User Manual of HTB12 AC Drilling Motor

HTB12 AC Drilling Motor

User Manual

YJ12.000.000SC

Chengdu Hongtian Electrical Drive Engineering CO., LTD

Mar. 2009
 User Manual of HTB12 AC Drilling Motor

Please read this manual carefully before the operation of this motor, it provides
information to encourage proper installation, operation and maintenance.
And keep it for future reference.

Contents

1. Basic Parameters .......................................................................................................... 3

2. Structure Introduction................................................................................................... 4

3. Installation and Operation ............................................................................................ 5

4. Fault Analysis and Treatment....................................................................................... 7

5. Maintenance................................................................................................................... 9

6. Transportation and Storage........................................................................................ 11

7. Main Parts List ............................................................................................................. 12

Attachment:
Attached drawing 1 HTB12 AC Motor Outside Drawing
Attached drawing 2 HTB12 AC Motor Disassembly Drawing

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 User Manual of HTB12 AC Drilling Motor

Referenced standards:
GB 755-2008
<Rotating electrical machines— Rating and Performance> (idt IEC 60034-1:2004)
TB/T 3001-2000
<Electric convertor-fed alternating current electrical machines for Rail Vehicles> (eqv IEC 60349-2-1993)
GB/T 1032-2005
<Test procedures for three-phase induction motors> (neq IEC 60034-2-1972, neq IEC 61972-2002, neq
IEEE Std 112-1996)

Safety Warnings

◆ This manual is applicable for HTB12, HTB12A three-phase induction motor, please read it
carefully before use the equipment.
◆ Be sure all power is off before dismantle motor; and must press lockout switch before motor
repair.
◆ Assembly after inspection and repair, if the replace with the tightening bolt and screw of which
performance is not lower.
◆ If the parts with protection requirement are needed to replace due to damage or rust, it is
recommended to contact the manufacturer to choose desired ones.

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 User Manual of HTB12 AC Drilling Motor

1. Basic Parameters

3.1 Motor Main Parameters

Structure type: three-phase and squirrel-cage induction motor
Rated power: 1200 kW
Rated speed: 500 r/min
Rated frequency: 68 Hz
Rated voltage: 575 V (fundamental wave)
Rated current: 1531 A (fundamental wave)
Rated torque: 22918 N·m
Rated power factor: 0.82
Rated efficiency: 96%
Short-time current: 2297 A
Short-time torque: 34377 N·m
Max. speed at constant power: 700 r/min
Stator winding wiring: Y
Duty: S1
Insulation grade: H
Protection degree: IP44
Cooling method: forced cooling (self-owned blower)
Weight: 3186 kg

1.2 Temperature-rise limit

Motor parts Insulation grade Measuring method Allowable temperature-rise

Stator winding H Resistance method 180K

To the extent of windings or other

Rotor Electric thermometer
parts damaged

1.3 Weight
Total weight: 3186 kg
Rotor assembly: 1232 kg
Stator assembly: 1575 kg

1.4 For HTB12, HTB12A three-phase induction motor outside drawing,

refer to attachment1.

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 User Manual of HTB12 AC Drilling Motor

1.5 Bolt tightening Torque

Thread diameter M6 M8 M10 M12

Tightening torque (N·m) 7±1 20±3 37±5 62±7

M14 (12.9
Thread diameter M16 M20 M24
expansion kits)
Tightening torque M
220±10 155±15 300±20 700±36
(N·m)

1.6 Winding resistance 0.0044 Ω (20℃)

2. Structure Introduction

2.1 Description
This type of motor is to be direct drive three-phase squirrel-cage induction structure, and designed
for driving HHF-1600 mud pump. The electrical power is generated from diesel engine set and
changes to an adjustable voltage & frequency AC power. It installed with horizontal type, no-bearing
and split structure; its stator is rigidly connected with mud pump by flange and high-strength bolt; the
rotor is mounted on the pinion shaft of mud pump with expansion kits to transmit torque and force.
Adopt forced ventilation for cooling, with the blower mounted on installation bracket of mud pump;
air intake is connected with frame by air duct, and stator connecting flange is also equipped with air
outlet.
Inside of connection box fitted with electrical heater for dehumidification; if the ambient temperature
lower than allowable value or exist condensation in motor, stop the motor and energize heater for
temperature-rise and preservation, in order to remove moisture and assure equipment safety.
There is installed PT100 platinum resistance temperature sensors between stator winding gaps, the
lead-out wires are connected to terminal block that mounted inside connection box and controlled
by auxiliary power.

2.2 Stator
Stator windings as form double-layer, and stator coils embedded in stator slots, the ends fastened
by glass polyester rope.The whole stator is impregnated in vacuum pressure impregnation (VPI)
process, with class H insulation. After impregnation, the three-phase windings are leaded to terminal
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box with copper bar.

2.2.1 Stator core

The stator core is laminated with 0.5mm thick 50W470 high-quality cold rolled silicon steel plates,
which are compressed and welded with the pull rods and pressing rings, and then apply shrink fit
stator frame.
2.2.2 Stator coil
Each coil is wound by 46 compound film lapped wire of polyimide-fluorin, and straight section
insulated by PI film, the coil end by PI film and DPE mica tape, the outer by alkalifree glass tape.

2.2.3 Lead-out wire

The lead-out wire of three-phase collector ring is welded with collector ring by form copper bus, and
is led out.
2.3 End-cover terminal box
The terminal box and end cover are integrated to one unit, taking full advantage of end space. The
termination is sunken inside, and terminal enclosure is jointed to stator frame. The terminal blocks
are mounted in the terminal box which is arranged at the end surface of stator; lead-out wire signs U,
V, W.

2.4 Rotor
The rotor bars adopt special trapezoidal copper bars to insert into slots and fasten with slot wedges.
The end rings are machined by 5mm copper plates, and welded with rotor bars by TIG method.
Meanwhile, there are clearances between end rings for natural cooling.
The rotor core is laminated with 0.5mm thick 50W470 high-quality cold rolled silicon steel plates,
which are compressed and welded with the pull rods and pressing rings. Rotor spider is to be
welded-steel plate construction. The core inner ring and spider body is to form ventilating duct.

2.5 Blower Assembly and Air Duct

The blower assembly is out purchased and installed on mounting bracket of mud pump, from
outside which supported by snail shell outlet and installed on the main motor.

3. Installation and Operation

The stator, rotor and blower are transported separately; after reaches at site, unpack and inspect
carefully for deformation or damage, if not, carry out the following assembly.
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3.1 Assembly of rotor, expansion kits with mud pump pinion shaft
3.1.1 Use expansion kits to connect rotor and pinion shaft
1) Use special device to lift the rotor slowly; and measure rotor axis with level instrument; adjust
lifting rope as necessary; push rotor on the shaft and in the place;
2) Loosen all bolts and connect the expansion kits into hole; meanwhile, for prevent inclination,
thoroughly tighten the bolts.
3.1.2 Procedures of tightening bolts
1) Use torque wrench to equably tighten the bolts of expansion kits in diagonal, cross way.
2) The tightening torque should meet the standard and detailed steps as follows: a. tighten with
1/3M torque; b. with 1/2M torque; c. with M torque; d. check all bolts with M torque
3.1.3 Disassembly of expansion kits
1) Loosen all bolts, but not screw out;
2) Take off the galvanized bolts and washers, and screw in the auxiliary holes on front pressing
ring and hammer the bolt head to let expansion kits loosen, finally pull out the bolt with the
kits together.
3.1.4 Protection
1) After assembly, smear with a coating of anti-corrosive grease over exposed end surface of the
kits and screw head.
2) If operate outdoor or in bad environment, the exposed end surface of the kits should be
smeared with anti-corrosive grease regularly.
3) If the expansion kits to be operated in corrosion medium, apply special protection to prevent
from corrosion, such as cover plate.

3.2 Stator Assembly

3.2.1 Inspection of flange rabbet dimension and test radial run-out value
Place dial indicator on external surface of stator core, and point to flange rabbet to test radial
run-out value, up and down difference not more than 0.35mm (the upside is larger, taking bearing oil
clearance into consideration), left and right difference not more than 0.25mm, and the whole radial
run-out value should be not exceed 0.35mm.
3.2.2 After lift stator horizontally, align flange rabbet and move forward to end ring and core, pay more
attention to protect coil ends; inspect clearance around stator and rotor with 0.5mm thick feeler
gauge, and along rotor axis to push in place.
3.2.3 Put M20X65 bolts in up/down/left/right direction, and tighten in diagonal and cross way; place flange
rabbet into stator and screw on the remaining bolts. Place dial indicator magnetic base, and point to
the smooth surface of stator frame and set to zero; screw 2 M16 bolts in auxiliary holes at the both
sides of bottom, for let stator move upwards 0.05mm, and fasten on mounting base with M20 bolts
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 User Manual of HTB12 AC Drilling Motor

and nuts.

CAUTION: The used bolts should be proper to avoid overlong from coil end damaged.

3.3 After finish the installation of stator and rotor, rotate pinion shaft and
check motor inside for noise and friction; find out and adjust in soon
as necessary.
3.4 Mount blower assembly and air duct.
3.5 On the upside of stator flange, fitted with rain cover.

4. Fault Analysis and Treatment

4.1 Motor Unable to Start

a. Rotary direction incorrect due to the wrong wiring of blower motor, and lead to air pressure
switch not activated;
b. Lockout switch not reset
c. Power supply connection incorrect
d. Not energized (at least for two phases);
e. Fuse burn-out (at least for two phases);
f. Over-current relay setting is too small;
g. The wring for control equipment is incorrect;
4.2 Fuse burn-out after motor energized:
a. Lacking of one phase to start, or one phase of stator coil connected reversely;
b. Stator winding grounded
c. Stator winding phase short-circuit;
d. Stator winding wiring incorrect;
e. Fuse cross-sectional area is too small
f. Power supply cable short-circuit or grounded
4.3 Motor dose not rotate after energized but humming:
a. Stator winding is open-circuit (because of one phase broken off) or one phase of power supply
blackout
b. Winding lead-out wire connects incorrect or winding inside connected reversely;
c. motor overloaded;
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 User Manual of HTB12 AC Drilling Motor

d. stator or bearing stuck;

e. power supply loop contact loosen, contact resistance much higher;
f. supply voltage below level;
4.4 Motor Enclosure Live:
a. power supply line and grounding line mixed;
b. motor winding dampened, insulation ages seriously;
c. lead-out wire and terminal box grounded
4.5 Motor is difficult to start, and speed is much lower than rating at
rated loading
a. supply voltage is too low
b. squirrel-cage stator cracks or broken;
c. stator partial coils incorrectly connected
d. motor overloaded
4.6 Ammeter pointer sways when the motor is no-loading or
overloading:
The main reason is open-weld or broken bar of rotor;
4.7 Insulation resistance lower
a. winding affected with moisture;
b. winding insulation covered with dust or oil;
c. winding insulation aged;
4.8 No-load current unbalanced and large difference of three phases:
a. winding incorrect connected
b. supply voltage unbalanced
c. Winding inter-turn short –circuit , coil connected reversely
4.9 No-load current balanced but much higher:
a. supply voltage is too high
b. the core of stator and rotor not aligned after motor re-assembled;
c. air gap uneven
4.10 Sound abnormally when the motor running:
a. MP pinion shaft’s supporting bearing worn, or grease exists mixed sand or other foreign
materials;
b. stator and rotor core loosen;
c. voltage is too high or unbalanced;
d. stator winding incorrectly connected or short-circuited;
e. MP pinion shaft’s supporting bearing lacking of grease;
f. stator, rotor core friction;
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4.11 Motor Vibration

a. air gap uneven;
b. rotor unbalance;
c. installation unstable;
d. rotor cracks or breakdown;
e. stator winding faulty (short-circuit, open circuit, ground, or wrong wiring, etc);
f. core deformation or loosening;
g. stator and rotor have not been adjusted, or failed to meet requirement;
h. fastening bolts of stator flange or at mounting base became loosening;
i. MP pinion shaft’s supporting bearing worn and clearance overlarge;
j. main shaft bending
4.12 Motor overheating or smoking
a. over-higher voltage leads to core flux density supersaturation, and then motor temperature-rise
much higher;
b. when motor is running with rated load and at lower voltage, its temperature-rise is much higher;
c. stator , rotor core friction
d. motor overload or driving force overlarge, or motor overheating because of frequent start;
e. broken bar of rotor;
f. motor lacking of phase;
g. winding covered with dust or other foreign materials affects motor heat radiation;
h. cooling temperature is too high;
i. blower fan failures cause blocked air duct and bad ventilation;
j. stator winding interturn short-circuit, phase fault and winding grounded or incorrect internal
wiring;
WARNING: if the motor fault cannot be treated because of the limited condition, please
contact with manufacturer!

5. Maintenance

5.1 General Technical Requirements

5.1.1 Clean up motor frame and blower, inspect for cracks and defection, screw thread and nameplate
in good condition.
5.1.2 Ensure that no damage or burn is found in the insulation of stator coil, wires, collecting ring; and
lead-out wire should be marked clearly;
5.1.3 Measure stator winding resistance and the difference should not be not more than ±10% of
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 User Manual of HTB12 AC Drilling Motor

standard value at 20℃.

5.1.4 Motor insulation resistance
Measure cold insulation resistance with megohmmeter and no less than the following values:

Position Cold insulation resistance Tool

stator winding to earth 1.5 MΩ 1000V megohmmeter
auxiliary electric system to earth 0.5MΩ 500V megohmmeter

5.1.5 Withstand-voltage test between stator winding to ground

Test voltage should be 50HZ, 1760V sine wave AC power and last for 1 minute, there should be
free of flashover.
5.1.6 Measure the interturn insulation of stator winding by pulse withstand voltage insulation tester:
3600V pulse voltage for each phase and last for 3 minutes, as the result of no damaged.
5.1.7 Motor idles as the following condition, as a result, no abnormal vibration and noise for bearing,
and all parts in good condition:

RPM(r/min) 100 500 700

TIME(min) 5 30 5

5.2 Original data and limit value

Item Name Original shape Limit

+0.105
1 Stator connecting flange rabbet diameter (mm) Φ1008H7 0
+0 .081
2 Fitting surface diameter of rotor shaft sleeve and Φ281H8 0
expansion kits (mm)
3 Stator winding wire resistance at 20℃ (Ω) 0.0044 10%

5.3 Procedures and Requirements

5.3.1 Disassemble motor and remove power supply and auxiliary cables; dismantle end-cover terminal
box; remove stator flange connecting bolts and dismantle stator; loosen expansion kits bolts and
dismount the kits and rotor.
5.3.2 Clean and remove dust from end cover and expansion kits, etc.
5.3.3 Blow the stator and rotor with ≤0.6Mpa compressed air, and clean with gasoline or mild cleaning
solution and then wash off by water. So lift them into drying cabinet and increase temperature by
30℃ per hour; till reaches 60℃ around to keep for 2 hours, so as to evaporate steam completely;
and till increases to 110～120℃ and keep drying for 4 hours. During this period, measure winding

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 User Manual of HTB12 AC Drilling Motor

insulation resistance with 1000V megohmmeter at interval of 1 hour, if the difference of 3

consecutive results is not more than 10% and hot insulation resistance no less than 1.5MΩ, this
drying can be considered up to standard.
5.3.4 Stator Maintenance
Inspect the clean and dry stator for insulation damage, and wiring fastening and order.
Measure stator winding resistance with double bridge, the standard value can be referred to 5.2.
Withstand voltage test: test voltage as 1760V, last for 1min and without breakdown or flashover.
No damage or collision for stator flange rabbet.

5.3.5 Rotor Maintenance

Do not accumulate oil particles or dust on rotor bars, end rings or spider ventilating holes.
Ensure rotor bars and end rings without cracks or deformation.
For the rotor which lacks of balance, becomes loosening and has large vibration when idles, apply
dynamitic balance adjustment, and the unbalance tolerance is 29444g•mm.
The connection place of spider shaft sleeve and expansion kits should be without damage.
5.3.6 Inspect expansion kits for cracks, scratches on inside and outside ring, crack and damage on
tightening bolts; replace as necessary. Smear anti-corrosion oil after the inspection meets with
standard.
5.3.7 Motor assembly
Lift rotor onto MP pinion shaft with special tools, and fix expansion kits in place by tightening all
bolts and adjusting; and connect stator and MP with flange, but assure the coaxiality of rotor core
and stator core no more than 0.2; fasten end-cover terminal box and check the sealed area and
sealing strip, add as necessary; inspect the lead-out wires for firm; mount blower assembly by
connecting volute with motor air inlet. Refer to chapter 3 Installation and Operation for details.
5.3.8 The reassemble motor should be performed the idle test as 5.1.7, as a result, motor should be
running normally.
5.3.9 After carry out medium maintenance, should be tested as the routine items and standards.

6. Transportation and Storage

6.1 Transportation
6.1.1 Pack the stator, rotor, blower and expansion kits in container and transport separately. Protect
stator air inlet with rain cover; and place steadily, do not turn over or collide.
6.1.2 During transportation, prevent from moisture, pollution or damaged due to bad package.

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6.2 Storage
6.2.1 After motor arrives on location, customer should check the motor for damage, moisture and
corrosion.
6.2.2 Take necessary measures for connection to prevent from corrosion.
6.2.3 Store the motor at the location of dry, clean and free of acid, alkali and corrosive. Motor should be
placed steadily and keep upright, and on the top, don’t put anything.

7. Main parts list

S/N Name Code Qty. Weight Remark
1 Rotor assembly YJ12.100.000 1 1232
2 Expansion kits JB/T 7934 1 17.5 Purchased
Z5-215.9×281 part
3 Blower assembly BL12-11C 1 250 Purchased
part
4 Washer 12 GB/T 97.1 12 0.072 Dacrotized
5 Washer 12 GB/T 93 6 0.024
6 Nut M12 GB/T 6170 6 0.12 Dacrotized
7 Bolt M12×35 GB/T 5783 6 0.3 Dacrotized
8 Air duct YJ12.400.000 1 28
9 Bolt M8×30 GB/T 5783 12 0.18 Dacrotized
10 Washer 8 GB/T 93 12 0.024
11 Washer 8 GB/T 97.1 12 0.024 Dacrotized
12 Stator assembly YJ12.200.000 1 1575
13 Bolt M6×12 GB/T 5783 20 0.16 Dacrotized
14 Washer 6 GB/T 93 20 0.02
15 End-cover terminal box YJ12.300.000 1 84
16 Ex. cable joint PG16 WH-05 3 0.6 Purchased
part
17 Plug and socket 16GZ-10K/16YT-10J 1 0.8 Purchased
part
18 Ex. cable joint PG42 WH-07 7 2.8 Purchased
part

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