GEK-95351

�GE Industrial Systems

Instructions

Vertical Induction Motors

High Thrust Hollow & Solid-Shaftand In-Line Solid-Shaft

Frames 182-405 NEMA Type P BaseTEFC & Explosion-Proof

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Safety Precautions

High voltage and rotatingparts can cause serious or fatalinjuries. Installation, opera-tion, and maintenance of elec-tric machinery should be per-formed by qualified personnel.

Familiarization with NEMA Publication MG-2,Safety Standard for Construction and Guide forSelection, Installation and Use of Electric Mo-tors and Generators, the National ElectricalCode, and sound local practices is recom-mended.

For equipment covered in this instruction book,it is important to observe safety precautions toprotect personnel from possible injury. Amongthe many considerations, personnel should beinstructed to:

• Avoid contact with energized circuits orrotating parts.

• Avoid by-passing or rendering inoperativeany safeguards or protective devices.

• Avoid use of automatic-reset thermal pro-tection where unexpected starting of equip-ment might be hazardous to personnel.

• Avoid contact with capacitors until safe dis-charge procedures have been followed.

• Be sure that the shaft key is fully captivebefore the motor is energized.

• Avoid extended exposure in close proximityto machinery with high noise levels.

• Use proper care and procedures in handling,lifting, installing, operating, and maintainingthe equipment.

• Do not lift anything but the motor with themotor lifting means.

Safe maintenance practices by qualified person-nel are imperative. Before starting maintenanceprocedures, be positive that:

• Equipment connected to the shaft will notcause mechanical rotation.

• Main machine windings and all accessorydevices associated with the work area aredisconnected from electrical power sources.

If a high-potential insulation test is required,procedure and precautions outlined in NEMAStandards MG-1 and MG-2 should be followed.

Failure to properly ground the frame of this ma-chine can cause serious injury to personnel.Grounding should be in accordance with theNational Electrical Code and consistent withsound local practice.

These instructions do not purport to cover all of the details or variations in equipment nor to provide for every possiblecontingency to be met in connection with installation, operation, or maintenance. Should further information be desiredor should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should bereferred to the General Electric Company.

© Copyright 1989, 1999 General Electric Company

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Table of Contents

Subject Page

Safety Warnings......................................................................................................................2Introduction ........................................................................................................................4Receiving, Handling, and Storage............................................................................................4

Unpacking...................................................................................................................5Installation ........................................................................................................................5

Location and Mounting ...............................................................................................6Pump and System Precautions .....................................................................................6Alignment of Solid Shaft Motors .................................................................................6Couplings for Hollow-Shaft Motors.............................................................................7

General............................................................................................................7Self Release Couplings.....................................................................................7Bolted Couplings .............................................................................................9Non-Reverse Couplings .................................................................................10

Power Supply and Connections .................................................................................12Wiring and Grounding....................................................................................12Allowable Voltage Frequency ........................................................................12Position of the Conduit Box...........................................................................12

Lubrication................................................................................................................12Operation ......................................................................................................................13

Steps Prior to Initial Startup ......................................................................................13Initial Startup ............................................................................................................15Jogging and Repeat Starts .........................................................................................15

Maintenance ......................................................................................................................15General......................................................................................................................16Explosion-Proof Motors for Hazardous Locations.....................................................16General Cleanliness....................................................................................................17Relubrication.............................................................................................................17

Oil Lubricated Bearings .................................................................................17Grease Lubricated Bearings ...........................................................................19

End-Play Adjustment ............................................................................................................20General .....................................................................................................................20Lower Thrust Bearings – 182-286 Frames .................................................................20Upper Ball Thrust Bearings – 320-405 Frames, Oil Lubricated ..................................21Bearing Replacement.................................................................................................21Insulation and Winding Maintenance..........................................................................22

General..........................................................................................................22Vacuum and Compressed Air Cleaning ..........................................................22Cleaning with Water and Detergent................................................................23Cleaning with Solvents...................................................................................23Re-Varnishing Windings ................................................................................23

Renewal Parts ......................................................................................................................24Trouble Shooting Chart.........................................................................................................25

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VERTICAL INDUCTION MOTORSHIGH THRUST HOLLOW & SOLID-SHAFT AND IN-LINE SOLID SHAFT

FRAMES 182-405 NEMA P BASETEFC & EXPLOSION-PROOF

I. INTRODUCTION

General Electric High-Thrust vertical mo-tors covered by these instructions are care-fully constructed of high-quality materialsand are designed to give long and trouble-free service when properly installed andmaintained. These motors are generallyused to drive pumps.

Both HOLLOW-SHAFT and SOLID-SHAFT motors are described in this in-struction book. Hollow-shaft construction isavailable in frame sizes 213 and largerwhereas solid-shaft construction is availablein 182 and larger. Figure 1 shows a typical213-286 frame hollow-shaft high thrustmotor and Figure 2 shows the 324-405frame construction. Solid-shaft constructionis shown in Figures 3 and 4 with the motorshaft extending out the bottom of the mo-tor. Solid-shaft high-thrust motors are notsuitable for driving loads that impose sig-nificant radial load on the motor shaft; theyshould not, for example, be used for belt-drive applications.

Motors may be supplied with differentbearing arrangements for various externalthrust conditions imposed by the pump,such as different magnitudes of down-thrustand either momentary or continuous up-thrust. A typical high-thrust motor with an-gular-contact ball bearings is shown in Fig-ures 1 and 2. This standard construction isfor high continuous down-thrust and is suit-able for momentary up-thrust equal to 30%of the rated down-thrust capacity of a high-thrust motor. NOTE THAT ANGULAR-CONTACT BEARINGS CAN ONLYCARRY THRUST IN ONE DIRECTION.IN-LINE motors (designed to be mounted

on pumps which are directly in the pipe-line,and hence called IN-LINE motors) are alsocovered by this instruction book. Thesemotors have two opposed-mounted angu-lar-contact ball thrust bearings so they cancarry either up or down thrust. The guidebearing is a radial-ball type. IN-LINE mo-tors are always of the solid-shaft type. Thisclamped construction is shown on Figures3a and 4a.

Since overloading greatly reduces bearinglife, the amount of thrust applied should notexceed the recommended values.

This instruction book applies to motors witheither Totally Enclosed Fan Cooled or To-tally Enclosed Fan Cooled-Explosion-Proofenclosures as defined by NEMA.

Enclosed motors are characterized by anenclosure and ventilating system that pre-vents the free exchange of air between theinside and outside of the motor. The air in-side the motor is circulated by the rotor fansto carry heat to the enclosing parts, while anexternal fan blows ambient air over themotor to complete the cooling process.

II. RECEIVING, HANDLING, ANDSTORAGE

Each motor should be carefully examinedwhen received and a claim filed with thecarrier for any damage. The nearest officeof the General Electric Company may offerguidance.

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The motor should be lifted bythe lugs provided. These lugsare intended for lifting the mo-tor only and must not be usedto lift any additional weight. Be

careful not to touch overhead power lines withlifting equipment. Failure to observe thiswarning may result in personal injury or death.

If the motor is not to be installed immedi-ately, it should be stored in a clean, dry lo-cation. Precautions should be taken to pre-vent the entrance of moisture, dust, or dirtduring storage and installation. Precautionsare taken by the factory to guard againstcorrosion. The machined parts are slushedto prevent rust during shipment. Examinethe parts carefully for rust and moisture ifthe equipment is to be stored and re-slushwhere necessary.

Motors are shipped without oil in the bear-ing reservoirs (320 frame and larger). An oilfilm remains on the bearings, but if the stor-age period is to exceed three months, thereservoirs should be filled. It is suggestedthat such oil-filled motors be conspicuouslytagged in order to prevent mishandling,which would cause oil spillage and subse-quent damage to the internal parts of themotor. When filling for storage, fill to themaximum level shown on the gage or ap-proximately 1/2” over the mark showing thestandstill level. Before operating the motor,drain this oil and refill with fresh oil.

See instructions under RELUBRICATIONfor oil recommendations.

During storage, windings should be pro-tected from excessive moisture absorptionby some safe and reliable method of heating.Space heaters, if supplied, may be used forthis purpose. The temperature of the wind-ings should always be main

tained a few degrees above the temperatureof the surrounding air. It is recommendedthat motors in storage be inspected, thewindings meggered, and a log of pertinentdata kept. Any significant decrease in insu-lation resistance should be investigated.

If a motor is to be in storage for over oneyear, it is recommended that competenttechnical inspection service be obtained toensure that the storage has been adequateand that the motor is suitable for service.Contact your nearest General Electric Salesoffice to arrange for inspection service.

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If the machine or machine parts havebeen exposed to low temperatures,unpack it only after it has reached thetemperature of the room in which itwill be unpacked or located; otherwisesweating will occur.

III. INSTALLATION

Installation should be in ac-cordance with the NationalElectrical Code and con-sistent with sound local prac-tices. Coupling guards

should be installed as needed to protectagainst accidental contact with movingparts. Machines accessible to personnelshould be further guarded by screening,guardrails or other suitable enclosure toprevent anyone from coming into contactwith the equipment. This is especially im-portant for motors that are remotely orautomatically controlled or have automaticre-setting overload relays, since such mo-tors may start unexpectedly. Failure to ob-serve these precautions may result in injuryof death to personnel.

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A. Location and Mounting

Allow enough space around the motorto permit free flow of ventilating airand to maintain an ambient tempera-ture not over 40º. Where a choice oflocations is possible, install the motorso that it will be subjected to the leastamount of dirt, dust, liquids, or otherharmful materials. Mount the motorsecurely on a level, firm foundation,align accurately with the drivenequipment, and tighten mounting boltssecurely.

Because of their special enclosurefeatures, enclosed motors can be op-erated out-of-doors and in dirty loca-tions.

Explosion-proof motors suitable foruse in hazardous locations bear theUnderwriters Laboratories label andshould be applied only in the areas forwhich they are designed, as specifiedin the National Electrical Code. (SeeMOTORS FOR HAZARDOUSLOCATION).

Installation of the machinewhere hazardous, flammable, orcombustible vapors or dustspresent a possiblity of ex-plosion or fire should be in

accordance with The National Electrical Code,Articles 500-503, and consistent with sound lo-cal practices. Extreme care is required for allexplosion-proof motors or TEFC motors sup-plied with an explosion-proof or dust-ignitionproof accessory device or conduit box sinceany nicks or burrs in the sealing surfaces dur-ing disassembly and reassembly may destroythe explosion-proof or dust-ignition proof fea-tures. Failure to observe these precautionsmay result in damage to the equipment, injuryto personnel, or both.

B. Pump and System Precautions

Some precautions are necessary toassure satisfactory operation of motorsin pumping service. The packing glandin the pump head should be kept ingood condition so that the liquid beingpumped will not be forced out alongthe shaft and enter the motor throughthe lower bearing housing.

Motors driving pumps in pressure sys-tems where the pressure is maintainedafter shutdown should be protectedfrom overspeeding by check valves ornon-reverse couplings.

The SYSTEM REED CRITICALFREQUENCY should be 25% aboveor below motor operating speed in or-der to avoid excessive vibration.

C. Alignment of Solid Shaft Motors

Accurate mechanical lineup is essentialfor successful operation. Mechanicalvibration and roughness when the mo-tor is running may indicate poor align-ment. In general, lineup by straightedge across, and feeler gages betweencoupling halves is not sufficiently accu-rate. It is recommended that the lineupbe checked with dial indicators. Thespace between coupling hubs should bemaintained as recommended by thecoupling manufacturer.

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D. Couplings for Hollow-ShaftMotors

1. General

Vertical hollow-shaft motors aredesigned for driving deep-well,turbine-type pumps and can beequipped with either self-release,bolted, or non-reverse couplingsas described in the following sec-tions. These couplings are lo-cated at the top of the motor andallow pump impeller position tobe adjusted easily. The type ofcoupling is specified by the cus-tomer. Remove the top cover andfan casing for access to the cou-pling

Two slots are provided in theoutside rim of the coupling sothat a bar can be inserted tokeep the assembly from turningwhile the adjustment of pumpimpeller clearance is being made.The motor fan must be removedfor access to these holes, but fanremoval is a normal step duringmotor installation since it ismounted on the upper half-coupling. A coupling bolt can bescrewed into one of the extratapped holes in the top endshieldto provide a stop for the bar.

To prevent breakage, couplingbolts must be tightened totorque values indicated belowfor bolted or non-reverse cou-plings.

Bolt Size Torque

1/4 10 lb-ft5/16 20 lb-ft3/8 37 lb-ft1/2 90 lb-ft5/8 180 lb-ft3/4 320 lb-ft1 710 lb-ft

It shall be the installer’sresponsibility in all casesto ascertain that thesetorque values are usedand maintained. This shallinclude those instances

when the coupling comes mounted in themotor. Failure to comply may cause thecoupling blots to b reak with resultant ex-tensive damage to the e quipment.

2. Self-Release Couplings

Self release couplingsmust not be used with ex-plosion-proof motors.Only non- reverse cou-plings with non-sp arkingratchets

should be used with explosion-proof ordust ignition-proof motors that drivepumps with sectional shafts. If the pumphas a solid, one pi ece shaft, a bolted cou-pling may be used.

Should the motor accidentally berun in the reverse direction, thepump line-shaft joints may un-screw. The self-release couplingacts to limit the amount of thisunscrewing. In normal opera-tion, torque from the motor istransmitted by the lower half-coupling through the drivingpins to the upper half-coupling,and then to the pump shaft. Ifreversal occurs and the pumpshaft starts to unscrew andlengthen, the up

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per half of the self-release cou-pling is lifted off of the drivingpins, thus uncoupling the pumpfrom the motor. See Figure 2,where a self-release coupling isshown to the left of the shaftcenter-line.

NOTE: Self-release couplingscannot carry up-thrust.

To install a motor with a self-release coupling, first lift off theupper half-coupling and the fanattached to it, and remove thefan from the coupling. Thenlower the motor onto the pumpwith pump shaft through motorshaft. Next, set the upper half-coupling into place on thelower half-coupling and put thegib-key in place. Then put thepump shaft nut in place, adjustthe pump and lock the nut. Fi-nally, set the fan on top of theupper half-coupling and secureit with its 3 capscrews.

Proper functioning of a self-release coupling depends uponseveral factors. The pump shaftadjusting nut must be securelyattached to the top half-coupling, and the top half-coupling must not bind on thelower half. Otherwise, the ad-justing nut lock-screw maybreak instead of the couplinghalves separating. Should thishappen, the motor would con-tinue to unscrew. Serious dam-age to both motor and line shaftmay result. Clearance

between the coupling halvesshould be checked by placing thetop half-coupling in positionprior to installing the motor. Itshould drop into place, and restsolidly on the lower half-coupling, without forcing.

Proper alignment of the pumphead-shaft within the motorhollow shaft is also important.After the coupling releases, it nolonger holds the pump shaftcentered. If the alignment is notgood, the motor shaft which isstill rotating may rub the pumpshaft which has stopped, anddamage will result.

A third requirement is that thedistance between the top of thepump shaft and the inside of thetop cap be at least enough toallow the top half-coupling,when it tries to release, to clearthe pins before the shaft hits thecap. Check this clearance afterthe adjusting nut has been drawnup to its final position. To fa-cilitate making the check, themotor outline print shows amaximum dimension “XH” fromthe top of the coupling to thetop of the pump shaft. Adheringto this design limit will allow theshaft and coupling to lift enoughto clear the pins and still leave asmall clearance between theshaft and cap. For standard mo-tors, “XH” is as shown in TableI.

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Table I

Frame Size XH

213-215 2.00 inches254-256 2.25 inches284-286 2.50 inches324-326 3.75 inches364-365 3.75 inches404-405 4.00 inches

Depending upon the circum-stances causing reversal andupon which line-shaft joint un-screw, there may be enough en-ergy stored in the rotating parts,at the time the coupling clearsthe pins, to cause the pump shaftto continue to rise and strike thetop cap. However, if the aboveconditions are met, damage,even in the most severe cases,should be limited to a brokentop cover or fan.

It is intended that self-releasecouplings will be called upon touncouple only infrequently.

NOTE: Any time a self-release coupling uncouples, it isnecessary to remove all powerand manually re-couple.

Un-coupling is most frequentlycaused by application of single-phase power after a power sup-ply disturbance, while the motoris being driven in the reverse di-rection by the pump; this single-phase power causes the motor totake over and drive the pump inthe reverse direction and thepump shaft joints will then un-screw. To prevent this, select amotor

starter which requires a manualstart after any stop (rather thanallowing automatic re-start assoon as power is applied to thestarter), or incorporates a back-spin timer to keep power frombeing automatically reapplied tothe motor until enough time haselapsed for water back-flowthrough the pump to stop andfor the motor to completelystop.

Power supply phase-sequencereversal will also cause the mo-tor to reverse and unscrew thepump shaft, but this rarely oc-curs. An antiphase-reversal relaycan be incorporated in the motorcontroller if desired.

To prevent un-coupling on initialstart-up, check motor rotation di-rection before installing the upperhalf-coupling to be sure directionis correct. To reverse direction ofrotation, interchange any twopower leads.

3. Bolted Couplings

Bolted couplings allow up-thrustfrom the pump to be taken bythe motor bearings. This type ofcoupling is similar to a self-release coupling except that thedriving pins are replaced bybolts, which should be securelytightened to hold the two halvesof the coupling solidly togetherso that torque is transmitted byface friction. See Torque Re-quirements. This type of cou-pling does not have the self-release feature and allows re-verse rotation.

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See the self-release couplingshown to the left of the motorcenter line in Figure 2, which isapplicable to bolted couplingsexcept that the headless drivepins are replaced by bolts as ex-plained above.

To install a motor with a boltedcoupling, first unbolt and re-move the fan, thus exposing thecoupling bolts. Then unbolt andremove the upper half-coupling.Next, lower the motor onto thepump with pump shaft throughthe motor shaft. Then set theupper half-coupling into placeon the lower half-coupling andput the gib-key in place, tight-ening the bolts as shown onpage ? Then put the pump nutin place, adjust the pump andlock the nut. Finally, put the fanin place on the upper half-coupling and secure it with the3 capscrews provided.

4. Non-Reverse Couplings

For explosion-proof motors,a special non-reverse end-shield cover made of bronzemust be used, so pinsstriking ratchet teeth will not

Spark.

The non-reverse type of cou-pling, as shown to the right ofthe motor centerline in Figures 1and 2, is also a bolted type, and,in addition, it keeps the pumpand motor from rotating in thereverse direction. Thus, it notonly prevents the pump shaftfrom unscrewing and damage towater-lubricated

pump shaft bearings, when dur-ing shutdown the residual waterin the system drives the pump inthe reverse direction. This typeof coupling also allows up-thrustfrom the pump to be carried bythe motor bearings. Motortorque is transmitted to thepump shaft through the twohalves of the coupling which arebolted together. See RequiredBolt Torques.

To install a motor with a non-reverse coupling, first unbolt andremove the fan, thus exposingthe coupling bolts. Next, put thefan bolts back in place to securethe pin-retaining plate to the pin-carrier and keep the non-reverseassembly from flying apart.Then, unbolt and remove theupper half-coupling and non-reverse assembly. Next, lowermotor onto the pump with pumpshaft through the motor shaft.Then set the upper half-couplingand non-reverse assembly intoplace on the lower half-couplingand bolt it to the lower half-coupling, tightening the bolts.Then install the gib-key andpump shaft nut, adjust the pumpand lock the nut. Finally, removethe three small capscrews se-curing pin-retaining plate, putthe fan in place and secure itwith these same capscrews.

The operation of a non-reversecoupling is explained as follows.When the motor is started in thecorrect or forward direction, theratchet pins are lifted

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by the ratchet teeth and are heldup by centrifugal force and fric-tion when motor speed becomeshigh enough. When power is re-moved, the speed decreases, andthe pin will catch on a ratchettooth and prevent backward ro-tation. The number of pins differsfrom the number of teeth to mul-tiply the number of stopping po-sitions.

A very rapid decrease in speedcan result in acceleration forcesgreat enough to prevent the pinsfrom dropping. This condition isfurther aggravated when the pinsbecome dirty and their actionsluggish. If the time from shut-down (the instant the “stop”button is pressed) to zero speedis greater than two seconds, op-eration will be satisfactory.

To permit operation when stop-ping time is less than two sec-onds, the pins are spring-loaded.For those cases involving cycling(frequent starting and stopping)and stopping times greater thantwo seconds, the springs may beremoved to decrease wear onthe ratchet plate.

Pins and springs are made ofheat-treated stainless steel.

A complete non-reverse cou-pling consists of a self-releasecoupling plus a non-reverse as-sembly, which includes pin car-rier, pins, springs, pin retainingplate, and capscrews.

On motors covered by this in-struction book, the ratchet teethare an integral part of the End-shield cover casting.

A self-release or a bolted cou-pling can be converted to a non-reverse coupling on 324-405frame motors without disturbingthe adjustment of the pump shaftnut.

The non-reverse assembly willnormally be received as a unit.To assemble it onto the motor,unbolt and remove the fan, thusexposing the coupling pins orbolts. Next, remove the drive-pins or bolts from the lower half-coupling. Next, insert the longcapscrews through the plate, pincarrier, and top coupling.Tighten them securely so thattorque will be transmitted byfriction between the couplingfaces rather than through thebolts. See TORQUEREQUIREMENTS. Next, re-move the three smaller cap-screws securing the pin-retainingplate to the pin-carrier. Finally,put the fan into place on top ofthe pin-retaining plate and se-cure it with the three capscrewsjust removed. On 213-286 framemachines, the pump shaft nutmust be removed and the boltedor self-release coupling replacedwith a non-reverse coupling.

The top half of the couplingshould seat solidly on the lowerhalf and the pins should

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touch the bottom of the pocketsbetween the teeth in the ratchet.The clearance between the pin-carrier and the top of the ratchetteeth should be between 1/16”and 1/8”.

A non-reverse assembly mustnot be added to explosion-proof motors unless a bronzeend-shield cover is also in-stalled. This is to avoid spark-ing that

might occur when the steel pins of the non-reverse assembly strike the endshield cover.

When installing a non-reversecoupling do not use lubricant.Lubrication will lower the coef-ficient of friction between pinsand pin carrier, and the pins maynot stay up when motor reachesfull speed.

E. Power Supply and Connections

1. Wiring and Grounding

Motor and control wiring, over-load protection, and groundingshould be in accordance withthe National Electrical Code andconsistent with sound local

practices. Failure to observe these precautionsmay result in damage to the equipment, injuryto personnel, or both.

Stator winding connectionsshould be made as shown on theconnection diagram or in accor-dance with the wiring diagramattached to the inside of theconduit box cover. For 3 leadmotors, no connection diagramis needed or supplied.

The motor frame may begrounded by attaching a groundstrap from a known groundpoint to the bronze groundingbolt in the conduit box.

2. Allowable Voltage andFrequency

The power supply must agreewith the motor nameplate volt-age and frequency. Motors willoperate (but with characteristicssomewhat different from name-plate values) on line voltageswithin ±10% of nameplate valueor frequency within ±5%, and acombined variation not to ex-ceed ±10%.

3. Position of the Conduit Box

When mounting conditions per-mit, the conduit box may beturned so that entrance can bemade upward, downward, orfrom either side.

F. Lubrication

Motors with oil-lubricated bearings(324-405 frames) are shipped withoutoil. Before starting the motor, fill eachreservoir to the standstill level shownon the sight gage. Be careful to keepdirt out of the lubricant and bearinghousing.

Use only the oil specified on the lubri-cation nameplate or the lubrication in-struction supplied with each motor.See RELUBRICATION, Table II andLUBE NAMEPLATE for oil gradeand viscosity and further instructions.

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If reservoirs have had oil in them dur-ing storage period, drain out this oldoil when installing the motor for op-eration.

IV. OPERATION

Before energizing the motorfor the first time or after anextended shut-down, it is ad-visable to check insulationresistance, power supply andmech-

anical freedom of the motor. If the motor hasbeen stored in a damp location, dry it outthoroughly before operating.

Be sure that the motor is notrunning and the power supplyis disconnected before work-ing on motor.

A. Steps Prior to Initial Start-UpAfter a Long Idle Period

1. Check insulation resistance asindicated in the caution above.

Before measuring insulationresistance, the machine mustbe at stand-still and all wind-ings to be tested must be elec-trically connected to the frame

and to ground for a time sufficient to removeall residual electrostatic charge. Failure to ob-serve these precautions may result in injury topersonnel.

In accordance with establishedstandards, the recommendedminimum insulation resistancefor the stator winding is as fol-lows:

RS = VS +1 1000

Where RS is the recommendedminimum insulation resistance inPHJRKPV� DW� ��&� RI� WKH� HQWLUHstator winding obtained by ap-plying direct potential to the en-tire winding for one minute, andVS is rated machine voltage.

NOTE: See ieee recommendedpractice for testing insulation re-sistance of rotating machinespublication no. 43 for morecomplete information.

If the insulation resistance islower than this value, it may bewet and it is advisable to elimi-nate the moisture in one of thefollowing ways

a. Dry the stator in an air cir-culating oven with the airsurrounding the part at95ºC to 115ºC. until thestator has been above 90ºCfor at least four hours.Then the air temperaturemay be raised to 135ºC to155ºC. Continue to heatuntil the insulation resis-tance is constant for a one-half hour period.

b. Enclose the motor withcanvas or similar covering,leaving a hole at the topfor moisture to escape. In-sert heating units or lampsand leave them

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on until the insulation re-sistance is constant forone-half hour period. Becareful not to get heatingunits so close to the wind-ing that they cause local-ized damage.

c. With the rotor locked andusing approximately 10%of rated voltage, pass acurrent through the statorwindings. Increase the cur-rent gradually until thetemperature reaches 90ºC.Do not exceed this tem-perature. Maintain a tem-perature of 90ºC until theinsulation resistance be-comes constant for a one-half hour period.

2. Check bearing oil reservoirs tobe sure they have been filled tothe proper level with fresh oil.See RELUBRICATION, TableII and LUBE NAMEPLATE onmotor for oil grade and viscosityand further instructions. Be surefiller caps and drain plugs aresecurely tightened.

3. Examine the motor for looseobjects or debris which mayhave accumulated and removeany foreign material.

4. If possible, turn the rotor byhand to be sure that it rotatesfreely.

5. Check all connections with theconnection diagram. Check allaccessible factory-made connec-tions for tightness to make

sure none has become looseduring shipment.

6. If possible, leave motor uncou-pled (or uncouple it) for initialoperation so that motor vibra-tion, noise, current, and bearingscan be checked uncoupled be-fore they are masked by thepump. To run a VHS motor un-coupled, it is recommended thatthe pump head-shaft be re-moved. If this cannot be done,remove the upper half-couplingand be sure the pump shaft iswell centered in the motor shaftso it will not rub. IF THIS ISDONE, ROTATE MOTOR BYHAND TO BE SURE THEREIS NO INTERFERENCEBETWEEN SHAFTS. Do nottry to run motor un-coupled byjust removing gib-key.

7. When the driven machine is likelyto be damaged by the wrong di-rection of rotation, it is impera-tive to uncouple the motor fromits load during the initial start andmake certain that it rotates in thecorrect direction. If it is neces-sary to change rotation, inter-change any two line leads. Formultispeed motors, check eachspeed independently. On VHSmotors, do this before installingpump head-shaft and upper half-coupling.

Some motors are designed forunidirectional rotation. Rotationof these motors must be in ac-cordance with the rotation indi-cated on the nameplate and theoutline furnished with theequipment.

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B. Initial Start

1. After inspecting the machinecarefully as outlined above,make the initial start by follow-ing the regular sequence ofstarting operations in the controlinstructions.

2. Run the motor uncoupled ini-tially, if possible, checking forabnormal noise, vibration, orbearing temperatures and forcurrent and voltage balance.Then check motor operation un-der load for an initial period ofat least one hour to observewhether any unusual noise orhotspots develop.

3. In the event of excessive vibra-tion or unusual noise, remove allpower and disconnect the ma-chine from the load and checkthe mounting and alignment.

4. Space heaters should be de-energized during motor opera-tion.

5. Check line voltage on all threephases to be sure it is balancedand within 10% of motor ratedvoltage with motor drawing loadcurrent.

6. Check the operating currentagainst the nameplate value. Donot exceed the value of name-plate amperes X service factor(if any) under steady continuousload. Also, check to be sure thatcurrent in all three lines is bal-anced.

C. Jogging and Repeat Starts

Repeated starts and/or jogs ofinduction motors greatly re-duce the life of the winding in-sulation. The heat produced byeach acceleration or jog ismuch

more than that dissipated by the motor at fullload. If it is necessary to repeatedly start or joga motor, it is advisable to check the applicationwith the local general electric sales office.

Check motor heating but do not de-pend on your hand to determine tem-perature. Use the temperature detec-tors furnished in the motor if there areany (e.g., RTD’s or thermocouples),or use a thermometer. If there is anydoubt about the safe operating tem-perature, take the temperature of thepart in question and confer with thenearest sales office of the GeneralElectric Company. Give full details,including all nameplate information.

Overheating of the motor may becaused by improper ventilation, exces-sive ambient temperature, dirty condi-tions, excessive current due to over-load, unbalanced AC voltage, or (if avariable speed controller is used) har-monics in power supplied to the mo-tor.

VI. MAINTENANCE

Before initiating maintenanceprocedures, disconnect allpower sources to the motor andaccessories. For machinesequipped with surge capaci-tors,

do not handle capacitor until it is discharged bya conductor simultaneously touching all termi-nals and leads, including ground. This dis-charge conductor should be insulated for han-dling. Replace all normal grounding connec-tions prior to operating. Failure to observethese precautions may result in injury to per-sonnel.

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A. General

Inspect the motor at regular intervals,as determined by service conditions.Keep the motor clean and the ventila-tion openings clear.

In addition to a daily observation ofthe overall condition, it is recom-mended that a regular inspection rou-tine be set up to check periodically thefollowing items:

1. General Cleanliness

2. Insulation and Windings

3. Lubrication and Bearings

4. Coupling Bolt Tightness

B. Explosion-Proof Motors forHazardous Locations

Motors which are suitable for use inhazardous locations have special fea-tures and are called explosion-proofmotors or dust ignition-proof motors.They bear the Underwriters Laborato-ries label which specifies the particulartype of location in which the motormay be operated.

Special features include wide metal-to-metal joints with limited clearancesbetween surfaces; the sealing of leadsinto the frame; enclosing parts andholding bolts of proper design forstrength; fans, seals, and non-reversecouplings of non-sparking metals; theavoidance of removable plugs in theenclosure; etc.

Motors for hazardous locationsrequire more than ordinary carein their maintenance and repairto assure their continuedsafety. When major repairs are

necessary or new parts are required (except forbearings), it is recommended that the motor besent to an authorized General Electric serviceshop. Minor repairs and routine maintenancecan be done locally provided proper precau-tions are taken not to alter the original explo-sion or dust-ignition proof features. However, itshould be emphasized that failure to observethese precautions may result in a motor whichis unsafe for use in hazardous locations andsuch use may result in a serious explosioncausing property damage, personal injury, orboth.

Whenever it is necessary to disassem-ble one of these motors, it is essentialthat it first be disconnected from thesupply circuit and removed from thehazardous area. All machined metalsurfaces forming joints in the motorhousing must be protected from dam-age. Hammers or prying tools shouldnot be used where they come in con-tact with joint surfaces.

No clearance should be increased ei-ther at joints, around shaft, or betweenrotor and stator. No new openingsshould be made and changes that alterthe strength of the parts must beavoided. Before reassembling themotor, carefully clean the joint sur-faces and then apply a thin coating ofGredag 52 graphitized grease or otherUnderwriters Laboratories approvednon-hardening material.

During assembly, carefully fit the partstogether. All holding bolts and cap-screws should be returned to theircorrect place, and properly tightened.Substitution of bolts or other partsshould not be made. Bolts may be partof a flame cooling path, and mainte-nance of proper clearance betweenbolt and bolt hole is essential.

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C. General Cleanliness

While TEFC and Explosion-Proofmotors are enclosed for protectionagainst adverse conditions of service,they should be kept reasonably cleanfor longer trouble-free life. Externalair passages in the top endshield andstator frame should be cleaned peri-odically to prevent overheating of themotor. Oily vapor, debris, or dust maybuild up and block off ventilation. Anyof these contaminants can lead to earlymotor failure. Motors should be disas-sembled and thoroughly cleaned peri-odically as needed.

Motors may be blown out with dry,compressed air of moderate pressure.However, cleaning by suction is pre-ferred because of the possibility ofwater in the compressed air lines andthe danger of blowing metal chips intothe insulation with compressed air.

To prevent injury to eyes andrespiratory organs, safetyglasses and suitable ventilationor other protective equipmentshould be used. Operator must

not use compressed air to remove dirt or dustfrom his person or clothing.

D. Coupling Maintenance

The condition of non-reverse cou-plings should be checked periodicallyby removing the tip cap. If dirt hascaused the action of the pins to be-come sluggish, the pin-carrier shouldbe removed, disassembled, and thor-oughly cleaned with a suitable solvent.The parts should then be dried and re-assembled in accordance with the in-structions given under NON-REVERSE COUPLINGS.

Sometimes, after a long period of op-eration with frequent stops and starts,the surface of the holes in the pin-carrier becomes polished, so that fric-tion forces will no longer hold the pinsclear of the ratchet teeth when themotor is running. This condition canbe remedied by roughening these sur-faces with a piece of emery paperwrapped around a rod.

NOTE: Whenever the dismantling ofcouplings is necessary, the use of wit-ness marks will assure a balancedcondition when reassembly is com-plete.

Bolts on both bolted couplings andnon-reverse couplings should bechecked periodically to be sure theyare tight. See Recommended Tight-ening Torques.

E. Relubrication

1. Oil Lubricated Bearings

Motors 320 frame sizes andlarger generally have an oil lu-bricated upper bearing. The fol-lowing instructions apply to thatbearing. Grease lubricated in-structions for all other bearingsare included in the followingsection.

Motors covered by these in-structions have oil lubricatedbearings. Maintain proper lubri-cation by checking the oil levelperiodically and adding oil whennecessary. Because of the clear-ing action of the bearing as themotor accelerates up to speedand the expansion of the oil as itcomes up to operating tem-perature, the oil level will behigher after the motor has been

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in operation for a while than it iswith the motor at standstill. Thenormal level, with the motorstopped and the oil cold, ismarked STANDSTILL LEVELon the sight gage.

Overfilling should be avoidednot only because of the possibil-ity that expansion may force theoil over the oil sleeve and intothe motor, but also because op-erating with the oil level toohigh prevents the bearing fromclearing itself of excess oil. Theresultant churning can cause ex-tra loss, high temperatures, and

oxidized oil. If, during opera-tion, the oil level goes above themaximum shown on the sightgage, drain enough oil to bringthe level back within the oper-ating range. A hole is providedinside the drain plug to make itpossible to do this without com-pletely removing the plug.

Do not permit the operating oillevel to fall below the minimumshown on the gage. Should itever become necessary to addexcessive amounts of make-upoil. investigate immediately foroil leaks.

Table II

OIL VISCOSITY(For a particular motor, refer to the lubrication nameplate or instructions)

Bearing Functionand location

BearingType

OilViscosity@ 100ºF

SUS@ F GE Spec.

Thrust Bearing(In top endshield)320-405 Frame

Angular Contact Ball 150 45 D6B6A

Guide Bearing(In base endshield)405 frame, 3600 rmp only –others are grease lubricated

Ball 150 45 D6B6A

Change oil at regular intervals.The time between oil changesdepends upon the severity ofoperating conditions and,hence, must be determined bythe motor user. One or twochanges a year is average, butspecial conditions, such as highambient temperature, may re-quire more frequent changes.Avoid operating motor withoxidized oil.Use only best grade, oxidation

and corrosion inhibited turbineoil produced by reputable oilcompanies. The viscosity(weight) of the oil to be useddepends upon the type and sizeof the bearing, its load andspeed, the ambient tempera-ture, and the amount and tem-perature of the cooling water(if used). The lubricationnameplate or instruction witheach motor specifies the vis-cosity range of oil suitable for

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average conditions. The usualrecommendations are summa-rized in Table II, Oil Viscosity.Operation in ambient tem-peratures that are near or be-low freezing may require pre-heating the oil or the use of aspecial oil.

In some cases, water coolingfor the oil is impractical or un-desirable and the normal oper-ating oil temperature will be inrange of 170º to 210ºF. Also,in some cases, the bearing size,thrust-load and speed are sohigh that even with watercooling the normal oil tem-perature may be as high as210ºF. In these cases, it is es-pecially important that properviscosity, high-grade oil con-taining an oxidation inhibitorbe used. Observe the conditionof the oil frequently andchange oil when it begins toshow signs of deterioration.

Oil-lubricated bearing housingsare provided with large settlingchambers in which dust, dirt,and sludge collect. Unless theoil has been permitted to oxi-dize, the draining of the old oilduring regular changes willusually provide sufficientflushing action to clean out thereservoir.

Whenever the motor is disas-sembled for general cleaningand reconditioning, the bear-ing housing may be washedout with a suitable cleaningsolvent. 1,1,1, Trichloro-ethane may be used, followingthe same instructions andcautions as shown for clean-ing windings. Avoid using

any solvent that will softenthe paint used on the interiorof the oil reservoir. Be surethat the oil metering hole isclear, and then dry the hous-ing thoroughly before reas-sembly.

2. Grease LubricatedBearings

The thrust bearing on 182-286(bottom bearing) and the guidebearing on the 182-405 frame(182-286 top bearing and 324-405 top bearing) are generallygrease lubricated. The thrustbearings of motors with speedsabove 1800 RPM should beregreased every 1000 hours ofoperation with an interval notto exceed three months. Formotors with speeds 1800 RPMand below, regrease every2000 hours of operation withthe interval not to exceed 6months. The guide bearingsshould be regreased in accor-dance with attached schedule.

Type Service Typical ExamplesRelubrication

Interval

Easy Infrequent operation 1 year

Standard One or two shift operation 6 months

Severe Continuous Operation 3 months

Very Severe Dirty locations and/ or highambient temperatures

2 months

Relubrication should be withGeneral Electric D6A2C5grease for best results unlessspecial grease is specified onthe nameplate.

The following procedureshould be used in regreasing:

a. Stop the unit.

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b. Disconnect unit from thepower supply.

c. Remove the relief plugand free the hole of hard-ened grease.

d. Wipe the lubrication fit-ting clean and add greasewith a hand-operatedgun..

e. Leave the relief plugtemporarily off. Recon-nect the unit and run forabout 20 minutes to ex-pel the excess grease.

f. Stop the unit; replace theplug.

g. Restart the unit.

Failure to observe the fore-going instructions for re-greasing may result in greaseleakage and/or bearing dam-age.

F. End-Play Adjustment

1. General

Most high-thrust motors aredesigned to withstand onlymomentary up-thrust. This up-thrust, which can exist for afew seconds during starting, istaken by the guide bearing. Toprevent the thrust bearing fromlosing radial stability duringthis time, the motor endplay islimited to a small amount byadjustment of the motor shaftnut or by shimming. This ad-justment is made at the factory

and need not be disturbed on anew motor. However, should

the motor be diassembled forany reason, the adjustmentmust be made during reassem-bly to avoid damaging thebearings or having some ro-tating part rub against a sta-tionary part. The proceduredepends upon the type ofthrust bearing.

2. Lower Thrust Bearings –182-286 Frames,Grease Lubricated

Standard high-thrust motorsare designed to withstandonly momentary up-thrust.This up-thrust which can existfor a few seconds duringstarting, is taken by the guidebearing. To prevent the thrustbearing from losing radial sta-bility during this time, themotor end play is limited to afew thousandths of an inch byshims inserted in the housingabove the upper bearing. Thisadjustment is made at thefactory and need not be dis-turbed on a new motor. How-ever, should the motor be dis-assembled for any reason, theadjustment must be madeupon reassembly to avoiddamaging the bearings.

Whenever these motors arereassembled, the shims shouldbe replaced and the end playchecked to see that it fallswithin the allowable 0.005 to0.007”. See Figures 1 and 3.

Motors which must withstandcontinuous up-thrust have a

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somewhat different construc-tion. The thrust bearing is ar-ranged to take this up-thrustand is clamped in the bearinghousing. No shims are used inthese motors since the lowerbearing is of the type whichcan withstand axial load inboth directions. See Figure 3A.

3. Upper Ball Thrust Bearing–

324-405 Frames,Oil Lubricated

For a motor with angular-contact ball thrust bearings,refer to Figures 2 and 4. Whenthe motor shaft nut is tight-ened, the rotor, shaft andlower bearing are drawn upuntil the outer ring of thelower bearing seats against thelower bearing cover. Furthertightening of the nut preloadsthe bearings. (Note that theshoulder on the shaft below thelower half-coupling is pur-posely located so that it doesnot seat against the coupling.)

The best way to adjust the nutis by trial, using an indicatorbetween the lower half-coupling and top endshield,and lifting the rotor to checkthe end-play after each settingof the nut until between 0.002”and 0.005” is obtained. Thenut should then be locked withits lockwasher. If equipment isnot available to use thismethod, the following proce-dure may be used. Tighten themotor shaft nut carefully untilall end-play is removed and therotor just fails to turn

freely. Then back the nut off1/6 turn and lock with itswasher. An assembly name-plate giving this information ismounted on the motor.

Motors which must withstandcontinuous up-thrust have asomewhat different construc-tion. The upper (thrust) bear-ing is arranged to take this up-thrust; it consists of angular-contact thrust bearingsmounted back-to-back (DB).(See Figure 4A). The innerrings are locked on the lowerhalf-coupling with a nut andthe outer rings are clamped inthe endshield with a ring. Theshaft shoulder below the lowerhalf-coupling is so located thatit seats against the lower half-coupling before the lowerbearing comes up against itscover. No special adjustment isnecessary when reassemblingthis type of motor, and themotor shaft nut can be pulleddown tight and locked. Theend play of the motors usingDB-mounted bearings will thenbe very small, 0.005” or less.

G. Bearing Replacement

In general, replacement bearingsshould be of the same type and in-stalled in the same relative positionas the original bearings.

When removing bearings, applysteady, even pressure parallel to theshaft or lower half coupling centerline. Apply this pressure to the innerrace whenever possible. Angular-

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contact bearings which have failedand are especially tight on the cou-pling, can sometimes be removed byusing the following procedure: sepa-rate the bearing by forcing the outerrace over the balls; then, with atorch, apply quick heat to the innerrace while also applying pullingpressure.

Angular-contact bearings which areto be stacked together should havetheir high points of eccentricity (in-dicated by a burnished spot on theinner race) lined up. All bearingsshould be of the same manufacturerand of the type that permits stack-ing.

Some motors with angular-contactball bearings are supplied with re-movable spacer rings under the outerrace of the thrust bearing so that thethrust capacity can be increased byadding an extra bearing or bearings.When these bearings are installed,the high points of eccentricity shouldbe lined up with the keyway in thelower half-coupling. If the originalbearings have been in service, theyshould be replaced at the time thisconversion is made.

H. Insulation and WindingMaintenance

1. General

For long life and satisfactoryoperation, insulated windingsshould be kept clean and freeof dirt, oil, metal particles, andother contaminants. A variety

of satisfactory and acceptablemethods are available forkeeping equipment clean. Thechoice of method will dependgreatly on time, availability ofequipment, and on the insula-tion system. However, vacuumand/or compressed air cleaningwith nonmetallic hose tipsshould precede cleaning withwater and detergent or withsolvents. Tightly adhering dirtmay require gently brushing orwiping to get it loose.

To prevent injury to eyes andrespiratory organs, safetyglasses and suitable ventilationor other protective equipmentshould be used.

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Compressed air may be used toremove loose dirt and dustfrom air passages such as airducts.

Suction should be used to re-move dirt and dust particlesfrom windings to avoid drivingparticles into the windings anddamaging the coils.

Care must be taken to makesure that the air supply is dryand that excessive air pressureis not used. Generally a pres-sure of not more than 30 psi isrecommended.

Operator must not use com-pressed air to remove dirt ordust from his person or cloth-ing.

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3. Cleaning with Water andDetergent

This method is very effective incleaning windings when usedwith a low pressure steamjenny (maximum steam flow309 PSI and 90ºC).

To minimize possible damageto varnish and insulation, afairly neutral, non-conductingtype of detergent such as Du-bois Flow should be used. A

pint of detergent to 20 gallons of water is rec-ommended.

If a steam jenny is not avail-able, the cleaning solution maybe applied with warm water bya spray gun. After the cleaningoperation, the windings shouldbe rinsed with water or low-pressure steam. It is advisableto dry the windings. Referback to Insulation Resistancesection for instructions on howto proceed.

4. Cleaning With Solvents

Many cleaning fluids are flam-mable and/or toxic to preventinjury to personnel and prop-erty. Care should be taken toavoid flames, sparks, etc.

Safety glasses should be used and contact withthe skin should be avoided. The area should bewell ventilated or protective equipment shouldbe used.

Although cleaning with waterand detergent is the preferredmethod, solvent cleaning maybe used when heat drying fa-cilities are not available.

1,1,1 Trichloroethane is rec-ommended for use as thecleaning solvent. Solventcleaning of silicone-insulatedwindings (Class H insulatedmachines) is not recom-mended.

While 1,1,1, trichloroethane isconsidered to be non-flammable and has a relativelylow order of toxicity, it shouldbe used only in a well venti-lated

area that is free from open flames. Avoid pro-longed exposure to its vapor. Failure to observethese precautions may result in injury to per-sonnel.

Windings cleaned with solventshould be dried thoroughly bycirculation of dry air beforevoltage is applied.

5. Revarnishing Windings

After several cleanings withwater and detergent, it may benecessary to re-varnish thewindings. GE 9522 or equiva-lent varnish treatment is rec-ommended for Class B andClass F systems. This varnishis available from the GeneralElectric Company InsulatingMaterials Department of GEService Shops.

All systems treated with var-nish No. 9522 or equivalentmust be baked until the wind-ings are at 150ºC for fourhours.

* One commercial source of 1,1,1 Trichloro-ethane is Chlorothene NU, which is a trade-mark of the Dow Chemical Company, Mid-land, Michigan.

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VI. RENEWAL PARTS

When ordering parts, give description and statequantity of parts desired, together with thenameplate rating, model, and serial number ofthe motor. For couplings, also specify the type,bore, and keyway size.

Requests for additional copies of these instruc-tions or inquiries for specific information shouldbe addressed to the nearest sales office of theGeneral Electric Company.

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VII.TROUBLE SHOOTING CHART

Affected Parts Difficulty What to CheckWindings Overheating • Calibration of measuring instrument

• Excessive load• Unbalanced AC current• Improper or restricted ventilation• Excessive ambient temperature• Short circuited coil or windings• Dirty windings• Unbalanced voltage• Harmonics in Power Supply (Variable Frequency Control• Fan Broken

Bearings Overheating • Calibration of measuring instrument• Worn out or dirty oil• Insufficient Oil• Misalignment• Excessive thrust or radial loading• Shaft currents• Improper end-play• Fan broken

Bearing Housing Oil Leaks • Incorrect grade of oil (type or viscosity)• Loose fittings• Cracked/porous casting• Over-filled• Water in oil

Motor Excessive Vibration • Unbalance• Misalignment• Improper or settled foundation• Non-uniform air gap• Rubbing parts• Bent shaft• Unbalanced stator current• Damaged bearings• Reed Critical Frequency• Incorrect end-play• Fan broken

Motor Failure to Start • Wrong transformer taps• Wrong connections• Open circuit• Excessive line drop (low voltage at motor)• Excessive load• Rotor rubs• Wrong direction of rotation

Insulation Low InsulationResistance or

• Moisture, dirt, metal particles, oil, or other contaminants onthe insulated windings

Insulation Failure • Wrong voltage• Excessive temperature• Voltage surges/lightning• Mechanical damage• Excessive vibration with resultant mechanical damage• Single-phasing

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Figure 1 213-286 Frame Motors

Typical Hollow-Shaft High-Thrust,Totally Enclosed Fan Cooled Or Explosion-Proof Motor

With Angular Contact Ball Lower Thrust Bearing

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Figure 2 324-405 Frame Motors

Typical Hollow-Shaft High-Thrust,Totally Enclosed Fan Cooled Or Explosion-Proof Motor

With Angular Contact Upper Bearing.

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Figure 3 182-286 Frame Motors

Typical Solid Shaft High-Thrust, Totally Enclosed Fan CooledOr Explosion-Proof Motor With Angular Contact Lower Bearing. Typical Solid Shaft

Construction For Continuous Up And Down Thrust Is Shown In Figure 3A.

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Figure 4 324-405 Frame Motors

Typical Upper Bearing And Fan Construction For TEFC AndExplosion-Proof Solid Shaft Motors Suitable For High Down Thrust,

Momentary Up-Thrust And Limited Endplay. Typical Solid ShaftAnd Inline Pump Motor Construction For Continuous Up

And Down Thrust Are Shown In Figure 4A.

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Document Revision History

Rev # Date Author ISAAC # Description0 10/11/99 GJG N/A Conversion from PageMaker.