WOLONG BROOK CROMPTON 30 Series Maintenance and service guide

Keeping Industry Turning
Installation & Maintenance
Series 30 AC motors
30
30
Series
2022-06 EN iss 1


Introduction
Your Brook Crompton motor is designed for long life,
and low running costs.
Careful installation and maintenance will ensure
that you achieve reliable operation and optimum
efficiency
Pre-installation requirements
WARNING
Handling and lifting of electric motors must only be
undertaken by authorised personnel. Full product
documentation and operating instructions must be
available together with tools and equipment
necessary for safe working practice.
Receipt
Before any motor is accepted on site it should be
inspected carefully for damage or loss incurred
during transit.
Packing materials may be damaged including
sheeting and crate timbers.
Handling operations may have damaged fan cowls,
terminal boxes or auxiliaries.
Where an instance of droppage or loss is evident or
suspected, it may be necessary to unpack the goods
to establish the full extent of the problem.
Wherever possible, damage should be recorded,
photographed and witnessed.
Report any damage to the carriers and
Brook Crompton as soon as possible,
quoting the item number and consignment note
reference.
Lifting
Eyebolts and/or lifting trunnions supplied with the
motor are designed to support only the weight of the
motor, not the weight of the motor and any ancillary
equipment attached to it. Be absolutely sure that
cranes, jacks, slings and lifting beams are capable
of carrying the weight of equipment to be lifted.
Where an eyebolt is provided with the motor, this
should be screwed down until its shoulder is firmly
against the face of the stator frame to be lifted.
Eyebolts are normally designed for a vertical lift.
Storage
If motors have to be stored before installation,
precautions should be taken to prevent deterioration.
Environment
Depending on the site conditions it may be necessary
to create a suitable stores area to hold the motor
prior to installation.
Packing cases are not waterproof.
Motors should be stored in a dry, vibration free and
clean area at normal ambients (–20°C to 40°C),
unless other arrangements have been agreed with
Brook Crompton.
Where low temperature ambient storage is
anticipated, special precautions should be taken
with the type of grease, no plastic parts etc. to
ensure trouble free start-up.
Motors must be stored away from
corrosive or chemically damaging fumes.
Before placing motors into storage, machined
components should be carefully inspected.
Bearings and shafts are normally covered with
a corrosion resistive barrier. If this coating is
damaged it should be made good. The component
should be cleaned and the protective coating
reapplied.
Under no circumstances should rust be merely
covered over.
Drain holes
Motors provided with drain holes have drain plugs.
Bearings
To avoid static indentation the storage area should
be vibration free. If this is not possible it is strongly
recommended that the motors be stood on thick
blocks of rubber or other soft material. Shafts
should be rotated by hand one quarter of a
revolution weekly.
Where the exposure to some vibration is
unavoidable the shaft should be locked in position
to avoid static indentation of the bearings. Roller
bearings may be fitted with a shaft locking device.
This should be kept in place during storage.
Grease
Factory fitted bearings use a Polyurea based
grease with a recommended shelf life of two years.
If stored for a longer period, grease may need to
be replaced.*
Shielded bearings have a storage life of five years
and a further two years operational life following
installation.
* Wash all bearing parts with a noncontaminating
solvent. Lightly pack the bearings with grease
applying a 33% fill by volume into the bearing and
housings.
Heaters
Where space heaters are fitted, and the storage
environment has wide humidity and temperature
variations, it is strongly recommended they be
energised.
Warnings should be placed on the motors to make
operatives aware of the live heaters.
A low voltage DC supply could be used as an
alternative.
Insulation resistance
During extended storage a three monthly
insulation test is recommended to avoid possible
lengthy drying out periods when installing. Use
a 500 volt d.c. Megger. The insulation resistance
between phases and between the windings and the
frame should be checked.
The insulation resistance should be maintained
above 10 megohm. If a lower reading is measured,
use one of the drying out methods recommended
on page 3 until an acceptable reading is obtained.
If heaters are fitted but not energised, they should
be used in future.
Location
Motors must be installed with adequate access for
routine maintenance. A minimum of 0.75m of
working space around the motor is recommended.
Adequate space around the motor, particularly at
the fan inlet is also necessary to facilitate airflow.
See table 1 for minimum distance.
Where several motors are installed in close
proximity, care must be taken to ensure that there
is no recirculation of exhausted warm air.
Installation & Maintenance
Introduction / Storage
80 to 90 25 mm
100 to 132 30 mm
160 to 180 45 mm
200 to 225 60 mm
250 to 280 90 mm
315 to 355 110 mm
Frame size minimum distance ‘X’
Table 1 - Minimum distance between the fan
inlet and an obstruction
Foundations
Foundations must be solid, rigid and level.
X


Mechanical / Electrical connection
Installation & Maintenance
Mechanical
Drain holes
Prior to installation remove drain plugs if fitted. If
any water has accumulated, the integrity of all
gaskets, sealants etc. should be checked. Drain
plugs should be put back into place after draining.
Alignment
When the application calls for direct coupling, the
shafts must be correctly aligned in all three planes.
Bad alignment can be a major source of noise and
vibration. Allowance must be made for shaft
end-float and thermal expansion in both axial and
vertical planes. It is preferable to use flexible drive
couplings.
Noise levels
The noise levels published in current Sales
Specifications are equal to or less than the limiting
values for rotating machines specified International
Standards IEC 60034-9.
In most cases noise levels also meet limiting values
for exposure to noise in the work place.
It is the responsibility of the purchaser to ensure
that other overriding lower noise levels if required,
eg Machinery Directive, are specified at the time of
order, or that the installation incorporates noise
attenuating measures.
Free rotation
The shaft must be free to rotate.
Where uneven or bumpy rotation occurs the
bearings should be inspected to establish that they
have not been damaged during transportation or
storage.
B14 (IM3601) & B34 (IM2101)
Where a motor is fitted with a ‘C’ face flange, ie B14
or B34 mounted, care must be taken to ensure
mounting bolts do not protude beyond the ‘C’ face
casting thickness. See table 2.
Electrical connection
The connection diagram is shown on the leaflet
enclosed in the motor terminal box or the diagram
inside the terminal box lid (copy on page 5).
The cables used should be capable of carrying the
full load current of the motor (see motor
name-plate) without overheating or excessive
voltage drop under starting conditions.
Cable terminations
All cable terminations should be tightly secured
(see Table 3 for tightening torques).
Mains lead terminal lugs should be in face to face
contact with the motor lead lugs and securing nuts
and lockwashers screwed firmly over the
connection (where possible).
There should be no nuts or lockwashers fitted
between the mains and motor lugs.
Wiring should be carried out or checked by a
qualified electrician and equipment must be
earthed in accordance with current regulations.
The equipment must be correctly fused and
isolated.
Supply
It is important that a motor is operated within the
limits of its design voltage and frequency.
Standard motors for the UK will operate without
damage on any voltage in the range 94% to 106%
of the nameplate voltage.
The supply cables must be capable of carrying the
full load current of the motor (see motor name-
plate) without overheating or excessive voltage
drop under starting conditions.
Earthing
All motors are fitted with an earthing terminal, in
or adjacent to the terminal box, to enable connec-
tion to an effective earthing bond. The terminal is
designed for connecting the correct size of copper
earth connector. If a different material is to be
used please refer to Brook Crompton.
The motor must be earthed by connecting the
shortest possible length of cable to the earth
terminal.
The cable must have a capacity at least that
of the main connections up to 16mm² phase
conductors. Between 16 and 35mm² phase
conductors, the earth should be a minimum of
16mm² . Above 35mm² phase conductors, the
earth conductor should be a minimum of half the
phase conductor.
An earthing bond should not be terminated under
the motor fixture bolts or terminal cover screws.
The earth lead could be over-looked on
reconnection after maintenance
Auxiliary electrical items (where fitted).
Heaters should be checked for continuity prior to
connection to their appropriate supply.
Heaters must be switched off when the motor is
running.
Thermistor continuity (PTC):
Do not apply a megger across the thermistor.
Do not apply more than 6V across the thermistor.
It is recommended that thermistors are connected
to an appropriate protection relay.
(Thermistors provide good thermal overload
protection).
Resistance Temperature Detector (RTDs) should
have rsistance checked against manufacturers
data.
Thermostats (PTO)
These are ‘Normally closed’ device for connection
into the motor control circuit.
It is imperative that any overload trips and
emergency shutdown circuits are working
correctly before the motor is energised.
All covers must be in position.
Where a motor is fitted with a separately driven fan
unit, the interlocks and thermal overload
protection circuits must be operative.
Connection diagrams
Refer to the motor rating plate for supply details
for the required winding connection.
80 - 112 M4 0.8 - 1.4
132 M5 1.5 - 3.5
160 - 180 M6 3 - 6
200 - 225 M8 5.8 - 8.5
250 - 280 M10 10 - 16
315 - 355 M12 16 - 25
Frame size Terminal size Torque (Nm)
Table 3 - Terminal tightening torques
All covers must be in position prior to running.
WARNING
Isolate power supply to motor before
commencing any routine cleaning or maintenance
work.
Drying out procedures
It is preferable to dismantle the motor to the point
where the rotor is removed. This is not essential
but the drying out process will take longer in the
assembled state.
The temperature of the windings and the
insulation resistance should be monitored at
regular intervals.
On initial application of heat the insulation
resistance will drop quickly and then start to rise
slowly until level. On discontinuation of the drying
process, a further rise in resistance will occur.
There are several methods which can be used:
1place the motor in a warm (typically 40°C), dry
airstream (fan or convector heater) or in a warm
oven with a temperature not exceeding 80°C. This
method is preferred if the motor is dismantled.
2connect the motor to a low voltage* three phase
supply and inject a current not exceeding 50% of
the full load current into the stator winding
(*approximately 10% of the line voltage). If this is
carried out on an assembled motor, it is possible
though unlikely that the motor will turn. If so the
rotor should be locked in position.
3connect two phases in parallel, and the third in
series. Apply a low voltage a.c. or d.c. supply up to
a maximum of 50% of full load current. The stator
winding temperature must not be allowed to
exceed 80°C. In practice the frame should not be
hot to the touch, to guard against internal
overheating and consequent damage to the
insulation.
4where heaters are fitted these can be
energised.
80 12 mm
90 to 112 16 mm
132 20 mm
160 24 mm
Frame size casting thickness ‘LA’
Table 2 - C face casting thickness
LA

Installation & Maintenance
Electrial connection / Maintenance
Rotation
Before coupling the motor to the drive, run the
motor briefly to check rotation.
All covers must be in place
Motors fitted with angular contact or duplex
bearings must be run in the correct mounting
position eg vertical.
To reverse rotation interchange any two supply
lines.
Starting
Motors are rated by the output required, the number
of starts per hour, the load curve/ inertia, and
environmental considerations.
Operating outside the contractual parameters may
thermally overload the motor eg too many starts per
hour, or mechanically stress components eg
overspeeding.
Correct starter to be chosen for the method of start
required.
Running
After one hour of running, check the general
vibration levels. If these are excessive, check
alignment (and belt tensioning if belt driven).
Some initial bearing noise may be present during
the running in period. This is normal because the
grease has to settle down within the bearing. The
noise should disappear after a few hours of
operation.
Check that the motor runs up smoothly and within
the permitted run-up time. Note that repeated
starting in quick succession may lead to a thermal
overload of the motor.
Bearings, grease
Bearings are prepacked with a polyurea based
grease, Polyrex EM.
Regreasing
Standard regreasing facilities, where provided, are
situated on the periphery of the drive end and non
drive endshields.
An overgreased bearing will cause overheating of
the bearing with the possible escape of the grease,
loss of lubrication qualities, leading to ultimate
bearing failure.
See relevant tables on page 5 for regreasing intervals
and grease quantity.
Maintenance
On-going maintenance
Induction motors by their very nature require very
little maintenance. However a regular regime of
inspection is recommended to ensure minor
problems do not escalate to breakdowns. Typical
intervals would be 2000 hours of operation or
3 months, whichever is the sooner.
Checklist
• no visible damage ie fans cracked, fan cowls
bent, foot cracked etc
• no accumulation of dust or fibres on the frame
or around the fan inlet
• no significant corrosion of the lifting lugs/
eyebolts
• no excessive vibration
• no loose fasteners
• cables and earths are sound
• sealing of the motor and gland plate in good
condition
• insulation resistance adequate, imperative
this is checked after a prolonged shutdown
• regrease required, particularly large output
2 pole motors
• bearing condition
Spares and repairs
When ordering spares it is important to state the
motor item / serial number to ensure that the
correct spares will be supplied.
Notes
a) fixing bolts, nuts, studs, screws, spacers or
washers are not included with these parts and, if
required, should be clearly specified on the order
in addition to the part description number.
The fixing duty and part description reference
number for which they are required should also be
clearly stated.
b) if ordering bearings direct from a bearing
manufacturer, then please check the motor
nameplate for the correct bearing size, type
and fit.
Periodic maintenance
Remove the cover and the fan which is keyed,
clamped, pinned or knurl located to the shaft
extension. Loosen and remove bearing cover
screws and endshield bolts/studs. The endshields
should then be eased off their spigots.
The rotor can now be carefully withdrawn from the
stator, taking care not to damage the stator bore
or the stator windings.
Having dismantled the motor, maintenance can be
carried out to remove all dirt. For this purpose, the
use of an air line supplying dry compressed air
under comparatively low pressure is best, as a
high velocity air-stream can force dirt into the
spaces between the windings and insulation, etc.
Greaseremoving solvents should only be used very
sparingly to avoid damage to impregnating varnish
or insulation.
Motors should be re-assembled in the reverse
order from dismantling, remembering to ease
endshields onto bearings and spigots.
Do not use force.
Before starting, check that the shaft revolves
freely. Ensure that the electrical connections are
correct and terminal nuts tight (see Electrical
Connection).
Enquiries
Please contact Brook Crompton for information on
any aspects of the motor performance that need
clarifying.
Any attempt at remedial action and/or
modification without the prior written consent
of Brook Crompton may invalidate the warrant /
guarantee offer on this product
Please quote the item number / serial number in
all such cases with full details of the problem.
Policy
Our policy is one of continuous improvement and
we reserve the right to alter any detail of our
products at any time without giving notice.

Installation & Maintenance

Regreasing intervals.
250 30 30 1800 3900 6500 9000
280 33 33 1800 3500 6000 8000
315 33 33 1500 - - -
315 45 45 - 3000 5000 7500
355 45 45 1500 - - -
355 60 60 - 3000 4000 6000
Quantity (gms) Lubrication intervals (hours)
Frame size DE brg NDE brg 3000 min-1 1500 min-1 1000 min-1 750 min-1
Relubrication intervals - ball / ball arrangement
Figures above are based on a horizontal mounted motor for both standard design &
alternative design.
Bearings are filled with a high quality Polyurea based grease.
The regreasing time should be reduced if the bearing operating temperature is in excess of 70°C.
For vertical applications, the above figures should be halved.
250 30 30 1200 3900 6500 9000
280 33 33 1000 3500 6000 8000
315 33 33 1000 - - -
315 45 45 - 3000 5000 7500
355 45 45 500 - - -
355 60 60 - 2500 3500 6000
Quantity (gms) Lubrication intervals (hours)
Frame size DE brg NDE brg 3000 min-1 1500 min-1 1000 min-1 750 min-1
Relubrication intervals - Roller bearing at drive end
Figures above are based on a horizontal mounted motor for both standard design &
alternative design.
Bearings are filled with a high quality Polyurea based grease.
The regreasing time should be reduced if the bearing operating temperature is in excess of 70°C.
For vertical applications, the above figures should be halved.
Connection diagram - Dual voltage (∆/Υ) single speed motors
W2 U2 V2
L1
V1 W1
U1
L2 L3
W2 U2 V2
L1
V1 W1
U1
L2 L3
Low voltage (Δ) High voltage (Υ)
To reverse direction of rotation, change over any two supply lines
Generally standard motors frame sizes
80 to 225 are sealed for life bearings.
Sealed for life bearings can be identified on the
motor name plate with ‘ZZ’ or ‘2Z’ appearing
after the bearing size, for example 6310ZZ
Motor frame sizes 250 to 355 are supplied with
re-lubrication facilities, breaings are pre-greased
with Mobil Polyrex EM. The re-lubrication
interval and grease quantity are shown in the
tables below.
Mains supply Auxiliaries (where fitted)
Thermistors
Connect to thermistor control unit. <6V
TP TP
Single voltage heater
Connect to single phase supply. 1Ø
HE HE
~
Dual voltage heater - (220-240V)
Fit jumper lead across: 22 & 23.
Connect to single phase 220-240V
supply.
Dual voltage heater - (110V)
Fit jumper leads across:
21 & 23 and 22 & 24.
Connect to single phase 110V
supply.
21 22 23 24
220-240V
1Ø
~
21 22 23 24
110V
1Ø
~
Thermostats
Connect to overload protection circuit.
TB TB

dh2022-05/*/**/06/22 2022-05 Issue 1.3 (Series 30)
© Copyright Brook Crompton UK Ltd. All rights reserved.
Every care has been taken to ensure the accuracy of the
information contained in this publication, but, due to a policy
of continuous development and improvement the right is
reserved to supply products which may differ slightly from
those illustrated and described in this publication
Europe
Brook Crompton UK Ltd
St Thomas’ Road Huddersfield
West Yorkshire HD1 3LJ UK
T: [phone]
F: [phone]
E: [e-mail]
www.brookcrompton.com
Brook Crompton UK LTD -
Sede secondaria in Italia
Via De Chirico, 9/11
42124 – Reggio Emilia (RE)
T: [phone]
E: [e-mail]
www.brookcrompton.com
Asia
Brook Crompton Asia Pacific Pte Ltd
19 Keppel Road #08-01, Jit Poh Building
Singapore 089058
T: [phone]
F: [phone]
E: [e-mail]
www.brookcrompton.com
Brook Crompton Australia Pty Ltd
5/220 New Cleveland Road,
Tingalpa, Queensland
Australia
T: [phone]
E: [e-mail]
www.brookcrompton.com
Americas
Brook Crompton Inc
1100 E. 222nd Street
Euclid, Ohio 44117, USA
T: [phone]
T: +1 - 800 463 8917
E: [e-mail]
www.brookcromptonna.com
Brook Crompton Ltd
264 Attwell Drive
Toronto, Ontario, M9W 5B2, Canada
T: + 416 675 3844 (Toronto)
T: [phone] (Quebec)
E: [e-mail]
www.brookcromptonna.com