WEG S Series User manual

Motors I Automation I Energy I Transmission & Distribution I Coatings

Synchronous Motors

S Line – Horizontal

Brushless

Installation, Operation and Maintenance Manual

Document Number: 11866576

Models: SEA, SED, SET, SEV, SEF, SER, SEI, SEW, SEL, SFA, SFD,

SFT, SFV, SFF, SFR, SFI, SFW and SFL

Language: English

Revision: 04

May 2016

www.weg.net

11866576 Installation, Operation and Maintenance Manual – Synchronous Motors – S Line – Brushless – Horizontal l 5

Dear Customer,

Thank you for purchasing a WEG motor. Our products are developed with the highest standards of

quality and efficiency which ensures outstanding performance.

As the electric motor plays a role of great importance to the comfort and well-being of the humanity, it

must be identified and treated as an electrical machine, whose features require certain precautions,

such as for storage, installation and maintenance.

All efforts have been made to ensure that the information contained in this manual is faithful to the

configurations and operation of the motor.

Therefore, we recommend that you read this manual carefully before proceeding with the installation,

operation or maintenance of the motor in order to ensure safe and reliable operation of your

equipment and facility. If you need any further information, please contact WEG.

Always keep this manual close to the motor, so it can be consulted whenever necessary.

ATTENTION

1. It is imperative to follow the procedures contained in this manual for the warranty to be valid;

2. The motor installation, operation and maintenance procedures must be performed only by qualified

personnel.

NOTES

1. The total or partial reproduction of information supplied in this manual is authorized, provided that

reference is made to its source.

2. If this manual is lost, an electronic PDF file is available at www.weg.net or another printed copy may be

requested.

WEG EQUIPAMENTOS ELÉTRICOS S.A.

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11866576 Installation, Operation and Maintenance Manual – Synchronous Motors – S Line – Brushless – Horizontal l 7

INDEX

1INTRODUCTION .................................................................................................11

1.1SAFETY WARNINGS IN THE MANUAL ...........................................................................................11

2GENERAL INSTRUCTIONS .................................................................................12

2.1QUALIFIED PERSONNEL ................................................................................................................12

2.2SAFETY INSTRUCTIONS ................................................................................................................12

2.3STANDARDS...................................................................................................................................12

2.4ENVIRONMENTAL CONDITIONS....................................................................................................12

2.5OPERATING CONDITIONS .............................................................................................................13

2.6VOLTAGE AND FREQUENCY .........................................................................................................13

3RECEIVING, HANDLING AND STORAGE .............................................................14

3.1RECEIVING .....................................................................................................................................14

3.2HANDLING......................................................................................................................................14

3.3STORAGE .......................................................................................................................................15

3.3.1Outdoor storage .................................................................................................................................15

3.3.2Extended storage ...............................................................................................................................15

3.3.2.1Storage location..................................................................................................................15

3.3.2.1.1Indoor storage ................................................................................................15

3.3.2.1.2Outdoor storage .............................................................................................16

3.3.2.2Separate parts ....................................................................................................................16

3.3.2.3Space heater.......................................................................................................................16

3.3.2.4Insulation resistance............................................................................................................16

3.3.2.5Exposed machined surfaces................................................................................................16

3.3.2.6Bearings..............................................................................................................................16

3.3.2.6.1Grease-lubricated rolling bearing.....................................................................16

3.3.2.6.2Oil-lubricated rolling bearing............................................................................16

3.3.2.6.3Sleeve bearing................................................................................................16

3.3.2.7Terminal box .......................................................................................................................17

3.3.2.8Radiator ..............................................................................................................................17

3.3.2.9Inspections and records during storage...............................................................................17

3.3.2.10Maintenance plan during storage.........................................................................................18

3.3.3Preparation for commissioning............................................................................................................19

3.3.3.1Cleaning..............................................................................................................................19

3.3.3.2Bearing inspection...............................................................................................................19

3.3.3.3Bearing lubrication...............................................................................................................19

3.3.3.4Insulation resistance verification...........................................................................................19

3.3.3.5Others.................................................................................................................................19

4INSTALLATION...................................................................................................20

4.1INSTALLATION SITE .......................................................................................................................20

4.2SHAFT LOCK ..................................................................................................................................20

4.3ROTATION DIRECTION...................................................................................................................20

4.4INSULATION RESISTANCE.............................................................................................................20

4.4.1Safety instructions ..............................................................................................................................20

4.4.2General considerations .......................................................................................................................20

4.4.3Measurement on the stator windings...................................................................................................20

4.4.4Measurement on the rotor and exciter windings ..................................................................................21

4.4.5Additional Information .........................................................................................................................21

4.4.6Polarization index................................................................................................................................21

4.4.7Conversion of the measured values.....................................................................................................21

4.4.8Insulation assessment.........................................................................................................................22

4.5PROTECTIONS ...............................................................................................................................22

4.5.1Thermal protections ............................................................................................................................22

4.5.1.1Temperature sensors ..........................................................................................................22

4.5.1.2Temperature limits for the windings .....................................................................................23

4.5.1.3Alarm and trip temperatures ................................................................................................23

4.5.1.4Temperature and ohmic resistance of the PT100 thermoresistance .....................................24

4.5.2Space heater ......................................................................................................................................24

4.5.3Water leak sensor ...............................................................................................................................24

4.6COOLING........................................................................................................................................24

4.6.1Air-water heat exchanger cooling........................................................................................................24

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8 l Installation, Operation and Maintenance Manual – Synchronous Motors – S Line – Brushless – Horizontal 11866576

4.6.1.1Radiators for application with sea water.............................................................................. 24

4.6.2Independent ventilation cooling .......................................................................................................... 25

4.7ELECTRICAL ASPECTS ................................................................................................................. 25

4.7.1Electrical connections......................................................................................................................... 25

4.7.1.1Main electrical connections................................................................................................. 25

4.7.1.2Grounding .......................................................................................................................... 25

4.7.1.3Field power supply and control ........................................................................................... 25

4.7.2Connection diagram........................................................................................................................... 26

4.8MECHANICAL ASPECTS ............................................................................................................... 26

4.8.1Foundations....................................................................................................................................... 26

4.8.2Foundation loads ............................................................................................................................... 26

4.8.3Base types......................................................................................................................................... 26

4.8.3.1Concrete base.................................................................................................................... 26

4.8.3.2Metal base.......................................................................................................................... 26

4.8.4Natural frequency of the base............................................................................................................. 26

4.8.5Mounting ........................................................................................................................................... 26

4.8.6Anchor plate set................................................................................................................................. 27

4.8.7Leveling ............................................................................................................................................. 27

4.8.7.1Support.............................................................................................................................. 27

4.8.8Alignment........................................................................................................................................... 27

4.8.9Inspection of pedestal bearings.......................................................................................................... 28

4.8.10Couplings........................................................................................................................................... 29

4.8.10.1Direct coupling ................................................................................................................... 29

4.8.10.2Gear coupling..................................................................................................................... 29

4.8.10.3Coupling of motors equipped with sleeve bearings ............................................................. 30

4.9BRAKE ........................................................................................................................................... 30

4.10HYDRAULIC UNIT .......................................................................................................................... 30

5STARTING .........................................................................................................31

5.1DIRECT ON-LINE STARTING ......................................................................................................... 31

5.1.1Direct start with discharge resistor...................................................................................................... 31

5.1.2Direct start without discharge resistor................................................................................................. 31

5.1.3Direct online start frequency............................................................................................................... 31

5.1.4Locked rotor current (Ip/In)................................................................................................................. 31

5.2STARTING WITH REDUCED CURRENT......................................................................................... 32

5.2.1Starting with reactor........................................................................................................................... 32

5.2.2Starting with autotransformer ............................................................................................................. 32

5.2.3Starting with frequency inverter .......................................................................................................... 32

5.2.4Starting with soft-starter..................................................................................................................... 32

5.3EXCITATION CIRCUITS .................................................................................................................. 33

5.3.1Excitation circuit with voltage control (Random) .................................................................................. 33

5.3.3Excitation circuit with frequency control.............................................................................................. 34

5.3.4Excitation circuit for AC exciter........................................................................................................... 35

6COMMISSIONING ..............................................................................................36

6.1PRELIMINARY INSPECTION .......................................................................................................... 36

6.2FIRST START ................................................................................................................................. 36

6.2.1Initial starting procedure ..................................................................................................................... 36

6.3OPERATION ................................................................................................................................... 37

6.3.1Operation procedures ........................................................................................................................ 37

6.3.2Resynchronization.............................................................................................................................. 37

6.3.3Data recording ................................................................................................................................... 37

6.3.4Temperatures..................................................................................................................................... 37

6.3.5Bearings ............................................................................................................................................ 37

6.3.5.1High-pressure oil injection system....................................................................................... 38

6.3.6Radiators ........................................................................................................................................... 38

6.3.7Vibration ............................................................................................................................................ 38

6.3.8Vibration causes................................................................................................................................. 38

6.4SHUTDOWN................................................................................................................................... 38

7MAINTENANCE..................................................................................................39

7.1GENERAL....................................................................................................................................... 39

7.2GENERAL CLEANING .................................................................................................................... 39

7.3WINDING INSPECTIONS................................................................................................................ 39

7.4WINDING CLEANING ..................................................................................................................... 39

7.4.1Inspections ........................................................................................................................................ 39

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11866576 Installation, Operation and Maintenance Manual – Synchronous Motors – S Line – Brushless – Horizontal l 9

7.4.2Re-impregnation .................................................................................................................................40

7.4.3Insulation resistance............................................................................................................................40

7.5COOLING SYSTEM MAINTENANCE...............................................................................................40

7.6RADIATOR MAINTENANCE ............................................................................................................40

7.7VIBRATION .....................................................................................................................................40

7.8SHAFT GROUNDING DEVICE.........................................................................................................40

7.9EXCITER MAINTENANCE................................................................................................................40

7.9.1Exciter ................................................................................................................................................40

7.9.2Insulation resistance............................................................................................................................40

7.9.3Diode test...........................................................................................................................................40

7.9.3.1Diode Replacement.............................................................................................................41

7.9.4Thyristor test.......................................................................................................................................41

7.9.4.1Thyristor replacement..........................................................................................................41

7.10BEARING MAINTENANCE ..............................................................................................................42

7.10.1Grease-lubricated rolling bearings .......................................................................................................42

7.10.1.1Lubrication instructions........................................................................................................42

7.10.1.2Procedures for rolling bearing relubrication ..........................................................................42

7.10.1.3Rolling bearing relubrication with drawer device for grease removal .....................................42

7.10.1.4Type and amount of grease.................................................................................................43

7.10.1.5Grease compatibility............................................................................................................43

7.10.1.6Bearing disassembly ...........................................................................................................43

7.10.1.7Bearing assembly .................................................................................................................44

7.10.2Oil-lubricated rolling bearing................................................................................................................44

7.10.2.1Lubrication instructions........................................................................................................44

7.10.2.2Oil type................................................................................................................................44

7.10.2.3Oil change...........................................................................................................................44

7.10.2.4Bearing operation .................................................................................................................45

7.10.2.5Bearing disassembly ...........................................................................................................45

7.10.2.6Bearing assembly................................................................................................................45

7.10.3Sleeve bearings. .................................................................................................................................46

7.10.3.1Bearing data........................................................................................................................46

7.10.3.2Bearing installation and operation ........................................................................................46

7.10.3.3Cooling by water circulation.................................................................................................46

7.10.3.4Oil change...........................................................................................................................46

7.10.3.5Sealings........ ......................................................................................................................46

7.10.3.6Sleeve bearing operation .....................................................................................................47

7.10.3.7Sleeve bearing maintenance................................................................................................47

7.10.4Protection setting................................................................................................................................47

7.10.5Disassembly/assembly of the bearing temperature sensors.................................................................47

8MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................48

8.1DISASSEMBLY ...............................................................................................................................48

8.2ASSEMBLY .....................................................................................................................................48

8.3TIGHTENING TORQUE ...................................................................................................................48

8.4AIR GAP MEASURMENT ................................................................................................................49

8.5SPARE PARTS................................................................................................................................49

9MAINTENANCE PLAN.........................................................................................50

10ABNORMALITIES, CAUSES AND SOLUTIONS.....................................................51

11DECLARATION OF CONFORMITY.......................................................................53

12ENVIRONMENTAL INFORMATION.......................................................................54

12.1PACKAGE .......................................................................................................................................54

12.2PRODUCT.......................................................................................................................................54

12.3HAZARDOUS WASTE .....................................................................................................................54

13WARRANTY TERM .............................................................................................55