POLARTEKNIK PMC OY AB 1/17

FINLAND

GENERAL INSTRUCTIONS FOR

INSTALLATION, OPERATION AND
MAINTENANCE

FOR
HYDRAULIC SYSTEMS SUPPLIED BY
POLARTEKNIK

To get the best possible performance out of your

hydraulic system, make sure that you carefully carry
out these operating and maintenance instructions.
POLARTEKNIK PMC OY AB 2/17
FINLAND

1.0 SAFETY IN INSTALLATION AND MAINTENANCE ............................................ 3

1.1 Safety at work........................................................................................................ 3
1.2 Electric motors....................................................................................................... 3
1.3 System pressure ................................................................................................... 3
1.4 Accumulators......................................................................................................... 3
1.5 Handling hydraulic oil ............................................................................................ 4

2.0 SITING OF THE HYDRAULIC AGGREGATE...................................................... 5

3.0 INSTALLATION OF THE HYDRAULIC SYSTEM................................................ 5

3.1 Hydraulic aggregate .............................................................................................. 5
3.2 Hydraulic cylinders ................................................................................................ 5
3.3.Hydraulic motors ................................................................................................... 6
3.4 Filling the hydraulic system ................................................................................... 6

4.0 HYDRAULIC LINES.............................................................................................. 6

4.1 Material.................................................................................................................. 6
4.2 Working methods .................................................................................................. 6
4.3 Hoses .................................................................................................................... 7
4.4 Pipework design .................................................................................................... 7

5.0 FLUSHING THE PIPEWORK ............................................................................... 8

5.1 Flushing................................................................................................................. 8
5.2 Purity classes ........................................................................................................ 9

6.0 HYDRAULIC OILS................................................................................................ 9

6.1 Quality requirements ............................................................................................. 9
6.2 Choice of hydraulic oil ........................................................................................... 9
6.2.1 Choice of viscosity class.................................................................................. 9
6.2.2 Low-temperature operating conditions ............................................................ 11

7.0 COMMISSIONING OF A HYDRAULIC SYSTEM................................................. 11

7.1 Before start-up....................................................................................................... 11
7.2 Items to be checked .............................................................................................. 11
7.3 Bleeding the system .............................................................................................. 12
7.4 Adjustments........................................................................................................... 12

8.0 PROPORTIONAL VALVES .................................................................................. 13

9.0 HYDRAULIC ACCUMULATORS.......................................................................... 14

9.1 Pre-filling gas......................................................................................................... 14
9.2 Pre-filling gas pressure.......................................................................................... 14

10.0 MAINTENANCE .................................................................................................. 15

10.1 General................................................................................................................ 15
10.2 Regular service ................................................................................................... 15
10.2.1 Daily checks .................................................................................................. 15
10.2.2 After 50 operation hours................................................................................ 16
10.2.3 After 500 operation hours.............................................................................. 16
10.2.4 After 5000 operating hours (annual service .................................................. 16
10.3 Servicing the components ................................................................................... 17
POLARTEKNIK PMC OY AB 3/17
FINLAND
1.0 SAFETY IN INSTALLATION AND MAINTENANCE

1.1 Safety at work

All the actuators must be driven into a position where they cannot be
accidentally operated during maintenance. If this is not possible, all
moving parts must be properly secured.

1.2 Electric motors

To prevent accidental starting of electric motors, use an isolation

switch designed for this purpose or open and lock the safety switches,
or detach the motor cables before starting any installation or service
work.

1.3 System pressure

The system must be depressurised before work is started.

Release any oil under pressure in the hydraulic accumulator.

In large nitrogen-pressurised accumulators, all the shut-off cocks on

the lines leading to the accumulator must be carefully closed before
starting work.

14. Accumulators

If a large accumulator is to be drained, proceed as follows:

- Open the manhole in the oil tank top.

- Open carefully the accumulator discharge valve and drain the

oil in the accumulator to the hydraulic oil tank by making use
of the pressure exerted by nitrogen.

- When all the oil has been drained, close the valve.

- Then discharge the nitrogen into the atmosphere using a

hose.
POLARTEKNIK PMC OY AB 4/17
FINLAND

The accumulator must be thoroughly ventilated with compressed air

before any inspection of its inside. Always wear suitable protective
gear such as a compressed air mask.

NOTE!

NEVER INHALE NITROGEN GAS.

1.5 Handling hydraulic oil

If properly handled, hydraulic oils do not present much of a risk to

users. However, it is advisable to take the following precautions:

- avoid prolonged skin contact

- use suitable protective lotion or gloves

- never keep oily rags in your pockets

- beware of any oil jets

- clean oily skin with care using water and soap

- use a nail brush if necessary

- do not use petrol, diesel oil or solvents to clean your skin

- apply a high-quality skin lotion after washing

- follow the instructions given in the material safety data sheets

provided by oil companies

- never smoke or use open fire when handling oil.

Used hydraulic oil and filter inserts are regarded as hazardous wastes
that must not be allowed to contaminate the soil, water bodies, or
sewers.

NOTE!

One litre of oil is capable of contaminating one million litres of water and
making is non-potable
POLARTEKNIK PMC OY AB 5/17
FINLAND

2.0 SITING OF THE HYDRAULIC AGGREGATE

When selecting the installation site for the aggregate, consider the
following:

- cleanliness (dust, humidity, splashes, etc.)

- ambient temperature

- level base

- noise produced by the aggregate (whether noise-suppression

is required)

- aggregate cooling air circulation

- space required for service and maintenance.

3.0 INSTALLATION OF THE HYDRAULIC SYSTEM

3.1 Hydraulic aggregate

Install the aggregate on a level base and secure it firmly in position. If

necessary, use vibration dampers under the unit.

If the electric motor is of the B3 type, coupling alignment must

ALWAYS be checked when starting the machine. To correct any
misalignment, add or remove packing pieces under the pump foot or
electric motor.

3.2 Hydraulic cylinders

The cylinders must be mounted so that they will not be subjected to

any bending forces at any point of their travel.

The cylinder bleed screws or output connectors must be placed on top

to permit bleeding.

Do not remove the protective plugs from cylinder connectors until the
actual connection is made to prevent ingress of dirt into the cylinder.

Grease the cylinder rocker bearing before start-up.

Do not grease bearings greased for life.

POLARTEKNIK PMC OY AB 6/17
FINLAND

3.3 Hydraulic motors

Install the hydraulic motors in accordance with the instructions given

by the motor manufacturers.

Always mount the motor overflow connection at the top.

If the aggregate is placed lower than the hydraulic motor, the overflow
line must be fitted with a stop valve to ensure that the motor case
remains filled with oil. The stiffness of the stop valve spring will be
determined by the difference in height (12 m equivalent to approx.1
bar).

The back-pressure in the oil overflow line must not exceed the value
specified by the manufacturer.

Always fill the motor case with hydraulic oil via the overflow connector
before starting the machine.

3.4 Filling the hydraulic system

Check that the inside of the oil tank is clean before filling it with oil.

Always use a filter when filling hydraulic systems. Use 10 µm filters in

standard systems and 3 µm filters in servo systems.

4.0 HYDRAULIC LINES

4.1 Material

Hydraulic lines must be made of precision-drawn pipes specially

designed for use in hydraulic systems.

4.2 Working methods

Always use cold bending and correct bending radii.

All burrs must be removed and the pipes thoroughly cleaned before
installation. To clean the pipes, use cleaning plugs or compressed air
or pull a rag through the pipe by means of a wire. When installing the
pipes, make sure that it is possible to re-tighten the connectors of two
adjacent pipes using two spanners.

For pipe connectors, always use specially designed hydraulic pipe

connectors with adequate pressure rating.

Install bleed valves or pressure gauge connector at the highest point

of the pipework to enable it to be bled.
POLARTEKNIK PMC OY AB 7/17
FINLAND

4.3 Hoses

For hoses, use hydraulic hoses with correct pressure rating. Hose
ends should be compressible.

When installing hoses, follow the instructions given by the hose

manufacturer concerning bending radii, twisting, etc.

4.4 Pipework design

When designing a hydraulic pipework, consider its total length,

operating pressure, flowrate, and permissible pressure losses. The
following guideline values are recommended.

Pressure range Output Flowrate

bar l/min m/s
0 to 160 0 to 10 1 to 2
160 to 400 0 to 10 2 to 3
0 to 160 10 to 400 3 to 5
160 to 400 10 to 400 5 to 7

Suction pipe v = 0.5 to 1.5 m/s

Return pipe v = 1 to 4 m/s

A support spacing of 0.7 to 2 m is recommended depending on the

pipe diameter.

Pipe diameter Support spacing

mm m

6 - 12 0.7
14 - 22 1.2
25 - 28 1.5
30 - 42 2.1

Before the system is commissioned, the pipework must be tested at a

pressure that is 1.5 times the operating pressure or at least the
operating pressure +70 bar.
POLARTEKNIK PMC OY AB 8/17
FINLAND

5.0 FLUSHING THE PIPEWORK

5.1 Flushing

Hydraulic pipework must always be flushed before commissioning.

We recommend that an external flushing aggregate be used. If such

an external aggregate is not available, flushing can also be carried out
using the aggregate’s own pump. To do this, an extra flushing filter
must be fitted in the return line before the aggregate. Monitor the
indicator showing the filter condition and replace the filter insert (clean
the wire mesh) when an alarm is received. Continue flushing as long
as the filter insert no longer become clogged in 2 to 3 hours following
cleaning or replacement of the filter insert. An oil flowrate of 8 to 10
m/s is recommended for flushing, but it should be at least 1.5 times
the flowrate for normal operation. The temperature of the flushing oil
must be +70 to +80oC.

Before flushing, use hoses to link pipework sections into suitable

flushing circuits.

For the duration of flushing, servo valves must be replaced by flushing

plates or conventional check valves. When check valves are used, the
actuators can also be operated and thus flushed.

Use 10 µm filters in standard systems and 3 µm filters in servo

systems.

Pipework must not be commissioned until its cleanness has been

verified, e.g. with a particle counter.
POLARTEKNIK PMC OY AB 9/17
FINLAND

5.2 Purity classes

Recommended purity classes:

Type of system Pressure class ISO 4406

bar purity class
Systems sensitive to silt 13/10
Servo systems 14/11
Proportional, high- 250-400 15/12
pressure and lubrication
systems
Standard pressure 150-250 16/13
systems
Medium-pressure systems 50-150 18/15
Low-pressure systems 0-50 19/16
Large-clearance systems 21/18

The purity of oil is measured during flushing with a particle counter.

Flushing can be stopped when the required purity class is achieved.

6.0 HYDRAULIC OILS

6.1 Quality requirements

Only high-quality hydraulic oils may be used in hydraulic systems.

High-quality hydraulic oils contain efficient additives to minimise wear,

oxidisation, foaming, water separation, and corrosion.

6.2 Choice of hydraulic oil

6.2.1 Choice of viscosity class

Use ISO VG 15 - 100 class oils, preferably VG 32 - 68 depending on

the operating temperature.
POLARTEKNIK PMC OY AB 10/17
FINLAND

At the operating temperature (+40 to +60oC), oil viscosity must be

within the range of 13 to 100 cSt, the optimum being 16 to 36 cSt.

Recommended viscosity range

In cold starting, the lower limit for viscosity varies according to pump
type. The following values can be used as guidelines:

- fly pumps 800 - 860 cSt

- gear pumps max 1000 cSt
- piston pumps max 1000 cSt

NOTE!

The above values are indicative only. Viscosity values must always be checked for
each individual pump if the hydraulic system is installed out of doors or in a cold
space.
POLARTEKNIK PMC OY AB 11/17
FINLAND
6.2 Low-temperature operating conditions

For hydraulic systems operated at low temperatures, it is advisable to

select a synthetic hydraulic oil with a high viscosity index and wide
operating temperature range.

7.0 COMMISSIONING OF A HYDRAULIC SYSTEM

7.1 Before start-up

Make sure that the system is flushed as instructed. Use a particle

counter or similar device to verify this.

Fill the system with hydraulic oil using a special filtering pump.

NOTE!
Make sure that the inside of the tank is clean.

Fill the hydraulic pump and motor cases with the hydraulic oil to be
used in the system.

7.2 Items to be checked

Check the following items before system start-up. Make sure that

- the operating and control voltages correspond to rated value

- the suction and delivery cocks are open

- the connections used for flushing have been removed and the
connectors retightened

- connections have been according to the circuit diagram

- no mechanical structures prevent the free movement of the

actuators

- the nitrogen pressure in the hydraulic accumulator is as

specified in the circuit diagram
POLARTEKNIK PMC OY AB 12/17
FINLAND

- the electric motors and pumps are running in the right direction
(to check this, start the unit for a short time). The correct
direction of rotation is indicated by an arrow marked on the
electric motors and pumps.

7.3 Bleeding the system

For safety reasons, carry out bleeding at as low a system pressure as

possible.

Start the pumps and make sure that they start pumping oil. If a pump
does not pump oil, stop and re-start it a couple of times. If this does
not help, fill the pump delivery and/or suction pipe with hydraulic oil
and restart the pump. This usually solves the problem.

To bleed the pipework, open the bleed valve or pressure gauge

connector at the highest point of the pipework. If these do not exist,
open the pipe connector carefully to bleed the system.

Care must be taken when activating the first movements. Check that
all movements are unobstructed.

Bleed the hydraulic cylinders using the bleed screws or connectors.

To bleed the cylinders, open the bleed screw or connector on the

piston rod side when driving the + movement and, conversely, the
bleed screw or connector on the cylinder bottom side when driving the
- movement. Bleed oil long enough to ensure that it contains no
bubbles. After bleeding, retighten the bleed screws and connectors
and wipe the cylinders and pipes clean to make sure they are airtight.

Bleed the hydraulic motors by operating them for about 30 minutes

without load.

After bleeding, check the oil level in the tank and top up if necessary
(see section 3.4 Filling the hydraulic system).

7.4 Adjustments

Use the pressure regulating valves and control volume pump regulator
to adjust pressures to the levels indicated in the circuit diagram.
POLARTEKNIK PMC OY AB 13/17
FINLAND

NOTE!
The setting of the pressure relief valve must be 15 to 20 bars higher than the pump
regulator setting.

Adjust the desired speed of movements with the flow regulator valves.

Hydraulic cylinders are always supplied without any factory settings for
orifice attenuation, load relief valves, etc. These adjustments must be
made during start-up after the system has been bled.

The pressure switches are adjusted at the factory to the values

indicated in the circuit diagram.

Thermostat settings must always be checked during commissioning.

WE RECOMMEND the following settings for the thermostats:

* Heating element thermostat +10 to +30oC

* Cooler thermostat +40 to +50oC
* Alarm thermostat +60oC
* Stop thermostat +70oC

Adjust system pressure at full load. Set the pressure 10 to 20% higher
than required by the load. This ensures that the system will not be
unnecessarily loaded but all functions will be performed.

8.0 PROPORTIONAL VALVES

At the installation site, the following should be considered:

- ambient temperature can vary within a range of -20 to +50oC.

If the temperature drops below 0oC, heating should be
provided in the control board box to eliminate moisture
problems.

- proportional valves must be bled at a low pressure. Usually,

the bleed screws are located on valve coils.

- more detailed installation and operating instructions given by

board and valve manufacturers must be followed.
POLARTEKNIK PMC OY AB 14/17
FINLAND

When the system is commissioned, make sure that

- nominal values of the board match the operating conditions

- all connections are properly made
- the supply voltage is correct
- the voltage supply capacity (loadability) is sufficient

- Cabling has been carried out with proper care:

- the feedback cable must be sheathed and the sheath

grounded only at the board-side end
- the valve control cables are galvanically separated from one
another.

The amplifier board is correctly installed:

- there must be no large contactors or other equipment that may

cause current and/or voltage peaks
- the boards must be installed so that they do not vibrate and
are not exposed to vibration
- the board control potentiometers must be easily accessible
and the LED’s clearly visible.

9.0 HYDRAULIC ACCUMULATORS

9.1 Pre-filling gas

Nitrogen gas (N2) is the ONLY permissible pre-filling gas. No other

gases may be used because of EXPLOSION RISK.

9.2 Pre-filling gas pressure

Nitrogen pressure in the hydraulic accumulators will be checked in

connection with service or when necessary. Use a suitable filling
device to add nitrogen into the accumulator up to the value specified
in the circuit diagram.

WARNING!

If the hydraulic system incorporates a hydraulic accumulator, it will be pressurised

even if the pumps are not running. Release the oil pressure from the accumulator
before any service or repair work.

See the safety regulations.

POLARTEKNIK PMC OY AB 15/17
FINLAND

10. MAINTENANCE

10.1 General

The hydraulic oil in a hydraulic system transmits energy and serves as

a lubricant. Therefore it is essential for the correct operation and
durability of the system that the oil is clean and of the correct grade.

Studies show that approx. 70% of system malfunctions are due to

dirty, low-quality or unsuitable oil.

For these reasons, hydraulic systems must always be topped up using

a filter. Use 10 µm filters for standard systems and 3 µm filters for
servo systems. Cleanness is of utmost importance at every stage. No
open containers or cotton waste must be used in connection with
servicing or oil handling.

10.2 Regular service

10.2.1 Daily checks

- oil level
- oil temperature
- filter condition indicator
- replacement of filter inserts when necessary
- checking components and pipework for leaks and repairing
when necessary
- operating noise
- visual inspection of hoses (abrasions, cracking, etc.)
- surface temperatures of actuators and components using a
surface thermometer (max. temperature 65oC)
POLARTEKNIK PMC OY AB 16/17
FINLAND

10.2.2 After 50 operation hours

- Drain the oil tank into clean containers using a filtering pump.

- Clean the oil tank.

- Replace the filter inserts.

- Pump the oil back into the tank using the filtering pump.

- Top up with oil of the same grade if necessary.

- Tighten the connectors and component fixing screws.

- Clean the outside of the hydraulic aggregate.

10.2.3 After 500 operating hours

- Replace the filter inserts if necessary.

- Check the pipe and component fastenings.
- Check the oil quality visually and/or determine its purity with a
particle counter.
- If necessary, change the oil or send a sample to the oil
company laboratory for analysis.
- Check the air filter inserts and replace when necessary.
- If the system includes suction filters, they must be replaced or
cleaned if reusable.
- Clean the outside of the aggregate.

10.2.4 After 5000 operating hours (annual service)

- All hydraulic systems must be serviced at least once a year,

including those with few operating hours.

- Annual service must be planned in advance. When planning

the service operation, take account of defects and
malfunctions found in daily checks as well as the need for
repairs and replacement according to the service life of
individual components.
POLARTEKNIK PMC OY AB 17/17
FINLAND

- Drain the tank into clean containers if the oil is to be reused.

- If the system is small, change the oil.

- With large system, it is advisable to send an oil sample to the

oil company laboratory for analysis to determine the need for
oil change.

- Clean the inside of the tank with care and check the paint
finish.

- Replace filter inserts and air filters.

- Clean the water cooler and check its condition.

10.3 Servicing the components

All defective components should be replaced.

Disassembly and cleaning of parts

- Check the parts for wear and replace when necessary.

- Always replace seals and check valve centering springs and

bearings when necessary.

- Wash the cylinders, dismantle them and check the parts. If the
parts are OK, assemble the cylinders using new seals. Carry
out a pressure and leak test.

- When handling oil, follow the instructions given in section 10.1.

 Induction motor
Machine Instructions GB 3

Drehstrom-Käfigläufermotor
Betriebsanleitung DE 10

Moteur à cage
Notice technique FR 18

Motores de jaula de ardilla

Instrucciones ES 26

Motore a gabbia di scoiattolo

Istruzioni IT 34

Kortsluten motor
Motorinstruktioner SE 42

Oikosulkumoottori
Asennus- ja hoito-ohje FI 49

ABB Motors
Machine Instructions
NOTE!
These instructions must be followed to ensure safe and
proper installation, operation and maintenance of the
motor. They should be brought to the attention of
anyone who installs, operates or maintains this
equipment. Ignoring the instruction may invalidate the
warranty.
Declaration of Conformity
Declarations of Conformity with respect to the Low
voltage Directive 73/23/EEC amended by Directive 93/68
EEC are issued separately with individual machines.
The Declaration of Conformity also satisfies the
requirements of a Declaration of Incorporation with
respect to the Machinery Directive 89/392/EEC,
amended by 91/368/EEC, 93/44/EEC and 93/68/EEC.
Validity
The instructions are valid for the following ABB Motors
electrical machine types, in both motor and generator
operation.
series MU, MT*, MBT*, MXMA,
series M2A*, M2B*, M2C*, M2F*, M2L*, M2M*, M2R*,
series *QU, QUT,
in frame sizes 63 - 400.
(Additional information may be required for some
machine types due to special application and/or design
considerations.)
Putting into service (starting)
Reception check
Immediately upon receipt check the machine for external
damage and if found, inform the forwarding agent without
delay.
Check all rating plate data, especially voltage and
winding connection (star or delta). The type of bearing is
specified on the rating plate from size 112 and larger.
Turn shaft by hand to check free rotation, remove
transport locking if employed.
Motors equipped with roller bearings: Running the
motor with no radial force applied to the shaft may
damage the roller bearing.
Motors equipped with angular contact bearing:
Running the motor with no axial force applied in the right
direction to the shaft may damage the angular contact
bearing.
Motors equipped with regreasing devices:
When starting the motor for the first time, apply at least
the specified quantity of grease until new grease forced
out of the grease outlet.
For details see section “Machines with relubrication
system” on page 6.
LV Motors/Machine Instructions 99-09
Insulation resistance check
Measure insulation resistance before commissioning and
when winding dampness is suspected.
Resistance, measured at 25°C, shall exceed the
reference value, i.e.
10 M ohm (measured with 500 V dc Megger)
WARNING
Windings should be discharged immediately after
measurement to avoid risk of electric shock.
Insulation resistance reference value is halved for each
20°C rise in ambient temperature.
If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
Oven temperature should be 90°C for 12-16 hours
followed by 105°C for 6-8 hours.
Drain hole plugs, if fitted, must be removed during
heating.
Windings drenched in seawater normally need to be
rewound.
Direct-on-line or star/delta starting
The terminal box on standard single speed machines
normally contains 6 winding terminals and at least one
earth terminal.
Earthing must be carried out according to local
regulations before the machine is connected to the
supply voltage.
The voltage and connection are stamped on the rating
plate.
Direct-on-line starting (DOL):
Y or ∆ winding connections may be used.
eg 660 VY, 380 V∆ indicates Y-connection for 660 V and
∆-connection for 380 V.
∆) :
Star/Delta starting (Y/∆
The supply voltage must be equal to the rated voltage of
the machine in ∆-connection.
Remove all connection links from the terminal block.
For two-speed, single phase and special machines,
supply connection must follow the instructions inside the
terminal box.
Terminals and direction of rotation
Direction of rotation is clockwise when viewing the shaft
face at the machine drive end, when the line phase
sequence L1, L2, L3 is connected to the terminals as
shown in the figure 1.
To alter the direction of rotation, interchange the
connection of any two line cables.
If the machine has a uni-directional fan, ensure that the
direction of rotation is according to the arrow marked on
the machine.
3
 needed the position of the eyebolt must be adjusted with
Use suitable washers.
Ensure that proper lifting equipment is used and that the
Operating conditions sizes of the hooks are suitable for the lifting lugs.
The machines are intended for use in industrial drive Care must be taken not to damage auxiliary equipment
applications. and cables attached to the motor.
Normal ambient temperature limits are -25° to +40°C.
Maximum altitude 1000 m above sea level. Machine weights
Total machine weight can vary within the same frame
Safety considerations size (center height) depending on different output,
The machine is intended for intallation and used by mounting arrangements and added features.
qualified personnel, familiar with relevant safety
requirements. The following table shows estimated maximum weights
for machines in their basic versions as a function of
Safety equipment necessary for the prevention of frame material.
accidents at the installation and operating site must be
provided in accordance with the local regulations. On machines weighing more than 25 kg, the actual
weight is stated on the rating plate.
WARNING
Small motors with supply current directly Aluminium Cast iron Steel
switched by thermally sensitive switches can Frame Weight Add. Weight Weight
start automatically. size kg for brake kg kg
Points to observe 63 6 - - -
1. Do not use the machine to step on 71 8 5 13 -
2. The temperature of the outer casing of the 80 12 8 20 -
machine may be hot to the touch during normal 90 17 10 30 -
operation. 100 25 16 40 -
3. Some special machine applications require 112 36 20 50 -
special instructions (e.g. using frequency 132 63 30 90 -
converter supplies) 160 110 55 170 -
4. Lifting lugs must only be used for lifting the motor. 180 160 65 250 -
They must not be used to lift the motor when it is 200 220 - 300 -
attached to other equipment. 225 295 - 400 -
250 370 - 550 -
Handling 280 - - 800 600
315 - - 1300 1000
Storage 355 - - 2300 2200
The machine should always be stored indoors, in dry, 400 - - 3500 3000
vibration free and dust free conditions.
Installation
Unprotected machined surfaces (shaft-ends and flanges)
should protected with anti-corrosive paint. Cooling
Normal ambient temperatures should not exceed 40°C
It is recommended that shafts be rotated periodically by (marine standard 50°C) if standard performance is to be
hand to prevent grease migration. achieve. Check that the motor has sufficient airflow.
Ensure that no nearby equipment or surfaces radiate
Anti condensation heaters, if fitted, should preferably be additional heat to the motor. For more information about
energised. higher ambient temperatures and cooling, see “the Motor
Guide” or contact ABB Motors.
The characteristics of electrolytic capacitors, if fitted to
single-phase motors, will require “reforming” following Foundation
periods of storage exceeding 1-2 years. The purchaser bears full responsibility for preparation of
Contact ABB Motors for details. the foundation.

Transportation Metal foundations should be painted to avoid corrosion.

Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices
during transport.
Lifting
Only lift the motor using the lifting lugs.
The center of gravity of motors with the same frame
may vary due to different outputs, mounting arrange-
ments and auxiliary equipment.
Check that eyebolts or the lifting eyes integrated with
the motor frame are undamaged before lifting. Damaged
lifting eyes must not be used.
Lifting eyebolts must be tightened before lifting. If
Foundations must be even, and sufficiently rigid to
withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
to resonance.
Foundation studs
Bolt the foundation studs to the feet of the motor and
place a 1-to-2 mm shim between the stud and the feet.
Align the motor directly using appropriate means.
Grout the studs with concrete, check, alignment and drill
holes for locating pins.

4 LV Motors/Machine Instructions 99-09

Drain holes
Always check that open drain holes face downward.
Machines with closable plastic drain plugs are delivered
with these open.
In extremely dusty environments, all drain holes should
be closed.
Alignment
Correct alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions.
Slide rails and belt drives
• Fasten the machine to the slide rails as shown in
figure 2.
• Place the slide rails horizontally on the same level.
• Check that the machine shaft is parallel with driven, or
driving, shaft.
• Any belt must be tensioned according to the supplier's
instructions.
WARNING
Excessive belt tension will damage bearings and
can cause shaft breakage.
Do not exceed the maximum belt forces (i.e. radial
bearing loading) stated in the relevant product
catalogues.
Connection
The normal machine design is with the terminal box on
top and with cable entry possible from both sides.
Some machines are available, as a special option, with
top mounted terminal boxes rotatable 4 x 90°, and some
with side mounted terminal boxes.
Availability of these solutions is described in the product
catalogues.
Unused cable entries must be closed.
As well as main winding and earthing terminals, the
terminal box can also contain connections for
thermistors, standstill heating elements, bimetallic,
switches, or PT 100 resistance elements.
WARNING
Voltage may be connected at standstill inside the
terminal box for heating elements or direct
winding heating.
Connection diagrams for auxiliary elements are found
inside the terminal box cover.
WARNING
The capacitor in single-phase motors can retain
a charge that appears across the motor
terminals, even when the motor has reached
standstill.
In frequency converter applications motor frame
external earthing must be used for equalising the poten-
tial between the motor frame and the driven machine,
unless the two machines are mounted on the same
metallic base. For motor frame sizes above IEC 280,
use 0.75 x 70 mm flat conductor or at least two 50 mm²
round conductors. The distance of the round conductors
must be at least 150 mm from each other.
LV Motors/Machine Instructions 99-09
This arrangement has no electrical safety function; the
purpose is to equalise the potentials. When the motor
and the gearbox are mounted on a common steel funda-
ment, no potential equalisation is required.
Potential equalisation
V1 Plate/strip Cables/wires
U1 W1
PE
3~M
> 150 mm
0.75 mm
70 mm
min 50 mm
Driven machinery
To comply with EMC-requirements, only cables and connec-
tors approved for this purpose. (See instruction for frequency
converters.)
Assembly and dismantling
General
Dismantling and assembly of machines must be carried
out by qualified personnel using only suitable tools and
working methods.
Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by
heating or using special tools for the purpose.
How to replace bearings is described in detail in a
separate instruction leaflet available from ABB Motors.
Fitting coupling halves and pulleys
Coupling halves and pulleys must be fitted using suitable
equipment and tools that do not damage the bearings.
Never fit a coupling half or pulley by hammering into
place or remove it using a lever pressed against the
body of the machine.
Mounting accuracy of coupling half :
check that the clearance b is less than 0,05 mm and
that the difference a1 to a2 is also less than 0,05 mm.
See figure 3.
Balancing
The rotor of the machine is dynamically balanced.
As standard, balancing has been carried out using half
key, and the shaft is marked with a RED tape, with the
text “Balanced with half key”.
To avoid vibration the coupling-half or pulley must be
balanced with half key after the keyway has been
machined.
In the event of balancing with full key the shaft is
marked with a YELLOW tape, with the text “Balanced
with full key”.
To avoid vibration the coupling-half or pulley must be
balanced without a key after the keyway has been
machined.
In case balancing without key, the shaft is marked with
a BLUE tape, with the text “Balanced without key".
5
Maintenance and lubrication ABB Motors policy is to have reliability as a vital issue
in bearing lubrication intervals. That is why we follow the
General inspection L1-principle (meaning that 99 % of the motors are sure
- Inspect the machine at regular intervals. to make the interval time). According to L1 policy the
- Keep the machine clean and ensure free lubrication intervals are as follows:
ventilation airflow.
- Check the condition of shaft seals (eg V-ring) and Frame Amount 3600 3000 1800 1500 1000 500-900
replace if necessary. size of grease r/min r/min r/min r/min r/min r/min
- Check the condition of connections and mounting g/bearing
and assembly bolts.
Ball bearings
- Check the bearing condition by listening for
Lubrication intervals in duty hours
unusual noise, vibration measurement, bearing
112 10 10000 13000 18000 21000 25000 28000
temperature, inspection of spent grease or SPM
132 15 9000 11000 17000 19000 23000 26500
bearing monitoring.
160 25 7000 9500 14000 17000 21000 24000
* When changes of condition occur,
180 30 6000 8000 13500 16000 20000 23000
dismantle the machine, check the parts
200 40 4000 6000 11000 13000 17000 21000
and replace if necessary.
225 50 3000 5000 10000 12500 16500 20000
250 60 2500 4000 9000 11500 15000 18000
Lubrication
280 70 2000 3500 8000 10500 14000 17000
315 90 2000 3500 6500 8500 12500 16000
Machines with permanently greased bearings
355 120 1200 2000 4200 6000 10000 13000
Machines up to frame size 180 are normally fitted with
400 120 1200 2000 4200 6000 10000 13000
permanently greased bearings of either Z or 2Z types.
Bearing types are specified in the respective product Roller bearings
catalogues and on the rating plate of each motor from Lubrication intervals in duty hours
size 112 and larger. 160 25 3500 4500 7000 8500 10500 12000
180 30 3000 4000 7000 8000 10000 11500
As a quide, adequate lubrication can be achieved for the 200 40 2000 3000 5500 6500 8500 10500
following duration, according to L1 at ambient 225 50 1500 2500 5000 6000 8000 10000
temperature of 25° C. 250 60 1300 2000 4500 5700 7500 9000
32 000 - 45 000 duty hours for 4 pole machines.1) 280 70 1000 1700 4000 5300 7000 8500
16 000 - 26 000 duty hours for 2 and 2/4 pole 315 90 1000 1700 3300 4300 6000 8000
machines.1) 355 120 400 1000 2000 3000 5000 6500
400 120 400 1000 2000 3000 5000 6500
The shorter times apply to larger frame sizes.
Lubrication intervals for vertical machines are half of the
1)
Depending on application and load conditions, see above values.
applicable product catalogue.
Hours of operation for vertical motors are half of the The amount of grease stated in the table should be
above values. doubled if an automatic regreasing system is used.

Machines with relubrication system
WARNING
Beware of all rotating parts!
Relubrication procedure:
- Remove grease outlet plug if fitted.
- Press fresh grease into the bearing until all old grease
has been forced out
- Let the motor run 1-2 hours to ensure that all excess
grease is forced out of the bearing. Close the grease
outlet plug if fitted.
Regrease motors while running. If this is not possible,
lubrication can be carried out while the machine is at a
standstill. In this case, use only half the quantity of
grease, then run the motor for a few minutes at full
speed. When the motor has stopped, the remaining
quantity of grease can be forced in until the old grease
has been replaced.
After 1-2 running hours close the grease outlet plug (if
fitted).
The table values are based on the motor running at rated
output in an ambient temperature of about + 25° (approx.
80°C bearing temperature). The values should be halved
for 15°C increase in bearing temperature and may be
doubled for 15°C decrease in ambient temperature.
WARNING
The maximum operating temperature of the
grease and bearings must not be exceeded.
Higher speed operation, eg in frequency converter
applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult ABB Motors in such
cases.
Typically a doubling of speed will require a reduction of
lubrication intervals to approx. 40 % of values tabulated
above.
Suitability of bearings for high speed operation must also
be checked.

The grease outlet plug must be removed permanently

with automatic lubrication.
If the machine is fitted with a lubrication information
plate, follow the values given, otherwise use the values
in table below.

6 LV Motors/Machine Instructions 99-09

Lubricants
When regreasing, use only special ball bearing grease
with the following properties:
- good quality grease with lithium complex soap and with
mineral- or PAO-oil
- base oil viscosity 100-150 cST at 40°C
- consistency NLGI grade 2 or 3
- temperature range -30°C - +120°C, continuously.
Environmental requirements
Noise levels
Smaller machines have a sound pressure level that not
exceeding 70 dB(A).
The following table shows cataölogue values of sound
pressure levels at 1 m from the machine surface.

Grease with the correct properties is available from all Frame Guideline sound pressure level, dB(A)
the major lubricant manufacturers. size 2 pole 4 pole 6 pole 8 pole
The following (or similar) high performance grease can
be used 132 69 59 61 56
• EssoUnirex N2 or N3 160 69 62 59 59
• Shell Albida RL2 180 69 62 59 59
• SKF LGHQ 3 200 72 63 63 60
• Mobil Mobilith SHC 100 225 74 66 63 63
• Klüber Kluberplex BEM 41-132 250 75 67 63 63
• BP Energrease LC2 280 77 68 66 65
315 80 71 68 72
NOTE! 355 83 80 75 75
Always use high speed grease for high speed machinens 400 83 80 - -
and some other models, e.g. M2_ 355 and 400 2-pole Values for specific machines can be found in the
machines, where the speed factor is higher than 400 000 relevant product catalogues. Tolerance acc ± 3 dB(A).
(calculated as Dm x n where Dm = average bearing
diameter, mm ; n = rotational speed, rpm). The following, The table values refer to 50 Hz sinusoidal supply
or similar, types of grease can be used: conditions.

• Kluber Asonic GHY 72 For 60 Hz sinusoidal supply, add 4 dB(A) to the above
• Kluber Asonic HQ 72-102 values.
• Shell Syntix 100
• Esso LT2 For sound pressure levels with non-sinusoidal supplies,
• Mobil Mobilith SHC 100 contact ABB Motors.

The following normal type of grease can be used if the Sound pressure levels for all machines in the above
regreasing interval is halved (these types of grease frame sizes having separate cooling systems and for
should not be used when bearing temperature is above series M2F*, M2L*, and M2R*, are indicated in separate
100°C) specific Machine Instructions.

• Esso Beacon 2 or 3
• Shell Alvania G2 or G3 Rewinding
• SKF LGMT 2 or 3
• Mobil Mobilux 2 Rewinding should always be carried out by qualified
• Kluber Centoplex 2 repair shops.
• BP Energrease LS2
Smoke venting and other special motors should not be
If the make of grease is changed and compatibility is rewound without first contacting ABB Motors.
uncertain, consult ABB Motors.
Highly loaded and/or slowly rotating bearings require EP-
grease.
If the ambient temperature is below -25°C or above
+55°C, or bearing temperature is above 110°C, consult
ABB Motors regarding suitable grease.

WARNING
Grease can cause skin irritation and eye
inflammation.
Follow all safety precautions specified by the
manufacturer.

Spare parts
When ordering spare parts, the full type designation and
product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.

LV Motors/Machine Instructions 99-09 7

These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please contact
the nearest ABB Sales Office.
Motor trouble shooting chart
Your motor service and any trouble shooting must be handled by qualified persons with proper tools and equipment.
TROUBLE CAUSE
Motor fails to start Blown fuses
Overload trips
Improper power supply
Improper line connections
Open circuit in winding or control
switch
Mechanical failure
Short circuited stator
Poor stator coil connection
Rotor defective
Motor may be overloaded
Motor stalls One phase may be open
Wrong application
Overload
Low voltage
Open circuit
Motor runs and then Power failure
dies down
Motor does not come Not applied properly
up to speed Voltage too low at motor terminals
because of line drop
Starting load too high
Broken rotor bars or loose rotor
Open primary circuit
Motor takes too long to Excessive load
accelerate and/or draws Low voltage during start
high amp Defective squirrel cage rotor
Applied voltage too low
Wrong rotation Wrong sequence of phases
Motor overheats while Overload
running underloaded Frame or bracket vents may be
clogged with dirt and prevent proper
ventilation of motor
Motor may have one phase open
Grounded coil
Unbalanced terminal voltage
8 LV Motors/Machine Instructions 99-09
WHAT TO DO
Replace fuses with proper type and rating.
Check and reset overload in starter.
Check to see that power supplied agrees with motor
name plate and load factor.
Check connections with diagram supplied with
motor.
Indicated by humming sound when switch is
closed. Check for loose wiring connections. Also,
ensure that all control contacts are closing.
Check to see if motor and drive turn freely. Check
bearings and lubrication.
Indicated by blown fuses. Motor must be rewound.
Remove end bells, locate with test lamp.
Look for broken bars or end rings.
Reduce load.
Check lines for open phase.
Change type or size. Consult manufacturer.
Reduce load.
Ensure the name plate voltage is maintained.
Check connection.
Fuses blown, check overload relay, stator and push
buttons.
Check for loose connections to line, fuses and
control.
Consult supplier for proper type.
Use higher voltage or transformer terminals or
reduce load. Check connections. Check conductors
for proper size.
Check load motor is supposes to carry at start.
Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Locate fault with testing device and repair.
Reduce load.
Check for high resistance. Adequate wire size.
Replace with new rotor.
Get power company to increase power tap.
Reverse connections at motor or at switchboard.
Reduce load.
Open vent holes and check for a continuous stream
of air from the motor.
Check to make sure that all leads are well
connected.
Locate and repair.
Check for faulty leads, connections and
transformers.
TROUBLE CAUSE WHAT TO DO
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor
rotor and coupling
(half key – full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing air shield Remove interference.
Fan striking insulation Clear fan.
Loose on bedplate Tighten holding bolts.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
Hot bearings general Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Hot bearings ball Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in
contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be
more than 1/2 filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing thoroughly.

LV Motors/Machine Instructions 99-09 9

 Figure 1. Connection diagram
Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio

Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figur 2. Remdrift
Kuva 2. Hihnakäyttö

56 LV Motors/Machine Instructions 99-09

 Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshälften und
Riemenscheiben
Figure 3. Montage des demi-accouplements et des
poulies
Figura 3. Montaje de mitades de acoplamiento y
poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus

LV Motors/Machine Instructions 99-09 57

 1 2 3 4 5 6 7 8

B
556 A A
A

504 151

1 1.5

B 11 1.4
16
1.3
15
13
25 B 455 50 12.5 695 12.5
530 ø13, 4pcs 720
~620
C OPENING
1.2

PROTECTION ENCLOSURE
5
12
2
9 3
2 14 4

500
RETURN CONNECTION
6
G3/4" FEMALE
7
D 10
8
1
PRESS. CONNECTION 3
DIRECTION A - A
400
G3/4" FEMALE TANK CONNECTION
G1/2" FEMALE

Name Type Drawing number Manufacturer/

E DIRECTION B - B Part Pcs
Standard
Product Project
Customer KALMAR INDUSTRIES OY AB
Customer`s Attached Code
Dwg nr BF337358 KON-0612
Scale Design tpi 2002-11-25
Polarteknik PMC Oy Ab
1 :12.5 Drawn tpi 2002-11-25
Work number

VANTAA FINLAND Weight 165

7524

kg Appr.
Drawing nr Sheet
DIMENSIONED DRAWING
F 70/25/160/7.5 BF337359 Rev
Replaced
Mark Field Changed Date Name Appr. HYDR. PUMP UNIT Replace