600 hp

TOP DRIVE MOTOR

Motor Model # WL381060VSSSPAB

401 Watertown Road

Thomaston, CT 06787
Phone: 860-283-5801
Fax: 860-283-5777 June 2009
Web: www.wardleonard.com Rev -
 Instruction Manual for 600 HP Motor

Product Type: AC Induction Motor

Description: Frame size WL381

Index Page

1. Motor Data Sheet……………………………………………………………… 2

2. Temperature Classification…………………………………………………... 3

3. List of Standards………………………………………………………………. 3

4. Safety Warning………………………………………………………………... 3

5. Storage……………………………………………………………….………… 3

6. Installation and Commissioning………………………………………..……. 4

7. Thermal Protection…………………………………………………………..... 5

8. Heaters……………………………………………………………………….… 5

9. General Inspection & Maintenance………………………………………..…5

10. Bearing Replacement/ Dismantling Instructions…………………………… 6

11. Spare Parts…………………………………………………………………….. 8

12. Motor Fault Finding Chart……………………………………………………..9

Appendices:

Appendix A – Drawing, Outline: WL381060VSSSPAB

Appendix B – Drawing, Wiring Diagram: D6008

1. Data Sheet for WL381060

Specifications EN60034 Rotating Electrical Machines

EN60079 Electrical apparatus for potentially explosive
atmospheres
EN60079 Increased safety ‘e’
Electrical Rated Output 447.6 kW (600HP)
Rated Voltage 600 V
Rated Frequency 50 Hz
Rated Speed 982 RPM
Speed Range 0-2400 RPM
Duty S1 continuous
Full Load Current 552 Amps
No Load Current 220 Amps
Power Factor 0.86
Efficiency 93.5% (FL)
Number of Poles 6 Poles
Environmental Ambient Temp -20°C to + 50°C (122°F)
Max. Altitude Up to 1000 m ASL (3250 ft)
Hazardous Area Zone 1 Group IIC
Temperature Class T3 200°C
Mechanical Mounting Vertical
Arrangement Shaft Material Steel Grade 4340
Rotation Reversible
Balance Precision
Overspeed 2880 rpm for two minutes
Estimated Weight 1680 kg (3700 lbs) depending on final build
specification
Bearings Type Drive end:
Roller Bearing: FAG 558826D
130 x 280 x 58mm
Non drive end:
Ball Bearing: QJ318N2MPA-C4
90 x 192 x 43 mm
Life 25,000 hours
Lubrication details Every 6 months
Grease Shell Cyprina RA
Bearing Seals Drive end:
- Internal: 170 x 200 x 15 mm – Viton 75
- External: 115 x 190 x 15 mm – Viton 75
Non drive end:
- Internal: 105 x 130 x 12 mm – Viton 75
- External: 105 x 130 x 12 mm – Viton 75
Cooling Cooling Method Separate Forced Ventilation
Air Flow 0.94 m3/sec/ 2000 CFM minimum
Enclosure Motor IP23
Auxiliaries Thermal Protection 6-off Stator Winding RTDs (PT100)
(2) Bearing RTDs (PT100)
Self-limiting block heater fitted to inside of
end shields

2
2. Temperature Classification

The motor type WL381 is designed for increased safety Exe in accordance with
EN60079. The temperature classification is T3: 200° C.

3. List of Standards

The motor is designed and manufactured in accordance with the following specific
standards.

EN 60034-1 Rotating Electrical Machines

EN 60079-1 Electrical apparatus for potentially explosive atmospheres
EN 60079-7 Increased safety ‘e’

In addition, the motor complies with:

ƒ The EMC Directive 89/336/EEC and amended by 92/31/EEC, 93/68/EEC
ƒ The Low Voltage Directive 73/23/EEC and amended by 93/68/EEC
ƒ Declaration of Incorporation with respect to the Machinery Directive 89/392/EEC
and amended by 91/368/EEC, 93/44/EEC and 93/68/EEC

4. Safety Warning

This motor has been designed for use in a potentially hazardous area and is
marked as increased safety Ex e.

The following instructions must be adhered to for safe installation, operation and
maintenance of the motor. Additionally, there will be National and/or Site Safety
Standards that must be complied with.

The installation, operation and maintenance of the motor must be carried out by
qualified personnel.

5. Storage

• If motors are to be stored before installation, precautions must be taken to

prevent deterioration.

• Motors should be stored in a dry condition, standing clear from damp, free from
condensation and protected from extremes of temperature. If damp storage
cannot be avoided then connecting the motor heaters (when fitted) should be
considered. Adequate precautions must be taken for safety as parts of the motor
will be live.

• The motors should be protected from the ingress of dust, especially

concrete/cement dust. When protecting motors from dust care should be taken
that condensation is not caused.

• Motors must be stored away from corrosive or chemically damaging fumes.

• Damage can be caused to ball and roller bearings if these are subject to
vibration.

3
• To prevent damage to the bearings it is recommended that the shaft is given a
few turns by hand every four weeks to load the bearing at different places
randomly.

• It is recommended that the motors are inspected at 6 monthly intervals.

• Inspect bearing grease before putting motor into operation and renew if it has
deteriorated.

• Check insulation resistance before putting motor into operation. If this is less than
10 Mohm, carry out drying operation as detailed in the General Maintenance
section below.

6. Installation and Commissioning

• If the motor is to be installed in a potentially explosive atmosphere, perform an

ignition hazard assessment in accordance with EN 13463-5 (Non electrical
equipment intended for use in potentially explosive atmospheres – Protection by
constructional safety).

• On receipt of motor after delivery, ensure that no damage has occurred during
transit. If there is any evidence of damage to the packaging then the motor must
be inspected and checked by qualified personnel before putting into service.

• The motor must be lifted using the facilities provided.

• Ensure that the motor rating plate data meets the required specification exactly.
Operating the motor outside the stated design limits could cause a potential
hazard and may invalidate the warranty.

• The installation must provide for adequate guarding of rotating or heated parts.
Where fitted, these guards must be in position and secured.

• Adjustments or measurements must not be made through ventilation or similar

openings unless the motor has been disconnected from the supply.

• Any cover provided for live electrical parts or connections must be in place.

• Power cables to and from the motor must be of adequate current carrying
capacity and rated for the appropriate voltage.

• Control cables for auxiliary circuits must be intrinsically safe.

• The motor must be connected to a supply system with overload, over

temperature and over speed protection.

• Except in special cases where it is part of the order requirement, the motor must
be earthed in accordance with the Site Regulations.

• Cabling to the motor must be connected in accordance with the diagram supplied.

• It is essential that the motor is supplied with sufficient ventilation from the ambient
air (maximum 50°C). It is recommended that the controls for the ventilation
4
 system operate in conjunction with the main motor drive system and ensures that
ventilation is available at the same time as the motor starts. If the motor is
operated without cooling air, then heating will occur and the drive will trip on over
temperature. To prevent this, it is recommended that an air pressure switch is
connected.

• Precautions must be made to ensure that ventilation openings are free from
obstruction and re-circulation of the motor outlet air is not possible.

• Before starting it is necessary to confirm that the shaft is free to rotate.

• The motor must be run without excessive vibration.

• Drain points must be open and free from obstruction.

7. Thermal Protection

• The motor will be fitted with over temperature protection for the stator windings.
Refer to the motor data sheet for number and type of thermal protection used.

• Thermal protection for the windings must be intrinsically safe. The standards
require that one thermal protection device is fitted in each phase as a minimum. It
is essential that the thermal protection is connected to protect the motor from
overheating and thus prevent a potential explosion hazard occurring.

• It is the responsibility of the end user to connect the thermal protection that is
fitted to the motor to ensure safe operation.

• One thermal protection device per phase must be connected to a separate and
intrinsically safe control circuit. This ensures that thermal protection is always
maintained, even in the event of a fault with the drive.

• If fitted, the additional set of three may be routed back to the inverter drive.

8. Heaters

• When specified in the motor data sheet, heaters will be fitted inside the motor end
shields. To prevent condensation deteriorating the insulation, heaters should be
switched on when the motor is not in operation. Adequate safety measures must
be taken to ensure that access to live connections cannot be made whilst the
heaters are energised.

9. General Inspection & Maintenance

Important Note – Any repair arranged by the end user, unless expressly
approved by manufacturer, releases the manufacturer from his responsibility to
conformity.

Inspection and maintenance must only be carried out by qualified personnel.

5
Inspection

• Check the motor at regular intervals and develop an inspection/maintenance

routine. Isolate the motor from its supply if access covers are to be removed.
- Check that the electrical connections and mounting bolts are secure.
- Ensure ventilation openings are not blocked or obstructed.
- Check the condition of shaft seals and replace if necessary.

• Bearing condition can be checked by listening for excessive noise, inspection of

used grease, observing/monitoring bearing temperatures or measurement of
vibration.

• In no instance must the motor design be modified, unless approved in writing by

the manufacturer.

• If the motor needs to be rewound, this may only be carried out by the
manufacturer or nominated representative. Failure to do so will invalidate the
warranty and could compromise design features that affect the conformity to the
specifications.

10. Bearing Replacement/ Dismantling Instructions

• If re-greasable bearings are fitted, this will be mentioned in the motor data sheet
along with recommended lubrication details.

• Shaft seals must be replaced when the bearings are changed.

• Old bearings must be removed using suitable pullers and the replacements fitted
by heating.

NOTE: Hoists are required for lifting the motor brackets.

Drive End Bearing and Oil Seal Assembly:

1. Using appropriate bearing press tool, press drive end bearing outer race into
drive end bracket until bearing is seated against the shoulder of the bearing bore
of the bracket.
2. Grease bearing outer race.
3. Smear sealing lip of new oil seals with clean grease.
4. Apply jointing compound to outside diameter of drive end external oil seal.
5. Fit drive end external oil seal with spring towards drive end extension of shaft.
Using appropriate oil seal press tool, press the external oil seal home into
housing recess in the drive end bracket.
6. Apply jointing compound to outside diameter of drive end internal oil seal.
7. Using appropriate press tool, press the greased drive end internal oil seal home
into the drive end internal cap (oil seal spring to be towards drive end extension
of shaft).
8. Fit drive end cap over shaft, then fill drive end cap 2/3 full of grease.
9. Heat drive end bearing inner race to no hotter than 90oC and slide onto shaft, up
to shaft shoulder. Allow bearing to cool, then grease inner race of bearing.
10. Fit drive end bearing nut to shaft and tighten nut up to bearing.
11. Fit copper slug and grub screw to hole in drive end bearing nut and tighten grub
screw.
6
12. Fit drive end bracket over shaft and bearing, to dimensions on outline drawing.
13. Fit bearing cap to drive end bracket using screws and washers.
14. Fit drive end bracket assembly to frame assembly.

Non Drive End Bearing and Oil Seal Assembly:

1. Fit non-drive end cap over shaft, then fill cap 2/3 full of grease.
2. Heat non-drive end bearing to no more than 90oC and slide onto shaft until the
bearing is seated against the shaft shoulder. Allow bearing to cool, and then
grease bearing.
3. Fit non-drive end bearing lock washer with inside tab seated in keyway of shaft.
4. Fit non-drive end bearing nut to shaft and tighten up to bearing washer.
5. Fold external tab in bearing lock washer back to fit into slot in bearing nut.
6. Smear sealing lip of oil seal with clean grease.
7. Apply suitable jointing compound to outside diameter of oil seal.
8. Place greased non-drive end external oil seal with spring towards drive end
extension of shaft. Using appropriate oil seal press tool, press oil seal into the
housing recess of the non-drive end bracket, until it is flush with bracket.
9. Fit non-drive end bracket over shaft and bearing.
10. Fit bearing cap to non-drive end bracket using screws and washers.

After fitting bearings:

1. Insert studs through holes in frame.

2. Fit drive end bracket assembly to frame assembly.
3. Fit non-drive end bracket assembly to frame assembly.
4. Fit flat washers, spring washers and slotted hexagon nuts to studs at one end of
motor, so that hole in stud can be seen in slot in nut.
5. Fit split pins through slot in nuts and hole in studs and secure.
6. Fit flat and spring washers at other end of stud.
7. Fit slotted hexagon nuts and tighten.
8. Drill hole through slot in nut and also through stud.
9. Fit split pins and secure.
10. Grease bearings using lubrication holes in Brackets.

Drive End Bearing Disassembly:

1. Remove split pin from studs in drive end bracket.

2. Undo slotted nut, remove nuts and washers from studs.
3. Remove screws and washers that are securing drive end inside cap to drive end
bracket.
4. Remove bracket from studs.
5. Remove drive end bracket.
6. Loosen grub screw holding drive end bearing nut to shaft.
7. Remove drive end bearing nut.
8. Using appropriate bearing extractor tool, remove drive end bearing.

Drive End Internal Oil seal Disassembly:

As ‘drive end bearing disassembly’, then:

1. Remove internal drive end cap.
2. Remove drive end internal oil seal from drive end cap by using a suitable drift.
After removal, the oil seal must be scrapped.

7
Drive End External Oil Seal Disassembly:

Same as Drive End Bearing Disassembly, then:

1. Remove external drive end oil seal from drive end bracket by using a suitable drift
and tap out from inside of bracket. After removal, the oil seal must be scrapped.

Non Drive End Bearing Disassembly:

1. Remove split pin from studs in non-drive end bracket.

2. Undo slotted nut, remove nuts and washers from studs.
3. Remove screw and washers holding non-drive end inside cap to non-drive end
bracket.
4. Remove cables from gland assembly.
5. Remove non-drive end bracket.
6. Remove non-drive end bearing nut and bearing lock washer.
7. Using appropriate bearing extractor tool, remove non-drive end bearing.

Non Drive End External Oil Seal Disassembly:

Same as Non Drive End Bearing Disassembly, then:

1. Remove non-drive end external oil seal from non-drive end bracket by using a
suitable drift and tap out from inside of bracket.
After removal, the oil seal must be scrapped.

11. Spare Parts

• Make a note of the motor serial number from the name plate and contact the
manufacturer or approved Agent.

8
12. Motor Fault Finding
This chart aims to provide basic information that may assist with resolving a fault. If in
doubt, refer to the manufacturer or approved Agent.
Symptom. Potential Fault.
Motor will not start Problem within inverter drive
Incorrect connections
Motor winding fault
Mechanical Problem
Motor stalling Application error
Insufficient supply
Motor Winding Fault
Incorrect direction of Phases incorrect
rotation
Motor trips out on Over load
over temperature
Voltage unbalanced
Ventilation openings
obstructed
Insufficient ventilation
High ambient
Bearing noise Worn bearings
Motor misalignment
Bearing overloaded
Incorrect greasing
Motor vibration Alignment
Incorrect balance
***
Action.
Check inverter drive fault indication,
fuses and overload if fitted. Refer to
drive instructions.
Check motor connections are made
according to the diagram.
Check that winding resistance agrees
with manufacturer’s value. I.e. that
winding is not shorted or open circuit.
Check the motor insulation resistance
to earth. Value > 2Mohm but
preferably >10Mohm.
Check that motor turns without
resistance. If motor will not turn,
dismantle from coupling/drive system
and establish the location of the
problem. If motor cannot be turned by
hand, establish reason for seizure.
Check motor is rated for the required
torque.
Ensure full voltage is applied to the
motor and that inverter can provide
sufficient current.
See above comment.
Reverse two phases to motor.
Reduce load.
Check supply, connections and leads.
Check and remove obstruction.
Check/improve ventilation.
Ensure hot motor air is not re-
circulating. Check maximum
allowable motor ambient temperature.
Replace bearings and seals.
Check and realign.
Check bearing is suitably rated for
load. Check belt tension, if applicable.
Check and maintain a proper record
of greasing to prevent under or over
lubrication.
Check motor alignment is correct.
Check couplings have been balanced
correctly.
Check motor balance.
9
 8 7 6 5 4 3 DWG NO WL381060VSSSPAB SH 1 1
3.35
REVISIONS-REVISION STATUS ALL SHEETS
.71 CENTRES REV. DESCRIPTION ECN NO. DATE APPR.
ISOMETRIC VIEW 2.95 - INITIAL ISSUE EC-01767 04/01/08 AW / JAH
.20 CUT OUT A REMOVED PRELIMINARY NOTE, ADDED NOTES IN ZONE A1 EC-01872 20 MAY 08 JAH / MM
VIEW LOOKING TOWARDS PINION END
BRAKE END B CHANGED CERTIFICATION BODY TO AUTHORIZED PERON IN ZONE 1 EC-01913 7 JUN 08 JAH / MM

DETAIL A C REDRAWN TO SOLIDWORKS, ADDED ISOMETRIC VIEWS EC-02122 11/10/08 JAH

4 x 5/16"-18 UNC THRU SCALE 1 : 4

D SHOWING FIXINGS AND CUT OUT VIEW ON TOP AND BOTTOM PINION END BRACKET D
SHOWING FIXINGS AND CUT OUT
SECTION B-B TYP 4 PLACES .2

6.30 CENTRES
5.91 CUT OUT
0 C 3.3
EN 5
12.20 CENTRES
SCALE 1 : 6
TR
ES 4 x 5/16"-16 UNC THRU
.20 11.8 CUT OUT

CUT OUT
SHOWING FIXINGS AND CUT OUT = =

2.95
TYP 4 PLACES C 2.9
UT 5
O

.20

.39
.7 UT
1

.30
.2 VIEW ON PINION END BRACKET R.4
0
SHOWING FIXINGS AND CUT OUT
5.
91
C
EN
5.

.20

CENTRES
TR
51

ES

3.35
C
UT

=
O

15.1
UT
07

UT
8.

O
UT
=

ES
C

TR
09
R.4 4 x 5/16"-18 UNC THRU

EN
PINION END VIEW

7.
4 x 3/8"-16 UNC THRU

C
48
7.
0
=

.2
UT

B
27.32
O

7.
UT

52
=

BRAKE END VIEW

C

42.56
ES
91

TR
5.

26.54
EN

BRAKE END PINION END

C

LIFTING EYEBOLTS
22
6

C 1-1/8" UNC
C
6.
.1

5.6 TYP
1.5 TYP 12.01
3
.9

B 1.8 TYP

A 10.5
5.00±.03
GREASING POINT BRAKE MTG 4.995 GREASING POINT
BLANK PLUG FITTED BLANK PLUG FITTED

13.50
4.985

RTD TERMINATION
20.015
20.000
SEAL C
ACCESS COVER
SEAL SEAL

4.3830
4.3821

7.950
7.945
3.252
3.250

28.27

30.16
3.210 SEAL
.23 3.150 50° 50°
.20

+.000
- .010
+.00
3.75

15.000
- .03

.375
AIR INLET
1680 CFM
B
B CAB;E PLATE C/W STRAIN RELIEF GLANDS 1.73
7.76

1.63
SUITABLE FOR 3 x ARMOR CABLE 3.59 14.81 TYP
FLEXIBLE POWER CABLE, SINGLE CONDUCTOR 4 x 1.56
11 FT LENGTH 2.33 SEALING FACE THRU HOLES
5.00 8.07 29.63 CENTRES
& BEARING HOUSING
23.82 16.38

11.91
32.76
1.80 8.650 .005

+.06
13.75 CENTRES 10.45 NOTES:
- .00

1. DETAILS OF PINION END AND BRAKE END SHAFT EXTENSIONS

AS PER CANRIG DRG No. DT13482 REV E.
.13
.06
5.54

THIS DRAWING RELATES TO A CERTIFIED PRODUCT AND MUST NOT BE

11.06

REVISED WITHOUT APPROVAL OF THE AUTHORIZED PERSON.

REF: IEC 60079-0 (8.1 & 17.4.3)

17.00

THIS PART MUST NOT CONTAIN MORE THAN 6% MAGNESIUM. EST WEIGHT 3700 LBS

UNLESS OTHERWISE SPECIFIED

A
MATERIAL:
6 x 1/2"-13 UNC THRU
DETAIL C DIMENSIONS ARE IN INCHES
TOLERANCES ARE:
Ward Leonard Electric Company Inc.
Thomaston, CT 06787
A
SCALE 1 : 3 DECIMALS: X.X ±
DECIMALS: X.XX ±
0.04
0.02 DRAWN BY: AW TITLE
DECIMALS: X.XXX ±
ANGLES: X.X ±
0.005
0.5
FINISH: DRAWN DATE: 04/01/08 AC MOTOR IP23,
ISOMETRIC VIEW
THIS DRAWING IS THE PROPERTY OF WARD LEONARD ELECTRIC
COMPANY INC., THOMASTON, CT. THIS DOCUMENT AND/OR THE THIRD ANGLE PROJECTION
CHECKED: JAH IC17, V1 MOUNTING
APPROVED: MM
5.50 INFORMATION CONTAINED THEREIN SHALL NOT BE DUPLICATED,
VIEW LOOKING TOWARDS 11.00
USED, LOANED, OR DISCLOSED IN WHOLE OR IN PART FOR THE SURFACE FINISH: 125 DATE: 05/20/08
SIZE CAGE CODE DWG NO REV
PINION END MANUFACTURE OR PROCUREMENT OF ANY ITEM OR ITEMS SHOWN
12.43 APPROVAL:
24.86 ON OR THEREBY WITHOUT THE WRITTEN CONSENT OF WARD BREAK ALL SHARP EDGES D 63743 WL381060VSSSPAB C
LEONARD ELECTRIC COMPANY INC. THIS PRINT IS LOANED
SUBJECT TO RETURN ON DEMAND. DO NOT SCALE DRAWING SCALE: 1:8 WT: LBS SHEET 1 OF 1

8 7 6 5 4 3 2 1