Installation and maintenance manual for Impak cage

and wound rotor induction motors

Frames 355, 400 and 450
Electric motors produced by MARATHON ELECTRIC comply with all Indian Standard
requirements relating to such machines, and to specific customer requirements.

The motors are carefully inspected and individually tested before despatch to ensure that
they comply with the requirements of the relevant specifications in respect of both
electrical and mechanical features, and that they are safe in operation.
This manual covers the installation and maintenance procedures to be adopted for CACA
cage and wound rotor induction motors, and should be read carefully before installing
and commissioning the machine. Additional guidance may be obtained from the following
publications:
IEC Recommendation BS EN 60034-1 : Rating and performance’.
IS325 : 1996 ‘Three Phase Induction Motors – Specification’

MARATHON ELECTRIC MOTORS (INDIA) LIMITED

DHQ
58,Taratala Road, Kolkata – 700024
Tel : 24695560/61/65/66
Fax : 2469 8530/24695369
Contact for Service – Ananda Majumdar, Cell 09903900891
ADDENDUM TO PAGE 10 OF PUBLTCATTON C51 F11

GREASE LUBRICATED BEARINGS –VERTICALLY MOUNTED MOTORS.

The top and bottom bearing assemblies, of motors in storage for two years or more, should be
dismantled immediately prior to installation, as there is a possibility that the Degraded grease will
not be expelled by the grease relief system.

As much as possible of the old grease should be removed by hand. If separation of the oil and the
base has occurred all traces of the old grease must be removed in a degreasing plant, care being
taken to ensure absolute cleanliness.

The dismantling re-greasing and re-assembly procedures are given on pages 33-38 and a copy of
QA4910, which details the squareness and clearance checklist for duplex bearings, is included as
an addendum to page 38.

ADDENDUM TO PAGE 38 OF PUBLICATION C51F11

MARATHON ELECTRIC MACHINES

QA4910 (10/82)

SQUARENESS AND CLEARANCE CHECKLIST FOR DUPLEX BEARINGS

 Index
Page
Receipt and storage..................................................................................................................................... 5
Lifting and handling ..........................................................................................................................................5
Conditions of storage ........................................................................................................................................5
Preparation for storage ......................................................................................................................................6
Care of bearings.................................................................................................................................................6
Shaft clamps ......................................................................................................................................................6
Windings ............................................................................................................................................................6
Brushgear ..........................................................................................................................................................7
Storage after installation ....................................................................................................................................7
Pre-commissioning....................................................................................................................................... 8
General..............................................................................................................................................................8
Insulation resistance testing...........................................................................................................................8
Auxiliary circuits .................................................................................................................................................8
Safety precautions .............................................................................................................................................8
Methods of test...................................................................................................................................................8
Recommended minimum value (Rw) .................................................................................................................9
Polarisation index...............................................................................................................................................9
Drying out .........................................................................................................................................................9
General ..............................................................................................................................................................9
Methods of drying out.........................................................................................................................................10
Grease-lubricated bearings-horizontal and vertical mounting machines...................................................10
Oil-lubricated bearings-horizontal mounting machines ...............................................................................10
Oil-lubricated bearings-vertical mounting machines....................................................................................10
Recommended lubricants and capacities...........................................................................................................10
Installation ..................................................................................................................................................... 14
Location .............................................................................................................................................................14
Foundations .......................................................................................................................................................14
Alignment-horizontal mounting machines ..........................................................................................................14
Pulley drives.......................................................................................................................................................14
Direct-coupled drives .........................................................................................................................................14
Belt and coupling guards....................................................................................................................................15
Alignment-vertical mounting machines...............................................................................................................15
Dowelling of machines .......................................................................................................................................15
Connection to supply-cage motors.....................................................................................................................16
Connection to supply-wound rotor motors..........................................................................................................19
Desiccators units................................................................................................................................................19
Methods of starting.............................................................................................................................................19
Routine maintenance.................................................................................................................................... 20
General ..............................................................................................................................................................20
Cleaning.............................................................................................................................................................20
Grease-lubricated rolling bearings .....................................................................................................................20
Oil-lubricated rolling bearings.............................................................................................................................20
Disc-lubricated plain bearings-horizontal machines only....................................................................................21
Terminal Box ......................................................................................................................................................21
Drying out desiccators........................................................................................................................................21
Brush gear, brushes & slip-rings ........................................................................................................................22
Summary of routine maintenance ......................................................................................................................22
Overhaul – dismantling and reassembly .................................................................................................... 23
General..............................................................................................................................................................23
Terminal Box ....................................................................................................................................................23
Bearings and end brackets-horizontal foot mounting machines.................................................................25
Grease lubricated bearings ................................................................................................................................25
 Oil-lubricated rolling bearings with CIRCON system ..........................................................................................28
Disc-lubricated plain bearings ............................................................................................................................31
Bearings and end brackets-vertical mounting machines.............................................................................32
Removal of top bearing and bracket (non-drive end) .........................................................................................33
Removal of bottom bearing and bracket (drive end) ..........................................................................................35
Removal of rotor.................................................................................................................................................37
Reassembly of bearings and brackets ...............................................................................................................37
Brushgear ......................................................................................................................................... 39
General ..............................................................................................................................................................39
Number 3 brushgear ..........................................................................................................................................39
Number 4 brushgear ..........................................................................................................................................40

Receipt and storage

The following general instructions should be read in
conjunction with any specific data applicable to a
particular order. Each machine is thoroughly inspected
and tested before leaving the works and every care is
taken to ensure safe transit to its destination. Damage
Lifting and handling
may however occur during transit and the machine
should be inspected on receipt. Any damage or defect
should immediately be reported to both the carrier and
supplier.

All impak motors are provided with lifting lugs or

trunnions, suitably positioned to allow safe lifting of the
machine.
Vertical mounting machines should be lifted using a
beam and vertical chains or ropes to each of the two
trunnions as shown.
Horizontal mounting machines should be lifted using four
chains, one to each lifting lug. Must machines will be
fitted with a top cover, which must be protected from
damage, during lifting, by fitting load spreaders between
the chains and the cover.

Table 1. Approximate standard motor mass (net kg)

Foot mounting – rolling bearings
MARATH Cage motors Wound rotor motors
ON
ELECTRI
C
Style IP22S IP44 IP22S IP44
IC01 IC0161 IC01 IC0161
355-6B -- 1520 -- --
355-7B 1500 1660 - --
355-8A -- -- 1875 2065
355-8B 1950 2100 2055 2245
355-9B 2110 2420 2225 2580
400-3A 2840 3160 3000 3370
400-3B 3020 3340 3180 3555
400-3C -- -- 3265 3635
450-3A 3600 3840 3845 4150
450-3B 3860 4100 4025 4335
450-3C 3950 4190 4110 4415
450-4A 5850 6500 6200 6890
450-4B 5850 6500 6200 6890
Conditions of storage
Motors should be stored in a plain, dry, well-ventilated
store with temperature and humidity not in excess of
Preparation for storage
Project all shaft extensions, exposed keyways, half-
couplings, jacking screws and any other unpainted
surfaces with an anti-rust preparation. Where a shaft-
locking device has been fitted, this must be left in
position until the motor is installed, apart from its
temporary removal in order to rotate the shaft as
indicated later.
Care of bearings
Rolling bearings
If a motor fitted with rolling bearings is subjected to
vibration for long periods while stationary, damage to the
rolling elements and races may be caused by fretting
corrosion (commonly called ‘stationary vibration’). The
following precautions are to be taken to prevent this :
1. The motor should not be placed on a vibrating
floor.
2. The shaft should be turned through at least a
quarter of a revolution each week.
3. If storage on a vibrating floor cannot be avoided,
the motor should be placed on thick blocks of
rubber, cork or felt.
Grease-lubricated rolling bearings
These should be overfilled with an approved grease (see
‘Grease’ page 12). This will prevent moisture entering
the bearings and any surplus grease will be forced out
when the machine is started. Every 12 months inject
fresh grease into the bearing assembly.
Plain bearings
Shaft clamps
Where a shaft clamp has been fitted to prevent axial
shaft movement during transit, this should be left in
position. The motor should still be placed on rubber
blocks if necessary, and the clamp removed every 3
months to allow shaft rotation which will re-distribute the
20°C and 75% respectively. They should not be
subjected to contamination form dust, dirt, or oil.
Inspect all exterior paintwork and touch-up where
necessary. Lift the brushes on slip-ring machines and
apply self adhesive tape to the rings.
Stand vertical machines on substantial stable packing
with the shaft axis vertical and shaft extension clear of
the ground.
Although stationary vibration should not normally be a
problem with plain sleeve bearings, precautions should
still be taken to isolate the motor from any external
vibration, by standing it on rubber blocks, if necessary.
Where lubricant is fed from an external sources, seal
inlet and outlet flanges to prevent ingress of
contamination.
Bearings housings should then be filled with either one
of the recommended oils (see ‘Oils’ pages 12 and 13) or
with a turbine oil of any viscosity grade. The method of
filling should follow the procedure detailed for the
appropriate type of bearing ( see pages 11 and 12).
In all cases, after filling, the shaft should be turned at
least 10 revolutions. Every 3 months the shaft must be
turned (at least 10 revolutions) to re-establish the
protective film of lubricant.
lubricant. When refitting the shaft clamp use a torque
spanner to obtain the following torque values:-
M 8 nuts - 2, 6 Nm
M 10 nuts - 2, 6 Nm
 M 12 nuts - 5, 7 Nm
Windings
Temporary covers should be fitted to all terminal box or
sealing chamber openings. Heaters, if fitted, should be
energised to prevent condensation if a suitable supply is
available during the storage period.
The insulation resistance should be checked at 3
monthly intervals using a Megger. (For preferred
voltages see page 8). Take individual phase valus to
earth and measure between phases if permitted by the
winding connection.
Brushgear
On slip-ring machines fitted with a short-circuiting device
(brush-lifting and /or short-circuiting gear), operate the
Storage after installation
If a motor is first coupled and commissioned and then
not required for a considerable period the preceding
conditions still apply, and the machine should be treated
as though it were in storage. It nust be isolated from all
sources of vibration, excess humidity and atmospheric
pollution. If vibration is present the motor should
The safety precautions and methods of test are
described under ‘Insulation Resistance Testing’ on
pages 8 and 9. The associated temperature at the time
of test should be recorded.
It is important to remember that the winding should be
completely discharged by earthing after each insulation
test.
mechanism at each winding inspection. Check that the
surface of the rings are fully protected by adhesive tape.
uncoupled and rubber blocks placed under the feet.
Before lifting the motor, two of the feet should be
dowelled to facilitate replacement. Alignment should be
re-checked before starting up. It is essential that the
rotor be turned every 3 months as described previously,
after uncoupling if necessary.
Pre-commissioning
General
Remove rust preventative from shaft extensions,
keyways and half-couplings using petrol or white spirit
(observing all relevant safety precautions when using
these volatile cleaning agents). All exposed insulated
surfaces such as terminal arrangements or brushgear
should be wiped clean with a lint-free cloth.
Contaminants should be removed with a solvent such as
ICI ‘Genklene’. If the machine is slip-ring version,
remove adhesive tape from slip-rings and clean, check
the operation of brushes which should slide freely in their
Insulation resistance
The insulation systems used on the windings of modern
machines are designed to give reliable service life under
the specified operating conditions. Certain basic
precautions must be taken to ensure that the integrity of
the insulation is maintained during periods when the
motor is in storage, under installation, or not operating.
These precautions have already been outlined in the
section ‘Windings’ on page 6. To ensure that insulation
has not degraded due to moisture absorption during long
outage periods it is essential to check its resistance
value.
Insulation resistance tests are carried out normally using
a d.c. tester or ‘Megger’. For polarisation index values to
be taken, the equipment must be capable of supplying a
steady voltage for 10 minutes.
The preferred d.c. test voltages for machines of various
voltages are given below:
Auxiliary circuits
The insulation resistance of all auxiliary circuits other
than bearing temperature detectors must be measured
with a 500V Megger. Measurements on bearings
Safety precautions
Before attempting any insulation resistance test it is
essential to earth the frame of the machine and any
holders, and ensure that the tensioning device operates
freely and is set to the correct tension. See page 22.
Inspect and operate any brush lifting or short-circuiting
device and lubricate if necessary. Do not over-lubricate.
Turn the rotor by hand to ensure that there are no
obstructions, check the condition of sealing gaskets in
the terminal enclosure, and remove any temporary seals
added for storage purposes.
Machine voltage d.c. test voltage
Up to 660V 500V
661 to 4160V 1000V
4161 to 6600V 2500V
6601-110000V 5000V
Before carrying out the test, the surface of the windings
should be clean and dry. In the case of a new machine,
which has been properly stored, contamination should
not be present, but for re-built motors that have been in
service for some years the windings should be cleaned
in accordance with the instructions given under
‘Cleaning’ page 20.
temperature detector circuits must be made at a voltage
less than 100V e.g. by use of an AVO.
parts of the winding not being tested, including all
auxiliary circuits.
Dry insulation with a high resistance is capable of
holding an electrical charge for several hours after
removal of the applied voltage.
Methods of test
On low voltage machines (up to 660V) disconnect all
supply cables, and terminal links where fitted, from the
machine before carrying out the test, to eliminate the
possibility of false readings.
On high voltage machines (above 660) the insulation
resistance can be measured at the control gear. If the
recommended minimum values are not obtained the
supply cables must be disconnected and the test
repeated.
For reasons of both safety and accuracy it is essential
that the winding under test is adequately earthed both
before and after the application of the test potential. 15
minutes is the recommended minimum time.
is not possible to separate individual phases then the
formula must be applied directly.
The duration of each test is one minute at the end of
which resistance reading R1 is taken. If resistance
reading R! is below the recommended medium value.

Insulation resistance should be measured between each

individual phase and earthed with the remaining phases
earthed. The insulation resistance (Rph) of one phase to
earth on a three-phase winding is approximately twice
that of the complete winding, therefore the measured
value must be divided by two to obtain a figure for
comparison with the value Rw recommended. Where it

Recommended minimum value

The recommended minimum value Rw for the winding

can be calculated from the following formula:

Rw = Pt (kV + 1) Megohms

Where kV = Line voltage (in kilovolts)

Pt is a factor dependent on the condition of the winding

and on the ambient temperature at which the test is
carried out, but for reasons of safety the pity factor itself
should be limited to a minimum value of 1.

Values of Pt are shown in Fig 1.

The value of Pt must be decided by considering the age

and amount of contamination on the machine end-
windings, condition (A) should be adhered to for all new
machines whereas condition (C) should be considered
as the minimum value for an old machine.
Polarisation index

The polarisation index of a winding is defined as the ratio
of the insulation resistance after 10 minutes (R10) to the
insulation resistance after one minute (R1).
i.e. Polarisation index (P.I.) = R10/R1
On a clean dry winding the index value should not be
less than 1,5. Where a winding has a satisfactory
polarisation index but a value of insulation resistance R1
Drying out
General
When the results of the insulation resistance and
polarisation index tests indicate that a dry-out is
necessary then the moisture should be removed by one
of the methods specified in ‘Methods of drying out’.
In order to ensure that a satisfactory final result is
achieved the most important factors to watch are:
(a) The rate of temperature rise during the initial heating
period when moisture may be trapped inside the
winding, and
(b) The maximum temperature of the dry-out.
Where a winding has been allowed to get damp due to
moisture pick-up from a highly humid atmosphere, then
the rate of temperature rise should be limited to
approximately 10K per hour.
Where a winding has been soaked thoroughly with water
then the rate of temperature rise should be limited to 5K
per hour, otherwise damage to the insulation can occur.
In general when using direct heating of the winding by
passing current, the temperature should be raised to
approximately 85°C, as measured by thermometers
attached to the end-windings, or 90/95°C when
measured by embedded temperature detectors (ETDs)
located in the slot separators between coil sides in the
core.
below the recommended minimum Rw, then the winding
can only be considered acceptable provided that the
resistance value R10 is greater than the recommended
minimum. If neither of these conditions is satisfied then
the windings should be dried out in accordance with the
following procedure.
Once the maximum temperature is reached it should be
maintained throughout the dry-out period. To ensure that
the moisture is effectively removed there must be free
circulation of air around the windings. On totally-
enclosed machines covers must be opened to allow
continuous interchange of air.
A convenient method of following the progress of the
dry-out is to take insulation resistance readings (R1 and
R10) at regular intervals and to plot them, along with the
calculated value of polarisation index and winding
temperatures, on a chart as shown on Fig. 2. For damp
windings readings should be taken every 1 or 2 hours.
On grossly contaminated windings the dry-out will be
slower and the intervals may be increased to 4 to 8
hours.
The dry-out process should be continued beyond the
time of which the insulation resistance has started to
increase, and heat should be maintained until the
insulation resistance is above the minimum acceptable
value obtained from Fig. 1 for the temperature at which
the dry-out is being carried out, and preferably until three
consecutive measurements indicate that R1 has reached
a steady value. Polarization index is not substantially
affected by temperature and hence a value of 1,5 would
be achieved.

With machines which have been immersed in water, a

careful watch should be kept on the winding --
particularly at the positions where the leads enter the coil
-- to see if amy actual drops of water come out. If these
are observed before the maximum temperature is
reached, then the rate of temperature rise should be
reduced to approximately 2K per hour to permit the
moisture to evaporate without ‘blowing’ the insulation.
Methods of drying out
Space heater
Electric space heaters may be useful for drying out
windings where the moisture is on or close to the surface
of the outer layer of insulation. However, if the moisture
has penetrated the winding, especially on old machines,
then the method is unlikely to be successful on its own.
Heaters should be located in the air spaces under the
machine end windings and sited so as to allow even
distribution of heat throughout the end windings and
core. A clearance of not less than 300 mm must be
allowed between any high temperature heater and the
nearest part of the winding, otherwise scorching may
occur. The machine should be lagged with temporary
covers to limit convection and give more uniform
heating.
Where possible all phases should be connected in series
using copper strip or cable of adequate section to carry
the full-load current.
Initially the value of current should be set at
approximately 15% of the full-load rating and adjusted as
the temperature rises to follow the heating schedule. The
supply and any external cables must be disconnected
before any insulation resistance readings are taken.
MARATHON ELECTRIC Ltd. have facilities available for
overhaul, drying out and testing of rotating electrical
machines, either on or off site in accordance with the
principles set out in this section.

Low voltage heating

Where a controllable low-voltage a.c. or d.c. supply is

available then this may be used for drying out stator
windings (with or without the rotor in position).

Grease-lubricated bearings – horizontal and vertical mounting machines

Machines will already have been over-filled with grease
prior to storage, but further grease should be added as
soon as possible after the machine is started. Surplus
grease will be expelled into the grease tray on horizontal
machines or the excess grease chamber on vertical
machines.

Oil-lubricated bearings – horizontal mounting machines
Rolling bearings using the CIRCON® system
On horizontal machines, the constant-level lubricator is
mounted adjacent to, but separate from, the bearing
housing assembly. See Fig. 6. To fill the assembly
proceed as follows:
1. Remove the overflow plug from the overflow pipe or
bearing housings.
2. Remove the filler pipe cap and clean out the end of
the pipe.
3. Remove the oil reservoir by depressing and turning
the protective cover to release the bayonet-type
fixing.
4. Pour oil steadily down the filler pipe until the
indicated oil level is slightly below the horizontal
centre line of the sight glass (located on oil reservoir
base). Allow time for the oil wetted surfaces of the
bearing housing to drain. Check that the oil level is
still below the centre line of the sight glass.
5. Replace the plug in the overflow pipe or bearing
housing.
6. Fill the oil reservoir and replace, taking care that oil
from the bottle does not escape into the bearing
housing before the reservoir is finally assembled.
There is an integral flap valve designed to retain the
oil when the glass reservoir is inverted.
Fig.5 A general view of a duplex bearing on an IP22
vertical mounting motor showing lubrication point.(Right-
hand side looking at non-drive end). The lubrication point
is also accessible on IP44 motors.
7. Check that the indicated oil level is at the centre line
of the sight glass, if the level is too high drain off
excess oil by removing the overflow plug.
8. Replace the filler pipe cap.
Disc-lubricated plain bearings
Disc-lubricated plain bearing assemblies are filled via
either of the two filling plugs on the top half bearing
housing. If the bearing has been filled with oil for storage
purposes it should be drained, or flushed with lubricating
oil if the bearing is empty as shipped from MARATHON
ELECTRIC Ltd. Pour in oil slowly until it reaches the
indicated limit shown on the ‘standing’ oil level
indicators, situated on each side of the lower half
bearing housing. Take care not to introduce any oil into
the top reservoir as this could result in the bearing
housing being overfilled.
When the motor is started the level of oil in the ‘standing’
oil level gauges will fall, indicating that rotation of the oil
disc is raising oil from the lower to the upper reservoirs
where the oil level will be seen to rise above the
minimum indicated level on the ‘running’ oil level
gauges.
This circulation of oil will be maintained while the motor
is running. When the motor is stopped the oil will slowly
drain back to the lower reservoir and the oil level will rise
back to the original ‘standing’ level. This could take
several hours.
Do not attempt to fill to the ‘standing’ level while the
motor is running or flooding and leakage will occur.
These instructions apply to standard bearings with available for bearings with oil-flow cooling from an
natural or water cooling. Special instructions are external source.

Oil-lubricated bearings – vertical mounting machines

On vertical mounting machines, the oil reservoir is
integral with the housing assembly, (see Figs. 8, 9 and
10) and the filling procedure is as follows:-
1. Remove filler plug and clean.
2. Pour in oil steadily until the level is in line with the
mark on the sight glass.
3. Replace filler plug.
Approved lubricants and capacities are shown below and
on page 12.
Recommended lubricants and capacities
The branded lubricants referred to below have been approved
after consideration of their manufacturer’s specifications and,
where desirable, after laboratory and rig testing. The omission
of a lubricant does not imply that it has been tested and found
unsuitable.
The use of a non-approved lubricant, provided it had been
recommended by a reputable supplier after full consideration of
the application, would not normally be regarded as invalidating
our guarantee.

Grease
The standard lubricating grease used in rolling bearing
machines is:
Shell Alvania RA
This is a lithium-base grease and contains oxidation and
corrosion inhibitors. We also approve the use of the
Table 2 Grease to be added at each re-greasing interval
lithium-base greases given below* for machines not
exceeding kW output and speeds not exceeding 1500 ( See Table 5, page 21, for regreasing intervals )
r/min.
BP Energrease LS3 MARATH
Castrol Companies Spheerol AP3 ON Up to 751-1200 1201-1800 Over 1800
Esso Beacon 3 ELECTRI 750 r/min r/min r/min r/min
Mobile Mobilux 3 C style
Shell Alvania 3 355-6
If a change from one approved grease to another is 355-7 15 20 40 35
comtemplated, try to remove as much of the existing
355-8
grease as possible before applying the new grease.
355-9 20 30 60 35
355-6 Not
20 30 60
355-7 applicable

The above figures for grease quantity are strokes of an

average hand-operated grease gun, (approx 11/2 grams)
and apply to both horizontal and vertical mounting
machines. They are approximate figures only to be used
as a guide for standard motor operating in a – 40°C to
+40°C ambient, lubricated with Shel Alvania RA.

Oils Fina Hydran 31 Fina Hydran 32

Gulf Harmony 44 Gulf Harmony 47
We recommend the use of light and medium grade turbine oils Mobil DTE Oil Light Mobil DTE Oil Medium
to BS489.1955. The light grade oils should be used for rolling Shell Turbo T32 Shell Turbo T46
bearing machines, and either light or medium grade oils for Total
plain bearing machines. *Note: The order of listing is alphabetical and does not
imply any order of preference.
If the ambient temperature exceeds 30°C or heavy
Among the oils which have been approved*, the following are shock loads are likely, always use the medium grade for
widely obtainable: plain bearing machines.

Light oils Medium oils

BP Energol THB32
Caltex/Texaco Turbine EE32
Burmah Castrol Perfecto T32
Esso Teresso 43
Table 3 Approximate oil capacities
BP Energol THB46
Caltex/Texaco Turbine EE46
Burmah Castrol Perfecto T46
Esso teresso 32
When a motor must start in an ambient temperature
below 5°C, the specialized advice of the oil supplier must
be sought to ensure that an oil with suitable low-
temperature properties is selected.

Horizontal mounting- CIRCON® system, rolling bearings Horizontal mounting- Disc-lubricated plain bearings
( natural or water cooling )
Bearing Size Litres per bearing Bearing size
Oil capacity per ‘es bearing
RRM080 1.0 BRM080 Bearing size (inches/mm)
(litres)
RRM090 1.2 BRM090
2.5 / 64 2.0
RRM100 1.5 BRM100
3.0 / 76 2.0
RRM120 1.8 BRM120
3.5 / 89 3.0
4.0 / 102 3.0
4.5 / 114 4.5
5.0 / 127 4.5

Vertical mounting- Top bearing taper roller

Bottom bearing roller

Top bearing sizes Oil Capacity Bottom bearing size Oil capacity
Lower Upper (litres) ( litres )
98350-98788 78250-78551 3.0
EE197045-197100 98350-98788 3.5 RRM090 3.5
EE195500x-195116x 98400-98788 4.0
Installation
Location
The machine should be installed in a well ventilated
location, as the total temperature and hence the
permissible output depends on the temperature and
hence the permissible output depends on the
temperature of the surrounding air. The following points
should be borne in mind.
1. Ensure that the motor enclosure is correct for
service at the site selected.
2. Ensure that air circulation around the machine is not
restricted due to close proximity to walls etc. it is
important to guad against the possibility of re-
circulation taking place i.e. hot outlet air being drawn
back into the machine.
3. The trunking connected to pipe-ventilated machines
should not exceed 15m in length and there should
should not be more than two right-angle bends. The
cross-sectional area of the trunking must not be less
than 150% of the area of the inlet opening of the
machine.
Foundations
In any foundation, the essential qualities are rigidity and
freedom from transmitted vibration. Concrete provides
the best foundation materials with bolts securely grouted
in position. If required MARATHON ELECTRIC
4. If the machine is water-cooled, ensure that an
adequate supply of clean water is available, in
accordance with the details specified on the general
arrangement drawing appropriate to the machine.
Piping must be installed in such a way that it does
not exert any restraint on the motor, and incorporate
flexible sections if necessary. Adequate precautions
must be taken to guard against water leakage or
loss of supply.
5. Sufficient space should be allowed round the
machine for routine maintenance to be carried out.
6. The location should be such as to along suitable
lifting equipment to be used, with adequate access.
Only the eyebolts or lifting hooks provided on the
machine must be used. Read carefully any
instruction plates fitted to the motor which may refer
to lifting or handling, particularly where fabricated
enclosures are fitted to the top of the machine.
Machines Ltd. will advice on suitable mounting
arrangements, including the provision of bed plates on
slide rails Alignment – horizontal mounting machines.
Alignment- horizontal mounting machines
It is essential that the motor and its driven machine be motor by the drive system do not exceed are
correctly aligned, and that any forces imposed on the recommended figures. See publication C51A01.
Pulley drives
Overhung pulleys on all two-bearings motors must be hours of running. It is therefore advisable to check the
fitted so that the effective centre of the drive is as near tension after 1 hour’s running and again after 1 hour’s
as possible to the motor drive-end bearing and within the running and again after 2 day’s running.
shaft extension length. If a pulley is tight on the shaft the
pulley bore should be checked, and if correct it should be
heated in an oil bath before fitting. Damage to bearings
can result from imposed shock loads when a fitment is
forced on the shaft.
When installing a set of V-belts ensure that all belts in
the set are matched in length and cross-section.
Pulley centre distances should not be less than four
Slide rails are generally required with belt drives . The
times the diameter of the large pulley, unless an idler
correct method of mounting slide rails and aligning the
pulley is used. V-belts should be tensioned in
two pulleys is shown in Fig. 11. If the and driven pulleys
accordance with BS 1440, and with belt manufacturer’s
are not of identical widths, allowance must be made for
recommendations. Belts should only be sufficiently tight
this to ensure that the pulley grooves are aligned.
to prevent slip. V-belts may stretch during the first few
Direct-coupled drives
Correct alignment of direct drive can be achieved by Fig. 12 shows a suitable method of checking a parallel
following the instructions given below, in conjunction with misalignment using a dial indicator gauge. The couplings
the coupling manufacturer’s recommendations. BS3170 : half should be loosely connected together with a driving
1972 (Flexible couplings for power transmission) is also pin and readings taken at 90° intervals. This will indicate
recommended for consultations. whether vertical and / or lateral adjustment is required. It
General is worth noting that errors may be introduced with any
method of alignment involving relative rotation of the two
Where a coupling is large or heavy, ensure that the
coupling halves.
machine ventilation is not impaired and that shaft and
bearing permitted loads are not exceeded (see Angular alignment
publication C51A01 for allowable loads ). Undue force
should not be applied when fitting half couplings to motor
shafts. The method alignment should not rely on the
accuracy of machining or mounting of individual half-
coupling.
Special care must be taken when ‘inching ‘ a motor into
its final position, to avoid damaging the feet.
Parallel alignment
Axial alignment
On rolling bearing machines, the rotor is located axially
within the confines of the ball bearing clearance, and
care must be taken to ensure that the axial component of
coupling load is within the capacity of the locating ball
bearing on the motor. Thrust capacities of ball bearings
on horizontal foot mounting machines are shown in
publication C51A11.
On plain sleeve bearing motors, the rotor is allowed to
float +5mm either side of it’s mean position, and the
thrust faces fitted to either end of the bearing bushes are
only suitable for accepting the inherent thrust of the
motor during uncoupled test running (which will rarely
exceed 250 Newtons ). It is essential that the coupling
between the motor and driven equipment should be of
the limited, end float type thus ensuring the motor shaft
runs within the limits marked on it.The burden of axially
locating the shaft the system of motor and drive is thus
placed on the driven equipment.
Thermal expansion
Final tests for alignment should be preferably be carried
out with the motor and driven equipment at normal
running temperature.
Where that is not possible allowance should be made for
differential thermal expansion. It can be assumed that
the centre height
Of a motor will increase by 0.5mm per metre for a
temperature rise of 50° measured on the frame of the
Belt and coupling guards
Adequate guards must be provided to cover all types of
drive systems. Reference may be made to the
recommendations of the British Standard Code of
Practice 3004, BS 1649 : 1950 ‘Guards for shaft
Alignment – vertical mounting machines
During manufacture every care is taken to ensure a
close degree of accuracy between the mounting flange
and recess of the skirt base (if fitted) and the shaft.
As a precautionary measure, the alignment of the driving
and driven shafts should be checked with dial indicators
Dowelling of machines
When the alignment is correct and performance
satisfactory, all machines pedestals etc, should be
dowelled to the bed-plate or base plate on which they
motor. (this is the approximate frame temperature rise
for a standard Class B insulated Impak).
If class F insulation has been specified and the full
output temperature limit is 100k, the figure will be 0, 6
mm per metre. Table 4 shows the increase in centre
height in mm for each frame size. Guards should be
designed so that they do not restrict the cooling of the
motor or its bearings.
Table 4
MARATHON Class B Class F
ELECTRIC
style
355 0.18 0.21
400 0.20 0.24
450 0.25 0.27
Limits of accuracy
These will normally be specified by the coupling
manufacturer, but it is usual to allow a difference in
reading of 0,.5mm, when measuring either parallel
alignment as shown in Fig. 12 or angular alignment as
shown in Fig. 12a for coupling up to 400mm diameter.
For larger couplings the permissible tolerance is 0,
13mm per metre of coupling diameter.
couplings’. For machines installed in the UK it is
necessary to meet the requirements of the Factory
Inspectorate with regard to the protection of personnel
against accidental contact with rotating machinery.
as for a horizontal mounting machine (shown in Figs. 12
and 12a).
are mounted. This will facilitate future re-positioning. Use
the terminal marking and connection diagram in
conjunction with the controller or starter diagram when
making connections to the machine. Ensure that the
supply voltage and frequency are in line with those
quoted on the motor rating plate and that the incoming
cable section is suitable for the motor full load current
and any other limitations such as system fault level.
Check that the supply is isolated, that line fuses are
Connection to supply – cage motors
Use the terminal marking and connection diagram in
conjunction with the controller or starter diagram when
making connections to the machine. Ensure that the
supply voltage and frequency are in line with those
quoted on the motor rating plate and that the incoming
Standard terminal box
Standard terminal boxes, which may be of cast iron
fabricated steel, are fitted with a blanking plate drilled
and tapped to receive the incoming cable gland or
adaptor. Remove the front terminal box cover plate to
expose the terminals, which are marked for easy
identification, and feed the supply cable through the
sealing chamber gland and into the box. Connection can
then be made using the cable lugs supplied. The
machine must be earthed in a manner which is both
electrically and mechanically sound, using the earth
Phase insulated BEAMA/CEGB box
The BEAMA/CEGB box contains a separate sealing
chamber through which the cables are taken before
connection to the terminal studs. On some applications
the machine may be supplied with the complete
removed, and all safety precautions have been
observed.
The method of connection inside the terminal box will
depend upon the particular box fitted, which will normally
be one of the following types:
cable section is suitable for the motor full load current
and any other limitations such as system fault level.
Check that the supply is isolated, that line fuses are
removed, and all safety precautions have been
observed.
terminal provided, and any auxiliary connections made. It
is important to ensure that continuity of the earth circuit
between the motor frame and the terminal box is
maintained. Finally, re-check all connections and test the
installation, replace loose covers and line fuses, tighten
cable gland, and check motor for correct rotation (see
‘Methods of starting’ page 19). Coupling and pulley
guards must be in position before starting.
termination made at the terminal studs, and a short
length of flexible cable 11 taken through into a deep
sealing chamber for connection to customer’s cable 12
(see Fig. 16). More commonly, however, the customer’s
cable will be taken straight through a shallow sealing
chamber to the terminal stud 6. Where this is the case
the terminations are made as shown on following page:

1. Remove steel cover 1 and integral flash plate.
2. Remove sealing chamber from terminal box,
where this has not already been done. (A
protective cover will have been fitted to the
aperture to seal the terminal box during transit.
This should be removed and discarded).
3. Feed incoming supply cable through gland,
connect to cable lugs 7 supplied, fit heat-shrink
sleeves 10 to each phase lead and fit neoprene
rubber terminal caps 3 and cable seals 4. Apply
gentle heat to sleeves, starting at the cable
crutch and working up to the terminal, to
accommodate axial contraction.
4. Attach cable lugs to terminal studs, and secure
with two outer nuts 5.
5. Slide rubber terminal caps and cable seals into
position, and place cable spacing block 9 in
position.
Note: Make sure the phase sequence selected will give
the required direction of rotation. For full installation and
maintenance instructions for the BEAMA/CEGB box, see
BEAMA publication No. 203, available from BEAMA, 36
Kingsway, London WC2.
To fill the sealing chamber with insulating compound,
tighten the cable gland, replace the cover plate 8, and
pour compound into the chamber via the top aperture.
Access to this can be gained through the terminal box
front opening. The chamber is correctly filled when the
compound level reaches the indicated mark inside the
sealing chamber.
Recommended sealing compounds
Maximum Softening
Manufacturer’s
pouring temperature
List No.
temperature (°C) (°C)
AEI 57046 140 / 175* 59
AEI 57017 Cold pouring 56
BICC G8 145 / 155* 84 #
BICC G93 Cold pouring 60
Note: Sealing compounds usually shrink on cooling to
ambient temperature. Topping-up may therefore be
required. The quantity of material required for the
shallow sealing chamber is approx 10kg (9 litres), and
for the deep chamber 14kg (12 litres).
Phase –segregated terminal box (PSTBs)
On high voltage machines, a phase-segregated terminal
box may be fitted. These units are supplied with the
terminal connections already made within the terminal
box. A short length of cable 5 is taken through into the
sealing chamber, where the connections are made to the
incoming supply cable (see Fig. 18).
The procedure for connecting to this type of box is as
follows:-
1 If the sealing chamber is not already fitted to the
terminal box, remove protective covering from the
cable tails and terminal box aperture, and bolt
chamber into position.
2 Feed supply cable through gland and connect to
incoming cable tails 5 in the sealing chamber. This
are marked for easy identification.
Note: make sure the phase sequence selected will give
the required direction of rotation.
Sealing chambers can only be filled correctly when they
are in a vertical attitude, with the cable entry at the
bottom.
If the specified mounting position for the terminal box
places the sealing chamber in any other position, the
chamber should be unbolted from the terminal box
(complete with cables), twisted into a vertical position
and filled. (If this is not possible a sealing plate is
supplied to seal the aperture between terminal box and
chamber, which can then be filled from the gland end).
Ensure that the relative positions of the phase leads in
the sealing chamber are not disturbed during filling.
Replace sealing chamber.
The motor must then be earthed in a manner, which is
both electrically, and mechanically sound, using the
earth terminal provided, and any auxiliary connections
made. Finally, re-check all connections and test the
installation, replace loose covers and fuses and fit
desiccators unit to terminal box. The motor is then ready
for starting, when pulley and coupling guards are in
position (see ‘Methods of starting’ page 19).
* Must not exceed 150°C for PVC insulated cables.
# For use in ambient temperatures above 30°C.
To fill the sealing chamber with insulating compound
(required in case tail cables are used which is NOT a
recommended practice as on date), tighten the cable
gland, replace the cover plate and pour compound
through each of the two filling holes provided. The level
is correct when sealing compound reaches the
underside of the filling plugs.
The recommended sealing compounds are those
already listed on page 17(required in case tail cables
are used which is NOT a recommended practice as
on date). The quantity of material required to fill the
chamber is approximately 18kg (15 litres).
If the mounting position of the terminal box is such that
the sealing chamber cannot be filled via the holes
provided, e.g., it may be at 90° to the vertical, the
chamber should be removed and turned into a an upright (See Fig. 18.).
position before filing
This involves disconnecting inside the phase
compartments as follows.

1. Unbolt and remove the steel covers 1 with their

glass reinforced plastic linings 2.
2. Unbolt and remove the cable clamps 3 which couple
the incoming cable tails 5 to the respective motor
winding cables 4.
3. Unscrew and remove the larger of the nylon gland
nuts from both the bottom and the back of each
phase compartment. A light blow, with a flat-ended
bar located in one of the slots, is all that is required
to lock or unlock these nuts.
4. Remove the twelve nylon fixing screws, and
withdraw the three glass-reinforced plastic phase
compartments 6 leaving the nylon glands attached to
the cables.
5. Remove the bolts which secure the sealing chamber
7 to the terminal box, and remove the sealing
TAIL
chamber and cable assembly. Take care not to
disturb the relative position of the phase leads within
the chamber.
(If the sealing chamber cannot be turned into a n upright
position prior to filling, a sealing plate is provided to seal
the aperture between terminal box and chamber, which
can then be filled from the gland end).

When the sealing chamber has been filled and cooled to

ambient temperature, it may be re-assembled to the
terminal box, and an earth connection made which is
both electrically and mechanically sound. An earth
terminal is provided for this purpose. Connections to
auxiliary terminals can be made at this stage.

Finally, re-check all connections and test the

installations, fit loose covers, desiccator units and line
fuses. When pulley and coupling guards are in position
the motor is ready for starting (see ‘Methods of starting’,
page 19).
Connection to supply – wound for motors
Stator windings of slip-ring machines are connected in be connected to the starter in a similar manner to the
exactly the same manner as described previously for stator windings.
cage machines, on page 16 to 18.
Connectors to the rotor slip-rings are brought from the
brushgear to a separate terminal box, which should then
Desiccator units
For terminal boxes fitted with desiccators, these units are so, the units should be screwed into the threaded
supplied loose in sealed tins. Only after cable jointing bushes provided on the terminal box.
and compound sealing has been completed, and all If the 6mm diameter portion of the indicator head is pink
covers replaced, should the desiccator units be removed in colour, contrasting sharply with the blue outer ring, it
from their containers. will be necessary to dry out the desiccators before fitting
An examination of the front face of each unit should, if them into the terminal box. The procedure for drying out
the desiccator is dry, shoe the 6mm diameter portion of desiccators in given on page 21.
the indicator head to be coloured blue. Providing this is
Methods of starting
Instructions for starting will normally be supplied by the 3. Check also that all holding-down bolts, cabling and
starter manufacturer, whose manual should be consulted cleaning and secure. Safety guards must be in
for the detailed procedure. Certain precautions are, position.
however, applicable to any motor/starter combination, 4. Check that all fuses are in position, and are of the
and the following points should be noted: correct rating.
1. Before main switches are closed, ensure that the
starter is in the ‘off’ position, and that brush lifting
If all is correct switch on the motor and check that it runs
and short-circuiting gear on slip-ring machines is in
up to full speed.
the ‘START’ position.
2. Check overload release settings, and that any
dashpots fitted to the overload trips are correctly
filled with oil.
ROUTINE MAINTENANCE
General
It is strongly recommended that a system of regular
maintenance be adopted ,as the efficient operation of
any machine depends on correct installation and the
care which it subsequently receives in service.
It is also recommended that a maintenance record card
be prepared on which to record dates and details of all
maintenance and repair work carried out. This card is
useful not only to the maintenance engineer but also to
the manufacture should the machine ever be returned to
the works.
During the first few weeks of service a new machine
should receive particular attention. Faulty installation is
more likely to cause trouble during this period in which
the moving parts are settling down to working surfaces
and temperature. Careful attention to the following,
shortly after commissioning, may help prevent serious
trouble developing later.
1. Ensure that all external cables are adequately
cleated and are secure and that there is no evidence
of chafing.
2. Check that all terminals are clean and tight.
Cleaning
Moisture, oil, dirt, grease and carbon or metallic dust are
the principal causes of electrical breakdown. As far as is
practicable, machines should be kept clean and dry both
internally and externally. The tubes of heat exchangers
can be cleaned using compressed air or a non-metallic
tube brush. It may be necessary to remove air deflectors
or silencers from the body of the heat exchanger to gain
access to the tubes. Ensure that debris is not blown into
the machine, and gasket seals are not damaged.
Grease-lubricated rolling bearings
Horizontal and vertical machines
All grease-lubricated rolling bearings fitted to Impak
machines are protected from overgreasing by a pressure
3. Ensure that the windings and bearings are not
overheating and that the motor runs quietly and
smoothly. Bearings usually operate with a
temperature rise above ambient between 20 K and
40 K measured on the outside surface.
4. Check the security of all fixing bolts, couplings,
coupling guards etc. check that all air vents are
unobstructed and filters, if fitted, are clean.
5. Compare the actual load current with the full load
current given on the rating plate.
6. Check that there is no sparking between brushes
and slip-rings on wound rotor motors.
Note: Should any fault occur which cannot be
diagnosed, please communicate with out nearest office
or agent or with the works. A staff of experienced
engineers is available who can assist or advise
customers on the rectification of any fault or breakdown.
If the windings are contaminated but in a dry state the
contaminant can be removed by hand brushing, dry
compressed air blowing or by vacuum cleaning. Great
care must be taken not to damage the windings. The
windings may be washed with a hot detergent solution
and rinsed with clean hot water. This must be followed
by drying out and an insulation resistance check (see
page 8).
relied system. Surplus grease is ejected from the
bearing, during running, into a tray on horizontal
machiens, or into a chamber on vertical mounting
machines. It is not possible to cause damage by expressed as strokes of a normal hand-operated grease
overgreasing, although it should be noted that up to 24 gun.
hours may be required for all excess grease to be Grease should preferably be added whilst the machine is
expelled, and some rise in operating temperature may running, and it should be free from contamination by dirt
occur during this period. or water. The importance of ensuring cleanliness of
Every 12 months or at intervals shown in Table 5, grease fittings before and after lubrication cannot be
whichever is the most frequent, grease should be added over-emphasized. Expelled grease should be removed
to the bearings. from the tray after lubrication.
For location of greasing points see Figs. 3, 4 and 5
pages 10 and 11. The quantity varies with motor size
and running speed, and is given in Table 2, page 12,
Oil-lubricated rolling bearings
Horizontal and vertical machines On vertical mounting machines the minimum oil level is
Every 12 months the oil system should be drained, marked on the sight glass. Oil should be added to the
flushed out and refilled with clean new oil of an approved system when the level reaches the lowest mark.
grade. See ‘Oils’ pages 12 and 13. This period can be It is not possible to give any fixed periods between
extended providing regular checks are carried out on oil normal replenishments as so much depends on
acidity and sludging. circumstances. If, however, oil is being lost at such a
Regularly, the level of oil in the constant-level lubricator rate that attention is required more than once a month,
or reservoir should be checked. The position of the oil- as attempt should be made to find and rectify the leak
level indicator is shown in ‘Pre-commissioning’ pages 11 which probably exists. The procedure for refilling a
and 12. On horizontal mounting machines a graduated bearing housing and reservoir is given on pages 11 and
mark on the glass reservoir shows the minimum oil level. 12.
Table – 5 : Suggested lubricating intervals
For standard motors operating in a 40°C (max.) ambient on a 50 Hz supply.
MARATHO Horizontal mounting Vertical mounting
N Running Size of bearing (mm) Running Size of bearing (mm)
Poles
ELECTRIC
hours Drive end Non drive end hours Drive end Non drive end
style
2 2000 080 080 -- -- --
355-6
4-12 8000 080 080 -- -- --
2 2000 080 080 2000* 080 --
355-7 4 8000 080 080 4000 080 100
6-12 8000 080 080 8000 080 100
2 2000 080 080 -- -- --
355-8 4 4000 120 120 -- -- --
6-12 8000 120 120 -- -- --
2 2000 080 120 -- -- --
355-9 4 8000 120 120 4000 120 100
6-12 8000 120 120 8000 120 100
4 4000 120 120 4000 120 100
400
6-12 8000 120 120 8000 120 120
4 4000 120 120 4000 * 120 --
450
6-12 8000 120 120 8000 120 120
When adding oil to a machine, great care must be taken transporting oil must be clean, and filters and the
to ensure that dirt and other foreign matter does not surrounding areas should be cleaned to prevent dirt
contaminate the oil. Containers used for handling and being dislodged and falling into housings, reservoirs etc.
Disc-lubricated plain bearings – horizontal machines only
Every 12 months – or at longer intervals if these have
been established by periodic checks of oil acidity and
sludging – the oil system should be drained, flushed with
normal lubricating oil and refilled with clean oil of an
approved grade. ( See ‘Oils’ page 13, Table 3). The
position of filling plugs and the method of filling is
outlined in ‘Disc-lubricated plain bearings’, page 11.
Regularly check the level of oil in the bearing housing,
and top up if necessary. This can be done with the motor
running or stationary. If the machine is running, the
minimum level of oil is shown in the oil-level indicator
(running) on the upper half bearing housing. If the motor
Terminal box
It is necessary to make a regular check on the security of
connections. The interior of the box should be wiped with
a clean lint-free cloth and vacuum cleaned if necessary.
Where phase-segregated or phase-insulated
BEAMA/CEGB type boxes are fitted, the desiccator
Drying out desiccators
Unscrew the indicating head from the body of the
desiccator and place the body only in an oven
maintained at 120°C for two or three hours. Take care
during handling to avoid damage to the unit. Remove
from the oven and replace the indicating head on the
body. Place the complete unit in a sealed air tight
container while still hot and allow the unit to cool down to
normal temperature. The desiccator will now be re-
Brushgear, brushes and slip-rings
The slip-rings of wound rotor machines should be
smooth, burnished and free from oil and dirt. if
roughened, they should be cleaned with fine glass
paper mounted on a wooden block shaped to their
curvature. Emery cloth must not be used. Should the
roughness be due to sparking, the cause should be
investigated, i.e., vibration, excessive load ,spring
pressure to low, brushes worn down, etc. If ridged or
eccentric, e.g., more than 0,1 mm TIR for 999r/min
machines or slower and 0,05 mm TIR for 1000r/min plus
machines, the ring should be or turned in a situ on a
lathe, concentric with the bearing seatings, until a
smooth, true surface is restored.
Slip-rings must not be turned below the
is stationary, the oil level is that shown on the oil-level
indicator (standing) on the lower half bearing housing.
Oil should not be added when the machine is stationary
until the upper reservoir has emptied. This may take
several hours. No attempt should be made to restore the
‘standing’ oil level when the machine is running, as this
could lead to flooding on shut-down.
A plain bearing is usually safe if it operates at a
temperature below 90°C, but a rapid change towards
this limit is a danger signal calling for prompt attention.
This figure applies where the temperature is measured
by thermometer in the top reservoir.
should be checked regularly. If the units have become
damp, the 6mm diameter inner portion of the indicator
head will be coloured pink and the desiccator must be
dried out as follows:
activated and the unit ready for use. This will be shown
by the colour change of the desiccator head, which have
returned to its original blue.
If the presence of moisture has been indicated by a
colour change in the desiccator the winding insulation
resistance should be checked and the enclosure
examined for sources of leaks. The procedure is
described in ‘Insulation resistance testing’, page 8.
Minimum diameter shown in the table
Brushgear Diameter when Minimum
reference No. new (mm) diameter (mm)
3 203 193
4.4A
222 210
4M
Examine brushes regularly to ensure that they are free in
their boxes and bedding properly on the rings. Brush
pressure can be checked by attaching a spring balance
to the brush tail and placing a piece of paper between
the slip-ring and brush surface. Pull gently on the spring
balance in line with the brush axis until the paper just
slides between the brush and the slip-ring. The pressure
is correct at approximately 0,21kgf/cm2 of brush cross-
section for brush grade CM 3H. Our engineers will
advise on pressure settings for brush grades other than
CM 3H.
If the brushes are worn, they should be replaced with
brushes of the same size and grade. The safe limit of
wear is up to 50% of the original length of the brush.
New brushes are usually 35 to 45mm in length, and
replacement should be considered when brush length
reaches 20mm.
To renew a brush, disconnect the tail, lift the pressure
spring and remove the brush from its box. Place the new
brush in the box and bed it down to the surface of the
Summary of routine maintenance
slip-ring. This can be achieved by placing a strip of fine
glass paper (not Emery paper) round the periphery of the
slip-ring, with the pressure spring holding the brush in
contact with the paper. Work the strip backwards and
forwards until the brush face has acquired the curvature
of the ring. Ensure that the glass paper does not lift away
from the ring at the brush edges. Carefully remove
deposits of dust and carbon.
Brush lifting and short-circuiting gear, which may be
fitted to some machines, should be lightly lubricated at
pivot and bearing points, and short-circuiting contacts
cleaned.

Regular checks
See page

1. Check bearing oil levels 20, 21

2. Check desiccators 21

3. Check bearing temperatures 20, 21

Every 12 months or at each re-greasing interval, whichever is most frequent (see Table 5, page 21)

1. Re-grease bearings 20

2. Check desiccators 21

3. Check bearing temperatures 20, 21

4. Check brush length and pressure 22

5. Check condition of slip-rings 22

Every 12 months

1. Check security of terminals, cables, fixing 20

bolts, couplings and guards

2. Clean air vents and filters 20

3. Drain and refill oil lubricated 20, 21

4. Lubricate brush gear 22

5. Clean motor 20
Overhaul - dismantling
And re-assembly
General
Wherever possible the complete machine should be
removed from its site to a dry and dust-free location. This
particularly important for machines mounted out of
doors. Dowelling should be checked to ensure accurate
re-location after overhaul.
Before attempting to carry out any work on the machine,
it should be isolated from its electrical supplies, both
main and auxiliary. It is important that all necessary
safety precautions are taken. Disconnection at the
terminal box can be achieved by reversing the procedure
described on pages 16 to 18. Identify all leads. Where a
phase isolated insulated, phase-segregated or any type
of terminal box with a compound filled sealing chamber
is fitted, disconnection will have to be made inside the
terminal box, and the sealing chamber unbolted and left
attached to the mains supply cabin. (As an alternative
the compound may be removed if preferred ). Protect
any exposed cabin, or open sealing chamber apertures,
to prevent the ingress of dirt or moisture and support the
sealing chamber to prevent damage to the main cable.
Auxiliary connections, and those to slip-ring brushes, in
the case of wound rotor machines, should be removed
and carefully identified to aid future re-connection.
Remove pulley or coupling guards, external cooling
ducts, water/oil supplies an uncouple the motor from its
drive system. If a coupling is fitted, do not forget to mark
the two halves so that they can be reassembled in their
Terminal Box
Disconnection of the motor from its mains supply, by
reversing the procedure outlined on pages 24-30 will
have already left the main terminal box in a partially
correct angular relationship. After removal of dowels and
securing bolts, the machine can be lifted from its site.
Observe the safety precautions and procedures outlined
on page 5, “Lifting and Handling”.
Any shims which have been used should be identified
and carefully retained. Use load spreaders when lifting
machines fitted with fabricated top covers, such as heat
exchangers or silencers, to avoid damage to these
items. If the machine is vertical mounting version with oil-
lubricated rolling bearings it should be placed vertically
on substantially packing pieces, with the shaft extension
well clear of the floor. Sufficient space should be allowed
under the shaft extensions for a jack or packing piece to
be placed to support the weight of the rotor during
removal of the top bearing assembly.
If the machine is vertical mounting version with grease-
lubricated bearings, it can be laid on its side for
dismantling. If the top bearing only is to be removed, this
can be done with the motor in a vertical attitude, with the
shaft jacked up to support the rotor weight.
Where a non-standard assembly has been fitted to a
vertical motor, such as tilting pad-type bearing, the
machine must be placed in a vertical attitude only.
Special instruction are available for dismantling
machines with non-standard bearing arrangements, and
application should be made to MARATHON ELECTRIC
Machines Ltd. or their agents.
dismantled state. To remove the box completely from the
machine, proceed as follows:
Standard terminal box

Disconnect the motor cables from the terminal support Remove the securing bolts attaching the terminal box to
bar, by pulling the cables through their grommets until the motor frame and remove the box, complete with the
the cables eyes are free from their respective terminal terminal support bar.
studs. Avoid unnecessary strain on the cables, which
may caused damage. On low voltage application, there
may be additional auxiliary connections within the main
box, which should also be disconnected.

To re fit the box, reverse the procedure outlined above.

Phase-insulated (BEAMA/CEGB) terminal box

Removal of the BEAMA/CEGB box can be achieved by

removing the bolts securing the terminal box to its
adaptor, and lifting the box clear. The terminal base and
stud assembly can be left attached to the terminal box
adaptor face. If it is necessary to dismantle the terminal
base and stud assembly proceed as follows:
1. Remove the two locknuts from each terminal stud. A
hexagon on the stud, which locates in the terminal
base, will prevent it from rotating.
2. Remove the bolts securing the terminal base to the
terminal box adaptor.
3. Carefully ease the terminal base over the terminal
studs, noting the position of the sealing rings fitted
between base and stud assembly.
Re-fitting the terminal box is a reversal of the above procedure.
Replace any damaged gaskets or sealing rings, check the
condition the pressure relief diaphragm, and clean the interior of the terminal box, particularly the terminal base.
Phase-segregated terminal box

To remove the phase-segregated terminal the following

procedure should be followed:
1. Remove the glands from the motor cables by
unscrewing the remaining gland nuts and easing the
gland body and its packing off the end of the cable.
2. Remove the bolts securing the terminal box to the
motor frame and ease the box free of the motor
cables.
Before re-assembling the terminal box , check the
condition of the gland packings and all gaskets and
grommets. Clean the interior of the box and check that
the pressure relief disc is in good condition.
When re-fitting glands, the gland nuts should be hand
tightened only, to avoid damaging the threads.

Re-connection

Re-connection to the main supply is described on pages 16 to 18.

Bearings and endbrackets – horizontal foot mounting machines