- INDEX –

PAGE

1. Introduction ---------------------------------------------------- 5

2. Explanation Of Terms And Symbols ----------------- 6

3. Installation Method ------------------------------------------- 7

4. Safety ---------------------------------------------------------------- 10

4.1 Safety Rules

4.1.1 Safety During Transportation
4.1.2 Storage Location
4.1.3 Long-Term Storage
4.1.4 Safety At Installation Site
4.1.5 Safety During Installation
4.1.6 Safety Before Operation
4.1.7 Safety During Operation
4.1.8 Safety During Checking / Servicing
4.1.9 Protection Of Motor

5. Unloading And Storage ------------------------------------- 13

5.1 Unloading
5.2 Storage

6. Installation And Wiring ------------------------------------- 14

6.1 Installation
6.2 Wiring
6.2.1 Precautions
6.2.2 Selecting Cable
6.2.3 Wiring

2
 - INDEX –
PAGE

7. Operation ---------------------------------------------------------- 16

7.1 Preparation For Operation

7.1.1 Checking Installation
7.1.2 Terminal Section
7.1.3 Insulation Resistance
7.2 Operation
7.3 During Operation
7.3.1 Checking For Unusual Sound
7.3.2 Checking For Unusual Vibration
7.3.3 Divergence Of The Damper ( if installed )

8. Maintenance ----------------------------------------------------- 18

8.1 Purpose
8.2 Daily Checking
8.3 Periodic Checking
8.4 Overhaul And Checking
8.5 Checking Bearing
8.6 Replacing Bearing

9. Troubleshooting ----------------------------------------------- 24

9.1 Procedure For Troubleshooting

9.2 Safety Precautions

3
1. Introduction
This manual includes, in addition to operating instructions, safety guidelines which anyone
working with the machine should observe.
Please read the complete manual to familiarize yourself with the entire unit before
installing.
Failure to observe these instructions contained in this manual may cause serious
personal injury and / or property damage.

! Warning
△

Always take proper precautions when using this product.

Otherwise death or severe personal injury can result.
Operator and maintenance staff must carefully read all procedures described in this
manual before beginning any operation, maintenance or troublesomeness activity.

● Operation, adjustments, troubleshooting, service and maintenance on this machine.

Should only be carried out by personal who completely understand the information
described in this manual.
● Keep this manual at a location open to everybody and make it ready to read.
● If the ownership of the product is transferred, this manual should be kept by the new
owner.
● Should this manual is lost or damaged, immediately order the replacement manual from
us or our agent.
● Do not modify this product without our prior consent.
● Before carrying out troubleshooting on this product, contact us.
Improper troubleshooting will cause problem.

5
2. Explanation of terms and symbols
The following safety symbols and signs are used throughout the manual to
alert the reader to personal safety hazards or to identify conditions that may
result in equipment or property damage.
Special attention will be required when any of these symbols are used.

! WARNING
△

Indicates that death, severe personal injury will result if proper precautions are
not taken.

! CAUTION
△

Indicates that medium or minor personal injury or property damage

can result if proper precautions are not taken.
It should be noted that failure to observe the safety rules described under the symbol .

! CAUTION ” may result in severe personal injury or property damage in a

“ △
particular situation.
Since these safety guidelines contain important information about the personal and
property safety, special attention will be required when any of these symbols are used.
The safety guidelines described in this manual cannot of course include all imaginable
precautions. As on extra aid, warning symbols have been attached to certain parts of
the machine as a means to alert the machine operator to personal safety hazards.
However, these means still cannot cover all imaginable precautions. It is obvious that
the person carrying and to check whether the operation/maintenance he/ she is
performing or is about to perform is correct.

It should be noted that certain illustrations in this manual are for a particular
model and may not exactly represent ones on your machine.

6
3. Installation method for axial flow fans

7
4. Safety

4.1 Safety rules

4.1.1 Safety during transportation

! Warning
△

● Use special caution when loading or unloading the product, which involves dangerous
works.
● When using crane to load or unload the product, make sure that the look of the crane
is positively engaged with the eyebolts or eyepieces on the product before lifting.
Disengagement of the hook will cause severe personal injury and/or properly damage.
The operator must keep enough distance from the crane while handling it so that
he/she can quickly leave the site in case the crane/product drops or falls down.
● When using a forklift for loading or unloading the product, pay special attention to
the weight of the product, stability of the load at the lift up position.
Severe personal injury or substantial property damage will result if the forklift/product
drops of falls down.
The operator must keep enough distance from the forklift while handling it so that
he/ she can quickly leave the site in case the forklift/product drops or falls down.

! Warning
△

● Once the product has been loaded, secure it with suitable fasteners such as wire rope,
fixing metal and square lumber. The loosen product will cause property and/or
equipment damage or personal injury.

! CAUTION
△

● Select a vehicle having enough capacity to carry a load of equal to or more weight
marked on the nameplate of the product.
● During transportation use sheeting to protect the quality of product against rain and dust.

10
4.1.2 Storage location

! CAUTION
△

● Do not expose the product directly to weather. The winding of weathered motor will
decrease the insulation resistance and may cause burning while the motor is running.

4.1.3 Long-term storage

! CAUTION
△

● When storing the product for a long period, completely cover the entire fan
with watertight sheet. Put enough quantity of moisture absorbent (e.g. silica gel )
inside the sheet and tightly secure it with tape or string for positive sealing to
prevent entry of moisture, oil, dust and other foreign materials.

4.1.4 Safety at installation site

! CAUTION
△
● Provide enough space around the product to ensure during maintenance and service.
Failure to observe this safety rule may cause personal injury.

4.1.5 Safety during installation

! WARNING
△
● When using a crane, make sure that the hook of the crane is positively engaged with
the eyebolts or eyepieces on the product. Disengagement of the hook will cause severe
personal injury and/or property damage.
● Never climb on the product to reach certain parts. Sever personal injury can result
due to drop down and falling down.

4.1.6 Safety before operation

! CAUTION
△

● Ensure that the multi-phase devices are properly wired and connected. Reverse rotation
causes the air to flow in reverse direction which may result in personal injury.
● Ensure that required insulation resistance is maintained. Lower insulation resistance
will cause current leakage, resulting in personal injury.
● Do not touch the terminals during measurement of insulation resistance. Failure to
observe this caution may result in personal injury from electric shock.

11
4.1.7 Safety during operation
! CAUTION
△
● Do not operate the unit with the damper (if installed) fully or nearly fully closed.
The motor is cooled by the air coming from the impeller.
Fully or nearly fully closed damper will cause the motor to burn.

4.1.8 Safety during checking/servicing

! WARNING
△
● Never touch the rotating portion while it is operate. Failure to this warning will result
serious personal injury.
● Do not touch the motor while it is running. It is hot.
● Wear a helmet, safety shoes and gloves when working near the impeller.
Do not wear loose clothes and a tie which may be sucked by the impeller.
● Do not perform adjustments/troubleshooting/service/maintenance with the power supply
still on to avoid personal injury. During adjustments, maintenance, troubleshooting,
etc., take the proper precautions not to allow anyone to operate the machine.
Tag warning label having wording “ Under maintenance. Do not operate!” on the start
button of the starter. Work area should be designated to caution people that
equipment is being serviced.
● Do not touch the terminal box or motor with wet bare hands. Take necessary precaution
not to wet the terminal when the terminal box is open. The wet terminal will cause
personal injury due to electric shock or leakage, or burn due to short circuit.

! WARNING
△
● Secure the cover of the terminal box. The loosen cover will allow water to penetrate into
the terminal box and motor may burn, or cause personal injury due to electric shock or
leakage.

! CAUTION
△
● Do not drop a spanner, bolts, etc. If these touched the impeller damage to the impeller
may result.

4.1.9 Protection of motor

! CAUTION
△
● Equip the starter with motor protection circuit required by rules and regulations.
The motor is not provided with protection circuit.
Without a protection circuit, the motor may burn.

12
5. Unloading and storage

5.1 Unloading

! WARNING
△

● When using crane to load or unload the product, make sure that the hook of the crane
is positively engaged with the eyebolts or eyepieces on the product before lifting.
Disengagement of the hook will cause severe personal injury and/or property damage.
The operator must keep enough distance from the crane while handling it so that
he/she can quickly leave the site in case the crane/product drops or fails down.
● When using a forklift for loading or unloading the product, pay special attention to
the weight of the product, stability of the load at the lift up position. Severe personal
injury or substantial property damage will result if the forklift while handling it so that
he/she can quickly leave the site in case the forklift/product drops of falls down.

1) When unloading the product by using a crane, attach eyebolts (or shackle) to each
flange Hole. Insert hooks of the crane into the eyebolts ( or shackles).
2) When unloading the product by using a forklift, take special precautions to maintain
stability while the product is lifted high since the product is top heavy.

5.2 Storage

! CAUTION
△

● Do not expose the product directly to weather. The winding of weathered motor will
decrease the insulation and may cause burning while is running.

Like other electric equipment, the product is susceptible to water, high temperature, high
humidity and dust. Store the product in a location free from these detrimental effects.

13
6. Installation and wiring

6.1 Installation
! WARNING
△
● There is a fear of personal injury, therefore, arrange a safety guard over exposed
rotating portion.
● When using a crane, make sure that the hook of the crane is positively engaged with
the eyebolts or eyepieces on the product. Disengagement of the hook will cause severe
personal injury and/or property damage.

Attach the eyebolts (or shackle) into each of the 2 flange holes. Lift the product by eyebolts
(or shackle) and move the product to the installation position.
Secure the flanges with bolts.

6.2 Wiring

6.2.1 Precautions
! WARNING
△
● Do not touch the terminal with wet bare hands.
The wet terminal will cause personal injury due to electric shock or leakage, or burn
due to short circuit.
● Positively clamp the terminal of each phase. Any loose connection may result in
single – phase operation or short circuit and may cause personal injury due to
electric shock or leakage, or damage to the motor due to burned.
● Secure the cover of the terminal box. The loosen cover will allow water to penetrate
into the terminal box and the motor may burn, or cause personal injury due to
electric shock or leakage.

6.2.2 Selecting cable

! CAUTION
△
● Select cables which can carry the rated cable current can supply the rated fan
voltage to the terminal. Excessive voltage drop through the cable lowers the terminal
voltage of the fan, causing excessive current to flow like overloading. When running a long
cable between the power source and the fan, select a cable of appropriate size so that
the voltage on the terminal of the fan is kept at the rated value.
When running a long cable between the power source and the fan, select a cable of
appropriate size so that the voltage on the terminal of the fan is kept at the rated value.

14
6.2.3 Selecting cable

After installation, connect electric wiring referring to the below which illustrates various
starting methods. Find the correct wiring diagram that matches the starting method given in the
approval drawing or finally drawing.

Connection for single speed motors :

Two separate windings for two speed motors :

Dahlander system for two speed motors, constant torque :

Dahlander system for two speed motors, quadratic torque :

15
7. Operation

7.1 Preparation for operation

7.1.1 Checking installation

1) Ensure that all bolts are correctly tightened.
2) Make sure that unusually vibration is not transmitted from the hull, especially when the
ship is sailing.
If the fan excessively vibrates even when the ship is in stop, the hull is excessively
Vibrating under this condition will damage the shaft and bearing and even cause motor
Burning. Reinforce the hull.

7.1.2 Terminal section

1) Make sure that lead wire insulation is free from damage and cracks. If any, repair
the wire.
2) Check phase terminals for looseness. If any, retighten and apply locking paint.
3) Check phase wiring for correct phase sequence. If wrong, correct.
Check to see if the rotating direction is correct.
The rotational direction of the fan is indicated by an arrow on the fan casing,
the fan protection or the name plate.
The should be checked by briefly starting the motor and observing the rotating parts.
If it is wrong, the electrical leads must be reconnected.
! CAUTION
△
● Before the rotational direction is reversed, the impeller must come to a complete standstill.
The high moment of inertia can otherwise lead to damage.

4) Ensure that the inside of the terminal box is free from water and dust. If any, clean
the inside of the box.

7.1.3 Insulation resistance

1) Using 500 V megger, measure the insulation resistance between each winding
and the ground.
The resistance should be greater than the value given in the equation below :

Rated voltage x 3 (V) The resistance should

Insulation resistance = (㏁)
not smaller than 1 ㏁.
Rated output (㎾) + 1000

16
7.2 Operation

Operation is made from the starter. For operating information of the starter, refer to the
starter manual supplied by the starter maker.

7.3 During operation

7.3.1 Checking for unusual sound

! WARNING
△
● Do not touch the listening rod directly to the motor. If the rod touches the impeller,
sever personal injury or damage to the impeller may result. Instead, touch the rod
to the casing.

During operation, check parts for unusual sounds. To check the motor and bearing byear.
use the listening rod.

7.3.2 Checking for unusual vibration

During operation, check parts for unusual vibration. Unusual vibration is caused by
resonance of fan vibration and hull vibration, or stiffness of the base, mounting plate or floor
on which the unit is mounted is low. Continuous operation under this condition promotes
wear of the shaft and bearing and may burn the motor. Reinforce the base, mounting
plate and floor.

7.3.3 Divergence of the damper ( if installed )

! CAUTION
△
● Do not operate the unit the damper fully or nearly fully closed. The motor is cooled by
the air coming from the impeller. Fully or nearly fully closed damper will cause the
motor to burn.

The motor driving the fan is cooled by the air flowing the impeller. If the damper ( if installed )
is fully or nearly fully closed, the motor will overheated and should be stopper.

17
8. Maintenance

! WARNING
△
● Never touch the impeller while it is running. Failure to this warning will result in severe
personal injury.
● Do not touch the motor while it is running. It is hot.
● Wear a helmet, safety shoes and gloves when working near the impeller. Do not wear
loose clothes and a tie which may be sucked by the impeller.
● Do not perform adjustments/ troubleshooting/service/maintenance with the power supply
still on to avoid personal injury. During adjustments, maintenance, troubleshooting, etc.,
take the proper precautions not to allow anyone to operate the machine.
Tag warning label having wording “ Under maintenance. Do not operate! ” on the start
button of the starter. Work area should be designated to caution people that equipment
is being serviced.
● Do not touch the terminal box or motor with wet bare hands. Take necessary precaution
not to wet the terminal when the terminal box is open. The wet terminal will cause personal
injury due to electric should be designated to caution people that equipment is being
serviced.
● Secure the cover of the terminal box. The loosen cover will allow water to penetrate
into the terminal box and motor may burn, or cause personal injury due to electric
shock or leakage.

8.1 Purpose

The purpose of maintenance is to prevent possible fault by detecting and eliminating

defective as earlier as possible so that the system can maintain top performance.
Keeping the maintenance records is also important.

18
8.2 Daily checking

The purpose of maintenance is to prevent possible fault by detecting and eliminating

Carry out daily check on the items given in Table 8-1 before and during operation without
disassemble the machine.

Table 8-1 Daily checking

Inspection items
Items Limits Action
Check Method
Power Voltage Voltmeter Rated value ± 2~3%
supply regulation If outside the limits,
regulate the voltage
Current Ammeter Rated value or less ※ 1
regulation
Operation Vibration Finger touch Normal, no level change If unusual, stop the
or vibration Machine and isolate
the cause
Noise By ear or Normal, no level change If excessive stop the
listening rod Machine and isolate
the cause
Fume By noses No odd fume Stop the machine and
isolate the cause

※ 1 : In winter or when the ship is sailing in extremely cold area, the air density is high
and requires more power for the motor to allow it to easily flow the air. The current
value may exceed the rated value but the low ambient temperature will allow heat due
to over current to dissipate, allowing the motor to operate under the rated power.
However, settings on the thermal relay on the starter should be changed.
For resetting, consult us.

19
8.3 Periodic checking

Check the parts likely to wear and measure values which can be determined in a short time,
every 2 or 3 months, according to Table 8-2

Table 8-2 Periodic checking

Inspection items
Items Limits Action
Check Method
Installation Bolts Visual check No looseness Retighten, if loosen
coating
Peeling or Visual check No damage, discoloration Remove rusts, apply
Rust , peel, rust rust preventive
coating and finish
coating

Insulation Between 500 V megger Higher than the value Measure again after
resistance stator specified in 7.1.3 drying the stator
winding and winding. If still low,
ground repair

Terminal Junction Visual check No loosen connection Retighten

box No broken cable and lead Repair
wires
Internal Visual check No evidence of water and Remove the cause,
check dust inside the box repair or clean
packing Visual check No degradation, damage, Replace
deformation

20
8.4 Overhaul and checking

Overhaul the machine to expose the parts which cannot be checked without first
Disassembling, once every 1 or 2 years, according to Table 8-3. Also perform checking
described in item 9.3.

Table 8-3 Overhaul

Inspection items
Items Limits Action
Check Method
Impeller Dust, peel- Visual check No excessive dust, Remove the cause and
Ing of coat- peeling, rust repair and clean
Ing, rust
Motor, Visual check No excessive dust, Remove the cause and
appearance Dust, peel- peeling, rust repair and clean
Ing of coat-
Mounting Ing, rust Visual check No excessive dust, Remove the cause and
foot Dust, peel- peeling, rust repair and clean
Ing of coat-
Bolts and Ing, rust Visual check No rust, corrosion Replace
fasteners Rust
Packings corrosion Visual check No degradation, Replace
degradation, damage,
damage, deformation
deformation

21
8.5 Checking bearing

Condition of ball bearing can be exactly checked by monitoring sound from the bearing,
provided that the person performing the checking is well experienced in distinguishing
between normal and unusual sound. Familiarize yourself with normal bearing sound by
listening the bearing sound as often as possible. To do so, use the listening rod and
touch it to the bolts securing the mounting base of motor casing.
Table 8-4 / 8-5 shows guidelines for diagnosing bearing.
When you hear a sound which is different from those you are familiar with, stop operation
and check the bearing in question and take necessary action.

Table 8-4 Bearing diagnostic guidelines

Sound Level Limits Action

Ball race Low Should sound in the way when such ball Isolate the cause
bearings rotating normally
Retainer Low to Retainer is struck by bearing Replace the
high bearing
Scratch Moderate Generates when a shaft is turned to a particular Replace the
sound to high position. Continuously heard when the bearing is bearing
rusty
Dust sound Low irregular sound, indicating possible wear Replace the
bearing

22
 Table 8-5 Trouble investigation guidelines

No. Trouble Characteristic Probable cause

1 Noise Low noise (rustle Dent formed on the race face owing

or rumble) to careless installation.

Dents formed on the race face by

external vibration while the fan is at rest.

High-pitched noise Too small clearance

Intermittent noise Foreign matter clearance.

Resonance due to careless assembly

about the housing.

2 Abnormal Insufficient clearance during operation.

temperature rise Overload

Axial check on the Too tight fitting.

3 Crack
inner or outlet ring Uneven installing surface.

Housing deformation

Circumferential crack Uneven installing surface.

on the inner or outer ring Extreme overload.
Crack on the retainer or ball due
Irregular crack
to grease aging.

4 Indentation Indentation of the Knock during installation.

on the race face same pitch as the ball
Great blow struck on the bearing while the
fan is at rest
5 Retainer Grease aging.
damaged Ball damaged.
Rivet damaged by vibration.
Local sports on the Corrosion by acid or moisture while
6 Rust race face the fan is at rest for a long time.
Surface rust Incomplete contact (Faulty fitting)

8.6 Replace bearing

The bearing used on the motor is sealed type ball bearing containing grease, requiring no
additional grease. The life expectancy of the sealed type ball bearing is approx. 2 years but
depending on its size, grease used, operating temperature and operation hours.
It should be replaced whenever suspective, regardless of operating hours.

23
9. Troubleshooting

After the installation of an air moving system is completed the system sometimes fails
to achieve its designed performance.
This part will help you find what is wrong and decide how to correct lt.

9.1 Procedure for troubleshooting

1. Look in the “Master Troubleshooting Appendices” for a subject which corresponds

with the apparent problem.
2. Check each of the “ Probable Causes ” listed.
3. It the problem has still not been solved, it is now advisable to contact the representative
of the fan manufacturer.

9.2 Safety Precautions

Before checking the fan and system it will be necessary to shut down the fan.
During inspection the fan must be electrically isolated and all disconnect switches and other
Controls locked in the “OFF ” position. Where these are in locations remote from the fan,
prominent DO NOT START signs should also be in place.

! CAUTION
△
● Even when locked out electrically, fans located outdoors or in a parallel or series fan
system may be subject to “ windmilling .“ Therefore, as an added precaution, the impeller
should be secured to physically restrict rotational movement.

24
 Table 9-1 Troubleshooting

Source Symptom Probable cause

a. Impeller nor centered in inlet or housing.
b. Inlet or housing damage.
c. Crooked or damaged impeller
Impeller Hitting Inlet d. Shaft loose in bearing
or Housing e. Impeller loose on shaft
f. Bearing loose in bearing support.
g. Bent shaft.
h. Misaligned shaft and bearings.
a. Cutoff not secure in housing.
Impeller Hitting Cutoff b. Cutoff damaged.
c. Cutoff improperly positioned.
a. loose on shaft
b. Defective impeller.. Do not run fan.
Contact the manufacturer.
c. Unbalance.
NOISE
d. Coating loose.
Impeller
e. Worn as result of abrasive or corrosive
Material moving through flow passages.
f. Blades rotating close to structural member.
g. Blades coinciding with an equal number
of structural members.

a. Foreign material in housing.

Housing b. Cutoff or other part loose (ratting during
operation)

a. Lead-in cable not secure.

b. AC hum in motor or relay.
c. Starting relay chatter.
Motor
d. Noisy motor bearing.
e. Single phasing a 3 phase motor.
f. Cooling fan striking shroud.

25
Source Symptom Probable cause
a. Defective bearing.
b. Needs lubrication.
c. Loose on bearing support.
d. Loose on shaft.
e. Seals misaligned.
Bearing
f. Foreign material inside bearing
g. Worn bearing.
h. Fretting corrosion between inner race and
shaft.
i. Bearing not sitting on flat surface.
a. Bent.
Shaft b. Undersized. May cause noise at impeller,
bearings or sheave.
a. Needs lubrication
b. Misaligned.
Shaft Seal Squeal c. Bent shaft.
d. Bearing loose on support
NOISE
a. Coupling unbalanced, misaligned, loose
Coupling May need lubricant.
b. Loose key.
a. Ductwork too small for application.
b. Fan selection too small for application.
High Air Velocity c. Registers or grilles too small for application
d. Heating or cooling coil with insufficient face
area for application.
a. restricted system causes fan to operate at
poor point of rating.
b. Fan to large for application.
c. Ducts vibrate at same frequency as fan
Pulsation Or Surge pulsations.
d. Rotating stall.
e. Inlet vortex surge.
f. Distorted inlet flow.
g. Unbalance of impeller.

26
 Source Symptom Probable cause
a. Impeller installed backwards.
b. Impeller running backwards.
c. Improper blade angle setting.
d. Cutoff missing or improperly installed.
e. Impeller not centered with inlet collar(s).
Fan
f. Fan speed too slow.
g. Impeller / inlet dirty or clogged.
h. Improper running clearance.
i. Improper inlet cone to wheel fit.
j. Improperly set inlet vane or damper.
a. actual system is more restrictive (more
resistance to flow) than expected.
INSUFFICIENT
b. Dampers closed.
AIR FLOW Duct system
c. Registers closed.
d. Leaks in supply ducts.
e. Insulating duct liner loose.

a. Dirty or clogged.
Filters b. Replacement filler with greater than
specified pressure drop.

a. obstruction near fan outlet or inlet.

b. Sharp elbows near fan outlet or inlet.
Obstructions In High
c. Improperly designed turning vanes.
Velocity Air Stream
d. Projections, dampers or other obstruction
a part of the system where air velocity high.
a. Fan speed too high
Fan
b. Blade angel not set properly.
POWER a. Oversized ductwork.
HIGH b. Face and by-pass dampers oriented so co
System
c. Filler(s) left out.
d. Access door open.

27
 Source Symptom Probable cause

Mechanical and electrical problems are usually

Straightforward and are normally analyzed in
a routine manner by service personnel.

a. blown fuses.
b. Broken belts.
c. Loose pulleys.
FAN DOES
Electric Or Mechanical d. Electric turned off.
NOT OPERATE
e. Impeller touching housing
f. Wrong voltage.
g. Motor too small and overload protector has
broken circuit.
h. Low voltage, excessive line drop or inade-
Quate wire size.
i. Load inertia too large for motor.
j. Seized bearing.

28
12. Normal type electric motor

39
Index

rotor nl electric motors

3

Insulation class
Various insulation materials, each with their 3
own function, are used in electromotors.

The most important of these are:

- insulation of the winding wire
- slot and phase insulation materials as 1 2
insulation between the windings and the
2 1
stator stack and the phase windings
mutually.
- impregnation of the complete winding.
- insulation sleeves for the connections.
- insulation of the leads (including the Stator winding not yet completely finished and not Stator winding completely finished.
connection between the winding and the impregnated.

N
terminal board). 1. groove insulation 1. insulation sleeves
2. phase insulation 2. bandaging tape
All of these insulation materials are sub- 3. leads 3. leads
divided into classes that are designated by a
letter (Y - A - E - B - F - H - C). Each class has
its own temperature limit (see table). An
insulation material of a certain class retains its
mechanical and electrical properties at the
accompanying limit temperature with a
reasonable long life-cycle.

The temperature limits are taken as the basis

for ascertaining the maximum permissible rise
in temperature of the winding (see table). This
is based on continuous use (S1) of the
nominal output at an ambient temperature of
40 ºC for land-based systems.

When the motor is being used the temperature

of the winding will rise, primarily as a result of
the copper and iron losses in the motor. It is
customary to determine the average tempera-
ture rise of the winding using the resistance
method (measurement of the increase in the
winding resistance caused by the rise in tem-
perature). Because this method cannot be
used to measure the highest temperature at
one point in the winding, lower values than
those of the temperature limits of the insula-
tion materials applied are taken for calculating
the maximum permissible rise in temperature.

There is presently an increasing demand for a

standard motor with insulation class F and a
winding temperature rise corresponding to the
B class (max. 80 K). For this design an extra
temperature reserve of 25 K is provided as
standard. The user can use this reserve
(among other things) for the application of a Insulation class A E B F H F*
higher ambient temperature (above 40 ºC), for
loads above the nominal output and for appli- Temperature limit 105°C 120°C 130°C 155°C 180°C 155°C
cations in which allowance has to be made for Max. temperature of
the winding 100°C 115°C 120°C 145°C 165°C 145°C
a greater supply voltage fluctuation than
normal. It will be clear that this usually invol- Ambient temperature of 40°C 40°C 40°C 40°C 40°C 40°C
ves an or/or situation in which it is always the land-based system
advisable to discuss the options with the Maximum ∆ T (K) of the 60 K 75 K 80 K
GA
105 K 125 K L
LC
80 K
manufacturer. stator winding AC LD W
F

Extra thermal reserve + 25 K

T LA

* Insulation class F (155ºC) with a winding temperature rise corresponding to the B-class (max. 80 K).
DA
S

This results in an extra thermal reserve of 25 K.

M
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Index

rotor nl electric motors

Protection class IP
For rotating electrical machines protection
classes are laid down against the penetration
of solid particles and water. These aspects are
laid down in the standard: IEC 34-5 (NEN-EN
60034-5).
Key figures
The protection level is designated with an IP
class with two key figures for protection
against solid particles and water respectively.
By way of example we will take the protection
class
The rotor nl® motors are presently supplied in
IP55, so that the motors are suitable for
normal outdoor use.
The more or less tightness for dust and water
is accompanied by a number of problems. Of
these, the two given below are the most
important:
1st: Good dust seals ‘drag’ and lead to more
heat generation in the bearing construc-
tion, especially in fast-running motors.
2nd: Condensation holes that serve to provide
internal pressure equalisation and allow
the motors to ‘breath’ must be partially
(for IP55) or fully (IP56) closed.
The problem is more serious for the protection
class IP56, especially for motors from frame
size 100 upwards. The free air content of these
motors is so great that condensation has to
occur during fluctuating temperatures caused
by the motor itself.
The chance of condensation forming is
minimal if the internal temperature is kept at
least 5ºC above the ambient temperature. This
of course only applies when the motor is not
running, as a running motor always heats up.
A frequently used solution is to install stand-by
heating. It must however be borne in mind that
this stand-by heating must never be used

N
IP-55:
IP = class designation that indicates the
protection level against the penetration
of foreign objects.
5 = (1st key figure) dust-proof to a limited
extent. The dust may not penetrate to the
extent that it adversely affects correct
functioning.
5 = (2nd key figure) Protection against water
sprays (at a certain pressure) from any
given direction.
The higher the figures, the higher the level of
protection (see the tables).
Appropriate measures can be taken for the first
problem in the seals in the shields or the
bearing covers, but because of the considera-
ble heat generation not in the bearings them-
selves. The second problem is less simple
because the formation of condensation beco-
mes much greater at a higher protection level.
For protection class IP55 an extra moisture-
resistant coating (tropical insulation is
standard) is usually sufficient to protect the
winding.
when the motor is running.
The choice of a protection class is always
based on reducing the chance of a motor
malfunctioning. However, this can never
guarantee that the motor will never
malfunction. It will be clear that a higher
protection class than is strictly necessary for a
certain application can often have an adverse
effect on reliability.
Furthermore, the motor must be set up in
compliance with the mounting given on the
typeplate.

protection classes indicated by the first key figure protection classes indicated by the second key figure

1st protection against solid particles 2nd protection against water

0 No special protection 0 No special protection

50 mm.

Protection against the penetration of solid Protection against water falling directly
1 particles with a diameter greater than 50 mm.
1 onto the motor

12 mm.

Protection against the penetration of solid Protection against water falling onto the
2 particles with a diameter greater than 12 mm.
2 motor at a maximum angle of 15º.

2,5 mm.

Protection against the penetration of fixed Protection against water that falls onto the
3 particles with a diameter greater than 2.5 mm.
3 motor at a maximum angle of 60º.

1 mm.
Protection against the penetration of Protection against spattering water that
4 solid particles with a diameter greater than 1 mm.
4 falls onto all sides of the motor.

Dust-tight to a limited extent. The dust may not Protection against water sprays (at
GA LC a
5 penetrate in such quantities that the proper 5 certain pressure) from any given direction.
L
functioning of the motor is adversely affected. AC LD W
F

Protection against showers

T LA or powerful

6 water sprays (e.g. upper deck set-up on

DA
S

ships)
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rotor nl electric motors

Connection diagrams
Single-speed motors suitable for 2 voltages by winding connection in Υ or ∆
A B B A Low power motors (≤ 2.2 kW) are usually switched on
directly in Υ position (D.O.L). With a supply voltage of 3 x
400V-50Hz, for instance, the motor used has a winding that
W2 U2 V2 W2 U2 V2 W2 U2 V2
is suitable for 3 x 230V/400V-50Hz.
U1 V1 W1 U1 V1 W1 (switching ∆ and Υ respectively).
U1 V1 W1
B For greater outputs motors should preferably be switched in
Υ position during the starting period so that the winding is
L1 L2 L3 L1 L2 L3 L1 L2 L3 suitable for √3 x the mains supply voltage. In actual fact the
motor then starts operating at an under-voltage, which
significantly limits the starting current during the starting
Running connection Running connection
period. With a supply voltage of 3 x 400V-50Hz, for instance,
Start-up connection
motor 3 x 230V / 400V - 50Hz motor 3x400V/690V-50 Hz motor 3x400V/690V-50 Hz the motor used has a winding that is suitable for
supply voltage 3x400V-50 Hz supply voltage 3x400V-50 Hz supply voltage 3x400V-50Hz 3 x 400V/690V-50Hz.
(switching ∆ and Υ respectively).
Pole-changing motors with 2 separate windings
type number of start up 1 Motors with an output lower than 2.2 kW at the low speeds
are usually designed as Υ / Υ.
connection terminals low speed high speed
2 Motors with an output greater than 2.2 kW in the low speeds
1 Υ/Υ 6 direct direct*
in ∆ / Υ. Motors with connection types 3 and 4 are available
2 ∆/Υ 9 star-delta direct*
at an extra price (special on request). An advantage here is
3 Υ/∆ 9 direct star-delta
the low starting current during the entire start-up period,
4 ∆/∆ 12 star-delta star-delta
also at the high speeds.
1 1 2 2 2
L1 L2 L3 L1 L2 L3
2U 2V 2W 2U 2V 2W 2U 2V 2W 2U 2V 2W 2U 2V 2W

1U 1V 1W 1U 1V 1W 1W2 1U2 1V2 1W2 1U2 1V2 1W2 1U2 1V2

1U1 1V1 1W1 1U1 1V1 1W1 1U1 1V1 1W1

L1 L2 L3

L1 L2 L3 L1 L2 L3

Running connection Running connection Start up connection Running connection Running connection
low speed high speed low speed low speed high speed

*note
It is usual to switch on the high speed via start-up in the low speed. The starting current for the direct switching in the high speed is not limited by this, but
the starting time with this high current is however shorted.
Pole changing motors with Dahlander winding
type perc. output low number of connection
connection speed compared to high terminals low speed high speed
5 ∆ / ΥΥ 50 a 80 % 6 direct direct*
6 ∆ / ΥΥ 50 a 80 % 9 star-delta direct*
7 Υ / ΥΥ 20 a 30 % 6 direct direct*

5 7 5 7 6 6 6
L1 L2 L3 L1 L2 L3
2U 2V 2W 2U 2V 2W 2U 2V 2W 2U 2V 2W 2U 2V 2W

1U 1V 1W 1U 1V 1W 1W2 1U2 1V2 1W2 1U2 1V2 1W2 1U2 1V2

1U1 1V1 1W1 1U1 1V1 1W1 1U1 1V1 1W1

L1 L2 L3

L1 L2 L3 L1 L2 L3
Running connection Running connection Start up connection Running connection Running connection
low speed high speed low speed low speed high speed

5 6 Dahlander B connection ∆ / ΥΥ; delta/double star GA LC

At low speed the winding is connected in delta, for which there are two options: with 6 terminals for outputs lower than 2.2 kW and possibly
L 9
AC LD W
terminals for greater outputs.
F

7 Dahlander C connection Υ / ΥΥ; star/double star T LA

The nominal output at the low speed is 20 to 30% of the output at the high speed (fan usage). The low speed is constantly connected in star
DA

internally and directly switched on (no switch to delta). The high speeds are also double-star connected, also for direct switching (no switch to
S
M
22,5

delta).
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Index

rotor nl electric motors

Motor safeguards P.T.C. thermistors

As required and customary, electromotors are
safeguarded against overloading. An electro-
motor will malfunction if the insulation
materials lose their mechanical and electrical
properties as a result of ageing caused by
overheating (burning).
Life cycle
The standardised value for the life cycle of
insulation materials is 20,000 to 25,000 hours,
based on the maximum permissible limit
temperature of the material in question.
Furthermore, the rise in temperature does not
immediately assume the final value if a certain
current runs through the winding. The
temperature rises gradually. It is therefore
possible to gain an idea of the temperature in
the electromotor by measuring the current.
This is done by using a thermal motor
safeguard switch. The motor current heats the
bi-metals in the switch, which also slowly heat
up. The switch is manufactured in such a way
that the bi-metals cut out the switch after a
certain period of time if the set temperature is
exceeded.
To get the most out of a motor and only
intervene if the maximum permissible winding
temperature is reached use can be made of
built-in P.T.C. thermistors (temperature
sensors) which detect when a certain winding
temperature is exceeded and shut down the
motor. If these resistors are connected in the
motor’s auxiliary power circuit, it will
automatically be shut down. This method is
therefore independent of the current and
responds exclusively to the temperature of the
winding.

Experience shows that this theoretical life
cycle is usually exceeded many times over.
The insulation class of the motor determines
the maximum permissible winding temperature
of 120ºC for class B (limit temp. 130ºC) and
145ºC for class F (limit temp. 155ºC).
For each 10 degrees that the maximum
winding temperature is exceeded, the life cycle
of the winding reduces by half.
The rotor nl® electromotors are fitted as
standard with class F (155ºC) insulation
materials, but are measured so amply that the
temperature of the winding remains far below
the F class. The anticipated life cycle will
therefore exceed the standardised life cycle
many times over.
N
An electromotor can therefore not be
safeguarded against overheating by using
fuses because they cannot be adapted to the
motor current and because they do not heat up
and cool down at the same time as the motor.
It is even inadvisable to select fuses that are
only a little higher than the input motor
current. If one fuse melts the motor will run on
2 phases, resulting in the possibility of the
thermal motor safeguard switch cutting out
too late or not at all. For motor switches the
fuses should be used exclusively as
safeguards against short circuits.
Machine safeguards

Motor safeguard switch
The temperature of the winding is determined
among other things by the power losses in the
motor. The ‘copper losses’ play an important
role in this respect. These copper losses are
proportional to the square of the input current
(Pcu = I2 x R).
The thermal motor safeguard switch can also
be used to safeguard the machine being
driven. If the safeguard is set by the input
motor current rather than the maximum
permissible (type plate) current, the motor will
cut out if the usual current is exceeded. The
motor is then shut down if something goes
wrong, although that does not mean that the
motor is being overloaded. Electromotors
usually run at only 30 - 80% of the maximum
permissible load. It is therefore better to set
the thermal motor safeguard switch to this
value, so that a change in the situation is
quickly responded to.

GA LC
The inside of a thermal motor safeguard switch The temperature of the winding can beLmonitored
showing the bi-metals (right) and the current setting AC by the PTC thermistors (temperature
LD sensors)
W fitted
F

(left). here.
T LA
DA
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Index
Motor cooling
Completely closed electromotors (TEFC) are
usually air-cooled by an airflow and are
therefore fitted with an external cooling fan
that is mounted on the motor shaft or driven
separately. It is also possible that the entire
motor without a fan (TEAO) is placed in an air
flow, usually together with the machine. For
some applications the motors (TENV) are not
fitted with a cooling fan and are not cooled
using another method either.
This is mainly the case for operation of very
short duration, e.g. S2 - 10 min.
Electromotors with forced cooling (TEFC and
TEAO) do however require at least 25 to 30
m3/min. cooling air per 100 kW.
Aspects important to the motor cooling
include a.o. the following:
- blade shape
- drive
- noise production
- power consumption
- motor mounting and maintenance
Blade shape
The simplest approach is when the cooling fan
is mounted directly on the motor shaft and
therefore runs at the same speed as the motor.
For industrial standardised motors the desired
direction of rotation is not generally known,
and electromotors of this type will therefore be
supplied with a neutral cooling fan with a
straight blade shape (radial fan) that is suitable
for both directions of rotation (clockwise or
counter clockwise). The disadvantage of these
fans is their relatively high power consumption
and their considerable noise production when
used with high speed motors.
An axial fan (such as that used for a ring
ventilator) is much more suitable and causes
much less noise. These economical cooling
fans can be mounted onto the motor shaft
using a special fitting, where the circumferen-
ce of the fan has to run within a ring to obtain
a good axial air flow. This calls for a completely
different fan hood, which will also be longer.
This extra length is needed to give the air a
divergent course of direction because the air
intake opening is not in line with the cooling
fins viewed axially. However, an axial fan is
only suitable for one direction of rotation.
axial cooling fan
Drive
N
For continuous use (S1 operation) the cooling
fan can be directly driven by the motor and is
therefore mounted directly on the motor shaft.
If an electromotor is frequently switched on
and off (e.g. S4 operation) extra heat will be
generated in the motor, certainly if the
machine has considerable moment of inertia,
because of the high and longer-lasting starting
current. Also, it will be clear that a motor which
is not running cannot be cooled by a fan that is
mounted directly on the same motor shaft.
If required by the application, motors can be
fitted with a separately driven cooling fan that
remains switched on during the electromotor’s
entire operating cycle.
This model is also used for electromotors that
are controlled by a voltage/frequency invertor
and where the motor has to turn slowly with a
relatively too high torque. (NB: if a ventilator
only runs at half speed, the air production will
only be 1/8).
AC
Rotor nl ® electromotor with forced cooling and separate drive.
M
22,5
45
44
rotor nl ®
(neutral) radial cooling fan
Noise production and power consumption
Noise levels can be substantially reduced by
using axial cooling fans instead of radial
cooling fans. This does of course depend on
the power and the speed. For 6 and 8 pole
motors ( 1000 and 750 min-1 respectively) the
advantageous effect is minimal. Also, axial
fans use considerably less power, which can
be quite important for larger motors.
Installation and maintenance
When assembling and installing electromotors,
it is important to guarantee the unobstructed
supply of sufficient cooling air. In a dusty
environment, for instance, inadequate
maintenance can close off the air supply of the
cooling fan, causing the electromotor to burn
out!
concepts
- direction of rotation CW = Clockwise
(right, viewed towards the drive side of the
motor)
- direction of rotation CCW = Counter clock
wise (left, viewed towards the drive side of
the motor).
- TEFC= Totally Enclosed Fan Cooled
- TEAO= Totally Enclosed Air Over
- TENV= Totally Enclosed Non Ventilated
GA LC
L
LD W
F
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Index

rotor nl electric motors

Bearing constructions and
SPM bearing monitoring
Foreword
The bearing system in an electromotor is used
B Enclosed bearing

D.E. N.D.E.
to support the rotor, to relieve the forces
created in the rotor and to position the rotor in
the stator in the case of a floating bearing
construction. Strict requirements are set for
the precision of the bearing construction in
order to ensure that the motor functions
optimally. If the motor is connected directly to B With an enclosed bearing construction, the
outer ring of at least one ball bearing is
the machine, the motor bearings are often also enclosed with a bearing cover or several
used to absorb the forces that originate in the bearing covers in the bearing fitting so that
machine. Rotor nl® motors are fitted as that bearing cannot slide in an axial direction.

N
standard with enclosed + fixed bearings with Unlike a floating bearing construction, in an
axial pre-loading. enclosed bearing there is only a slight axial
shift in the rotor in relation to the stator. In nor-
mal cases this is only possible by means of the

A C
axial play in the ball bearing.

Floating bearing Enclosed + fixed bearing with axial pre-loading

D.E. N.D.E. D.E. N.D.E.

A This type of bearing is used, for example, for C With a fixed bearing the inner ring of the
bearing is ‘fixed’ on the motor shaft using a
motors with slide bearings. Virtually no circlip. The inner ring will then be unable to
mechanical axial limit is imposed by the shift axially in relation to the shaft. A fixed
bearing, so that it can freely move backwards bearing construction is normally used in
and forwards. The neutral position is often combination with an enclosed bearing
marked on the shaft. This is the position taken construction and if there is a large axial load.
by the shaft when the motor is rotating freely.

D
For couplings, account has to be taken of
considerable axial play (in the direction of the
Enclosed + fixed bearing with reinforced axial preloading
shaft).
A floating bearing construction is created by
fitting the outer rings of both ball bearings with
a sliding fit in the bearing frame and not
axially enclosed.

D.E. N.D.E.

D For a bearing construction with 2 ball bearings

only one ball bearing can be enclosed. The
other bearing GAmust be able to slideLCaxially in
L
AC the bearing fitting, and is LD
usually mounted
W with
F

a standard wave spring (normal axial pre-

T LA
loaded) or in some cases with reinforced wave
springs/cup springs (reinforced axial pre-
DA
S

loaded).
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rotor nl electric motors
Bearing constructions
Bearings are virtually the only components in
electromotors that are subject to wear. To
achieve the intended life-cycle, it is possible in
many cases to apply a standard bearing
construction in which one bearing is enclosed
and the other can shift axially (loose fitting).
None the less, the life cycle can be extremely
adversely affected by extreme loads
originating from the machine or as a result of
bearing damage caused by the operating
conditions. Specifically, the application of
pumps and fans with the blades attached
‘fluttering’ on the motor shaft can result in
damage caused by what is known as the
‘Brinell effect’. To eliminate this damage as far
as possible, a ‘pre-loaded bearing construction’
can be chosen.
In motors with the pump or fan mounted
‘fluttering’ on the motor shaft, transferred
force is exerted on the outer ring of the
bearings, so that the outer ring of the free
(axially sliding) bearing will tend to rotate in
the bearing frame. This phenomenon mainly
occurs with fans with a high moment of inertia
(J fan ≥ 5 x J rotor), if there is an imbalance in
the fan and as a result of vibrations. In addition
to wear in the bearing frame, this can also
result in fitting rust between the outer ring and
the bearing chamber, which can cause axial
jamming as a result of the free bearing seizing
up. The application of axial pre-loading
consisting of approximately 1% of the
dynamic load rating of the smallest bearing
will strongly inhibit the rotation of the outer
ring.
A frequent cause of bearing damage is
vibration when the motor is not running. When
the motor is not running, there is no
lubrication film between the ball bearings and
the races. The rotor is therefore able to move
radially (rattle) in the free play in the bearing as
a result of external vibrations. The result of this
is that the bearings make indentations in the
bearing races (‘Brinell effect’). With the
application of axial pre-loading the free play
(superfluous in this situation) is removed, thus
limiting this damage.
A pre-loaded bearing construction is only one
solution that can be used to obtain good
results in certain cases. Many bearing
constructions are conceivable, and the right
construction for a specific application or
operating condition can only be determined
under close consultation with the motor
manufacturer.
SPM feeler gauge
N
SPM
Bearing monitoring
More and more companies are applying the The position of the measurement nipple is very
condition-dependent maintenance method. important to obtaining a correct measurement
This means that maintenance is performed result, and certain requirements can also be
depending on the condition of a certain set regarding how the nipple is fitted. To be
machine rather than on the number of sure that these requirements are met, we
operating hours or other standard. recommend immediately having the
This is subject to the condition that the measurement nipples or sensors fitted to the
company has the equipment necessary to new motors by experienced professionals.
measure the variables that determine the The rotor nl® motors can be supplied with SPM
machine’s condition. measurement nipples or sensors for an extra
price.
There are various methods available for
measuring the condition of bearings in
operating condition. The best known of these
is the SPM method, or shock pulse method.
High-frequency shocks that occur in a bearing
through contact with roller elements and races
are ‘translated’ into a bearing condition by a
sensor system with a measurement
instrument.
Various sensor types are available.
Measurements can be taken with a feeler
gauge directly on the frame, a piezo sensor can
be mounted on the bearing frame or
measurement nipples can be fitted onto which
a sensor with a quick-release coupling can be
attached. The big advantage of the latter 2
measurement methods is that they yield
results that can more easily be replicated
because they are less dependent on individuals.
LC
GAmeter with feeler gauge
SPM shock pulse
L
AC LD W
F
T LA
DA
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13. Explosion proof type electric motor

57
ROTATING ELECTRICAL MACHINES - LOW VOLTAGE
 INSTRUCTIONS FOR USE AND MAINTENANCE

ROTATING ELECTRICAL MACHINES - LOW VOLTAGE

59
INTRODUCTION
The electrical machines referred to in these
instructions are intended as components for
use in industrial areas. The information con-
tained in this documentation is designed for use
by qualified personnel who are familiar with the
current rules and regulation in force. They are
not intended to replace any installation regula-
tions issued for safety purposes.
NOTE REGARDING ELECTRO-MAGNETIC COMPATIBILITY
Low voltage induction motors, if installed correctly and connected to the power supply,
respect all immunity and emission limits as set out in the regulations relating to electro-
magnetic compatibility (EMC “Generic Standard” for industrial environments).
In the case of supply by means of electronic impulse (inverters, soft starters etc.), all
verifications and any modifications, necessary to ensure that emission and immunity limits,
as stated within the regulations, are respected, are the responsibility of the installer.

0. GENERAL SAFETY WARNINGS

DANGER

Rotating electric machines are dangerous.
Consequently:
- improper use
- removal of protection and
disconnection of protection devices
- lack of inspection and maintenance
can cause serious harm.
The personnel must be informed of any dan-
ger caused by contact with:
- live parts
- rotating parts
- hot surfaces. In normal working
conditions the motor exceeds 50 °C.
The safety manager must ensure and guaran-
tee that:
- the machine is moved, installed, put in serv-
ice inspected, maintained and repaired only
by qualified personnel, who should have:
- specific technical training and experience
- knowledge of technical standards
and applicable laws
- knowledge of general safety regulations as
well as national, local and installation
regulations
- ability to recognize and avoid all possible
dangers.
Work on the electric machine should be
carried out upon authorization of the safety
manager after having ensured that:
a) the motor has been disconnected from the
power supply and that no parts of the motor
including auxiliary parts are live
b) discharge of the condenser has been done
for single phase motors
c) the motor is completely stopped and there is
no danger of accidental restarting
d) the right precautions against faulty braking
operations have been taken for self-braking
motors
where thermal protection with automatic
reset is used care must be taken to ensure
automatic restart cannot occur. Since the elec-
tric machine referred to is intended to be used
in industrial areas, additional protective meas-
ures must be taken and guaranteed by the
person who is in charge of installation where
more stringent protective measures are
needed.

1. STORAGE AND INSTALLATION

1.1 Control
The motors are shipped ready for installation.
Upon receipt remove packaging and turn the
shaft to check the motor has not been dam-
aged, also check all physical aspects of the
machine for damage. In the case where the
machine is damaged an immediale notification
must be given in writing by the storeman and the
representative of the carrier to CEMP INTERNA-
TIONAL within 3 days.
1.2 Storage procedure
1.2.1 If the motors are not used immediately,
they should be stored in a clean, dry and tem-
perate environment free of vibrations and pro-
tected from the weather. (If stored below -15 °C,
and before starting, the motor temperature
must be restored to the permissable working
temperature range (i.e. -15 °C ➝ 40 °C). In this
case, it is necessary to specify these particu-
lar storage conditions during the ordering
stage so that proper precautions can be
taken during building and packaging.
1.2.2 When the motors are stored properly,
bearings do not need maintenance. However, it
is a good idea to turn the shaft by hand every
three months. After storage for over one year
motors with unshielded bearings (usually such
motors have a lubricator and bear a lubrication
plate), it is advisable to check the condition of
the lubrication and motor components.

61
1.2.3 Before installation check the motor
windings using the appropriate instruments to
ensure the condition of the insulation between
phases and between phase and earth are of the
corrects resistance values.
Do not touch the terminals during and
immediately after measuring as they are live.
If the insulation resistance value is less than 10
megaohm, or after storage in a damp environ-
ment, the motors must be put to dry in an oven
for about 8 hours by gradually bringing the
temperature up to 100 °C. To ensure that the
dampness has been completely expelled, the
motors must be disassembled.
1.2.4 All operations listed above must be car-
ried out by qualified personnel. In case of flame-
proof motors it is necessary:
- to be very careful that the flame-proof charac-
teristics are not altered
- to have the procedure described in point 1.2.2
carried out by authorized repair shops
- to understand dismantling or opening of the
motor during the warranty period without au-
thorization of CEMP INTERNATIONAL may in-
validate the warranty.
1.3.3 Direct connection
Use couplings that have been made and bal-
anced perfectly align the motor shaft and the
operating machine precisely. Inaccurate align-
ment may cause vibrations and damage to
the bearings or breakage of the shaft end.
1.3.4 Connection by means of pulley
Check that alignment with the pulley of the
operating machine has been carried out per-
fectly. The tension of the belts must be enough
to avoid slipping. Excessive tension of the belts
causes harmful radial loads on the motor shaft
and bearings, reducing their life.
It is advisable to assemble the motor on belt-
stretching slides in order to regulate tension of
the belts exactly.
Connection with belts must be such as to
avoid accumulation of static charges in the
moving belts which could cause sparks.
1.3.5 Connection to power supply
Use cables with sufficient section to bear the
maximum current absorbed by the motor, avoid-
ing overheating and/or drops in voltage. Con-
nect the cables to terminals by following the
instructions on the plate or on the diagram
included in the terminal box. Check that termi-
nal nuts are tightened.
1.3.6 Connection of auxiliary parts
(Table B)
a) thermal protection
Check which type of protection is installed be-
fore making connections. If thermistors (PTC)
are used, it is necessary to utilize a suitable
relay.
b) anti-condensation heaters
If the motor is fitted with anti-condensation
heaters, their power supply must be separated
from that of the motor, using the terminals
housed in the terminal box.
WARNING: the supply of the heater is
always monophase and the voltage is different
from that of the motor. Check that it corre-
sponds to the one indicated on the plate.
c) auxiliary ventilation
Connect the supply of the auxiliary ventilation
motor separately from that of the main motor.
WARNING: use a device that allows
starting and operation of the main motor only
when the auxiliary fan is working.
d) all the above-mentioned operations must be
carried out by following the instructions shown
on the diagrams of connection provided with
the motor.

1.3 Installation Connections to the terminals must be

Work on the electric machine must
be carried out when the machine has stopped
and been disconnected from the power sup-
ply (including auxiliary parts, such as
anticondensation heaters).
1.3.1 Lifting
Before using the lifting rings make sure they
have been tightened.
The lifting rings are big enough to bear
the weight of a single motor, therefore they
must not be used to lift the equipment con-
nected to the motor.
In environments where the temperature is below
-20 °C, these lifting rings should be used with
caution as they could break at low temperatures
and cause damage.
1.3.2 Fitting devices to shaft
Fitting if pulley, coupling or gear to the motor
shaft must be carried out with care to ensure no
damage is caused to the bearing. Remove the
protective paint finish from the shaft and smear
with oil then fit the device heating before fitting
if possible to ensure an easy fit.
Any component that is assembled on the motor
shaft must be accurately balanced. Connection
with fitments not balanced properly causes
anomalous vibrations during operation that
jeopodises proper working of the motor and
drastically reduces its life.
made in order to guarantee safe distances
between live uncovered parts.
Do the earthing by using the screw located
inside the terminal box. Flame-proof motors are
provided with a second earth stud located on
the motor casing outside the terminal box. Earths
must of sufficient size and installed accord-
ing to relevant standards. The area of contact
of connections must be cleaned and protected
against corrosion.
When the cable inlet is made by means of a
cable gland, it must be chosen properly in
relation to the type of plant and type of cable
used. The cable gland must be tightened so
that the retaining rings create the pressure nec-
essary to:
a) prevent transmission of mechanical stress to
the motor terminals
b) to ensure the mechanical (IP degree) protec-
tion of the terminal box.
For flame-proof motors the cable inlet must be
made by complying with the regulations in points
12.1 and 12.2 of the standard EN 50.018. Aper-
tures not used must be closed in accordance
with specifications in point 12.5 of the same
standard.
When reassembling the terminal cover, make
sure that if there is a seal, it is in the right place.
Flame-proof motors do not have a seal so
before reassembling the terminal box it is nec-
essary to replace the layer of grease. The termi-
nal box cover must be tightened to ensure it is
properly sealed.

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62
2. PUTTING INTO OPERATION
It is the responsibility of the installer to
establish the motor's fitness to be used in a
certain plant, after analysing the characteris-
tics of danger existing in the installation area
with respect to current provisions of the law and
to those issued for safety purposes.
2.1 Initial Controls
Before starting the motor it is important to
check that:
a) installation has been carried out properly
b) the bearings have not been damaged during
installation
c) the motor base is sturdy enough and the
foundation bolts have been tightened
d) the design data corresponds to those given
on the plate and in the technical documentation
The electric motor is a component made
to be mechanically connected to another ma-
chine (single or part of a plant). Consequently,
it is the responsibility of the person who looks
after installation to guarantee that during op-
eration there is an adequate degree of pro-
tection for people or things against the dan-
ger of accidental contact with moving parts.
2.2 Control of Design Data
Make sure that the motor is suited for use in the
working conditions foreseen and check the fol-
lowing:
2.2.1 Environmental conditions
a) environmental temperature:
standard motors may work between -15 °C and
+40 °C
b) altitude:
normal motors have been designed to work
between 0 and 1.000 m above sea level
c) protection against the presence of harmful
agents like: sand, corrosive substances, dust
and/or fibre, water, mechanical stress and vi-
brations
d) mechanical protection:
installation inside or outside considering the
harmful effects of the weather, the combined
effect of temperature and humidity and the
formation of condensation
e) adequate space around the motor particu-
larly on the fan side to allow proper ventilation
f) motors mounted in the vertical, shaft down
require a protective cowl over the fan inlet
g) any danger of explosion or fire
2.2.2 Working conditions
a - operation type:
the motors are normally for S1 type continuous
operation
b - load type:
carefully evaluate machines with high moments
of inertia and the relative starting times
c - for motors intended for operation in hazard-
ous areas (EEx-d or EEx-e) the motor type and
temperature classification must comply with the
area rating
When there is an “X” on the plate near the 2.4.2 Before starting the motor after a long
certificate number, it is necessary to check resting period, repeat the controls described in
on the certificate which additional condi- section 1.
tions are required for proper working. When supplied, heater must not be ener-
d - for self-braking motors see the special appli- gised when the motor is running.
cations envisaged in the relative catalogue.
2.4.3 The motor must be used solely for
2.2.3 Electric characteristics applications it was designed for and must be
a - voltage and frequency should correspond to utilized and controlled complying with the pre-
those on the plate cautionary standards.
b - motor power should be adequate as re-
If the machine shows anomalous work-
quired by the load
ing characteristics (greater absorption, in-
c - power supply protections against overloads
crease in temperature, noisiness, vibrations),
and/or short circuits should be adequate for
inform the personnel in charge of mainte-
nominal currents and starting currents
nance immediately.
d - for connection to control circuits follow the
connection diagram supplied with motor
(Table A)
Abnormal working conditions must al-
ways be defined when placing order to en-
sure that the site conditions are not prejudicial
to the proper operation of the machine
2.3 Starting
2.3.1 Before starting the motor ensure that the
incoming supply cables are connected cor-
rectly
2.3.2 For motors with forced ventilation by
means of external ventilation make sure that the
motor starter is interlocked with the, contactor
of the external ventilator to ensure the fan is
operational.
2.3.3 When all previous checks have been
made satisfactorily, the motor may be started.
Unless oterwise started all motors can be direct
on line started. Save when otherwise indicated,
all motors are fit for direct starting. If you intend
to start the motor by means of static starters,
rheostats or the star-delta system, they must
be chosen and set property to avoid incor-
rect functioning of the motor.
2.4 Conditions of Use
2.4.1 Once the motor has started it is neces-
sary to check that during operations the working
conditions remain within the limits envisaged,
and that the following does not occur:
a) overloading
b) dangerous rise in environmental temperature
c) excessive drop in voltage
E very time there is a change in the working
conditions, it is necessary to check that the
complete fitness of the motor has been main-
tained for the new operating conditions.
For example:
- variation in working cycle
- the function of the motor has not altered
- moving of the motor to a different environment
(from outside to inside)
- moving of the motor from a low temperature
environment to one with a higher temperature.
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63
3. MAINTENANCE
Any operation on the motor must be
carried out with the machine stopped and dis-
connected from the power supply (including
auxiliary circuits, especially the anticondensation
heaters). Maintenance of the original charac-
teristics of electric machines over time must
be ensured by a schedule of inspection, main-
tenance and setting up managed by qualified
technicians. The type and frequency of mainte-
nance depends on environmental and working
conditions. For flame-proof motors, apart from
specifications in this document, refer to the
CEMP INTERNATIONAL manual entitled “MAIN-
TENANCE AND REPAIR GUIDE FOR ELEC-
TRIC FLAME-PROOF MOTORS”. As a rule, it is
recommended that the first inspection is made
after about 500 hours of operations (or, within 1
year), while subsequent inspections should fol-
low the schedules established for lubrication
and general inspection.
3.1 Inspection
3.1.1 Check that the motor works normally
without anomalous noise or vibrations. If it does
not, locate the cause of the anomaly.
3.1.2 Make sure that the ventilation is not
obstructed. Clean the motor by removing any
dust or fibre deposits from the fins and from the
fan cover.
3.1.3 Check that the supply cable does not
show signs of wear and that the connections are
tight. Make sure that the earth and supply
cables are not damaged.
3.1.4 Check that the transmission elements are
in perfect condition and that the screws and
nuts are tight.
3.1.5 When the motor is installed in a very
damp environment or is subject to drips of
water, check regularly that the seal and retain-
ing rings and any protective devices work effi-
ciently. Ensure that there are no infiltrations
inside the casing or terminal box.
3.1.6 The motors furnished with drainage de-
vices should be checked and cleaned regularly
so that such devices continue to work properly.
3.1.7 Make sure that thermal protections have
not cut out and have been set properly.
The right selection and setting of thermal
protections for EEx-e motors is essential to
guarantee the temperature class and safety
against the danger of explosion.
3.1.8 Check that no modifications have
been made that alter the electric and me-
chanical operation of the motor.
3.1.9 When the motor is installed in an environ-
ment where there are corrosive agents it is
recommended to paint the motor itself to pro-
tect the outer surfaces from corrosion if neces-
sary.
3.1.10 Every irregularity or anomaly found
during inspection must be fixed immediately.
3.2 Lubrication
3.2.1 Motors with shielded or sealed bearings
(type ZZ or 2RS) do not require lubrication.
Therefore, if used properly, they do not require
maintenance.
3.2.2 Motors with unshielded bearings are fur-
nished with lubricators. The interval of time
between lubrications depends on the type of
grease, environmental temperature, overheat-
ing of the motor and type of operation the motor
carries out. The table C shows the intervals
foreseen for 70 °C as a working temperature of
the bearings in normal operating conditions. It is
recommended to use a good quality lithium
based grease with great penetration capacity
and high dropping point like Athesia 3 by IP,
Beacon 3 by Esso or Avana 3 by Shell. If the
velocity is different from the one given in the
table, the intervals must be modified in inverse
proportion.
Eg. bearing 6314 at 1.800 RPM
1500
1= x 3550 h = 2950 h
1800
Regardless of working hours, the grease must
be renewed after 1 or 2 years or during a
complete overhaul. When the motor is furnished
with a lubrication plate, refer to the dates shown
on it.
3.3 Disassembly and
Reassembling the Motor
All operations must be carried out bearing in
mind health and safety regulations.
3.3.1 Before working on the motor it is advis-
able to consult the relevant catalogue and have
all the tools ready.
3.3.2 Before proceeding with the disassembly
the motor must be disconnected from the power
supply. Make sure that the power is off and
disconnect supply cables and auxiliary cables
when there are any.
3.3.3 In order to work on the motor satisfacto-
rily it should be removed from its mounting and
placed on a work bench.
3.3.4 Take off the fan cover by removing the
fixing screws. Using an extractor remove the
cooling fan. Remove the end shields and with-
draw the rotor being careful not to damage the
windings. Precautions must be taken with
flameproof motors so that the spigots on the
frame and the end shields are not damaged.
When the motor is disassembled and before it is
reassembled it is necessary to protect the vari-
ous components (particularly the bearings and
windings) to avoid damage caused by dust or
knocks.
3.3.5 For disassembly of self-braking motors
follow the instructions shown in the relative
catalogue.
64
3.4 Replacing the Bearings
3.4.1 Remove the bearings using an extractor.
Ensure the respective housings have not been
damaged then fit the new bearings - these must
be the same type as the old ones.
3.4.2 To fit the new bearings it is advisable to
use a press and a sleeve which rests on the inner
ring and must not put pressure on the outside
ring of the bearing. The surfaces of the relative
housings should be oiled slightly.
3.4.3 If the facilities are available, however, it is
recommended that the bearings are heated to
90-100 °C and fitted quickly to the shaft. Use a
brass sleeve resting on the internal ring of the
bearing and if a press is not available use a
mallet.
3.4.4 After the assembly has been finished the
internal rings of the bearings must rest against
the relative shaft shoulders.
3.4.5 Before reassembling, clean the internal
parts of the motor carefully and check that the
components have not been damaged. Renew
the layer of grease where needed on the abut-
ting spigots and proceed with the reassem-
bling. For more detailed information on the
proper procedure, consult the catalogues
relative to the various types of motors.
3.5 Overhauls and Repairs
3.5.1 When needed, all motor components
should be replaced by original spare parts. To
request spare parts use the nomenclature shown
in the catalogues and always give:
- motor type
- serial number
- year built
3.5.2 Overhauls and repairs must be carried
out by trained personnel who guarantee res-
toration of the motor to its original condi-
tions, we recommend that you contact an
authorised repair agent. For further informa-
tion please contact our sales department.
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Connecting diagrams - Table A

Connection for single speed motors:

Y-Connection U1 Connection-∆ U1
W2 U2 V2 W2 U2 V2

U1 V1 W1 U1 V1 W1

W1 V1 W1 V1
L1 L2 L3 L1 L2 L3

Number of pole: 2, 4, 6, 8 .... - Synchronous speed at 50 Hz: 3000, 1500, 1000, 750 ....

Two separate windings for two speed motors:

L1 L2 L3

High Speed W2 Low Speed U1

W2 U2 V2 W2 U2 V2

U1 V1 W1 U1 V1 W1

V2 U2 W1 V1
L1 L2 L3

Number of pole: 2/6, 2/8, 4/6, 6/8 ....

Synchronous speed at 50 Hz: 3000/1000, 3000/750, 1500/1000, 1000/750 ....

Dahlander system for two speed motors, constant torque:

L1 L2 L3
U1
High Speed W2 Low Speed
W2 U2 V2 W2 U2 V2
V2 W2

U1 W1 U1 V1 W1 U1 V1 W1
W1 U2 V1
V1
V2 U2 L1 L2 L3

Number of pole: 2/4, 4/8 - Synchronous speed at 50 Hz: 3000/1500, 1500/750

Dahlander system for two speed motors, quadratic torque:

L1 L2 L3

High Speed W2 Low Speed U1

W2 U2 V2 W2 U2 V2
W2
W1
U1 V1 U1 V1 W1 V2 U2 U1 V1 W1

V2 U2 W1 V1
L1 L2 L3

Number of pole: 2/4, 4/8 - Synchronous speed at 50 Hz: 3000/1500, 1500/750

Single phase motors connecting diagram

µF

V2 V2
Right rotation Starting w. W2 V2 Left rotation Starting w.
W2 V2
µF

U1 W1 W1
U1

W2, U1 W1 U1 W1,W2
Main w. Main w. L1 L2
L1 L2

65
Additional terminal marking - Table B

Identification number Additional terminals for

12 - 13 Thermistor PTC

20 - 21 - 22 Thermistor PT 100

32 - 33 Normally closed
bi-metallic switch

42 - 43 Normally open
bi-metallic switch

70 - 71 Space heater

80 - 81 - 83 Forced ventilation

5-6 Tachogenerator and others

Lubrication intervals in hours for unshielded bearings - Table C

3000 1500 1000 750

Bearings Amount of Grease “in Grammes” RPM RPM RPM RPM

6 205 4 4500 9500 10000 10000

6 206 5 4000 8500 10000 10000
6 306 6,5 3750 8000 10000 10000
6 208 10 2800 6000 9000 10000
6 308 10 2800 6000 9000 10000
6 309 12,5 2350 5600 8500 10000
NU 309 12,5 1180 2800 4250 6000
6 310/11 17 1800 4500 7500 10000
NU 311 17 950 2350 3750 5000
6 312 21 1600 4000 7100 9500
NU 312 21 800 2250 3550 4750
6 313 24 1400 3750 6700 9000
NU 313 24 700 2000 3350 4500
6 314 26 1250 3550 6300 8500
NU 314 26 600 1800 3150 4250
6316/7316 33 900 3150 5600 8000
3 316 58 - 3150 5600 8000
NU 316 33 450 1600 2800 4000
3318/7318 41 - 2650 5000 7100
3 318 70 - 2650 5000 7100
NU 318 41 - 1400 2650 3550
6320/7320 51 - 2360 4500 6300
3 320 90 - 2360 4500 6300
NU 320 51 - 1180 2360 3350

66