03 PDF
03 PDF
03 PDF
MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO DE
1525mm x 2870mm (60x113)
TIPO NT
CHANCADOR GIRATORIO TRAYLOR
VOLUMEN 3 of 3 (ELECTRICIDAD)
SOCIEDAD MINERA
CLIENTE:
CERRO VERDE S.A.A.
UBICACION PLANTA : AREQUIPA, PERU
ORDEN DE COMPRA NO.: A1WF-59-001-PO
FFEM CONTRATO NO.: 04-31645-720
EQUIPO NO.: C-3110-CR-001
COPYRIGHT FFE Minerals USA Inc. 2004
RENUNCIA
DISCLAIMER
Manual Volume all Manual Section preface Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500267
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO
SEGURIDA
SAFETY STATEMENT
Manual Volume all Manual Section prefac Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500268
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
TRAYLOR CRUSHER
CHANCADOR TRAYLOR
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO
*******************************************************
TRANSLATION WARNING
Manual Volume all Manual Section prefac Contract ALL
Orig. by SRH Date 08/19/2004 FFEM DWG. No. 7.500433
Rev. by MDS Date 08/19/2004 Rev. 0 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO
VOLUMEN 3: ELECTRICIDAD
ai Cubierta 5.401478 0
aii Registro de Distribucin y Revisin 5.401479 0
aiii Exencin de Responsabilidad 7.500267 1
aiv Declaracin de Seguridad 7.500268 1
av Algunos datos sobre este manual 7.500433 0
avi Acerca de este Manual 7.500468 0
INDICE TABLA DE CONTENIDOS 5.401480 0
1 DIATRAMAS DE CONTROL & INSTRUMENTOS
1 Hoja con texto 1 8.500980-1 0
2 Hoja con texto 2 8.500980-2 0
3 Hoja con texto 3 8.500980-3 0
TABLA DE CONTENIDOS
Vol. Manual 3 Seccin INDICE Contrato No. 04-31645-720
TABLA DE CONTENIDOS
Vol. Manual 3 Seccin INDICE Contrato No. 04-31645-720
PERU, S. AMERICA
CONTRACT NO. 04-31645-720
No.: 8.500982 2
confidential property of FFE MINERALS and may not be duplicated
FFE MINERALS USA INC.
disclosed or utilized without written consent from FFE MINERALS.
DOCUMENT NO. 8.500982
31 HS-6505B 5 PUSH BUTTON 1 CRUSHER HYDRAULIC MAIN OIL PUMP PUSH BUTTON STOP
31 HS-6510A 5 PUSH BUTTON 1 CRUSHER HYDRAULIC STANDBY OIL PUMP PUSH BUTTON START
31 HS-6510B 5 PUSH BUTTON 1 CRUSHER HYDRAULIC STANDBY OIL PUMP PUSH BUTTON STOP
31 PDSH-6506 5 DIFF PRESS SWITCH 1 CRUSHER HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE HIGH
31 YS-6601 6 RELAY OUTPUT 1 SPIDER LUBRICATION LOCAL CONTROLLER REMOTE RUN COMMAND
31 FQS-6603 6 CYCLE SWITCH SPIDER LUBRICATION SUPPLY LINE GREASE FLOW FIELD SWITCH WIRED TO CONTROLLER
31 XA-6602 6 RELAY 1 SPIDER LUBRICATION LOCAL CONTROLLER SYSTEM FAULT
31 HS-6705A 7 PUSH BUTTON 1 CRUSHER LUBRICATION MAIN OIL PUMP PUSH BUTTON START
31 HS-6705B 7 PUSH BUTTON 1 CRUSHER LUBRICATION MAIN OIL PUMP PUSH BUTTON STOP
31 HS-6710A 7 PUSH BUTTON 1 CRUSHER LUBRICATION STANDBY OIL PUMP PUSH BUTTON START
31 HS-6710B 7 PUSH BUTTON 1 CRUSHER LUBRICATION STANDBY OIL PUMP PUSH BUTTON STOP
31 LSL-6721 7 SWITCH 1 CRUSHER LUBRICATION RESERVOIR OIL LEVEL LOW
31 PDSH-6719 7 SWITCH 1 CRUSHER LUBRICATION OIL SUPPLY FILTER DIFFERENTIAL PRESSURE HIGH
31 TE-6718 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION LUBE OIL COOLER OUTLET OIL TEMPERATURE
31 TE-6722 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION RETURN OIL LINE OIL TEMPERATURE CONTROL HEATERS
31 TE-6723 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE
31 ZSC-6716 7 CLOSED LIMIT SWITCH 1 CRUSHER LUBRICATION OIL COOLER DRAIN DRAIN VALVE CLOSED
31 ZSC-6717 7 CLOSED LIMIT SWITCH 1 CRUSHER LUBRICATION LUBE OIL FILTER DRAIN VALVE CLOSED
31 ZSO-6716 7 OPEN LIMIT SWITCH 1 CRUSHER LUBRICATION OIL COOLER DRAIN DRAIN VALVE OPEN
Prepared for:
Table of Contents
1 About This Document ................................................................................... 4
Equipment ....................................................................................................... 4
Normal Startup Sequence ............................................................................... 4
Normal Operation............................................................................................ 4
Normal Shutdown Sequence........................................................................... 5
Abnormal and Emergency Shutdowns ............................................................ 5
HMI Control Summary..................................................................................... 5
Alarms ............................................................................................................. 5
Interlocks......................................................................................................... 6
2 Overview ........................................................................................................ 8
A. Function Groups ........................................................................................ 8
B. System Startup Sequence ......................................................................... 8
C. System Shutdown Sequence..................................................................... 8
D. Equipment/Device Descriptions ................................................................. 9
E. Equipment/Device Parameter Descriptions ............................................. 13
F. Reference Documents ............................................................................. 15
Page 2
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Page 3
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Equipment
This section lists and describes the equipment included in each function group,
including a description of the auxiliary devices associated with the equipment.
Equipment and devices will be identified by their descriptive name, which can be
used to cross-reference the corresponding tag numbers, listed in the Equip-
ment/Device Descriptions section (Section D of Chapter 2), for use with other
FFE Minerals documents.
Normal Operation
This section describes the function groups normal operation, including operator
functions (if any). There are three modes of operation, as described below:
PAGE 4
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Alarms
This section describes alarm messages and alarm conditions/parameters for all
equipment or devices within the function group.
Some alarms are debounced using timers of various durations to help prevent
nuisance chatter or spikes. Non-debounced alarms are generated without a time
delay from the control system, to immediately begin the Abnormal and Emer-
gency Shutdown process (Section E of the same chapter).
PAGE 5
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Interlocks
The Interlocks section describes all interlocks for the individual equipment or
function groups of equipment within the associated software function group. In-
terlock is defined herein as an input/output signal or a PLC/DCS internal logic
condition, which automatically prevents the operation of an individual or function
group of equipment from the control system Human Machine Interface (HMI).
That is, only PLC/DCS software interlocks are listed in the interlock table. Hard-
wired interlocks (not through the PLC/DCS) are NOT listed in the interlock table.
Interlocks are defined in the condition or state which permits operation, so loss of
this signal or logic condition inhibits operation. When the condition of an interlock
or interlocks is such that operation of a related piece of equipment or an equip-
ment group is permitted, the interlock is defined as being satisfied. Interlocks
consist of three types and are described in detail below:
Example
Safety interlock for a fan or pump would be no high-high bearing
temperature.
Safety interlocks for every motor will also include the MCC/motor
ready signal and receipt of a run confirmation from the motor con-
tactor after a run command is sent. These interlocks apply to all
motors and are not listed in the interlock table for this reason.
Start interlocks: Start interlocks are those interlocks which prevent an in-
dividual or function group of equipment from being started in Operation
Auto mode only (not Operation Manual or Maintenance mode). Once
the individual or function group of equipment is running, the start interlock
will no longer inhibit operation.
Example
A start interlock for a fixed speed fan with automatic damper would
be that the damper be closed (limit switch or position transmitter)
prior to starting.
PAGE 6
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Example
A process interlock for a belt conveyor would be that the down-
stream conveyor is running.
The following table summarizes the modes of operation for the three types of in-
terlocks defined above:
OPERATION
MANUAL X --- ---
AUTO X X X
PAGE 7
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
2 Overview
This functional specification is for the Electrical Control of a Gyratory Crusher
and its auxiliary components for the Cerro Verde Project.
A. Function Groups
The following function groups combine to deliver a complete Gyratory
Crusher control and operating system. Details for FFEM-supplied function
groups are described in each groups relevant chapter:
PAGE 8
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
D. Equipment/Device Descriptions
Note: All instrument tags are prefixed by 31.
Equipment/Device Tag Equipment/Device Description
PAGE 9
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 10
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 11
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 12
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 13
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 14
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
F. Reference Documents
FFE Doc./Dwg. Number Document/Drawing Description
PAGE 15
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
A. Equipment
This group consists of the following equipment, which is monitored and con-
trolled by the Control system:
The Crusher Lubrication System and Crusher Hydraulic System share one
common reservoir with an internal sealed partition. The Crusher Lubrica-
tion System Reservoir has the following devices associated with it:
1. Level Switches
There are two (2) oil level switches 31-LSL-6721 and 31-LSLL-
6721located in the lubrication system reservoir. The level switches share
a common housing. The level switch contacts for Lube Oil Reservoir
Low Level and Lube Oil Reservoir Low-Low Level are wired to the
Control system for alarming and interlocking.
2. Temperature Elements
Three (3) temperature elements are provided as part of the Crusher Lu-
brication System; one (1) element 31-TE-6723 is located in the lube oil
reservoir, one (1) element 31-TE-6718 is located in the Crusher lube oil
system cooler outlet line, and one (1) 31-TE-6722 is located in the
Crusher lube oil system return line.
PAGE 16
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
The element located in the cooler outlet line is wired to the Control system
and its signal is used to generate the Lube Oil Cooler Outlet Tempera-
ture Moving Average 31-TY-6718 . The Lube Oil Cooler Outlet Tem-
perature 31-TE-6718 Moving Average is compared to the Lube Oil
Cooler Main Fan Off 31-TCLL-6718, Lube Oil Cooler Main Fan On
TCH-6118, Lube Oil Cooler Standby Fan Off 31-TCL-6718and the Lube
Oil Cooler Standby Fan On 31-TCHH-6718 set points to cycle the cooler
fans on and off to control the temperature of the lube oil supply to the
Crusher. The moving average is continuously calculated over an operator
selected time period called the Lube Oil Cooler Outlet Temperature
Moving Average Interval to smooth out transient temperature swings
that might cause rapid on-off cycling of the Lube Oil Cooler fans. The best
setting of this interval is determined empirically in the field during actual
operation of the crusher.
The element located in the Crusher lube oil system return line 31-TE-6721
is wired to the Control system. Its signal is compared to the Lube Oil High
Return Line Temperature and Lube Oil High-High Return Line Tem-
perature set points for alarming and interlocking.
3. Heaters
Four (4) oil immersion heaters are located in the reservoir. The ON-OFF
cycling of the reservoir heaters is done through the control system in re-
sponse to the signal from the temperature element 31-TE-6723described
above.
The Lubrication Supply Circuit has the following devices associated with it:
There are two (2) Lube Oil pumps. In normal operation only one of the
pumps is running and the other is standby. Each pump has inlet and out-
let isolation valves for maintenance.
PAGE 17
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
There is one (1) oil filter with a differential pressure switch 31-PDSH-6719.
If the filter is dirty, as indicated by an input to the control system from its
differential pressure switch, when the pressure exceeds the Lube Oil Fil-
ter High Differential Pressure set point, an alarm is generated. The dirty
filter should be manually taken out of service and cleaned or replaced.
4. Flow-Switches
Three (3) flow switches monitor the oil flow rate to the countershaft bear-
ings and the inner eccentric and outer eccentric bushings. Each flow
switch is wired to the Control system for alarming and interlocking when
the lube oil flow is below the Inner Eccentric Bushing Lube Oil Low
Flow 31-FISL-0143 , Outer Eccentric Bushing Lube Oil Low Flow 31-
FISL-0141, or the Countershaft Bearings Lube Oil Low Flow 31-FISL-
0142 set points as applicable.
The Lube Oil Cooler consists of two (2) heat exchangers (radiators), each
with its own cooling fan for controlling the temperature of the lube oil sup-
ply to the Crusher.
One (1) pressure relief valve 31-PSV-6713 is provided to bypass lube oil
flow around the Lube Oil Cooler assembly in the event of a blockage or
inadvertent closure of individual cooler isolation valves.
Two (2) normally closed motorized valves 31-HV-6716 & 31-HV-6717 are
provided to automatically drain oil from the coolers and filters to the reser-
voir, when the Lubrication System is not in operation. These valves are
wired to the Control system for automatic lube oil draining.
PAGE 18
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
1. Temperature Elements
Two (2) temperature elements monitor the countershaft (inboard and out-
board) bearings temperature. The signal from the countershaft inboard
bearing is compared to the Countershaft Inboard Bearing High Tem-
perature 31-TAH-0111A and Countershaft Inboard Bearing High-High
Temperature 31-TAHH-0111A set points for alarming and interlocking.
The signal from the countershaft outboard bearing is compared to the
Countershaft Outboard Bearing High Temperature 31-TAH-0111B
and Countershaft Outboard Bearing High-High Temperature 31-
TAHH-0111B set points for alarming and interlocking.
1. Verify that the Crusher Lube System Oil Reservoir is not at the Lube Oil
Reservoir Low Level 31-LAL-6721.
3. Verify that the desired lube oil supply pumps inlet and outlet isolation
valves are fully open.
After the operator has performed the actions listed above, the normal order of
starting the Crusher Lubrication Group is as follows:
1. Place cooler drain valve in AUTO mode A/M STATION 31-XS-6717, 31-
XS-6716, so that they may open (pump off) and close (pump on) auto-
matically as determined by the status of the lube oil supply pumps.
3. Place the cooling fans in AUTO 31-XS-6715 and 31-XS-6716 run mode,
so that they may start automatically as determined by the Crusher supply
line lube oil temperature element 31-TE-6718.
4. Start the desired lube oil supply pump. The pump cannot start unless the
reservoir temperature is above the Lube Oil Reservoir Low Tempera-
ture 31-TCL-6723 set point. Once started, this temperature may drop
momentarily while the lube circuit heats up. If after 15 minutes the
temperature is not above the Lube Oil Reservoir Low Temperature set
point, an alarm is initiated 31-TAL-6723.
PAGE 19
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
C. Normal Operation
Once the Crusher Lubrication Group is started, normal operation simply con-
sists of ensuring that lubricating oil is steadily supplied to the receiving points.
Also, normal operation ensures that the required function group interlocks
(listed in Section H of this chapter) are satisfied.
The Lube Oil Cooler Fans will automatically cycle on and off as required to
maintain the lube oil supply temperature at or below the Lube Oil Supply
Standby Cooler Fan On set point 31-TCHH-6718.
1. After the Crusher has come to a complete stop, stop the operating lube oil
supply pump. If desired (i.e., to lower the lube oil temperature), the lube
oil pump can be allowed to run continuously even after the Crusher has
stopped.
2. If the cooling fans are running, allow them to first lower the return line oil
temperature to the coolers OFF temperature setting 31-TCL-6718. These
motors may then be taken out of AUTO" mode by the operator.
3. The cooler drain valves may then be taken out of AUTO mode by the
operator.
If the Crusher Lubrication Group is operating and the running lube oil sup-
ply pump trips, the Control system will provide an alarm 31-XA-6705
(MAIN), 31-XA-6710 (STANDBY) to the operator. The remainder of the
Crusher Lubrication Group (Crusher lubrication oil cooling system) will
continue to operate unless shutdown by the operator or other required in-
terlocks (see Section H of this chapter).
PAGE 20
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
If the Crusher Lubrication Group is operating and either of the lube oil
cooling fans trip, the Control system will provide an alarm 31-XA-6715
(MAIN) 31-XA-6720 (STANDBY) to the operator. The remainder of the
Crusher Lubrication Group (Crusher lubrication oil supply system) will con-
tinue to operate unless shutdown by the operator or other required inter-
locks (see Section H of this chapter).
3. Emergency Shutdowns
If the emergency stop push button(s) (by others) is depressed while the
Crusher Lubrication Group is running all function group motors will imme-
diately and simultaneously stopped. Furthermore, all motors associated
with the Crusher Lubrication Group are prohibited from restarting until the
emergency stop push button(s) is reset.
PAGE 21
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
G. Alarms
Debounced Alarms
Alarm Tag Alarm Text
Non-debounced Alarms
Alarm Tag Alarm Text
31-XA-6705 CRUSHER MAIN LUBE SUPPLY PUMP TRIP
(If trips on run command)
PAGE 22
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
H. Interlocks
Equipment or Interlock Type
Control System Signals Safety Start Process
Permissive
LUBE OIL LUBE OIL RESERVOIR TEMPERATURE
RESERVOIR NOT HIGH (below the Lube Oil Reservoir X
HEATERS High Temperature)
LUBE RESERVOIR OIL LEVEL NOT LOW-
LOW (below the Lube Oil Reservoir Low- X
Low Level)
MAIN LUBE OIL RESERVOIR LEVEL NOT LOW-
LUBE OIL LOW (below the Lube Oil Reservoir Low- X
SUPPLY PUMP Low Level)
LUBE RESERVOIR OIL TEMPERATURE
NOT LOW (below the Lube Oil Reservoir X X
Low Temperature
STANDBY LUBE OIL SUPPLY PUMP NOT
RUNNING X X
STANDBY LUBE OIL RESERVOIR LEVEL NOT LOW-
LUBE OIL LOW (below the Lube Oil Reservoir Low- X
SUPPLY PUMP Low Level)
LUBE OIL RESERVOIR TEMPERATURE
NOT LOW (below the Lube Oil Reservoir X X
Low Temperature
MAIN LUBE OIL SUPPLY PUMP NOT RUN-
NING X X
LUBE OIL LUBE OIL COOLER OUTLET TEMPERA-
COOLER FAN A TURE MOVING AVERAGE NOT LOW (below X
the Lube Oil Cooler Main Fan Off)
MAIN OR STANDBY LUBE OIL PUMP RUN-
NING X X
LUBE OIL COOLER OUTLET TEMPERA-
LUBE OIL
COOLER FAN B
TURE MOVING AVERAGE NOT LOW (below X
the Lube Oil Cooler Standby Fan Off)
MAIN OR STANDBY LUBE OIL PUMP RUN-
NING X X
LUBE OIL
COOLER DRAIN
ANY ONE (1) OIL LUBE PUMPS RUNNING
(CLOSE VALVE) X
VALVE
BOTH OIL LUBE PUMPS NOT RUNNING
(OPEN VALVE) X
PAGE 23
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
H. Interlocks (contd)
Equipment or Interlock Type
Control System Signals Safety Start Process
Permissive
LUBE OIL START
PERMISSIVE FOR
LUBE RESERVOIR OIL LEVEL NOT LOW
(below the Lube Oil Reservoir Low Level) X
THE CRUSHER
MAIN DRIVE MO- COUNTERSHAFT BEARINGS OIL FLOW
TOR NOT LOW (below the Countershaft Bearings X
Lube Oil Low Flow)
C1LBSTART INNER ECCENTRIC BUSHING OIL FLOW
(SEE CHAPTER 7,
SECTION H)
NOT LOW (below the Inner Eccentric Bush- X
ing Lube Oil Low Flow)
OUTER ECCENTRIC BUSHING OIL FLOW
NOT LOW (below the Outer Eccentric Bush- X
ing Lube Oil Low Flow)
LUBE OIL RETURN LINE TEMPERATURE
NOT HIGH (below the Lube Oil High Return X
Line Temperature)
COUNTERSHAFT INBOARD BEARING TEM-
PERATURE NOT HIGH (below the Counter-
shaft Inboard Bearing High Temperature) X
COUNTERSHAFT OUTBOARD BEARING
TEMPERATURE NOT HIGH (below the
Countershaft Outboard Bearing High Tem- X
perature)
PAGE 24
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
H. Interlocks (contd)
PAGE 25
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
The Crusher mantle is supported by a volume of oil between the piston and the
cylinder cover. This volume of oil supports the mantle and all crushing loads.
The volume of this oil is intentionally varied, in order to change the vertical posi-
tion of the shaft and to thereby adjust the Crusher open-side setting (material
discharge size setting).
A. Equipment
This group consists of the following equipment, which is monitored and controlled
by the Control system:
The Crusher Hydraulic System and Crusher Lubrication System share one
common reservoir with an internal sealed partition. The Crusher Hydraulic Oil
Reservoir has the following devices associated with it:
1. Level Switches
There are two (2) oil level switches 31-LSL-6511 & 31-LSLL-6511 located in
the oil reservoir. The level switches share a common housing. The level
switch contacts for Hydraulic Oil Reservoir Low Level and Hydraulic Oil
Reservoir Low-Low Level are wired to the Control system for alarming and
interlocking.
PAGE 26
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
Other local instruments, such as temperature gauges and level indicators etc.
are identified on the Control and Instrumentation Diagrams and the Field In-
strument List.
The Crusher Hydraulic Oil Supply Circuit has the following devices associated
with it:
There are two (2) high pressure hydraulic oil pumps. In normal operation only
one of the pumps is running and the other is standby. Each pump has an inlet
and an outlet isolation valve for maintenance.
The Hydraulic Oil Pumps are protected by a pressure relief valve at the
discharge piping. The relief valve outlet is piped back to the Hydraulic Oil
Reservoir. A local pressure gauge is also provided.
A four way, solenoid operated, spring return directional control valve is pro-
vided and is used to control the direction of high pressure oil flow. The sole-
noids of the directional control valve are wired to the Control system. The
function of the directional control valve is described in Section C of this chap-
ter.
PAGE 27
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
1. Hydraulic Accumulator
The hydraulic accumulator receives pressurized fluid from the pumping sys-
tem and provides local pressure accumulation. The accumulator is of the hy-
dro-pneumatic type, with an integral gas bladder. Before operating the
Crusher, the customer must pre-charge the gas bladder as stated in the
FFEM Installation, Operation and Maintenance Manual for the Gyrator Crush-
ers (see the Contract Instruction Manual).
One (1) pressure relief valve 31-PSV-0103 is provided to protect the accumu-
lator and other hydraulic adjustment group components from excessive pres-
sure. The relief valve outlet is piped back to the hydraulic oil reservoir
One (1) pressure gauge 31-PI-6504 is provided to monitor the hydraulic oil
supply pressure.
The hydraulic cylinder contains a volume of fluid. As the volume of fluid be-
low the piston is varied, the vertical position of the Crusher mantle is
changed.
PAGE 28
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
1. Verify that the Crusher Hydraulic Oil Reservoir is not at the Hydraulic Oil
Reservoir Low Level 31-LAL-6511.
After the operator has performed the actions listed above, the normal order of
starting the Crusher Hydraulic Adjustment Group is as follows:
C. Normal Operation
Once the Crusher Hydraulic Adjustment Group is operating, normal operation
simply requires periodic adjustment of the volume of oil in the hydraulic cylinder,
in order to maintain the mantle elevation (position) at the desired point for crush-
ing operations. Also, normal operation ensures that the required function group
interlocks (listed in Section H of this chapter) are satisfied.
When the operator presses the MANTLE RAISE button 31-HS-6507A, the hy-
draulic oil supply pump automatically starts (if it is not already running), the
LOWER solenoid S2 remains de-energized and the RAISE solenoid S1 is ener-
gized. Oil is then ported towards the hydraulic cylinder. Simultaneously, a thirty
(30) minute run timer begins timing out. When the run timer expires, the hydrau-
lic oil supply pump is automatically stopped. The function of the run timer is to
allow the hydraulic oil to circulate through the filter.
When the operator presses the MANTLE LOWER button 31-HS-6507B, the hy-
draulic oil supply pump automatically stops (if it is running), the RAISE S1
solenoid remains de-energized and the LOWER solenoid S2 is energized.
Hydraulic oil from the main piston then drains back to the reservoir.
When the RAISE and LOWER solenoids are both de-energized, hydraulic oil in
the main piston is blocked off at the solenoid valve port to maintain mantle posi-
tion. Oil from the hydraulic oil supply pump is ported back to the reservoir.
The Control system shall ensure that the hydraulic pump is not started dur-
ing the mantle lowering operation.
PAGE 29
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
The normal order for short-term shutdown of the Crusher Hydraulic Adjustment
Group is as follows:
After the Crusher has come to a complete stop, the hydraulic oil supply pump (if
operating) will automatically stop. If the run timer is still timing, the pump will
automatically stop after the timer times out.
Operate the LOWER push button 31-HS-6507B, to lower the mantle elevation to
the zero point (fully-lowered point of travel).
If the Crusher is operating and the operating hydraulic oil pump trips, the Con-
trol system will provide an alarm to the operator. The Crusher will continue to
operate until shutdown by the operator.
2. Emergency Shutdowns
If the emergency stop push button(s) (by others) is depressed while the
Crusher Hydraulic Adjustment Group is running all function group motors
must be immediately and simultaneously stopped. Furthermore, all motors
associated with the Crusher Hydraulic Adjustment Group are prohibited from
restarting until the emergency stop push button(s) is reset.
1. Status of the Hydraulic Oil Reservoir level (within normal limits or alarm states
31-LAL-6511, 31-LALL-6511.
2. Status of Hydraulic Pump Motor ready, running, stopped (31-XL-6505 or
tripped 31-XA-6505)
3. Crusher Mantle Position 31-ZI-0118
PAGE 30
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
G. Alarms
Debounced Alarms
Alarm Tag Alarm Text
LAL-6511 CRUSHER HYDRAULIC TANK LOW LEVEL
Non-debounced Alarms
Alarm Tag Alarm Text
31-XA-6505 CRUSHER HYDRAULIC MAIN OIL PUMP TRIP
(If trips on run command)
31-XA-6510 CRUSHER HYDRAULIC STANDBY OIL PUMP TRIP
(If trips on run command)
PAGE 31
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
H. Interlocks
Equipment or Interlock Type
Control System Signals
permissive Safety Start Process
PAGE 32
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
A. Equipment
The Crusher Spider Bushing Lubrication Group consists of the following compo-
nents:
The Grease Pump is a rotary driven electric pump that pumps the grease out
of a refinery drum (by others) to the supply line divider valve when the Pump
is energized by the Local Timer/Controller Panel.
1. Divider Valve
PAGE 33
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
2. Cycle Switch
Other local instruments are identified in the Lincoln Lube Controller Manual.
The Modular Lube Controller controls and supervises all components of the
Spider Lubrication Group. It is a microprocessor-based unit and includes the
following functions:
1. Control Timers
Internal timers are provided to control the frequency and the duration of the
grease pump.
2. Flow Counter
An internal counter receives the signals from the cycle switch and counts the
number of pulses (cycles). If the required number of pulses (cycles) are not
counted within a preset and adjustable time, a fault is annunciated.
When pressed, the local MANUAL RUN button (in the controller) forces the
grease pump to perform a grease injection for the preset duration.
4. Indicating LEDs
LEDs are located on the panel for POWER ON, PUMP ON, and FAULT
local indication.
PAGE 34
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
1. Ensure that the fuses in the Local Timer/Controller Panel are installed and are
in satisfactory condition.
2. Ensure that the Local Timer/Controller Panel has been programmed from the
front display panel per Modular Lube Controller instructions and the FFEM In-
stallation, Operation and Maintenance Manual for the Gyrator Crushers (see
the Contract Instruction Manual).
The normal order of starting the Crusher Spider Bushing Lubrication Group is as
follows:
1. Based on the signal that Crusher Main Drive Motor is running, the customer
control system should close a contact, which applies external power to the
Modular Lube Controller Local Timer/Controller Panel. This POWER ON sig-
nal should be maintained at all times when the Crusher Main Drive Motor is
running.
C. Normal Operation
The frequency and duration of the grease pump operation are automatically con-
trolled by the Modular Lube Controller Local Timer/Controller Panel, based upon
programmed settings.
Modular Lube Controller Local Timer/Controller Panel will determine the ON-OFF
cycling of the Grease Pump.
The normal order of shutdown of the Crusher Spider Bushing Lubrication Group
is as follows:
Based on the signal that the Crusher Main Drive Motor is stopped (off), the
POWER ON signal from the Control system is turned off and the external power
will thereby be removed from the Modular Lube Controller Local Timer/Controller
Panel. The reason for power-off is to prevent unnecessary injection of grease
when the Crusher is not operating.
PAGE 35
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
If, while operating normally, insufficient cycles are detected by the Local
Timer/Controller, a fault has occurred in the lubrication system (e.g., grease
drum exhausted, blocked lines, broken lines, etc.). The local fault-indicating
light is energized and a fault alarm signal is sent to the Control system. The
Crusher will continue to operate unless shutdown by the operator.
The following signals are displayed on the operator control station graphics
screen:
G. Alarms
Debounced Alarms
Alarm Tag Alarm Text
XA-6602 CRUSHER SPIDER BUSHING LUBRICATION CONTROLLER FAULT
STOP FEED TO CRUSHER (20 MINUTES)
XA-6602 CRUSHER SPIDER BUSHING LUBRICATION CONTROLLER FAULT
TRIP CRUSHER (30 MINUTES)
H. Interlocks
Equipment or Interlock Type
control system
permissive Signals Safety Start Process
SPIDER LU- CRUSHER MAIN DRIVE MO-
BRICATION TOR RUNNING
POWER-ON X X
SIGNAL
PAGE 36
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
The Crusher Dust Seal Air Blower Group pressurizes the outer eccentric bushing
to prevent the ingress of dust. Refer to FFE Minerals Control and Instrumenta-
tion Diagram 8.500980 sheet 4 for details.
A. Equipment
The Crusher Dust Seal Air Blower Group consists of the following compo-
nents:
There is one (1) dust seal air blower supplying air to the outer ec-
centric bushing.
1. Using the operator control stations, place all function group motors in AUTO
mode (by others).
After the operator has performed the actions listed above, the normal order of
starting the Crusher Dust Seal Air Blower Group is as follows:
1. Start the dust seal air blower and allow it to run continuously.
C. Normal Operation
Once the Crusher Dust Seal Air Group is operating, normal operation simply con-
sists of ensuring that air is steadily supplied to the receiving points. Also, normal
operation ensures that the required function group interlocks (listed in Section H
of this chapter) are satisfied.
PAGE 37
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
1. Based on the signal that the Crusher Main Drive Motor is stopped (off), the
operator may stop the operating dust seal air blower.
If the Crusher Dust Seal Air blower group is operating and the running dust
seal air blower trips, the Control system will provide an alarm to the operator.
If the Crusher Main Drive Motor is already running, it will continue to operate
unless shutdown by the operator.
2. Emergency Shutdowns
If the emergency stop push button(s) (by others) is depressed while the
Crusher Dust Seal Air Blower Group is running all function group motors must
be immediately and simultaneously stopped. Furthermore, all motors associ-
ated with the Crusher Dust Seal Air Blower Group are prohibited from restart-
ing until the emergency stop push button(s) is reset.
1. Status of dust seal air blower motor ready, running, stopped (31-XL-0110 or
tripped 31-XA-0110).
PAGE 38
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
G. Alarms
Non-debounced Alarms
Alarm Tag Alarm Text
31-XA-0110
DUST SEAL AIR BLOWER TRIPPED (If trips on run command)
H. Interlocks
Interlock Type
Equipment Signals
Safety Start Process
PAGE 39
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
A. Equipment
This group consists of the following equipment, which is monitored and controlled
by the Control system:
The Crusher Main Drive Motor has the following devices associated with it:
1. Temperature Elements
Six (6) motor winding temperature elements are used for monitoring Crusher
Main Drive Motor Winding High Temperature 31-TAH-0112 and Crusher
Main Drive Motor Winding High-High Temperature 31-TAHH-0112 and
two (2) motor bearing temperature elements are used for monitoring Crusher
Main Drive Motor Inboard Bearing High Temperature 31-TAH-0111A,
Crusher Main Drive Motor Inboard Bearing High-High Temperature
31-TAHH-0111A, Crusher Main Drive Motor Outboard Bearing High Tem-
perature 31-TAH-0111B, Crusher Main Drive Motor Outboard Bearing
High-High Temperature 31-TAHH-0111B These temperature elements are
wired to the Owners Motor Protection Relay.
From the Owners Motor Protection Relay, the following status and Crusher
Main Drive Motor parameters are wired to the Control system:
PAGE 40
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
PAGE 41
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
2. The Crusher Hydraulic Adjustment Group is started and mantle position is ad-
justed to minimum elevation as described in Chapter 4 of this document.
5. The Crusher Main Drive Motor Minimum Stop Time has elapsed since the
last Crusher operation.
6. All FFE Minerals interlocks for the Crusher are confirmed to be normal per the
Interlock section (section H of the same chapter).
8. The Crushing chamber is empty, so that the motor may be started in the
unloaded condition.
If the above conditions are satisfied, a permissive signal is sent to the Crusher to
permit local operation. This signal shall be hardwired to the Crusher Main Drive
Motor control circuit to prevent local operation when the permissive is not satis-
fied.
Normal startup is defined as startup under no load. When starting the Crusher
under load, refer to the FFEM Installation, Operation and Maintenance Manual
for the Gyrator Crushers (see the Contract Instruction Manual).
Normal startup of the Crusher main drive motor and accessories proceeds as fol-
lows:
1. The operator issues a START command from Control system to start the
Main Drive Motor.
2. If the Crusher Main Drive interlocks are satisfied, the motor start command is
accepted. A pre-start warning horn (by others) sounds for 10 seconds, to
alert any personnel in the Crusher area that the Crusher is about to start.
PAGE 42
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
3. After the warning horn (by others) sounds, the Crusher Main Drive Motor is
started.
C. Normal Operation
After the motor is running for the Crusher Main Drive Motor Minimum Run
Time, the Crusher Mantle Position (as sensed by the position transmitter) can
be adjusted to the required crushing setting. Material may then be fed to the
crushing chamber.
2. Allow the Crusher material to flow out of the Crusher, until it is completely
empty. This step is to ensure that the Crusher may later be re-started without
a high starting load on the Crusher Main Drive Motor.
3. The Crusher Main Drive Motor stop is then initiated by the operator and the
Crusher Main Drive Motor automatically stops.
6. Also, the Crusher Dust Seal Air Group may continue to operate, until shut-
down by the operator as described in Chapter 7 of this document.
PAGE 43
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
If the Crusher is operating and any of the delayed trip interlock conditions oc-
cur (see Section H of this chapter), the Control system will provide an alarm
to the operator.
The Control system shall immediately stop the Owners upstream feed
conveying equipment, ensuring that no material continues to be
dumped into the Crusher.
If the Crusher is operating and any of the instantaneous trip interlock condi-
tions occur (see Section H of this chapter), the Control system will provide an
alarm to the operator. The Crusher Main Drive Motor is immediately stopped.
Refer to the Operating and Maintenance Instructions in the Contract Instruc-
tion Manual for further details of restarting.
3. Emergency Shutdowns
If the emergency stop push button(s) (by others) is depressed while the
Crusher Main Drive Motor is running the Crusher Main Drive Motor will imme-
diately stopped. Furthermore, the Crusher Main Drive Motor is prohibited
from restarting until the emergency stop push button(s) is reset.
1. Status of the Crusher Main Drive Motor (ready, running, stopped or tripped).
2. Crusher Main Drive Motor Current (within normal limits or alarm state).
3. Crusher Main Drive Motor Inboard Bearing Temperature (within normal limits
or alarm state).
4. Crusher Main Drive Motor Outboard Bearing Temperature (within normal lim-
its or alarm state).
5. Crusher Main Drive Motor Hottest Winding Temperature (within normal limits
or alarm state).
6. Status of the Owner-supplied Crusher Main Drive Motor Protection Relay
(satisfied or alarm state).
PAGE 44
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
G. Alarms
Non-debounced Alarms
Alarm Tag Alarm Text
Debounced Alarms
Alarm Tag Alarm Text
PAGE 45
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01
H. Interlocks
Equipment or Interlock Type
Control System Signals
Permissive Safety Start Process
PAGE 46
EME000077-d
SERIES
INSTRUCTION MANUAL
CONTENTS
1. Introduction.............................................................................................................. 3
4. Storage .................................................................................................................... 6
5. Installation ............................................................................................................... 8
5.1 Foundation design and engineering............................................................... 8
5.2 Centering and alignment ................................................................................ 8
5.3 End play and damage prevention of sleeve bearing...................................... 10
5.4 Mortar grouting.............................................................................................. 11
5.5 Prevention of shaft current ............................................................................. 12
5.6 Piping .............................................................................................................. 13
8. Normal run............................................................................................................... 19
8.1 Starting............................................................................................................ 19
8.2 Running........................................................................................................... 20
9. Maintenance ............................................................................................................ 20
9.1 Contents of inspection .................................................................................... 20
9.2 Interval of regular inspection .......................................................................... 20
9.3 Major inspection items .................................................................................... 21
9.4 Test run after inspection ................................................................................. 22
11. Troubleshooting....................................................................................................... 41
EME000077-d
3
1. Introduction
Thank you very much for purchasing our company motor. This manual has
been published to ensure safe and efficient use of your motor. Please be sure to
read through this manual carefully as it has been prepared to provide you with a full
knowledge of installation, operation, maintenance and inspection.
Besides this manual, be sure to read other manuals and all Danger / warning /
caution name plates which are attached to the motor.
Every motor is fitted with a name plate containing the basic rating data according
to relevant standards. A typical rating nameplates is shown in Fig. 1.
Before using the motor, be sure to check the power source voltage against the
value indicated on the rating nameplate.
Operate the motor with current at or below the value indicated on the rating
nameplate.
2.5 RATING
This shows the kind of duty cycle the motor is designed for.
In the case of continuous duty or unspecified, the motor is capable of continuous
running.
When the value is expressed by the hour or minute, the motor is capable of
operation only for the time indicated on the rating nameplate. Run the motor again
only the motor has cooled down.
3. Acceptance inspection
Upon receipt of your motor, please take care of the following points.
(1) We have already provided a packing list or an invoice with your motor. Check
the motor against the invoice.
(2) First unpack carefully. Check each component for shipping damage.
(3) Make sure that the output, voltage, frequency and model designation indicated
on the rating nameplate comply with your ordering specifications.
(5) Check the entire motor carefully for damage, rust parts, fouled parts and
intrusion of harmful objects. If you have any question about your motor, please
do not hesitate to contact our representative.
Data indicated on the rating nameplate (type, frame No., number of poles
output, voltage and frequency)
Serial No. (indicated on the rating plate)
Your specific requested information or questions.
EME000077-d
6
4. Storage
(2) In case of
anti-friction
bearings:
Supply grease.
5. Installation
(1) The foundation should not only have enough strength to support static and
dynamic loads of the motor itself, but also it must endure the mechanical
vibrations.
(2) The load supporting areas, shape and weight of the foundation should be
determined so as not to develop ground subsidence, sliding, floatation and
wandering.
If the subsoil conditions are poor, the usual practice is to drive in piles and it
should be considered that all loads are borne only by the piles. In this case,
the supporting capacity of the soil is usually neglected.
(3) When a ventilation duct is to be set in the foundation, care should be taken not
to allow ground water into the duct. If water seeps into the duct, the coil
insulation will deteriorate due to moisture.
(4) During the first four weeks after concrete is poured, and particularly in the first
one to two weeks, the concrete will increase its strength sharply. Thus, the
concrete surfaces and boards should be covered with mats, cloths or sand and
sprayed with water. They should be kept wet for at least one week in summer
and at least two weeks in winter in order to ensure thorough curing.
(5) Be sure to cover the anchor bolt holes to prevent foreign objects entering.
(6) The upper surface of the foundation should be finished as flat as possible in
order to facilitate the motor installation.
(7) Chip the concrete foundation surface to a depth of about 50mm and roughen in
enough to allow easy centering or increase adhesion between mortar and
foundation.
(1) While checking the magnetic center gauge at the bearing end, adjust the rotor
end play to the value specified in the drawing. The end play means the
maximum axial play of the rotor. Standard end-play tolerances are as shown in
Table 2, except when equipped with special thrust bearings, when requested
from directly-coupled machines or when the end-play is slightly restrained as in
the case of wound-rotor motors with brush-lifting devices. Adjust the axial
center of the stator by measuring the relative positions of the stator and rotor
cores.
EME000077-d
9
(2) As shown in Fig.2, install the dial indicator onto the coupling of the motor side,
measure the parallelism and the degree of eccentricity while quietly turning the
rotor of the motor by using the coupling section, and adjust the shaft center.
However, since this may vary depending on the type of the machine, also contact
the machine manufacturer for further details.
Generally, for measurement of the parallelism, the thickness gage or taper gage
is used, whereas, for measurement of the degree of eccentricity, a dial gage is
installed on the coupling of one side and the shaft is turned by 0 degree, 90
degrees, 180 degrees and 270 degrees to read the values of the four locations.
(see Figures 3 and 4)
90 B
Left-to-right A-C
corrected quantity = 2
180 0 C A
Top-to-bottom B-D
corrected quantity =
2
270 D
Measurement of parallelism
Measure and record the values of the four locations, E1, F1, G1, and H1, with a
thickness gauge at the combination position of both shafts for the measurement of
parallelism. Next, rotate the both shafts by 180 degrees, and then measure and
record the values of the other locations, E2, F2, G2, and H2. Find the measured
values as shown below.
F1 F2
Left-to-right (F1+F2)-(H1+H2)
corrected quantity =
2
G1 E1 G2 E2
Top-to-bottom (E1+E2)-(G1+G2)
corrected quantity =
H1 H2 2
(3) Next, measure the gap between the stator and rotor at three or four positions for
both the coupling side and the opposite side, and be sure that the differences
between the maximum and minimum gaps is within 20% of the average values
gap measurements.
[1] There are cases that the motor end play becomes zero, because the coupling
can move freely due to the absence of torque to transmit when the motor
stops.
If the motor is restarted at this time, the bearing side surface of the motor will
be in a state of metallic contact.
[2] If the motor shaft receives an axial thrust during rotation, the result will be the
same as above.
In general, the end-play of the bearing of motor should have a greater value than
that of flexible coupling or gear coupling, in order to prevent the burning of the
bearing.
When installing the motor, check the dimensions in Fig.5.
EME000077-d
11
Fig.5 Relation between the end-play of the bearing and the flexible coupling
When assembling the two flanges, align the magnetic center gauge with the red
datum-line of the shaft, in order to decide the position of the motor.
Note: Examine the connecting surface of the coupling or faucet whether there are
scars on it. If any, polish the surface gently with an abrasive stone.
(1) Roughen the foundation surface in order to ensure adhesion of mortar after
clearing thoroughly.
(3) During mortar grouting work, take care not to move the packers and subpackers
by mistake.
(4) After the mortar has been grouted, thoroughly cure it by the same way as the
foundation concrete work.
The curing period should be at least one week in summer and at least two
weeks in winter.
After the concrete has cured enough, tighten up the anchor bolts, and check the
record of the alignment workmanship. If there is nothing wrong with the
installation, assemble the floor deck plates and piping, and drive dowel pins into
the foot of the stator frame. For some motors, the dowel pins are driven in after
trial run and readjustment.
EME000077-d
12
5.6 Piping (For motors requiring external lubrication oil supply or water cooling)
When the piping system is designed and executed on your part, pay attention to
the following points.
(1) Prepare the oil discharge system of the motor as described below, in order that
the vapor in the bearing on the machine side and the oil tank may not cause the
counterflow into the bearing of the motor.
a) Separate the oil discharge pipes of the motor from those of the machine. Do
not connect them in the middle.
b) Establish the oil tank with a vapor drain, which is big enough to have either
[1] or [2], in order to decrease the inside pressure of the oil tank and of the
pipes to a natural atmospheric pressure.
[1] a discharge drain without a fan
[2] a drain with an exhaust fan
c) As for the oil draining pipes from the common pipes to the oil tank, the
gradient must be between 1/30 and 1/50. If the gradient of the oil draining
pipes is not sufficient, and/or its cross section is too small, then, the oil wont
flow smoothly, and it may overflow or cause a leak.
d) The pipe diameter must be large enough.
(5) The oil piping should be designed and adjusted with account taken of the oil
pump, pressure regulator and other pipes so that the pressure and flow rate
specified in the outline drawing can be attained at the motor bearing inlets.
(6) Make sure that there are no foreign objects like rags left inside the pipes. Then,
clean them thoroughly and connect them. The cleaning before the pipe
connection is accomplished in one of the following two methods.
One method is to blow in steam at a pressure of 200 to 300 kPa. The other is
to pickle with 10% aqueous solution of sulfuric acid or hydrochloric acid,
neutralize immediately with a 20% aqueous solution of caustic soda, and then
rinse with water.
Either method should be followed by lubrication with turbine oil for preventing
rust.
(7) Return oil lines utilize gravity for flow. This requires the lubrication oil system
to be below the motor bearing elevation and a continually dropping elevation of
the return oil piping.
(8) After the piping has been completed, it should be flushed thoroughly before
being fitted to the motor bearings.
The flushing can be carried out by using the oil feed pump furnished together
with the motor or a separate oil pump which doubles as a filter.
When the flushing has been carried out by using the oil feed pump, be sure to
clean the oil tank thoroughly before a trial run. Since flushing oil circulating in
the piping system is including foreign matter, it should not be run into the
bearing metals. Specifically, the piping should be modified to bypass the
bearing metals and to connect the inlet and outlet lines at the outside of the
bearing housing.
The flushing oil returning to the oil tank should be passed through an 80-to 100-
mesh wire filter. The flushing will be complete when foreign matter is no longer
trapped by the filter.
The filter should be replaced at an interval of several hours.
The flushing will take 24 to 48 hours, or as long as a week if the piping is long.
For the purpose of flushing, prepare reclaimed oil as well as fresh oil.
The flushing oil is used by heated to 70 to 80. During flushing operations,
hammer the pipes to dislodge incrustations from the pipe inner walls and scour
them away with the running oil. Clean the bearing housings, bearings, oil tank
and oil cooler thoroughly, and make sure that there is no foreign matter left in
the piping system.
After the flushing has been completed, set up the original piping, charge fresh
oil, and check for oil leaks and adjust the oil quantity to prepare for the trial run.
EME000077-d
15
6.4 Bearings
For the inspection of the bearings, refer to the bearing cooling system described
in the motor specifications and outline drawing. If the bearing cooling system is not
stated, the bearings are the natural cooling type; the anti-friction bearings are
lubricated by grease, and the sleeve bearings are lubricated by oil rings. Be sure
to greases and oils specified in the nameplate or outline drawing.
Instruction for connecting conductor (WAGO Rail Mount Terminal Blocks with CAGE CLAMP)
Stripping of WirePlease strip a conductors stripped length related as drawings.
Please fix splayed, bent or twisted wire.
[1] Put a screwdriver to the [2] Insert a screwdriver to the [3]The screwdriver will be
operating slot. inside of the terminal block. fixed when operated
correctly.
[4] Insert a wire to the wire [5] Pull out a screwdriver [6] Pull a wire slightly to check
hole. from the operating slot. if connecting has been
(Please hold a wire.) done completely.
(Do not pull strongly.)
Measure the insulation resistance, and make sure that it is higher than the
specified limit. Then conduct a dielectric strength test according to the following
procedures.
The test voltage to be impressed should have an effective value specified below
and should be free of harmonics. The test voltage should also be adjustable up to
a specified value. To test the motor, increase the test voltage to a specified value
at the rate of 1000V/sec. Keep the test voltage at that value for a specified period,
and then reduce it to zero immediately.
(Caution: When impressing the test voltage, be sure to use a device capable of
adjusting the test voltage. Never impress or cut off the full voltage directly by
making use of a switch.) After the dielectric strength test has finished, be sure to
discharge the tested winding. Never touch the windings until they have been
discharged.
To carry out the dielectric strength test, connect together those terminals which
are rated at the same voltage, and impress a specified test voltage between this
connection and the ground. All other windings except those to be impressed with
the voltage must be grounded.
When a specific phase or a part of a specific winding is subjected to a dielectric
strength test, disconnect the ends of that phase or that part completely and connect
the ends together. Impress a test voltage between the ends and the ground.
All other phases and windings should be grounded in advance. Since a high
voltage is used in the dielectric strength test, take care to shield people from electric
shock by keeping them away from the motor during the test.
For the rules concerning the dielectric strength test voltages, refer to the specific
technical standards applicable.
Excerpts from the Technical Standards for Electrical Instruments.
Chapter 1; Section 3, Insulation and Earthing of Distribution Line
Article 15
The generators, motors, synchronous condensers and other rotating machinery (exclusive of
rotary converters) shall withstand for consecutive 10 minutes the test voltages specified below in
relation to their maximum service voltage when applied between their windings and the ground.
The test voltage shall be 1.5 times as high as the maximum service voltage if the maximum
service voltage is up to 7,000V.
(If the test voltage calculated as above is less than 500V, it shall be set at 500V.)
The test voltage shall be 1.25 times the maximum service voltage if the maximum service voltage
is higher than 7,000V.
(If the test voltage calculated as above is less than 10,500V, it shall be set at 10,500V.)
Further, the foregoing dielectric strength test voltage apply to new motors, and
when the dielectric strength test is being conducted after a regular inspection, etc., it
is necessary to review the voltage value.
EME000077-d
18
6.6 Others
Check for loosened bolts, nuts, dowel pins and connections. Unless
otherwise designated, use the tightening torques listed in Table 4 when
tightening bolts.
Table 4 Specified torques for bolt tightening
7. Trial run
1) Measure the supply voltage to check if the line voltages are balanced and are
roughly in agreement with the rated motor voltages.
2) When starting the motor, keep the driven machine free from or at minimum
possible load. Cut off the power source immediately after starting and perform
the following inspection while it is rotating freely by inertia.
(1) Confirm that the motor is running in the rotating direction specified in the
outline drawing or in the rotational arrow plate.
(2) Confirm that the bearing oil ring is turning normally.
(3) Confirm that there are no abnormal noises or vibration, or there is no
smell insulating materials burning.
3) If there is no abnormalities under the above inspection, restart the motor and
inspect the bearing temperature, vibration, end play and oil ring rotation.
4) Continue the no-load running until the bearing temperature reaches saturation.
After confirming that there are no abnormalities, proceed to full-load operations.
8. Normal run
8.1 Starting
(4) To restart after a long-term stop of two weeks or more, check the following.
(a) Insulation resistance measurement of the motor circuit.
When it does not satisfy the values noted in section 10.3, dry with a
space heater, etc., and restart after the insulation resistance has
recovered.
(b) The oil level should be in the indicated line.
(c) Upon starting, the noise, vibration and oil ring turning condition should be
as usual.
(d) Conduct the routine inspection of Table 5-1.
EME000077-d
20
8.2 Running
During a run, check by Tables 5-1 and 5-2 to confirm that there are no
abnormalities.
9. Maintenance
The service life of motor is dependent largely upon maintenance. Record the
data at regular intervals according to the following maintenance and inspection
standard.
The data logging makes clear the trend of motor conditions to prevent troubles.
(1) Check for the looseness of stator coil wedges and stator coil end bound by
strings
The core slot part of the stator coil and the coil end part are prevented from
looseness caused by the electromagnetic vibration acting on the coils by means
of wedges and binding strings. The coil, wedges, spacers and binding strings,
etc. are composed of insulators, and sometimes the wedges and binding strings
become loose due to electromagnetic vibration during operation and the
changing fit from the heat cycle. If these are left for a long period, insulator
wear off and insulation may break down because the coils are caused to
oscillate by the electromagnetic force and mechanical vibration. Therefore, it
is necessary to inspect them at regular interval.
(2) Check for the looseness, dislodgment of soldered parts and axial movement for
rotor bars
In the case of the squirrel cage type induction motor, fatigue progress on the
rotor bars, the short-circuit rings and its soldered part because of thermal stress
and electromagnetic force caused by inrush current at the starting time and
centrifugal force caused by rotation act on them. When checking the rotor at
the regular inspection, etc., there may be cases where the rotor bars are
slackened, all of the rotor bars shifted in the axial direction, and the soldered
parts between the rotor bars and the short-circuit ring are partially dislodged. If
operation continues under this condition, cracks and breakage may develop in
the rotor bar end part, the end part is expanded in the radial direction by the
centrifugal force, thus causing damage to the stator coil and developing
insulator breakdown. Therefore periodic inspection of these items is important.
(3) Bearing
The bearing periphery needs inspection for temperatures, abnormal noises, the
scars on the journal surface due to vibrations, and foreign objects. In particular,
the bearing periphery pay attention to (a) metal contacts and scars, (b)
movement, deformation and abrasion of oil rings, (c) oil blackening or grease
discoloring (d) oil level (e) oil leakage.
(4) Dust adhering to the stator coil and ventilation duct space of the core
Dust adhering to the stator coil will worsen the thermal conduction, and dust
adhering to ventilation duct space of the core will reduce the amount of cooling
air. Both causes lead to increase of temperature rise.
In case dust adhesion is found, either determine the cleaning interval
appropriate to the dust quantity or take countermeasures to prevent dust
intrusion.
(5) Checking the looseness of the stator core saddle plate stud and bolt fastening
parts
The saddle plate which supports the stator core is fixed to the frame with studs
and nuts (these are bolts if the machine is bipolar). Due to torque reactions and
machine vibrations resulting from operation, the stud and bolt fastening parts
may become loose. Leaving this unattended for a long time may cause the
adjustment plate to fall off or the stator to move thus resulting coming in contact
EME000077-d
22
with the rotor. Therefore, it is necessary to periodically check the looseness of the
stud and bolt fastening part and tighten the bolts more, as shown in Fig. 7 .
2 poles
Large machines
Table 5-1 Maintenance and inspection standard - Daily inspection (during motor operation)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Power Voltage Daily Voltmeter Limit: Within 10% of rated values at rated
source frequency.
Frequency Daily Frequency meter Limit: Within 5% of rated values
Where the voltage and frequency change
concurrently, the sum of the absolute values of
their changing ratio shall be within 10%.
2. Running Vibration Weekly Sense of touch Where the vibration is felt to increase over
conditions and vibrometer ordinary level, measure the value.
Judge the vibration level according to section
10.4.1.
Current Daily Ammeter The current shall be less than the rated value,
and shall be in order.
Odor Daily Sense of smell No burning smell.
Noise Daily Sense of hearing Check the noisy parts and use a stethoscope if
and stethoscope necessary.
Temperature Daily Sense of touch, No change in temperature rise from the values
(frame,bearing, thermometer at the initial time.
coil)
Cover and Weekly Visual inspection No falling off and loosening of fixing bolts.
the like
Ladder and Weekly Visual inspection No falling off and loosening of fixing bolts.
platform
No corrosion
3. Environ- Ambient Weekly Thermometer Within the standard values and normal
ment temperature
Ventilation Weekly Visual check No blockage in the ventilation grills, etc:
The motor blower, if working, is normal.
4. Bearing Temperature Daily Sense of touch, When the temperature is sensed as abnormal,
thermometer measure it with a thermometer.
4.1 Sleeve Temperature limits of self-cooled bearings:
bearing Up to 92, measured at the metal lower half
(reading value)
Oil level and Daily Visual inspection Be normal oil level.
oil leakage
Oil pressure Daily Visual inspection Be normal.
Oil ring Daily Visual inspection Be rotating smoothly.
4.2 Anti- Rotating Daily Sense of Be normal
friction noise hearing,
bearing stethoscope
Temperature Daily Sense of touch, When the temperature is sensed as abnormal,
(includes oil thermometer measure it with a thermometer.
slinger) Temperature limits (reading value):
Up to 100, measured by embeded
thermometer
Up to 95, measured on surface of housing
Grease fill-up As specified Grease gun Refill as required.
EME000077-d
24
Table 5-2 Maintenance inspection standard - Daily inspection (during motor operation)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
5. Cooler Water Daily Visual check No leak
leakage
Water Daily Pressure gauge Specified pressure
pressure
Water flow Daily Flow sight Flowing
EME000077-d
25
Table 6 Maintenance inspection standard - Daily inspection (when the motor is stopped)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Cooler Check in Monthly Service log
detail the
troubles
recorded on
the service
log
2. Appear- Damage and Monthly Visual check Clean and make repairs
ance dirt on the
frame and
terminals
Cooling Monthly Visual check Cleaning of found clogging
pipes, air duct
and filter
3. Bearing
3.1 Sleeve Oil contami- Monthly Visual check No sludge babbit metal chaffings or any other
bearing nation foreign objects
3.2 Anti- Discharged Monthly Drain port No metallic powder or any other foreign
friction grease objects, or contamination in grease
bearing
4. Earth brush The amount of Monthly Visual check Check the amount of brush wear with reference
(when brush wear to the following page, and exchange brushes
attached) according to the wear extent.
EME000077-d
26
The earthing brush may be attached near the bearing of a motor in order to prevent a
harmful shaft current. Some structures of earthing brush attachment are shown below, and
please check the amount of wear of a brush at the time of a motor stop. Brush exchange
should make the position of illustration a standard and should carry it out a little early.
[Example #1]
1. When the top of a brush comes to the position of A, exchange the brush for a new one.
2. If the wear extent of a brush is greater than 1mm per a month, adjust brush pressure within
18 to 22 kPa with adjusting screw.
Measuring method:
Put a thin paper between shaft and brush, and measure brush pressure
to pull up the support of a brush holder with a spring scale.
The brush pressure measured by a spring scale should be about 1kg
when the paper can be pulled out.
[Example #2]
This structure is a constant-pressure spring system.
Remove a brush at the time of a motor stop, and carry out a check of the amount of brush
wear and cleaning.
When it wears out from the metal plate of a brush to about 10mm as shown in a figure,
exchange the brush for a new one.
EME000077-d
27
Table 7-1 Maintenance inspection standard - Regular inspection (Simplified inspection, field
disassembly of the protective cover upper half and bearing housing upper half for inspection)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Investiga- Check in 2 years Service log Make repairs if necessary
tion operation log
for abnormal-
ities
2. Measure- Coil insulation 2 years Megger Desired values of stator coils
ment resistance R kV + 1 (M)
where
R: minimum insulation resistance at 40
kV: rated voltage (kV)
Table 7-2 Maintenance inspection standard - Regular inspection (Simplified inspection, field
disassembly of the protective cover upper half and bearing housing upper half for inspection)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
6. Bearing
6.1 Sleeve Metal 2 years (Overhaul ins- Lower metal to be in good working order
bearing Contact pection of Upper metal to be free from contact marks
bearing)
Visual check
(magnifying
glass)
Metal 2 years Color check 50% or more
adhesion
Metal 2 years Micrometer Refer to sleeve bearing instruction manual
clearance
Oil slinger 2 years Thickness Within limit
gauge
Oil ring 2 years Visual check Freedom from deformation and serious
wear: freedom from loosened setscrew
Oil 2 years Visual check Freedom from dirt, deterioration and foreign
objects
End play 2 years Thickness Within limit
gauge
Scale Refer to Sect. 5.2 Table 2.
6.2 Anti- Grease con- 2 years Visual check Grease replacement
friction termination
bearing
7. Instruments Dirt, damage 2 years Visual check Freedom from dust, oil, moisture, foreign
objects and damage
8. Coupling Deviation of As required Dial gauge Within tolerances, Refer to Sect. 5.2.
degree of ec-
centricity and
parallelism
Centering As required Dial gauge Within tolerances, Refer to Sect. 5.2.
Direct coupling As required Visual check Freedom from the loosening of the bolts and
nuts.
Damage As required Visual check Freedom from damage and breakage of key
way
(color check if No abnormal wear on tooth surface of the gear
required) coupling.
9. Operation Abnormal 2 years Sense of No abnormality
on load noise, hearing
vibration Sense of touch
abnormal odor Sense of smell
Rotational 2 years Visual check Normal rotational direction
direction
10.Shaft Protective 2 years Visual check After cleaning, measure insulation resistance
current device Tester : 0.5M or more at single motor
when disassembled
EME000077-d
29
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Investiga- Check the * Service log Make repairs if necessary
tion operation log 4 years
for abnormal-
ities
2. Measure- Shaft level Level meter Measure the level at both journals, and make
ment sure that the difference is within 0.05 mm/m.
Coil insulation 4 years Megger More than specified values
resistance Refer to Table 7.
Thermal class A Thermal class E Thermal class B Thermal class F Thermal class H
Stator windings
a. Output: 5000kW or
more
- 60 65 - 75 80 - 80 85 - 100 105 - 125 130
b. Output: In excess of
200kW; less than - 60 65 - 75 80 - 80 90 (1) 105 110 - 125 130
5000
1 c. Output: No more than
200kW and other (1) 60 - (1) 75 (1) 80 (1) 105 (1) 125
than d and e(2)
d. Output: Less than
600kW
(1) 65 - (1) 75 (1) 80 - 110 (1) 130
e. Self-cooled mold type
without cooling fans - 65 - - 75 - 80 - 110 - 130
(2)
2 Insulated rotor winding - 60 - - 75 - - 80 - - 105 - - 125 -
3 Squirrel-cage winding
Commutator, slip-ring,
4 brush
Cores and all structure The temperature of this part must not have harmful impacts on its insulating materials and
components (excluding neighbouring materials.
5 bearings) regardless of
contacts with winding
Notes 1: If agreed upon between the manufacturer and the purchaser, the decision can be
made in accordance with the thermometer method.
2: When applying the overlay equivalent load method is applied to the winding of the
induction machine whose heat-resistance classes are A, E, B and F and ratings are
no more than 200kW, it is all right to exceed the temperature increase limit of the
resistance method by 5K only.
EME000077-d
32
The insulation degradation for the winding of the induction machine is mainly
caused by heat and local discharge.
As other deteriorating factors, mechanical fatigue, pollution, and absorption of
moisture should be considered.
The windings cause early insulation degradation and the motor life is
proportionately shortened when the motor temperature rise remains higher than the
limit of temperature rise allowable by fouling of the air duct.
R kV + 1 (M)
where,
R: minimum insulation resistance at 40
kV: rated voltage (kV)
The measurement of the insulation resistance should be carried out at the motor
terminals for the stator winding and rotor winding.
For the stator windings, use a 500V megger when the rated voltage is less than
600V, and use a 1,000V megger when it is 600V or over.
Further, the value after the voltage is applied for one minute should be used as
the measured insulation resistance. At this time, it is also important to record the
measured winding temperature.
As reference, the insulation resistance secured in our factory is generally as
follows.
Stator winding More than 300M
10.4 Vibration
Each motor is sufficiently balanced in our factory. But vibration may increase,
when directly coupled with the driven machine, under the influences of insufficient
coupling accuracy, vibration caused by the driven machine or the installed condition
on the foundation or base.
Excessive vibration possibly incurs fatigue failure of the shaft, bearings, core,
windings, etc., and may cause insulation trouble, destruction of the foundation, etc.
It is very important, therefore, to maintain and monitor each motor so that its
vibration is kept within allowable range.
EME000077-d
33
JEC-2137 defines that "the rated voltage and the rated frequency are used to
perform no-load operations and the vibration speed at this time is measured." Our
company defines the goal value of the vibration speed on the on-site bearing bracket
as follows:
Conventionally, this is evaluated with the vibration amplitude value. One of the
most famous comprehensive surveys of the allowable values of general machine
vibration is VDI2056 complied by the VDI Vibration Expert Committee of Germany.
ISO also shows how to measure and evaluate the allowable value of vibration in
terms of the vibration severity.
These allowable values are, as it were experientially recommended value of
vibration, variable with the installed condition.
Shown in Fig. 8 are allowable values of vibration that we recommend. Fig. 8
shows allowable values of vibration measured per frequency spectrum, and when
the vibration exceeded the corresponding value indicated by the S line which
represents the standard level to require some measures against vibration for long
use, a suitable countermeasure must be taken in accordance with the result of
investigation into the cause of the vibration increase.
1
Peak to peak values (Unit mm = mm)
1000
Allowable value
of Vibration
(by frequency
spectrum)
Notes 1. The measuring location shall be on the top of the bearing housing.
2. Each value indicates one after directly coupled.
3. The vibration frequencies show the maximum amplitudes of the
actually measured vibration; be aware that they do not necessarily
agree with the synchronous frequency on the motor.
(e) Check the alteration of the amplitude when the rotational speed changes, to
judge whether the vibration is caused as the result of resonance or not.
(f) Check the vibration with reference to the alteration of lubricant temperature,
temperature of motor inside, bearing temperature, etc. and also check the shaft
behavior.
10.5 Noise
Typical causes of motor noise generation are described in the following Fig. 9.
Beat
Others
Fan noise
Ventilation noise
Air duct noise
Other noises
Race noise
Defect noise
Voltage change
110% (+)10 (-3) (+)
(+)21% unchanged (-)17% (+)0.4% (-)7%
voltage to 20% to 4% slight
Relation 1
with (voltage)2 constant (voltage)
voltage (voltage)2
90% (-)10 (+)10 (+)
(-)19% unchanged (+)23% (-)0.5% (+)11%
voltage to 12% to 15% slight
Frequency change
105% practically (-) (-)5 (-) (+)
(-)10% (+)5% (+)5%
frequency no change slight to 6% slight slight
Relation 1 1
with (frequency)
frequency (frequency) (frequency)
95% practically (+) (+)6 (+) (+)
(+)10% (-)5% (-)5%
frequency no change slight to 7% slight slight
(a) When the motor is operated with unbalanced voltage, the current for
each phase will be shown in Fig. 11.
With unbalanced voltage, the input will increase while the output, torque
and efficiency will decrease. As is obvious from Fig. 11, the phase
carrying the larger current may be overheated extremely, namely, the life
of its winding will be short, and at the same time the power cost will be
high as the result of increased loss. In addition, if the unbalanced
voltage is large, there is danger of increasing the vibration or noise.
(b) An extreme case of unbalanced voltage is one line fault. In this case,
the full-load slip rises to about twice against the value under three-
phase-running, and the line current rises to more than 3 times against
the value under three phases running. Avoid running the motor for long
periods under such a condition, because the winding may burn out.
11. Troubleshooting
2. The motor The motor condition One phase fuse is Check for wrong wires
generates remains one phase blown. One-phase of and contacts on the
abnormal starter circuit is wrong. circuit.
noise Starting contractor is
without wrong.
starting up.
Mechanical lock. The driven machine is Check the driven
locked. The coupling machine and coupling
connection is wrong and consider proper
(belting too tight: countermeasures.
misalignment; installa-
tion error, etc.)
Bearing is melted.
The metal contact in air
gap due to bearing
melting
7. Defect of The defect identified by Fatigue galling of Wash the bearing and
grease noise, vibration and raceways and rolling check for defects.
lubricated temperature. elements; Depressions If the bearing is found
anti-friction In many cases, the and other defects defective, replace it with
bearing trouble is concerned imparted upon the a new one.
For details, with grease. raceways and rolling
refer to the If the noise is elements caused by
bearing excessive, charge poor handling.
manual.) grease.
Shortage or excessive Supply a specified
charge of grease. quantity with grease of
specified brand.
REV. REV.ISSUED APPROVED BY REVIEWEDBY PREPARED BY
PAGE CHANGED PLACE AND CONTENTS
21-L SERIES
MANUAL DE INSTRUCCINES
CONTENIDO
(5) El conducto de aceite debe disearse y debe ajustarse tomando en cuenta la bomba
de aceite, regulador de presin y otros conductos deben ser adecuados para el flujo y
la presin especificada en el dibujo general de motor donde puede verse la informacin
de las entradas a las chumaceras del motor.
(6) Asegrese que no hay ningn objeto extrao como trapos o herramientas dentro de los
conductos. Entonces, lmpielos completamente y conctelos. La limpieza antes de la
conexin de los conductos se cumple en uno de los siguientes dos mtodos. Un
mtodo es inyectar vapor a una presin de 200 a 300 kPa. El otro es con un lavado de
10% de solucin acuosa de cido sulfrico o el cido clorhdrico, neutralice
inmediatamente con un 20% de solucin acuosa de sodio custico y entonces
enjuague con agua. Cualquier mtodo debe ser seguido de la lubricacin con aceite
tipo turbina para prevenir el xido.
(7) Las lneas de regreso utilizan la gravedad para el flujo. Esto exige al sistema de aceite
de lubricacin estar debajo de la elevacin de la chumacera del motor y una pendiente
continua dejando caer el aceite de retorno.
(8) Despus de que el conducto se ha completado, debe vaciarse completamente antes
de ajustarse a los soportes de motor.
El vaciado puede llevarse a cabo usando la bomba de alimentacin de aceite junto con
el motor o una bomba de aceite adicional que tambin se usar con un filtro. Cuando el
vaciado se ha llevado a cabo usando la bomba de alimentacin de aceite, asegrese
de limpiar el tanque de aceite completamente antes de un perodo de pruebas. Puesto
que el aceite de lavado puede contener materiales extraos, este no debe ser
introducido a las chumaceras.
Especficamente, los conductos deben tener una desviacin para que el aceite sucio
entre a las chumaceras de motor. El aceite vaciado que regresa al tanque de aceite
debe atravesar por un filtro de alambre de malla de 80 a 100. El vaciado estar
completo cuando los objetos extraos ya no se entrampen en el filtro. El filtro debe
reemplazarse a un intervalo de varias horas.
El vaciado tomar de 24 a 48 horas o una semana si el conducto es largo. Con el
propsito del vaciado, prepare el aceite regenerado as como el aceite nuevo. El aceite
para el vaciado se usa para temperatura de 70C a 80C. Durante las operaciones de
vaciado, martillen los conductos para desalojar las incrustaciones de los conductos, las
paredes internas y as arrastrarlos con el aceite de lavado.
Limpie completamente el alojamiento de chumacera, chumaceras, tanque de aceite y
enfriador de aceite; adems asegrese que no hay objetos extraos dejados en el
sistema de conductos. Despus de que el aceite se ha vaciado completamente,
prepare los conductos, cargue el aceite nuevo y verifique fugas y ajuste la cantidad de
aceite para el perodo de pruebas.
EME300051-a
5/19
3. El mantenimiento
El mantenimiento de las chumaceras se describe abajo.
Las chumaceras deben mantenerse y deben inspeccionarse en programas apropiados
adaptados a las condiciones del operacin de la mquina.
3.1 mantenimiento diario
(1) La temperatura de chumacera
La temperatura anormal de la chumacera puede descubrirse a travs de la
comparacin de los archivos acumulado de datos diarios y por esta razn, los archivos
de datos de operacin diarios son importantes.
La temperatura de la chumacera es medida por los mtodos siguientes:
(a) Use un termmetro de dial, o un termocople, o un R.T.D. u otros instrumentos
adecuados.
(b) El uso de un termmetro de barra. Un termmetro de barra se inserta en el
agujero de la medicin del alojamiento de chumacera como se muestra en Fig.2. (Este
agujero normalmente est tapado, pero el tapn es movible para permitir la instalacin
de un termmetro de dial o el instrumento adecuado.) Al instalar instrumentos en este
agujero, avsenos para tomar previsiones.
(c) Con chumaceras con lubricacin forzada la temperatura de la chumacera
puede conocerse por la temperatura del aceite a la salida de flujo, adems de los
mtodos (a) y (b). Sin importar el mtodo, cuando la temperatura anormal de
chumacera se descubre, la chumacera debe inspeccionarse inmediatamente.
Dado que la viscosidad del aceite aumenta en invierno o en las regiones fras, la
C = 1.185 d + 0.1
100
(3) Reparacin
Cuando la chumacera se encuentra en las condiciones descritas en la tabla 2,
ejecute la reparacin respectiva.
EME300051-a
8/19
4. Lubricante
En chumaceras use aceite tipo turbina como lubricante. Asegrese que el lubricante usado
es del tipo especificado en el dibujo general.
Nota: debido a las fusiones, etc de las compaas de aceite, algunos nombres pueden ser cambiados o
reintegrados; por tanto, para mayores detalles, contacte a las compaas de aceite ms importantes
EME300051-a
10/19
5. Solucin de Problemas
Se muestran las causas y posibles soluciones a varios tipos de problemas en la tabla de abajo.
Si el problema es considerado serio, avsenos inmediatamente.
6.2.2 Remueva la mitad superior del Alojamiento de chumacera (vea Fig. 3, Fig. 4)
(1) Quite los tornillos (3) para la mitad superior de chumacera (1) y quite la
tapa mitad superior (2).
(2) Quite los tornillos sujetadores (5) de la mitad superior de chumacera y quite
la mitad inferior del alojamiento de chumacera (4)
(3) Muevan la cubierta de chumacera despacio y evite a toda costa que se caiga.
(1) Desabroche el resorte (9), y quite la mitad superior (10) del sello flotante
(2) Gire el sello flotante-mitad inferior (11) a la posicin superior y qutelo. Al sacar los
sellos flotantes ponga atencin para evitar dao.
Sincronice los procedimientos del desensamble en el lado de carga y el lado opuesto a la carga.
EME300051-a
14/19
(1) Levante el rotor dentro del lmite que pueda quitar la mitad inferior de la chumacera
(8). En este procedimiento, tenga cuidado para evitar el contacto entre el rotor y el
estator.
El lmite de levantamiento aceptable es 0.5 mm.
o Ejemplo de mtodo de levantamiento de rotor
i) Alzando el cople.
ii) Levante el extremo de flecha opuesto a la carga con un block cadena de
ajuste fino, aplique una proteccin a la cadena de levantamiento para no
daar la flecha.
Como otro mtodo, est el caso del lado de carga opuesto tambin se
levanta como se muestra en i), o cuando el eje no est extendido, esta el caso
donde un tubo se inserta en el extremo del eje y el tubo se levanta con una soga
(vea Fig. 9).
iii) Este trabajo debe ejecutarse con cuidado y suma atencin y debe
confiarse al personal experimentado.
(2) Durante el levantamiento del rotor, gire la mitad baja de la chumacera (8) a la
posicin superior para su extraccin.
(3) Atornille los tornillos de ojo a la mitad baja de la chumacera (8), y levntela (vea
Fig. 10).
Tenga mucho cuidado en este procedimiento de la misma manera que en el caso
de la mitad superior de la chumacera.
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6.2.7 Desmontaje de la mitad inferior del alojamiento de chumacera (vean Fig. 11)
La mitad inferior del alojamiento de chumacera slo se desmonta cuando el rotor est
desensamblado
(1) Quite el seguro de los tornillos para el portador del sello (12) en el lado de la carga
y en el lado opuesto de la carga.
(2) Ponga los tornillos de ojo en los agujeros de la mitad inferior del alojamiento de
chumaceras, pasando el cable sobre las ranuras, ponga atencin a la ubicacin
del centro de gravedad.
(3) Quite los tornillos que estn sujetando la mitad inferior del alojamiento de
chumacera del rotor.
(4) Remueva la mitad inferior del alojamiento de chumacera para prevenir la salida del
rotor, en general el rotor es jalado por el lado opuesto a la carga, baje la mitad
inferior del alojamiento de chumacera del lado de la carga solamente lo suficiente
para liberar el acoplamiento (el dimetro de la pestaa exterior del acoplamiento
debe ser ms pequea que la perforacin del ncleo del estator), y quite la mitad
inferior del alojamiento del soporte del lado opuesto para prevenir dao al colector,
etc.
(1) Aplique compuesto que no endurezca o grasa ligera en las caras laterales (A en
fig. 7) del sello flotante y aplique aceite lubricante ligero en el dimetro interior del
sello flotante.
(2) Inserte la mitad inferior del sello flotante (con el agujero de dren de aceite) en el
soporte de sello y la mitad inferior girndolas. Asegrese que el orificio de dren
est hacia adentro del recipiente de aceite.
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(3) Instale la mitad superior del sello flotante. Coloque el resorte alrededor del sello
flotante y cirrelo. Cuidadosamente alinee las mitades superior e inferior del sello
flotante para hacer que sus superficies sean continuas. Despus de ensambladas,
asegrese que esta libremente colocado y no esta atascado de tal forma que al
girar se pueda deformar.
(4) Durante el reensamble de la mitad superior del soporte de sello, confirme que el
perno anti-rotacin del sello est correctamente en su ranura.
(3) Con una chumacera de lubricacin forzada reensamble los conductos de entrada y
salida de aceite. Ponga lubricante al nivel indicado en la mirilla de nivel de aceite
del soporte de chumacera.
(4) Con un motor del tipo intemperie aplique una capa de sellador (ver fig. 13 )
Siempre que desensamble asegrese de aplicar una capa de sellador en las reas
perifricas segn figura 13.
(El rea de aplicacin de sellador esta achurado en la fig. 13 )
Dado que el motor ha sido sellado en todas las partes que as lo requieren , no es
necesario desensamblar y sellar nuevamente al recibirlo en su planta.
Use sellador marca Three Bond 1207D o equivalente.