machine needs to be stored outdoors, the machine must never be left ‘as is’ in its transportation package.
Instead the machine must be
• Taken out from its plastic wrap.
• Covered, as to completely prevent rain from entering the machine. The cover should allow ventilation of the
machine.
• Placed on at least 100 mm (4”) high rigid supports, as to make sure that no moisture can enter the machine
from below.
• Provided with good ventilation. If the machine is left in its transportation package, large enough ventilation
openings must be made in the package.
• Protected from harmful insects and vermin.
Use checklists in Appendix Storage in Appendix Commissioning report.
2.6.2 Long term storage (more than 2 months)

In addition to the measures described with short-term storage, the following should be applied.
Measure the insulation resistance and temperature of the windings every three months, see Chapter 7.6 Maintenance
of stator and rotor windings.
Check the condition of the painted surfaces every three months. If corrosion is observed, remove it and apply a coat
of paint again.
Check the condition of anti-corrosive coating on blank metal surfaces (e.g. shaft extensions) every three months. If
any corrosion is observed, remove it with a fine emery cloth and perform the anti-corrosive treatment again.
Arrange small ventilation openings when the machine is stored in a wooden box. Prohibit water, insects and vermin
from entering the box, see Figure 15 Ventilation holes.
Use checklists in Appendix Storage in Appendix Commissioning report.
Figure 15 Ventilation holes
Following paragraph for cooling method: Water jacket
Machines with so-called water jacket cooling are to be filled with a mixture of water and glycol with a minimum of
50% glycol. Instead of glycol, another similar liquid can be accepted. Make sure that the liquid mixture tolerates the
storage temperature without freezing. The liquid inlets and outlets are to be closed after filling.
Following chapter for bearing type: Rolling bearing

2.6.3 Rolling bearings

Apply the following measures:
• Rolling bearings should be well lubricated during storage. Acceptable grease types are presented in Chapter
2.1.2 Bearing plate.
• Turn the rotor 10 revolutions every three months to keep the bearings in good condition. Remove any possible
transport locking device during turning the rotor. See Chapter 3.3.2 Disassembly of the transport locking device
• Machines may be provided with a locking device to protect the bearings against damage during transport and
storage. Check the bearing locking device periodically. Tighten the transport locking device according to the
axially locating bearing type, see Chapter 2.6.3 Rolling bearings.
NOTE: A too high tightening torque on the transport locking device will damage the bearing.
NOTE: The type of bearings used are found on the bearing plate, see Chapter 2.1.2 Bearing plate,
and axially locating bearing information from the dimension drawing.
Following table for mounting type: Horizontal
Table 1 Tightening torque for horizontal machines (lubricated screw)
Axially locating bearing Tightening torque [Nm] Tightening torque

type [pound foot]
6316 45 33
6317 50 37
6319 60 44
6322 120 90
6324 140 100
6326 160 120
6330 240 180
6334 300 220
6034 140 100
6038 160 120
6044 230 170
6048 250 180
6060 250 180
6064 250 180
Following table for mounting type: Vertical
Table 2 Tightening torque for vertical machines (lubricated screw)

type [pound foot]
7317 30 22
7319 30 22
7322 60 44
7324 60 44
7326 90 66
7330 160 120
7334 350 260
7344 350 260
Following chapter for bearing type: Sleeve bearing
2.6.4 Sleeve bearings

Apply the following measures:
• Machines with sleeve bearings are delivered without lubricant, i.e. oil. The inside of the bearings should be
checked for a protective oil layer. Tectyl 511 or other corresponding substance should be sprayed into the
bearing through the filling hole, if the storing period is longer than two months. The corrosion protection
treatment is repeated every six months for a period of two years. If the storing period is longer than two years,
the bearing has to be taken apart and treated separately.
• The bearings should be opened, and all parts inspected after storage and before commissioning. Any corrosion
must be removed with a fine emery cloth. If the shaft has left imprints on the lower liner-half, it must be
replaced with a new one.
• Machines with sleeve bearings are provided with a transport locking device to protect the bearings against
damage during transport and storage. Check the transport locking device periodically. Tighten the transport
locking device according to the axially locating bearing, see Chapter 2.6.3 Rolling bearings.
NOTE: A too high tightening torque on the transport locking device will damage the bearing.
Table 3 Tightening torque (lubricated screw). Axially locating bearing carries the locking force

type [pound foot]
ZM_LB 7 100 74
EF_LB 9 250 180
EF_LB 11 300 220
EF_LB 14 600 440
EM_LB 14 600 440
EF_LB 18 900 670
EF_LB 22 1200 880
EM_LB 22 1200 880
EF_LB 28 1200 880
EM_LB 28 1200 880
2.6.5 Openings
If there are any openings where cables are not connected to terminal boxes or flanges that are not connected to the
piping, they are to be sealed. The coolers and the piping within the machine are to be cleaned and dried before they
are sealed. The drying is made by blowing warm and dry air through the pipes.
2.7 Inspections, records

The storage period, taken precautions and measurements, including dates, should be recorded. For relevant check-
lists, see Appendix Commissioning report.
—
Chapter 3 Installation and alignment
Installation and alignment
3.1 General
Good planning and preparation result in simple and correct installation and assure safe running conditions and
maximum accessibility.
Following paragraph for protection type: All machines for hazardous areas
Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration, especially national standards for installation (see standard IEC 60079-14).
NOTE: General, as well as local work safety instructions must be followed during installation.
NOTE: Ensure the protection of the machine while working nearby.
NOTE: Do not use the machine as a welding earth.
3.2 Foundation design
3.2.1 General
The design of the foundation should assure safe running conditions with maximum accessibility. Sufficient free
space should be left around the machine to ensure easy access for maintenance and monitoring. The cooling air
should flow to and away from the machine without obstruction. Care has to be taken to ensure that other machines
or equipment nearby do not heat the machine cooling air or constructions such as bearings.
The foundation must be strong, rigid, flat and free from external vibration. The possibility of machine resonance with
the foundation has to be verified. In order to avoid resonance vibrations with the machine, the natural frequency of
the foundation together with machine must not be within a ±20% range of the running speed frequency.
A concrete foundation is preferred, however, a correctly designed steel construction is also acceptable. The
anchorage to the foundation, the provision of air, water, oil and cable channels as well as the location of the grouting
holes should be considered prior to construction. The position of the grouting holes and the height of the foundation
must agree with the corresponding dimensions on the provided dimensional drawing.
The foundation shall be designed to permit 2 mm (0.8 inch) shim plates under the feet of the machine in order to
ensure an adjustment margin, and facilitate the possible future installation of a replacement machine. Machine shaft
height and foundation feet location have a certain manufacturing tolerance, which are compensated with the 2 mm
(0.8 inch) shim plate.
NOTE: The calculation and design of the foundation is not included in the ABB scope of supply
and the customer or a third party is therefore responsible for it. Furthermore, the grouting
operation is also normally outside the scope and responsibility of ABB.
3.2.2 Forces to the foundation

The foundation and the mounting bolts must be dimensioned to withstand a sudden mechanical torque, which
occurs every time the machine is started, or at short circuit. The short circuit force is a gradually damped sine wave
that changes direction. The magnitude of these forces is mentioned on the dimensional drawing of the machine.
Following chapter for mounting type: Vertical

INSTALLATION AND ALIGNMENT 31
3.2.3 Flanges for vertically mounted machines

Vertical flange mounted machines are equipped with a mounting flange according to IEC-standard publication
60072. The flange of the machine should always be mounted to an opposite flange on the foundation.
A mounting adapter is recommended to enable an easy coupling connection and inspection during operation.
3.3 Machine preparations before installation

Prepare the machine for installation as follows:
• Measure the insulation resistance of the winding before any other preparations are done as described in
Chapter 3.3.1 Insulation resistance measurements.
• Remove the transport locking device when applicable. Store it for future use. See Chapter 3.3.2 Disassembly of
the transport locking device for further instructions.
• Verify that the grease available is according to the specification on the bearing plate, see Chapter 2.1.2 Bearing
plate. Additional recommended greases can be found in Chapter 7.5.3.5 Bearing grease.
Following bullet and note for bearing type: Sleeve bearing
• Fill the sleeve bearings with appropriate oil. For suitable oils, see Chapter 7.5.2.4 Oil qualities. Clean the sleeve
bearings before filling in oil if the machine has been stored for a long period (over two months) and the
bearings have been treated against corrosion.
NOTE: Sleeve bearings are always delivered without oil!
• Remove the anti-corrosive coating on the shaft extension, and machine feet with white spirit.
• Install the coupling half as described in Chapter 3.3.4 Assembly of the coupling half.
• Check that the drain plugs at the lowest part of both ends of the machine are in open position, see Chapter
3.3.6 Drain plugs.
3.3.1 Insulation resistance measurements

Before a machine is started up for the first time, after a long period of standstill or within the scope of general
maintenance work, the insulation resistance of the machine must be measured. This includes measuring the stature
winding and all auxiliary devices. For machines equipped with slip ring, the measuring also includes the rotor
winding, see Chapter 7.6.4 Insulation resistance test.
3.3.2 Disassembly of the transport locking device

Some machines and all machines with sleeve or roller bearings have transport locking devices installed. For machines
with sleeve or cylindrical roller bearings, the transport locking device is made of a steel bar attached to both the
bearing shield on the D-end and to the end of the shaft extension.
The transport locking device has to be removed prior to installation. The shaft extension has to be cleaned of its anti-
corrosive coating. The locking device should be stored for future use.
Alternative 1
• The transport locking device is a heavy unit, weighing approximately 100 kg.
• Support the transport locking device properly when removing the fasteners.
• Dismantle the whole rotor locking gear, bar and studs from the D-end.
Figure 16 Example of a rotor locking device (1)
Alternative 2
• Unscrew the locking bolt (tagged with a red label) on the D-end bearing by 5 mm and re-lock using a jam nut.
Figure 17 Example of a rotor locking device (2)
NOTE: In order to avoid bearing damages, the transport locking device must be fitted to the
machine whenever the machine is moved, transported to another location or stored. See
Chapter 2.1 Protective measures prior to transport.
3.3.3 Coupling type

Following paragraph for bearing type: Rolling bearing
Machines with rolling bearings must be connected to the driven machine with flexible couplings, e.g. pin couplings, or
gear couplings.
If the axially locked bearing is at the N-end (see dimension drawing), make sure that a continuous free axial
movement is possible between the coupling halves in order to permit thermal expansion of the machine shaft
without damaging the bearings. The expected axial thermal expansion of the rotor can be calculated as defined in
the Chapter 3.6.4 Correction for thermal expansion.
Following paragraph for mounting type: Vertical
Vertical machines may be designed to carry some load from the shaft of the driven machine. If this is the case, the
coupling halves have to be locked against slipping in the axial direction by a lock plate on the end of the shaft.
NOTE: The machine is not suitable for belt, chain or gear connection unless it is specifically
designed for such use. The same applies for high axial thrust applications.
Following paragraph for bearing type: Sleeve bearing with axial float
The sleeve bearing construction allows the rotor to move axially between the mechanical end float limits. Standard
bearings cannot withstand any axial forces from the driven machine. Any axial force from the load will cause bearing
damage. Therefore, all axial forces must be carried by the driven machine and the coupling must be of limited axial
float type.
3.3.4 Assembly of the coupling half
3.3.4.1 Balancing of coupling

The rotor is dynamically balanced with half key as standard. The way of balancing is stamped to the shaft end:
• H = half-key and
• F = full key.
The coupling half must be balanced respectively.
3.3.4.2 Assembly
The following instructions must be taken into account when assembling the coupling half.
• Follow the general instructions of the coupling supplier.
• The weight of the coupling half can be considerable. A suitable lifting gear may be needed.
• Clean the shaft extension of its anti-corrosive coating, and check the measurements of the extension and the
coupling against the provided drawings. Ensure also that the keyways in the coupling and the shaft extension
are clean and free from burrs.
• Coat the shaft extension and hub bore with a thin layer of oil as to facilitate the mounting of the coupling half.
Never coat mating surfaces with molybdenum disulphide (Molykote) or similar products.
• The coupling must be covered with a touch guard.
NOTE: In order not to damage the bearings, no additional forces should be applied to the
bearings when assembling the coupling half.
3.3.5 Belt drive

Machines designed for belt drives are always equipped with cylindrical roller bearing in the D-end. If a belt drive is
used, make sure that the driving and the driven pulleys are correctly aligned.
NOTE: Suitability of the shaft end and the bearings for the belt drive must be always checked
before use. Do not exceed the radial force specified in the order definitions.
3.3.6 Drain plugs

The machines are equipped with drain plugs in the lowest part of the machine. The drain plug is constructed in such
a way that it keeps dust outside the machine and lets condensation water run out. The drain plugs should always be
open, with half the plug inside and half outside. The drain plug is opened by pulling it out of the frame. In AMA/AMI
560-630 machines the drain plug (M12 screw) is opened 6 - 12 mm (0.2” - 0.5”). The structure of AMI 710, AXR, and NXR
drain plugs is different: they must be closed during operation.
Following paragraph for mounting type: Horizontal
For horizontal machines, two drain plugs are fitted at both ends of the machine.
Following paragraph for mounting type: Vertical
For vertical machines, two drain plugs are fitted to the lower end shield.
The main terminal box has one drain plug at the lowest part of the box which has to be closed during operation.
Following chapter for mounting type: Horizontal with concrete foundation
3.4 Installation on concrete foundation
3.4.1 Scope of delivery

The machine delivery does not normally include installation, shim plates, mounting bolts, foundation plate set or sole
plate set. These are delivered according to special orders.
If new fixing holes need to be drilled, please contact ABB to ensure suitability.
3.4.2 General preparations

Before starting the installation procedure, consider the following aspects:
• Reserve sheet steel material for shimming the machine. Possible alignment adjustments require shims with
thicknesses of 1, 0.5, 0.2, 0.1 and 0.05 mm (40, 20, 8, 4 and 2 mil).
• Reserve a recoil hammer, adjusting screws or hydraulic jacks for axial and horizontal adjustments.
• Reserve dial indicator gauges, or preferably a laser optical analyzer, to achieve accurate and precise alignment
of the machine.
• Reserve a simple lever arm for turning the rotor during alignment.
• With outdoor installations provide sun and rain protection to eliminate measuring errors during installation.
NOTE: Machines are delivered with jacking screws for vertical adjustment at each foot.
3.4.3 Foundation preparations
3.4.3.1 Foundation and grouting hole preparations

Foundation studs or sole plates are used when the machine is anchored to a concrete foundation.
Consider the following aspects when preparing the foundation:

• The upper part of the foundation has to be swept or vacuum cleaned.
• Walls of the grouting holes must have rough surfaces to give a good grip. For the same reason they must be
washed and rinsed and thus free from pollution and dust. Oil or grease must be removed by chipping away
slices of the concrete surfaces.
• Check that the position of the grouting holes and the height of the foundation agree with corresponding
measurements on the drawing provided.
• Attach a steel wire on the foundation to indicate the center line of the machine. Mark also the axial position of
the machine.
3.4.3.2 Foundation studs or sole plate preparations

If shims and foundation studs are part of the delivery, they will be delivered as separate items. The assembly of these
will be made at site.
NOTE: To ensure that the foundation studs will be satisfactorily attached to the concrete, they
must be unpainted and free from pollution and dust.
Figure 18 Typical foundation stud assembly
Item Name of the parts Size Quantity/set [pcs]

1 Plate 70x200x440 4
2 Stud M36x500/4S+100 8
3 Flange 10x60x210 4
4 Nut M36 16
5 Jacking screw M24x60 8
6 Fixing screw M36x90/90 4
7 Shim 2x170x250 4
8 Support plate 25x100x180 4
9 Taper pin 10x100 2
10 Jacking screw M16x55 4
The taper pin (part 9) is needed only at drive-end of the motor.
X) The tape is not included in the delivery.
Anchor bolt to be mounted in the foundation.
Fundation stud will be delivered as loose items.
One set includes parts for one machine (4 pcs).
In order to assemble the foundation stud or sole plate set, the machine must be suspended above the floor by a
crane. Proceed as follows, see Figure 18 Typical foundation stud assembly:
• Clean the parts protected by an anti-corrosive coating with white spirit.
• Screw the greased leveling screws into the foundation studs (part 5) or sole plates.
• Wrap a layer of tape around the upper part of the anchor bolts (part 2) according to Figure 18 Typical
foundation stud assembly. The tape will prevent the upper part of the bolt from being stuck in the concrete and
enables it to be retightened after the concrete has set.
• Fit the anchor bolt (part 2) in the foundation plates (part 1) or sole plates so that the top of the anchor bolts is
1...2 mm (40...80 mil) above the upper surface of the nuts (part 4).
• Fit the anchor flange (part 3) and the lower nut (part 4) to the anchor bolts (part 2). Bridge the anchor flange
(part 3) to the bolts by welding and tighten the nuts. If the bridging cannot be done, lock the anchor flange
between two nuts.
• After the assembly of the foundation plates is done; the machine should be lifted up and suspended above
the floor. The machine feet, and the side and bottom surfaces of the foundation plates as well as anchor bolts
should be cleaned with white spirit.
• Mount the assembled foundation studs or sole plates under the machine feet with the mounting bolt (part
6) and washer (part 3). Center the mounting bolt (part 6) in the hole of the machine by wrapping e.g. paper,
cardboard or tape on the upper part of the bolt.
• Place the 2 mm (0.8 inch) shim (part 7) between the foot and the plate (part 1). Fasten the plate tightly against
the foot with the mounting bolt (part 6).
• Place the leveling plate (part 8) under the leveling screw (part 5).
• Check that the space between the plate (part 1) and the anchor bolts (part 2) is tight. If concrete penetrates
through this interstice up to the nuts, the retightening cannot be done.
NOTE: The tape and the steel plate are not included in the delivery of the foundation studs.
3.4.4 Erection of machines

The machine is carefully lifted and placed onto the foundation. A rough horizontal alignment is made with the aid of
the previously installed steel wire and the marking of the axial location. A vertical alignment is made with the leveling
screws. Required positioning accuracy is within 2 mm (80 mil).
3.4.5 Alignment
The alignment is made as described in Chapter 3.6 Alignment.
3.4.6 Grouting
The grouting of the machine into the foundation is a very important part of the installation. The instructions of the
grouting compound supplier must be followed.
Please use high-quality non-shrinking grouting materials to avoid difficulties with the grouting in the future. Cracks
in the grouting compound or a poor attachment to the concrete foundation cannot be accepted.
3.4.7 Final installation and inspection

After the concrete has set, lift the machine from the foundation and retighten the anchor bolts. Lock the nuts by
bridging or hitting sufficiently hard with a center punch. Lift the machine back on the foundation and tighten the
mounting bolts.
Check the alignment in order to ensure that the machine will run with the permissible vibration. If necessary, make
the adjustment with shims, and then complete the doweling according to the holes in the feet at the machine D-end.
3.4.7.1 Dowelling of the machine feet

The machine has one dowel hole per foot at the D-end. Deepen the holes by drilling through to the steel foundation.
After that, the holes are tapered with a reaming tool. Suitable tapered pins are fitted to the holes to ensure the exact
alignment, and to allow easier reinstallation after any possible removal of the machine.
3.4.7.2 Covers and enclosures

Complete the coupling installation by attaching both coupling halves to each other according to the coupling
manufacturer’s instruction.
NOTE: The coupling must be covered with a touch guard.
After the machine has been erected, aligned and its accessories are installed, check carefully that no tools or foreign
objects have been left inside of the enclosures. Clean also any dust or debris.
Check that all sealing strips are intact when installing the covers.
Store the alignment and assembly accessories together with the transport locking devices for future use.
Following chapter for mounting type: Horizontal with steel foundation
3.5 Installation on steel foundation
3.5.1 Scope of delivery

The machine delivery does not normally include installation, shim plates or mounting bolts. These are delivered
according to special orders.
If new fixing holes need to be drilled, please contact ABB to ensure suitability.
3.5.2 Check of foundation

Before lifting the machine onto the foundation, the following checks should be made.
• Clean the foundation carefully
• The foundations shall be flat and plain parallel within 0.1 mm (4.0 mil) or better
• The foundation shall be free from external vibration.
3.5.3 Erection of machines

The machine is carefully lifted and placed onto the foundation.
3.5.4 Alignment
The alignment is made as described in Chapter 3.6 Alignment.
3.5.5 Final installation and inspection
3.5.5.1 Doweling of the machine feet

The machine has one dowel hole per foot at the D-end. Deepen the holes by drilling through to the steel foundation.
After that, the holes are tapered with a reaming tool. Suitable tapered pins are fitted to the holes to ensure the exact
alignment, and to allow easier reinstallation after any possible removal of the machine.
3.5.5.2 Covers and enclosures

Complete the coupling installation by attaching both coupling halves to each other according to the coupling
manufacturer’s instruction.
NOTE: The coupling must be covered with a touch guard.
After the machine has been erected, aligned and its accessories are installed, check carefully that no tools or foreign
objects have been left inside of the enclosures. Clean also any dust or debris.
Check that all sealing strips are intact when installing the covers.
Store the alignment and assembly accessories together with the transport locking devices for future use.
Following chapter only for mounting type: Vertical
3.5.6 Installation of flange mounted machines on steel foundation

The purpose of a mounting flange for vertically mounted machines is to enable an easy installation and coupling
connection, as well as an easy inspection of the coupling during operation. In order to fit the ABB machines, the
mounting flanges shall be designed according to the IEC standard.
The mounting flange is not included in the ABB scope of delivery.
Figure 19 Mounting flange
The machine is lifted and placed onto the mounting flange. The mounting bolts are tightened lightly.
3.6 Alignment
3.6.1 General
In order to ensure a long and satisfactory lifetime of both the driving and the driven machine, the machines need to
be properly aligned to each other. This means that the radial, as well as the angular deviation between the two shafts
of the machines have to be minimized. The alignment must be performed with great caution because alignment
errors will lead to bearing and shaft damages.
Before the alignment procedure is started, the coupling halves have to be installed, see Chapter 3.3.4 Assembly of
the coupling half. The coupling halves of the driving and driven machines must be bolted together loosely in order to
move freely in respect to each other during the alignment.
The following text refers to installation on both concrete and steel foundations. Shimming is not necessary in case of
a concrete foundation if the alignment and grouting is done correctly.
3.6.2 Rough levelling

In order to facilitate the alignment and enable the mounting of shims, jacking screws are fitted to the feet of the
machine, see Figure 20 Vertical positioning of machine foot. The machine is left standing on the jacking screws. Note
that the machine must stand on all four feet (screws) on a plain parallel within 0.1 mm (4.0 mil) or better. If this is not
the case, the frame of the machine will be twisted or bent, which can lead to bearing or other damages.
Check that the machine is vertically, horizontally and axially in level. Make adjustments accordingly by placing shims
under the four feet. The horizontal level of the machine is checked with a spirit level.
1. Machine foot
2. Shim
3. Foundation
4. Fixing bolt
5. Jacking screw.
Figure 20 Vertical positioning of machine foot
3.6.3 Rough adjustment

In order to facilitate the alignment in axial and transversal directions, place bracket plates with adjusting screws at
the corners, see Figure 21 Positioning of bracket plates.
1. Bracket with adjusting screw.

Figure 21 Positioning of bracket plates
Bracket plates are placed against the foundation edge and tied down with expansion bolts, see Figure 22 Mounting
of the bracket plate. Move the machine by using the adjusting screws until the shaft centerline and the driven
machine centerline are aligned roughly and the desired distance between the coupling halves is reached. Leave all
adjusting screws only lightly tightened.
1. Bracket with adjusting screw

2. Expansion bolt.
Figure 22 Mounting of the bracket plate
NOTE: Figure 22 Mounting of the bracket plate shows bracket plate mounted to concrete
foundation, place similar bracket plate on steel foundation.
Following paragraph and figure for bearing type: Sleeve bearing with axial float
The sleeve bearing in the D-end is equipped with a pointer for showing running center, which is marked with a groove
on the shaft. There are also grooves on the shaft for rotor mechanical end float limits. The position is correct when
the tip of the pointer is in line with the machined running center groove on the shaft, see Figure 23 Markings on shaft
and running center pointer. Notice that the running center is not necessarily the same as the magnetic center as the
fan may pull the rotor from the magnetic center.
1. Pointer
2. Outer seal
3. Running center
4. Rotor end float limits.
Figure 23 Markings on shaft and running center pointer
3.6.4 Correction for thermal expansion
3.6.4.1 General
Running temperatures have a considerable influence on the alignment, and should therefore be considered during
the alignment. The machine temperature is lower during erection than under operating conditions. For this reason,
the shaft center will be higher, i.e. further away from the feet during operation than standstill.
It may therefore be necessary to use heat compensated alignment depending on the operating temperature of the
driven machine, coupling type, distance between machines, etc.
3.6.4.2 Thermal expansion upwards

Thermal expansion between the feet and the shaft center of the electrical machine can be approximately calculated
as follows:
ΔH = α × ΔT × H where
ΔH=thermal expansion[mm]
-6 -1
α=10 × 10 K
ΔT=40 K
H=shaft height [mm]
NOTE: Consider the thermal expansion of the driven machine in respect to the electrical machine
in order to define the total thermal expansion.
3.6.4.3 Thermal axial expansion

Thermal axial expansion needs to be taken into consideration if the axial movement of the non-drive end bearing is
locked. See dimension drawing to determine which end is locked.
The expected axial thermal expansion of the rotor is proportional to the length of the stator frame, and can be
approximately calculated as follows:
ΔL = α × ΔT × Lwhere
ΔL=thermal expansion[mm]
α=10 × 10-6 K-1
ΔT=50 K (for AMA, AMB, AMK, AMI, NMH, NMI, NMK), 80 K (for AMH, AXR, HXR, M3BM, M3GM, NXR)
L=frame length [mm]
NOTE: Make sure that continuous free axial movement is possible between the coupling halves
(excluding rigid couplings) to permit axial thermal expansion of the machine shaft as not to
damage the bearings.
3.6.5 Final alignment
3.6.5.1 General
In the following, the final alignment is made with dial gauges, although there is other and more exact measuring
equipment on the market. The reason for using dial gauges in this text is to provide some alignment theory.
NOTE: Measurements should be made only after proper shimming and with fixing bolts properly
tightened.
NOTE: The final alignment measurements should always be recorded for future reference.
3.6.5.2 Run-out of the coupling halves

The alignment procedure is started by measuring the run-out of the coupling halves. This measurement will show any
inaccuracy of the shaft and/ or coupling halves.
The run-out of the coupling half in respect to the bearing housing of the machine is measured. Place the gauges
according to Figure 24 Measuring the run-out at the coupling half. Similarly check the run-out of the coupling half of
the driven machine in respect to its bearing housing.
A simple lever arm is needed to turn a rotor of a sleeve-bearing machine.
Following note for bearing type: Sleeve bearings
NOTE: Sleeve bearings must be filled with oil before turning.
The admissible run-out error is less than 0.02 mm (0.8 mil).

Figure 24 Measuring the run-out at the coupling half
3.6.5.3 Parallel, angular and axial alignment

After the machine has been roughly positioned, as described in Chapter 3.6.2 Rough levelling and Chapter 3.6.3 Rough
adjustment, the final alignment can start. This step must be performed with great caution. Failure to do so can result
in serious vibrations and damage to both driving and driven machine.
The alignment is done in accordance with the recommendations given by the coupling manufacturer. Parallel, angular
and axial alignment of the machine is required. Some standard publications give recommendations for coupling
alignment, e.g. BS 3170:1972 "Flexible couplings for power transmission".
In accordance with common practice, parallel and angular misalignment should not exceed 0.05-0.10 mm and axial
misalignment should not exceed 0.10 mm, see Figure 25 Definition of misalignment The corresponding run-out is
0.10-0.20 mm for parallel and angular misalignment.
1. Parallel misalignment ∆r
2. Angular misalignment ∆b
3. Axial misalignment ∆a.
Figure 25 Definition of misalignment
3.6.5.4 Alignment
The alignment of the machine is performed according to these guidelines.
Following note for bearing type: Sleeve bearings
NOTE: Sleeve bearings must be filled with oil before turning.
1. The machine should stand on its jacking screws.

2. Rotate the rotor and check the axial end float, see Chapter 3.6.3 Rough adjustment.
3. Mount the alignment equipment. If gauges are used, it is practical to adjust the dial gauge in such way that
approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets in order
to eliminate the possibility of sag, see Figure 26 Alignment check with gauges.
1 Radial alignment
2 Angular alignment.
Figure 26 Alignment check with gauges

4. Measure and note readings for parallel, angular and axial misalignment in four different positions: top, bottom,
right and left, i.e. every 90°, while both shafts are turned simultaneously. The readings are recorded.
5. Align the machine vertically by turning the jacking screws or by jacking with hydraulic jacks. To facilitate the
alignment in the vertical plane, jacking screws are fitted to the feet of the horizontal machine, see Figure 20
Vertical positioning of machine foot. The alignment accuracy of the machine is sometimes affected by the
thermal expansion of its frame, see Chapter 3.6.4 Correction for thermal expansion.
6. Measure the distance between the bottom of the machine feet and the bedplate and make corresponding solid
blocks or wedges or reserve necessary amount of shims.
7. Fit the solid blocks or shims under the machine feet. Slacken the jacking screws and tighten the fixing bolts.
8. Check the alignment again. Make corrections if necessary.
9. Draw up a record for future checks.
10. Re-tighten nuts and lock the nuts by tack welds or hitting sufficiently hard with a center punch.
11. Dowel the feet of the machine for easy future re-installation of the machine, see Chapter 3.4.7.1 Dowelling of
the machine feet.
3.6.5.5 Permissible misalignment

Definite alignment tolerances are impossible to state as too many factors have an influence. Too large tolerances
will cause vibration and may possibly lead to bearing or other damages. Therefore, it is recommended to aim at as
narrow tolerances as possible. Maximum permissible misalignments are shown in Table 4 Recommended permissible
misalignments. For definitions of misalignment, see Figure 25 Definition of misalignment.
NOTE: Tolerances given by the coupling manufacturers indicate tolerances for the coupling,
not for the driving-driven machine alignment. The tolerances given by the coupling
manufacturer should be used as a guideline for the alignment only if they are narrower than
the maximum permissible misalignments shown in Table 4 Recommended permissible
misalignments.
Table 4 Recommended permissible misalignments
Coupling information Permissible misalignment

Coupling Coupling Type Parallel Angular Axial
Diameter Δr Δb Δa
100 – 250 mm Rigid Flange 0.02 mm 0.01 mm 0.02 mm

(4 – 10”) (0.8 mil) (0.4 mil) (0.8 mil)
Gear 0.05 mm 0.03 mm 0.05 mm

(2 mil) (1 mil) (2 mil)
Flexible 0.10 mm 0.05 mm 0.10 mm

(4 mil) (2 mil) (4 mil)
250 – 500 mm Rigid Flange 0.02 mm 0.02 mm 0.02 mm

(10 – 20”) (0.8 mil) (0.8 mil) (0.8 mil)
Gear 0.05 mm 0.05 mm 0.05 mm

(2 mil) (2 mil) (2 mil)
Flexible 0.10 mm 0.10 mm 0.10 mm

(4 mil) (4 mil) (4 mil)
3.7 Care after installation

If the machine will not be in operation for a longer period after it has been installed, the same measures as
mentioned above in Chapter 2.6.1 Short term storage (less than 2 months) should be applied. Remember to rotate
the shaft 10 revolutions at least every 3 months, and that self-lubricated bearings must be filled with oil. If external
vibration is present, the shaft coupling should be opened and suitable rubber blocks should be placed under the feet
of the machine.
Following note for bearing type: Rolling bearing
NOTE: External vibration will damage the bearing rolling surfaces and therefore shorter the
bearing lifetime.
Following note for bearing type: Sleeve bearing
NOTE: External vibration will damage the bearing sliding surfaces and therefore shorter the
bearing lifetime.
—
Chapter 4 Mechanical and electrical connections
Mechanical and electrical connections
4.1 General
Mechanical and electrical connections are made after the installation and alignment procedures. The mechanical
connections include the connection of air ducts, water tubes and/or oil supply system where applicable.
The electrical connections include the connection of main and auxiliary cables, earthing cables and possible external
blower motors.
In order to determine proper actions, please read the Dimensional Drawing, the Connection Diagram and the Data
Sheet provided with the machine.
NOTE: Additional installation holes or threads should never be drilled through the frame, as this
may damage the machine.
4.2 Mechanical connections

Following chapter for cooling method: Ducted air
4.2.1 Cooling air connections

Machines designed for cooling airflow to and/or from the machine with air ducts have connection flanges as
specified in the dimensional drawing.
Clean the air ducts thoroughly before connecting them to the machine, and check for possible obstructions in
the ducts. Seal the joints with appropriate gaskets. Check for possible leaks in the air ducts after they have been
connected.
Following chapter for cooling method: Air-to-water, and water jacket
4.2.2 Cooling water connections

Following chapter for cooling method: Air-to-water
4.2.2.1 Air-to-water coolers

Machines equipped with an air-to-water heat exchanger have flanges specified in standards DIN 633 or ANSI B 16.5.
Connect the flanges and seal the joints with appropriate gaskets. Prior to starting the machine, the water has to be
turned on.
Following chapter for cooling method: Water jacket
4.2.2.2 Water cooled frames

Steel frame water-cooled construction is only to be used with a closed fresh water circulation. The water cooling
circuit flanges are made according to the customer's specifications, and are defined on the dimensional drawing.
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: S235 JRG2, equivalent with DIN 17100 - RSt 37-2. 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 and inhibited water in the cooling system.
MECHANICAL AND ELECTRICAL CONNECTIONS 47
Standard values for the cooling water to be used in the cooling system:
• pH 7.0 - 9.0
• Alkalinity (CaCO3) > 1 mmol/kg
• Chloride (Cl) < 20 mg/kg
• Sulphate < 100 mg/kg
• KMnO4-concentration < 20 mg/kg
• Al-concentration < 0.3 mg/kg
• Mn-concentration < 0.05 mg/kg.
In most of the cases, normal tap water, i.e. water for domestic consumption, fulfils all these requirements.
The cooling water must also be inhibited with an agent protecting the cooling system against corrosion, fouling and
when necessary, against freezing. All materials in touch with the cooling water (pipes, heat exchanger, etc.) must be
taken into account when selecting a suitable inhibitor.
Recommended inhibitor:
Manufacturer ASHLAND
Product RD-25
which is suitable for steel, copper, aluminium and many other materials.
Use only suitable and high-class connection parts and seals to connect the machine to the water circuit. Check for
possible leaks after the piping and joints have been connected.
4.2.3 Sleeve bearing oil supply

Machines with flood lubrication system are equipped with oil pipe flanges, and possibly with pressure gauges and
flow indicators. Install all necessary oil pipes and connect the oil circulating units.
Install the oil supply system near the machine in equal distance from each bearing. Before connecting the pipes to
the bearings, test the oil supply system by flowing rinsing oil through it. After this, remove the oil filter and clean it.
The oil container should be constructed so that no pressure can enter the oil return piping from the container
towards the bearing.
Install and connect the oil inlet pipes to the bearings. Install the oil outlet pipes downwards from the bearings at
a minimum angle of 15°, which corresponds to a slope of 250 - 300 mm/m (3 - 3½ inch/ft). The oil level inside the
bearing will increase if the slope of the pipes is too small; the oil will flow too slowly from the bearing to the oil
container, and this can result in oil leaks or disturbances in the oil flow.
NOTE: Do not drill holes through the frame during the installation of the pipes or any other
equipment, as this can damage the machine seriously.
Fill the oil supply system with appropriate oil with correct viscosity. The correct type of oil and viscosity is indicated
on the dimensional drawing. If in any doubt of the cleanness of the oil, use a 0.01 mm (0.4 mil) mesh to filter
unwanted debris from the oil.
Turn the oil supply on, and check the oil circuit for possible leaks prior to starting the machine. The normal oil level is
obtained when half of the oil sight glass is covered.
NOTE: The bearings are delivered without lubricant.
NOTE: Running the machine without lubricant will result in immediate bearing damage.
Following chapter for protection type: Ex p
4.2.4 Connection of purging air pipe

The EEx p or Ex p machine is explosion protected by pressurizing. It is equipped with a control system, which
includes an air control unit and a relief valve. The system works with uncontaminated pressurized air as the
protective gas. Before the start, the machine is purged to remove any hazardous gases. During operation, the
machine is kept under over-pressure to keep hazardous gases from entering the machine.
Purging and pressurizing air supply is connected to the flange provided on the air control unit. The air supply
pressure must be between 4 and 8 bar. Required flow rate during purging and pressurizing is specified on the Ex -
certificate. For more detailed information of the control system, see the supplier’s instruction manual.
4.2.5 Mounting of vibration transducers

If the installed vibration transducers project from the machine frame, they are delivered uninstalled in order to avoid
damages during transportation.
For taking vibration transducers into use, proceed as follows:
1. Disconnect the detached vibration transducers from their cables.
2. Remove the shield plugs from the tapped mounting holes on the end shield of the machine.
3. Protect the mounting surfaces against rust with a suitable anti-corrosion agent.
4. Mount the vibration transducers to the tapped mounting holes. The tightening torque depends on the used
transducer type:
- PYM TRV18 : 10 Nm
- PYM 330400_ : 3,3 Nm
- PYM 330500_ : 4,5 Nm
5. Finally, connect the cables to the vibration transducer.
Following chapter for protection type: Ex e and Ex n
4.2.6 Provision for purging air

Depending on the Ex-classification, the motor may be equipped with air connections. If provisions are used, make the
connections as illustrated in the following.
For more information, see Safety Instructions.
Connections for AMA/AMI machines
1. Air outlet
2. Potential equalisation.
Figure 27 Connections for AMA/AMI machines
• Air inlet: connect only to one side of frame, use all three connections
• Air outlet: connect to cooler on one side.
Connections for HXR machines
Air inlet and air outlet must be connected to the opposite side and opposite ends of the motor.
1. Air outlet
2. Air inlet
3. Top view
4. D-end
5. N-end.
Figure 28 Air inlet and air oulet connections for HXR machines
Following chapter for bearing type: Antifriction bearing with oil mist lubrication
4.2.7 Roller bearing oil mist supply

Machines with oil mist lubrication are equipped with pipe connectors. Connect the oil circulating units.
Install the oil supply system near the machine. Before connecting the pipes to the bearings, test the oil supply system
by flowing rinsing oil through it. After this, remove the oil filter and clean it.
Install and connect the oil inlet and outlet pipes to the bearings.
NOTE: Do not drill holes through the frame during the installation of the pipes or any other
equipment, as this can cause serious damage to the machine.
Fill the oil supply system with appropriate oil with correct viscosity. The correct type of oil and viscosity are indicated
in the dimensional drawing. If you are not sure that the oil is clean, use a 0.01 mm (0.4 mil) mesh to filter debris from
the oil.
Turn the oil supply on and check the oil circuit for possible leaks before starting the machine.
NOTE: The bearings are delivered without lubricant.
NOTE: Do not run the machine without lubricant, as it will damage the bearings.
4.3 Electrical connections
4.3.1 General information

The safety information in Safety Instructions must be observed at all times.
The electrical installation should be thoroughly planned before taking any action. The connection diagrams received
with the machine have to be studied before starting the installation work. It is important to verify that the supply
voltage and the frequency are the same as the values indicated on the rating plate of the machine.
The network voltage and frequency should be within given limits according to the applicable standard. Note
rating plate markings and connection diagram in the terminal box. For additional information, see the machine
performance data sheet.
NOTE: Prior to installation work, it is important to check that the incoming cables are separated
from the supply network, and that the cables are connected to protective earth.
NOTE: Check all rating plate data, especially the voltage and winding connection.
Following paragraph for rotor type: Permanent magnet
Machines are intended only for variable speed drives, i.e. to be supplied by frequency converters. The frequency
converter must be designed to operate with a permanent magnet synchronous machine. If there is uncertainty
concerning the compatibility of the permanent magnet synchronous machine and the frequency converter, please
contact ABB Sales Office.
4.3.2 Safety
Electrical work must be carried out only by skilled persons. The following safety rules must be applied:
• De-energize all equipment, including auxiliary equipment
• Provide safeguard against re-energizing the equipment
• Verify that all parts are isolated from their respective supply
• Connect all parts to protective earth and short the circuits
• Cover or provide barriers against live parts in the surrounding area
• If the secondary circuit of the current transformer is extended, make sure that it does not become open-
circuited in use.
Following bullet for rotor type: Permanent magnet rotor
• The permanent magnet synchronous machine produces voltage when the shaft is rotating. Prevent rotation of
the shaft before opening the terminal box. Do not open or touch the unprotected terminals while the shaft of
the machine is rotating. Follow Safety Instructions.
4.3.3 Insulation resistance measurements

maintenance work, the insulation resistance of the machine must be measured, see Chapter 7.6.4 Insulation
resistance test.
4.3.4 Main terminal box options

The inside of the main terminal box must be free from dirt, moisture and foreign debris. The box itself, cable glands,
and unused cable entrance holes must be closed in a dust- and watertight manner.
The main terminal box is equipped with a drain plug at the lowest part of the box. The plug should be in open
position, i.e. half of the plug is inside and half of the plug is outside, during transportation and storage. During
operation of the machine, the plug should be kept in shut position but opened from time to time. If the box is turned
after delivery the drain plug function must be checked, and possibly re-positioned at the lowest part of the box.
Some main terminal boxes can be turned in 90 degrees steps. Before turning, check that the length of the cables
between the stator winding and the terminal box is sufficient.
4.3.4.1 Delivery without main terminal box

If the machine is delivered without a main terminal box, the stator connection cables have to be covered with earthed
protective structure before commissioning. The structure must have the same or higher enclosure classification and
hazardous area certifications as the machine.
To avoid cable failure, stator connection cables must be shortened to minimize free movement of the cables. The
supplier of the terminal arrangement is responsible for ensuring that adequate stator connection cable supports are
used. The stator connection cable arrangement has to be spacious in order to avoid overheating of the cables. Stator
connection cables must not touch sharp corners. The minimum bending radius of stator connection cable is 6 times
the cable outer diameter.
4.3.5 Insulation distances of main power connections

The connections of the main power cables must be designed to withstand demanding operation conditions where
the insulators can be subjected to dirt, humidity and surge voltages. In order to ensure lasting and trouble-free
running, it is therefore important that the length of the insulation and creepage distances are sufficient. The
minimum insulation and creepage distances should be equal or exceed demands set by:
• Local requirements
• Standards
• Classification rules
• Hazardous area classification.
The insulation and creepage distances apply both for insulation distances between two different phases, and for
insulation distances between one phase and earth. The air insulation distance is the shortest distance through
air between two points with different electrical potential (voltage). The surface creepage distance is the shortest
distance along surfaces next to each other between two points with different electrical potential (voltage).
4.3.6 Main power cables

The size of the input cables has to be adequate for the maximum load current and in accordance with local
standards. The cable terminals have to be of appropriate type and of correct size. The connection to all devices has
to be checked.
The main power cable connections should be tightened correctly to ensure reliable operation. For details, see
Appendix Typical main power cable connections.
Following note for protection type: All hazardous areas
NOTE: For Ex-machines, cable glands or cable bushings for supply cables must be Ex certified.
Glands or bushings are not included in the manufacturer’s delivery.
NOTE: Prior to installation work, it is important to check that the incoming cables are separated
from the supply network, and that the cables are connected to protective earth.
The stator terminals are marked with letters U, V and W according to IEC 60034-8 or T1, T2, and T3 according to
NEMA MG-1. The neutral terminal is marked with N (IEC) or with T0 (NEMA). Stripping, splicing and insulating of the
high-voltage cables must be performed in accordance with instructions by the cable manufacturer.
The cables must be supported so that no stress is applied to the bus bars in the terminal box.
NOTE: Check the phase sequence from the connection diagram.
Following paragraph for rotor type: Permanent magnet rotor
NOTE: Permanent magnet synchronous machines must be cabled by using shielded symmetrical
cables and cable glands providing 360° bonding (also called EMC glands).
Following paragraph for rotor type: Slip rings
4.3.7 Secondary cables for slip ring connections

The slip ring housing at the non-drive end of the machine serves as a terminal box for the secondary cables, and it
has the same degree of protection as the machine.
The cables can be connected from either side. The connection is made to the rotor terminals on the termination
plate, which is designed to fit up to six cable lugs per phase. The terminals are marked K, L and M in accordance with
IEC Publications 60034-8.
NOTE: Study the connection diagram delivered with the machine carefully before connecting any
cables.
4.3.8 Auxiliary terminal box

Auxiliary terminal boxes are attached to the frame of the machine according to accessories and customer needs, and
their positions are shown on the dimensional drawing of the machine.
The auxiliary terminal boxes are equipped with terminal blocks and cable glands, see Figure 29 Typical auxiliary
terminal box. The maximum size of the conductors is normally limited to 2.5 mm² (0.004 sq. in.), and the voltage is
limited to 750 V. The cable glands are suitable for cables of 10 – 16 mm (0.4”– 0.6”) diameter.
Following note for protection type: All machines for hazardous areas
NOTE: For Ex-machines, cable glands or cable bushings for supply cables must be Ex certified.
Glands or bushings are not included in manufacturer’s delivery.
Figure 29 Typical auxiliary terminal box
4.3.8.1 Connection of auxiliaries and instruments

Connect the instruments and auxiliary equipment according to the connection diagram.
NOTE: Study the connection diagram delivered with the machine carefully before connecting
any cables. The connection and functioning of accessories must be checked before
commissioning.
NOTE: Label terminals of accessories, which are normally under voltage when the machine is
switched off, correspondingly.
4.3.8.2 Connection of external blower motor

The external blower motor is normally a three phase asynchronous motor. A connection box is usually located on the
frame of the blower motor. The external blower motor rating plate shows the voltage and frequency to be used. The
direction of rotation of the fan is indicated by an arrow plate on the flange of the main machine.
NOTE: Check visually the direction of rotation of the external blower motor (fan) before starting
the main machine. If the blower motor is running in the wrong direction, the phase
sequence of the blower motor must be changed.
4.3.9 Earth connections

The machine frame, main terminal box, auxiliary terminal box and associated equipment must be connected to
protective earth. The connections to protective earth and power supply have to be able to protect the machine frame
from harmful or dangerous electrical potential (voltage).
NOTE: The earthing must be carried out according to local regulations before the machine is
connected to the supply voltage.
NOTE: The warranty does not cover destroyed bearings due to improper earthing or cabling.
Mark the machine and terminal boxes with earth symbols according to relevant national standards.
Following chapter for application type: Variable speed drive
4.3.10 Requirements for machines fed by frequency converters

In compliance with the EMC directive (89/336/ EEC, as amended by 93/68/EEC) it is required that an AC machine fed
with frequency converter is installed with screened cables as specified below. For information on other equivalent
cables, please contact your local ABB representative.
4.3.10.1 Main cable

The main supply cable between the machine and the frequency converter must be a symmetrical three conductor
screened cable in order to fulfil the radiated emission requirements stated in the generic emission standard for
industrial environment, EN 50081-2.
4.3.10.2 Earthing of main cable

The compliance with EMC directive requires high-frequency earthing of the main cable. This is achieved by a 360°
earthing of the cable screens at the cable entries in both the machine and in the frequency converter. The earthing at
the machine is implemented for example by means of the EMC ROX SYSTEM cable transits for shielded installations.
NOTE: 360° high-frequency earthing of cable entries is made in order to suppress electromagnetic
disturbances. In addition, cable screens have to be connected to protective earth (PE) in
order to meet safety regulations.
4.3.10.3 Auxiliary cables

The auxiliary cables must be screened to meet the EMC requirements. Special cable glands must be used for the 360°
high-frequency earthing of the cable screens at the cable entries.
COMMISSIONING AND START-UP 55
—
Chapter 5 Commissioning and start-up
Commissioning and start-up
5.1 General
A commissioning report is a vital tool for future service, maintenance and fault finding.
The commissioning is not to be considered finalized before an acceptable commissioning report has been
documented and filed.
The commissioning report has to be available in warranty requests in order to obtain warranty for the machine. For
contact information, see Chapter 9.1.3 Contact information for Motors and Generators Service.
The recommended commissioning report can be found in Appendix Commissioning report.
5.2 Check of mechanical installation

Check alignment of the machine prior to commissioning:
• Go through the alignment report and ensure that the machine is accurately aligned according to ABB alignment
specifications in Chapter 3.6 Alignment
• The alignment protocol should always be included in the commissioning report.
Check that the machine is properly anchored to the foundation:
• Check for cracks in the foundation and the general condition of the foundation
• Check the tightness of the mounting bolts.
Additional checks, when applicable:
• Check that the lubrication system is commissioned and is running before the rotor is turned
• If possible, turn the rotor by hand and make sure that the rotor turns freely and that no abnormal sound can be
heard
• Check the assembly of the main terminal box and cooling system
• Check the connection of oil and cooling water pipes and check for leaks when running
• Check pressure and flow for oil and cooling water.
5.3 Insulation resistance measurements

maintenance work, the insulation resistance of the machine must be measured, see Chapter 7.6.4 Insulation
resistance test.
5.4 Check of electrical installation

The power cables can be permanently connected to the terminals in the main terminal box when the stator insulation
resistance has been measured, see Chapter 7.6.4 Insulation resistance test.
Check connection of power cables:
• Check that the cable lug bolts are tightened with proper torque
• Check that the power cables are suitably routed
• Check that the power cables are stress-relieved in a proper way
• Check the connections of the auxiliary equipment.
NOTE: If the machine is delivered without a main terminal box, see Chapter 4.3.4.1 Delivery
without main terminal box.
NOTE: If an anti-condensation heater, without self-regulation, is turned on immediately after

the motor is shut down, take suitable measures to control the inside motor housing
temperature. The anti-condensation heaters can only operate within a temperature-
controlled environment.
5.5 Control and protection equipment
5.5.1 General
The machine is equipped with temperature detectors to be connected to a temperature monitoring and protection
system. The location and type, as well as the settings for these detectors, can be found on the dimensional drawing,
and the connection diagram of the machine.
The temperature alarm level for resistance temperature detectors (RTD, Pt-100) should be set as low as possible.
The level can be determined based on the test results, or the noticed operating temperature. The temperature alarm
can be set 10K (20°F) higher than the operating temperature of the machine during maximal load at highest ambient
temperature.
If a two-function temperature monitoring system is used, the lower level is normally used as an alarm level and the
higher as a trip level.
NOTE: In case the machine trips, the reason must be found and eliminated before the machine
is restarted. In case of an alarm, find the reason and correct the situation. Use the trouble
shooting guide, see Chapter 8.1 Trouble shooting.
Following note for rotor type: Permanent magnet rotor
NOTE: Permanent magnet synchronous machines are equipped with Pt100 resistance elements
and/or thermistors. The use of these protective elements is mandatory to avoid the risk of
overloading the machine.
5.5.2 Stator winding temperature
5.5.2.1 General
The stator windings are manufactured according to temperature rise class F, which has a temperature limit of 155°C
(300°F). A high temperature will age the insulation and shorten the lifetime of the winding. Therefore, thorough
consideration should be made when deciding the temperature trip and alarm levels for the winding.
5.5.2.2 Resistance temperature detectors
Recommended maximum temperature settings:
For determining the temperature settings, see the Connection Diagram delivered with the machine. It is
recommended to apply the method described in Chapter 5.5.1 General when setting the temperature alarm.
5.5.2.3 Thermistors
If the machine is equipped with thermistors (PTC), the operating temperature of the thermistors is found on the
Connection Diagram. The operating function can be chosen to be an alarm or a trip signal. If the machine is equipped
with six thermistors, both alarm and trip signals can be used respectively.
5.5.3 Bearing temperature control
5.5.3.1 General
The bearings can be equipped with temperature detectors for monitoring the bearing temperatures. The viscosity
of the grease or oil used will become smaller as a function of higher temperature. When the viscosity falls below a
certain limit, the ability to form a lubricating film inside the bearing will cease, and the bearing will fail, and possibly,
shaft damage will occur as a result.
If the machine is equipped with resistance temperature detectors, the temperature of the bearings should preferably
be monitored continuously. If the temperature of a bearing unexpectedly starts to rise, the machine should be shut
down immediately, as the temperature rise might indicate a bearing failure.
5.5.3.2 Resistance temperature detectors
Recommended maximum temperature settings:
For determining the temperature settings, see the Connection Diagram delivered with the machine. It is
recommended to apply the method described in Chapter 5.5.1 General when setting the temperature alarm.
5.5.3.3 Thermistors
If the rolling bearings are equipped with thermistors (PTC), the operating temperature of the thermistors is found on
the Connection Diagram. The operating function can be chosen to be an alarm or a trip signal. If the rolling bearings
are equipped with two thermistors, both alarm and trip signals can be used respectively.
5.5.4 Protection equipment

The machine has to be protected against various disturbances, faults and overloading that might damage the
machine. The protection must be in accordance with the instructions and regulations for each country where the
machine is used.
The machine parameter values for relay settings are informed in the document “Performance data of machine” which
is included in the documentation provided with the machine.
NOTE: The machine manufacturer is not responsible for the adjusting the protection equipment
at the site.
5.6 First test start
5.6.1 General
The first test start is a standard procedure after the installation and alignment procedure is finished, the mechanical
and electrical connections are made, the commissioning procedure is gone through and the protective devices are
active.
NOTE: If possible, the first start is made with uncoupled coupling between the driving and driven
machine. The load on the machine must in any case be as small as possible.
5.6.2 Precautions before first test start

A visual inspection of the machine and its equipment is made before the first test start. It is verified that all
necessary tasks, checking and adjustments have been performed.
Before the test start, the following checks and measures must be made:
• If the coupling half is not assembled, the shaft extension key is either locked or removed.
Following bullet for bearing type: Sleeve bearing
• The sleeve bearing oil reservoirs and possible oil supply systems are filled with recommended oil to the correct
level. The oil supply system is turned on.
Following bullet for bearing type: Rolling bearing
• The rotor is turned by hand, and it is verified that no abnormal noises are heard from the bearings. To turn a
rotor with sleeve bearings, a simple lever arm is needed.
Following bullet for bearing type: Rolling bearing with oil mist
• The oil supply systems are filled with recommended oil to the correct level. The oil supply system is turned on.
Following bullet for cooling method: Air-to-water
• In case of water-cooled machines, the cooling water is turned on. The tightness of the flanges and the cooling
unit is checked.
• The cabling, cables and bus bar connections are verified to be according to the connection diagram.
• The earth connections and earthing devices are verified.
• The starting, control, protection, and alarm relays of each device are inspected.
• The insulation resistance of the windings and other equipment verified.
• The machine covers are assembled, and the shaft seals are tightly fitted in.
• The machine and the environment are cleaned.
Following bullet for protection type: Ex p
• Ex machine enclosure has been purged and it is pressurized. Refer to the purging and pressurizing system
instructions.
5.6.3 Starting
The first start should last only about one (1) second, during which the direction of rotation of the machine is verified.
The direction of rotation of possible external blower motors must also be verified. It is also verified that the rotating
parts do not touch any stationary parts.
NOTE: If the machine does not have an axially locating bearing, and the machine is started
uncoupled, it is normal that the shaft will move axially before stabilizing.
5.6.3.1 Direction of rotation

The objective of the first starting is to check the direction of rotation of the machine. The machine should turn in
the same direction as is shown with an arrow located on the frame or the fan cover. The direction of rotation of the
external blower motor is indicated by an arrow near the blower motor. The machine may only be operated in the
specified direction of rotation. The direction of rotation is indicated on the marking plate, see Appendix Typical
position of plates.
Machines suitable for reversing operation are labelled with a double-headed arrow on the rating plate, as well as on
the frame.
If the desired direction of rotation for some reason is different from the one specified on the machine, the cooling
fans, in inner and/or outer cooling circuit, must be changed, as well as the stamp on the rating plate.
To alter the direction of rotation, interchange the power supply phases.
Following chapter for rotor type: Slip rings

5.6.3.2 Starting of machines with slip rings

Machines with slip rings cannot be operated without a starter. The starter is typically a variable resistance connected
to each rotor phase via the slip rings. The selection of the starter is done according to required starting torque and
current. Starting is typically done with nominal current and nominal torque.
During starting the starter resistance is decreased and speed for breakdown torque is shifted towards higher speed.
The speed of the machine is always between actual breakdown torque speed and synchronous speed. Operation
between standstill and breakdown torque, or stalling during starting, is not allowed.
NOTE: Failure in starting the machine without checking the adjustments of the complete slip ring
gear can result in serious damage! The connections to the starter and its functions shall
also be verified.
NOTE: The brush-lifting device must be in starting position before starting the machine.
Following chapter for protection type: Ex p
5.6.3.3 Starting of Ex p machines

The Ex p machine enclosure is explosion protected during operation by pressurizing. Before pressurizing,
the machine enclosure shall be purged with clean air. Detailed commissioning instructions for the purge and
pressurization equipment are given in a separate manual. In case of eventual noticeable air leaks from the machine
enclosure, the leaking joints shall be properly sealed.
The purging and pressurizing system must be included in the starting interlocking system. Connect the alarm and
status switch signals of the unit to the main circuit breaker control system. This ensures that it is not possible to
start the machine before the purge is complete and the machine enclosure is pressurized.
5.7 Running the machine the first time

After a successful first test start, the coupling between the driving and driven machine should be coupled, and the
machine can be restarted.
5.7.1 Supervision during the first run

During running the machine the first time, it is verified that the machine functions as expected. The vibration level,
the temperature of the windings and bearings, and other equipment are monitored frequently. If the machine
functions as expected, the machine can be left running for a longer time.
Check the operating load of the machine by comparing the load current with the value given on the rating plate of the
machine.
Record the temperature readings given by the temperature detectors placed in the windings and possibly in the
bearings. Check the temperatures frequently to ensure that they remain below the limits. Continuous temperature
monitoring is recommended.
NOTE: If resistance temperature detector (RTD, Pt-100) or equivalent is not available, the surface
temperature of the bearing area shall, if possible, be measured. The bearing temperature is
approximately 10°C (20°F) higher than the surface temperature.
In case of any deviations from expected normal operation, e.g. elevated temperatures, noise or vibration, shut down
the machine, and find the reason for the deviations. If necessary, consult the manufacturer of the machine.
NOTE: Do not disengage any protective devices during running of the machine, or during search
for a reason for unexpected function of the machine.
5.7.2 Checks during running of the machine

During the first days of running, it is important to keep a close surveillance of the machine in case of any changes in
vibration or temperature levels or abnormal sounds should occur.
5.7.3 Bearings
The rotating electrical machines manufactured by ABB are equipped with either rolling or sleeve bearings.
5.7.3.1 Machines with rolling bearings

In case of a newly installed machine or a machine, which has been out of service for more than 2 months, inject new
grease into the bearings immediately after start-up. This ensures that bearings have fresh grease and re-greasing
interval is valid.
New grease must be injected when the machine is running, and is injected until old grease or excess new grease
is discharged through the lubrication channel in the bottom of the bearing housing, see Figure 30 Example of
lubrication channel through bearing arrangement of horizontal machine.
1. D-END
2. N-END.
Figure 30 Example of lubrication channel through bearing arrangement of horizontal machine
NOTE: Start-up greasing may take several grease portions (3-10 times amount mentioned at the
lubrication plate).
NOTE: The re-lubrication interval will never be longer than 12 months.
The type of original grease used is found on the bearing plate on the machine. Acceptable types of grease can be
found in Chapter 7.5.3 Rolling bearings.
NOTE: Do not mix greases! There must be only one type of grease inside the bearing - not mixture
of two or more greases.
The temperature of the bearings will initially increase because of the excess grease. After few hours, the excess
grease will be discharged through the lubrication valve and the temperature of the bearing will return to normal
running temperature.
If available, and after the machine has been running for several hours, measure the vibrations or SPM-values from the
SPM-nipples, and record the values for future reference use.

5.7.3.2 Machines with sleeve bearings

Verify that no rotating parts rub against any stationary parts. Verify through the oil sight glass that the oil level inside
bearing is correct. The correct oil level is in the middle of the oil sight glass, but as long as the oil level is within the oil
sight glass, the level is acceptable.
Check the temperature and the oil level of the bearings continuously in the beginning. This is particularly important
for self-lubricating bearings. If the temperature of the bearing suddenly rises, the machine should be stopped
immediately, and the reason for the temperature rise must be found before the machine is re-started. If no logical
reason is found from the measurement equipment, it is recommended that the bearing is opened, and its condition
verified. If the machine is under warranty, the manufacturing factory must always be contacted before any action is
taken.
For self-lubricating bearings, the rotation of the oil ring is verified through the inspection window on top of the
bearing. If the oil ring is not rotating, the machine must be stopped immediately, as a stopped oil ring will result in
bearing failure.
For flood-lubricated machines, the oil supply pressure is adjusted with the pressure valve and orifice. The normal
supply pressure is 125 kPa ± 25 kPa (18 psi ± 4 psi). This gives the right flow of oil to the bearing. Using higher supply
pressure gives no additional benefit, but can cause bearing oil leakages. The rate of oil flow is also specified on the
dimensional drawing.
NOTE: The lubrication system should be constructed so that the pressure inside the bearing is
equal to the atmospheric (outside) pressure. Air pressure entering the bearing from either
inlet or outlet oil pipes will cause bearing oil leakages.
5.7.4 Vibrations
For a comprehensive discussion on vibrations, see Chapter 7.4.2 Vibration and noise.
5.7.5 Temperature levels

The temperatures of the bearings, stator windings and cooling air should be checked when the machine is running.
The winding and bearing temperature may not reach a stable temperature until after several (4-8) hours, when
running at full load.
The stator winding temperature depends on the load of the machine. If full load cannot be obtained during or soon
after commissioning, the present load and temperature should be noted and included in the commissioning report.
For recommended settings for alarm and trip levels, see the main connection diagram.
Following chapter for cooling type: Air-to-air and air-to-water
5.7.6 Heat exchangers

Prior to start, check that the connections are tight and there is no leakage in the system. After running the machine
for some time, the cooling system should be checked. Verify that the cooling fluid, where applicable, and air is
circulating without any obstruction.
5.7.7 Slip rings

Check that the brushes on the slip rings are not sparking.
5.8 Shut down

The shutdown of the machine depends on the application, but main guidelines are:
• Reduce the load of the driven equipment, if applicable
• Open the main breaker
• Switch possible anti condensation heaters on, if not automatically done by switch gear.
Following bullet for cooling type: Air-to-water, and water jacket
• On water cooled machines, switch off the cooling water flow to avoid condensation inside the machine.
OPERATION 63
—
Chapter 6 Operation
Operation
6.1 General
To ensure trouble-free running a machine must be looked after and carefully supervised.
Always before starting up the machine ensure that:
• The bearings are greased or filled with oil to a correct level in accordance with the manufacturer’s technical
specifications and the dimensional drawing
• The cooling system is functioning
• The machine enclosure has been purged and is pressurized if applicable
• No maintenance is ongoing
• The personnel and equipment associated with the machine are ready to start up the machine.
For start-up procedure, see Chapter 5.6.3 Starting.
In case any deviations from expected normal operation are noticed, e.g. elevated temperatures, noise or vibration,
shut down the machine, and find the reason for the deviations. If necessary, consult the manufacturer of the
machine.
NOTE: The machine may have hot surfaces when running with load.
NOTE: Overloading the machine may cause demagnetization of the permanent magnets as well as
winding damages.
6.2 Normal operating conditions

The machines manufactured by ABB are individually designed to operate in normal operation conditions according to
the IEC or NEMA standards, customer specifications and internal ABB standards.
The operation conditions, such as maximum ambient temperature and maximum operating height, are specified
in the performance data sheet delivered as a part of the project documentation. The foundation shall be free from
external vibration, and the surrounding air shall be free of dust, salt and corrosive gases or substances.
NOTE: The safety precautions shown in Safety Instructions must be observed at all times.
6.3 Number of starts

The number of allowed consecutive starts of direct on line supplied machines depends essentially on the load
characteristics (torque curve vs. rotational speed, inertia), and on the machine type and design. Too many and/or too
heavy starts cause abnormally high temperatures and stresses on the machine, thus accelerating the ageing of the
machine and resulting in an abnormally short lifetime, or even a machine failure.
For information on the allowed consecutive or annual starts, please see the performance data sheet or consult the
manufacturer. The load characteristics of the application are needed for determining the starting frequency. As a
guideline, the maximum number of starts in a typical application is 1000 starts per year.
A counter system for controlling the number of starts should be used and maintenance intervals should be
determined based on equivalent operating hours, see Chapter 7.3 Maintenance program.
NOTE: The safety precautions shown in the Safety Instructions must be observed at all times.
6.4 Supervision
The operating personnel should inspect the machine at regular intervals. This means that they should listen, feel and
smell the machine and its associated equipment in order to obtain a feeling for normal operating condition.
The object of the supervision inspection is to familiarize the personnel with the equipment. This is essential in order
to detect and fix abnormal occurrences in time.
The difference between supervision and maintenance is rather diffuse. Normal supervision of operation includes
logging of operating data such as load, temperatures and vibrations. This data is useful basis for maintenance and
service.
• During the first period of operation (- 200 hours) supervision should be intensive. Temperatures of bearings
and windings, load, current, cooling, lubrication and vibration shall be checked frequently.
• During the following duty period (200 - 1000 hours), a check-up once a day is sufficient. A record of supervision
inspections should be filed and saved for further reference. The time between inspections may be extended if
the operation is continuous and stable.
For relevant check-lists, see Appendix Commissioning report.
6.4.1 Bearings
The bearing temperatures and lubrication should be monitored closely, see Chapter 5.7.3 Bearings.
6.4.2 Vibrations
The vibration levels of the driving-driven machine system should be monitored, see Chapter 7.4.3 Bearing housing
vibrations.
6.4.3 Temperatures
The temperatures of the bearings, stator windings and cooling air should be checked when the machine is running,
see Chapter 5.7.5 Temperature levels.
Following chapter for cooling type: Air-to-air, and air-to-water
6.4.4 Heat exchanger

Check that the connections are tight and there is no leakage in the system. Verify that the cooling fluid, where
applicable, and air is circulating without any obstruction.
6.4.5 Slip ring unit

Follow the wear of the carbon brushes and change them before the wear limit is reached. Verify that the brushes are
not sparking.
Ensure that the slip ring surfaces are smooth. If not, the slip rings must be smoothed on a lathe. Under ideal
conditions, an even layer of brown patina will form on the slip rings during the first few hours of operation.
Check the tightness of the slip ring housing. Water, grease, oil, or dust should not be permitted to enter the housing.
6.5 Follow-up
The follow-up of operation includes logging of operating data such as load, temperatures and vibrations. This data is
useful basis for maintenance and service.
OPERATION 65
6.6 Shut down

When the machine is not in operation, anti-condensation heaters have to be switched on where applicable. This is to
avoid condensation effect inside the machine.
Following paragraph for cooling method: Air-to-water, and water jacket
For machines with water-cooling, the cooling water supply must be switched off in order to avoid condensation
inside the machine.
NOTE: Voltage may be connected to the terminal box for heating element.
—
Chapter 7 Maintenance
Maintenance
7.1 Preventive maintenance

A rotating electrical machine often forms an important part of a larger installation and if it is supervised and
maintained properly, it will be reliable in operation and guarantee a normal lifetime.
The purpose of maintenance is therefore to:
• Secure that the machine will function reliably without any unforeseen actions or interventions
• Estimate and plan service actions in order to minimize down time.
The difference between supervision and maintenance is rather diffuse. Normal supervision of operation and
maintenance includes logging of operating data such as load, temperatures, vibrations, as well as verification of the
lubrication, and measurement of the insulation resistances.
After commissioning or maintenance, the supervision should be intensive. Temperature of bearings and windings,
load, current, cooling, lubrication and vibration shall be checked frequently.
This chapter presents recommendations regarding maintenance program, and work instructions how to conduct
common maintenance tasks. These instructions and recommendations should be read carefully and be used as a
basis when planning the maintenance program. Note that the maintenance recommendations presented in this
chapter represent a minimum level of maintenance. By intensifying maintenance and supervision activities, the
reliability of the machine and the long-term availability will increase.
The data obtained during supervision and maintenance is useful for estimating and planning additional service. In
case some of this data indicates something out of the ordinary, the trouble shooting guides in Chapter 8. Trouble
shooting, will aid in locating the reason for the trouble.
ABB recommends the use of experts in the creating maintenance programs, as well as in performing the actual
maintenance and possible trouble shooting. The ABB Motors and Generators Service organization is happy to assist
in these issues. The ABB After Sales contact information can be found in Chapter 9.1.3 Contact information for
Motors and Generators Service.
An essential part of the preventative maintenance is to have a selection of suitable spare parts available. The best
way to have access to critical spare parts is to keep them on stock. Ready-made spare part packages can be obtained
from the ABB After Sales, see Chapter 9.1.3 Contact information for Motors and Generators Service.
7.2 Safety precautions

Before working on any electrical equipment, general electrical safety precautions are to be taken into account,
and local regulations are to be respected in order to prevent personnel injury. This should be made according to
instructions of the security personnel.
Personnel performing maintenance on electrical equipment and installations must be highly qualified. The personnel
must be trained in, and familiar with, the specific maintenance procedures and tests required for rotating electrical
machines.
Following three paragraphs for protection type: All machines for hazardous areas
Machines for hazardous areas are specially designed to comply with official regulations concerning the risk of
explosion. If improperly used, badly connected, or altered, no matter how minor, their reliability could be in doubt.
Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration, especially national standards for installation (see standards: IEC 60079-14, IEC 6000-17 and
IEC 6007-19). Only trained personnel familiar with these standards should handle this type of apparatus.
Disconnect and lock out before working on the machine or the driven equipment. Ensure that no explosive
atmosphere is present while the work is in progress.
For general safety instructions, see Safety Instructions.

MAINTENANCE 67
NOTE: The permanent magnet synchronous machine produces

voltage when the shaft is rotating. Prevent rotation of the
shaft before opening the terminal box. Do not open or touch
the unprotected terminals while the shaft of the machine is
rotating. Follow the Safety Instructions.
1. Magnetic field emission

Category 2
EN 12198.
Following note for application type: Variable speed drive
NOTE: The terminals of a machine with frequency converter supply may be energized even when
the machine is at standstill.
7.3 Maintenance program

This chapter presents a recommended maintenance program for ABB machines. This maintenance program is of a
general nature, and should be considered as a minimum level of maintenance. Maintenance should be intensified
when local conditions are demanding or very high reliability is required. It should also be noted that even when
following this maintenance program, normal supervision and observation of the machine's condition is required.
Please note that even though the maintenance programs below have been customized to match the machine, it
might contain references to accessories not available on all machines.
The maintenance program is based on four levels of maintenance, which rotate according to operating hours.
The amount of work and down time vary, so that level 1 includes mainly quick visual inspections and level 4 more
demanding measurements and replacements. More information about the spare part packages suitable for
these maintenances can be found in Chapter 9.2 Spare parts for rotating electrical machines. The recommended
maintenance interval can be seen in Table 5 Maintenance intervals. The operation hour recommendation in this
chapter is given as equivalent operating hours (Eq. h), that can be counted by the following formula:
Following paragraph for application type: Variable speed drive
Equivalent operating hours (Eq. h) = Actual operating hours.
Following paragraph for application type: Constant speed drive
Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts x 20.
Level 1 (L1)
Level 1 or L1 maintenance consists of visual inspections and light maintenance. The purpose of this maintenance
is to do a quick check whether problems are beginning to develop before they cause failures and unscheduled
maintenance breaks. It gives also suggestions what maintenance issues must be performed in the next larger
overhaul.
The maintenance can be estimated to last approximately 4 - 8 hours, depending on the type and installation of the
machine and the depth of the inspections. Tools for this maintenance include normal servicing tools i.e. wrenches
and screw drives. The preparations consist of opening the inspection covers. It is recommended that at least the
Operational spare part package is available when commencing this maintenance. The packages are shown in Chapter
9.2.5 Typical recommended spare parts in different sets.
The first Level 1 maintenance should be performed after 4 000 equivalent operating hours or six months
after commissioning. Subsequently the L1 maintenance should be performed yearly halfway between Level 2
maintenances, see Table 5 Maintenance intervals.
Level 2 (L2)
Level 2 or L2 maintenance consists mainly of inspections and tests and small maintenance tasks. The purpose of this
maintenance is to find out whether there are problems in the operation of the machine and to do small repairs to
ensure uninterrupted operation.
The maintenance can be estimated to last approximately 8 - 16 hours, depending on the type and installation of the
machine and the amount of servicing to be done. Tools for this maintenance include normal servicing tools, multi
meter, torque wrench and insulation resistance tester. The preparations consist of opening the inspection covers
and bearings if necessary. Spare parts suitable for this level of maintenance are included in the Operational spare
part package. The packages are shown in Chapter 9.2.5 Typical recommended spare parts in different sets.
The first Level 2 maintenance should be performed after 8 000 equivalent operating hours or one year after
commissioning. Subsequently the L2 maintenance should be performed yearly or after every 8 000 equivalent
operating hours, see Table 5 Maintenance intervals.
Level 3 (L3)
Level 3 or L3 maintenance consists of performing extensive inspections, tests and larger maintenance tasks that
have come up during L1 and L2 maintenances. The purpose of this maintenance is to repair encountered problems
and replace parts subjected to wear.
The maintenance can be estimated to last approximately 16 - 40 hours, depending on the type and installation of
the machine and the amount of repairs and replacements to be done. Tools for this maintenance include the same
tools as for L2 and in addition an endoscope and an oscilloscope. The preparations consist of opening the inspection
covers, the bearings and the water cooler, if applicable. Spare parts suitable for this level of maintenance are
included in the Recommended spare parts package. The packages are shown in Chapter 9.2.5 Typical recommended
spare parts in different sets.
The Level 3 maintenance should be performed after every 24 000 equivalent operating hours or at a three to five year
interval. When L3 maintenance is conducted it replaces the L1 or L2 maintenance otherwise scheduled, and it leaves
their rotation unaffected, see Table 5 Maintenance intervals.
Level 4 (L4)
Level 4 or L4 maintenance consists of performing extensive inspections and maintenance tasks. The purpose of this
maintenance is to restore the machine into a reliable operating condition.
The maintenance can be estimated to last approximately 40 - 80 hours, depending mostly on the condition of the
machine and the needed reconditioning actions. Tools for this maintenance include the same tools as for L3, and
in addition, the rotor removal equipment. The preparations consist of opening the inspection covers, bearings and
water cooler, if applicable, and the removal of rotor.
The amount of spare parts required for this level of maintenance needs to be determined before the maintenance. At
least the Recommended spare part is needed. Spare parts included in the capital spare part package would ensure a
fast and successful execution of this maintenance.
The Level 4 maintenance should be performed after every 80 000 equivalent operating hour. When a L4 maintenance
is conducted it replaces the L1, L2 or L3 maintenance otherwise scheduled, and it leaves their rotation unaffected, see
Table 5 Maintenance intervals.
7.3.1 Recommended maintenance program

Abbreviation used in maintenance program:
• V = Visual checking
• C = Cleaning
• D = Disassembling and assembling
• R = Reconditioning or replacement
• T = Testing and measurement.
Not all options are applicable for all machines.
MAINTENANCE 69
Table 5 Maintenance intervals
MAINTENANCE INTERVAL
In equivalent operating hours or time period, whichever comes first
L1 L2 L3 L4
4,000 8,000 24,000 80,000
12,000 16,000
20,000
28,000
Biannual Annual 3-5 years Overhaul
7.3.1.1 General construction

Maintenance object L1 L2 L3 L4 Check / Test
Machine operation V/T V/T V/T V/T Starting, shut down, vibration measurement,
no-load point
Mounting and V V/T V/T V/T/ Cracks, rust, alignment
foundation D
Exterior V V V V Rust, leakage, condition
Fastenings V V/T V/T V/T Tightness of all fastenings
Anchor bolts V V V/T V/T Fastening, condition
7.3.1.2 Main supply connection

High voltage cabling V V/T V/T V/T/ Wear, fastening
D
High voltage V V/T V/T V/T/ Oxidation, fastening
connections D
Terminal box V V V V General condition
accessories, i.e.
surge capacitors,
arrestors and
current transformers
Cable transits V V V V Condition of cables entering the machine and
inside the machine
7.3.1.3 Stator and rotor

Stator core V V V V/C Fixing, cracks, welds
Stator winding V V/T V/T/ V/T/ Wear, cleanliness, insulation resistance, turn
insulation C C insulation test, (high voltage test)
Stator coil over V V V V Insulation damages
hangs
Stator coil supports V V V V Insulation damages
Stator slot wedges V V V V Movement, tightness
Stator terminal bars V V V V Fixing, insulation
Instrumentation V V V V Condition of cables and cable ties

Rotor winding V V/T V/T/ V/T/ Wear, cleanliness, insulation resistance
insulation C C
Rotor balancing V V V V Movement
weights
Shaft center V V V V Crack, corrosion
Connections in rotor V V V/T V/T Fixing, general condition
Earthing brushes V V V V Operation and general condition
NOTE: It is not recommended that totally enclosed machines are dismantled and inspected
internally more often than every 3-5 years (L3).
7.3.1.4 Auxiliaries
Pt-100 elements V V/T V/T V/T Resistance
(stator, cooling air,
bearing)
Anticondensation V V/T V/T V/T Operation, insulation resistance
heaters
Encoders V V V/T V/T Operation, general condition, alignment
Auxiliary terminal V V/T V/T V/T General condition, terminals, wiring condition
boxes
Following table for rotor type: Slip rings
7.3.1.5 Slip ring unit

Assembly V V/C V/C V/C Mounting, insulation
Brush holders v V/T V/T V/T Alignment
Brushes V V/T V/T V/T Arching, clearance
Slip ring cabling V V V V Wear, arching
Slip rings V/T V/T V/T V/T Wear, roundness, patina
Brush gear V V/T V/T V/T Insulation resistance
Pt-100 elements V V/T V/T V/T Resistance
Anticondensation V V/T V/T V/T Operation, insulation resistance
heaters
Encoders V V V/t V/T Operation, general condition, alignment
Auxiliary terminal V V/T V/T V/T General condition, terminals, wiring condition
boxes
7.3.1.6 Lubrication system and bearings

Following table for bearing type: Rolling bearing

Bearing during T T T/R T/R General condition, extra noise, vibration
operation
Waste grease V V/C V/C V/C Condition, purging, empty grease waste box
MAINTENANCE 71

Re-greasing V V/R V/R V/R According to bearing plate
Seals V V/D V/D V/D Leakage
Bearing insulation V/C V/C V/C/ V/C/ Endshield cleanliness, insulation resistance
T T
Following table for bearing type: Sleeve bearing

Bearing assembly V V/T V/T V/T Fixing, general condition
Bearing shells V/T/ V/T/ General condition, wear
D D
Seals and gaskets V V V/T/ V/T/ Leakage
D D
Bearing insulation V V/T V/T/ V/T/ Condition, insulation resistance
D D
Lubrication piping V V V/TD V/T/ Leakage, operation
D
Lubrication oil V/R V/R V/R V/R Quantity, quality, flow
Oil ring V V V V Operation
Oil flow regulator V V/T V/T V/T/ Operation
D
Oil tank V V/C V/C V/C Cleanliness, leakage
Jack-up system V V/T V/T V/T Operation
Oils cooler / heater T T T T Oil temperature
7.3.1.7 Cooling system

Following table for cooling type: Open air

Fan(s) V V V V Operation, condition
Filters V/C V/C V/C/ V/C/ Cleanliness, operation
R R
Air ways V V/C V/C V/C Cleanliness, operation
Noise damping V V V V Condition
material
Following table for cooling type: Air-to-air

Fan(s) V V V V Operation, condition
Tubes V V/C V/C V/C Cleanliness, operation
Ducts V V/C V/C V/C Cleanliness, operation
Plate fins V V/C V/C V/C General condition
Vibration dampers V V V V Condition and profile
Noise damping V V V V Condition
material
Following table for cooling type: Air-to-water

Heat exchanger V V V V Leakage, operation, pressure test
Fan V V V V Operation, condition
Tubes V V/C V/C V/C Cleanliness, corrosion
Ducts V V/C V/C V/C Cleanliness, operation
End cases V V/C V/C V/C Leakage, condition
Seals and gaskets V V/C V/C V/C Leakage, condition
Plate fins V V/C V/C V/C General condition
Vibration dampers V V V V Condition and profile
Protective anodes V/C V/C Condition, activity
Water flow regulator V / T V/T V/T V/T Operation
7.4 Maintenance of general constructions

To ensure a long life span for the general construction of the machine, the machine exterior should be kept clean and
should periodically be inspected for rust, leaks and other defects. Dirt on the machine exterior exposes the frame to
corrosion and can affect the cooling of the machine.
7.4.1 The tightness of fastenings

The tightness of all fastenings should be verified regularly. Special focus should be given to the grouting, the anchor
bolts and the rotor parts, which must remain correctly tightened at all times. Loose fastening in these parts can lead
to sudden and severe damage to the entire machine.
General values for tightening torques are presented in Table 6 General tightening torques.
Table 6 General tightening torques
Tightening torque in Nm (pound-feet) Property class 8.8 for bolts

Size Oiled [Nm] Oiled [pound Dry [Nm] Dry [pound feet]
feet]
M4 2.7 2.0 3.0 2.2
M5 5.0 3.7 5.5 4.1
M6 9 6.6 9.5 7.0
M8 22 12 24 18
M 10 44 32 46 34
M 12 75 55 80 59
M 14 120 88 130 96
M 16 180 130 200 150
M 20 360 270 390 290
M 24 610 450 660 490
M 27 900 660 980 720
M 30 1200 890 1300 960
M 36 2100 1500 2300 1700
M 39 2800 2100 3000 2200
M 42 3400 2500 3600 2700
M 48 5200 3800 5600 4100
MAINTENANCE 73
NOTE: The values in Table 6 General tightening torques are general, and do not apply to various
items, such as diodes, support insulators, bearings, cable terminals or pole fastenings,
bus bar terminals, surge arrestors, capacitors, current transformers, rectifier and thyristor
bridges, or if some other value is given elsewhere in this manual.
7.4.2 Vibration and noise

High or increasing vibration levels indicate changes in the machine's condition. Normal levels vary greatly depending
on the application, type and foundation of the machine. Some typical reasons that might cause high vibration or
noise levels are:
• Alignment, see Chapter 3. Installation and alignment
• Air gap, see Chapter 3. Installation and alignment
• Bearing wear or damage
• Vibration from connected machinery
• Loose fastenings or anchor bolts, see Chapter 3. Installation and alignment
• Rotor unbalance
• Coupling.
7.4.3 Bearing housing vibrations

The following instructions are based on ISO 10816-3:1998 Mechanical vibration - Evaluation of machine vibration
by measurements on non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal
speeds between 120 r/min and 15000 r/min when measured in situ.
7.4.3.1 Measurement procedures and operational conditions
Measurement equipment
The measurement equipment shall be capable of measuring broad-band r.m.s. vibration with flat response over a
frequency range of at least 10 Hz to 1 000 Hz, in accordance with the requirements of ISO 2954. Depending on the
vibration criteria, this may require measurements of displacement or velocity or combinations of these (see ISO
10816-1). However, for machines with speeds approaching or below 600 r/min, the lower limit of the flat response
frequency range shall not be greater than 2 Hz.
Measurement locations
Measurements will usually be taken on exposed parts of the machine that are normally accessible. Care shall be taken
to ensure that measurements reasonably represent the vibration of the bearing housing and do not include any local
resonances or amplification. The locations and directions of vibration measurements shall be such that they provide
adequate sensitivity to the machine dynamic forces. Typically, this will require two orthogonal radial measurement
locations on each bearing cap or housing, as shown in Figure 31 Measuring points. The transducers may be placed at
any angular position on the bearing housings. Vertical and horizontal directions are usually preferred for horizontally
mounted machines. For vertical or inclined machines, the location that gives the maximum vibration reading shall
be one of those used. In some cases it may be recommended to measure also in the axial direction. The specific
locations and directions shall be recorded with the measurement.
Figure 31 Measuring points
7.4.3.2 Classification according to support flexibility

Two conditions are used to classify the support assembly flexibility in specified directions:
• rigid supports
• flexible supports.
These support conditions are determined by the relationship between the machine and foundation flexibilities. If the
lowest natural frequency of the combined machine and support system in the direction of measurement is higher
than its main excitation frequency (this is in most cases the rotational frequency) by at least 25 %, then the support
system may be considered rigid in that direction. All other support systems may be considered flexible.
If the class of a machine-support system cannot be readily determined from drawings and calculation, it may be
determined by testing. Large- and medium-sized electrical machines with low-speed would normally have rigid
supports.
7.4.3.3 Evaluation
ISO 10816-1 provides a general description of the two evaluation criteria used to assess vibration severity on various
classes of machines. One criterion considers the magnitude of observed broad-band vibration; the second considers
changes in magnitude, irrespective of whether they are increases or decreases.
Evaluation zones
The following evaluation zones are defined to permit a qualitative assessment of the vibration of a given machine
and provide guidelines on possible actions.
Zone A: The vibration of newly commissioned machines would normally fall within this zone.
Zone B: Machines with vibration within this zone are normally considered acceptable for unrestricted long-term
operation.
Zone C: Machines with vibration within this zone are normally considered unsatisfactory for long-term continuous
operation. Generally, the machine may be operated for a limited period in this condition until a suitable opportunity
arises for remedial action.
Zone D: Vibration values within this zone are normally considered severe enough to cause damage to the machine.
MAINTENANCE 75
Table 7 Classification of vibration severity zones for large machines with rated power above 300 kW and not more
than 50 MW; electrical machines with shaft height H/315 mm or higher
Support class Zone boundary R.m.s. velocity [mm/

s]
Rigid A/B 2.3
B/C 4.5
C/D 7.1
Flexible A/B 3.5

B/C 7.1
C/D 11.0
Operational limits
For long-term operation, it is a common practice to establish operational vibration limits. These limits take the form
of ALARMS and TRIPS.
Table 8 Initial ALARM and TRIP vibration velocity values for bearing housing vibration in mm/s r.m.s. shows the
initial ALARM and TRIP values for machines based on experience with similar machines. After a period of time the
steady-state baseline value on-site will be established and the ALARM setting should be adjusted accordingly (see
ISO 100816-3).
Table 8 Initial ALARM and TRIP vibration velocity values for bearing housing vibration in mm/s r.m.s.
Support class Initial ALARM TRIP

[mm/s] [mm/s]
Rigid 3.4 7.1
Flexible 5.3 11.0
NOTE: These values are standard values that can be adjusted when additional information on the
machine type and application is available.
7.4.4 Shaft vibrations

For more instructions for relative shaft vibrations can be found in standards ISO 7919-1:1996 Mechanical vibration of
non-reciprocating machines - Measurements on rotating shafts and evaluation criteria: Part 1: General guidelines and
Part 3: Coupled industrial machine. Initial ALARM and TRIP values for shaft vibrations vary between machine types
and should be asked from the factory.
7.5 Maintenance of bearings and lubrication system

This chapter covers the most important maintenance tasks in the bearings and in the lubrication system.
Following chapters for bearing type: Sleeve bearing

In normal operating conditions, sleeve bearings require little maintenance. To ensure reliable operation, the oil level
and the amount of oil leakage should be regularly checked.
7.5.1.1 Oil level

The oil level of a self-lubricated sleeve bearing needs to be checked regularly. The correct oil level is in the middle of
the oil sight glass, but as long as the oil level is within the oil sight glass, the level is acceptable.
If necessary, refill with suitable lubricant, see Chapter 7.5.2.4 Oil qualities.
The correct oil level of a flood-lubricated sleeve bearing is the same as for a self-lubricated bearing. In flood-
lubricated bearings, the oil sight glass might be exchanged for an oil outlet flange.
7.5.1.2 Bearing temperature

The bearing temperatures are measured by Pt-100 resistance temperature detectors. Since a temperature rise
above the alarm limit can be caused either by increased losses in the bearing, or by decreased cooling capacity, it
often indicates a problem somewhere in the machine or in the lubrication system, and should therefore be closely
monitored.
The reasons for abnormal bearing temperature vary, but for some possible reason see Chapter 7.5.2 Lubrication of
sleeve bearings or Chapter 8.1.2 Lubrication system and bearings. If the temperature rise is followed by an increase
in vibration levels, the problem might also be related to the machine's alignment, see Chapter 3. Installation and
alignment or to damage in the bearing shells in which case the bearing needs to be dismantled and checked.
7.5.2 Lubrication of sleeve bearings

The machines are equipped with sleeve bearings with a very long service life provided that the lubrication functions
continuously and that the oil type and quality are as per ABB recommendations, and that the oil change instructions
are followed.
7.5.2.1 Lubrication oil temperature

The correct lubrication oil temperature is essential in keeping the bearing at the correct operating temperature,
and in ensuring sufficient lubrication effect and the correct viscosity of the lubrication oil. For machines equipped
with oil supply, the poor operation of oil cooler or heater and incorrect oil flow can cause oil temperature problems.
For all bearings, the correct oil quality and quantity need to be checked if temperature problems appear. For more
information, see Chapter 7.5.2.3 Recommended control values for the lubricating oil and Chapter 7.5.2.4 Oil qualities.
NOTE: The minimum ambient temperature in starting (without oil heater) is 0°C (32° F).
7.5.2.2 Control of the lubricant

During the first year of operation, it is advisable to take samples of the lubricating oil after about 1000, 2000 and
4000 operating hours. The sample should be sent to the oil supplier for analysis. Based on the results it is possible to
determine a suitable oil change interval.
After the first oil change, the oil may be analyzed at about the middle and the end of the oil change interval.
7.5.2.3 Recommended control values for the lubricating oil

The lubricating oil should be verified regarding the following aspects:
• Check the oil visually with respect to color, turbidity and deposits in a test bottle. The oil should be clear or
negligibly turbid. The turbidity may not be caused by water.
• The water content must not exceed 0.2%.
• The original viscosity must be maintained within a tolerance of ±15%.
• The oil should be free from debris, and its cleanliness according to ISO 4406 class 18/15, or NAS 1638 class 9.
• The quantity of metal impurities should be less than 100 PPM. An increasing trend of the value means that the
bearing is wearing.
• The total acid number (TAN) should not exceed 1 mg KOH per gram of oil. Please note that the TAN value is not
the same as the TBN (total base number) value.
• Smell the oil. Strong acid or burnt smell is not acceptable.
An oil check should be performed a few days after the first test run of the machine, just before the first oil change,
and subsequently as required. If the oil is changed just after the commissioning, it can be used again after removing
wear particles by filtering or centrifuging.
MAINTENANCE 77
In doubtful cases, an oil sample may be sent to the laboratory to determine viscosity, acid number, foaming
tendency, etc.
7.5.2.4 Oil qualities

The bearings are designed for one of the oil qualities listed below.
The oils listed below include the following additives:
• Oxidation and rust inhibitor
• Anti-foaming agent
• Anti-wear additive.
NOTE: Verify the correct oil quality from the bearing plate and the dimension drawing.
Oil type ISO VG 22 ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100

Viscosity 22 cSt Viscosity 32 cSt Viscosity 46 cSt Viscosity 68 cSt Viscosity 100
at 40 °C at 40 °C at 40 °C at 40 °C cSt at 40 °C
Mineral oils
Castrol Hyspin AWS 22 Hyspin AWS 32 Hyspin AWS 46 Hyspin AWS 68 Hyspin AWS 100
Chevron Randon HDZ 22 Randon HDZ 32 Randon HDZ 46 Randon HDZ 68 Randon HDZ 100
Klüber - LAMORA HLP 32 LAMORA HLP 46 LAMORA HLP 68 CRUCOLAN 100
Mobil - Terrestic T 32 Terrestic T 46 Terrestic T 68 Terrestic T 100
Shell Tellus S3 M 22 Tellus S3 M 32 Tellus S3 M 46 Tellus S3 M 68 Tellus S3 M 100
Total Azolla ZS 22 Azolla ZS 32 Azolla ZS 46 Azolla ZS 68 Azolla ZS 100
Synthetic oils
Castrol - Optileb HY 32 Optileb HY 46 Optileb HY 68 -
Chevron Clarity Synthetic Clarity Synthetic Clarity Synthetic -
Hydraulic Oil AW Hydraulic Oil AW Hydraulic Oil AW
32 46 68
Klüber - Summit SH 32 Summit SH 46 Summit SH 68 Summit SH 100
Lubcon Turmosynthoil Turmosynthoil Turmosynthoil Turmosynthoil Turmosynthoil
GV 22 GV 32 GV 46 GV 68 GV 100
Mobil SHC 624 SHC 625 SHC 626 SHC 627
Shell - Morlina S2 B 32 Morlina S2 B 46 Morlina S2 B 68 Morlina S2 B 100
Total NEVASTANE SH NEVASTANE SH NEVASTANE SH NEVASTANE SH
32 46 68 100
7.5.2.5 Oil change schedule for mineral oils

For self-lubricated bearings cleaning intervals with oil changes of approximately 8000 operating hours are
recommended and approx. 20000 operating hours for bearings with oil circulation systems.
Shorter oil change intervals may be necessary in case of frequent start-ups, high oil temperatures or excessively high
contamination due to external influences.
The correct oil change interval can be found on the bearing plate and dimensional drawing, see Chapter 2.1.2 Bearing
plate.
7.5.3 Rolling bearings

7.5.3.1 Bearing construction

In normal operating conditions, rolling bearings require little maintenance. To ensure reliable operation, the bearings
should be regularly re-greased with high-quality rolling bearing grease.
7.5.3.2 Bearing plate

All machines are supplied with bearing plates attached to the machine frame. The bearing plates provide bearing
information, such as:
• Bearing type
• Lubricant used
• Re-greasing interval, and
• Re-greasing amount.
For more details regarding the bearing plate, see Chapter 2.1.2 Bearing plate.
NOTE: It is essential that the information provided on the bearing plate is taken into account
when using and maintaining the machine.
7.5.3.3 Re-greasing intervals

Rolling bearings of electrical machines need to be re-greased at regular intervals. The re-greasing interval is found on
the bearing plate.
NOTE: Regardless of the re-greasing interval, the bearings need to be re-greased at least once per
year.
The re-greasing intervals are calculated for an operating temperature of 70°C (160°F). If the operating temperature is
lower or higher than the assumed, the re-grease interval has to be altered accordingly. Higher operating temperature
decreases the re-greasing interval.
NOTE: An increase in the ambient temperature raises the temperature of the bearings
correspondingly. The values for the re-greasing interval should be halved for every 15°C
(30°F) increase in bearing temperature and may be once doubled for a 15°C (30°F) decrease
in bearing temperature.
Re-greasing intervals for frequency converter drives
Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy load will require shorter
lubrication intervals or a special lubricant. Consult ABB Motors and Generators Service in such cases.
NOTE: The constructional maximum speed of the machine must not be exceeded. The suitability
of the bearings for high-speed operation must be checked.
7.5.3.4 Re-greasing
All rolling bearings of rotating electrical machines need to be re-greased, see Chapter 7.5.3.3 Re-greasing intervals.
The re-greasing can be performed either manually or by means of an automatic system. In either case, it has to be
verified that a suitable amount of the correct grease is entering the bearing at suitable intervals.
NOTE: Grease can cause skin irritation and eye inflammation. Follow all safety precautions
specified by the grease manufacturer.
Manual re-greasing of the bearings
Machines suited for manual re-greasing are equipped with grease nipples. In order to prevent debris from entering
the bearings, the grease nipples, as well as the surrounding area has to be cleaned thoroughly before re-greasing.
MAINTENANCE 79
Manual re-greasing while the machine is running
Re-greasing while the machine is running:
• Verify that the grease to be used is suitable.

• Clean the grease nipples and the area around them.
• Verify that the lubrication channel is open, if equipped with a handle, open it.
• Press the specified amount and type of grease into the bearing.
• Let the machine run 1-2 hours in order to ensure that all excess grease is forced out of the bearing. The bearing
temperature may temporarily increase during this time.
• If equipped with a handle, close it.
NOTE: Beware of all rotating parts during the re-greasing.
Manual re-greasing while the machine is at a standstill
Preferably, re-grease the machine while it is running. If this is not possible, or considered dangerous, the re-greasing
has to be carried out while the machine is at a standstill. In this case:
• Verify that the grease to be used is suitable.

• Stop the machine.
• Clean the grease nipples and the area around them.
• Verify that the lubrication channel is open, if equipped with a handle, open it.
• Press only half the amount of the specified type of grease into the bearing.
• Run the machine for a few minutes at full speed.
• Stop the machine.
• After the machine has stopped, press the specified amount of the correct grease into the bearing.
• Let the machine run 1-2 hours in order to ensure that all excess grease is forced out of the bearing. The bearing
temperature may temporarily increase during this time.
• If equipped with a handle, close it.
Automatic re-greasing
A variety of automatic re-lubrication systems is available on the market. However, ABB recommends only the use of
electromechanical re-lubrication systems. The quality of the grease entering the bearing has to be checked at least
once per year: the grease has to look and feel like new grease. Any separation of the base oil from the soap is not
acceptable.
NOTE: If an automatic re-greasing system is used, double the amount of grease indicated on the
bearing plate.
7.5.3.5 Bearing grease

It is essential to use grease of good quality and with the correct base soap. This will ensure a long and trouble free
lifetime of the bearings.
Grease used for re-greasing should have the following properties:
• Be special rolling bearing grease.
• Be of good quality with a lithium complex soap, and with mineral-, or PAO-oil.
• Have a base oil viscosity of 100 to 160 cSt at 40°C (105°F).
• Have a consistency NLGI grade between 1.5 and 3. For vertically or in hot conditions mounted machines, NLGI
grade 2 or 3 is recommended.
• Have a continuous temperature range between -30°C (-20°F) and at least +120°C (250°F).
Grease with the correct properties is available from all major lubricant manufacturers. If the make of grease
is changed and compatibility is uncertain, consult the manufacturing ABB factory, see Chapter 9.1.3 Contact
information for Motors and Generators Service.
NOTE: Do not mix greases! There must be only one type of grease inside the bearing - not a
mixture of two or more greases.
NOTE: Grease additives are recommended. However, a written guarantee should be obtained
from the lubricant manufacturer stating that the additives do not damage the bearings
or the properties of the grease in the field of the operating temperature. This is especially
important for EP additives.
NOTE: Lubricants containing EP admixtures are not recommended.
Recommended rolling bearing grease

ABB recommends any of the following high performance greases:
Mineral oil base

Mobil Unirex N2
Unirex N3
Synthetic oil base
Klüber Klüberplex BEM 41-132
Lubcon Turmogrease Li 802 EP Plus
Mobil Mobilith SHC 100
Rhenus LKZ 2
Shell Gadus S5 V100 2
Total Multiplex S 2 A
Re-greasing intervals should be halved for other greases fulfilling the required properties.
Rolling bearing grease for extreme temperatures
If the bearing operating temperature is above 100°C (210°F), please consult the manufacturing ABB factory for
suitable greases.
7.5.3.6 Bearing maintenance

The lifetime of the bearings is likely to be shorter than the lifetime of the electrical machine. Therefore, the bearings
will have to be changed periodically.
The maintenance of rolling bearings requires special care, tools and arrangements as to ensure a long lifetime of
newly fitted bearings.
During bearing maintenance, ensure that:
• No dirt or foreign debris is allowed to enter the bearings at any time during the maintenance.
• The bearings are washed, dried and pre-greased with suitable and high quality rolling bearing grease before
assembly.
• The disassembly and mounting of the bearings does not damage the bearings. The bearings must be removed
by using pullers and fitted by heating, or using special tools for the purpose.
If there is a need to change bearings, please contact ABB Motors and Generators Service. See Motors and Generators
contact information in Chapter 9.1.3 Contact information for Motors and Generators Service.
7.5.4 Bearing insulation and bearing insulation resistance check

The bearing insulation resistance check is a maintenance operation made primarily in the factory during the final
assembly and testing. It should also be made during all comprehensive overhauls of the machine. Good insulation
is necessary in order to eliminate the possibility of circulating bearing currents, which might be induced by shaft
voltages. The insulation of the non-drive end bearing cuts the path of the bearing current and thus eliminates the risk
of bearing damages due to bearing currents.
Both the shaft ends should not be insulated from the frame, as an electrically floating shaft would have an unknown
electrical potential compared to the surroundings and would, therefore, be a potential source of damage. However,
to make the testing of the non-drive end bearing insulation easier, the drive end bearing is also often insulated. This
MAINTENANCE 81
insulation is short-circuited by an earthing cable during normal operation; see Figure 32 D-end bearing earthing
cable.
NOTE: Not all machines are equipped with insulated bearings.
NOTE: Machines with insulated bearings have a sticker indicating the insulated bearing.
7.5.4.1 Procedure
For machines with an insulated drive end bearing, the short-circuit earthing cable in the drive end bearing must be
removed prior to commencing the non-drive end bearing insulation resistance test. If the drive end bearing is not
insulated, it is required to perform the non-drive end bearing insulation resistance test, to remove the drive-end
bearing shells or the bearing shield and to lift the shaft. This ensures that there is no electrical contact between the
shaft and any other part, for example, frame or bearing housing.
Figure 32 D-end bearing earthing cable
For all machines any optional shaft earthing brush, rotor earth fault brush and coupling (if it is made out of
conductive material) must be removed. Measure the insulation resistance from the shaft to earth using no more
than 100 VDC, see Figure 33 Measuring the insulation resistance of a sleeve bearing and Figure 34 Measuring the
insulation resistance of a roller bearing. The measuring points over the bearing insulation are circled in the figures.
The insulation resistance is acceptable if the resistance value is more than 10 kΩ.
Figure 33 Measuring the insulation resistance of a sleeve bearing

Figure 34 Measuring the insulation resistance of a roller bearing
Following chapter for bearing type: Roller bearing
7.5.4.2 Cleanliness of bearing insulation

The bearing insulations are installed in the end shields. To avoid decrease of the insulation resistance caused by
foreign agents (salt, dirt) building up on the insulation surface, the cleanliness of the bearing insulation and the end
shield surfaces around it should be checked regularly and cleaned if necessary. See Figure 35 Bearing insulation and
end shield surfaces for areas that should be checked regularly and kept clean. The areas are marked with a circle and
the bearing insulation is pointed out by an arrow in the figure.
Figure 35 Bearing insulation and end shield surfaces
7.6 Maintenance of stator and rotor windings

The windings of rotating electrical machines are subjected to electrical, mechanical and thermal stresses. The
windings and insulation gradually age and deteriorate due to these stresses. Therefore, the service life of the
machine often depends on the insulation durability.
Many processes leading to damages can be prevented or at least slowed down with appropriate maintenance and
regular testing. This chapter offers a general description on how to perform basic maintenance and tests.
In many countries, ABB Service offers complete service maintenance packages, which include comprehensive testing.
Before conducting any maintenance work on the electrical windings, general electrical safety precautions are to
be taken and local regulations are to be respected in order to prevent personnel accidents. See Chapter 7.2 Safety
precautions for more information.
Independent test and maintenance instructions can also be found in the following international standards:
1. IEEE Std. 43-2000, IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machines
2. IEEE Std. 432-1992, IEEE Guide for Insulation Maintenance for Rotating Electrical Machinery (5 hp to Less Than 10
000 hp).
MAINTENANCE 83
7.6.1 Particular safety instructions for winding maintenance

Some of the hazardous works of the winding maintenance include:
• Handling of hazardous solvents, varnishes, and resins. Hazardous substances are required for cleaning and re-
varnishing windings. These substances can be dangerous if inhaled, swallowed or in any contact with skin or
other organs. Seek proper medical care if an accident occurs.
• Dealing with flammable solvents and varnishes. Handling and use of these substances should always be by
authorized personnel and proper safety procedures must be followed.
• Testing at high voltage (HV). High-voltage tests should only be conducted by authorized personnel and proper
safety procedures must be followed.
Dangerous substances used in winding maintenance are:
• White spirit: solvent
• 1.1.1-trichloroethane: solvent
• Finishing varnish: solvent and resin
• Adhesive resin: epoxy resin.
NOTE: There are special instructions for handling dangerous substances during maintenance
work. These instructions must be followed.
Some general safety measures during winding maintenance are as follows:

• Avoid breathing air fumes: ensure proper air circulation at the work site or use respiration masks.
• Wear safety gear such as glasses, shoes, hardhat and gloves and suitable protective clothing to protect the
skin. One should always use protective creams.
• Spray-varnish equipment, the frame of the machine, and the windings should be earthed during spray
varnishing.
• Take necessary precautions when working in pits and cramped places.
• Only people trained to do high-voltage work can carry out a voltage test.
• Do not smoke, eat, or drink at the work site.
For a test record for winding maintenance, see Appendix Commissioning report.
7.6.2 The timing of the maintenance

There are three main principles for timing the winding maintenance:
• Maintenance of the windings should be arranged according to other machine maintenance.
• Maintenance should be performed only when necessary.
• Important machines should be serviced more often than the less important ones. This also applies to windings
that become contaminated rapidly and to heavy drives.
NOTE: As a thumb rule, an insulation resistance test should be made once a year. This should
suffice for most machines in most operating conditions. Other tests should only be
conducted if problems arise.
A maintenance program for the complete machine, including windings, is presented in Chapter 7.3 Maintenance
program. This maintenance program however, should be adapted to the customer's particular circumstances, i.e.
servicing of other machines and operating conditions as long as recommended servicing intervals are not exceeded.
7.6.3 The correct operating temperature

The correct temperature of the windings is ensured by keeping the exterior surfaces of the machine clean, by seeing
to the correct operation of the cooling system and by monitoring the temperature of the coolant. If the coolant is too
cold, water may condense inside the machine. This can wet the winding and deteriorate the insulation resistance.
Following paragraph for cooling type: Open air
For air-cooled machines, it is important to monitor the cleanliness of the air filters. The cleaning and change interval
of the air filters should be planned according to the local operating environment.
The stator operating temperatures must be monitored with resistance temperature detectors. Significant
temperature differences among the detectors could be a sign of damage in the windings. Make sure that the
changes are not caused by the drifting of the measuring channel.
7.6.4 Insulation resistance test

During general maintenance work and before the machine is started up for the first time or after a long period of
standstill, the insulation resistance of stator and rotor windings must be measured.
The insulation resistance measurement provides information about the humidity and dirtiness of the insulation.
Based upon this information, correct cleaning and drying actions can be determined.
For new machines with dry windings, the insulation resistance is very high. The resistance can, however, be extremely
low if the machine has been subjected to incorrect transportation and storage conditions and humidity, or if the
machine is operated incorrectly.
NOTE: Windings should be earthed briefly immediately after measurement in order to avoid risk of
electric shock.
7.6.4.1 Conversion of measured insulation resistance values

In order to be able to compare measured insulation resistance values, the values are stated at 40°C. The actual
measured value is therefore converted to a corresponding 40°C value with the help of the following diagram. The use
of this diagram should be limited to temperatures fairly near to the standard value of 40°C, since large deviations
from it could result in errors.
1. Coefficient Kt for Insulation Resistance

2. Winding temperature Degrees Celsius °C.
Figure 36 Correlation between the insulation resistance and the temperature
R = Insulation resistance value at a specific temperature

R40 = Equivalent insulation resistance at 40°C
R40 = k x R
Example:
MAINTENANCE 85
R = 30 MΩ measured at 20°C
k = 0.25
R40 = 0.25 x 30 MΩ = 7.5 MΩ
Table 9 Temperature values in degrees Celsius (ºC) and degrees Fahrenheit (ºF)
°C 0 10 20 30 40 50 60 70 80 90 100 110
°F 32 50 68 86 104 122 140 158 176 194 212 230
7.6.4.2 General considerations

The following consideration should be noted, before deciding any actions based upon the insulation resistance tests:
• If the measured value is considered too low the winding must be cleaned and/or dried. If these measures are
not sufficient, expert help should be acquired.
• Machines, that are suspected to have moisture problem, should be dried carefully independent of the measured
insulation resistance value.
• The insulation resistance value will decrease when the winding temperature rises.
• The resistance is halved for every 10 ... 15 K temperature rise.
NOTE: The insulation resistance indicated in the test report is normally considerably higher than
the values measured on site.
7.6.4.3 Minimum values for insulation resistance

Criteria for windings in a normal condition:
Generally, the insulation resistance values for dry windings should exceed the minimum values significantly. Definite
values are impossible to give, because resistance varies depending on the machine type and local conditions. In
addition, the insulation resistance is affected by the age and usage of the machine. Therefore, the following values
can only be considered as guidelines.
The insulation resistance limits, which are given below, are valid at 40 °C, and when the test voltage has been applied
for 1 minute or longer.
• Rotor.
For induction machines with wound rotors: R(1-10 min at 40 °C) > 5 MΩ.
NOTE: Carbon dust on slip rings and naked copper surfaces lower the insulation resistance values
of the rotor.
• Stator.
For new stators: R(1-10 min at 40 °C) > 1000 MΩ. If the measuring conditions are extremely warm and humid, R(1-10 min at 40
°C) values above 100 MΩ can be accepted.
For used stators: R(1-10 min at 40 °C) > 100 MΩ.
NOTE: If the values given here are not reached, the reason for the low insulation resistance should
be determined. A low insulation resistance value is often caused by excess humidity or dirt,
although the actual insulation is intact.
7.6.4.4 Stator winding insulation resistance measurement

The insulation resistance is measured using an insulation resistance meter. The test voltage is 1000 VDC. The test
time is 1 minute, after which the insulation resistance value is recorded. Before the insulation resistance test is
conducted, the following actions must be taken:
• Check that the secondary connections of the current transformers (CT's), including spare cores are not open.
See Figure 37 Connections of the stator windings for insulation resistance measurements.
• Verify that all power supply cables are disconnected.
• Verify that the frame of the machine and the stator windings not being tested are earthed.
• The winding temperature is measured.
• All resistance temperature detectors are earthed.
• Possible earthing of voltage transformers (not common) must be removed.
The insulation resistance measuring should be carried out in the terminal box. The test is usually performed to the
whole winding as a group, in which case the meter is connected between the frame of the machine and the winding;
See Figure 37 Connections of the stator windings for insulation resistance measurements. The frame is earthed
and the three phases of the stator winding remain connected at the neutral point, see Figure 37 Connections of the
stator windings for insulation resistance measurements.
If the measured insulation resistance of the whole winding is lower than specified, and the phase windings can easily
be disconnected from each other, each phase can also be measured separately. This is not possible for all machines.
In this measurement, the tester is connected between the frame of the machine and one of the windings. The frame
and the two phases not measured are earthed; see Figure 37 Connections of the stator windings for insulation
resistance measurements.
When phases are measured separately, all star-points of the winding system must be removed. If the star-point of
the component cannot be removed, as in a typical tri-phase voltage transformer, the whole component must be
removed.
Figure 37 Connections of the stator windings for insulation resistance measurements
a) Insulation resistance measurement for star connected winding.

b) Insulation resistance measurement for delta connected winding.
c) Insulation resistance measurement for one phase of the winding. The 'MΩ' represents the insulation resistance
meter.
After the insulation resistance measurement the winding phases must be earthed briefly in order to discharge them.

MAINTENANCE 87
7.6.4.5 Rotor winding insulation resistance measurement

The insulation resistance of the rotor winding is measured with an insulation resistance meter. The test voltage of
the rotor windings should be 1000 VDC. Required notes and measures:
• Verify that all power supply cables are disconnected from the main supply.
• Verify the slip ring unit connection cables are disconnected from their supply.
• Verify that the frame of the machine and the stator windings are earthed.
• The shaft is earthed.
• The rotor winding phases not been tested are earthed. The rotor winding can be internally connected in a delta
or star connection. If this is the case, it is not possible to measure the phases individually.
• The carbon brush connections are checked to be in good order.
• The measurement device is checked.
• The stator winding temperatures are measured, and considered as a reference value for the rotor winding
temperature.
The insulation resistance meter is connected between the whole rotor winding and the shaft of the machine, see
Figure 38 Insulation resistance measurement of the rotor winding. After performed rotor winding measurements, the
rotor winding phases must be briefly earthed in order to discharge the windings.
Figure 38 Insulation resistance measurement of the rotor winding
In the figure above the rotor is star-connected.
7.6.5 Insulation resistance measurement for auxiliaries

To ensure correct operation of the machines protections and other auxiliaries, their condition can be determined
by an insulation resistance test. The procedure is described in detail in Chapter 7.6 Maintenance of stator and rotor
windings. The test voltage for the space heater should be 500 VDC and for other auxiliaries 100 VDC. The insulation
resistance measurement for Pt-100 detectors or proximity probes is not recommended.
7.6.6 The polarization index

For the polarization index test the insulation resistance is measured after the voltage has been applied for 15
seconds and 1 minute (or 1 minute and 10 minutes). The polarization index test is less dependent on the temperature
than the insulation resistance. When the winding temperature is below 50ºC (122ºF), it may be considered
independent of temperature. High temperatures can cause unpredictable changes in the polarization index,
therefore the test should not be used at temperatures above 50ºC (122ºF).
Dirt and humidity accumulating in the winding normally reduces the insulation resistance, and the polarization index,
as well as their dependence on temperature. Thus, the line in Figure 36 Correlation between the insulation resistance
and the temperature becomes less steep. Windings with open creepage distances are very sensitive to the effects of
dirt and humidity.
There are several rules for determining the lowest acceptable value with which the machine can be safely started. For
the polarization index (PI), the values usually range between 1 and 4. Values close to 1 indicate that the windings are
humid and dirty.
The minimum PI value for class F stator windings is more than 2.
NOTE: If the insulation resistance of the winding is in the range of several thousands of MΩ, the
polarization index is not a meaningful criterion of the condition of the insulation, and it can
be disregarded.
7.6.7 Other maintenance operations

Usually, ABB-made winding are trouble free and in addition to periodical monitoring they require only occasional
cleaning and drying as described above. If extraordinary circumstances occur and other maintenance is required,
it is best to acquire professional help. The ABB After Sales organization is eager to assist in questions regarding
maintenance of electrical machine winding, for contact information see Chapter 9.1.3 Contact information for Motors
and Generators Service.
Following chapters for rotor type: Slip rings
7.7 Maintenance of slip rings and brush gear

A machine with slip rings will function properly only if the slip rings and the brush gear are inspected and subjected
to maintenance regularly.
7.7.1 Care of slip rings

The sliding surfaces of the slip rings should be kept smooth and clean. The slip rings should be inspected and the
surfaces of the insulation cleaned. Wearing of brushes produces coal dust that easily builds up conducting bridges
over the insulation surfaces. Electric discharges may take place between slip rings and a flash might appear, leading
to interruption in operation of the machine. The contact surface of slip rings forms a patina, or skin, together with
the brushes. The patina can be seen as a colored surface, it is normal behavior and in many cases a benefit to brush
operation, so the patina is not be considered as a fault in operation and should not be cleared away.
7.7.1.1 Standstill period

When a longer standstill period for the machine begins, the brushes should be lifted up. During transport, storage,
installation or longer interruptions, the sliding surfaces of the slip-rings might be tarnished or covered with dirt, etc.
Before restarting the machine, the sliding surfaces should be inspected and cleaned.
7.7.1.2 Wear
In case that the slip rings have become coarse or uneven, they should be ground or turned on a lathe. The asymmetry
of the whole ring diameter should be less than 1.0 mm, but for a short distance, a value of maximum 0.2 mm is
allowed. In case of the slip rings are worn out or badly burned, new rings should be assembled.
Measure the eccentricity of the slip-rings using a dial indicator gage. Let the measuring point lie on the slip ring
or on the outer surface of a brush. The highest and lowest values during one turn of the shaft are recorded. The
difference of the maximum and minimum values should be no more than 1.0 mm and locally no more than 0.2 mm.
The difference of the outer diameters of the two slip rings shall preferably not be more than 2 mm.
7.7.2 Care of brush gear

The brush gear should be inspected and the surfaces of the insulation cleaned.
Wearing of brushes produces coal dust that easily builds up conducting bridges over the insulation surfaces. The coal
dust is best removed by vacuum cleaning brush gear.
7.7.2.1 Brush pressure

The brush pressure should be evenly distributed over the whole contact surface, i.e. the brush should conform to
the slip ring curvature. Brush pressure is one of the most important single factors in brush operation. The pressure
MAINTENANCE 89
should be 18-20 mN/mm2 (180-200 g/cm2). Use a spring-balance to measure the brush pressure. Attach a spring
balance to the tip of the lever pressing the brush and pull in a radial direction until the pressure is just relieved from
the brush. Use a piece of paper between brush and press lever to detect when pressure is relieved, see Figure 39
Checking brush pressure with spring balance.
Figure 39 Checking brush pressure with spring balance
Following chapters for cooling type: Open air, Air-to-water and Air-to-air
7.8 Maintenance of cooling units

The cooling units normally require little maintenance but it is advisable to regularly check their condition in order to
ensure trouble-free operation.
The condition of the noise damping material in heat exchangers and air silencers should be inspected frequently. If
the material looks crumbling or has already crumbled, the material needs to be replaced and heat exchanger must be
cleaned from any loose particles that may block the air ways.
Following chapter for cooling type: Open air
7.8.1 Maintenance instructions for machines with open air cooling

The cooling air is normally circulated by a fan and/or by the rotor. The fan may be mounted on the shaft or driven
by a separate motor. A connection to external air pressure is also possible. Depending on the machine design, the
circulation may be axially symmetrical or asymmetrical. The cooling air should be as clean as possible, because any
dirt, which drifts into the machine, causes contamination and reduces the efficiency of the cooling.
The upper covers of the standard weather protected machines are delivered with or without filters according to the
specification. By special order, the upper cover is equipped with a differential pressure switch for monitoring the
condition of the filters.
If the winding or cooling air temperature detectors show an abnormal temperature, a check of the cooling system
has to be made. The two maintenance issues are to check the condition of air filters and to ensure good air
circulation inside the machine. The machine interior should be cleaned and checked during overhauls or if problems
arise.
Other possible causes for poor cooling system performance might include elevated ambient temperature or high
intake air temperature. In addition, lubrication or bearing malfunction might lead to high bearing temperature.
A seemingly high temperature might also be caused by a problem in the temperature measurement system Chapter
8.3.2 Pt-100 resistance temperature detectors.
7.8.1.1 Cleaning of filters

The filters should be cleaned regularly. The cleaning interval depends on the cleanliness of the air in the surrounding
environment. The filters have to be cleaned when the temperature detectors in the winding show abnormal
temperature or approach the alarm level.
If a filter differential pressure monitoring system is being used, the filters should be changed immediately after
a pressure alarm. The alarm level is such that 50% of the air filter surface is obstructed. The operating personnel
should also manually inspect the filters frequently.
Remove the air filters for cleaning. If the surrounding air is sufficiently clean, the filters can be changed during
operation. They should regularly be cleaned by vacuuming first from the upstream side, then on the discharge side.
Periodically, a thorough wash with clean water is recommended to release any dirt not removed by vacuuming. When
heavy grease concentrations are encountered, the filters should be washed with a detergent solution. This solution
should be rinsed thoroughly before returning the filter to service. Be careful to install the air filters in the correct
direction, i.e. the arrows on the air filter frame indicate the direction of airflow. Some filters can be installed in either
direction. Refer also to the air filter manufacturer information.
Following chapters for cooling type: Air-to-water
7.8.2 Maintenance instructions for air-to-water heat exchangers

If the temperature detectors show normal operating temperature, and the leakage detectors indicate no leaks,
usually no additional supervision is required for the cooling system.
Following chapters for cooling type: Air-to-air
7.8.3 Maintenance instructions for air-to-air heat exchangers

The cooling unit is installed on the machine. The air tubes in the heat exchanger are normally made of Aluminium.
7.8.3.1 Air circulation

The inner air is normally circulated by a fan and/or by the rotor. The fan may be mounted on the shaft or driven by a
separate motor. Depending on the machine design, the circulation may be axially symmetrical or asymmetrical.
The outer air flow is normally created by a fan, mounted on the shaft or driven by a separate motor. Connection to
external air pressure is also possible.
Figure 40 Cooling air flow (typical asymmetric construction)

MAINTENANCE 91
The machine can be equipped with temperature detector(s) for monitoring the internal cooling air. If the
temperature detectors show normal temperature, no additional maintenance to the supervision inspection is usually
required for the cooling system.
If the temperature detectors show abnormal temperature or close to the alarm level in winding or in cooling air, the
cooling system has to be checked. If the coolers have to be cleaned, see the instructions below.
7.8.3.2 Cleaning
Some fouling of the cooling surface and the tube wall will eventually occur. This fouling reduces the cooling capacity.
The heat exchanger should therefore be cleaned at regular intervals, to be determined from case to case, depending
of the properties of the cooling air. During the initial period of operation, the heat exchanger should be inspected
frequently.
Blow the heat exchanger clean with compressed air or clean it with a suitable brush. Do not use a steel brush in
aluminium tubes as it can damage the tubes; a soft round brass wire brush can be used instead.
7.8.4 Maintenance of external blower motors

The external blower motors are maintenance free units, e.g. the bearings of external blower motors are greased for
life. A spare external blower motor is recommended. The maintenance of the blower motor is performed according to
the motor's manual.
7.9 Repairs, disassembly and assembly

All the actions related to repairs, disassembly and assembly should be done by trained service personnel. For more
information, please contact After Sales, see Chapter 9.1.3 Contact information for Motors and Generators Service.
NOTE: Machines in hazardous areas must only be serviced by repair shops qualified and
authorized by ABB.
Following note for rotor type: Permanent magnet
NOTE: When disassembling the permanent magnet synchronous machine, always contact ABB
Motors and Generators Service for more instructions.
—
Chapter 8 Trouble shooting
Trouble shooting
8.1 Trouble shooting

This chapter is intended as a help in the event of an operational failure with an ABB delivered rotating electrical
machine. The trouble shooting charts given below can aid in locating and repairing mechanical, electrical and thermal
problems, and problems associated with the lubrication system. The checks and corrective actions mentioned should
always be conducted by qualified personnel. If in any doubt, the Motors and Generators Service of ABB should be
contacted for more information or technical assistance regarding trouble shooting and maintenance.
8.1.1 Mechanical performance

Observed Possible cause Corrective action
malfunction
Vibration
Noise
• • Lubrication malfunction Check lubricant quality and quantity and

lubrication system function
• • Bearing malfunction Damaged bearing parts Check bearing condition and replace bearing
parts
• • Faulty bearing assembly Open and readjust the bearing
• • Faulty cooling fan(s) Imbalanced or damaged Check and repair cooling fan(s)
fan(s)
• Malfunctioning cooling system Inspect and repair cooling system
• • Machine misalignment Check machine alignment
• • Rotor or shaft imbalance Rebalance rotor
• • Vibration coming from connected machinery Check the balance of connected machinery
and coupling type
• • Axial load coming from connected machinery Check alignment and coupling function and
type
• • Faulty or incorrectly assembled coupling Check coupling function
• Insufficient foundation strength Reinforce foundation as per ABB instructions
• Winding fault Check windings
• • Excessive network unbalance Check that network balance fulfils
requirements
• Foreign material, moisture or dirt inside the machine Check and clean machine interior, dry
windings
8.1.2 Lubrication system and bearings

TROUBLE SHOOTING 93
8.1.2.1 Rolling bearings

malfunction
High bearing temperature
Bearing noise or vibration

Lubricant leaks
• • Insufficient lubrication Insufficient amount of Check bearing condition, add grease

grease
• • • Unsuitable grease quality or viscosity Check ABB grease recommendations, change
grease
• Excessive axial forces Faulty coupling or mounting Check coupling, mounting and alignment
• • Reduced grease quality Incorrect regreasing period Check ABB recommendations, regrease
• • Faulty operating conditions Check ABB operating and grease
recommendations
• • Excessive lubrication Clean bearing and add correct amount of
lubricant
• • Damaged bearing parts Impurities in grease Change grease, check bearing condition
• • Bearing currents Check bearing and insulation condition
• • Complete bearing failure Replace bearing
• • Normal wearing Replace worn bearing parts
• Faulty instrumentation Faulty temperature Check bearing temperature measurement
detector system
• • Faulty bearing seals Check bearing seals and lubricant quality
• Incorrectly assembled bearing Replace bearing, ensure correct assembly
• • Outer ring is rotating due to unbalanced load Rebalance machine, repair bearing bore and
replace bearing
• Bearing noise due to deformed roller element Replace bearing
• Foreign matter inside the bearing Clean bearing assembly, check seal
conditions and replace bearing
8.1.2.2 Sleeve bearings with self lubrication

Observed malfunction Possible cause Corrective action
Visibly poor oil quality

Oil inside the machine
Oil leaks
• • • Insufficient lubrication Low oil level Check bearing for leakage, add oil
• • • • Unsuitable oil quality Check ABB oil recommendations
• • Oil quality is reduced Incorrect oil change Clean bearing and change oil
period
• • • • Excessive axial load Faulty coupling or Check coupling, mounting and
mounting alignment
• • • Machine misalignment Realign machine
• • Incorrectly assembled bearing Verify correct bearing assemblage and
adjustments
• • • Excessive amount of oil Clean bearing and add correct amount
of lubricant
• • • Damaged bearing shells Oil impurities Change oil, check bearing condition,
replace bearing shells
• • Bearing currents Restore bearing insulation, replace
bearing shells
• • Complete bearing failure Replace bearing parts
• • Normal wearing Replace bearing shells
• • Operating speed too low Check the operating speed range of
bearing
• Faulty instrumentation Faulty temperature Check bearing temperature
detector measurement system
• Damaged or worn-out bearing seals Replace bearing seals
• External vacuum Rotating equipment Check pressure levels, relocate rotating
nearby equipment
• • Internal over pressure Pressure compensation Remove cause for internal over pressure
failure
• Damaged machine seal Replace or repair machine seal
• Poor oil ring or disc operation Open bearing and adjust operation
• • Foreign matter inside the bearing Clean bearing and check seal condition
TROUBLE SHOOTING 95
8.1.2.3 Sleeve bearings with flood lubrication

Observed malfunction Possible cause Corrective action
Visibly poor oil quality

Oil inside the machine
Oil leaks
• • • Insufficient lubrication Oil flow malfunction Check oil pump, oil reduction valve and
oil filter
• Oil viscosity too high Check oil temperature and oil type
• • • • Unsuitable oil quality Check ABB oil recommendations
• Oil inlet temperature too high Check lubrication system and adjust oil
temperature
• • Oil quality is reduced Incorrect oil change Clean bearing and change oil
period
• • • • Excessive axial load Faulty coupling or Check coupling, mounting and
mounting alignment
• • • Machine misalignment Realign machine
• • Incorrectly assembled bearing Verify correct bearing assemblage and
adjustments
• • • Damaged bearing shells Oil impurities Change oil, check bearing condition,
replace bearing shells
• • Bearing currents Restore bearing insulation, replace
bearing shells
• • Complete bearing failure Replace bearing parts
• • Normal wearing Replace bearing shells
• • Operating speed too low Check the operating speed range of
bearing
• Faulty instrumentation Faulty temperature Check bearing temperature
detector measurement system
• Damaged or worn-out bearing seals Replace bearing seals
• Oil flow too high Faulty regulator settings Check and correct oil flow
• Problem in oil return Faulty oil piping Check oil return pipe inclination
flow
• External vacuum Rotating equipment Check pressure levels, relocate rotating
nearby equipment
• • Internal over pressure Pressure compensation Remove cause for internal over pressure
failure
• Damaged machine seal Replace or repair machine seal
• Faulty assembled or maintained lubrication piping Check pipeline connections and oil filter
tightness
• • Foreign matter inside the bearing Clean bearing and check seal condition
NOTE: For oil leakage of sleeve bearings, see Chapter 8.2 Oil leakage of sleeve bearings.
8.1.3 Thermal performance
8.1.3.1 Open air cooling system

malfunction
High cooling air temperature
High winding temperature
• • High intake air temperature Ambient temperature too Add ventilation to decrease ambient
high temperature
• • Exiting air is pulled back in Ensure sufficient clear distances surrounding
the machine
• • Heat source nearby Place heat sources further away, check
ventilation
• • Faulty air flow Dirty machine interior Clean machine parts and air gaps
• • Faulty cooling arrangement Inspect cooling arrangement condition and
correct assembly
• • Air intakes are blocked Clear air intakes of debris
• • Air filter is clogged Clean or replace air filters
• • Damaged cooling fan(s) Replace fan(s)
• • Cooling fan rotating in the wrong direction Replace fan(s) or change rotating direction of
external fan
• Overload Control system setting Check machine controls, eliminate overload
• • Overspeed Check actual speed and ABB speed
recommendations
• Network unbalance Check that network balance fulfils
requirements
• • Faulty instrumentation or Check measurements, sensors and wiring
measurement system
NOTE: For high bearing temperatures, see Chapter 8.1.2 Lubrication system and bearings.
TROUBLE SHOOTING 97
8.1.3.2 Air-to-air cooling system

malfunction
• • Low primary cooling circuit Damaged cooling fan(s) Replace fan(s)

performance
• • Fan rotating in wrong Replace fan(s)
direction
• • Dirty machine interior Clean machine parts and air gaps
• • Low secondary cooling Damaged external fan Replace fan
circuit performance
• • Fan rotating in wrong Change shaft mounted fan or correct
direction external blower motor operation
• • Leaking cooler Repair cooler
• • High intake air temperature Ambient temperature too Add ventilation to decrease ambient
high temperature
• • Exiting air is pulled back in Ensure sufficient clear distances surrounding
the cooler
• • Heat source nearby Place heat sources further away, check
ventilation
• • Overspeed Check actual speed and ABB speed
recommendations
requirements
• • Faulty instrumentation or measurement system Check measurements, sensors and wiring
• Too many starts Let the machine cool down before restarting
8.1.3.3 Air-to-water cooling system

malfunction
Water leakage alarm
• • Low primary cooling circuit Damaged cooling fan Replace fan

performance
• • Fan rotating in wrong Change shaft mounted fan or correct external
direction blower motor operation
• • Dirty machine interior Clean machine parts and air gaps
• • Low secondary cooling Coolant pipes are blocked Open cooler and clean pipes
circuit performance
• • Faulty coolant pump Check and repair the pump
• • Faulty flow regulator Check and adjust coolant flow
settings
• • • Leaking cooler header Replace the cooler header
• • Air inside the cooler Bleed the cooler through bleeder screw
• • Emergency cooling hatch Close emergency cooling hatch tightly
open
• • Cooling water inlet temperature too high Adjust cooling water temperature
requirements
• • • Faulty instrumentation or measurement system Check measurements, sensors and wiring
TROUBLE SHOOTING 99
8.1.3.4 Rib cooling

malfunction

• Overspeed Check actual speed and ABB speed
recommendations
requirements
• Faulty instrumentation or measurement system Check measurements, sensors and wiring
• Dirty machine exterior Clean machine exterior
• Air flow is reduced Remove obstacles. Ensure sufficient air flow,
see Dimension Drawing of the machine
NOTE: For high bearing temperature, see Chapter 8.1.2 Lubrication system and bearings.
Following chapters for bearing type: Sleeve bearing
8.2 Oil leakage of sleeve bearings

The construction of a sleeve bearing is such that it is very difficult to avoid oil leakage completely, and therefore
small amounts of leakage should be tolerated.
However, oil leakage can also appear because of reasons other than the bearing design, such as incorrect oil
viscosity, overpressure inside the bearing, underpressure outside the bearing, or high vibration levels at the bearing.
If excessive oil leakage is noted, please check/verify the following:
• Verify that the oil used is according to specifications.
• Re-tighten the bearing housing halves, and the labyrinth seal cover. This is especially important, if the machine
has been stopped for a long time.
• Measure the vibrations of the leaking bearing in three directions under full load. If the vibration level is high, the
bearing housing might "loosen" just enough to permit the oil to wash away the sealant between the housing
halves.
• Open the bearing, clean the surfaces and apply new sealant between the bearing housing halves.
• Verify that there is nothing, which might cause low pressure next to the bearing. A shaft or coupling cover can
for instance be designed so that it will cause low pressure near the bearing.
• Verify that there is no overpressure inside the bearing. Overpressure may be entering the bearing through the
oil outlet piping from the oil lubrication unit. Apply breathers or vents to the bearing housing as to relieve the
overpressure from the bearing.
• In case of a flood bearing lubrication system, check that the slope of the oil outlet pipes is sufficient.
If excessive oil leakage is found even after all of the above and below mentioned things have been checked and
verified, please fill in the form Oil Leakage's at RENK Sleeve Bearings and send it to the local Motors and Generators
Service department.
8.2.1 Oil
In order for the bearings to function as expected, the oil has to meet certain criteria like viscosity and cleanliness, see
Chapter 7.5.2.2 Control of the lubricant and Chapter 7.5.2.3 Recommended control values for the lubricating oil.
Viscosity
The bearings are designed to run with an oil of a certain viscosity, which is mentioned in the documentation provided
with the electrical machine.
Incorrect viscosity will lead to lubrication failures, and can damage the bearings, as well as the shaft.

The sleeve bearings used in rotating electrical machines are often 'standard bearings' used in a number of
applications. Therefore, the bearing design in itself is normally not the cause of bearing leakages, and the reason for
the leakage should be found elsewhere.
However, the bearing is assembled from several parts, and the joints between the parts can leak due to faulty
assembly or lack of sealing compound.
Bearing housing
The bearing housing consists of an upper and lower half, which are joined together. In addition, labyrinth seals are
mounted at the bearing housing entrance of the shaft. This construction is not completely hermetic, and therefore
very small leakages have to be tolerated.
A tolerable amount of leakage for self-lubricating bearings is such that the bearing does not need a top-up between
the oil change intervals.
The oil can leak from the bearing in two ways:
• Past the labyrinth seals

• Through the split line of the bearing housing.
Sealant
In order to prevent the oil from leaking from the bearing through any split lines, sealant is applied on the split lines.
ABB recommends the Hylomar Blue Heavy sealing compound. Curil T or other similar compounds can be used as well.
8.2.3 Bearing verification

In case the oil leakage is suspected to originate from the bearing housing itself, the following steps can be taken:
1. Re-tighten the bearing housing.
This is especially important during the commissioning of the machine, or if the machine has been standing still
for a longer period, as the parts may set.
If the bearing housing halves are not in a tight fit in respect to each other, the oil might wash away the sealant
from the split line. This in turn will cause oil leakage.
2. Open the bearing housing.
The bearing housing can be opened, and new sealant applied on the split lines. Care has to be taken that no
dirt or foreign matter enter the bearing during this procedure. The split lines have to be completely degreased
before a thin layer of sealant is applied.
Following chapter for bearing type: Sleeve bearing with flood lubrication
8.2.4 Oil container and piping

A separate oil container and piping is used only for flood-lubricated bearings.
Oil container
The oil container can be either a separate container, or in some cases, the crankcase of a diesel engine. In both cases,
the container has to be well below the bearings, in order for the oil to flow to the container from the bearing.
TROUBLE SHOOTING 101
The oil container should be constructed in such a way that no pressure can enter the oil return piping from the
container towards the bearing.
Oil piping
The function of the oil return piping is to allow the oil to return to the oil tank with as little of friction as possible.
This is normally obtained by choosing a piping diameter of a large enough diameter, so that the flow of the oil in the
return line does not exceed 0.15 m/s (6 inch/s) based on the pipe cross section.
Install the oil outlet pipes downwards from the bearings at a minimum angle of 15° which corresponds to a slope of
250 - 300 mm/m (3 – 3½ inch/ft).
The assembling of the piping must be performed in such-a-way that above mentioned slope is present at all points of
the piping.
Following chapter for bearing type: Sleeve bearing with flood lubrication
8.2.5 Oil container and piping verification

In case the oil leakage is suspected to originate from the construction of the oil container or the oil piping, the
following steps can be taken:
Pressure in oil container
The atmospheric pressure inside the oil container must be verified. The pressure may not be larger than the pressure
outside the bearing. If this is the case, a breather must be installed to the oil container.
Oil piping
It should be verified that the piping has a sufficient diameter, is not clogged, and that the slope is downward and
sufficient throughout the oil return piping.
8.2.6 Use
Causes for bearing leakages, apart from being installation-related, some causes are 'use' related.
Following paragraphs for bearing type: Sleeve bearing with flood lubrication
Oil pressure
The inlet oil pressure for each bearing is calculated according to the desired oil flow, and therefore the oil pressure
should be adjusted accordingly during commissioning.
The specific oil pressure value for each machine must be verified from the documentation provided with the machine.
Following paragraph for bearing type: Sleeve bearing with self lubrication
Oil level
The oil level of a self-lubricated sleeve bearing needs to be checked regularly, see Chapter 7.5.1.1 Oil level.
Oil temperature
The correct lubrication oil temperature is essential in keeping the bearing at the correct operating temperature, in
ensuring sufficient lubrication effect, and correct viscosity of the lubrication oil, see Chapter 7.5.2.1 Lubrication oil
temperature. See also the connection diagram and dimensional drawing.
Vibrations
All machines are subjected to, and designed to withstand vibrations. Large vibrations might cause the various parts
in the bearing to function different as intended.
Heavy vibrations can cause different phenomena in the oil film between the shaft and the white metal, but this will
rather seldom lead to oil leakages, but to bearing failures.
Heavy vibrations can cause the bearing housing parts to set, or to 'loosen up' just enough to allow the oil to enter the
split surface between the upper and the lower bearing housing halves. The vibrations will cause the bearing housing
parts to move in respect of each other. This can cause a 'pumping' effect in such a way, that oil will be pumped in and
out from the split surface. This will eventually remove the sealant, and cause the bearings to leak.
Air pressure inside bearing
The bearing housing is not a hermetic compartment, and therefore any overpressure inside the bearing housing will
escape the bearing housing via the labyrinth seals. In escaping, the air will bring oil mist with it, thus causing the
bearing to leak.
Overpressure inside the bearing is normally caused by other components than the bearing itself. The most common
reason for overpressure inside the bearing is overpressure in the oil return piping.
Air pressure outside of bearing
Similar to overpressure inside the bearing, under pressure outside the bearing will 'suck' air out from inside the
bearing, thus bringing oil with it, and causing the bearing to leak oil.
Under pressure inside the bearing is normally not caused by the bearing itself, but by parts outside the bearing.
Under pressure near the bearing housing is caused by rotational parts moving the air next to them in such a way that
a local under pressure is formed next to the exit of the shaft of the bearing.
8.2.7 Use verification
Oil
The oil quality must be verified.
Following paragraphs for bearing type: Sleeve bearing with flood lubrication
The inlet pressure of the oil must be verified and adjusted accordingly.
The normal value for the oil pressure is 125 kPa ± 25 kPa (1.25 bar ± 0.25 bar), but the specific oil pressure value for
each machine must be verified from the documentation provided with the machine.
Following paragraphs for bearing type: Sleeve bearing with self lubrication
The oil level in the bearing must be verified.
The temperature of the oil must be verified. A too high temperature will cause the viscosity of the oil to diminish,
thus making it easier to escape from the bearing.
NOTE: Bearings with only one Pt-100 temperature detector normally detect the temperature of
the bearing, not the oil. The temperature of the oil is approximately 10°C (20°F) lower than
the bearing temperature.
Following paragraph for bearing type: Sleeve bearing with flood lubrication
The normal oil inlet temperature is 45 °C (113 °F), but must be verified from the documentation provided with the
machine.
Vibrations
Vibration readings of the bearing housings should be taken in three directions: axial, transversal (horizontal) and
vertical, see Chapter 7.4.3 Bearing housing vibrations.
Air pressure inside the bearing
The air pressures inside and outside the bearings should be verified.
Overpressure is, as stated above, normally caused by overpressures in the oil tank. The overpressure from the oil tank
is then transmitted to the bearing via the oil return piping.
The best way to measure the pressure inside a bearing, is from the oil fill entrance or the inspection glass on top of
the bearing.
In case overpressure inside the bearing is found, the following measures should be taken in the following order:
• Mount breather in the oil tank if possible. This is not suitable for diesel engine crankcases.
• Make sure the oil return pipe enters the oil tank below the oil level. This is essential for diesel engine
crankcases.
• Make a U-shaped 'water lock' on the oil return piping.
• Install a breather on top of the bearing housing.
Air pressure outside the bearing
The air pressure near the exit of the shaft from the bearing needs to be verified. This is especially important if the
bearing is flange mounted to the machine, or if the shaft is mounted inside a cover or other construction which
might form a 'centrifugal fan' together with the shaft.
Flange bearings have two canals between the bearing housing and the flange, which normally are enough to
compensate for any under pressure near the exit of the shaft from the bearing housing. However, if for some reason
a very large under pressure is present near this area, the two canals might not be enough, and some air is additionally
sucked from inside the bearing. This is especially likely to happen to sleeve bearings with axial thrust pads, as the oil
flow in these bearings is larger than in pure radial bearings.
If a large under pressure is noticed or suspected, the air pressure has to be measured near the exit of the shaft from
the bearing housing.
In order to verify that the under pressure outside the bearing can cause the leakage, the pressure outside the bearing
(p0) inside the bearing (p2), and the pressure in the area between the end shield and the machine seal (p1) must be
measured as well. When measuring (p1), the tube has to be inserted as deep as possible, and the canals must be
temporarily closed, see Figure 41 Verification of air pressure inside and outside of a sleeve bearing.
In order to analyze the situation, p1 and p2 have to be compared with p0, which has to be measured free from any
disturbances or turbulence near the machine. The following situations can appear:
• p0 = p1 = p2. If all pressure readings are the same, the leakage is not caused by pressure differences. However,
bear in mind what has been stated about diesel engines earlier.
• p2 > p1(= p0). If the pressure inside the bearing is larger than the outside pressure, there is only a situation with
overpressure inside the bearing.
• p2 (= p0) > p1. If the pressure outside the bearing is smaller the pressure elsewhere, there is under pressure
near the bearing.
• p2 > p0 > p1. If all pressure readings are different, there might be a situation where both overpressure inside
the bearing, and under pressure outside the bearing are present.
Figure 41 Verification of air pressure inside and outside of a sleeve bearing
If a large under pressure is found to be inside the machine, e.g. between the end shield and the machine seal, the
situation is tricky; it is normally very difficult to remove the machine seal, and to re-seal it.
NOTE: In no case should a breather be installed to remedy under pressure in the bearing, as it will
only make the leakage worse.
8.3 Electrical performance, control and protection

The electrical performance of a rotating electrical machine is mostly defined by the condition of the rotor and stator
windings. The machine winding maintenance is described in Chapter 7.6 Maintenance of stator and rotor windings. In
this chapter, the focus is on the trouble shooting of the control and protection systems.
8.3.1 Protection trips

The machine needs to be protected with alarms and trips for abnormal running conditions, both electrical and
mechanical. Some of these protections can be reset and the machine restarted directly as the fault is located.
Examples of protections that, if they give an alarm or trip, may need further investigation:
• High temperature in bearing, see Chapter 7.5 Maintenance of bearings and lubrication system
• High temperature in winding or in cooling air, see Chapter 7.6 Maintenance of stator and rotor windings and
Chapter 8.5 Thermal performance and cooling system
• Overcurrent, current and voltage unbalance, overvoltage
• Vibration protection, Chapter 7.4.2 Vibration and noise.
8.3.2 Pt-100 resistance temperature detectors

Pt-100 resistance temperature detectors are an essential part in the machine's condition monitoring and protection
system. They are used to measure temperatures in the windings, bearings and in the cooling air. The Pt-100 detector
uses a fine platinum filament for the temperature measurement, which can be damaged e.g. by incorrect handling or
excessive vibration.
The following symptoms might suggest a problem in a Pt-100 detector:
• Infinite or zero resistance over the detector
• Disappearance of measurement signal during, or after start up
• A significantly different resistance value in a single detector.
If a Pt-100 failure is suspected the findings should always be confirmed from the connection box, by measuring
the resistance at the detector with its cables disconnected. The findings should by registered. For the correct
measuring current see the appropriate Pt-100 detector. For resistance values at different temperatures, see Table 10
Temperature values for Pt-100 elements.
Table 10 Temperature values for Pt-100 elements
PT100 TEMP TEMP PT100 TEMP TEMP PT100 TEMP TEMP

RES Ω °C °F RES Ω C °F RES Ω °C °F
100.00 0 32.00 127.07 70 158.00 153.58 140 284.00

100.78 2 35.60 127.84 72 161.60 154.32 142 287.60
101.56 4 39.20 128.60 74 165.20 155.07 144 291.20
102.34 6 42.80 129.37 76 168.80 155.82 146 294.80
103.12 8 46.40 130.13 78 172.40 156.57 148 298.40
103.90 10 50.00 130.89 80 176.00 157.31 150 302.00
104.68 12 53.60 131.66 82 179.60 158.06 152 305.60
105.46 14 57.20 132.42 84 183.20 158.81 154 309.20
106.24 16 60.80 133.18 86 186.80 159.55 156 312.80
107.02 18 64.40 133.94 88 190.40 160.30 158 316.40
107.79 20 68.00 134.70 90 194.00 161.04 160 320.00
108.57 22 71.60 135.46 92 197.60 161.79 162 323.60
109.35 24 75.20 136.22 94 201.20 162.53 164 327.20
110.12 26 78.80 136.98 96 204.80 163.27 166 330.80
110.90 28 82.40 137.74 98 208.40 164.02 168 334.40
111.67 30 86.00 138.50 100 212.00 164.76 170 338.00
112.45 32 89.60 139.26 102 215.60 165.50 172 341.60
113.22 34 93.20 140.02 104 219.20 166.24 174 345.20
113.99 36 96.80 140.77 106 222.80 166.98 176 348.80
114.77 38 100.40 141.53 108 226.40 167.72 178 352.40
115.54 40 104.00 142.29 110 230.00 168.46 180 356.00
116.31 42 107.60 143.04 112 233.60 169.20 182 359.60
PT100 TEMP TEMP PT100 TEMP TEMP PT100 TEMP TEMP

RES Ω °C °F RES Ω C °F RES Ω °C °F
117.08 44 111.20 143.80 114 237.20 169.94 184 363.20

117.85 46 114.80 144.55 116 240.80 170.58 186 366.80
118.62 48 118.40 145.31 118 244.40 171.42 188 370.40
119.40 50 122.00 146.06 120 248.00 172.16 190 374.00
120.16 52 125.60 146.81 122 251.60 172.90 192 377.60
120.93 54 129.20 147.57 124 255.20 173.63 194 381.20
121.70 56 132.80 148.32 126 258.80 174.37 196 384.80
122.47 58 136.40 149.07 128 262.40 175.10 198 388.40
123.24 60 140.00 149.83 130 266.00 175.84 200 392.00
124.01 62 143.60 150.57 132 269.60 176.57 202 395.60
124.77 64 147.20 151.33 134 273.20 177.31 204 399.20
125.54 66 150.80 152.04 136 276.80 178.04 206 402.80
126.31 68 154.40 152.83 138 280.40 178.78 208 406.40
There are two possible remedies for stator Pt-100 detector damage. If there are operational spare detectors
remaining in the stator core, they can be taken into use. If all the working factory assembled detectors are in use, a
new detector can be retrofitted in the winding end.
8.4 Slip rings and brushes
8.4.1 Brush wear

In case the brushes are wearing rapidly or unevenly, the following points shall be observed:
• Is the brush pressure within the specified range? See Chapter 7.7.2.1 Brush pressure.
• Are all brush pigtail cables reliably connected?
• Are the sliding surfaces of the slip rings deteriorated?
• Is it probable that carbon brushes have absorbed oil or moisture?
• Is the brush quality as specified for the machine?
Always when feasible:
• Control that the brushes are in good condition and that they can move freely in the brush holders
• Check that the brush pigtail cables are in order and that they are reliably connected
• Remove coal dust by vacuum cleaning.
8.4.2 Brush sparking

Any possible sparking of the brushes can be observed through a window in the slip ring enclosure. Sparking is often
an indication of inadequate operation. Measures to prevent sparking must be taken immediately. The reasons of
sparking shall be cleared up and undisturbed running restored. Possible causes for sparking:
• Inadequate loading condition
• Brushes sticking in their holders
• Brushes too loose in their holders
• Loose connection of brush terminal
• Imperfect brush bedding
• Incorrect or unequal brush pressure
• The sliding surfaces of the slip-rings are deteriorated
• The type of carbon brushes is not acceptable for the operating conditions
• Misalignment of shaft couplings
• The machine is out of balance
• Worn bearings giving unequal air gaps.
8.5 Thermal performance and cooling system

There are two fundamental reasons that might cause an increase in the machine's temperature:
• The effect of the cooling system has declined
• The machine is producing excessive amount of heat.
If the machine temperature exceeds the normal values, measures should be taken to determine which one of the
above mentioned two causes is dominant cause in a particular incident.
NOTE: An excessive heat production might be caused by a winding problem or by network

unbalance, and in these cases corrective actions on the cooling system would be ineffective
or harmful.
If the winding or cooling air temperature detectors show an abnormal temperature, a check of the cooling system
has to be done. Two separate maintenance issues affect the cooling system. The apparent part is to ensure the
uninterrupted and correct operation of the heat exchanger. This task is accomplished by periodically cleaning and
checking the heat exchanger for correct operation.
The air or water flow through the heat exchanger must also be checked. If the cooler is equipped with an external
blower fan, its operation needs also to be checked.
The less apparent but equally important part is to ensure good air circulation in the primary cooling circuit inside
the machine. This task can be fulfilled by cleaning and checking the machine interior during overhauls or if problems
arise.
Other possible causes for poor heat exchanger performance might include elevated ambient temperature, high
intake air or water temperature, and low air or water flow.
In addition, lubrication or bearing malfunction might lead to high bearing temperature. A seemingly high
temperature might also be caused by a problem in the temperature measurement system Chapter 8.3.2 Pt-100
resistance temperature detectors.
—
Chapter 9 Life cycle services for motors and generators
Life cycle services for motors and generators
9.1 Motors and Generators Service

From installation and commissioning, through spares and maintenance, to upgrades and replacements – ABB Motors
and Generators Service has got it covered. Based on 120 years of experience in building motors and generators, we
provide services that help plant operators to add value and optimize their cost of ownership.
With the market’s widest service network globally, and certified service engineers standing by to carry out repairs on-
site or in authorized workshops, we can offer different service options to match your needs.
9.1.1 Service products

We can offer the following services for motors and generators:
• Installation and commissioning
• Spare parts
• Maintenance:
- Preventive maintenance
- Predictive maintenance
- Condition monitoring
• Repairs:
- On-site and workshop
- Remote troubleshooting
- Technical support
• Engineering and consulting
• Extensions, upgrades and retrofits
• Replacements
• Training
• Service agreement.
For more information, please visit www.abb.com/motors&generators or contact the local ABB Motors and
Generators Service.
9.1.2 Support and warranties

All motors and generators are covered by factory warranty which covers component, design, workmanship and
manufacturing defects. Warranty terms and period are defined in the sales agreement.
Warranty claim is typically processed through the official ABB sales channel of the machine. A warranty claim must be
done always in a written form and a good warranty claim includes at least:
• the serial number of the machine
• location of the machine
• description of the problem as detailed as possible:
- pictures, measurement results or reports which help to analyse the problem
• customer expectations
• customer contat information.
Contact Information for technical support and warranties can be found in the next chapter. For more information,
please visit www.abb.com/motors&generators.
9.1.3 Contact information for Motors and Generators Service

Find your local service contact from www.abb.com/motors&generators
LIFE CYCLE SERVICES FOR MOTORS AND GENERATORS 109
Contact the Global Technical Support Center Finland by:

• Phone 7 am - 5 pm (GMT +2): +358(0)10 22 11
• 24-Hour Supprt Line: +358(0)10 22 21 999
• E-mail for sales: [email protected]
• E-mail for warranties and technical supprt: [email protected]
• Fax: +358(0)10 22 22544.
NOTE: If available, please add the serial number of the machine (seven digits, starting with
46#####) to your e-mail for reference information.
9.2 Spare parts for rotating electrical machines
9.2.1 General spare part considerations

The machines manufactured by ABB are designed and manufactured to provide reliable and trouble-free operation
for decades. This requires, however, that the machines are properly maintained and operated. This maintenance
includes changing of parts subjected to normal wear.
There is always an inevitable amount of uncertainty related to wearing. The wear rates of these parts vary greatly
according to application, environment and particular conditions. Therefore, the condition of these parts should
be inspected regularly and a sufficient amount of spare parts should be kept in stock. These spares help to
minimize down time if the need appears. The extent of the stock should be decided based upon the criticality of the
application, the availability of the particular spare part and the recommendation of the manufacturer.
9.2.2 Periodical part replacements

There is always mechanical wear when two moving surfaces are in contact with each other. In electrical machines
most of the mechanical wear occurs between the rotating shaft and stationary parts. The bearing parts such as
rolling bearings, bearing shells and oil rings in sleeve bearings will eventually wear out and need to be replaced, even
if correct lubrication is maintained. Other wearing parts include seals that are in constant contact with the rotating
shaft and brushes, brush gears and slip rings of the slip ring unit.
The parts mentioned above make an extensive, but not a complete, list of the mechanically wearing parts. These
parts have an estimated life span, but as mentioned earlier, their actual durability can vary significantly. For this
reason, at least these parts should be kept in stock. It should also be noted that the replacement of these parts, due
to normal wearing, is not covered by the warranty.
9.2.3 Need of spare parts

Other types of wear occur due to elevated temperatures, electrical disturbances and chemical reactions.
Air filters, which protect the machine interior from contamination, become themselves saturated with air impurities
and need to be replaced to ensure the correct operation of the cooling unit, and the continuous protection of
sensitive machine parts.
The electrical windings of the ABB machines have good protection against wear, but only if correct maintenance and
operating conditions are followed. The correct operating temperature must not be exceeded and the windings must
be cleaned from dirt regularly. The winding can also be subjected to accelerated wear due to a number of electrical
disturbances.
There are stator winding Pt-100 temperature detectors located inside the stator core slots, which cannot be
replaced. Therefore, the ABB practice is to add spare Pt-100 detectors in the stator core. These detectors are not
to be considered as regular spare parts because they are intended to be used as a replacement in case of a stator
Pt-100 element failure during commissioning. However, these elements can be taken into use also during operation
if the primary detector fails. If the spare element should fail, the possible corrective action is to add Pt-100 elements
into the stator winding end.
9.2.4 Selection of the most suitable spare part package

ABB provides three levels of ready-made spare part packages. The personnel best informed of the machine's
operational conditions should select the most suitable package based on criticality of the application and on the
financial risk related to the duration of downtime and loss of production.
Operational spare part package for commissioning and to ensure usability:
• These are the most essential spare parts that should always be available.
Recommended spare part package for trouble shooting and to ensure availability:
• These parts should be available during medium term maintenance. These parts also enable fast recovery in case
of failure in the accessories.
Capital spare parts to reduce repair time in case of serious damage:
• These spare parts are recommended when the machine is a part of an essential process. These spare parts
enable fast recovery even in case of a serious damage.
9.2.5 Typical recommended spare parts in different sets

Below is presented a general recommendation of the typical spare parts for different packages. To receive
a quotation for specific parts for a specific machine, please contact the ABB Motors and Generators Service
organization.
Please note that even though ABB has customized the spare part sets to match the machine, they might contain
references to accessories not found on all machines.
The following chapters for product family: AXR, HXR and NXR
9.2.5.1 Operational spare part package

Spare part Amount
Bearing RTD 1 pc
Alternatively for antifriction bearing machines:
Antifriction bearing 2 pcs
Alternatively for sleeve bearing machines:
Bearing shell for DE 1 pc
Bearing shell for NDE 1 pc
Bearing oil ring for DE 1 pc
Bearing oil ring for NDE 1 pc
Bearing labyrinth seals for 2 pcs
DE
NDE
9.2.5.2 Recommended spare part package

Spare part Amount
Operational spare part 1 pc
package
Space heater 1 pc
Stator Pt-100, retrofit kit 1 pc
Support or bushing 1 pc
insulators
9.2.5.3 Capital spare parts

Spare part Amount
Stator 1 pc
Rotor 1 pc
The following chapters for product family: AMA, AMB, AMI, NMH and NMI

Spare part Amount
Air filters (for IPW24/IC01 1 set
machine)
Water leakage detector (for 1 pc
IP55/IC81W machine)
Bearing RTD 1 pc
Alternatively for antifriction bearing machines:
Antifriction bearing 2 pcs
DE
NDE

Spare part Amount
Operational spare part 1 pc
package
Space heater 1 pc
Water cooler element and 1 pc
gaskets
insulators

Spare part Amount
Rotor 1 pc
Stator 1 pc
The following chapters for product family: AMK and NMK


Spare part Amount
Air filters (for IPW24/IC01 1 set
machine)
Air filter for slip ring carbon 1 pc
dust
Brushes 1 set
Brush holder 1 set
Water leakage detector (for 1 pc
IP55/IC81W machine)
Bearing RTD 1 pc
Alternatively for rolling bearing machines:
Rolling bearing 2 pcs
DE
NDE

Spare part Amount
Operational spare part 1pc
package
Space heater 1 pc
Space heater for slip ring 1 pc
unit
Slip ring unit 1 pc
Pressure switch for 1 pc
condition monitoring of
brush dust filter
Water cooler element 1 pc
insulators

Spare part Amount
Rotor 1 pc
Stator 1 pc
9.2.6 Order information

To ensure fast and correct spare part order and delivery, our After Sales personnel should be provided with the serial
number of the machine in question. The serial number can be found either on the rating plate fixed to the machine
frame, or stamped on the machine frame. In addition, provide specific and detailed information about the parts
ordered.
The contact information of ABB's Motors and Generators Service organization can be found in Chapter 9.1.3 Contact
information for Motors and Generators Service.
—
Chapter 10 Recycling
Recycling
10.1 Introduction
ABB is committed to its environmental policy. ABB continuously strives to make its products more environmentally
sound by applying results obtained in recyclability and life cycle analyses. Products, manufacturing processes and
even logistics have been designed to take environmental aspects into account. ABB's environmental management
system, certified to ISO 14001, is the tool for carrying out the environmental policy.
The following instructions should only be seen as recommendations for environmentally sound disposal of machines.
It is the customer's responsibility to ensure that local regulations are followed. Some customer-specific items may
not be included in this User’s Manual. Additional documentation will be found in the project documentation.
10.2 Average material content

The average material content used in the manufacturing of the electrical machine is as follows:
Cast iron frame induction Modular steel frame

machines induction machines
Steel 46 - 55 % 77 - 83 %
Copper 7 - 12 % 10 - 12 %
Cast iron 35 - 45 % 1-5%
Aluminium 0-2% 0-1%
Plastics, rubber, insulation 1 - 2 % 1-2%
materials etc.
Stainless steel less than 1 % less than 1 %
Other less than 1 % less than 1 %
10.3 Recycling of packaging material

Once the machine has arrived on site, the packaging material will need to be removed.
• Any wood packaging can be burned.
• For some countries, the packaging used for shipping by sea is made of impregnated wood that must be
recycled according to local regulations.
• Plastic material around the machine can be recycled.
• Any anti-corrosive agent covering the machine surface can be removed using a petrol based detergent and a
cleaning rag. The rag must be disposed of in accordance with local regulations.
10.4 Dismantling of the machine

Dismantling the machine is a basic procedure as it is assembled with bolts. However, due to the weight, it requires an
operator trained in handling heavy components to prevent dangerous situations.
10.5 Separation of different materials
10.5.1 Frame, bearing housing, covers and fan

These parts are made of structural steel, which can be recycled according to local instructions. All the auxiliary
equipment, cabling as well as bearings have to be removed before melting the material.
RECYCLING 115
10.5.2 Components with electrical insulation

The stator and the rotor are the main components, which include electrical insulation materials. There are, however,
auxiliary components which are constructed of similar materials and which are hence dealt with in the same manner.
This includes various insulators used in the terminal box, exciter, voltage and current transformers, power cables,
instrumentation wires, surge arrestors and capacitors. Some of these components are used only in synchronous
machines and some are used only in a very limited number of machines.
All these components are in an inert stage once the manufacturing of the machine has been completed. Some
components, in particular the stator and the rotor, contain a considerable amount of copper which can be separated
in a proper heat treatment process, where the organic binder materials of the electrical insulation are gasified. To
ensure a proper burning of the fumes, the oven shall include a suitable after burning unit. The following conditions
are recommended for the heat treatment and for the after burning to minimize the emissions from the process:
Heat treatment
Temperature: 380-420°C (716...788°F).
Duration: After obtaining 90% of the target temperature, the object shall stay a minimum of five hours at this
temperature.
After burning of the binder fumes
Temperature: 850-920°C (1562-1688°F).
Flow rate: The binder fumes shall stay a minimum of three seconds in the burning chamber.
NOTE: The emission consists mainly of O2-, CO-, CO2-, NOx-, CxHy-gases and microscopic particles.
It is on the user's responsibility to ensure that the process complies with the local
legislation.
NOTE: The heat treatment process and the maintenance of the heat treatment equipment
require special care in order to avoid any risk for fire hazards or explosions. Due to various
installations used for the purpose it is not possible for ABB to give detailed instructions
of the heat treatment process, or the maintenance of the heat treatment equipment and
these aspects must be taken care of by the customer.
10.5.3 Permanent magnets

If the permanent magnet synchronous machine is melted down as a whole, nothing needs to be done to the
permanent magnets.
If the machine is dismantled for more thorough recycling and if the rotor must be transported after it, it is
recommended that the permanent magnets are demagnetized. The demagnetization is done by heating the rotor in
the oven until the permanent magnets reach a temperature of +300 °C (572°F).
WARNING: Magnetic stray fields, caused by an open or disassembled permanent magnet synchronous
machine or by a separate rotor of such a machine, may disturb or damage other electrical
or electromagnetic equipment and components, such as cardiac pacemakers, credit cards
and equivalent.
10.5.4 Hazardous waste

The oil from the lubrication system is a hazardous waste and has to be handled according to local instructions.
10.5.5 Land fill waste

All insulation material can be handled as a land fill waste.
—
Appendix Commissioning report
Commissioning report
Rating plate information:

Serial no.
Manufacturer: ABB Oy
Address: P.O. Box 186 FIN-00381 HELSINKI FINLAND
Telephone: +358 (0) 10 22 11
Fax: +358 (0) 10 22 22544
Customer:
Customer address:
Contact person:
Telephone:
Mobile phone:
Fax:
Email:
COMMISSIONING REPORT 117
Transportation
General:
Arrival date of the machine:
Inspection date and location:
Signature of consignee:
Open box inspection: no yes, done by:
Damages:
Packing list: no yes, missing items:
Machine: no yes, what kind of:
Package: no yes, what kind of:
Accessories: no yes, what kind of:
Spare parts + tools: no yes, what kind of:
Actions taken in response to damages:
Photographed: no yes, date:
Reported to the transportation company: no yes, to whom: date:
Reported to the supplier: no yes, to whom: date:
Reported to the insurance company: no yes, to whom: date:
Method of transportation:
Railway Airfreight Truck Mail Shipped by M/S ___________ Other:
Comments:
Storage
General:
Storage: no yes, begin:_______________end:_____________________
Storage time longer than 6 months: no yes
Person responsible for storage:
Storage place:
indoors outdoors
in packing case protected by a waterproof cover

Daily temperamax._______ - _______ºC Humidity:_______%
Storage actions:
Transportation package is ventilated: no yes
External heating/fan is used: no yes, type:______________________________________
Machine space heaters are used: no yes, voltage:____________________________________
Bearings are flushed: no yes, oil type:____________________________________
Bearing shells are removed: no yes, date:______________________________________
Shaft end anti-corrosion protection no yes, type:______________________________________
checked:
Shaft end anti-corrosion protection no yes, date:______________________________________
renewed:
The rotor is turned 10 revolutions every no yes
two months:
There are vibrations in the storage place: no yes, __________mm/s, rms
There are corrosive gases in the air: no yes, what kind of:________________________________
Brushes are lifted up: no yes
Machine documents are saved and no yes, location:_____________________________________
protected for future use:
Comments:
Mechanical installation
Foundation is checked according to no yes, drawing number:_____________________________
machine drawing:
Possible foundation anchor bolts or no yes
sole plates are mounted according to
instructions:
Air gap is measured, if applicable: For D-end N-end Exciter N-end
pedestal bearings, mark values 1-4,
top top top
and for flanged bearings, values A-D 1
____________ A ____________ 2 ____________
B ____________ 3 ____________ C
____________ 4 ____________ D ____________
For alignment of the coupling, use either Radial alignment of coupling Angular alignment of coupling
values 1-4 or values A-D 1 ____________ 2
top top
____________ 3 ____________ 4 ____________
A ____________ B ____________ C
____________ D ____________
Axial position of the rotor: ET #1:__________mm, ET #2:__________mm

Axial distance between shaft ends: __________mm
Rotor support distance:
______mm ______mm
Crankshaft deflection is checked: no yes

Tapered guide pins are used to lock the no yes
position of the machine after alignment:
Foundations bolts are tightened with no yes, bolt size:_____________torque:_______________Nm
torque wrench:
Bolt lubrication: dry oil, MoS2
Cooling water: no yes, amount
3
m /s
Cooling element piping: flexible rigid
Transport locking device is removed: no yes
Rotor rotates without noise or scraping: no yes
Lubrication check
Self lubrication
Bearing oil: Manufacturer:__________________ Type:_________________________
The oil quality is the same as no yes
recommended:
Bearing oil is filled up to the indicated
level:
Please mark the level in the sight glass Sight Glass
circle on the right
Lubrication rings rotate freely: no yes
Flood lubrication
Bearing oil: Manufacturer:__________________ Type:_________________________
The oil quality is the same as no yes
recommended:
Lubrication rings rotate freely: no yes
Flood lubrication oil pressure: ___________kPa
Oil flow: ___________liters/min
Rotation of the pumps checked: no yes
Jack-up pumps checked: no yes, alarm setting:_____kPa, relief valve setting:______kPa
Oil filters checked: no yes
Grease lubricated bearings:

Grease: Manufacturer:__________________ Type:_________________________
The grease quality is the same as no yes
recommended on the bearing plate:
The first greasing has been done: Date:_______________ Quantity:________g
Comments:
Electrical installation
Network variation: no yes, voltage:______-______V, frequency:_____-______Hz
Space heater operation: no manual automatic, controlled by:_________________
Space heater for slip ring unit: no yes, voltage:_____________V, power:_______________W
Insulation resistance test

Stator winding (1 min., 1000 VDC): __________MΩ, tested by________ kV, winding temperature:______ºC
Stator winding (15 / 60 s. or 1 / 10 min.): PI =__________, tested by________ kV, winding temperature:______ºC
Rotor winding (1 min.): __________MΩ, tested by________ kV, winding temperature:______ºC
Exciter stator (1 min., 500 VDC): __________MΩ, tested by________ kV, winding temperature:______ºC
Space heater: __________MΩ (500 VDC)
Temperature detectors: __________MΩ (100 VDC)
N-end bearing insulation: __________MΩ (100 VDC)
Accessories resistance test

Stator 1 Pt 100: __________Ω
Stator 2 Pt 100: __________Ω
Stator 3 Pt 100: __________Ω
Stator 4 Pt 100: __________Ω
Stator 5 Pt 100: __________Ω
Stator 6 Pt 100: __________Ω
Bearing Pt 100 D-end: __________Ω

Bearing Pt 100 N-end: __________Ω
Air temperature 1 Pt 100: __________Ω

Air temperature 2 Pt 100: __________Ω
Anti-condensation heater: __________Ω
Testing of space heater for hazardous areas
The resistance test cannot be used to test the space heaters, because the heaters are based on self-limiting
thermistors. Instead, the testing of the heating performance is used.
Test requirements:
• Steady state condition (minimum of one hour in operation)

• Ambient temperature +20 °C to +25 °C
• Power supply: 230 VAC
• Measured current value should be min 0.1 A ... 0.9 A.
Machine protection settings

Overcurrent tripping: _______________A _________________ s
Instant overcurrent tripping: _______________A _________________ s
Overvoltage setting: no yes, setting:
Earth fault setting: no yes, setting:
Reverse power setting: no yes, setting:
Differential protection setting: no yes, setting:
Vibration monitoring: no yes, alarm:__________mm/s, trip:______________mm/s
Temperature monitoring: - in stator no yes, alarm:__________ºC, trip:______________ºC
winding
- in bearing no yes, alarm:__________ºC, trip:______________ºC
- in ______________________________ no yes, alarm:__________ºC, trip:______________ºC
Other protection units: no yes, type:

Test run
First start (a few seconds only)
NOTE: Check that possible flood lubrication is on!
Direction of rotation (viewed from D-end):

CW CCW
Are there abnormal noises? no yes, from:
Second start (uncoupled, if possible)
NOTE: Check that possible flood lubrication is on!
Are there abnormal noises? no yes, from:

Does the machine vibrate abnormally? no yes, where/how:
Bearing vibration level measured: D-end:__________ mm/s, rms; N-end:_________ mm/s, rms
Running: machine run OK operation stops, why:
Table 11 Checking schedule and information
Time Bearing temperature Bearing vibration Stator Stator winding

levels temperature
D-end N-end D-end N-end Current Power Excit. U V W
mm/s mm/s Factor Current
h:min ºC ºC rms rms A cos φ A ºC ºC ºC
0:00
0:05
0:10
0:15
0:20
Comments:
Observations:
Test run (with load)

Table 12 Checking schedule and information
Time Load Bearing temp. Bearing vibration Stator Stator winding

levels temperature
D-end N-end D-end mm/ N-end Current Power Excit. U V W
s mm/s Factor Current
h:min % ºC ºC rms rms A cos φ A ºC ºC ºC
0:00
Vibration spectrum attached: no yes

Acceleration time: __________ s.
Cooling air temperature: Inlet: __________ ºC Outlet:__________ ºC
Cooling water temperature: Inlet: __________ ºC Outlet:__________ ºC
Comments:
Machine approval
Machine approved for use Date:
Commissioning done by:
Approved by:
Fax cover sheet

Date:
To: ABB Oy Telefax: +358 (0) 10 22 22544
From:
Fax number:
Phone number:
Email:
Number of pages: 1 + 9 + _________
Message:
TYPICAL POSITION OF PLATES 127
—
Appendix Typical position of plates
Typical position of plates
A HXR Horizontally mounted

B HXR Vertically mounted
1 Rating plate of the machine
2 Bearing plate of the machine
3 Marking plate for direction of rotation
4 View A
Machine ends
5 D-end = drive end
6 N-end = non-drive end

Direction of rotation seen from the drive end towards the machine
7 Clockwise
8 Counter-clockwise
9 Reversing
TYPICAL MAIN POWER CABLE CONNECTIONS 129
—
Appendix Typical main power cable connections
Typical main power cable connections
Connection screw M12

1. Screw: M12-steel
2. Hexagon nut: M12-steel.
Tightening torque 55 Nm.
Connection screw
1. Screw: M16-bronze
2. Hexagon nut: M16-brass.
Tightening torque 40 Nm.
Round-terminal: DIN 46223

1. Screw: M10-steel.
Tightened until a reliable connection is obtained.
Earthing screw M12

1. Screw: M12 - AISI 316
2. Hexagon nut: M12-AISI 316.
Tightening torque 55 Nm. Do not tighten with machine.
It is recommended to use grease with spring locked nuts.
—
ABB Oy
Motors and Generators
P.O. Box 186
00381 Helsinki, Finland
Phone: +358 (0)10 2211
Fax: +358 (0)10 22 22220
www.abb.com/motors&generators
3BFP 000 050 R0101 REV L
Original instructions.
Unauthorized translations forbidden.
Copyright 2020 ABB.
All rights reserved.

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Motors and Generators

Manual for induction motors and generators

7. Maintenance and servicing

Additional safety instructions for permanent magnet synchronous

Electrical connection and operation

WARNING: Beware of reverse-power when working at the supply system.

Maintenance and servicing

Additional safety instructions for electrical motors for explosive

Non-sparking Ex nA, Class I Div 2, Class I Zone 2, and increased safety Ex ec

• AMA induction machines, sizes 315 to 500

• AMA induction machines, sizes 315 to 500

Flame proof Ex db, Ex db eb

• AMD induction machines, sizes 355 to 500.

• AMA induction machines, sizes 315 to 500

• AMA induction machines, sizes 315 to 500

Conformity with standards

Standards concerning general requirements for explosive atmospheres:

Std. concerning Ex db protection:

Std. concerning Ex p protection:

Std. concerning Ex e protection:

Std. concerning Ex nA protection:

Std. concerning combustible dust protection:

National Electric Code (NEC):

Canadian Electrical Code, Part II (CE Code):

ABB machines can be installed in areas corresponding to the following markings:

Zone (IEC) Category (EN) Marking

G - explosive atmospheres caused by gases

D - explosive atmospheres caused by dust.

Note the following rules during any operation!

Starting and re-starting

Earthing and equipotentialing

Clearances, creepage distances and separations

Connections in terminal boxes

Motors in Gas Group IIC or Dust Group III

Flame paths (AMD machines)

Chapter 2 Transport and unpacking..................................................................................................................................... 18

Chapter 3 Installation and alignment................................................................................................................................... 30

3.3 Machine preparations before installation................................................................................................................. 31

Chapter 4 Mechanical and electrical connections.............................................................................................................. 46

Chapter 5 Commissioning and start-up...............................................................................................................................55

5.7.6 Heat exchangers...........................................................................................................................................61

Chapter 8 Trouble shooting................................................................................................................................................... 92

Chapter 9 Life cycle services for motors and generators...............................................................................................108

Chapter 10 Recycling............................................................................................................................................................. 114

Commissioning report.......................................................................................................................................................... 116

Typical position of plates.....................................................................................................................................................127

Typical main power cable connections.............................................................................................................................. 129

1.1 General information

1.2 Important note

1.3 Limitation of liability

1.4.1 Documentation of the machine

1.4.2 Information not included in documentation

1.4.3 Units used in this User’s Manual

1.5 Identification of the machine

1.5.1 Serial number of the machine

1.5.2 Rating plate

2.1 Protective measures prior to transport

Following bullet for bearing type: Rolling bearing