Use and Maintenance ManualforThree-phase Synchronous Motor Dalian Yulin Electric Motor Co., Ltd.1. OverviewThis manual provides the instructions and guidance on the receipt, storage, installation, operation and maintenance of a synchronous motor.Only when the installation, operation and maintenance are performed in strict accordance with the requirements of the manual, can the long-term, safe and reliable use of the motor can be ensured.1.1Main components of motorThe main components of the motor are: stator, rotor, rolling bearing, end cap, terminal box, chassis, slip ring, etc.1.2Meaning of sign code1.2.1 Ingress protectionDepending on installation location and use conditions, the types of protection for the motor enclosure include IP23 and IP44.1.2.2 Cooling methodThe sign of cooling method consists of characterization letters "IC" and the subsequent characterization numbers and letters. This series is IC01, self-cooling open-type, with a fan mounted on the shaft.1.3 Terminal of stator and rotor1.3.1 The wire terminals of three-phase winding of synchronous motor stator use U, V, W and N as the signs and use N as the ground terminal.1.3.2 The initial and final terminals of winding of synchronous motor rotor (magnetic field) use F1 and F2 as the signs.1.4 Rotation directionThe rotation direction of synchronous motor is clockwise looking from the drive end.2. Installation2.1 Packing and deliveryThe packing for the motor shall adopt unit packing. For this reason, the user should refer to the outline drawing to determine the content receiving, verify that the receipt is complete, and inspect that the box has signs of damage.If the box is indeed defective or damaged, please notify the manufacturer’s business sector in severe cases. Preferably in the presence of representatives of the transport sector, open the damaged box for check. If the motor body is found to have damage, the necessary testing and repair should be conducted according to the damage degree prior to installation. Meanwhile, the motor nameplate must be stated with the relevant data, including model, power, voltage, speed, production number and date of manufacture and so on.2.2 Lifting and handling2.2.1 The slings must be used, so that the motor can be lifted via lifting bar, lifting hole or boom.2.2.2 When the entire motor is lifted, the weight distribution must be appropriate.2.3 Storage informationThe motor should be stored in a clean and dry place and be covered. If the place is kept cold, wet or humidity-variable, and the temperature of the motor winding should be several degrees higher than the ambient temperature, in order to avoid dew condensation or damping. During long-term storage, the electric heater on the motor can be electrified to get rid of moisture insidethe motor.Preferably, the insulation resistance shall be measured once every month to test the protective effect of storage. When there are significant changes in insulation resistance, indicating the cause is damping. Now, you should consider improving the storage conditions.2.4 Preparation before installation2.4.1 UnboxingRemove all packaging, clean away anti-rust oil and dirt with petroleum solvent, and comply with necessary safety precautions.2.4.2At the installation site, check all the items in the packing list of the motor. If you receivethe parts and components are missing or the equipment is damaged, you should immediately notify the manufacturer.2.4.3On the base frame, the location marker shall be determined to identify the center line andof the unit and the elevation of the base surface.2.4.4According to the outline drawing, the foundation shall be verified to determine that the pit,ventilation pipes, cables and tubing position is correct, and there is enough space for the installation of the unit and its accessories.2.4.5According to the outline drawing, the size and location of foundation bolt hole, and theelevation on the top of bolt.2.5Selection of installation locationWhile deciding where to install the motor, you should consider the following factors:2.5.1 Environmental conditions for the installation of the motor:a. Altitude of not more than 1000m;b. Ambient air temperature of not exceeding 40 ℃;c. The monthly average maximum relative humidity of ambient air in the wettest month is 90%, while the monthly average minimum temperature is not higher than 25 ℃.In case of failure to meet the above three requirements, special orders shall be needed, which will be indicated in special technical conditions.2.5.2 The motor shall be installed in a well ventilated place, and the air inlet and outlet on the motor shall be kept in appropriate positions, in order to prevent the exhaust hot air from entering the air inlet, resulting in repeated cycles, or prevent the hot air exhausted from a motor from directly entering another motor.2.5.3 There should be sufficient space around the motor to disassemble, clean, or check the motor.2.6 Foundation2.6.1 The foundation must be rigid, and the resulting vibration shall be reduced.2.6.2 The motor foot (or chassis side) must be placed on the base plate. The top surface of the base plate shall be a horizontal plane, and its elevation shall be slightly lower than the maximum size of the distance from the motor shaft centerline to the foot (or chassis side).2.7 GroutingThe clean sand and cement shall be mixed at the mixing ratio of 1: 1, and be mixed with water into slurry; the slurry shall be thin enough to fully fill the underside of the chassis or the base plate. The entire operation process of slurry mixing and pouring shall be as fast as possible without interruption. The slurry shall fill all the structural space of the chassis or the base, and be perfused to flush with the top surface of the chassis or the base plate.2.8 Adjustment of mounting surface2.8.1 The adjustment shims shall be made of the thin steel plates with different thicknesses, the width and length shall be slightly greater than the foot size (those with the chassis are not subject to this limit), and a gap or hole shall be provided to get out of the foundation bolts.2.8.2 After the adjustment in the direction of height, plugging shall be performed using the shims with the thickness used for measurement.2.8.3Upon the final alignment of axis, the shims shall adopt a small quantity of thick shims, instead of a large quantity of thin shims. In general, multiple shims with the thickness of 1.5mm and above shall be replaced by the single shim with the equal thickness. After the final alignment the center, the positioning pin hole shall be drilled and shorn, and then be installed with the positioning pins.2.8.4 In case the drive end of the motor needs to be installed with coupling, hammering shall be prohibited, in order to prevent the shaft from withstanding the impact.3. Operation Instructions3.1 Preparation before operation3.1.1 Inspect that the voltage, frequency, phase, etc on the motor nameplate are consistent with the parameters of power supply.3.1.2 Measure the insulation resistance of motor winding. For the minimum allowable value, see4.4.1. If necessary, dry it.3.1.3Inspect that the stator (armature) lead and power line signs of the motor to determine whether the motor rotation direction meet the requirements.3.1.4Inspect that the connections of motor control, protection and monitoring devices are in compliance with the specifications and the corresponding drawings.3.1.5 Inspection of slip ring and carbon brushThe carbon brush shall be able to move freely up and down in the carbon brush box, and the carbon brush shall maintain a certain pressure.3.1.6 Inspect for any foreign objects left in the motor, and use appropriate hand tools to move the rotor disk, and inspect for rubbing sound.3.2 Commissioning of motor3.2.1 It is recommended that the commissioning of synchronous motor should be conducted in the case of failure to butt the supporting machine.3.2.2 Verification of rotation directionFor the synchronous motor, inspect the correctness of the rotation direction in the way of post-electrification inching (press start control button, then immediately press the shutdown control button).3.2.3 Rotate the motor again to timely inspect the temperature of the bearing.3.2.4 For the allowable temperature of the bearing, see4.1.2.3.4 Startup and shutdown of synchronous motor3.4.1 For the salient-pole synchronous motor with slip ring, start-up resistance shall be connected in series within the loop of rotor (magnetic field) winding upon start-up, and start-up resistor element resistance, current and other parameters shall be consistent with the electrical documents.3.4.2 Start-up duty of synchronous motor3.4.3.1 When the initial state of the motor is the ambient temperature, the second consecutive start shall be allowed.3.4.3.2 When the initial state of the motor is rated operating temperature, only once start shall be allowed.3.4.3.3Only after an interval of 1-3 hours, can re-start-up be conducted according to Section 3.4.3.1 and Section 3.4.3.2.The start-up time interval stated in this section depends on the heat capacity and cooling conditions of start winding. In principle, the start-up winding shall be cooled to ambient temperature before re-start-up.3.4.4 Start-up mode of synchronous motor3.4.4.1 Direct start-up, i.e. the terminal of stator (armature) winding is connected directly to the power supply.3.4.4.2 Undervoltage start-up, i.e. during start-up, the terminal of stator (armature) winding is connected to the power supply via the reactor (or auto-transformer, heat rheostat). The start-up voltage upon undervoltage start-up shall be determined based on the motor parameters, in order to avoid the motor damage caused by overheating during start-up.3.4.5 Start-up of synchronous motor after electrification, i.e. after the motor is synchronized, the excitation current shall be adjusted to meet the need of the load.3.4.6 Shutdown of synchronous motor3.4.6.1 Turn-on of motor power switch.3.4.6.2 Input of start-up resistance, this will play the role of resistance de-excitation.3.4.6.3 Stop of auxiliary equipment (fuel pumps, water pumps, blowers, etc.).4 Maintenance and repairThrough regular periodic inspection, you can discover defects, in order to eliminate hidden dangers and prevent the occurrence of faults, and improve operational reliability.4.1 Temperature rise limit and allowable temperature of motor4.1.1 For the temperature rise limits of motor, see Table 6.4.1.2 Allowable temperature of motor bearing:Rolling bearing (at the ambient temperature of not exceeding 40 ℃) is 95 ℃.4.2 Monitoring for temperature of motor4.2.1 For the monitoring setting values (initial value) of Class B insulation and Class F insulation4.2.2 If the operating temperature values are known, then:Alarm value = operating temperature +5 ℃ Tripping value = operating temperature +10 ℃4.2.3 Normal operating temperature often changes with the ambient temperature; the setting value shall be adjusted according to the ambient temperatures in different seasons. 4.3 Vibration limits of motora. At the rated speed of 600r/min and above, the vibration limit of motor shall be 2.8mm / s; b At the rated speed of 600r/min below, the double-amplitude limit of motor shall be 0.075mm.4.4 Insulation resistance of motor4.4.1 Minimum allowable values of winding insulation resistance:a. At the ambient air temperature: 1MΩ/kV;b. In the hot state (under operating conditions):=1000+100UR PWhere: R- insulation resistance of motor winding, MΩ; U- rated voltage of motor winding, V;P - rated power of motor, kW; rated power of generator, kV A.4.4.2 At the ambient air temperature, the minimum allowable value of insulation resistance of embedded temperature detectors : 1MΩ4.4.3 At the ambient air temperature, the minimum allowable value of insulation resistance of insulation bearing:a. Newly installed motor: 1MΩ;b. After r egular overhaul: 0.3MΩ. 4.5 Drying of motorIf the insulation resistance value of motor winding is less than the minimum allowable value, heating and drying shall be performed to remove moisture.4.6 Maintenance and repair of stator (armature) winding and the rotor (magnetic field) windingIn order to fully examine and clean the motor, the rotor must be pulled from the stator.According to the degree and condition of accumulation of dust on the winding, you can clean the motor with the following method. 4.6.1 Wipe-dryWhen the surface that needs to be cleaned is just covered with dust, use a clean lint-free cloth to wipe it dry, but you can not use a waste cloth.4.6.2 BlowingSome gaps inside the motor, which are difficult to reach shall be blown with clean and dry compressed air (pressure less than 0.2MPa), in such a direction that the dust can not be brought deeper into the motor.4.6.3Solvent cleaning methodFor the removal of fat, dirt, wax, oil, etc from the winding, solvent cleaning method is particularly effective. A cloth moistened with mild detergent solution shall be used to wipe the surface, and then it shall be wiped with a dry cloth.4.7 Maintenance and repair of bearing4.7.1 Maintenance and repair of rolling bearingRolling bearing is the standard replaceable part.The grease grade used for rolling bearing shall comply with the standard requirements. The grease has a finite life, and under the influence of mechanical stress and chemical aging, it has gradually lost its lubricating properties. Therefore, it needs to be regularly replaced.For the allowable temperature of rolling bearing, see 4.1.2, so that the grease can achieve the expected normal life.4.7.2Replacement of lubricantGenerally, 50g lubricant shall be injected once a month, and complete replacement shall be conducted once a year. However, this depends largely on the running time, operating temperature and the degree of oil contamination. In case of severe turbidity or sudden rise in temperature without external influence, the lubricant shall be replaced.4.8Maintenance and repair of slip ring ring and carbon brush4.8.1 The surface of slip ring shall be kept smooth and cylindrical. After a period of running, slip ring contact surface will form a layer of oxide film containing graphite, and the surface film may be in color between light gray and black, depending on carbon brush grades, current density, air temperature and humidity.When the surface of slip ring is not smooth, but is covered with rust and burn marks, the fine sand paper can be used for grinding.4.8.2To make two rings be worn uniformly, their polarities need to be replaced once to twice within one year.4.8.3 During the running of motor, it is normal that the carbon brush wear is less than 6mm/1000 hours. When the carbon brush is worn too much, you should also get a new carbon brush. The grade of the new carbon brush must be the same as that of the original carbon brush. The contact surface between the new carbon brush and the slip ring shall be machined into the arc that is the same as the radius of slip ring, in order to ensure the good contact between the carbon brush and the slip ring.4.8.4On the insulation between the slip ring and the carbon brush holder, the extent of accumulation of dust shall be regularly checked and the dust shall be cleared away, preferably by removing the toner with a vacuum cleaner, and blowing with compressed air, and finally wiping with a clean dry cloth.4.9 Routine inspection of motor during running4.9.1 Measure the stator (armature) winding temperature, bearing temperature, inlet and outlet airtemperature, analyze the records, and inspect that there is abnormal situation.4.9.2 Inspect that the motor has unusual mechanical noise or the changing sound (such as friction or percussion sound, etc.).4.9.3Vibration measurement, the measuring point can be selected in the middle of the bearing chamber.4.9.4Inspection of lubrication system, including the oil level of bearing, the rotation state and oil-bring extent of slip ring, any oil spills and discoloring of lubricant, etc.4.10 Regular shutdown maintenance period of motorThe regular shutdown maintenance period of motor shall be based on site conditions and type of the motor structure, typically be in accordance with the following deadlines:a.Motor overhaul: once a year;b.Motor repair: 2-4 times per year.5 Motor failure analysis5.1 Possible failure of synchronous motor5.1.1 During start-up, due to the too low supply voltage, the motor can not rotate.The decrease rate of the motor start-up torque is proportional to the square of the voltage drop. If the decreased start-up torque is less than the load resistance torque, the motor will not rotate.5.1.2During start-up, the motor has magnetic noise, but the rotor does not rotate, with obviousvibration.This may be because the motor is started after being supplied with the excitation current. Now, the excitation status of the excitation device shall be inspected.5.1.3 During start-up, the motor gives normal magnetic noise, but the rotor does not rotate.This may be because the load torque is too large, or the increase in load is more than the motor start-up torque due to a failure of dragged machine.5.1.4 During start-up, the junction of damping ring sparks.Usually, the connecting bolts are not tightened, or the junction of damping ring has bad contact.5.1.5 The motor fails to be frequently started in accordance with the requirements of Section 3.4.3, so overheating is caused to the start-up winding, resulting in unsoldering or breaking of damping bar.5.1.6 During start-up, due to the low supply voltage and insufficient torque, the speed can not be increased to 95-97% of rated speed, resulting in non-pull-in synchronization.5.1.7 The setting range of excitation part of excitation device can also cause non-pull-in synchronization.5.1.8 Slip ring flash or singeing, mainly due to:5.1.9 The cylindrical coaxiality of slip ring is not good, or the surface of slip ring is rough.5.1.10 The grade of the carbon brush is inappropriate, or the pressure on the carbon brush is too small, which hinders the carbon brush from sliding because of being tightly packed in the carbon brush box.。