Flowpak HT MM REV

MANUAL FOR SAFETY,INSTALLATION AND
MAINTENANCE
FLOWPAK SERIES MEDIUM VOLTAGE
11/11/2010
INDUCTION MOTORS -0-
""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""
MANUAL FOR SAFETY,
INSTALLATION AND MAINTENANCE
FLOWPAK MEDIUM VOLTAGE
INDUCTION MOTORS
""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""
MARATHON ELECTRIC MOTORS(INDIA) LIMITED 58 & 1 TARATALA ROAD, KOLKATA, INDIA, TEL- 91 33 24695560-65 ; 2469 5370 ;
FAX 91 33 24698530, 24696988, CONTACT FOR SERVICE - 09903900891
MAINTENANCE
11/11/2010
WARNING
Users must follow the instructions and read the information contained in
this manual. Anyone working on the equipment supplied MUST fully under-
stand the instructions and information contained in this manual.
The personnel installing, commissioning and servicing the equipment MUST

be both qualified and experienced in these fields and satisfy all relevant
legal obligations, including all health and safety rules and recommenda-
tions applicable in the country where the equipment is to be installed.
………………………………………………………
Safety note
The "Warning or Caution" symbol is used to draw the user's attention
to important points.
.........................................................................
CAUTION
Before working on the motor, always :
• Check that the electric power to the motor is cut.

• Check that the motor cannot rotate.
• Ensure that electric power cannot intentionally or accidentally be restored
through-out the work, and that the motor cannot rotate
• Take all necessary steps to ensure personal safety and prevent damage to
equipment.
This manual contains the general safety, installation and maintenance in-
structions for the Flowpak 2 series motors.
It is therefore essential to read this manual carefully, and consult the draw-
ings, connection diagrams and data sheets.
Before the motor enters full service after installation, the installation report
must be completed, a specimen copy of which is to be found at the end of
this manual. This report will need to be produced for any intervention during
and the warranty period.
MAINTENANCE
11/11/2010
CONTENTS
Page
WARNING ………………………………………………………………………1
Contents …………………………………………………………………………2
1 - Definition of main graphical symbols ……………………………………..3-4
2 - Abbreviations and direction of rotation……………………………………5
3 - Shipping ……………………………………………………………………..6
4 - Receipt procedure ……………………………………………………..7
5 - Handling (motor in crate) ................................................................... 8
6 – Handling (handling diagrams) .......................................................... 9 to 10
7 - Storage .................................................................................................. 11
8 - Installation ............................................................................................. 12 to 16
9 - Stator insulation measurement .......................................................... 17
10 - Machine drying .................................................................................. 18-19
11 - Checks prior to start-up..................................................................... 20-21
12 - Start-up ................................................................................................ 22
13 - Troubleshooting procedure.............................................................. 23
14 - Maintenance ...................................................................................... 24 to 40
15 - After sales service .............................................................................. 40 to 41
MAINTENANCE
11/11/2010
1 - DEFINITION OF MAIN GRAPHICAL SYMBOLS
Symbols concerning packaging and handling.
Key Symbol Meaning

Fragile Handle with care Indicates :
a) That the contents of
the package are fragile;
b) That the package
should be handled with
care.
iso 7000/n° 0621
Do not use hooks Indicates that the pack-
age is not to be handled
using hooks.
iso 7000/n° 0622

This way up Indicates the correct
upright position of the
package.
iso 7000/n° 0623

Store away from heat Indicates that the pack-
age is to be stored away
from heat.
iso 7000/n° 0624

Store away from heat and Indicates that the con-
radioactive materials. tents of the package may
be damaged or rendered
useless by exposure to
high temperatures or ra-
dioactivity.
iso 7000/n° 0615
Lifting point Indicates the fixing points
for the slings used to lift
the package.
iso 7000/n° 0625
MAINTENANCE
11/11/2010
DEFINITION OF MAIN GRAPHICAL SYMBOLS
Key Symbol Meaning

Keep dry Indicates that the pack-
age must be kept dry.
iso 7000/n° 0626

Centre of gravity Indicates the centre of
gravity of the package.
iso 7000/n° 0627

Do not roll Indicates that the pack-
age must not be rolled.
iso 7000/n° 0628

No sack trucks on this Indicates the points
side. where sack and pallet
trucks must not be
placed.
iso 7000/n° 0629

Stack height Indicates the stacking
height for the package.
iso 7000/n° 0630

Lateral clamping points Indicates the clamping
points on the package.
iso 7000/n° 0631

Temperature limits Indicates the maximum
and minimum tempera-
tures between which the
package must be main-
tained and handled.
iso 7000/n° 0632
MAINTENANCE
11/11/2010
2 - ABBREVIATIONS AND DIRECTION OF ROTATION
CS : Coupling side OSC : Opposite side from coupling
DIRECTION OF ROTATION
The direction of rotation is always given for an observer looking at the motor
from the coupling side (CS) and identified by a single arrow-head for a single
direction of rotation, and by two arrow-heads for motors turning in both di-
rections.
The motor can only be operated in the direction of rotation for

which it was built.
F
CS OSC Anti - clockwise Clockwise
F
OSC Anti - clockwise Clockwise
CS
MAINTENANCE
11/11/2010
3 - SHIPPING
Motors in seaworthy packaging
When shipped by sea, or where the motor is likely to be exposed to adverse

weather conditions, we recommend it is packaged in accordance with offi-
cial standard SEI 4 c (standard seaworthy packaging).
Except where specifically written in the contract, we recommend following

the procedure below when the equipment is delivered:
• Remove the crate lid

• Remove the cover
• Check the quality of the equipment supplied
• Replace the crate lid
• Place the equipment and crate in storage (see storage page).
MAINTENANCE
11/11/2010
4 - RECEIPT PROCEDURE
Check that all packaging is perfect condition, indicating that the equipment
has not been damaged in transit.
Check that appropriate handling equipment for the equipment, weights

and sizes is available on-site.
Check the various items against the shipping documents and inspect the
equipment and accessories visually.
In the event of anomaly :
Any signs of impact or damage must be indicated.

All official reservations should be made to the shippers within 24 hours and to
ourselves by fax within 24 hours and by email to kms@marathonelctric.com
Toll free number - 18004191500
All necessary steps should be taken to keep the equipment safe and in good
condition.
Ideally, a legal damage report should be drawn up, and in all cases photo-
graphs clearly showing the damage are to be taken.
MAINTENANCE
11/11/2010
5 - HANDLING
Crated motors
Slings are to be fitted as indicated by the markings on the packaging.
Note the position of centre of gravity carefully, as it may not lie at the centre
of the crate.
Where crates have to be moved using a fork-lift truck, they should be careful-
ly centred on the forks, taking into account their dimensions and centre of
gravity.
Under no circumstances should crates be overturned or carried on their sides.
Crates should be properly lashed to, prevent impacts and overturning.
Do not stack crates, to avoid damaging them.
TOP
CUSTOMER
WEIGHT
BOTTOM
Example centre of
gravity
MAINTENANCE
11/11/2010
6 - HANDLING
The motor is supplied fully assembled.

Weight : see name plate on the motor.
Fragile equipment. Handle with care.

Use a lifting beam * or adjustable slings.
Fit hoisting shackles into the holes on the lifting lugs.
When handling the entire motor, use the lugs on the upper part of the frame
Always check that the rotor, locking device is fixed before moving the motor.
(*) Lifting beam, slings and hoisting shackles not supplied.
Refer to the enclosed dimensional drawings before moving the motor.

The drawings show the weight, centre of gravity and overall dimensions.
Example handling diagrams

Flowpak 2 horizontal motor.
Adjustable slings
MAINTENANCE
11/11/2010
INDUCTION MOTORS - 10 -
Flowpak 2 vertical motor
Warning: Suitable lifting arrangement should be available; such as a crane of sufficient capacity,
hooks and chains which are in good order. If the motor has to be unloaded of moved using a forklift
truck, it must be mounted on strong timbers running lengthwise under the feet with cross pieces to al-
low access for the forks. The truck must be capable of lifting the motor and of transporting it without
tipping over. The motor should be kept at the lowest practicable level of the forks and travel over
rough/uneven ground should be avoided to prevent shock load damage to the bearings.
MAINTENANCE
11/11/2010
7 - STORAGE
7.1 – Storage instructions
The equipment is to be stored in a clean, dry and adequately ventilated

place.
The equipment is to be stored at a temperature above -20°C, except where

expressly written into the contract.
The equipment is not to be placed directly on the ground, but on wooden

beams, in order to prevent damage from below and to allow air to circulate
freely around the equipment.
The storage area should be free from vibrations, which might otherwise dam-
age the equipment. If the motor is subjected to floor vibration greater than
50mm/sec rms whilst stationary, damage to the bearings may be caused,
particularly if they are of the rolling element type, i.e. ball or roller. If the vi-
bration is unavoidable, the stored motor should be stood on resilient mount-
ings such that resulting vibration measured on the motor frame is less than as
stated above.
The storage area should as far as possible be protected against potential ha-
zards such as flooding, animal infestations, etc.
The equipment is not to be stored in a saline or corrosive atmosphere, except

where expressly written into the contract.
MAINTENANCE
11/11/2010
8 - INSTALLATION
8.1 - Motor positioning
The rotor locking device is to remain fixed while the motor is handled, moved
and positioned next to the machine to be driven.
The rotor locking device should be dismantled :
• before adjusting the shaft alignment on horizontal machines ;

• before placing a vertical motor against the shaft of the driven machine.
Note : Two diagonally opposite ∅ 10 mm holes must be drilled into the base-
plate or frame to allow the motor to be pinned. This procedure is to be per-
formed prior to positioning the motor, in accordance with the floor plan for
the vertical holes, and after final tightening for the oblique holes (with the
motor acting as a template).
8.2 - Supply of base-plates and anchor rods
Placing adjusting shims between the base-plates and motor feet can align
the shaft heights of the two machines.
The upper surface of the base-plates must be adjusted as shown in the

diagram below:
Add : shims must be positioned as close as possible of lightning screws
Shims with excessive lengths cun generale the important bendings.
MAINTENANCE
11/11/2010
MotoDriven machine
shaft axis
Driven machine
Motor foot
X + 1 mm
Base plate
X = motor shaft height
8.3 - Machine adjustments
8.3.1 - Introduction
The parallelism (axial alignment) and concentricity (radial alignment) of the

coupling sleeves on the driving and driven machines must be set correctly.
Use the jack-bolts and adjusting shims supplied with the machine for this pur-
pose.
Axial misalignment
Collar rigide
Radial misalignment
Collar rigide
8.3.2 - Special cases: machines with axially free rotors

With axially free rotors, the rotor must be correctly centred in the
motor with the correct “X” or “Y” dimension, as shown below
MAINTENANCE
11/11/2010
The correct "X" or "Y" dimension is indicated on a plate fixed over the bearing
and in the test report.
Bearing seal
Shaft shoulder on coupling side

X= mm
With coupling sleeve
Y= mm With coupling flange
8.3.3 –
Tolerances
We cannot the alignment tolerances specified by coupling manufacturers. The

high precision of our bearings allows the following tolerances.:
. 0.03 mm (0.0012”) in all directions for coupling sleeves of external diameter

≤ 200 mm ( 8″ ).
. 0.05 mm (0.0012”) in all directions for coupling sleeves of external diameter

< 200 mm (8”) .
8.4 - Instructions
The motor should be aligned and vertically adjusted in accordance with the
manufacturer of the driven machine's instructions.
With semi-flexible couplings, refer to the tolerances given above.
With rigid couplings of all sizes, a single tolerance of 0.03 mm axe to axe (
0.0012” ) is to be taken into account.
PRECAUTIONS
MAINTENANCE
11/11/2010
Importance of instructions
The failure to respect the instructions and tolerances stated above will result
in :
• Excessive vibration ;
• Bearing overheating ;
• Premature wear of bearing components.
MAINTENANCE
11/11/2010
8.5 – Machine mounting screw torque settings
The torque settings given in the chart below must be respected in to prevent
screw fatigue or thread stripping, or damage to the motor caused by vibra-
tion.
Screw diameter(mm) Torque (N.m)

20 310
22 420
24 540
27 800
30 1000
33 1450
39 2450
42 3000
48 4550
52 5200
8.6 – Motor pinning
Pin the motor.
8.7 – Connection of forced oil lubricated sleeve bearings to the lubrication system
Refer to paragraph headed "Forced oil lubrication".
8.8 – Fitting of Half Couplings

If the half coupling has not been fitted, it shall be fitted as follows:
• Clean the anti-rust paint layer off the shaft and key. Check that there are no
burrs and if there are remove them with a fine file.
MAINTENANCE
11/11/2010
• Prepare the half-coupling for fitting in accordance with the maker’s instruc-
tion.
• The half-coupling can be pressed on or lightly driven-on. There is an axial

threaded hole in the end of the shaft for use when pressing on, for threaded
details see outline drawings.
• If the coupling is to be driven on, it will be necessary to support the shaft

axially to prevent shock loads being transmitted to the other bearings. To do
this, remove the fan inlet mesh to give access to the NDE of the shaft. Pre-
pare a piece of wood long enough such that one end will rest on the NDE
shaft and the other end on a convenient rigid structure in live with the shaft.
• Fit the coupling and key pressing or driving to the required position on the
shaft. Refit the fan mesh and spin the rotor to check that the fan is not rub-
bing. If sleeve bearings are fitted, check for clearance at the limits of shaft
movements.
MAINTENANCE
11/11/2010
9 – STATOR INSULATION MEASUREMENT
Moisture is particularly detrimental to the proper operation of electric motors.
Before switching on the power, check the insulation resistance of the stator
windings with respect to the earth.
- Stator voltage > 2500 Volts
A 2500 Volt megohmmeter (at least) should be to make these measure-

ments.
The insulation resistance must at least equal :
• R=3 (1+U)
• R=insulation resistance in megohms
• U=rated voltage in Kv.
- Stator voltage < 2500 Volts
Use a 500 Volt megohmmeter.
The insulation resistance must be ≥ 10 megohms.
Measuring d.c. voltage levels for medium and large machines of different
voltages are given below :
Machine Voltage D.C.Test Voltage
Upto 750 V 500V
751V-2.5kV 1000V
2.501kV-4.5kV 2500V
4.501kV-18kV 5000V
If the readings are lower than those started above, dry the motror
before starting it.
MAINTENANCE
11/11/2010
10 – MACHINE DRYING
10.1 - Drying
Connect the stator to a three-phase power supply of at most 10% of rated

voltage.
During the drying process, use stator temperature probes or a thermometer

to monitor the heating of the stator windings. The temperature is not to ex-
ceed 80°C.
Once drying is complete, disconnect the power supply and allow the motor
to cool to room temperature. Check the resistance values again, and if the
measured value is correct, the normal power supply may be connected
ready for start-up. If the value is not correct repent the procedure and check
again.
10.2 – Insulation resistance levels
Insulation measurements are to be made at three-hours intervals. Readings

are taken after disconnecting the power supply from the stator and following
the procedure described in the paragraph headed "Stator insulation mea-
surements".
At the stator of the procedure, the insulation resistance will decrease, before
gradually rising.
The drying procedure should be stopped two or three hours after the insula-
tion resistance reaches the required value.
The drying process may be quite slow (up to 48 hours).
It should be noted that the insulation resistance reading measured after the
machine has cooled may be higher than the value obtained with the ma-
chine hot at the time when drying was stopped.
MAINTENANCE
11/11/2010
10.3 – Heating elements
The heaters should not be left energized while the motor is running.
The purpose of the heating elements is to keep the motor warm enough to
prevent internal condensation.
Refer to the electrical connection diagram enclosed with the motor when
wiring the heating elements.
The thermal equilibrium in the motor may be upset by leaving the heating
elements switched on while the motor is running.
Note : The heaters should also not be left energized during the alignment
period.
MAINTENANCE
11/11/2010
11 – CHECKS PRIOR TO START-UP
Rotor is unlocked in axial direction (No thrust bearing)

The coupling used is to be fitted with axial play limitation device (± 0.5 mm)
During motor installation on site, it is mandatory to place motor/rotor to get
right size “X” (or”Y”). According to special label fitted on motor and as in-
dicated in workshop tests report.
11.1 – General electric motor start-up conditions for every electric motor
Before starting the motor, check that :
• The driving and driven machines are correctly coupled and fixed together.
• The safety covers on moving parts are fitted, in position and fixed to the
floor or a fixed object.
• Nobody is working on either the driving or driven machine.
• There are no loose objects in or on the driving or driven machine.
• The complete installation is suitable for the starting of the electric motor.
• The frame is correctly earthed, offering proper protection for workers.
• The electrical power and instrument connections comply with the wiring
diagram.
• The insulted bearing (s) is (are) correctly insulated.
• The power cables are correctly fitted to the motor terminals.
• All the protection devices (thermal, electrical, etc.) are operational and
correctly calibrated.
• The fluid systems have been connected and tested, and are fully opera-
tional.
• The diaphragms for every forced oil bearings have been correctly drilled
and fitted, and oil circulates efficiently.
• Water circulates in the water coolers and bearing cooling coils (sleeve
bearings cooled by water coils).
• Covers and inspection hatches are closed.
• Bearing oil tanks are filled in accordance with oil level instructions (oil bath
sleeve bearings).
• The protection degree and the certification level of the electrical motor
and all accompanying equipment is suitable for the risks and conditions
of the area in which it is to operate.
MAINTENANCE
11/11/2010
11.2 – Equipment located in hazardous areas
11.2.1 - General remarks
These motors may under certain circumstances produce sparks while starting.
Motors must always be scavenged before starting the motor, even after brief
accidental stoppages.
Where MARATHON has fitted a scavenging or pressurisation monitoring sys-

tem, the specific instructions contained in the appendix to this handbook
must be followed.
11.2.2 - Safety equipment - EEx "e"; Ex "N"; Ex "n"; Cl1 div.2 (IEC area 2 NEC
Class1 division 2)
These motors must be scavenged in accordance with the figures listed in the
table below and on the marking plate fixed to the motor frame.
It is essential to check that scavenging proceeds correctly. Such checks should form
part of the motor start-up logic. This logic is to be checked prior to all scavenging
procedures.
Motor Scavenging flow (m3/h) Scavenging (min)

FL 30 15
F3 60 30
N3 ≤ 630 60 30
N3 > 630 140 30
11.2.3 - Safety equipment - equipment - EEx "p" (area 1 or 2 )
The scavenging and pressurisation criteria indicated on the classification

certificate and the marking plate fixed to the motor frame must be res-
pected
The motor must always be stopped immediately in the event of a pressuri-

sation fault.
MAINTENANCE
11/11/2010
It is essential to check that scavenging proceeds correctly. Such checks

should form part of the motor start-up logic. This logic is to be checked prior
to all scavenging procedures.
MAINTENANCE
11/11/2010
12 - START-UP
12.1 – Checks during start-up
Once all the criteria described in the section headed "Checks prior to start-
up " have been met, the motor can be started.
As the motor begins to turn, check that.

• The motor is turning in the right direction;
• There are no abnormal vibrations on the bearings : immediately after start-
up, after 1 hour and after 4 hours running.
• There are no abnormal temperatures on the bearings or housing bearings.
• There are no abnormal noises.
Check the bearing temperatures after, 1, 2, 4, 8, 12, and 24 hours operation,

and log these temperatures on the installation report.
In the event of an anomaly, refer to the section headed "Troubleshooting
procedure".
12.2 – Ongoing checks
The readings given by the safety devices (temperature, vibration and

speed sensors, etc.) must remain within the set limits, in accordance with
the wiring diagrams appended to this handbook.
The service and safety settings appear on these wiring diagrams.
MAINTENANCE
11/11/2010
13 – GENERAL TROUBLESHOOTING PROCEDURE
PROBLEM DIAGNOSIS SOLUTION

Motor does not turn. No power. Check fuses, power ca-
ble and especially ter-
minals.
Motor does not start a) Too much resistance; Disengage motor and
under load ; high drive machine jammed; run it under no load.
magnetic noise le- binding rotor;
vels.
b) Voltage too low; possibly Measure supply voltage
less magnetic noise. as motor is started.
Motor starts but a) Noisy bearing. Grease bearing and
makes abnormal check alignment.
noise.
b) Excessive bearing vibra- Grease bearing, check
tions. alignment and check
shaft line balance.
c) Moving part rubbing on Check dimension "X"

static part. and check that fan is
not binding on air
guide.
Motor overheats dur- a) Wrong direction of rota- Check phase sequence
ing no – load operation. direction.
tion.
b) Air inlets blocked. Free air ducts.
c) Water system incorrectly Restore adequate wa-
connected. ter flow.
Motor overheats un- a) Motor overloaded. Reduce load.
der load.
b) Inadequate cooling. Check cooling system.
MAINTENANCE
11/11/2010
14 - MAINTENANCE
It is important to draw up a routine maintenance schedule so as to ensure

the correct running of the motor. All work undertaken is to be logged in a
maintenance record ; this record will be useful not only to be customer, but
also to the manufacturer.
Except where otherwise specified in the contract, a full inspection is be car-

ried out at least twice a year. (or after 4,000 service hours).
14.1 - Criteria for proper machine operation
• Air inlets to be kept clear ;

• Correct fluid flows (air, water & oil);
• Motor is to be frost - proofed (cooling system water, bearing oil);
• Bearing housings to be kept clean;
• Cooling air circuits, including the cooling fins; fan inlet mesh is to be kept
clean;
• Filters in good condition;
• Safety devices operating correctly;
• All criteria set out in contract to be respected.
14.1.1 Checkpoints for Examination of an electrically isolated motor

• Isolate the motor from the supply and open the terminal enclosure. Check
that the main connections are tight and there are no signs of over heating
or burning.
• Winding should be healthy enough. Typically accepted PI value should not
be less than 1.5; PI = IR 10min/IR 1min for a motor to run successfully.
• Check the bearing insulation if fitted. Electrically separate the coupling
halves and slacken the earth screws from the DE bearing. Use a 100Volt
range multimeter or a high input impedance meter to measure the insula-
tion resistance between the motor shaft and the frame, which should be
at least 1 k ohms. If the test is satisfactory, tighten the earth screw.
• Relubricate the bearings. The lubricant type and the quantity per bearing
will be given in the nameplate of the motor. For grease lubricated bear-
ings, before a new change of grease make sure that the grease nipple is
clean and if it is damaged, replace the same. The old grease will be
ejected from the bottom of the housing when the motor is run. Over greas-
MAINTENANCE
11/11/2010
ing may cause the bearing to overheat. For plain bearings, check the oil
levels at the sight of the window glass.
• Check that the holding down bolts are tight, replace the fan cowl and
check the fan clearances, re assemble the coupling (if appropriate) and
all other parts that were dismantled.
14.2 - Anti - friction bearing lubrication
A plate indicating greasing intervals and grease quantities and qualities is

fixed to each bearing (figures may vary between bearings).
These instructions must be respected.
We recommend using the grease specified on the plate or any equivalent,

miscible grease.
The recommended lubricants and equivalencies are valid for ambient

temperatures of -20°C a +40°C. For temperatures outside this range, refer
to specific information in contract.
14.2.1 - Equivalency chart
• Mobil Oil : Mobilux n° 2 or 3

• Esso Standard : Esso Beacon n° 2 or 3
Roller Grease 2
• Esso : Unirex N3
• Caltex : Caltex Régal Starfack Special
• Hougton : Cossolube n° 2
• Antar : Antar RT 33
• BP : BP Energrease LS 2 or 3
• ELF : Rolexa 2 or 3
• Total : Multis EP 1 or EP 2
• Shell : Albida RL 2
Alvania G3
MAINTENANCE
11/11/2010
14.2.2 - Greasing instructions
14.2.2.1 - Importance of correct greasing
Anti - friction bearings must be greased progressively, if possible at low

speed, over a period of several minutes, for a better initial distribution of the
grease.
The following list points out the risks associated with over - hasty, excessive or
poorly implemented greasing procedures :
• Grease leaks past baffles due to excessive grease pressure within the bear-
ing (over - hasty greasing or excessive grease).
• Bearing temperature increases of 10 to 25°C (or more) over normal operat-

ing temperatures, until the excess grease is expelled.
• Surplus grease may produce a braking effect in the ball races, which
might cause moving parts (ball and rollers) to shift from their raceway,
leading to heating, intermittent noises and bearing wear (scaling, micro -
seizures), as well as loss of grease performance (shearing in the lubricant
film and localised excessive grease temperatures in the affected area, or
grease pollution caused by metal particles breaking away from the unlu-
bricated area).
• Seizing of the bearing within a few minutes following lubrication, especially

at rotation speeds above 3000 rpm.
These risks are aggravated where :
• Grease is injected too quickly (continuous injection);
• There is little internal radial play within the bearing (small ball bearings);
• The motor operates at high speed (3000-3600 rpm).
14.2.2.2 - Bearing commissioning and servicing
When the motor is commissioned, inject two "doses" of grease at five minute
intervals. The quantity of greases is indicated on the marking plates on the
bearing, unless bearing noises typical of insufficient initial greasing can be
heard, do not re-grease for 24 hours. Several hours are required for the disc to
expel all the excess grease (especially from the bearings on vertical shaft
motors).
MAINTENANCE
11/11/2010
24 hours later, inject one further dose of the recommended grease. After two
weeks in service, inject one dose of the recommended grease, followed by a
second dose 24 hours later.
Thereafter, follow the normal servicing plan indicated on the plates on the
bearings (grease quantities & intervals). Under severe operating conditions,
e.g. bearing temperatures above 80°C, the greasing intervals can be halved.
14.2.2.3 - Greasing instructions
a) Calculating the number of pump strokes per dose of grease.
So as to inject the exact quantity of grease specified on the marking plates,

carefully check and calibrate the quantity of grease injected by the grease-
gun. For example, weigh the results of 10 pump strokes :
• W = Weight of 10 pump strokes of grease
• Q = Specified quantity of grease (dose)
• n = number of pump strokes for one dose (Q)

• n = ( 10xQ ) / W )
b) Greasing procedure
The grease nozzle should be cleaned in order to avoid injecting dirt or foreign
particles into the bearing lubrication circuit. Similarly, both the grease-gun
and grease should be clean.
The general conditions required for a good greasing operation are as follows
:
• leave at least 5 seconds between every gram or cm3 of grease injected,

where the motor speed is less than 3000 rpm.
• e.g. 1 pump stroke = 4 g. Therefore 4 g x 5 sec = 20 second gap between

pump strokes.
• leave at least 30 seconds between every gram or cm3 of grease injected,

where the motor speed is around 3000 rpm or higher, with no more than 5
g of grease injected at a time.
These general greasing instructions may, however, be refined for specific mo-
tor types :
MAINTENANCE
11/11/2010
c) Continuous operation constant speed motors
If there is no means of varying the motor speed, nor halting production (con-
tinuous operation), the following criteria MUST be respected :
• Leave at least 5 seconds between every gram or cm3 of grease injected,

where the motor speed is less than 3000 rpm.
• Leave at least 30 seconds between every gram or cm3 of grease injected,

where the motor speed is around 3000 rpm or higher, with no more than 5
g of grease injected at a time.
We emphasise that by failing to respect these conditions when greasing at

3000 or 36000 rpm, there is a serious risk of bearing damage (rapid heating,
seizing, etc…). It is therefore very important to respect the set pauses be-
tween each injection of grease, and the limit of 5 g or 5 cm3 per stroke.
d) Constant speed motors with short post-shutdown stopping times
Where motors cannot be greased at low speed (constant speed motors

which stop too quickly after power is switched off), they should be greased
just prior to shutting down the motor. By this means, the additional heat in the
bearing caused by the greasing procedure will be dissipated while the motor
is stopped, thus avoiding damage to the bearings.
Constant speed motors running at less than 3000 rpm
Respect the following recommendations :
• Leave at least 3 seconds interval per gram or cm3 of grease injected.
• Wherever possible, minimise the time (< 1 min) between greasing each
bearing.
• After greasing the last bearing, wait 2 minutes before shutting down the
motor, to allow the grease to be distributed within the last bearing.
• Wait 45 minutes before restarting the motor, in order to allow the addition-
al heat due to the greasing of the bearings to be dissipated.
Constant speed motors running at around 3000 rpm or more
Respect the following recommendations :
• Leave at least 5 seconds gap per gram or cm3 of grease injected.
• Wherever possible, minimise the time (<1 min) between greasing each
bearing.
MAINTENANCE
11/11/2010
• After greasing the last bearing, wait 30 seconds before shutting down the
motor, to allow the grease to be distributed within the last bearing, but not
more than 30 seconds, owing to the additional heat generated in the
greased bearings.
• Wait 1 h 15 minutes before restarting the motor, in order to allow the addi-
tional heat due to the greasing of the bearings to be dissipated.
e) Variable speed and slow stopping motors
• Where the rated motor speed is less than 3000 rpm, the greasing proce-
dure should be carried out at between 30 and 60% of rated speed.
• Where the rated motor speed is around 3000 rpm or more, the greasing
procedure should be carried out at between 10 and 40% of rated speed.
This is possible on variable speed motors and slow-stopping motors as they fall
into the recommended speed range specified above when shutting down.
During greasing, at least 3 seconds pause per gram or cm3 of grease should
be left between strokes.
Variable speed motors
After greasing the last bearing, wait 10 minutes at low speed (as specified
above) to allow the grease to be properly distributed, before increasing
speed gradually. Where the rated speed is around 3000 rpm or more, wait 20
minutes at the corresponding low speed before gradually increasing speed.
Constant speed motors operating at less than 3000 rpm
After greasing the last bearing, wait 30 minutes before restarting the motor, in
order to dissipate the additional heating of the bearings due to the greasing
procedure.
Constant speed motors operating at around 3000 rpm or more
After greasing the last bearing, wait 1 hour before restarting the motor, in or-
der to dissipate the additional heating of the bearings due to the greasing
procedure.
MAINTENANCE
11/11/2010
14.3 - Sleeve bearings lubrication
14.3.1 - Bearing identification
Key to reading the plate located on the side of the bearing.
Example : E F Z L K 14 - 125
1 2 3 4 5 6
1 Type E
2 Bearing housing F = Flanged with fins
3 Heat dissipation
N = Natural cooling
Z = Constant flow externally cooled oil lubrication
W = Water cooled (oil cooling coil)
U = Forced oil circulation pump plus natural cooling
T = Forced water circulation pump plus water cooling
4 Bore type and lubrication mode

L = Cylindrical bore with free oil ring
5 Thrust bearing B = Smooth shouldered guide bearing with oil baths

(no thrust)
K = Bracket bearing (do not exceed thrust specified in
contract)
Q = No thrust
6 Bearing size and shaft diameter
14.3.2 - Self-lubrication by free oil ring
Motors are supplied without oil in the bearings. Bearings must be filled with
the motor stopped.
14.3.2.1 - Filling
The oil should match the grade specified on the marking plates fixed to the
motor and the equivalency chart below.
MAINTENANCE
11/11/2010
Bearings are filled via the hole in the oil ring inspection glass, which is located
at the top of the bearing.
The inspection glass should be removed with care, possibly using an adjusta-
ble pin spanner.
Fill with new oil.
To avoid adversely affecting the quality of the new oil filling the bearings,
which could result in premature bearing wear, take all necessary precautions
to prevent foreign matter (dust, grit, sand, water, grease, rags, paper, etc…)
from entering the bearing.
Check that the oil level lies in the middle of the oil gauge. The oil gauge is fit-
ted on one side of the bearing. This check should be made with the motor
stopped.
Replace and correctly tighten the filler plug.
14.3.2.2 - Oil change
ENVIRONMENTAL HAZARD
Do not throw used oil in nature.

Follow the oil manufacturer's instructions as to how to dispose of used oil.
Use a large enough container to allow all the oil to be drained.
Remove the sump plug at the bottom of the bearing (see cross-sectional di-
agram).
Replace the sump plug with a new seal, and tighten to the torque settings
given in the table below :
Bearing size 9 11 14 18 22 28
Torque setting in Nm 30 30 30 40 60 60
Drain oil while hot, in order to prevent oil deposits in the tank.
First oil change after 150 service hours.
Oil change interval : every 8,000 service hours.
MAINTENANCE
11/11/2010
14.3.3 - Forced oil lubrication
The oil should comply with the grade specified on the marking plates fixed to
the motor and the equivalence chart below.
14.3.3.1 - Oil supply
To avoid running the bearings dry, the lubricating system should be designed
to provide an adequate safety margin by operating for a long enough pe-
riod before and after starting and stopping the motor.
A half-moon plate fitted into the pipework at the oil outlet ensures a
minimum safe oil level. Under no circumstances should this
pipework be removed.
The oil pumping system must deliver the recommended normal flow of oil.
MAINTENANCE
11/11/2010
14.3.3.4 - Oil return
The oil drain pipework leading from the bearings to the lubrication systems
must not retain oil in the circuit.
The pipe should have a gradient of at least 15 %. Any obstacles in the circuit
may cause a rise in the oil level within the bearings and to oil leaks.
14.3.3.5 - Oil change
ENVIRONMENTAL HAZARD
Do not throw used oil in nature.
The lubrication system is to be entirely drained every 20,000 hours in accor-

dance with the manufacturer's instructions.
Follow the oil manufacturer's instructions as to how to dispose of used oil.
Draining both bearings
Use a large enough container to allow all the oil to be drained.
Remove the sump plug at the bottom of the bearing (see cross-sectional di-
agram).
Replace the sump plug with a new seal, and tighten to the torque settings
given in the table below :
Bearing size 9 11 14 18 22 28
Torque setting in Nm 30 30 30 40 60 60
Always run the lubrication system before starting the motor, in order to restore
a satisfactory oil level in the bearings (see paragraph headed "Oil supply").
MAINTENANCE
11/11/2010
14.3.4 - Lubricant oil equivalency chart
14.3.4.1 - Oil grade : ISO VG 32
Kinematic viscosity Dynamic viscosity

in centiStokes at : in centiPoises at :
40°C 50°C 60°C 50°C 60°C
AGIP
30 14.8 12.8
Ote 32
ARAL
32 22 19.3
Motanol GM 32
B.P.
32.6 21.9 15 18.7 12.7
Energol CS 32
CASTROL
32 15 12.6
Perfecto T 32
CHEVRON
32 16 14
Mechanism LPS 32
ELF
32 14.9 13
Elfolna 32
ESSO
30 23 14.4 19.8 12.4
Teresso 32
FINA
31 21 18.3
Cirkan 32
MOBIL
29.6 20.2 14.3 17.1 12.4
DTE Oil Light
SHELL
Turbo T 32 32 15.3 13.3
Tellus oil C 32 32 22 18.7
TEXACO
Regal R et O 32 32.5 14.5 12.2
Rando oil 32 32 21 17.8
TOTAL
32 16 13.5
Azolla ZS 32
MAINTENANCE
11/11/2010

40°C 50°C 60°C 50°C 60°C
AGIP
44 20 17.4
Ote 46
ARAL
46 30 26.5
Motanol HK 46
B.P.
47 30.7 20.5 26.3 17.4
Energol CS 46
CASTROL
46 20.4 17.2
Perfecto T 46
CHEVRON
46 22 19
Mechanism LPS 46
ELF
46 20 17.5
Elfolna 46
ESSO
44.7 30 19.6 26 17
Teresso 46
FINA
46 30 26.3
Cirkan 46
MOBIL
46 28.7 19 24.4 16.6
DTE Oil Medium
SHELL
Turbo T 46 46
20.1 17.6
Tellus oil C 46 46 30 21.9
TEXACO
Regal R et O 46 47.6
21.2 18
Rando oil 46 46 29 25
TOTAL
46 22 18.7
Azolla ZS 46
MAINTENANCE
11/11/2010

40°C 50°C 60°C 50°C 60°C
AGIP
64 27 23.6
Ote 68
ARAL
68 43 38
Motanol HK 68
B.P.
68 42.6 28 36.0 23
Energol CS 68
CASTROL
64 27 22.8
Perfecto T 68
CHEVRON
68 29 25
Mechanism LPS 68
ELF
68 28.9 25
Elfolna 68
ESSO
64 43 26.7 37 23.2
Teresso 68
FINA
69 44 33
Cirkan 68
MOBIL
63.9 41 27.2 35.1 23.8
DTE Oil Medium
SHELL
Turbo T 68 68
23.4 24.9
Tellus oil C 68 68 43 28.7
TEXACO
28.5 24.2
Rando oil 68 68 41 35.3
TOTAL
68 29 24.9
Azolla ZS 68
MAINTENANCE
11/11/2010
14.3.4.4 - Oil grade : ISO VG 100

40°C 50°C 60°C 50°C 60°C
AGIP
100 40 35.4
Ote 100
ARAL
100 61 54
Motanol HK 100
B.P.
96 67.6 38.55 59 33
Energol CS 100
CASTROL
96 38.3 32.3
Perfecto T 100
CHEVRON
100 41 36
Mechanism LPS 100
ELF
105 40.5 35.8
Elfolna 100
ESSO
Teresso 100 154
56 50
Nuray 100 100 59 53
FINA
107 65 58
Cirkan 100
MOBIL
DTE 27 100
53
DTE Vactra Oil 94 48 47.2
50
Heavy
SHELL
Turbo T 100 100
40 35
Tellus oil C 100 100 62 53.3
TEXACO
39.39 33.6
Rando oil 100 100 62 54.1
TOTAL
100 39 33.5
Azolla ZS 100
MAINTENANCE
11/11/2010
15. DISMANTLING
It is assumed that dismantling will be carried out in a workshop, so the first part of these
instructions covers the removal of the motors from its location.
Detach the main supply cables at a convenient point depending on the type of cable
box fitted. Label the phases, protect the cable ends and tie them out of the way and
off the floor. Remove and label all auxiliary cables and disconnect the earth cable or
braided wire.
Remove the coupling guard and separate the halves of the coupling. It is good prac-
tice to match-mark the halves with an ink marker or center punch.
Remove the dowels and the holding down bolts from the motor feet. Fit lifting eyes in
the two tapped holes on top of the motor frame and lift the motor clear of the ground.
If there are shims under the feet, leave them in position on the base or soleplate to sim-
plify re-assembly. Make sure no shims are stuck to the feet when the motor is lifted. Re-
move the motor to the workshop and set it down at a convenient height and in the
right direction to the travel of the crane.
Pull the half-coupling of the shaft, remove the key and tie it to the half-coupling.
Remove the heater-wiring cover plate at the top of the DE end bracket and discon-
nect the heater from the wiring in the motor frame.
Remove the DE end bracket fixing screws, leaving the end bracket supported with a
crane. Remove the four screws at 45 degree that hold the bearing inner cap to the end
bracket.
Support the shaft end on a wooden block or a jack and hold the end bracket on the
crane. Use two of the end bracket fixing screws in the threaded jacking holes to jack
the end bracket off the dowels. It will slide over the bearing outer race, leaving the
bearing and the bearing inner cap on the shaft.
Insert soft packing in the gap between the rotor and the stator and remove the shaft
support.
Remove and protect the shaft seal. Loosen the grub screw, which retains the grease
finger on the shaft, and pull the flinger-off using a claw clamp. Remove the bearing re-
taining circlip. Move the inner cap along with shaft clear of the bearing. Pull the bear-
ing off using a claw clamp. If the bearing is to be used again, the pressure to remove it
must be applied to the inner race only. Remove the inner cap.
For Flowpak Motor, remove the Fan Cowl at the NDE side. Remove the circlip and pull
off the Fan. Tie the circlip and the Fan Keys to the Fan.
MAINTENANCE
11/11/2010
Remove the end bracket fixing screws.
Remove the four screws at 45 degree that holds the bearing inner cap to the end
bracket.
Remove the heater wiring cover plate and disconnect the heater from the frame wir-
ing.
Support the shaft and remove the end bracket in the same way as the DE, noting that it
may be necessary to hold the rotor at the DE to prevent it sliding. A wavy washer is fit-
ted between the bearing outer race and the end bracket i.e. on the outside of the
bearing. It is fitted to allow for differential expansion between the shaft and motor
frame.
Remove the grease finger, circlip and bearing in the same way as the DE was remove.
Do not mix up components from the two ends.
Remove the rotor carefully from the stator, using a suitable piece of steel tube as a
shaft extension, and set the rotor down on soft packing.
Clean the stator and the rotor by blowing them out with clean dry compressed air at
not more than 175 kN/M (25 lb/square inch). If the winding is greasy, wipe the surfaces
with a cloth dampened with white spirit. If contamination is severe consult MARATHON
ELECTRIC MOTORS (INDIA) LIMITED, Calcutta Works.
15.1 RE ASSEMBLY
In general this is the reverse of that the dismantling procedure. Before, starting, make
sure all surfaces are cleaned off rust and dirt and are free of burrs. If the original bear-
ings are to be refitted, wash out all the old grease and make sure they are thoroughly
clean and dry. If new bearings are to be fitted, make sure that they are the correct
type.
Bearings are on an interference fit on the shaft and need to be warmed before they
are fitted. Approved methods warming are either to use a thermostatically controlled
oil bath or an induction-type bearing heater.
WARNING : Warming bearings by direct flame or gas rings is NOT permitted.
If an oil bath is used it should be large enough for the bearing to be raised off the bot-
tom and be totally immersed. There must be a means of lifting the bearing in and out
and draining it. Appropriate safety gloves must be provided for handling.
MAINTENANCE
11/11/2010
Preheat the oil bath to 100 deg. cent. immerse the bath and leave it in for at least 10
minutes. The protective grease on a new bearing can be left on as it will dissolve in the
hot oil.
Fit the NDE inner bearing cap. Remove the heated bearing from the bath, allow it to
drain briefly, then push it fully right on to the bearing seat. Hold it in place until the circlip
if fitted. Fit the flinger and tighten the grub screw. When the bearing has cooled, fill it
with grease from both sides.
Lightly grease the recess in the end bracket in which the outer race fits, insert the wavy
washer and slide the end bracket over the outer race. When the bearing has cooled it
should be an easy push fit. Bolt the end bracket and the inner cap altogether.
Fit the DE inner cap and the insulation washer Heat and fit the bearing, holding it in
place while the Circlip is fitted, fit the flinger and tighten the grub screw, when the bear-
ing has cooled, fill fit with grease from both sides.
Thread the rotor. Use a steel tube as a shaft extension and gently guide the rotor in.
Remove the tube.
At the DE screw two lengths of M12 threaded rod into two opposite holes in the bearing
inner cap to act as guide. Unscrew the pointed earthing screw in the DE end bracket so
that it will not touch the bearing outer race. Put the DE end bracket over the shaft end,
and then support the shaft end on a jack or a block of wood so that it can slide. Thread
the M12 rods through the corresponding holes in the DE end bracket, then case the
shaft along towards the DE and NDE end bracket can be located on its dowels and
bolted up. Tighten the screws evenly.
Locate the DE end bracket on its dowels, bolt it up and insert two of the bearing inner
cap screws into the two vacant holes and tighten them, spin the rotor and check for
satisfactory running. It is locked or stiff, something has been wrongly assembled which
must be investigated and corrected. Once satisfactorily, replace the two lengths of rod
by the two remaining screws and fit the bearing seals.
Check the axial float by loosening the DE end bracket and pushing the De of the shaft
against the way washer in the NDE bearing. There should be about 1.5 mm of move-
ment, which is best measured by making marks on the shaft where it emerges from the
NDE housing. Retighten the DE end bracket.
Connect the heater wiring and test it. Refit the bearing grease pipes and make sure
they are full of grease and not air. Refit the external fan and fan cowl. Check for clear-
ance and rubbing. Refit the half coupling.
Check the bearing insulation (if fitted) using multimeter. On the DE bearing make sure
the earthing screw is unscrewed and measure the insulation resistance between the
motor shaft and the frame. This should be at least 1 Kilo ohm. If this test is satisfactory,
tighten the earthing screw.
MAINTENANCE
11/11/2010
Return the motor to its location where it was dowelled in place and the shims under the
feet have not been disturbed. The alignment should be correct, but if there is any
doubt, align the motor as for a new one.
Connect the main supply, if there is any doubts, the direction of rotation being correct,
check it before reassembling the coupling guard. Reconnect the auxiliaries.
MAINTENANCE
11/11/2010
16 - AFTER SALES SERVICE
We provide the following services:
• Supply of replacement parts, which are fully compliant with our tech-
nical specifications. Only MARATHON can guarantee that parts are ful-
ly interchangeable and easily fitted using the technical, quality or spe-
cific instructions supplied with the parts.
We draw the customer's attention to the serious risks caused by not knowing
about or not following these instructions, especially where motors are to be
located in hazardous areas (zone 1 or 2).
o Supervision of installation procedures for our equipment.
o Commissioning of our equipment.
o Servicing and repairs, on-site or at our workshops, as appropriate.
o Recommended spares Flowpak 2 motors
1. External Fan
2. Bearings
3. Terminal Connector
4. Terminal Isolator
Please contact at : 09903900891/3/4
Email us at ananda.majumdar@marathonelectric.com

Flowpak HT MM REV

Uploaded by

Copyright:

Available Formats

You might also like

Flowpak HT MM REV

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Flowpak HT MM REV

Uploaded by

Copyright:

Available Formats

MANUAL FOR SAFETY,INSTALLATION AND

MANUAL FOR SAFETY,

INSTALLATION AND MAINTENANCE

FLOWPAK MEDIUM VOLTAGE

The personnel installing, commissioning and servicing the equipment MUST

Before working on the motor, always :

• Check that the electric power to the motor is cut.

1 - Definition of main graphical symbols ……………………………………..3-4

2 - Abbreviations and direction of rotation……………………………………5

4 - Receipt procedure ……………………………………………………..7

5 - Handling (motor in crate) ................................................................... 8

6 – Handling (handling diagrams) .......................................................... 9 to 10

9 - Stator insulation measurement .......................................................... 17

10 - Machine drying .................................................................................. 18-19

11 - Checks prior to start-up..................................................................... 20-21

15 - After sales service .............................................................................. 40 to 41

1 - DEFINITION OF MAIN GRAPHICAL SYMBOLS

Symbols concerning packaging and handling.

Key Symbol Meaning

iso 7000/n° 0622

iso 7000/n° 0623

iso 7000/n° 0624

iso 7000/n° 0625

DEFINITION OF MAIN GRAPHICAL SYMBOLS

Key Symbol Meaning

iso 7000/n° 0626

iso 7000/n° 0627

iso 7000/n° 0628

iso 7000/n° 0629

iso 7000/n° 0630

iso 7000/n° 0631

2 - ABBREVIATIONS AND DIRECTION OF ROTATION

CS : Coupling side OSC : Opposite side from coupling

The motor can only be operated in the direction of rotation for

Motors in seaworthy packaging

When shipped by sea, or where the motor is likely to be exposed to adverse

Except where specifically written in the contract, we recommend following

• Remove the crate lid

Check that appropriate handling equipment for the equipment, weights

In the event of anomaly :

Any signs of impact or damage must be indicated.

Slings are to be fitted as indicated by the markings on the packaging.

Under no circumstances should crates be overturned or carried on their sides.

Crates should be properly lashed to, prevent impacts and overturning.

Do not stack crates, to avoid damaging them.

The motor is supplied fully assembled.

Fragile equipment. Handle with care.

Refer to the enclosed dimensional drawings before moving the motor.

Example handling diagrams

Flowpak 2 vertical motor

7.1 – Storage instructions

The equipment is to be stored in a clean, dry and adequately ventilated

The equipment is to be stored at a temperature above -20°C, except where

The equipment is not to be placed directly on the ground, but on wooden

The equipment is not to be stored in a saline or corrosive atmosphere, except

8.1 - Motor positioning

The rotor locking device should be dismantled :