INSTRUCTIONS

FOR INSTALLATION, COMMISSIONING,

OPERATION & MAINTENANCE

CGL LAM YOKE D.C. MOTORS - 315, 355, 400, 450, 500, 560 & 630 FRAMES MADE BY CGL
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Contents

1.0 Safety Advice 02

2.0 Introduction 03
• 2.1 Description of equipment 03
• 2.2 Standards 03
• 2.3 Scope of supply 03
• 2.4 Constructional details 03/04
3.0 Receiving, Handling & Storage 05
• 3.1 Visual examination on receipt 05
• 3.2 Handling 05
• 3.3 Storage 05
4.0 Installation & Commissioning 05
• 4.1 Precautions 05
• 4.2 Mechanical checks 05
• 4.3 Electrical checks 06
5.0 Operation 06
• 5.1 Before putting machine into service 06
• 5.2 Inspection after short time into service 06
6.0 Exploded View and Layout 07
• 6.1 Exploded view of IDDC motor 07
• 6.2 Layout of 315 frame 08
• 6.3 Layout of 500 frame 09
• 6.4 Layout of 630 frame 10
7.0 Maintenance 11
• 7.1 Routine checks & maintenance 11
• 7.2 Productive maintenance 11/12
• 7.3 Repairs & overhaul 13
• 7.4 Disassembly 13/14
• 7.5 Reassembly 14/15
• 7.6 Commutator and brush maintenance 16
• 7.7 Drying out of windings 16
• 7.8 Bedding of carbon brushes 17
• 7.9 Bearing maintenance 17
• 7.10 Blower/heat exchanger maintenance 17
• 7.11 Troubleshooting chart 18
8.0 List of Spares 19
9.0 Torque Tables (for Bolts) 19
10.0 Annexure 20
• A Alignment procedure 20
• B Interpole polarity with respect to armature 21
• C Brush axis setting in Neutral position 22
• D Bedding of brushes 22/23
• E Preparation of foundation 23/24
• F Terminal marking and direction of rotation 25
11.0 Environmental Guidelines 26

1
 1.0 Safety Advice

The information contained in this manual is intended to cover briefly the instructions for
• Installation
• Commissioning
• Operation and maintenance

By carefully adhering to these instructions long, safe and satisfactory service can be obtained from the
equipment. The instruction do not purport to provide all details for every possible contingency or hazards to
be met in connection with Installation, commissioning, operation and maintenance .

In case any further information is required, the user is advised to refer the matter to D.C. MACHINE GROUP,
M - 7 Division of Crompton Greaves Limited.
D - 5, Industrial area , Mandideep, Bhopal - 462046.
Use of rotating electrical machine can be hazardous as they are concentrated power and the installation,
commissioning, operation & maintenance of the same to be done by qualified personnel aware of safe and
sound industrial practices.

2
 2.0 Introduction

2.1 Description of Equipment

Crompton Greaves LTD, M-7 Division offer laminated yoke DC motors in IEC frames 315, 355, 400, 450, 500,
560 & 630. These motors find application in cement, sugar, steel rolling and other industries with
appropriate enclosures & cooling types.
Standard features are
• Shunt compensated version.
• Horizontal foot mounted type invariably. However vertical mounting also is given in 315, 355 & 400 frames.
• Standard enclosure & cooling types are
IP23,IC06 (motor mounted blower type)
IP54/55 IC0666 (air to air heat exchanger type)
IP54/55 ICW 37A86. (air to water heat exchanger type)
• Standard accessories: PT 100 type temperature detectors for stator windings and bearings.
• Class F insulation.
• Suitable for operating on 3 phase 6 pulse thyristor convertor supply.
• Generally with single cylindrical shaft extn for load transmission and other end suitable for mounting tacho
generator.
• Armature voltages upto 800V & field voltages upto 500V.
• Seperate terminal boxes for main supply terminals & control leads like RTD, BTD etc.

2.2 Applicable Standards

The performance of these m/cs generally comply with IEC 60034-1, BS 5000-PT99, DIN VDE 0530Pt-1,
IS 4722.Shaft extension and centre heights are in line with IEC 60072.

2.3 Normal Scope Of Supply

• Motor mounted Blower or heat exchangers (CACA/CACW) form part of the supply along with main motor.
• 6 Nos. PT100 winding RTDs & 2 Nos. BTDs are part of the supply along with motor. All other accessories are
on request.

2.4 Constructional Details

Stator
Stator stack is made of 1.5 thk CRCA, segmental laminations firmly stacked in between pressure plates.

Pole Bricks
Main pole & Interpole Stampings are made of 1.5 thk CRCA laminations & stacked firmly with studs and nuts.

Stator Windings
Shunt fields coils are made of 210°c class enamel round copper moulded with class ‘F’ epoxy resin system
for excellent consolidation and heat transfer. Interpole and compensating coils are former wound with
210°c class dual coated enamelled rectangular copper sections. Pole bricks with pole coils are bolted to
stator frame & wound stator is flood impregnated in class ‘H’ solventless polyster resin followed by another
cycle in class ‘H’ polyester varnish.

3
 Rotor
• Shaft material is of high tensile strength forging and section is designed to meet the maximum overloads that
occur in service.
• Armature stampings are of 0.5mm thick, low loss silicon grade and the slots are punched in a unique fashion in
a CNC notching press to achieve parallel skew of 7 slots for reduced noise level and torque pulsations at low
speeds.
• Armature core is held between pressure plates.
• The Commutator is of a non conventional construction. The copper mica segments are held by insulated press
rings for better electrical performance and mechanical rigidity.
• The equaliser winding basket is made of thick 210°c class dual coated round enamelled copper wire on a drum
fixture in a unique way and mounted below the armature overhang on commutator end.
• All the commutator/equaliser connections are by electric resistance brazing for best reliability & conductivity.
• Armature overhangs are banded with class ‘H’ resiglass adequately for winding to withstand centrifugal forces
at max speeds.
• Wound armature is VPI impregnated in class H solventless polyester resin for best consolidation & thermal
conductivity.
• Finally the armature is balanced to high precision.

Brush Gear Assembly

• The brush holders are of constant force type with tensator springs which gives constant pressure on brushes
through out their life.
• The brushes are of electro graphite grade and split version with elastic dampers on top to absorb vibrations and
keep better brush contact with commutator.
• The brush rocker is located on commutator end endshield and can be rotated to adjust the brush position in
neutral axis.

Bearings
• Bearing housing is integral with endshields in 315, 355 & 400 frames and cartridge type in 450, 500, 560 & 630
frames.

? Terminal Box
• Main Terminal box is ample sized to receive the required cross section aluminium cables for supply.
Terminal box can be given on LHS or RHS as per customer choice. An auxiliary terminal box is given on
opposite side of main terminal box for terminating the control leads like winding RTDs & BTDs.

4
3.0 Receiving, Handling & Storage

3.1 Visual Examination on Receipt

On receipt of equipment, it should be carefully examined as per packing list for any visual damage to the
equipment. In case of any discrepancy /damage, inform transporter and CROMPTON GREAVES LTD.,
M7 Division, Mandideep, Bhopal immediately.

3.2 Handling
Lifting hooks are provided on the machine which are designed for safe lifting of equipment, therefore only
these lifting hooks are to be used for lifting purpose. In case of blower or heat exchanger mounted on
machine, care is to be taken by using spreader bars with the chains, so that they are not damaged during
lifting. Machines shall not be dragged or rolled for transporting purpose. Shaft extension should be handled
with care and should be used only for power transmission.

3.3 Storage
If the motor is to be stored for long time before installation, precaution should be taken to prevent any
deterioration. Motors must be stored in a clean, dry atmosphere and must not be subjected to extreme
conditions of temperature and /or humidity. Motors are to be stored away from corrosive or chemically
damaging fumes. Motors should not be in position where they could be subjected to vibrations which may
cause brinelling or fretting corrosion causing noise and pre-mature failure of bearings in service. If motors
are stored for one year or more, grease may cake. In such case caked grease is to be flushed out and fresh
similar grease should be applied .

4.0 Installation & Commissioning

4.1 Precautions
Installation shall be done as per the national electricity rules by trained & skilled personnel. Disconnect
power supply before touching any live parts. Guards shall be provided for couplings, belts and chains to
avoid accidental contact with moving parts. Machines shall be installed where they are accessible for
inspection & maintenance. Ventilation openings shall not be obstructed in any manner that limit the free
passage of air. Windings, commutator, brush-gear & bearings shall be properly protected during installation
from any damage, paint spray, weld spatter and metal chips etc.

4.2 Mechanical Checks During Installation

• It is to be ensured, no foreign materials are present inside the machine. All rotating parts shall have enough
clearance from any stationary parts. Bearing lubricant should be changed, if the machine is stored for one
year or more, make sure bearing grease plugs are fitted and tight.
• As far as possible, parts like blowers & heat exchangers shall be fitted after the main motor is installed.
• Ensure all fasteners are tight like foundation- bolts, coupling bolts and hardware of the machine.
• In case of water cooled heat exchangers check for rate of flow of water, pressure & PH values specified.

5
 5.0 Operation & Maintenance

4.3 Electrical Checks During Installation

• All windings to be checked for insulation resistance, if the same is found to be less than 5 megaohms,
improving the same shall be done by drying out the windings by methods as given in maintenance
instructions separately.
• Brushes must have at least 85% contact with commutator surface. If not so, give an initial bedding to
brushes as per the procedure separately given in maintenance instructions.
• Commutator shall be free from any grease, oil and dirt.
• Commutator mica separators to be undercut.
2
• In case of adjustable spring pressure brush holders, adjust the spring pressure to 200-220 grams/cm
• Brushes should slide freely in brush holders.
• Brush pigtail connections to be tight and should not interfere with the action of spring and should not touch
any other parts.
• All terminal connections & polarities to be checked as per connection diagram.
• Check the continuity of space heaters, resistance of RTD’s/BTD’s in windings for healthiness.
• Check the blower/heat exchanger for direction of rotation as per the arrow fixed. Check fan motor currents to
be within name plate value.

5.0 Operation
5.1 Before Machine Putting into Service
• Give the shunt field supply first.
• Give the armature voltage supply gradually and observe the direction of rotation is as per connection
diagram .
• Observe any alignment problem, loose bolts etc.
• Observe any abnormal vibration, noise from the machine.
• Hear the bearings with a screwdriver or a rod.
• Observe any localized heating of windings, bearing overheating
• If no problem, increase machine speed to full speed on no load . If no problem, increase the load from no load
to full load over a period of 4 to 5 hours, so that the brushes get proper fit. Check for satisfactory
commutation.
• While shutting down, reduce the load to zero and reduce the armature voltage gradually and finally switch off
armature voltage first and shunt field voltage next and shutoff.

5.2 Inspection after Short time in Service

After the machine has been operating for short time in service, check for the following
• Vibration level and alignment
• Tightness of bolts
• Any rubbing of parts, loose connections
• Any worsening of commutation
• Brush holders correct position
• Commutator & brush surface conditions

6
 18
Exploded View of IDDC Motor 17
16
13 15
12 14
11
10
19
9 20
8 22 21
22
7
6.0 Exploded View

6
5
4
3
2
1
24

25

33 32 31 30 29 28 27
Assembled View
26
34

1 Tacho bracket 11 Yoke 21 End cover NCE 31 Brush holder

2 Lovjoy coupling 12 Foot plate NCE 22 Bearing NCE 32 Brush spindle
3 Outer bearing cover CE 13 Top cover plate NCE 23 Inner bearing cover 33 Clamping plate
4 Bearing cartridge CE 14 Commutator assembly 24 Cover plate 34 Bearing CE
5 End cover CE 15 Armature stamping 25 Terminal box
6 Inner bearing cover 16 Armature coil 26 Terminal box cover
7 Brush rocker 17 Armature shaft 27 Polycorbonate cover plate
Layout Of Iddc Motors

8 Cover plate 18 Shaft key 28 Foot plate CE

9 Foot plate CE 19 Outer bearing cover CE 29 Compensating coil
10 Top cover plate 20 Bearing cartridge NCE 30 End plate

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8
Layout of 315 Frame

1 Shaft 9 Main pole winding 17 Pressure ring 25 Outer bearing cover (CE)
2 Shaft extension key 10 Compensating winding 18 Interpole winding 26 Bearing (CE) (Ball)
3 Outer bearing cover (NCE) 11 Stator end plate (NCE) 19 Equaliser assembly 27 Grease filnger (CE)
4 Bearing (NCE) (Roller) 12 Stator stack machining 20 Stator end plate (CE) 28 Tacho mounting assembly
5 Grease flinger (NCE) 13 Armature core 21 Commutator assembly 29 Winding support (NCE)
6 Inner bearing cover (CE) 14 Main pole brick 22 Brush gear assembly
7 Balancing disc 15 Core key 23 End shield (CE)
8 End shield (NCE) 16 Armature winding 24 Inner bearing cover (CE)
 Layout of 500 Frame

1 Shaft 9 rmature winding 17 Pressure ring (NCE) 25 Outer bearing cover (CE)
2 Shaft extension key 10 Main pole winding 18 Interpole winding 26 Bearing (CE) (Roller)
3 Outer bearing cover (NCE) 11 Compensating winding 19 Equaliser assembly 27 Bearing (CE) (Ball)
4 Bearing (NCE) 12 Stator end plate (NCE) 20 Stator end plate (CE) 28 Grease flinger (CE)
5 Grease flinger (NCE) 13 Stator stack machining 21 Commutator assembly 29 Bearing cartridge (CE)
6 Inner bearing cover (CE) 14 Armature core 22 Brush gear assembly 30 Balancing ring
7 Bearing cartridge (NCE) 15 Main pole brick 23 End cover (CE) 31 Pressure ring (CE)
8 End shield (NCE) 16 Core key 24 Inner bearing cover (CE) 32 Force cooling unit

9
10
Layout of 630 Frame

1 Shaft 9 Armature winding 17 Pressure ring (NCE) 25 outer bearing cover (CE)
2 Shaft extension key 10 Main pole winding 18 Interpole winding 26 Bearing (CE) (Roller)
3 Outer bearing cover (NCE) 11 Compensating winding 19 Equaliser assembly 27 Bearing (CE) (Ball)
4 Bearing (NCE) 12 Stator end plate (NCE) 20 Stator end plate (CE) 28 Grease flinger (CE)
5 Grease flinger (NCE) 13 Stator stack machining 21 Commutator assembly 29 Bearing cartridge (CE)
6 Inner bearing cover (CE) 14 Armature core 22 Brush gear assembly 30 Balancing ring
7 Bearing cartridge (NCE) 15 Main pole brick 23 End cover (CE) 31 Pressure ring (CE)
8 End shield (NCE) 16 Core key 24 Inner bearing cover (CE)
 7.0 Maintenance

7.1 Routine Checks and Maintenance

The interior and exterior of the motor should be kept clean and dry. Dust, oil and moisture should never be
allowed to accumulate. All nuts and bolts and fasteners should be tight and secure. Prior to carrying out
maintenance on brushes, brushgears or commutator, the machine should be electrically disconnected.
Remove the brush springs completely from brush holders. The brushes can now be removed from the brush
holders. The brushes have to be replaced by new brushes of same grade when they wear out to the mark on
them. After fitting the new brushes it is necessary to ‘bed’ or ‘reset’ them to obtain necessary brush to
commutator contact. After fitting brushes of same or equivalent grade as used make sure that brushes slide
freely in brush holders. Bed the carbon brushes as per procedure given in section 5.8. Finally clean carbon dust
from commutator, brushes and brush holders by compressed air or by hand blower. Under healthy condition
of commutation, the commutator surface will develop a light /dark brown patina or skin. The commutator
surface should be clean and free from grease, oil, or any other contaminant vapors. To clean the surface of the
commutator petrol, CCl4 or benzene can be used with a clean brush and dry canvass to wipe. Machines are
dispatched with brush gear set in neutral position. There are corresponding marks on the brush rocker and end
covers where the rocker is fitted. If for any reason the brush gear is to be moved make sure that individual
markings are not removed. If the marking are not clearly visible make new markings before dismantling to
ensure that brush gear is in neutral after reassemble. In case armature is re-wound it is necessary to check
interpole connection with respective to armature & reset the brush position in neutral axis by simple
procedures given in annexures B & C.

7.2 Productive Maintenance

Productive maintenance goes one step beyond preventive maintenance techniques. Productive maintenance
means that maintenance should pay for itself in terms of less downtime, money saved in repairing equipment
and more total production for each rupee spent on maintenance operation. Productive maintenance means
that maintenance operation which do not more than pay for themselves is not justified. Such a case would be
saved if the equipment were not maintained and allowed to fail. Productive maintenance as applied to lamyoke
315 to 630 frame D.C. motors would means

• Making good records of machine data and setting up a means of recording maintenance performed and
measurement taken.
• Establishing a routine of measurements to be taken and inspection operations to be performed. Without other
experience to guide you, follow the suggested maintenance schedule given later. Experience can be quickly
built up by performing the inspection and measurements called for. These records will show whether or not
various component of the machine change quickly or slowly.

Maintenance schedule can then be readjusted as the experience dictate. Making more frequent and more
elaborate inspections at first and carefully recording results will give a feel for the important items and timing
of critical inspection items. Set up a program to balance between spending more on maintenance and
inspection than a failure would cost.
In some cases it is less expensive and will do no harm to repair or replace a part after it wears out rather than to
maintain it regularly. Equipment the size and the value of a lamyoke 315 to 630 D.C. motors will justify a certain
amount of routine maintenance. Accurate record will help form your judgement of what is important and will
also show gradual aging of insulation, wear of brushes, loosening of fastenings and roughing of commutator.
These records will also point out the approaching need for repair or replacement of components. The following
table shows a suggested schedule of routine maintenance operation and measurements. A time schedule is
given which may be modified as record of experience is being built with this equipment in particular
application. Motors on continuous process lines will have more operating hours than intermittently run
machines and will need more frequent attention.

11
 Monthly

Component Inspection or Maintenance Operation

Make sure that grease not leaking out of bearing housing, if any leakage is present, correct the condition
Bearings
before continuing to operate. Listen to a few bearings on a sample basis. Bearings that get progressively
noisier will need replacement at the next shut down. Regrease if called for under frequency of lubrication.
Check the brush length. Replace before or nearly crossing the line mark on the brush before the next
maintenance. Inspect for worn brush clips, loose pigtails, chipped or broken brushes, and indication of
Brushes overheating of the brush or pigtail at the socket. Remove a few brushes to check the brush
commutator contact face. Burnt area indicates commutation troubles.
Warning: High voltage and rotating machinery can cause serious or fatal injury.
Brushes must not be touched or replaced while the machine is energized or rotating

Check the commutator for roughness by careful feeling the brushes with a fiber stick. Jumping brushes
give advance warning of commutator going rough. Check for excessive commutator wear rate, streaking,
Commutator copper drag, pitch bar marking and heavy slot bar marking. Commutator should not have more than 60
microns total indicator runout & 5 microns bar-to- bar steps.

Mechanical
Air Filter If supplied with motor, keep cleaning periodically. Replace when necessary.
Bolts
Noise and Perform visual observation for loose bolts, loose parts or loose electrical connection. Check pole bolt
Vibration torque (See torque table for correct values of torque). Check for any unusual noise, vibration or change
Level from previous observation.

Every Six Month

Component Inspection or Maintenance Operation

Bearings Listen to all bearings

Commutator Check riser for cracks and dirt. If dirt is get deposited on riser portion, it should be cleaned properly.
Measure one-minute insulation resistance and compare with records. Wipe the deposits from brush-
spindle insulation and commutator creepage path . Remove heavy deposits from around field coils.
Insulation
Connections where grounding might occur. Blow out deposits of commutator riser area with clean and
dry air. Blow out any blocked ventilation openings in windings. Make visual inspection for signs of
overheating (dry, cracked, “roasted-out” insulation and varnish)

Mechanical Check all electrical connections for tightness. Look for signs of poor connections. (arcing, dislocation,
Bolts heat). Adjust inspection period to suit experience. Inspect foundation for signs of cracks, displace foot
shims. Check foot bolts for tightness. Check brush holders, brush spindle-etc on sampling basis.
Check pole bolts torque. Check coupling bolts.

Shaft Check corners of exposed end of shaft key way for cracks.
Ventilation If provided, check for clogged screens, louvers, filters, etc.
Vibration Check for excessive vibration that will indicate changes in balance or alignment.

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 7.3 Repair and Overhaul
Repair should be done by qualified personnel employing the material and process for which the motor was
designed. To protect the warranty during the warranty period, all repairs should be done by CGL or their
authorized repairer. Customer is advised to buy the replaceable parts only from CGL to ensure the genuineness,
life and reliability from operation point of view. Many of the repair can be carried out at the customer’s end, when
genuine spares supplied by CGL are available. Only when major repairs like armature rewinding is taken up
proper facilities like impregnation, ovens, banding, turning, mica undercutting, balancing, etc. should be
available. Refer the longitudinal layout of the machine for the disassembly and assembly operations involved in
repair and overhaul.

7.4 Disassembly Procedure

7.4.1 Disassembly (315, 355 & 400 Frames)
• Dismantle force cooling unit or heat exchanger.
• Disconnect brush rocker connections. Before that note the connections and see that the brush rocker position is
marked.
• Remove brush holder springs & carbon brushes.
• Wrap the commutator surface by a mehanically strong paper like presspan or polyester etc.
• Give packing in the air gap between bottom mainpole and armature with a mechanically strong paper like,
presspan or polyster or epoxy sheet.
• Unscrew the screws fastening the outer bearing cover & inner bearing cover through endshield on commutator
end. Remove outer bearing cover (CE).
• Unscrew the bolts fastening the CE endshield to stator stack.
• Use the two nos tapped holes for jacking out the endshield (CE) from stator stack spigot.
• Remove the endshield CE alongwith brush rocker assembly.
• Unscrew the bolts fastening the endshield (NCE) with stator stack.
• Put nylon slings on armature at two places, one at shaft extension and other at balancing disc (CE) for lifting by
crane.
• With the help of a crane and a stud at commutator end fixed to the end hole threading of shaft slowly move the
armature out from the stator stack. While doing so, maintain the horizontality of armature so that it will not
damage the compensation winding overhangs. Only skilled personel shall perform this operation.
• Once the armature is out, non commutator end bearing assembly can be dismantled and end shield (non
commutator end) can be taken out along with outer race of the Roller bearing.
• If Bearing to be replaced, remove circlip & jack out the grease flinger and then pullout the bearings by a puller
along with inner bearing caps.

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 7.4.2 Disassembly (450, 500, 560 & 630 Frames)
• Dismantle force cooling unit / Heat exchanger.
• Disconnect brush rocker connections.
• Remove brush holder springs & carbon brushes.
• Wrap commutator by a hard paper & place packing between armature & bottom mainpole.
• Dismantle tacho mounting bracket & outer bearing cover (commutator end) by unfastening the screws
connected to outer bearing cover & bearing cartridge. Remove circlip & jackout grease flinger.
• Unfasten the bolts connecting bearing cartridge (commutator end) and endcover (commutator end).
• Unfasten bolts fixing endcover (commutator end) & body.
• Pull out the bearing cartridge (commutator end) alongwith endcover (commutator end).
• Unfasten bolts connecting body to endcover (non commutator end).
• Using a suitable crane, nylon slings / ropes and a long pipe fixed to the commutator end shaft maintaining the
horizontality of armature, take out the armature carefully (to be performed by skilled personal).
• If bearings to be dismantled,
a.Remove outer bearing cover.
b.Remove circlip.
c.Jackout grease flinger.

7.5 Reassembly
7.5.1 Reassembly (315, 355 & 400 Frames)
Reassembly procedure is almost a reverse order process of disassembly. However the following sequence is
advised.
• Place inner bearing covers on both sides.
• Fix inner race of the roller bearing on non commutator end side of armature. It is necessary to heat inner race upto
100 °c in induction heater or oil bath for fixing them on shaft.
• Insert outer race of roller bearing on endshield (non commutator end) and mount on inner race along with
endshield (non commutator end)
• Fix grease flinger (non commutator end) by heating to 80°c.
• Fix circlip (non commutator end).
• Fix outer bearing cover (non commutator end) & fasten the screws fastening the inner & outer bearing covers
along with endshield (non commutator end).
• Wrap up the commutator surface by a hard paper.
• Insert armature into the stator in the horizontal condition with the help of crane & a long pipe using on
commutator end. This is a very skilled operation and only skilled personal shall do this.
• Fix the bolts fastening endshield (non commutator end) and stator stack.
• Maintain the horizontality of the rotor & insert some hard paper packing in the air gap between armature &
bottom main pole.
• Fix ball bearing and grease flinger on commutator end side of shaft by heating upto 100 °c. Fix circlip.
• Mount endshield commutator end along with brush rocker assembly (without carbon brushes) and fasten to
stator stack by the bolts.
• Fix outer bearing cover (commutator end) & fasten with inner bearing cover by screws.
• Fix tacho mounting bracket.
• Remove the paper wrapped around the commutator surface & packing between stator & rotor.
• Insert carbon brushes.
• Put grease into the bearing in sufficient quantity through greasing nipples given.
• Check the free rotation of armature .
• Complete connection on brush rocker as before.

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 7.5.2 Reassembly (450, 500, 560 & 630 Frames)
• Insert inner bearing cap (non-commutator end) of armature.
• Heat inner race of roller bearing (non-commutator end) upto 80-100°c & fix the same.
• Fasten end cover (non-commutator end) & bearing cartridge (non-commutator end).
• Fix roller bearing outer race in the bearing cartridge (non-commutator end).
• Mount bearing cartridge with endcover (non-commutator end) on to the inner race.
• Heat grease flinger both sides to 80°c and fix the same after the bearings.
• Fix the circlips (non-commutator end).
• Fix the outer bearing cover (non-commutator end).
• Insert the armature into stator maintaining horizontality with crane & nylon slings / ropes. Use a pipe on
commutator end of shaft also. (to be performed by skilled personnel)
• Fasten the bolts connecting the end cover (non-commutator end) to body.
• Insert the brush rocker assembly (without brushes) into the body spigot on commutator end.
• Fix inner bearing cover on commutator end side. Fix ball bearing, inner race of roller bearing on shaft
(commutator end) by heating upto 100°c.
• Fix end cover (commutator end) to the body.
• Fix outer race of roller bearing in bearing cartridge (commutator end) & push the cartridge on to ball bearing
and inner race of roller bearing fixed on shaft (to note that double bearing i.e 1 ball bearing + 1 roller bearing
is given in 500, 560 & 630 frames on commutator end side.)
• Heat grease flinger (commutator end) to 100°c & fix the same. Fix circlip.
• Fasten inner bearing cover (commutator end) with bearing cartridge(commutator end).
• Fix outer bearing cover (commutator end) & fasten it with bearing cartridge (commutator end).
• Grease the bearings.
• Check for free rotation of the armature.

7.5.3 Reassembly Continued

• The brush spindles connections shall be reconnected exactly the same way before.
• Set the brush holder height 2.0 to 2.5 mm from commutator surface with a hard paper spacer if they are
disturbed in the disassembly. All brush holders shall be at the same height from commutator.
• Brush rocker position shall be adjusted to align the brush axis in neutral position as per the mark given on
end cover and rocker.
• Assembly is easy in vertical condition. However, later to change the machine from vertical to horizontal
position is not an easy task in case of heavy motors. For these two or cranes or any other suitable means are
required.

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 7.6 Commutator and Brushgear Maintenance
1. Commutator Maintenance
Commutator can get a black colour when operating in various atmospheres and with certain type of brush
grades. Doing nothing may be the best procedure in these cases . Wiping with dry cloth helps upto certain
extent by removing the high resistance or high friction film. This helps to reduce arcing caused by high
resistance.
Generally it is little doubtful when it is necessary to turn a rough commutator. Mostly when situation occurs
like rough surface, noise, sparking, rapid brush wear and uneven load or speed fluctuations, hand stone can
be used for smoothening the normal rough surface of commutator. A hand stone should be used only to
keep the equipment operating until a shutdown is possible and should not be used on extremely rough
surface. For extremely rough commutator turning become necessary. The turned surface must be smooth
and concentric with the center of rotation. The segment insulation mica should be undercut if necessary and
the slots between commutator segments should be thoroughly cleaned.

2. Brush Maintenance
For obtaining good performance of brushes great care is required. Check the following points for brush
maintenance
• Check brushes are free in brush holders
• Check brush pigtails are tight and does not interfere with the free movement of the brushes.
• The brush-holders should be uniformly spaced 2.0 to 2.5 mm above the commutator surface.
• Running a machine on noload (such as during start up ) and the lack of proper filming on new commutator
sometimes leads to a short life for the first set of brushes. Before investigating or changing the brush grade,
wait and see the first set of replacement of brushes perform.
• Check spare brush supplies during installation to be sure that replacement brushes are on hand.
• The brushes originally supplied with the machine are of proper grade and when brush replacement are
necessary use the same grade of brush or substitute, as recommended by CGL. Never use brushes of
different grade mix. When new brushes are put, give them the curvature to match commutator dia. Follow
the brush bedding procedure given in section 5.8.

7.7 Drying out of Windings

Drying of machine is most effectively done by application of heat. The winding and the insulation should be
heated so that the temperature does not exceed 120+5°c at any location (do not make local hot spots).
Some airflow is required to allow moisture to be carried away. Methods of generation of heat includes
• Heating in oven
• Blowing hot air through the machine
• Heating with lamps
• Passing current through the windings
If the temperature as high as 125°c can be attained, they should be maintained to 6 to 8 hours duration.
Lower temperature will cause correspondingly longer drying times. Drying-out can be ended when the
insulation resistance to ground is restored to satisfactory value as compared with previous records. If
previous value do not restore, then a thorough cleaning or complete reconditioning may be necessary.

16
 7.8 Bedding of Brushes
See annexure D for brush bedding.

7.9 Bearing Maintenance

The lamyoke (315 to 630) D.C. motors manufactured by CGL have single width solid roller bearing for
supporting the armature on both the ends. Convenient fittings are provided for addition and removal of
grease from bearing housing without opening the bearing assembly. The grease used in this bearings are
mentioned on nameplate itself. Use the grease as mentioned on the nameplate for long life of bearings. The
soap and the oil in the grease must not separate at moderate temperature nor within a reasonable length of
time, nor should the grease harden objectionably with the age or exposure. The grease must not be corrosive
to any metal used in the construction of the motor. Lubricate motors at standstill. Remove grease nipple and
drain plug. Pump in grease until new grease appears at drain hole. After greasing run the motor for few
minutes before replacing the drain plug. The frequency of lubrication of the bearings depends on the type
and severity of service and the temperature of the surroundings. Approximate quantity of grease for different
type of lamyoke (315 to 630) frames are given in following table.

Frame Approximate Quantity of Grease (Grams)

315 900
355 1000
400 1100
450 1200
500 1500
560 1500
630 1500

7.10 Blower/Heat Exchanger Maintenance

• Check for change in vibration / noise levels and tighten/loose bolts, if any.
• Check for any blocade in the air flow.
• Check for filters once in a month.
• Check for any water leakage in case of water cooled heat -exchangers periodically.
• Check fan motor currents with tong tester & compare with name plate value and feel the body temperature.

17
 7.11 Troubleshooting Chart
Fault Cause Test Remedy

Machine not a. Brushes not seated Check brush pressure Bed the brushes and set
rotating after properly and bedding of brushes the correct spring pressure
giving the
supply b. Wrong connections Check the connection as per Reconnect as per
diagram connection diagram

c. Field circuit open Check resistance of field Repair or replace

windings faulty coil
d. Defective armature Inspect armature Rewind or replace the
armature
Motor running a. Wrong connections Check connections Make connections as
at higher speed per diagram
than normal
b. Shunt field reversed Check connections and Connect as per
or disconnected resistance of field windings diagram
c. Higher than normal Check voltage as per Rectify cause of high
voltage applied name plate supply voltage
a. Damaged bearing Remove bearing cover Fit new bearing, if
Excessive and inspect bearings found damaged.
vibration b. Armature not Measure vibrations Balance the armature
balanced accurately
Bearing a. Incorrect grade or Remove bearing cover Remove incorrect grade and
overheating quantity of grease and inspect grade and check quantity of grease, replace
quantity of grease with correct grade and quantity.
b. Damaged bearings Remove the bearing Fit new bearings, if
cover and inspect bearing. found damaged.

Overheating of a. Low voltage supply Check applied voltage is Rectify cause of low voltage.
armature as per name plate
b. Machine overload Measure load current and Rectify cause of
compare with name plate. overload.

c. Failure of ventilation Check whether air Remove any block in

circuit is blocked. air circuit.

Injurious d. Armature coil open Check resistance between Rectify or rewind the
sparking at short or earth adjacent segments by armature.
brushes millivolt drop test. Check
insulation resistance
a. Brushes not properly Inspect brush face Using sandpaper bed
bedded the brushes to curvature of
commutator.
b. Incorrect size or Check size and grade and Obtain correct replacement from
grade of brush compare with specification manufacturer
of manufacturer

c. Incorrect brush See ,whether brush rocker Rotate the brush rocker in the
rocker position is in marked position. marked position and lock.

d. Brushes sticking in Check whether the brushes Clean brushes and holders,
brush holders are free in holders and re-bed the brushes if
properly bedded necessary.

e. Reversed interpole Check polarities of mainpole rectify connections if

connections and interpole windings, found reversed
using magnetic needle

f. Short between Inspect commutator Clean or polish surface of

commutator segments surface commutator. Clean out
grooves between segments.

g. High mica Inspect commutator Undercut mica and

surface deburr the sharp edges.
h. Open, short, Check resistance between Repair or rewind the
armature grounded adjacent segments by armature
millivolt drop test

** Regarding any troubles in commutator, a chart given in IS: 9919-1981 may be referred,
which will be of immense help.

18
8.0 List of Spares
At the time of ordering the spares, state the quantity desired with the complete nameplate detail of that
particular motor. Note that the serial number of motor is mentioned that will enable us to issue necessary
instruction with a minimum time delay. Here given a list of minimum spares required to be maintained by
the user for one motor.

At The Commissioning Stage

Item Quantity (Sets)

Carbon brushes 01
Brush holders 01
Bearings 01

For Continuous Operation

Item Quantity (Sets)

Carbon brushes 02
Brush holders 01
Bearings 01
Field coils 01
Armature 01

9.0 Torque Table

Size of Pitch of Tightening Torque for Different

Bolts / The Bolts / Grades of Bolts / Screws in Kg-m
Screws Screw

GRADE
AS PER 4.6 4.8 46 8.8 10.9 12.9
IS:1367
M3 0.5 0.05 0.06 0.07 0.12 0.16 0.19
M5 0.8 0.22 0.28 0.32 0.55 0.74 0.87
M6 1.0 0.36 0.47 0.55 0.93 1.25 1.53
M8 1.25 0.90 1.1 1.3 2.2 3.0 3.7
M10 1.5 1.7 2.2 2.6 4.5 6.0 7.4
M12 1.75 3.0 3.9 4.6 7.9 10.7 12.8
M16 2.0 7.5 9.7 11.3 20 26.3 32
M20 2.5 14.6 18.9 22 38 52.0 62
M24 3.0 25.3 32.5 38 65.3 89.0 107
M30 3.5 50.0 65.0 76 130 177.0 212
M36 4.0 88.0 113 132 226 308.0 370

19
 Annexure A

Alignment Procedure
The electric motor must be accurately aligned with the driven machine, particularly in cases of direct
coupling. An incorrect alignment can cause bearing damage, vibration, shaft breaking and brushes sparking.
The best way to ensure correct alignment is to use dial indicator placed on each coupling half, one reading
radially and the other axially. In this way, simultaneous reading can be informed and one can check any
parallel (fig.1) or concentricity deviations (fig.2) by rotating the shaft. The dial indicator should not exceed
0.05mm. If the operator is sufficiently skilled, he can obtain alignment with clearance guage and a steel ruler,
providing that the couplings be perfect and centered. (fig.3) A measurement at 4 different points of the
circumference should not give a reading difference larger than 0.03mm.

Fig-1 Fig-2
Angular Clearance Radial Clearance
(Parallelism) (Concentricity) 0.05 mm

Fig-3
Axial Clearance of 3 to 4 mm
(Centered Bushings) 0.05 mm

20
 Annexure B

Interpole polarity check with respect to Armature

In case of the interpole winding is connected to armature in a reverse way, there will be heavy sparking at the
brushes commutator interface on no load or it may manifest at 10 % to 15% load itself. A simple check can be
done incase of a doubt about the connection.
1. Note the approximate neutral position of the brush. Generally the brush centre line will be approximately
matching with the centre line of the main pole in physical terms.
2. Loosen the brush rocker locking pieces and rotate rocker in either direction by 10 to 15°angle.
3. Give only armature circuit a few volts D.C. supply such that 10% to 15% of full load current will flow through
the armature circuit. In case the armature rotates in the same direction the interpole connections to rocker are
correct. In case armature rotates in a direction opposite to the direction in which rocker rotated, the interpole
winding connection is wrong & to be reversed. In such situation, the correction can be done in two ways:
a) If the cables connected on rocker are sufficiently lengthier, turn the rocker by 1 pole pitch, without disturbing
the connections.
b) Otherwise shift connections on each brush spindle on to next spindle (all in one direction only)

Approximate Neutral
Position of Brush
N

S S

15° 15°
10° 10 to 10 to

Armature
Rotation

After Rotating the Rocker Interpole Interpole

10 to 15 ° From Neutral Connection Correct Connection Reversed

21
 Annexure C & D

Setting Brush Axis in Neutral Position

There are several methods to set the brushes in neutral position, two methods are given here
I) Null Kick Method
• Keep loosend rocker and keep brush position approximately aligned with main pole position when armature
coil leads on overhang are equally bent which is most usually done in all bigger machines of size 315 to 630
frames.
• Connect a centre zero millivoltmeter between positive brush spindle & negative brush spindle (ie adjacent
brush spindles)
• Give a pulse ( on & off) D.C. supply (25% rated field volts first and later 100% voltage for final setting) to shunt
field winding.
• If the brush axis is not in neutral posion, a kick is seen in the milli voltmeter.
• Rotate brush rocker in either direction slightly. By hit & trial, find the brush position when there is almost zero
kick in the milli voltmeter.
• When zero kick position is achieved, tighten the locking pieces of rocker.
II) Dynamic Neutral Method
Run the machine on free shaft in both direction of rotation with the same field current & armature voltage. If
the speeds are same within 5 to 10 rpm, it is the neutral position, otherwise adjust the brush rocker and by hit
& trial set the position of rocker for which the speeds are achieved same. This method is suited to bidirectional
machines with radial brushes.
Either method can be used depending on convenience.

Annexure D

Bedding of Brushes
• Remove all the springs from brush holders.
• Wrap the commutator as shown in fig 1 by emery cloth, tight by as shown in fig 1 with the sanded surface
facing the brushes. Put the brushes & springs in position and rotate the armature slowly in one direction (see
fig 1) till the brushes take curvature of commutator. Remove emery cloth & blow out carbon dust.
• Put a strip of emery paper (if emery cloth of sufficient size to wrap entire commutator surface is not available)
between brushes of one spindle and commutator in such a way that the sanded surface facing the brushes.
• Press all the brushes of that particular brush spindle arm by some mechanical means or by hand
simultaneously. It must be kept in mind that equal pressure should be applied to all the brushes. Rotate the
armature slowly in forward and reverse direction and simultaneously rotate the sandpaper in the same
direction, until the tracks of all the carbon brushes appears on the sandpaper. (fig.2)
• Apply the same procedure with all the brush spindle arms.
• Clean the commutator by compressed air or hand-blower to remove all the carbon dust deposited on the
commutator.

22
 Annexure D & E

Sanded face
Emery paper
Sanded face

Rotate the Rotate this way

Rotor this tay

FIG-1 FIG-2
Bedding all brushes Bedding brushes of one
at a time spindle at a time

Annexure - E
Preparation of Foundation

Auxiliary Plates

Shim, 2 mm Base Plate

15

Reinforced Shrink - Free

Concrete Concrete
Mounting
Block
Foundation
Hole

Figure

23
 The Following Important Aspects are to be Ensured Before Making the Foundation of
Particularly Large Machine.
• Foundation shall be solid & adequate strength depending upon the size & weight of the machine.
• Foundation corresponds to the certified foundation drawing as per standard Civil Engineering practices.
• Accessibility is provided for inspection & service of the machine in foundation area.
• Check the mounting blocks, which are to be grouted, are not painted. If necessary please remove the paint
before grouting. This is applicable to all surfaces, which are to be grouted.

Following Sequence of Steps Shall be Followed with Respect to the Figure Given while
Preparing the Foundation.
• Foundation area to be made of steel reinforced concrete. It is to be ensured the entire foundation area to be in
same level.
• Two base plates are to be grouted in such a way those will not obstruct the mounting block as well as located
under mounting feet of the machine. These base plates are grouted in such a way it will be at same level as of
foundation.
• Now mounting blocks are bolted to fix at all the four mounting feet of machine.
• Holes are to be made in the foundation wherever the mounting blocks are coming.
• Entire D.C. machine along with mounting blocks to be rested on base plate through auxiliary plates in such a
way so that all the mounting blocks are to be located in the respective mounting holes, provided in
foundation. It is to be ensured that mounting blocks are to be free in their respective foundation holes.
• The height level between the machine & foundation to be maintained as mentioned in figure.
• Then these holes are to fill with shrink free concrete.
• To achieve satisfactory result, it is recommended that the shrink free concrete to be used to reinforce the
blocks in the foundation.
• Make sure that there are no air pockets to be left in poured concrete.
• The auxiliary plates are removed after the shrink free concrete has hardened.

Please Check the Compressive Strength of the Concrete and Ensure the Curing time to Be
in Accordance with the Manufacture’s Instruction.

Details of Mounting Hardwares

Minimum Tightening
Hole Size Required Thread Torque Spring
Sr. No. Frame Size in Bolt Size Engagement Value of Washer
Mounting (Minimum) in Mounting Mounting
Feet
Block Bolts
1 315 DIA 28 M24x90P8.8 60 MM 65.3 Kg-m B24
2 355 DIA 28 M24x90P8.8 60 MM 65.3 Kg-m B24
3 400 DIA 28 M24x90P8.8 60 MM 65.3 Kg-m B24
4 450 DIA 35 M30x110P8.8 70 MM 130 Kg-m B30
5 500 DIA 35 M30x110P8.8 70 MM 130 Kg-m B30
6 560 DIA 42 M36x120P8.8 85 MM 226 Kg-m B36
7 630 DIA 42 M36x120P8.8 85 MM 226 Kg-m B36

24
 Annexure F

Shunt Field Winding

Interpole + Compensating Winding
AI A2

Armature

C2 T. Box
F1 F2 A1
Red
Red Terminal Yellow Yellow
Terminal
Terminal Terminal

Direction of Rotation Looking from non Commutator end (Driving end)

F1+ C2+ Clockwise

F2- A1-
F1+ C2-
Anti-clockwise
F2- A1+

Terminal Markings & Direction of Rotation

(AS PER IEC: 60034-1 / IS:4722 / BS:5000)

25
 Environmental Guide Lines

Safe Disposal of IDDC Machines Components (After expiry of Useful Life)

CGL has adopted an environmental policy and pledged to fulfill its responsibility of protecting and conserving
the environment on account of its products.
Items/components used in an IDDC machine which have served their useful life are to be disposed off in an
environment friendly way to protect our resources and control environmental pollution. Guidelines listed below
go a long way in planning activity for scrapping the above effectively in an eco-friendly manner.
DC machines are basically manufactured using the following:
1 Metals.
2 Non Metals.
3 Lubricating Oils.
These items should be disposed off/recycled/re-used as per currently prevalent environmental laws of the
country.

Packaging Material
On reaching the machine at site, packaging material will need to be removed.
Wooden packaging can be reprocessed. In case of some countries, export packing box made of impregnated
woods must be recycled according to currently prevalent environmental laws of the country or local
regulations. Plastic material used for packaging can be recycled.

Metals (Structural Steel, Sheet Steel, Copper, Aluminium Etc.)

These may be sold as scrap metal for recycling and re-use.

Non Metals (Insulating materials like mica, glass, nomex, epoxy/polyester/silicone based bonding materials,
rubber like synthetic or natural and grease etc)
Big pieces and usable lengths of insulating materials may be salvaged for re-using as insulation in smaller and
lower voltage rating electrical equipment. Materials unfit for economic salvaging should be stored in an isolated
space for further safe disposal to agencies authorized by respective pollution boards.

Lubricating Oils
Oils should be recycled after cleaning and when become unserviceable, may be disposed off to recyclers
authorized by respective pollution boards.

Noise and Fire Hazards

The DC motors generally run at high speeds of the order of 500RPM to 2200RPM.
As such they generate unwanted high level noise that can be detrimental to the health of the operating personnel
and exposure over a longer period may lead to hearing loss. To avoid such health hazard, it is advised to wear
earplugs or suitable noise dampening headgear.

It is also advised to use helmets while dismantling the motor for repairs/overhauling.
Before operating the motor for any repair/inspection works, it is mandatory to ensure that all earthing points are
properly earthed. It is also mandatory that the power supply is completely isolated before undertaking any
repair work or opening the motor enclosure for inspection/repairs.

Various non-metals used in the machine may be susceptible to catching fire if exposed to open flame or very
high temperatures. It is advised to keep at least a 2kg electric fire extinguisher nearby for any such emergency.
Do not place volatile flammable materials near the machine in operation.

26
 Customer Satisfaction (Performance Feedback)

Customer Name & Address

Sub: Feedback on Product / Service Performance

Dear Sir,
Crompton Greaves Ltd. a leading supplier of electrical engineering products is in service of the Indian industry
since many decades. We at M7 division Mandideep have been providing traction products for Indian Railways and
IDDC Motors from frame size 315 to 630 and HT/LT motors up to 11KV and 4500 kW.

We would like to have your feedback regarding products / services supplied by us. Your feedback will drive us
further to improve our quality continually. Kindly rate the performance as per the format given below-

Thanking you and assuring of the best and prompt services, all the time For Crompton Greaves Ltd.

Customer Satisfaction Index

S.n Areas Rating Scale (1 to 5) Remarks
1 Quality of CGL Machines & Electric's 1 2 3 4 5

2 Aesthetics/ Exterior features/ Painting Finish 1 2 3 4 5

3 Condition of Packaging / labeling 1 2 3 4 5
4 Ease of fitment / Mounting/ Commissioning 1 2 3 4 5
5 Meeting delivery commitments 1 2 3 4 5
6 CGL response to your communication 1 2 3 4 5

7 CGL response for action on complaints 1 2 3 4 5

8 CGL provides expected service on failure 1 2 3 4 5
9 CGL's root cause analysis & sincere corrective 1 2 3 4 5
actions/no repetition of complaint
10 CGL product quality/reliability better than competition 1 2 3 4 5
11 Maintenance friendliness of CGL products 1 2 3 4 5
12 General performance of CGL products 1 2 3 4 5
13 CGL products – Safe to handle & use 1 2 3 4 5

14. Level of Noise/ Vibration / Heat dissipation ( Acceptable / High )

15. Is disposal of Packing Case / Polythene at proper identified place
16. What you like in CGL's product
17. Specific areas/ suggestions for improvement
18. A) Date of commissioning of CGL product
B) Approx. load at which motor running. Pls. give readings, if possible

For the Customer (Name & Sign)

Format no S 5.1/05/R1

27
 Warranty

We will take the guarantee of electric DC Motor against defective material and workmanship for 18 months from
date of dispatch or 12 month from date of commissioning which ever is earlier. Under the guarantee, we
undertake to replace or repair at our option the motor or any defective parts there of that need replacement or
repair by reason of defective material or workmanship.

The warranty will lapse if the motor is opened or its parts are tempered with any unauthorized persons. Under no
circumstance, we undertake liability for indirect or consequential loss or damage of any nature.

28
Service Plus
Performance.
Quality is when the customer comes back.
Crompton Greaves as a company of course
faces challenging market dynamics. All the
more reason to be proud of our extensive
reference list of loyal customers. We aim to
maintain this position by providing high-
quality products and even higher-quality
customer service. To us, responsibility and
customer proximity mean high mobility and
availability around the clock. Our customers
are assured quick access to service that
meets our high-quality standards should the
need arise. Our goal is to have satisfied
customers, which is what healthy, win-win
business partnerships are all about. And our
contribution in turn plays a big part in
helping our customers perform perfectly for
their own clients.
MANUFACTURING INDIA
UNITS OPERATIONS
CG INDIA REGIONAL OFFICES
NORTH

CG HUNGARY EAST

WEST

GLOBAL
OPERATIONS
INTERNATIONAL
SOUTH

REGISTERED
OFFICE