WEG DC Motor Installation Guide

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Motors | Automation | Energy | Transmission & Distribution | Coatings
DC Motors
D Series
Installation, Operation and Maintenance Manual
10061218 – DC Motors – D Series | 1

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2 l 10061218 – DC Motors – D Series

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Installation, Operation and Maintenance Manual
Document Number: 10061218

Models: DNF, DND, DNS, DNE, DNX, DNA, DNX, DCF, DCD, DCS,
DCE, DCX, DCA and DCW
Language: English
Review 6
September 2012

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Dear Customer,
Thank you for purchasing the WEG DC motor. It is a product developed with quality and efficiency
levels which ensure an outstanding performance.
Since the electric motor plays an important role in the comfort and well being of mankind, it must be
identified and treated as a driving machine whose characteristics involve certain care, such as proper
storage, installation and maintenance.
All efforts have been made to ensure that the information contained in this manual is faithful to the
configurations and operation of the motor.
Therefore, read carefully this manual before proceeding with the installation, operation or maintenance
of the motor in order to ensure the safe and continuous operation of the motor and also the safety of
your installations. If you need further information, please, contact WEG.
Keep this manual close to the motor, so it can be referred to when needed.
ATTENTION
1. It is imperative to observe the procedures contained in this manual for the warranty to be valid;
2. The motor installation, operation and maintenance procedures must be performed by qualified
personnel.
NOTES
1. Reproduction of the information contained in this manual, in whole or in part, is allowed since the
source is mentioned;
2. In case this manual is lost, the electronic file in PDF format is available at www.weg.net or another
printed copy may be requested.
WEG EQUIPAMENTOS ELÉTRICOS S.A.

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INDEX
1 INTRODUCTION .................................................................................................11
1.1 TERMINOLOGY ..............................................................................................................................11
1.2 SAFETY WARNINGS IN THIS MANUAL ..........................................................................................11
2 GENERAL INSTRUCTIONS .................................................................................12

2.1 QUALIFIED PERSONNEL ................................................................................................................12
2.2 SAFETY INSTRUCTIONS ................................................................................................................12
2.3 STANDARDS...................................................................................................................................12
2.4 CHARACTERISTICS OF THE ENVIRONMENT ................................................................................12
2.5 OPERATING CONDITIONS .............................................................................................................12
3 RECEIVING, STORAGE AND HANDLING .............................................................13

3.1 RECEIVING .....................................................................................................................................13
3.2 STORAGE .......................................................................................................................................13
3.2.1 Indoor storage ....................................................................................................................................13
3.2.2 Outdoor storage .................................................................................................................................13
3.2.3 Further care during storage .................................................................................................................13
3.2.4 Extended storage ...............................................................................................................................13
3.2.4.1 Storage location ..................................................................................................................14
3.2.4.1.1 Indoor storage ................................................................................................14
3.2.4.1.2 Outdoor storage .............................................................................................14
3.2.4.2 Separate parts ....................................................................................................................14
3.2.4.3 Space heater.......................................................................................................................14
3.2.4.4 Insulation resistance ............................................................................................................14
3.2.4.5 Exposed machined surfaces................................................................................................14
3.2.4.6 Bearings..............................................................................................................................15
3.2.4.6.1 Grease-lubricated rolling bearing.....................................................................15
3.2.4.6.2 Oil-lubricated rolling bearing............................................................................15
3.2.4.6.3 Sleeve bearing ................................................................................................15
3.2.4.7 Brushes ..............................................................................................................................15
3.2.4.8 Terminal box .......................................................................................................................15
3.2.4.9 Preparation for commissioning ............................................................................................16
3.2.4.9.1 Cleaning .........................................................................................................16
3.2.4.9.2 Bearing lubrication ..........................................................................................16
3.2.4.9.3 Checking the insulation resistance ..................................................................16
3.2.4.9.4 Brushes..........................................................................................................16
3.2.4.9.5 Others ............................................................................................................16
3.2.4.10 Inspections and records during storage ...............................................................................16
3.2.4.11 Maintenance plan during storage.........................................................................................17
3.3 HANDLING......................................................................................................................................18
3.3.1 Handling of horizontal motors..............................................................................................................18
3.3.2 Handling of vertical motors..................................................................................................................18
3.3.2.1 Positioning of vertical motors...............................................................................................18
4 INSTALLATION ...................................................................................................19
4.1 LOCAL OF INSTALLATION .............................................................................................................19
4.2 DIRECTION OF ROTATION .............................................................................................................19
4.3 INSULATION RESISTANCE.............................................................................................................19
4.3.1 Safety Instructions ..............................................................................................................................19
4.3.2 General considerations .......................................................................................................................19
4.3.3 Measurement on the windings ............................................................................................................19
4.3.4 Minimum insulation resistance.............................................................................................................20
4.3.5 Conversion of measured values ..........................................................................................................20
4.4 PROTECTIONS ...............................................................................................................................20
4.4.1 Thermal protections ............................................................................................................................20
4.4.1.1 Temperature sensors ..........................................................................................................20
4.4.1.2 Temperature limits for the windings .....................................................................................20
4.4.1.3 Alarm and tripping temperatures..........................................................................................21
4.4.1.4 Temperature and ohm resistance of the thermoresistors PT100 ..........................................21
4.4.1.5 Space heater.......................................................................................................................22
4.4.2 Water leak sensor ...............................................................................................................................22

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4.5 COOLING ....................................................................................................................................... 22

4.5.1 Water heat exchangers ...................................................................................................................... 22
4.5.1.1 Heat exchangers for application with seawater ................................................................... 22
4.5.2 Independent fans ............................................................................................................................... 22
4.6 ELECTRICAL CHARACTERISTICS ................................................................................................. 23
4.6.1 Electric connections ........................................................................................................................... 23
4.6.1.1 Main connection ................................................................................................................. 23
4.6.1.2 Grounding .......................................................................................................................... 23
4.6.2 Wiring Diagram .................................................................................................................................. 24
4.6.2.1 Main terminal box ............................................................................................................... 24
4.6.2.2 Accessory terminal box....................................................................................................... 25
4.6.2.3 General identification of the accessories and instrument ..................................................... 25
4.6.2.3.1 Thermostat wiring diagram............................................................................. 26
4.6.2.3.2 Thermistor (PTC) wiring diagram .................................................................... 27
4.6.2.3.3 Thermosensor (Pt-100) wiring diagram........................................................... 29
4.6.2.3.4 Space heater wiring diagram.......................................................................... 30
4.7 MECHANICAL CHARACTERISTICS ............................................................................................... 31
4.7.1 Foundations ....................................................................................................................................... 31
4.7.2 Forces on the foundations.................................................................................................................. 31
4.7.3 Base types......................................................................................................................................... 31
4.7.3.1 Concrete base.................................................................................................................... 31
4.7.3.2 Sliding base........................................................................................................................ 31
4.7.3.3 Metal base.......................................................................................................................... 31
4.7.3.4 Anchors.............................................................................................................................. 31
4.7.4 Alignment and leveling........................................................................................................................ 32
4.7.5 Couplings........................................................................................................................................... 33
4.7.5.1 Direct coupling ................................................................................................................... 33
4.7.5.2 Coupling by gears .............................................................................................................. 33
4.7.5.3 Coupling by means of pulleys and belts .............................................................................. 33
4.7.5.4 Coupling of motors equipped with sleeve bearings ............................................................. 34
5 START ............................................................................................................... 35
5.1 POWER SUPPLIES......................................................................................................................... 35
6 COMMISSIONING .............................................................................................. 36
6.1 PRELIMINARY INSPECTION .......................................................................................................... 36
6.2 INITIAL START-UP.......................................................................................................................... 36
6.3 OPERATION ................................................................................................................................... 37
6.3.1 General .............................................................................................................................................. 37
6.3.2 Data record........................................................................................................................................ 37
6.3.3 Temperatures..................................................................................................................................... 37
6.3.4 Bearings ............................................................................................................................................ 37
6.3.5 Heat exchangers................................................................................................................................ 37
6.3.6 Vibration ............................................................................................................................................ 38
6.3.7 Tripping ............................................................................................................................................. 38
7 MAINTENANCE .................................................................................................. 39
7.1 General........................................................................................................................................... 39
7.2 GENERAL CLEANING .................................................................................................................... 39
7.3 INSPECTIONS IN THE WINDINGS ................................................................................................. 39
7.4 WINDING CLEANING ..................................................................................................................... 39
7.5 CLEAN BRUSH COMPARTMENT .................................................................................................. 40
7.6 MAINTENANCE OF THE COOLING SYSTEM................................................................................. 40
7.6.1 Maintenance of heat exchangers........................................................................................................ 40
7.7 Commutator ................................................................................................................................... 40
7.7.1 Checking the commutation ................................................................................................................ 41
7.8 BRUSH HOLDER............................................................................................................................ 42
7.8.1 Adjustment of the neutral zone ........................................................................................................... 42
7.9 BRUSHES ...................................................................................................................................... 42
7.9.1 Adequacy of brushes to load conditions............................................................................................. 43
7.10 MOTOR OUT OF OPERATION ....................................................................................................... 43
7.11 SHAFT GROUNDING DEVICE ........................................................................................................ 44
7.12 BEARING MAINTENANCE.............................................................................................................. 44
7.12.1 Grease rolling bearings....................................................................................................................... 44

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7.12.1.1 Lubrication instruction .........................................................................................................44

7.12.1.2 Procedure to lubricate the rolling bearings ...........................................................................44
7.12.1.3 Bearing lubrication with spring device to remove the grease ................................................45
7.12.1.4 Grease type and quantity ....................................................................................................45
7.12.1.5 Optional greases .................................................................................................................45
7.12.1.6 Procedure for changing the grease......................................................................................45
7.12.1.7 Low-temperature greases ...................................................................................................45
7.12.1.8 Grease compatibility ............................................................................................................46
7.12.1.9 Horizontal bearing assembly and disassembly .....................................................................47
7.12.1.10 Vertical bearing assembly and disassembly .........................................................................48
7.12.2 Oil rolling bearings...............................................................................................................................49
7.12.2.1 Lubrication instruction .........................................................................................................49
7.12.2.2 Oil types………………….....................................................................................................49
7.12.2.3 Oil Change……………….....................................................................................................49
7.12.2.4 Bearing operation................................................................................................................50
7.12.3 Sleeve bearings ..................................................................................................................................50
7.12.3.1 Bearing data…………………...............................................................................................50
7.12.3.2 Oil change…………………..................................................................................................50
7.12.3.3 Seals………………………...................................................................................................50
7.12.3.5 Bearing maintenance...........................................................................................................51
7.12.3.6 Assembly and disassembly of the bearings..........................................................................51
7.12.4 Bearing protection ..............................................................................................................................51
7.12.4.1 Protection adjustments........................................................................................................51
7.12.4.2 Disassembly/assembly of the bearing temperature sensors .................................................51
8 MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................52

8.1 DISASSEMBLY ...............................................................................................................................52
8.1.1 Tacogenerator Disassembly ................................................................................................................52
8.2 ASSEMBLY .....................................................................................................................................52
8.3 MEASUREMENT OF THE AIR-GAP.................................................................................................53
8.4 GENERAL RECOMMENDATIONS...................................................................................................53
8.5 SPARE PARTS ................................................................................................................................53
8.6 LIST OF PARTS...............................................................................................................................53
9 MAINTENANCE PLAN.........................................................................................55
10 ANOMALIES, CAUSES AND SOLUTIONS ............................................................57

10.1 MOTORS.........................................................................................................................................57
11 WARRANTY .......................................................................................................59

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1 INTRODUCTION
This manual is intended to provide information on the DC motors.
Special motors can be supplied with specific documents (drawings, connection diagram, characteristic curves, etc.). Those
documents together with this manual must be thoroughly studied before proceeding with installation, operation or
maintenance of the motor.
All procedures and standards contained in this manual must be observed in order to ensure the proper operation of the
motor and safety of the personnel involved in the operation. Following these procedures is also important to ensure the
validity of the motor warranty. Thus, we recommend the careful reading of this manual before installing and operating the
motor. If any additional explanations are necessary, please, contact WEG.
1.1 TERMINOLOGY
D N F 160 . 190 S
SPECIFIES A DIRECT CURRENT MACHINE
COMPENSATION
N – Non compensated motors
C – Compensated motors
COOLING TYPES
F – Independent forced ventilation
D – Forced ventilation by means of ducts
S – Self-ventilated
E – Non-ventilated
X – Axial independent forced ventilation
A – Ventilation by means of air-air heat exchanger
W – Ventilation by means of air-water heat exchanger
IEC FRAME
CORE LENGTH IN mm
CODE OF THE ND-ENDSHIELD AND COMMUTATOR TRACKS

Frames 90 to 132
S – Short endshield (one size fits all)
Frames 160 to 500
S – Short endshield
M – Long endshield
Frame 560 and higher (single endshield)
A, B, C,... (code for the number of tracks on the commutator)
1.2 SAFETY WARNINGS IN THIS MANUAL

In this manual, the following safety warnings are used:
DANGER
The not following of the procedures recommended in this warning can lead to death, serious injuries and
considerable material damages.
ATTENTION
The not following of the procedures recommended in this warning can lead to material damages.
NOTE
The text aims at providing important information for the complete understanding and proper operation of
the product.

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2 GENERAL INSTRUCTIONS
All personnel working in the assembly, operation or maintenance of electrical installations must be permanently informed and
updated on the safety standards and instructions and are advised to strictly comply with them. Before beginning any job, the
person in charge must make sure that all points have been duly observed and warn the respective personnel about the
danger inherent to the task to be performed. Motors of this type, when inappropriately applied or lacking adequate
maintenance, or also when handled by people lacking qualification may cause serious personal injuries and/or material
damages. Therefore, it is highly recommended that services be always performed by qualified personnel.
2.1 QUALIFIED PERSONNEL That the protection devices of the individual component
parts are removed just before the installation.
The term qualified personnel represents those who, due to Individual parts must be stored in vibration-free
their training, experience, education level, knowledge of environments, avoiding falls and ensuring their protection
applicable standards, safety standards, accident against aggressive agents and/or that they do not present
prevention and knowledge of operating conditions, have risks to the safety of personnel.
been authorized by those in charge to execute all
necessary tasks, and are able to recognize and avoid any 2.3 STANDARDS
possible danger.
Such qualified personnel must also know first aid
The motors are specified, designed, manufactured and
procedures and must be able to provide them, if
necessary. tested according to the following standards:
All operation, maintenance, and repair tasks are to be Table 2.1: Applicable standards for DC motors
exclusively performed by qualified personnel.
IEC NBR NEMA
2.2 SAFETY INSTRUCTIONS Specification 60034-1 5116 MG1-1,10,20
Dimensions 60072 5432 MG1-4,11
Tests 60034-2 5165 MG1-12
DANGER
Degrees of
60034-5 6146 MG1-5
During operation, this equipment features protection
exposed energized or spinning parts which Cooling 60034-6 5110 MG1-6
may present high voltages or high Mounting 60034-7 5031 MG1-4
temperatures. Noise 60034-9 7565 MG1-9
Thus, the operation with open terminal Mechanical vibration 60034-14 5165 MG1-7
boxes, unguarded couplings, or improper
handling, failing to comply with the operating
standards, may cause severe personal
2.4 CHARACTERISTICS OF THE
injuries and material damages. ENVIRONMENT
The motors were developed for the following operating
The personnel in charge of the safety at installation must
conditions:
ensure that:
Only qualified personnel perform the installation and Ambient temperature: -15ºC to +40ºC;
operation of the equipment; Altitude up to 1,000 m.a.s.l.;
Such personnel must have immediate access to this Environment according to the motor degree of
manual and other documents provided with the motor protection.
as well as perform tasks in strict compliance with the
service instructions, relevant standards, and specific
ATTENTION
product documentation.
For motors with water cooling, the ambient
ATTENTION temperature should not be lower than +5ºC.
At temperatures below +5ºC, antifreeze
Failure to comply with the installation and additives must be added to the water.
safety standards will void the product
warranty.
Firefighting equipment and first aid notices Special operating conditions can be met on request,
must be available in visible and easily- which must be specified on the purchase order and are
accessible locations within the work site. described on the nameplate and specific data sheet for
each motor.
All qualified personnel must also observe: 2.5 OPERATING CONDITIONS

All technical data regarding allowed applications
(operating conditions, connections and installation For the product warranty to remain valid, the motor must
environment) provided in the catalog, purchase order operate according to the rated data indicated on the
documents, operating instructions, manuals, and other nameplate, and all applicable standards and codes, as
documentation;
well as the information provided in this manual, must be
The specific determinations and conditions for local
installation; observed.
The use of appropriate tools and equipment for
handling and transportation;

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3 RECEIVING, STORAGE AND HANDLING

3.1 RECEIVING 3.2.2 Outdoor storage
All the motors supplied are tested and are in perfect The motor must be stored in a dry location, free of
operating conditions. All machined surfaces are protected flooding and vibrations.
against corrosion. The package must be checked upon Repair all damages to the package before storing the
receipt for occasional damages during transportation. motor, which is necessary to ensure proper storage
conditions.
Place the motor on platforms or foundations to protect it
ATTENTION against land humidity and keep it from sinking into the soil.
Free air circulation underneath the motor must be
All damages must be immediately
assured.
photographed, documented, and reported to
The cover or canvas used to protect the motor against the
the transportation company, to the insurance
weather must not be in contact with its surfaces. In order
company and to WEG. Failure to comply with
to ensure free air circulation between the motor and such
such procedures will void the product
covers, place wooden blocks as spacers.
warranty.
3.2.3 Further care during storage
ATTENTION When the motor will be stored for over two months, the
Parts supplied in additional packages must be brushes must be lifted and removed from their holder in
checked upon receipt. order to prevent oxidation caused by the contact with the
commutator.
When lifting a package (or container), the correct ATTENTION

hoisting points, the weight indicated in the package or
on the nameplate, and the operating capacity of the Before putting the motor into operation, the
hoisting devices must be observed. brushes must be placed in their holders again
Motors packed in wooden crates must always be lifted and their proper setting must be checked.
by their own eyebolts or by a proper forklift, and must
never be lifted by its wooden parts;
The package must never be tumbled. Carefully place it
3.2.4 Extended storage
on the floor (without impact) to avoid bearing damage;
Do not remove the grease-based corrosion protection When the motor is stored for a long period of time
from the shaft end, nor the closing plugs in terminal box before being operated, it is exposed to external agents,
holes; such as temperature fluctuations, moisture, aggressive
These protections must remain in place until the final agents, etc.
assembly. A complete visual inspection of the motor Empty spaces inside the motor, such as bearing,
must be performed after removing the package; terminal boxes, and windings, are exposed to air
The shaft locking device must only be removed shortly humidity, which can cause condensation and,
before installing the motor and stored in a safe location depending on the degree of air contamination,
for future transportation. aggressive substances may also penetrate these empty
spaces.
Consequently, after long storage periods, the winding
3.2 STORAGE insulation resistance may drop below acceptable values.
Internal components, such as rolling bearings, may
Any damage to the painting or corrosion protection of the oxidize, and the lubricant power of the lubricant agent in
machined parts must be corrected. the bearings may be adversely affected.
All of these influences increase the risk of damage before
starting up the motor.
ATTENTION
Space heaters must remain active during
storage in order to avoid water condensation ATTENTION
inside the motor. All preventive measures described in this
manual, such as constructive aspects,
maintenance, packaging, storage, and
3.2.1 Indoor storage
periodical inspections, must be followed and
recorded in order to maintain the product
If the motor is not installed immediately after reception, it
warranty.
must remain inside the package and stored in a location
protected against humidity, vapors, fast heat variations,
rodents, and insects. The following instructions are valid for motors stored for
The motor must be stored in vibration-free locations in long periods of time and/or idle for two or more months
order to avoid bearing damage. before being operated.

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3.2.4.1 Storage location 3.2.4.2 Separate parts
In order to ensure the best storage conditions for the In case separate parts have been supplied (terminal
motor during long periods of time, the chosen location boxes, covers, etc.), these must be packed as specified
must strictly meet the criteria described below. in items Indoor Storage and Outdoor Storage of this
manual;
3.2.4.1.1 Indoor storage Air relative humidity inside package must not exceed
50%.
The storage room must be closed and covered;
The location must be protected against moisture, 3.2.4.3 Space heater
vapors, aggressive agents, rodents, and insects;
The location must be free of corrosive gases, such as
chlorine, sulphur dioxide, or acids; The motor space heaters must remain powered during
The environment must be free of continuous or storage to avoid moisture condensation inside the motor
intermittent vibrations; and ensure that the windings insulation resistance remains
The environment must present an air-filtered ventilation within acceptable levels.
system;
Ambient temperature between 5°C and 60°C, and must ATTENTION
not be subject to sudden temperature variations;
Relative humidity <50%; The motor space heater must be powered on
Protection against dirt and dust accumulation; while it is stored in a place with temperatures
It must feature a fire detection system; < 5°C and air relative humidity >50%.
The location must have power to supply the space
heaters.
3.2.4.4 Insulation resistance
In case the storage location does not meet any of these
requirements, WEG recommends that additional During the storage period, the motor windings insulation
protections be incorporated to the motor package during resistance must be measured and recorded quarterly
the storage period, as follows: before the motor installation.
Closed wooden crate or similar with proper electrical Any eventual insulation resistance reduction must be
installation, providing power to the space heaters. investigated.
If there is risk of infestation and fungus growth, the
package must be protected on the site by spraying or 3.2.4.5 Exposed machined surfaces
painting it with proper chemical agents;
Package preparation must be carefully executed by All exposed machined surfaces (e.g. shaft end and
experienced personnel. flanges) are factory-protected with a temporary rust
inhibitor.
3.2.4.1.2 Outdoor storage This protection film must be reapplied at least twice a year
or when removed and/or damaged.
Recommended Products:
ATTENTION Name: Dasco Guard 400 TX AZ, Manufacturer: D.A. Stuart
Ltda
Outdoor storage is not recommended
Name: TARP, Manufacturer: Castrol.
(weather).
In case outdoor storage is unavoidable, the motor must be

packed in a specific package for such condition, as
follows:
For outdoor storage, besides the packaging
recommended for internal storage, the package must
be covered with a protection against dust, moisture and
other foreign materials, using a resistant canvas or
plastic.
The package must be placed on platforms or
foundations, ensuring protection against dirt and
moisture and keeping the motor from sinking into the
soil;
After the motor is covered, a shelter must be
constructed in order to protect it against direct rain,
snow and excessive sun heat.
ATTENTION
In case the motor remains stored for long
periods of time, it is recommended to inspect
it regularly as specified in item Maintenance
plan during storage of this manual.

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3.2.4.6 Bearings
ATTENTION
3.2.4.6.1 Grease-lubricated rolling bearing
During storage period, every two months the
The rolling bearings are lubricated at the factory to shaft locking device must be removed and it
perform the tests in the motor. must be turned at 30 rpm in order to make
the oil circulate and keep the bearing in good
operating conditions.
ATTENTION
During storage period, every two months the If not possible to turn the motor shaft, the following
shaft locking device must be removed and it procedure must be carried out in order to protect the
must be turned at 30 rpm in order to make bearing inside and the contact surfaces against corrosion.
the grease circulate inside the rolling bearing Drain all the oil from the bearing;
and keep the bearing in good operating Disassemble the bearing;
conditions. Clean the bearing;
Apply an anticorrosive product (e.g.: TECTIL 511,
After 6 months of storage and before starting the Valvoline or Dasco Guard 400TXAZ) on the upper and
operation of the motor, the rolling bearings must be lower halves of the bearing sleeve and on the contact
relubricated. surface on the motor shaft;
If the motor remains stored for a period over two years, Assemble the bearing;
the rolling bearings must be disassembled, washed, Close all the threaded holes with plugs;
inspected and relubricated. Seal the interstices between the shaft and the bearing
seal on the shaft by applying water-proof adhesive
3.2.4.6.2 Oil-lubricated rolling bearing tape;
All the flanges (e.g.: oil inlet and outlet) must be
Depending on the assembly position, the motor can be protected with blind covers;
transported with or without oil in the bearings; Remove the upper sight glass from the bearing and
The motor must be stored in its original operation apply the anticorrosive spray inside the bearing;
position and with oil in the bearings, except when Put some dehumidifier bags (silica gel) inside the
specific documentation of the machine determines bearing. The dehumidifier absorbs the humidity and
another transportation and/or storage method; prevents condensation inside the bearing;
The oil level must be observed, remaining in the middle Close the bearing with the upper sight glass.
of the sight glass;
If the storage period exceeds 6 months.
Repeat the procedure described above;
ATTENTION Put new dehumidifier bags (silica gel) inside the bearing.
During storage period, every two months the If the storage period exceeds 2 years.
shaft locking device must be removed and it Disassemble the bearing;
must be turned at 30 rpm in order to make Preserve and store the bearing component parts.
the oil circulate and keep the bearing in good
operating conditions. 3.2.4.7 Brushes
After 6 months of storage and before starting the The brushes must be lifted on the brush holders, since
operation of the motor, the rolling bearings must be their contact with the collector rings during the storage
relubricated. period may cause oxidation of the commutator.
If the motor remains stored for a period over two years,
the rolling bearings must be disassembled, washed, 3.2.4.8 Terminal box
inspected and relubricated.
When the insulation resistance in the motor windings is
3.2.4.6.3 Sleeve bearing measured, the main junction box and the other terminal
boxes must also be inspected, especially considering the
Depending on the mounting position and lubrication following aspects:
type, the motor can be transported with or without oil in The inner part must be dry, clean, and free of any dust
the bearings and must be stored in the original accumulation;
operation position with oil in the bearings when The contact elements cannot be corroded;
specified; The sealing must remain under appropriate conditions;
The oil level must be observed, remaining in the middle The cable inlets must be correctly sealed.
of the sight glass. If any of these items is not correct, the parts must be
cleaned or replaced.

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3.2.4.9 Preparation for commissioning 3.2.4.10 Inspections and records during

storage
3.2.4.9.1 Cleaning
Stored motors must be periodically inspected and
The motor inner and outer parts must be free of oil, inspection records must be filed.
water, dust and dirt. The motor inner part must be
cleaned with compressed air at reduced pressure; The following points must be inspected:
Remove the rust inhibitor from the exposed surfaces 1. Physical damages;
with a cloth damped in a petroleum-based solvent; 2. Cleanliness;
Make sure the bearings and cavities used for lubrication 3. Signs of water condensation;
are free of dirt and the cavity plugs are correctly sealed 4. Protective coating conditions;
and tightened. Oxidation and marks on bearing seats 5. Paint conditions;
and on the shaft must be carefully removed. 6. Signs of vermin or insect activity;
7. Satisfactory operation of space heaters. It is
3.2.4.9.2 Bearing lubrication recommended that a signaling system or alarm be
installed in the location in order to detect power
Only use the specified lubricant to lubricate the bearings. interruption in the space heaters;
Information on bearings and lubricants are indicated on 8. Record ambient temperature and air relative humidity
the bearing nameplate, and lubrication must be performed around the machine, winding temperature (using
as described in the item Bearing maintenance of this RTDs), insulation resistance and index;
manual, always considering the relevant type of bearing. 9. The storage location must also be inspected to assert
its compliance with the criteria described in the item
Storage Plan.
NOTE
Sleeve bearings containing anticorrosive
products and dehumidifier bags must be
disassembled and washed, and the
dehumidifier bags removed.
Assemble the bearings again and lubricate.
3.2.4.9.3 Checking the insulation resistance
Before operating the motor, the insulation resistance must

be measured according to the item Insulation resistance of
this manual.
3.2.4.9.4 Brushes
Before installing and operating the motor, the brushes

should be lowered back to their original position.
3.2.4.9.5 Others
Follow the remaining procedures described in item

Commissioning of this manual before operating the motor.

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3.2.4.11 Maintenance plan during storage
During the storage period, the motor maintenance must be performed and recorded in accordance with the plan described
in Tabela 3.1.
.1: Storage plan

Before
Every 2 Every 6 Every
Monthly starting Note
months months 2 years
operation
Storage location
Inspect cleanliness conditions X X
Inspect humidity and temperature
X
conditions
Check signs of insects X
Measure vibration level X
Package
Inspect physical damages X
Inspect relative humidity inside X
Replace the dehumidifier in the package
X When necessary
(if applicable)
Space heater
Check operating conditions X
WHOLE MOTOR
Clean external part X X
Check paint conditions X
Check oxidation inhibitor in the exposed
X
machined parts
Reapply oxidation inhibitor X
Windings
Measure insulation resistance X X
Measure polarization index X X
Terminal box and grounding terminals
Clean the inner part of the boxes X X
Inspect the seals
Grease or oil rolling bearing
Spin the shaft X
Relubricate the bearing X X
Disassemble and clean the bearing X
Sleeve bearings
Spin the shaft X
Apply anticorrosive and dehumidifier X
Clean the bearings and relubricate them X
If the storage period
Disassemble and store the parts
exceeds 2 years
Brushes
Lift brushes During storage
Lower brushes and check contact with
X
the commutator

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3.3 HANDLING
Handling of vertical motors must be performed as shown
In order to lift the motor, use the eyes provided for that in Figure 3.2.
purpose only. If necessary, use a device to space the Always use the upper eyes of the motor for moving in the
lifting cables and thus protect parts of the motor; vertical position, ensuring that the lifting chains or cables
The frame eyebolts are designed to lift the motor only. also remain in the vertical position, thus avoiding too
Do not use them to lift the driven motor-machine unit; much effort in the eyes.
Observe the weight informed;
Do not lift the motor with jolts or place it abruptly on 3.3.2.1 Positioning of vertical motors
the floor, which can cause damages to the bearings;
The eyes on the covers, bearings, terminal box, etc., The vertical motors are supplied with eyes for lifting on
are designed to handle these components only; the front and rear.
Never use the shaft to lift the motor. Some motors are transported in the horizontal position
and need to be moved to their original position. The
following procedure shows the movement of the motors
ATTENTION from the horizontal to the vertical position and vice-versa.
In order to move or transport the motor, the
shaft must be locked with the lock device
supplied with the motor.
The lifting equipment and devices must be
capable of supporting the weight of the
motor.
3.3.1 Handling of horizontal motors
Máximo 30º
Figure 3.1: Handling of horizontal motors
Handling of horizontal motors must be performed as

shown in Figure 3.1.
The lifting chains or cables must have a maximum
angle of 30º to the vertical. Figure 3.3: Positioning of vertical motors
In order to lift the motor, use the eyes provided for that
purpose only. 1. Lift the motor by means of the side eyes using 2
hoists;
3.3.2 Handling of vertical motors 2. Lower the front part of the engine and at the same
time lift the rear part until it reaches balance;
3. Remove the cables from the front of the motor and
turn it 180º to allow the fixture of these cables to the
other eyes of the rear part of the motor;
4. Fix the loose cables to the eyes of the rear part of the
motor and lift it until it is in a vertical position.
ATTENTION
Noncompliance with these recommendations
may cause damage to equipment and/or
injury to people.
Figure 3.2: Handling of vertical motors

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4 INSTALLATION
4.1 LOCAL OF INSTALLATION 4.3.3 Measurement on the windings
Electric motors must be installed in easily accessible The insulation resistance must be measured with a
places, allowing periodic inspections, local maintenance megohmmeter. The test voltage for motor windings must
and, if necessary, removal for external services. be in accordance with the IEEE43 standard.
The following environment characteristics must be
ensured: Table 4.1: Voltage for the insulation resistance test of the
windings
Clean and well-ventilated location;
The installation of other equipment or walls must not Winding rated Insulation resistance test -
block or hinder the motor ventilation; voltage (V) continuous voltage (V)
The area around and above the motor must be < 1000 500
sufficient for its maintenance or handling; 1000 - 2500 500 - 1000
Fan cooled motors must be at least 50mm above the 2501 - 5000 1000 - 2500
floor to allow air inlet; 5001 - 12000 2500 - 5000
The environment must be in accordance with the motor > 12000 5000 - 10000
protection degree.
Before measuring the winding insulation resistance, check
4.2 DIRECTION OF ROTATION that:
The brushes are lifted;
The motor rotation direction is indicated on a plate fixed to All power cables are disconnected;
the frame on the drive end. The motor frame is grounded;
The winding temperature was measured;
All temperature sensors are grounded.
ATTENTION
Motors supplied with a single direction of Measure the winding insulation resistance as follows:
rotation must not operate in the opposite Commutation/compensation winding:
direction. Terminal B2 and frame;
In order to operate the motor in the opposite Excitation winding:
direction, please contact WEG. Terminals F1 / F2 and frame;
Armature winding: Wrap the commutator with a bare
flexible wire (or flexible braid) and measure the
commutator insulation resistance to the ground (frame).
4.3 INSULATION RESISTANCE
4.3.1 Safety Instructions ATTENTION
Much higher values may be frequently obtained
DANGER in motors being operated for a long period of
time. Comparison with values obtained in
In order to measure the insulation resistance, previous tests in the same motor, under similar
the motor must be shutdown and still. load, temperature, and humidity conditions, may
The winding being tested must be connected be an excellent parameter to evaluate the
to the frame and grounded until all residual winding insulation conditions, instead of
electrostatic charges are removed. exclusively using the value obtained in a single
Noncompliance with these procedures may test as the basis. Significant or abrupt reductions
result in personnel injuries. in the insulation resistance are considered
suspicious.
4.3.2 General considerations
When motor is not immediately operated, it must be

protected against moisture, high temperatures, and dirt,
avoiding impacts to the insulation resistance.
Winding insulation resistance must be measured before
operating the motor.
If the environment is too humid, the insulation resistance
must be measured periodically during storage. It is difficult
to establish fixed rules for the actual value of a motor
insulation resistance, as it varies according to
environmental conditions (temperature, humidity), machine
cleanliness conditions (dust, oil, grease, dirt), and quality
and condition of the insulating material used.
Evaluating periodical follow-up records is useful to
conclude whether the motor is able to operate.

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Table 4.2: Insulation resistance referential limits in electric

machines
Insulation resistance value Insulation evaluation
2MΩ or less Bad

< 50MΩ Dangerous
50...100MΩ Regular
100...500MΩ Good
500...1000MΩ Very Good
Coefficient of insulation resistance variation Kt40ºC

> 1000MΩ Excellent
4.3.4 Minimum insulation resistance
If the measured insulation resistance is below 100MΩ at

40ºC, before putting the motor into operation, contact
WEG.
4.3.5 Conversion of measured values
The insulation resistance must be kept at 40°C. If the

measurement is performed at a different temperature, it
will be necessary to correct the reading to 40°C by using
an insulation resistance variation curve according to the
temperature obtained from the motor itself. If this curve is
not available, the approximate correction provided by the
curve in Figure 4.1, according to the NBR 5383 / IEEE43
standard, may be employed.
4.4 PROTECTIONS
4.4.1 Thermal protections
The protection devices against overheating are installed on

the poles, bearings and other component parts that
require temperature monitoring and thermal protection. To convert the measured insulation resistance
(Rt) for 40ºC, multiply it by the temperature
Those devices must be connected to an external coefficient (Kt)
temperature monitoring and protection system.
4.4.1.1 Temperature sensors

Thermostat (bimetallic) - Bimetallic thermal detectors
Temperatura do enrolamento ºC
with normally closed silver contacts. They open at a
R40ºC = Rt x Kt40ºC
certain temperature. The thermostats are connected in
series or independently according to the wiring diagram. Figure 4.1: Insulation resistance variation coefficient according to
Thermistors (PTC or NTC) - Thermal detectors the temperature
composed of semiconductors that vary their resistance
sharply when they reach a certain temperature.
Thermistors are connected in series or independently
according to the wiring diagram. NOTE
The RTD thermoresistors provide monitoring by
NOTE means of the absolute temperature informed
by its instant resistance value. With this
The thermostats and thermistors must be information, the relay can perform the reading
connected to a control unit which will interrupt of the temperature, as well as the
the supply of the motor or will activate a parameterization for alarm and tripping
signaling device. according to the preset temperatures.
Thermoresistance Pt100 - Calibrated resistance element. 4.4.1.2 Temperature limits for the windings
Its operation is based on the principle that the electric
resistance of a metallic conductor varies linearly with the The temperature of the winding hottest spot must be kept
temperature. The detector terminals must be connected below the insulation thermal class limit. The total
to a control panel, which includes a thermometer. temperature is composed by the ambient temperature
plus temperature elevation (ΔT), plus the difference
between the average winding temperature and the
winding hottest spot temperature.

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The ambient temperature is normally, at most, 40°C. stator winding insulation class and for the bearings
Above this value, the working conditions are considered (according to the lubrication system).
special.
The numeric values and the composition of the acceptable Table 4.4: Stator maximum temperature
temperature at the winding hottest spot are indicated in Class of Maximum temperature set for
Table 4.3. Temperature - UL508 protections (ºC)
Alarm Tripping
Table 4.3: Insulation class F 130 155
H 155 180
Insulation class F H
Ambient temperature °C 40 40 Table 4.5: Maximum temperature of the bearings
ΔT = temperature rise (temperature Maximum temperature set for protections (ºC)
°C 105 125
measurement method by resistance variation) Alarm Tripping
Difference between the hottest spot and the 110 120
°C 10 15
average temperature
Total: hottest spot temperature °C 155 180
ATTENTION
ATTENTION The alarm and tripping values may be
determined as a result of experience, but
In case the motor operates with temperatures
cannot exceed the values indicated in Table
in the windings above the limit values of the
4.4 and Table 4.5.
insulation thermal class, the useful life of the
insulation and, consequently, of the motor, will
be significantly reduced or it may even cause
the burnout of the motor. ATTENTION
The motor protection devices are listed in the
4.4.1.3 Alarm and tripping temperatures WEG design - Specific wiring diagram of each
motor.
The temperature level for alarm and tripping must be set The decision of not using those devices is full
as low as possible. This temperature level can be responsibility of the user; and in case of
determined based on test results or through the motor damages, it can void the warranty.
operating temperature. The alarm temperature can be set
for 10ºC above the machine operating temperature at full
load, always considering the highest local ambient
temperature. The temperature values set for tripping must
not exceed the maximum acceptable temperatures for the
4.4.1.4 Temperature and ohm resistance of the thermoresistors PT100
Table 4.6 shows the temperature values as a function of the ohm resistance measured for thermoresistances PT100 type.
Formula: Ω - 100 = °C
0.386
Table 4.6: Temperature X Resistance (Pt100)
ºC 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67

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4.4.1.5 Space heater
When the motor is equipped with space heaters to ATTENTION

prevent water from condensing inside during long periods The data of the heat exchangers that
out of operation, you must ensure they are powered on compose the air-water heat exchanger are
right after the motor is shut down and that they are described on the nameplate and dimension
powered down before the motor goes into operation. drawing of the motor.
The motor wiring diagram and a specific nameplate fixed This data must be observed for the proper
to the motor specify the power supply and power rating of operation of the motor cooling system and
the space heaters. thus prevent overheating.
4.4.2 Water leak sensor

4.5.1.1 Heat exchangers for application with
Motors with air-water heat exchanger feature a water leak seawater
sensor intended to detect any water leak from the heat
exchanger into the motor. This sensor must be connected
to the control panel, according to the wiring diagram of ATTENTION
the motor. The signal of this sensor must be used for In case of heat exchangers to work with
alarm. seawater, in order to avoid corrosion, the
When this protection goes off, the heat exchanger must materials in contact with water (pipes and
be inspected and, if any water leak is detected, the motor flush plates) must be resistant to corrosion.
must be shut down and the problem corrected. Besides, the heat exchangers may feature
sacrificial anodes (for instance: zinc or
4.5 COOLING manganese) according to Figure 4.2. In this
application, anodes are corroded during
Only the proper installation of the motor and of the cooling operation of the heat exchanger, protecting
system can ensure its continuous operation without the exchanger heads.
overheating. In order to keep the integrity of the heads,
these anodes must be periodically replaced,
4.5.1 Water heat exchangers according to the corrosion degree presented.
The water heat exchanger (when used) is a surface heat

transmitter designed to dissipate heat of electrical
equipment or others in an indirect way, that is, air in
closed circuit is cooled by the heat exchanger after
removing the heat generated by the equipment that must
be cooled.
The heat transmission occurs from the equipment to the
air and from the air to the water.
Sacrificial Anodes
NOTE
The protection devices of the cooling system
must be monitored periodically;
NOTE
Figure 4.2: Heat exchanger with sacrificial anodes
The water inlets and outlets must not be
blocked, since that could cause overheating
and even the burnout of the motor. NOTE
The type, quantity and position of the
Clean water, with the characteristics below, must be used sacrificial anodes may vary from application to
as coolant: application.
PH: 6 to 9;
Chlorides: maximum 25.0 mg/l;
Sulfates: maximum 3.0 mg/l; 4.5.2 Independent fans
Manganese: maximum 0.5 mg/l;
Suspended solids: maximum 30.0 mg/l; Independent fans (when used) normally feature a three-
Ammonia: no traces phase asynchronous motor for the drive. The terminal box
of this motor is normally located on its frame. The
characteristic data (frequency, voltage, etc.) are indicated
on the nameplate of this motor and the direction of
rotation is generally indicated by a plate with an arrow
fixed to the fan housing or close to it.

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NOTE ATTENTION
Inspect visually the direction of rotation of the Before making the connections between the
independent fan before starting the machine. motor and the electric energy, it is necessary
If the fan is turning in the wrong direction, the to measure carefully the winding insulation
connection of two phases of the fan must be resistance.
inverted.
In order to connect the motor main power supply cables,
Also, the air filters that protect the motor inside against unscrew the stator terminal box cover, cut the sealing
contamination must be checked periodically. The filters rings (standard motors without cable gland) according to
must be kept in perfect conditions to ensure the proper the diameter of the cables to be used and insert the
operation of the cooling system and safe protection of the cables inside the sealing rings. Cut the power supply
sensitive internal parts of the motor. cables to the necessary length, strip the ends and mount
the terminals to be used.
4.6 ELECTRICAL CHARACTERISTICS
4.6.1.2 Grounding
4.6.1 Electric connections
The motor frame and the main terminal box must be
4.6.1.1 Main connection grounded before connecting the motor to the supply
system.
The motor stator terminals are fixed in insulators in the main Connect the metal cover of the cables (if applicable) to the
terminal box or by means of copper terminals, depending common grounding conductor. Cut the grounding
on the mounting style of the motor. conductor to the proper length and connect it to the
The location of the terminal boxes is identified in the specific connector in the terminal box and/or frame.
dimension drawing of each motor. Fasten all connections firmly.
The connections to the terminals must be done according
to the specific connection diagram for the motor.
Make sure the section and insulation of the connection
ATTENTION
cables are suitable for the motor current and voltage. Do not use steel washers or another low
The identification of the terminals and the corresponding electric conductivity material to fasten the
connection are indicated in the connection diagram terminals.
specific for each motor, in compliance with IEC60034-8 or
NEMA MG1 standards.
The direction of rotation of the motor can be changed by Before making connections, apply protective grease on all
reversing the polarity of the power supply of the excitation connections of the contacts.
or the armature. The motor must rotate in the direction of Insert all the sealing rings in the respective slots. Close the
rotation specified on the indicative connection plate fixed terminal box cover, always observing if the sealing rings
on the motor. are correctly placed.
ATTENTION
The inversion of the field can only occur with
the motor off.
NOTE
The direction of rotation is determined looking
at the shaft end from the drive end of the
motor.
Motors with a single direction of rotation must
only turn in the indicated direction, since the
fans and other devices are unidirectional.
In order to operate the motor in the direction
of rotation opposite the specified, contact
WEG.

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4.6.2 Wiring Diagram
4.6.2.1 Main terminal box
Wiring diagram with independent excitation – Code 9201 Wiring diagram with additive compound excitation - Code 9213
Clockwise rotation Clockwise rotation
Counterclockwise rotation.
Counterclockwise rotation
Wiring diagram with series excitation – Code 9202

Clockwise rotation
Counterclockwise rotation
When the terminals “F1+” and “F2” are connected to a rail with connectors (terminal block), the cable identification is
performed with sleeve and label, with an indication in accordance with the diagram Y:
Diagram 4.1: Identification of excitation cables (sleeves and labels)
XA - B - C
C: WEG Symbols, used to indicate the excitation terminals. The terminals are F1+,
F2-, as per connection diagrams above.
B: Indicates the connector number (terminal) to which the excitation terminal is

connected.
X: Indication of rail with connectors (terminal block);

A: Indicates the number of the rail with connectors where the excitation terminal is
connected.

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4.6.2.2 Accessory terminal box
ATTENTION
In case of anticipation of terminal box for accessories, there will be the connecting terminals of the thermal
protectors and other accessories. Otherwise, the terminals of the accessories will be in the main box.
4.6.2.3 General identification of the accessories and instrument
All the accessory and instrument cables are identified through sleeves with labels. These sleeves with labels are mounted in
the accessory and instrument cables and are located near the rail with connectors.
The identification of the accessory and instrument cable is performed by means of the encoding system according to
Diagram 4.2.
NOTE
When supplied the wiring diagram of the machine accessories and instrument, the information of the
diagram prevails in relation to the information contained in this item of the manual.
Diagram 4.2: Identification of the instrument cables (sleeves and labels)
XA - B - CDE
WEG Terminology, based in international standards, used to denote accessories

and instruments and their cables. This nomenclature is composed by:
C: Number assigned to the instrument or accessory.
When the instrument is for measuring temperature, it is attributed:
1 to 6 – Installation on the commutation pole(s);
7 to 12 - Installation on the excitation pole(s);
13 and 14 – Installation on the bearing(s);
15 to 20 – Installation on the compensation poles;
D: Letter(s)that defines the type of accessory or instrument, according to
Table 4.7.
E: Number corresponding to the accessory or instrument cable.
B: Indicates the connector number (terminal) to which the accessory or instrument

cable is connected.
X: Indication of rail with connectors (terminal block);

A: Indicates the number of the rail with connectors where the connector to which
the accessory or instrument cable is connected is locaed.

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Table 4.7: Codes of the terminology of accessories and instruments

ORDER CODE ACCESSORY / INSTRUMENT
1 TP Thermoresistance (PTC)
2 TN Thermoresistance (NTC)
3 R Thermoresistance (Pt-100)
4 TC Thermocouple
5 TB Thermostat
6 TE Thermometer with electric contacts
7 HE Space heater
8 SE Tachometric dynamo (tacogenerator)
9 SZ Pulse generator (Encoder)
10 SY Rotation sensor
11 CR Water leak sensor of the heat exchanger
12 BA AC brake
13 BD DC brake
14 F1+, F2- Main excitation
15 FW Water flow switch
16 FO Oil flow switch
17 FA Air flow switch
18 PW Pneumatic pressure switch
19 PO Differential pneumatic pressure switch
20 LW Level sensor
21 VS Vibration transducer (displacement)
22 VE Vibration transducer (speed)
23 VP Vibration transducer (acceleration)
NOTE
The column “Order” of Table 4.7 indicates the mounting sequence of the cables on the rail with connectors
according to the accessory or instrument type.
4.6.2.3.1 Thermostat wiring diagram
On the commutation pole (one per pole) - Code 9225.
1TB 2TB 3TB 4TB 5TB 6TB

XA-B-1TB1
XA-B-2TB1
XA-B-3TB1
XA-B-4TB1
XA-B-5TB1
XA-B-6TB1
XA-B-1TB2
XA-B-2TB2
XA-B-3TB2
XA-B-4TB2
XA-B-5TB2
XA-B-6TB2
On the excitation pole (one per pole) - Code 9226.

XA-B-10TB1
XA-B-11TB1
XA-B-12TB1
XA-B-10TB2
XA-B-11TB2
XA-B-12TB2
XA-B-7TB1
XA-B-8TB1
XA-B-9TB1
XA-B-7TB2
XA-B-8TB2
XA-B-9TB2

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One on the commutating winding, one on

One on the commutating pole and one
the excitation winding and one on the
on the excitation pole (connected in One per bearing – Code 9230
compensation winding (connected in
series) - Code 9227
series) - Code 9228
13TB 14TB
1TB 7TB
1TB 7TB 15TB
XA-B-14TB1
XA-B-13TB1
XA-B-13TB2
XA-B-14TB2
XA-B-15TB2
XA-B-1TB1
XA-B-7TB2
XA-B-1TB1
DE bearing NDE
bearing
On the compensation winding (one per pole) - Code 9231

XA-B-15TB1
XA-B-16TB1
XA-B-17TB1
XA-B-18TB1
XA-B-19TB1
XA-B-20TB1
XA-B-15TB2
XA-B-16TB2
XA-B-17TB2
XA-B-18TB2
XA-B-19TB2
XA-B-20TB2
4.6.2.3.2 Thermistor (PTC) wiring diagram
On the commutation winding (one per pole) - Code 9222
1TP 2TP 3TP 4TP 5TP 6TP
t° t° t° t° t° t°
XA-B-2TP1
XA-B-3TP1
XA-B-4TP1
XA-B-6TP1
XA-B-1TP1
XA-B-5TP1
XA-B-1TP2
XA-B-2TP2
XA-B-3TP2
XA-B-4TP2
XA-B-5TP2
XA-B-6TP2
On the excitation winding (one per pole) - Code 9223
t° t° t° t° t° t°
XA-B-10TP1
XA-B-12TP1
XA-B-11TP1
XA-B-10TP2
XA-B-11TP2
XA-B-12TP2
XA-B-8TP1
XA-B-7TP1
XA-B-9TP1
XA-B-7TP2
XA-B-8TP2
XA-B-9TP2

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Two on the commutating winding and one on the excitation winding

One per bearing – Code 9239
- Code 9224
13TP 14TP
1TP 2TP 7TP
t° t°
t° t° t°
XA-B-13TP1
XA-B-14TP1
XA-B-13TP2
XA-B-14TP2
XA-B-1TP1
XA-B-2TP1
XA-B-7TP1
XA-B-1TP2
XA-B-2TP2
XA-B-7TP2
DE bearing NDE bearing
t° t° t° t° t° t°
XA-B-15TP1
XA-B-16TP1
XA-B-17TP1
XA-B-18TP1
XA-B-19TP1
XA-B-20TP1
XA-B-15TP2
XA-B-16TP2
XA-B-17TP2
XA-B-18TP2
XA-B-19TP2
XA-B-20TP2
One on the commutating winding, one on the excitation winding and one on the compensation winding - Code 9238
1TP 7TP 15TP
t° t° t°
XA-B-15TP1
XA-B-15TP2
XA-B-1TP1
XA-B-7TP1
XA-B-1TP2
XA-B-7TP2

XA-B-1R1 XA-B-15R1 XA-B-7R1 XA-B-1R1
t°
7R
t°
t°
t°
1R
1R
15R
t°
8R
t°
t°
t°
2R
7R
16R
t°
9R
t°
t°
t°
3R
17R
15R
4.6.2.3.3 Thermosensor (Pt-100) wiring diagram
One on the commutating winding, one on the excitation winding

and one on the compensation winding (one per pole) - Code 9234
XA-B-18R1 XA-B-10R1 XA-B-4R1
t°
t°
10R
t°
4R
XA-B-13R1
XA-B-18R2 18R XA-B-10R2 XA-B-4R2
t°
13R
On the excitation winding (one per pole) - Code 9221
DE bearing
XA-B-13R2
On the commutation winding (one per pole) - Code 9219

t°
t°
11R
t°
5R
19R
XA-B-13R2
XA-B-14R1
t°
14R
One per bearing – Code 9236 XA-B-20R1 XA-B-12R1 XA-B-6R1
XA-B-14R2
10061218 – DC Motors – D Series

t°
12R
t°
t°
6R
20R
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|
XA-B-14R2 XA-B-12R2
XA-B-20R2 XA-B-6R2
NDE bearing
29
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4.6.2.3.4 Space heater wiring diagram
.. .. B1 B2 B3 B4 .. .. .. .. B1 B2 B3 B4
2 Connector bridges 1 Connector bridge

Arrangement layout with two space heaters Arrangement layout with four space heaters
1HE 2HE
XA-B2-3HE1
XA-B4-4HE2

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4.7 MECHANICAL 4.7.3 Base types

CHARACTERISTICS
4.7.3.1 Concrete base
4.7.1 Foundations The concrete bases are the most widely used for the
installation of these motors.
The foundation or structure where the motor will be The type and size of the foundation, bolts and anchoring
installed must be properly strong and flat, free of plates depend on the motor size and type.
external vibration and capable to stand the mechanical
forces it will undergo during the start or short circuit of
4.7.3.2 Sliding base
the motor;
The type of foundation will depend on the kind of soil at
In pulley drive, the motor must always be mounted on the
the assembly site or on the floor resistance;
sliding base (rails) and the lower part of the belt must be
If the dimensioning of the foundation is not carefully
tractioned.
done, serious vibration problems may affect the
The closest rail to the driving pulley must be mounted so
foundation set, motor and driving machine;
that the positioning bolt stays between the motor and the
The structure dimensioning of the foundation must be
driven machine. The other rail must be mounted with the
done based on the dimension drawing, on the
bolt in the opposite position as shown in Figure 4.4.
information regarding the mechanical forces on the
The motor is bolted on rails and positioned on the
foundations, and on the form of fixing the motor.
foundation.
The driving pulley is then aligned so as its center is in the
ATTENTION same plane as that of the driven pulley and the motor and
machine shafts are parallel.
Use shims of different thicknesses (total The belt must not be too tensioned. After the alignment,
thickness of approximately 2 mm) between the rails are fixed.
the motor feet and the foundation surfaces so
that later you can make a precise vertical
alignment.
NOTE
The user is responsible for dimensioning and
building the foundation.
Figure 4.4: Sliding base
4.7.2 Forces on the foundations 4.7.3.3 Metal base
Based on Figure 4.3, the forces on the foundation can be The motor feet must be settled evenly on the metal base
calculated by the equations: so as to prevent deformations of the frame. Occasional
height errors of the motor foot rest surface can be
corrected with shims (a maximum height of 2 mm is
(4C max)
F1 = +0.5.m.g . + recommended).
( A) Do not remove the machines from the common base to
(4C max) align them. The base must be leveled on the foundation
F2 = +0.5.m.g . − itself by using spirit levels or other leveling devices.
( A) When a metal base is used to adjust the height of the
Where: F1 and F2 - Reaction of the feet on the base (N) motor shaft end with the machine shaft end, it must be
g - Gravity acceleration (9.81m/s²) leveled on the concrete base.
m - Motor mass (kg) After the base is leveled, the anchors tightened and the
Cmax - Maximum torque (Nm) couplings checked, the metal base and the anchors are
A - Obtained from the motor dimension drawing cemented.
(m)
4.7.3.4 Anchors
Anchors are devices to fix motors directly on the

foundation, when the motors are applied with elastic
coupling. This kind of coupling is characterized by the
absence of force on the bearings, besides presenting
lower investment costs.
Anchors must not be painted, neither present rust, as this
would be detrimental to the adherence of the concrete
and would cause their take-up.
Figure 4.3: Forces on the foundations

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half the difference of the dial gauge measurement in the 0°

and 180° points represents the vertical coaxial error. In
case of deviation, it must be properly corrected, adding or
removing assembly shims. Half the difference of the dial
gauge measurement in the 90º and 270º points represents
the horizontal coaxial error.
This measurement indicates when it is necessary to lift or
lower the motor, or move it to the right or to the left on the
driven side in order to eliminate the coaxial failure.
Figure 4.5: Anchors Half the difference of the dial indicator maximum
measurement in a complete turn represents the maximum
4.7.6 Foundation natural frequency found run out.
The misalignment in a complete turn of the rigid or semi-
In order to ensure a safe operation, besides a solid flexible coupling cannot exceed 0.03 mm.
foundation, the motor must be precisely aligned with the When flexible couplings are used, values that are greater
equipment it is coupled with, and the component parts than those indicated above are acceptable, provided that
mounted on its shaft must be properly balanced. they do not exceed the acceptable value specified by the
With the motor mounted and coupled, the relations coupling manufacturer.
between the natural frequencies of the foundation are: Maintaining a safety margin for these values is
The motor rotation frequency; recommended.
The double of the rotation frequency;
The double of the line frequency. Angular misalignment
These natural frequencies must be in accordance with the

specified below:
Natural frequency of the first order of the foundation ≥
+25% or ≤ -20% in relation to the frequencies above;
Natural frequencies of the foundation of higher orders ≥
+10% or ≤ -10% in relation to the frequencies above.
4.7.4 Alignment and leveling
The motor must be correctly aligned with the driven

machine, mainly when using the direct coupling.
Incorrect alignment can damage the bearings, generate
excessive vibration and even break the shaft. Horizontal Mount Vertical Mount
The alignment must be carried out according to the
Axial measurement
recommendations of the coupling manufacturer.
Especially in direct couplings, the motor and driven Figure 4.7: Angular alignment
machine shafts must be aligned in the axial and radial
directions, as shown in Figure 4.6 and Figure 4.7. Figure 4.7 shows the angular misalignment and a practical
form to measure it.
Parallel misalignment
Measurement is performed in four points with a 90°
displacement from each other and with the two half-
couplings spinning together in order to eliminate the effects
of irregularities on the support surface on the tip of the dial
gauge. Choosing a vertical point greater than 0°, half the
difference of the dial indicator measurement in the 0° and
180° points represents a vertical misalignment. In case of
deviation, it must be properly corrected, adding or removing
assembly shims from the motor feet.
Half of the dial indicator measurement difference in the 90°
and 270° points represents a horizontal misalignment,
which must be adequately corrected by displacing the
motor in the lateral/angular direction.
Horizontal Mount Vertical M Half the difference of the dial indicator maximum
measurement in a complete turn represents the maximum
Radial measurement angular misalignment found.
Figure 4.6: Parallel alignment
The misalignment in a complete turn of the rigid or semi-
Figure 4.6 shows the parallel misalignment of the two flexible coupling cannot exceed 0.03 mm.
shaft ends and a practical form to measure it by using When flexible couplings are used, values that are greater
proper dial gauges. than those indicated above are acceptable, provided that
Measurement is performed in four points with a 90° they do not exceed the acceptable value specified by the
displacement from each other and with the two half- coupling manufacturer.
couplings spinning together in order to eliminate the Maintaining a safety margin for these values is
effects of irregularities on the support surface on the tip of recommended.
the dial gauge. Choosing a vertical point greater than 0°,

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In the alignment/leveling, the influence of temperature on 4.7.5.2 Coupling by gears

the motor and driven machine must be taken into
account. Different dilatations of the component parts may Coupling by gears poorly aligned generate vibration in its
change the alignment/leveling conditions during operation. transmission and motor. Therefore, the shafts must be
perfectly aligned, precisely parallel in the case of straight
4.7.5 Couplings gears and in the precise angle in the case of helical or
bevel gears.
Only proper couplings must be used, which convey only The perfect gear alignment can be controlled by inserting
torque, without generating transversal forces. a paper strip which will show the trace of all the teeth after
The centers of the motor and driven machine shafts must a complete turn of the gear.
be in a single line for elastic and rigid couplings as well.
Elastic couplings aim at mitigating the residual 4.7.5.3 Coupling by means of pulleys and
misalignment effects and preventing vibration transmission belts
between the coupled machines, which does not happen
when you use rigid couplings.
The coupling must be assembled or removed with the aid Correct
of proper devices and never by means of rudimentary
tools, such as hammers, mallets, etc.
Incorrect
ATTENTION
Pins, nuts, washers and leveling shims may Incorrect
be supplied with the motor when requested
by the customer in the purchase order. Figure 4.9: Coupling by means of pulleys and belts
When a speed ratio is necessary, the drive by belt is the

NOTES most commonly used.
In order to avoid unnecessary radial force on the bearings,
The user is responsible for installing the the shafts and pulleys must be perfectly aligned.
motor. Belts that work diagonally convey impacts to the rotor and
WEG is not liable for damages to the motor, may damage the bearing seat.
associated equipment and installation Belt slippage can be prevented by applying some resin
occurred due to: such as pitch.
Excessive vibration transmission; The belt tension must be just enough to prevent slippage
Poor installations; during operation.
Faulty alignment;
Improper storage conditions;
Noncompliance with the instructions before NOTE
commissioning; Belts too tensioned increase the stress on the
Incorrect electric connections. shaft end, causing vibration and fatigue, or
even the break of the shaft.
4.7.5.1 Direct coupling
Avoid using too small pulleys; they cause bends in the
Because of costs, space, absence of belt sliding, and motor because the tension increases in the belt as the
greater safety against accidents, direct coupling must be diameter of the pulley decreases.
used whenever possible. Also in case of using reduction
gearing, direct coupling is recommended.
ATTENTION
ATTENTION In each specific case of the pulley
dimensioning, WEG must be consulted to
Carefully align the shaft ends, and, whenever ensure correct application.
possible, use flexible coupling, leaving a
minimum clearance of 3 mm between the
couplings as shown in Figure 4.8.
NOTE
Always use pulleys properly balanced. Avoid,
in all cases, parts of the key, because they
represent an increase of the unbalancing
mass. If this is not observed, there will be an
increase in vibration levels.
8: of coupling (E)

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4.7.5.4 Coupling of motors equipped with In operation, the arrow must be positioned on the
sleeve bearings central mark (red), which indicates that the rotor is in its
magnetic center;
Axial clearance Axial clearance During the start, or even in operation, the motor may
move freely between the two external limit marks.
ATTENTION
Under no circumstances can the motor
operate constantly under axial force on the
bearing.
Shaft
The sleeve bearings used are not designed to stand
Bearing shell constant axial stress.
After aligning the set and having assured a perfect

Figure 4.10: Sleeve bearing alignment (both, cold and hot), the motor must be fixed on
the anchor plate or on the base, as shown in Figure 4.12.
Motors equipped with sleeve bearings must operate
with direct coupling to the driven machine or by means
of a gear box. This kind of bearing does not allow
coupling by pulleys and belts.
Motors equipped with sleeve bearings have three marks
on the shaft end, seeing that the central mark (painted red)
is the indication of the magnetic center, and the two
external marks indicate the allowed limits of axial
Weld in 4 spots
movement of the rotor.
Figure 4.12: Fixing of the motor
Axial clearance
Figure 4.11: Magnetic center mark
For the motor coupling, the following factors must be

taken into account:
Bearing axial clearance;
Axial displacement of the driven machine (if applicable);
The maximum axial clearance allowed by the coupling.
ATTENTION
Move the shaft fully forward and then
properly measure the axial clearance;
Carefully align the shaft ends, and,
whenever possible, use flexible coupling,
leaving a minimum clearance of 3 to 4 mm
between the couplings.
NOTE
If it is not possible to move the shaft, you
must consider the shaft position, the travel of
the shaft forward (according to the marks on
the shaft) and the axial clearance
recommended for the coupling.
Before starting operation, you must check if the motor

shaft allows free axial movement within the clearance
conditions aforementioned;

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5 START
The start of DC motors may be classified by the types of drives, as described below:
5.1 POWER SUPPLIES d. Pure DC (Battery bank )
In order to obtain a DC voltage of variable level, you can In case of pure DC or battery bank start, WEG
use various methods, some listed below: recommends that you use start resistors to drive the DC
motor.
The use of start resistors is intended to limit the current of
a. Starting Switches
the DC motor during its start.
The armature and field current can be set by means of
variable resistances on scales. K1 K2 K3 KX
The disadvantage is the high heat losses generated.
R1 R2 R3 RX
b. Ward-Leonard system
RA
The requirement for drives with fast regulation of the
rotation without scaling was met by the Ward-Leonard UA
regulation system.
Rotation of the DC motor can be changed continuously E Vti
by varying the exciting current of the generator. Its
disadvantage is the use of at least 3 machines. {R1, R2,...Rx - Resistors} - {K1, K2,...Kx - Connectors}
Figure 5.1: Electric diagram of DC motor by resistance
c. Static converters
These converters basically consist of a thyristor rectifier

bridge that provides DC voltage with variable tension ATTENTION
from a variable DC voltage.
The start by means of battery accumulators
The converters can be powered by three-phase network without using a start resistor may cause
in 220, 380 or 440V or by single-phase network, damage to the DC motor, due to the high
connected between phase and neutral or between phase start current, and, depending on the number
and phase. This will basically depend on the motor power of starts, it can decrease the battery useful
and its application in the system to drive. life.
Table 5.1: Usual voltages – DC Drives

Power Supply (V)
Single phase Three phase
220 380 440 220 380 440
Armature voltage
170
230
260
300
340
400
460 460
520
Field voltage
190 190
310 310
ATTENTION
In case of doubt about the converter, refer to
the manufacturer of this equipment.

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6 COMMISSIONING
6.1 PRELIMINARY INSPECTION 6.2 INITIAL START-UP
Before the first motor start or after a long time out of After all the inspections described above have been
operation, the following items must be checked: made, the following procedures must be followed to
1. The motor fixing bolts must be tightened; perform the motor initial start-up:
2. Measure the insulation resistance of the windings, 1. Disconnect all space heaters;
making sure they are within the specified value; 2. Adjust the protections in the control panel;
3. Check if the motor is clean and if the packages, 3. In oil-lubricated bearings, check the oil level;
measuring instruments and alignment devices were 4. In forced-lubrication bearings, start the oil circulation
removed from the motor operating area; system and check the level, the flow and oil pressure,
4. Check if coupling connecting components are in ensuring they comply with the data on the nameplate.
perfect operating conditions, duly tightened and 5. If the system has an oil flow detection device, you
greased, when necessary; must wait for the flow return signal of the circulation
5. The motor must be properly aligned; system of both bearings, which ensures the oil has
6. Check if the bearings are properly lubricated. The reached the bearings;
lubricant must be of the type specified on the 6. Start the cooling industrial water system and check
nameplate. the required flow and pressure (motors with air-water
7. Check the oil level in the motors with oil-lubricated heat exchanger);
bearings. Bearings with forced lubrication must have 7. Turn on the fans (motors with forced ventilation);
the oil pressure and flow as specified in their 8. Rotate the motor shaft slowly to make sure there are
nameplate; no parts dragging or unusual noises are occurring;
8. Inspect the cable connections of accessories 9. After the above steps have been completed
(thermal protectors, grounding, space heaters, etc.); satisfactorily, you can proceed with the star sequence
9. Check if all electric connections comply with the of the motor;
motor wiring diagram; 10. Start the motor, by first applying the excitation
10. The motor must be properly grounded; voltage (field);
11. The conductors connected to the main terminals 11. Soon after, apply voltage on the armature,
must be properly tightened to make a short circuit accelerating the motor up to the rated speed;
impossible or that they eventually get loose; 12. Check the direction of rotation with the motor
12. Inspect the cooling system. In motors with water uncoupled;
cooling, inspect the operation of the heat exchanger 13. The direction of rotation of the motor can be changed
water supply system. In motors with independent by reversing the polarity of the power supply of the
ventilation, check the direction of rotation of the fans; excitation or the armature.
13. Motor air inlets and outlets must be clear;
14. Check if the air cleaner is clean;
15. The movable parts of the motor must be protected ATTENTION
to prevent accidents; The inversion of the field can only occur with
16. The terminal box covers must be properly fastened; the machine off.
17. All the motor bolts must be properly fastened; Motors supplied with a single direction of
18. Check if the supply is in accordance with the data of rotation must not operate in the opposite
the motor nameplate; direction.
19. Check the conditions of the brush holder and In order to operate the motor in the opposite
commutator; direction, please contact WEG.
20. Check if the brushes are well settled, aligned with
the commutator and if they easily slide inside the
brush holders; 14. Keep the motor turning at the rated speed and record
the bearing temperatures at 1-minute intervals until
they become constant. Any sudden increase in
bearing temperature indicates lubrication or friction
surface issues;
15. Monitor the bearing temperature, oil level of the
bearings and the vibration levels. If there is a
significant variation of any value, interrupt the start of
the motor, detect the possible causes and make
corrections;
16. When bearing temperatures stabilize, you can
continue with the other steps to operate the motor.

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At the start of operation, the values must be checked

ATTENTION every 15 minutes. After some hours of operation, check
The noncompliance with the procedures those values every hour, progressively increasing.
described above may jeopardize the motor Make these records daily during a period of 5 to 6 weeks.
performance, cause damages and even lead
to a burnout, voiding the warranty. The temperatures of the commutation and compensation
windings, which are connected in series with the
armature, depend on the load condition of the engine.
6.3 OPERATION Therefore, the values of armature voltage and current
must be monitored during the motor operation too.
The operating procedures vary considerably due to the
application of the motor and type of equipment and 6.3.3 Temperatures
control used.
Only general procedures are described in this manual. The temperature of the bearings, poles and ventilation
For the operating procedures of the control system, you air must be monitored while the motor is running;
must refer to the specific manual of this equipment. The temperature of the bearings and poles must
stabilize in a period of four to eight hours of operation;
6.3.1 General
6.3.4 Bearings
After the first successful start test, couple the motor and
the load driven and then the start procedure can be The system start must be monitored carefully, as well as
restarted as follows: the first hours of operation.
Start the motor coupled to the load, first applying the
excitation voltage (field) by means of the AC/DC Before starting the motor, check:
excitation converter. If the external lubrication system (if applicable) is ON;
Soon after, apply voltage on the armature, using the If the lubricant used complies with all specifications;
acceleration ramp in accordance with the maximum Lubricant characteristics;
current of the parameterized start on the AC/DC The oil level (oil-lubricated bearings).
converter, accelerating the motor up to the rated The alarm and shutdown temperatures set for the
speed bearing;
Keep the motor running until it reaches its thermal During the first start-up, it is important to inspect for
stability and observe if unusual noises and vibrations or unusual vibrations or noises;
excessive heating are occurring. If there are significant If the bearing is not running silently and smoothly, the
vibration variations from the initial working condition to motor must be immediately shutdown;
the condition after it reaches its thermal stability, it is The motor must operate for several hours until bearing
necessary to check the alignment and leveling. temperatures stabilize within the previously specified
Measure and compare the consumed electric current limits;
to the value indicated on the nameplate; In case of overtemperature, the motor must be
In continuous duty, without load oscillation, the value immediately shutdown, bearings and temperature
of the current measured must not exceed the value sensors must be inspected and the causes corrected;
indicated on the plate multiplied by the duty factor; After the bearing temperatures stabilize, check if there
All measurement and control instruments and devices are no leaks through the plugs, gaskets or shaft end.
must be permanently monitored to detect occasional
alterations, determine the causes and make the proper 6.3.5 Heat exchangers
corrections.
To control the temperature at the heat exchanger inlet
and outlet and, if necessary correct the water flow;
ATTENTION
Set the water pressure just the necessary to overcome
Check the real condition of the load that the the resistance imposed by the pipes and heat
motor will be submitted in working duty and, if exchanger;
necessary, resize the brush set. If you have In order to control the motor operation, it is
any questions, contact WEG. recommended to install thermometers at the heat
exchanger air and water inlet and outlet and record
those temperatures at certain time intervals;
6.3.2 Data record When installing the thermometers, you may also install
recording or signaling instruments (siren, light bulbs) in
The following data must be collected and recorded certain places.
periodically during the motor operation:
Temperature of the bearings; Inspection of the performance of the heat exchanger
The oil level of the bearings (oil-lubricated bearings). In order to control the operation, it is recommended to
Temperature of the excitation, commutation and measure the temperatures at the heat exchanger water
compensation winding; and air inlet and outlet and record them periodically.
Temperature of the air inlet and outlet of the motor; The heat exchanger performance is expressed by the
Motor vibration level; temperature difference between the cold water and
Armature and field voltage and current. cold air during normal operation. This difference must
be periodically controlled. If an increase in this
difference is observed after a long period of normal

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operation, probably the heat exchanger must be 6.3.7 Tripping

cleaned.
A reduction of performance or damage to the heat The tripping of the motor depends on its application, but
exchanger may also occur by air accumulation inside the main directions are:
it. In this case, removing the air from the heat Reduce the load on the driven equipment, if possible;
exchanger and pipes may correct the problem; Reduce the armature voltage until the motor stops
The pressure difference on the water side may be and disconnect the armature supply;
considered an indicator of the need of cleaning the Disconnect the excitation supply
heat exchanger; Use regenerative or counter-current braking, according
We also recommend measuring and recording the to the options of the AC/DC converter. In case of
pressure difference of the water before and after the battery supply, first disconnect the armature voltage
heat exchanger. Periodically, the new values measured and after the excitation voltage.
are compared to the original value, and an increase of Shut down the oil circulation system of the bearings (if
the pressure difference indicates the need of cleaning applicable) after complete stop;;
the heat exchanger. Shut down the water supply system for the heat
exchanger heat exchangers (if applicable).
6.3.6 Vibration Shutoff the forced ventilation system (if applicable).
Turn on the space heater (if applicable) if it is not
The acceptable vibration levels must be directly obtained automatically done by control devices;
in the standard referring to the motor.
Figure 6.1: Standards to evaluate the vibration in coupled DANGER

motors
While the motor is turning, even after
Measurement disconnected, there is life danger when
Measurement in
Application in rotating touching any of the active parts of the motor.
non-rotating parts
parts
DC Motors ISO 10816-3 ISO 7919-3
Common causes of vibration are:

Misalignment between the motor and the equipment;
Inadequate fixation of the motor to the base, with
"loose shims" under one or more of the motor feet,
and loose fixation bolts;
Inadequate or not sufficiently strong base;
External vibrations from other devices.
ATTENTION
Operating the motor with vibration levels
above the values provided above may
jeopardize its useful life and/or performance.

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7 MAINTENANCE
7.1 General 7.3 INSPECTIONS IN THE WINDINGS
A proper motor maintenance plan, when properly The measurements of the insulation resistance of the
executed, includes the following recommendations: windings should be made at regular intervals, mainly
Keep the motor and all related equipment clean; during wet times or after prolonged motor stops.
Periodically measure the insulation resistance; The windings must undergo a careful visual inspection at
Routinely measure the temperature of windings, frequent intervals, recording and fixing any damage or
bearings and ventilation system; default observed.
Inspect wear, operation of the lubrication system and Low values or sudden variations in the insulation
useful life of the bearings; resistance must be carefully investigated.
Check possible wear of the brushes and commutators; At points where the insulation resistance may be low (due
Check the ventilation system to ensure air is flowing to an excess of dust or moisture), it may be increased
correctly; back to the required values by removing the dust and
Inspect the heat exchanger; drying up humidity on the windings.
Measure the machine vibration levels;
Inspect the associated equipment (hydraulic unit, 7.4 WINDING CLEANING
water system etc.)
Check all of the motor accessories, protections and For satisfactory operation and longer useful life of
connections, ensuring that they are operating properly; insulated winding, it is recommended to keep them free
of dirt, oil, metallic dust, contaminants, etc.
ATTENTION In order to do so, it is necessary that the winding be
periodically inspected and cleaned and that it operates in
Noncompliance with the recommendations clean air. If re-impregnation is necessary, contact WEG.
aforementioned may cause undesired stops The winding may be cleaned with industrial vacuum
of the equipment. cleaner with a non-metallic thin tip or just a dry cloth.
The frequency with which such inspections Winding drying time after cleaning varies depending on
are performed depends on local application weather conditions, such as temperature, humidity, etc.
conditions.
Where it is necessary to transport the motor,
care should be taken not to damage the DANGER
bearings. Use the device supplied with the Most solvents currently used are highly
motor to lock the shaft. toxic and/or flammable.
If the motor requires reconditioning or
replacement of any damaged parts, please
contact WEG.
Inspections
The following inspections must be performed after the
7.2 GENERAL CLEANING winding is carefully cleaned:
Check the connections and winding insulation.
The frame must be kept clean, without oil or dust built Check if spacers, bindings, groove wedges, bandages
up on its external part in order to make the heat and supports are fixed correctly.
exchange with the ambient easier. Check if there were no breaks, if there are no faulty
The interior of the motor must also be kept clean, and welds, short circuit between turns and against the
free from dust, debris and oils; mass in the coils and connections. In case of detecting
For cleaning, use brushes or clean cotton cloths. If the any irregularity, immediately contact WEG.
dust is not abrasive, an industrial vacuum cleaner must Ensure that all cables are properly connected and that
be used to remove the dirt from the fan cover and the terminal fixation components are duly tightened. If
excess of dust on fan blades and on the frame; necessary, do the retightening.
Debris impregnated with oil or moisture may be
removed with a cloth soaked in appropriate solvents; Re-impregnation
It is also recommended to clean the terminal boxes. If any layer of resin on the windings is damaged during
Terminals and connectors must be kept clean, rust- cleaning or inspection, such parts must be corrected with
free and in perfect operating conditions. Avoid contact adequate material (in this case, please contact WEG).
between connecting parts and grease or verdigris. Insulation resistance
Insulation resistance must be measured after all
maintenance procedures have been performed.

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7.6.1 Maintenance of heat exchangers

ATTENTION Using clean water, the heat exchanger may remain in
Before putting the motor into operation, in operation for several years, without having to be cleaned.
case it remained out of operation for some With too dirty water, it is necessary to clean it every 12
time, it is essential to measure the months.
insulation resistance of the windings and The level of dirt in the heat exchanger may be detected
ensure that the values meet the by the air temperatures increase in the outlet. When the
specifications. temperature of the cold air, in the same operating
conditions, exceeds the specified value, you can assume
the pipes are dirty.
7.5 CLEAN BRUSH COMPARTMENT If corrosion is observed, it is necessary to provide a
proper protection against corrosion (for instance, zinc
The dust from the brush compartment must be anodes, cover with plastic, epoxy or other similar
cleaned with a vacuum cleaner, removing dust from protection products) in order to prevent greater damages
the brushes out of the motor ; to the affected parts.
The commutator must be cleaned with a dry clean The external surface of all parts of the heat exchanger
cloth which does not release lint; must be always kept in good conditions.
The spaces between blades must be cleaned with a
vacuum cleaner hose; Instructions for removing and maintaining the heat
Do not use solvents to clean the commutator , exchanger
because the vapor of such products jeopardizes the In order to remove the heat exchanger for maintenance,
operation of the brushes and commutator; follow the steps below:
Do not remove the film formed by the deposit of 1. Close all the water inlet and outlet valves after
material of the brushes on the commutator (patina) stopping the ventilation;
since this is beneficial for the motor commutation. 2. Drain the heat exchanger water through the drain
Clear supports of the brush holders and the brush plugs;
connection terminals, which can be covered with dust 3. Loosen the heads and keep the bolts, nuts and
brushes; washers and gaskets together in a safe place;
Remove the brushes and clean them to ensure that 4. Carefully brush the pipes inside with nylon brushes to
they move freely in the enclosure; remove the residue. If during the cleaning operation,
Air filters (if applicable) must be removed and cleaned damages to the heat exchanger pipes are observed,
every two months or before if necessary. they must be repaired;
5. Reassemble the heads, replacing the gaskets if
necessary.
7.6 MAINTENANCE OF THE
COOLING SYSTEM 7.7 Commutator
The good condition of the commutator is essential for the
The air-air heat exchanger pipes (if applicable) must be
perfect behavior of the direct current machine.
kept clean and unblocked in order to ensure a perfect
Therefore, it is important its periodic observation.
heat exchange. In order to remove the dirt
The commutator must be kept free of the presence of oil
accumulated inside the pipes, a rod with round brush
and grease and the furrow among the blades must be
on the tip can be used.
kept clean.
For air-water heat exchangers, it is necessary to
In normal operation, the patina that is formed on the
periodically clean he heat exchanger pipes to remove
commutator will present a dark brown or lightly black
any crusts.
coloration. If the surface is bright, glossy or rough, it is
likely that the type of brushes must be replaced. On the
NOTE other hand, a layer of thick black coloration, which
generally occurs with prolonged overloads, in the
If the motor is equipped with filters in the air presence of moisture, indicates an excessive deposition
inlet and/or outlet, they should be cleaned of the material on the commutator. In these cases this
with a compressed air application layer must be removed by means of pumice (artificial) or
If the dust is difficult to remove, wash the filter fine sandpaper (no. 220).
in cold water with mild detergent and dry it in When leaving the factory, the commutator is machined
the horizontal position. and the patina is preformed in the test. Therefore, it does
not need any treatment on its surface before the motor is
put into operation.
The commutator wear normally occurs uniformly along
the tracks.
If it is determined visually an uneven wear along the
periphery of the commutator, contact WEG immediately.
The commutator wear is measured on the lane position
of the brushes in relation to the area not used. Whenever
this difference exceeds 0.1mm, the commutator should
be reconditioned.

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If the difference in height among any adjacent blades is edge of the edges of the plates must be broken,
greater than 0.005mm, the commutator must be therefore remove a minimum amount of copper.
repaired. The commutator ovalization must not surpass
0.1mm.
The reconditioning of the commutator basically consists ATTENTION
of a fine lathing and the subsequent lowering of the mica- It should be noted that the continuity of
blades. The Table below indicates the minimum “wear operation with a worn commutator may cause
diameter” that the commutator can have after successive sparking in excessive levels, and could
machining. damage the motor completely.
For a smaller diameter than the indicated, it is necessary
to replace the commutator.
7.7.1 Checking the commutation
Table 7.1: Diameter of the Commutator (mm)
A successful commutation is defined as the quality of
DIAMETER OF THE COMMUTATOR
commutation that does not result in damage and to the
FRAME (mm)
commutator and the brushes.
NEW WEAR The total lack of a visible sparking does not mean
90 85 82 essentially a successful commutation.
For the verification of the commutation, you should apply
100 85 82
load to the motor and note the sparking, attempting to
112 92 89 determine if it is normal or not. In case of unusual
112 105 102 sparking from level1 3/4 (Figure 7.2), you must determine
the cause or causes and eliminate them. Sparks resulting
132 125 121
from an unsatisfactory commutation may have
160 145 137 mechanical causes, as vibrations on the machine,
180 170 162 deformation on the commutator, inadequate pressure on
160 152 the brushes, etc. Electric causes such as poor contact
200 between brush and commutator, problems in the
190 180
windings of the commutation poles or the armature,
225 180 170 current peaks, inadequate air-gap, etc and
250 (C )* 210 200 physicochemical aspects, such as excessive air moisture
and the existence of corrosive gases or vapors in the
250 210 200
environment or the deposition of oils or dust on the
280 (C )* 240 228 commutator.
280 240 228 The air-gap of the commutation poles (for machines with
315 270 258
retractable poles) is adjusted at the factory, as well as the
neutral zone.
355 270 258
400 320 306
ATTENTION
450 380 364
* Offset machine In case you need to extract the poles, you
must necessarily respect the original air-gap,
The under cutting of mica should be such that the dept P at the mounting time, and the brush holder
of the slot between lanes is between 0.7 and 1.2 mm. rings must be adjusted at the neutral position.
This operation must be performed with utmost care, and
,
a cylindrical milling machine or a flat blade should be
used .milling machine Conical tools should not be used
for this operation.
The burrs formed must be removed by keeping the
bevels
BLADE
Figure 7.1: Lowering of mica
Note that no rest of mica remains in the slot walls. The

best way is to use a magnifying glass. Only the sharp

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7.8.1 Adjustment of the neutral zone

1 Black
When the rotor is replaced or reconditioned, it is possible
that the position of the brush holder has to be changed.
In order to adjust the brushes in the neutral position
1 ¼ Intermittent sparks (liming brushes), proceed as follows (practical method)”
Thick adjustment:
1. Loosen the bolts holding the ring of the brush
1 ½ Some sparks holder;
2. Power up the armature (50 to 80% of the rated
current for 30 seconds at most), field remains
disconnected. In order to limit the current, use a low
1 ¾ Numerous sparks voltage, for example, of battery;
ATTENTION
2 Sparks with some
projections The maximum time of 30 seconds must be
respected; otherwise you can damage the
commutator.
2 ¼ Sparks with some
projections
3. If the neutral zone is maladjusted, the rotor will tend
to rotate. In order to adjust the neutral position,
2 ¾ Sparks with numerous rotate the ring of the brush holder in the opposite
projections direction of the rotation of the motor
4. The neutral zone will be adjusted when the rotor is
stopped.
3 Sparks with accented

projections NOTE
If when you turn the brush holder ring to the
Figure 7.2: Sparking levels right, the rotor turns the opposite way, the
cables of the commutation poles that are
connected to the brush holder are inverted.
7.8 BRUSH HOLDER Connect the cables correctly and proceed as
in items 1, 2, and 3.
The enclosures must allow the free movement of the
brushes, but excessive clearances provoke trepidations Thin adjustment:
and hence sparking. The spring pressure should range 1. After neutral zone is adjusted (thick adjustment),
between 200 and 250 g / cm ², except in special cases. start the motor with rated voltage (if possible, rated
The distance between the brush holder and the current);
commutator surface should be approximately 2mm to 2. Check the two directions of rotation, the difference
avoid breakage of the brushes and damage to the cannot be greater than 1%;
commutator. 3. If the difference is greater than 1%, observe which
way the rotation is greater. To decrease the rotation,
turn the brush holder ring in the same direction of
rotation of the rotor;
4. To increase the rotation, in a certain direction, turn
the brush holder ring in the opposite direction of
rotation of the rotor.
7.9 BRUSHES
To each direct current machine is intended previously
one quality of brush, and it should always be used the
Figure 7.3: Brush holders same type and amount of brush originally supplied
(attend to that described in section 7.9.1). Brushes of
The sets of brush holders are adjusted in the factory in different types should not be mixed.
the most favorable position for the commutation. This The choice of the type of brush is made according to the
position (neutral zone) is indicated by reference marks on characteristics of each machine such as: speed, voltage,
the brush holder support. Once the set brush holder is current, etc.
adjusted, you should not change its position, because it
serves to any load value. In case of need of
disassembling the set, respect the mark for the
assembly.

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NOTE
ATTENTION
Any change in the type and quantity of
brushes should be done under WEG’s If the above is not observed, excessive wear
guidance, because different types of brushes of the brushes may occur, insulation marks
cause changes in the behavior of the machine and damage the insulation of the engine,
when in operation. damaging it completely.
The brushes should be constantly observed during

operation; look mainly for the following items: NOTE
Make sure that all the brushes have the same quality; WEG DC- motors are manufactured to work
Make sure that all the brushes have flexible braids in normal rated load or according to the
with the same length. Neither short nor too long to customer In case the customer uses the
allow a free sliding; motor with a different load from the one
Check if there is free movement in the brush holders specified, it is his responsibility to do the
and if there is no material embedded in its internal correct adaptation of the brushes.
surface, which damages the movement of the
brushes;
Lay-in the brushes with sandpaper placed between
the surface of the commutator and brushes with the ATTENTION
abrasive face facing the brush contact surface. Also WEG is not responsible for the adequacy of
use pumice; the brushes with a different load from the
In order to control the brush wear, observe the mark specified.
embossed on the side (axial) Figure 4.3. The
minimum height that the brush must have so that
damages do not occur to the commutator is the one 7.10 MOTOR OUT OF OPERATION
in which the wearing mark is still visible;
When replacing brushes, always replace the The following special measures must be taken in case
complete kit; the motor remains out of operation for long.
When replacing worn brushes by others of the same Turn on the space heaters (if applicable) so that the
granulation, the existing patina on the commutator temperature inside the motor be kept slightly above
should not be removed if it has a normal aspect; the ambient temperature, avoiding moisture
When replacing brushes by others of different quality, condensation and consequent drop of the winding
one must necessarily remove the existing patina on insulation resistance and oxidation of metallic parts;
the commutator, using fine sandpaper. The heat exchangers and all water pipes (if applicable)
must be drained in order to reduce corrosion and
7.9.1 Adequacy of brushes to load conditions build-up of suspended material in the cooling water;
Follow the other procedures described in the chapter
Performance of the brushes depends on them working “Extended Storage” of this manual.
within the normal conditions of the machine. If the power
permanently required from the machine is lower than the Storage of the heat exchanger after operation
rated power, there is the need of an adaptation of the When the heat exchanger remains for a long period out
brushes considering the operating load condition. of operation, it must be drained and dried. The drying
may be done with pre-heated compressed air. During
winter, if there is risk of freezing, the heat exchanger must
be drained even in short periods out of operation to
prevent deformation or damages.
NOTE
Wear mark During short stoppages, it is recommended to

keep the water circulation at low speeds
instead of interrupting its circulation through
the heat exchanger without its draining,
ensuring that harmful products, such as
ammonia compounds and hydrogen sulfide,
will be taken out of the heat exchanger and
will not settle inside.
Figure 7.4: Representation of the dimensions of the brushes

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7.11 SHAFT GROUNDING DEVICE 7.12.1.1 Lubrication instruction
In some motors, depending on application, a brush is The lubrication system was projected so that during the
used to ground the shaft. This device prevents the lubrication of the bearings, all the old grease is removed
circulation of electric current through the bearings, which from the bearing tracks and expelled through a drain
is highly harmful to their operation. The brush is put in which allows it to come out, but prevents the income of
contact with the shaft and connected by a cable to the dust or other harmful contaminants into the bearing.
motor frame, which must be grounded. Make sure the This drain also prevents damages to the bearings due to
fixation of the brush holder and its connection to the excessive lubrication.
frame have been done properly. It is recommended to make the lubrication with the motor
in operation, ensuring the renewal of grease in the
bearing enclosure.
If that is not possible due to the presence of rotating
parts near the grease nipple (pulleys, etc.) which may put
the operator at risk, follow the procedures below:
With the motor stopped, inject approximately half the
total estimated amount of grease and put the motor
into operation for about one minute at rated speed;
Shaft Stop the motor and inject the rest of the grease. The
injection of all the grease with the motor stopped may
Figure 7.5: Brush for grounding the shaft lead to the penetration of part of the lubricant into the
motor through the internal seal of the bearing case;
In order not to damage the motor shaft during
transportation, it must be protected with drying oil. In
order to ensure the proper operation of the grounding ATTENTION
brush, this oil, as well as any residue between the shaft
It is important to clean the grease nipples
and the brush, must be removed before starting the
before lubrication in order to prevent foreign
motor.
material from coming into the bearing.
The brush must be constantly observed during the
For lubrication, use manual grease gun only.
operation and, at the end of its useful life, it must be
replaced by another one of the same quality (granulation).
NOTE
7.12 BEARING MAINTENANCE
The bearing data, amount and type of grease
7.12.1 Grease rolling bearings and lubrication interval are informed on a
nameplate fixed onto the motor.
Grease inlet Check this information before making the
lubrication.
The lubrication intervals informed on the plate refer to

bearing working temperature of 70ºC;
Based on the operating temperature ranges listed
below, apply the following ratio-corrector factors for
the bearing lubrication intervals:
Operating temperature lower than 60ºC: 1.59.
Operating temperature of 70ºC to 80ºC: 0.63.
Grease outlet Operating temperature of 90ºC to 100ºC: 0.25
Figure 7.6: Horizontal grease rolling bearing
7.12.1.2 Procedure to lubricate the rolling
bearings
1. Remove the drain cover;

2. Clean with a cotton cloth the area around the grease
nipple;
3. With the rotor operating, inject the grease with a
Grease inlet manual grease gun until grease starts coming out from
the drain or until the proper amount of grease informed
Grease outlet
on the bearing nameplate is injected.
Figure 7.7: Vertical grease rolling bearing 4. Leave the generator running long enough for the
grease excess to drain;
5. Inspect the bearing temperature to make sure there
was no significant change.
6. Put the drain plug back on.

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7.12.1.3 Bearing lubrication with spring device Table 7.2: Options and characteristics of the optional greases
for normal applications
to remove the grease
(°C)
Multiplication
In order to lubricate the bearings, the removal of the old Manufacturer Grease
factor
grease is done by the spring device installed in each
bearing. UNIREX N3
Exxon Mobil (Lithium Complex (-30 to +150) 0.90
Procedures for lubrication: Soap)
ALVANIA RL3
1. Before beginning the bearing lubrication procedure, Shell (-30 to +120) 0.85
(Lithium Soap)
clean the grease nipple with a cotton cloth;
LUBRAX
2. Remove the rod with spring to remove the old grease, INDUSTRIAL
clean the spring and put the rod back; Petrobras (0 to +130) 0.85
GMA-2
3. With the motor running, inject the amount of grease (Lithium Soap)
specified on the bearing nameplate by means of a STAMINA RL2
Shell (-20 to +180) 0.94
manual grease gun; (Diurea Soap)
4. The grease excess comes out through the lower drain LGHP 2
SKF (-40 to +150) 0.94
of the bearing and settles on the spring; (Polyurea Soap)
5. Leave the motor running long enough for the grease
excess to drain; 7.12.1.6 Procedure for changing the grease
6. That grease must be removed pulling the rod of the
spring and cleaning the spring. This procedure must To replace the grease POLYREX EM103 by one of the
be repeated as many times as necessary until the optional greases, the bearings must be opened to
spring will not hold grease; remove the old grease and then filled with new grease.
7. Inspect the bearing temperature to make sure there If it is not possible to open the bearings, you must purge
was no significant change. all the old grease by applying new grease until it shows in
the outlet drawer with the motor running.
7.12.1.4 Grease type and quantity To replace the grease STABURAGS N12MF by one of
the optional greases, it is necessary that the bearings be
The bearing relubrication must be always done with the opened and the old grease totally cleaned and then filled
original grease specified on the bearing nameplate and with new grease.
on the motor documentation.
ATTENTION
ATTENTION
As there is no compatible grease with
WEG does not recommend the use of grease STABURAGS N12MF grease, you should not
different from the motor original grease. inject other grease in the attempt of purging it.
Through this procedure it is not possible to
completely expel the old grease, or prevent
7.12.1.5 Optional greases their mixture, which may cause damage to the
bearings.
If not possible to use original grease, the optional greases
listed in Table 7.2 can be used, since the following 7.12.1.7 Low-temperature greases
conditions are met:
1. The lubrication interval must be corrected by Table 7.3: Grease for use in low temperatures
multiplying the interval informed on the nameplate of
the bearings by the multiplication factor informed in Applicatio
Manufacturer Grease
Table 7.2; n
2. Use the correct procedure to change the grease, MOBILITH SHC 100 Low
according to item 7.12.1.6 of this manual. Exxon Mobil (Lithium Soap and (-50 to +150) Temperatur
Synthetic Oil) e
NOTE
In order to use optional greases in low-
temperature applications in place of grease
MOBILITH SHC 100, consult WEG.

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ATTENTION
1. In case the bearing is open, inject new
grease through the grease nipple to expel
the old grease that is in the grease inlet
pipe and apply the new grease to the
bearing, to the internal ring and external
ring, filling 3/4 of the empty spaces. In case
of double bearings (ball + roller), also fill 3/4
of the empty spaces between the
intermediate rings;
2. Never clean the bearing with cotton cloths,
because they may release lint as solid
particles;
3. It is important to perform a correct
lubrication, that is, apply the correct grease
and in the proper quantity, because either
an insufficient lubrication or an excessive
lubrication has harmful effects.
4. Excessive lubrication makes the
temperature rise due to the great resistance
against the movement of the revolving parts
and especially due to the beating of the
grease, which eventually completely loses
its lubrication properties.
NOTE
WEG is not responsible for changing the
grease, or even for occasional damages
caused by the change.
ATTENTION
Greases with different types of base must
never be mixed.
Example: Lithium-based greases must never
be mixed with others with sodium or calcium
base.
7.12.1.8 Grease compatibility
The compatibility of different types of grease may cause a

problem. You can say the greases are compatible when
the properties of the mixture lie within the property
ranges of the greases individually.
In general, greases with the same type of soap are
compatible with each other, but depending on the
proportion of the mixture, there might be incompatibility.
Therefore, it is not recommended the mixture of different
types of grease without consulting the grease supplier or
WEG.
Some thickeners and basic oils cannot be mixed with
each other, because they do not form a homogeneous
mixture. In this case, you cannot disregard the possibility
of hardening or, on the other hand, softening of the
grease or fall of the dropping point of the resulting
mixture.

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7.12.1.9 Horizontal bearing assembly and disassembly

1. Internal bearing cap
2. White felt
3. Ring fixing bolt
4. Disk fixing bolt
5. External bearing cap
6. Taconite seal
7. Centrifuge fixing bolt
8. Grease centrifuge
9. Grease outlet chamber
10. Rolling Bearing
11. Grease nipple
12. Thermal Protector
13. External shutdown disk
Figure 7.8: Parts of the grease rolling bearing
Before disassembling: Assembly

Remove the extension pipes form the grease inlet and Clean the bearings completely and inspect the
outlet; disassembled parts and the inside of the bearing caps;
Clean carefully the external part of the bearing; Make sure the bearing, shaft and bearing cap surfaces
Remove the grounding brush (if applicable); are perfectly smooth;
Remove the bearing temperature sensors and provide Fill with the recommended grease up to ¾ of the
a support for the shaft to prevent damages to the internal and external fixation cap deposit (Figure 7.11)
rolling bearing. and lubricate the rolling bearing with grease enough
before assembling it;
Disassembly Before assembling the bearing on the shaft, heat it to a
Take special care to prevent damages to the balls, rollers temperature between 50ºC and 100ºC;
and surfaces of the bearing and shaft. For the full assembly of the bearing, follow the
In order to disassemble the bearing, follow the instructions for disassembly in the reverse order.
instructions below carefully, keeping all the parts in a safe
place:
1. Remove the screws (4) that fix the closing cap (12);
2. Remove the taconite seal (6);
3. Remove the bolts (3 ) that fix the bearing caps (1 and
5);
4. Remove external bearing cap (5);
5. Remove the screw (7) that fixes the grease
centrifuge (8);
6. Remove the grease centrifuge (8);
7. Remove the D-endshield;
8. Remove the bearing (10);
9. Remove the internal bearing cap (1) if necessary.

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7.12.1.10 Vertical bearing assembly and disassembly
Figure 7.9: Lower bearing Figure 7.10: Upper bearing
1. Temperature sensor 1. Grease Cup

2. Grease nipple 2. Grease inlet pipe
3. Grease outlet chamber 3. Temperature sensor
4. Screw 4. Grease outlet chamber
5. Protection disk 5. Grease outlet pipe
6. Taconite seal 6. Screw
7. Screw 7. External bearing cap
8. External bearing cap 8. Spring
9. Screw 9. KMT nut
10. Grease centrifuge 10. Spacer ring
11. Lower shield 11. Screw
12. Rolling Bearing 12. Screw
13. Spring 13. Bearing hub
14. Internal bearing cap 14. Upper shield
15. Rolling Bearing
Before disassembling the bearings: 16. Intermediate ring
Remove the extension pipes form the grease inlet and 17. Grease centrifuge
outlet; 18. Guidance ring
Clean carefully the external part of the bearing; 19. Internal bearing cap
Remove the grounding brush (if applicable);
Remove temperature sensors.
Lower bearing disassembly: Upper bearing disassembly:

Take special care to prevent damages to the balls, rollers Take special care to prevent damages to the balls, rollers
and surfaces of the bearing and shaft. and surfaces of the bearing and shaft.
In order to disassemble the bearing, follow the instructions In order to disassemble the bearing, follow the instructions
below carefully, keeping all the parts in a safe place: below carefully, keeping all the parts in a safe place:
1. Place the motor in the horizontal position; 1. Backstop the motor shaft;
2. Remove the bolts (4), the protection disk (5) and the 2. Remove the screws (6) of the external bearing cap;
taconite seal (6) 3. Remove external bearing cap (7);
3. Remove the bolts (7 ) that fix the external and internal 4. Remove KMT nut (9);
fixation caps of the bearing (8 and 14); 5. Remove the screws (11 and 12) and remove the
4. Remove external bearing cap (8); bearing hub;
5. Remove the bolt (9) that fixes the grease centrifuge 6. Remove the upper shield(14);
(10); 7. Move the intermediate ring and the internal fixation
6. Remove the grease centrifuge (10); cap, deviate them from the rolling bearing to obtain
7. Remove the lower shield(11); space to place the device to remove the rolling
8. Remove the bearing (12); bearing;
9. Remove the internal bearing cap (14) if necessary. 8. Remove the bearing (15);
9. Remove the grease centrifuge (17), the intermediate
ring and the internal bearing cap, if necessary.

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Assembly
Clean the bearings completely and inspect the
disassembled parts and the inside of the bearing caps; NOTES
Make sure the bearing, shaft and bearing cap surfaces 1. All threaded holes that are not used must
are perfectly smooth; be closed with plugs and no connections
Fill with the recommended grease up to ¾ of the can present leak;
internal and external fixation cap deposit (Figure 7.11) 2. The oil level is reached when the
and lubricate the rolling bearing with grease enough lubricant can be seen approximately in
before assembling it; the middle of the sight glass;
Before assembling the bearing on the shaft, heat it to a 3. The use of a larger amount of oil will not
temperature between 50ºC and 100ºC; damage the bearing, still it can cause
For the full assembly of the bearing, follow the leaks through the shaft seals;
instructions for disassembly in the reverse order. 4. Do not use or mix hydraulic oil with the
lubricant oil of the bearings;
7.12.2.2 Oil types…………………
The type and quantity of lubricant oil to be used are

specified on the nameplate fixed onto the motor.
7.12.2.3 Oil Change………………

Figure 7.11: External bearing cap
The oil change of the bearings must be carried out
observing the Table below, according to the bearing
Rolling bearing replacement
working temperature:
The disassembling of the bearings must be done by using
proper tools (bearing extractor).
Below 75ºC = 20,000 hours
The arms of the extractor must be placed on the internal
Between 75 and 80ºC = 16,000 hours
ring side surface of the rolling bearing to be disassembled
or on an adjacent part. Between 80 and 85ºC = 12,000 hours
The useful life of the bearings depends on their operating

conditions, on the motor operating conditions and on the
maintenance procedures.
The following recommendation must be observed:
The oil selected for the application must have the
proper viscosity for the bearing working temperature.
The type of oil recommended by WEG already
Figure 7.12: Device to remove the rolling bearing considers those criteria;
Insufficient quantity of oil may damage the bearing;
7.12.2 Oil rolling bearings The minimum oil level recommended is reached when
the lubricant can be seen in the lower part of the oil
sight glass with the motor stopped.
7.12.2.1 Lubrication instruction
Oil removal: When it is necessary to change the bearing ATTENTION

oil, remove the oil outlet plug (3) and drain the oil
completely. The oil level must be inspected daily and
must remain in the middle of the oil sight
To put oil in the bearing: glass.
Close the oil outlet with the plug (3);
Remove the oil or filter inlet cap (1);
Fill with the specified oil up to the level indicated in the
oil sight glass.

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7.12.2.4 Bearing operation

NOTE
The system start must be monitored carefully, as well The oil level must be inspected daily and
as the first hours of operation. must remain in the middle of the oil sight
Before the start check: glass.
If the oil used complies with the specification on the
nameplate;
Lubricant characteristics; The bearings must be lubricated with specific oil,
Oil level; always observing the flow values informed on their
The alarm and shutdown temperatures set for the nameplate.
bearing. All threaded holes that are not used must be closed
During the first start-up, it is important to inspect for with plugs and no connections can present leak;
unusual vibrations or noises; if the bearing is not running The oil level is reached when the lubricant can be seen
silently and smoothly, the motor must be immediately approximately in the middle of the sight glass. The use
shutdown; of a larger amount of oil will not damage the bearing,
The motor must operate for several hours until the bearing still it can cause leaks through the shaft seals.
temperatures stabilize within the previously mentioned
limits. In case of overheating, the motor must be shut
down for inspection of the bearings and temperature
ATTENTION
sensors. The care with the lubrication will determine
After the bearing working temperature is reached, check if the useful life of the bearings and the safety
there are no leaks through the plugs, gaskets or through during the motor operation. Therefore, it is
the shaft end. extremely important to observe the following
recommendations:
7.12.2.5 Bearing operation The selected oil must be the one with
proper viscosity for the working
In order to obtain the part list, assembling and temperature of the bearings; That must be
disassembling instructions and maintenance details, refer observed in each oil change or in
to the specific installation and operation manual of the periodical maintenances;
bearings. Never use or mix hydraulic oil with the
lubricant oil of the bearings;
7.12.3 Sleeve bearings Lack of lubricant, due to incomplete filling
or the not monitoring of the level, can
7.12.3.1 Bearing data………………… damage the bearing shells.
The minimum oil level is reached when the
The characteristic data, such as oil flow, quantity and type lubricant can be seen touching the lower
are indicated on the bearing nameplate and must be part of the sight glass with the motor out
strictly observed; otherwise, overheating and damages to of operation.
the bearings may occur.
Hydraulic installation (for bearings with forced lubrication)
7.12.3.3 Seals………………………
and oil supply for the motor bearings are responsibility of
the user.
In case of maintenance of the bearings, when adjusting
them again, the two halves of the taconite seal must be
7.12.3.2 Oil change………………….. joined by a garter spring.
This spring must be inserted in the ring seat in such way
Self-lubricated bearings that the locking pin fits into its fillister in the upper half of
The oil change of the bearings must be carried out the frame. Improper installation destroys the seal.
observing the Table below, according to the bearing Before assembling the seals, clean the surfaces that touch
working temperature: the ring and its seat carefully, and cover them with a non-
hardening sealing component. The drain holes located in
Below 75ºC = 20,000 hours
the lower half of the ring must be cleaned and cleared.
Between 75 and 80ºC = 16,000 hours When installing this half of the sealing ring, press it slightly
Between 80 and 85ºC = 12,000 hours against the shaft lower part.
Bearings with (external) oil circulation

The oil of the bearings must be changed every 20,000
hours of operation or whenever the lubricant presents
modifications in its characteristics. The oil viscosity and pH
must be checked regularly.

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7.12.3.4 Bearing operation 7.12.4 Bearing protection
The operation of motors equipped with sleeve bearings is 7.12.4.1 Protection adjustments
similar to the operation of motors equipped with rolling
bearings.
The system start must be monitored carefully, as well as ATTENTION
the first hours of operation. The following temperatures must be adjusted
on the bearing protection system:
Before the start, check: ALARM 110ºC – SHUTTING DOWN 120ºC
If the lubricant used complies with all specifications; The alarm temperature must be adjusted
Lubricant characteristics; 10ºC above the working duty temperature,
Oil level; not exceeding the limit of 110ºC.
The alarm and shutdown temperatures set for the
bearing.
7.12.4.2 Disassembly/assembly of the bearing
During the first start-up, it is important to inspect for temperature sensors
unusual vibrations or noises; if the bearing is not running
silently and smoothly, the motor must be immediately
shutdown.
The motor must operate for several hours until the bearing
temperatures stabilize within the previously mentioned
limits. In case of overheating, the motor must be shut
down for inspection of the bearings and temperature
Conduit
sensors.
Conduit
After the bearing working temperature is reached, check if
there are no leaks through the plugs, gaskets or through
the shaft end. Non-
Insulated Insulated
7.12.3.5 Bearing maintenance Bearing Bearing
The sleeve bearing maintenance includes:

Periodic check of the oil level and lubricant conditions; Figure 7.13: Pt100 on the bearings
Check the bearing noise and vibration levels;
Monitor the working temperatures and retighten the Instructions for disassembly:
fixing and assembling bolts; If necessary to remove the Pt100 for bearing maintenance,
The frame must be kept clean, without oil or dust built the following procedures must be adopted:
up on its external part in order to make the heat Remove the Pt100 with care, locking the locknut (3) and
exchange with the ambient easier. unscrewing just from the bulb adjustment (4);
The NDE bearing is electrically insulated. The spherical The parts (2) and (3) must not be disassembled.
seat surfaces of the bearing shell on the frame are
covered with insulating material. Never remove this Instructions for assembly:
cover; Before performing the assembly of the Pt100 on the
The anti-rotation pin is also insulated, and the seals are bearing, check if it does not contain dents or any other
made out of non-conducting material; damage that may compromise its operation.
Temperature control devices that are in contact with the Insert the Pt100 on the bearing;
bearing shell must also be properly insulated. Lock the locknut (3) with a wrench;
Screw the bulb (4), adjusting it so that the end of the
7.12.3.6 Assembly and disassembly of the Pt100 touches the outer surface of the bearing.
bearings
NOTES
In order to obtain the part list, assembling and
disassembling instructions and maintenance details, refer The assembly of the Pt100 on non-
to the specific installation and operation manual of the insulated bearings must be done directly
bearings. on the bearing, without the insulating
adapter (4);
The tightening torque to assemble the
Pt100 and the adapters must not be
exceed 10Nm.

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8 MOTOR DISASSEMBLY AND ASSEMBLY

All the services referring to repairs, disassembly and assembly must be executed by duly qualified and trained personnel.
The disassembly and assembly sequence depends on the motor model.
8.1 DISASSEMBLY 8.1.1 Tacogenerator Disassembly
Tacogenerator 1R:
DANGER The tacogenerator 1R can be fixed by flange or by feet,
and it is coupled to the motor through a flexible coupling.
Before touching any interior part of the
In order to remove it, disconnect the supply cables,
machine, make sure that there are no
release the fixing bolts with the motor and remove the
voltages, opening all the armature and field
complete tacogenerator. Extract the half-coupling of the
supply cables.
motor shaft.
Below are listed some of the cares that must be taken Tacogenerator TCW:
when disassembling a synchronous motor: Up to 132-frame motors, the TCW rotor is assembled
1. Use proper tools and devices to disassemble the directly on the motor shaft and the TCW frame fixed on
motor; the motor endshield.
2. Before disassembling the motor remove the heat Above the 132-frame, the TCW rotor is assembled on a
exchanger or sirocco (if applicable). Disconnect the Puller and this is fixed to the motor shaft. TCW frame is
pipes in air-water heat exchangers (if applicable); fixed to the endshield as in the previous case.
3. Uncouple the tacogenerator (if applicable) according
to item 8.1.1; 8.2 ASSEMBLY
4. Remove the brushes;
Below are listed some of the cares that must be taken
when assembling an electric motor:
NOTE
1. Use proper tools and devices to assemble the motor;
It is recommended that an analysis on the 2. To assemble the motor, follow the disassembly
condition of brushes, seeking to determine procedures in the reverse order;
any anomalies. If the brushes have use Any damaged part (cracks, dents on machined parts,
conditions, put them in a safe place. faulty threads) must be preferably replaced, always
1. Protect the commutator with cardboard or avoiding restorations.
the like so that it does not get damaged Table 8.1 shows the tightening torques of the bolts
during disassembly. recommended for the assembly of the motor or its parts:
2. Remove the rear external fixing ring ,
release the NDE-endshield and extract it; Table 8.1: Bolt tightening torque
3. Remove the rotor together with the DE- Strength
4.6 5.8 8.8 12.9
endshield, from inside the motor. class
Diameter Tightening torque (Nm) – tolerance ±10%
M6 1.9 3.2 5.1 8.7
5. Disconnect the electrical and accessory connections; M8 4.6 7.7 12.5 21
6. Remove the temperature sensors from the bearings M10 9.1 15 25 41
and grounding brush (if applicable); M12 16 27 42 70
7. In order to prevent damages to the rotor, provide a M16 40 65 100 175
support to hold the shaft on the front and back sides; M20 75 125 200 340
8. To disassemble the bearings, follow the procedures M24 130 220 350 590
described in this manual;
9. The removal of the rotor from inside the motor must
be done with a proper device and with extreme care NOTE
for the rotor not to scrape the stator core or the coil
heads, preventing damages. The strength class is usually indicated on
the head of the hexagonal bolt.
When there is no marking on the bolt, it
indicates that the strength class of the bolt
is 4.6;
Allen-type hexagon socket cap bolts have
strength class 12.9.

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8.3 MEASUREMENT OF THE AIR-GAP 8.6 LIST OF PARTS

After the motor disassembly and assembly, check the air- 1. Fixing ring, external drive end.
gaps of the excitation and commutation poles. The original 2. Lubrication nipple
air-gaps must be exactly kept. 3. Nipple protector
4. Grease Collection box
8.4 GENERAL RECOMMENDATIONS 5. Grease centrifuge, drive end
6. Rolling bearing, drive end
7. D-endshield
ATTENTION 7.1. Lateral opening shield
7.2. Eyebolt;
All services described herein must be 8. Fixing ring, internal drive end.
performed by specialized and experienced 9. Compensation winding:
personnel; otherwise, personal injuries or 10. Excitation winding:
damages to the equipment may occur. If you 11. Commutation winding:
have any questions, contact WEG. 12. Frame
12.1. Frame ring, drive end
12.2. Frame ring, non drive end
8.5 SPARE PARTS 13. Complete rotor
13.1. Rotor balancing ring
WEG recommends keeping in stock the following spare 14. Commutator
parts: 14.1. Commutator flag
One DE bearing and one NDE bearing (motor with 15. Complete brush holder
rolling bearings) 15.1. Brush
One bearing shell for DE bearing and one bearing shell 15.2. Brush edge
for the NDE bearing (motor with sleeve bearings) 15.3. Brush edge retaining ring
Temperature sensor for each bearing (if applicable); 16. Fixing ring, internal non drive end.
Space heater; 17. Upper opening covered
Filter felts (if applicable); 17.1. Multi-leaf damper
Complete set of brushes and brush holders; 17.2. Upper plate
Shaft grounding brush (if applicable) 18. Rolling bearing, non drive end
Lubricant for the bearings 19. Grease centrifuge, non drive end
Filter (if applicable) 20. Fixing ring, external non drive end.
The spare parts must be stored in clean, dry, well- 21. Sealing disk
ventilated environments and, if possible, at constant 22. Air inlet screen
temperature. 23. Air direction adjuster
24. Fan housing
25. Fan
25.1. Hub fixing bolt
25.2. Hub mounting plate
25.3. Fan hub
26. Motor fan
27. Terminal box
27.1. Cable output cover
27.2. Connection plate for fixing cables
27.3. Connector fixing rail
27.4. Grounding

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Outlet
Air
Inlet
Air

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9 Maintenance plan
The maintenance plan described in Table 9.1 is only referential, considering that the intervals between each maintenance
intervention may vary according to the motor location and operating conditions.
Table 9.1: Maintenance plan

3
Monthl 6 annual 3
EQUIPMENT Weekly Note
y months ly years
months
STATOR:
Stator visual inspection x
Cleaning control X
Inspection of the slot wedge (offset

x
machines)
Stator terminal control x
Measure the winding insulation resistance x
ROTOR
Cleaning control x
x
Visual inspection
Shaft inspection (wear, incrustations) x
BEARINGS
Noise, vibration, oil flow, leak and

x
temperature control
Lubricant quality control x
Inspect the bearing shell and shaft track

x
(sleeve bearing)
According to the characteristic
Change the lubricant
indicated on the bearing nameplate
AIR-WATER HEAT EXCHANGER
Inspection of the heat exchangers x
Clean the heat exchangers x
Inspect sacrificial anodes of the heat Sacrificial anodes are used in heat
x
exchangers (if applicable)1 exchangers with seawater
Change the gaskets of the heat exchanger
x
heads
AIR-AIR HEAT EXCHANGER
Clean the ventilation pipes x
Inspect the ventilation x
BRUSHES, BRUSH HOLDER
Inspect and clean x
Check brush contact area x
Check free movement inside the brush

x
holder
Check the wear of the brushes and change
x
them if necessary

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3
Monthl 6 annual 3
EQUIPMENT Weekly Note
y months ly years
months
COMMUTATOR
Inspect and clean the commutator

x
compartment
Check commutator contact area x
Check commutator state and wear and

x
patina formation
Check the wire drawing machine of the
x
brushes
AIR FILTER(S)
Inspect, clean and replace if necessary X
PROTECTION AND CONTROL EQUIPMENT
Test operation x
Record values x
Disassemble and test its operation x
COUPLING
Inspect alignment x
Check after first week of operation
Inspect fixation x
WHOLE MOTOR
Inspect noise and vibration x
Drain condensate water x
Retighten the bolts x
Clean terminal boxes x
Retighten electric and grounding

x
connections
1) If excessive corrosion is found in the sacrificial anode, frequency of inspection must be increased in order to determine the corrosion
period and a plan with proper change intervals must be prepared then.

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10 ANOMALIES, CAUSES AND SOLUTIONS

10.1 MOTORS
NOTE
The instructions of Table 10.1 present only a basic list of abnormalities, causes and corrective actions. If you
have any questions, contact WEG.
Table 10.1: Basic list of abnormalities, causes and corrective actions
ANOMALY POSSIBLE CAUSES CORRECTION
Interrupted armature circuit Examine input and terminal conductors
Coil, commutation or armature in short circuit Identify the short circuit and recover it
Check if there is interruption or default

Motor will not start with no load Defective drive system
in the drive system.
Brush holder out of neutral zone Adjust the neutral zone
Interrupted field circuit Eliminate interruption
Defective drive system Remedy the default.
Motor starts jolting Short-circuit among turns in armature Refurbish the armature.
Examine commutator and eliminate the

Short-circuit among commutator blades
short circuit
Short-circuits among turns in armature Refurbish the armature.
Voltage fall. Check the network demand.

Motor does not accept load. Readjust the position of the brushes in
Brushes displaced from the neutral zone. the neutral zone as indicated on the
dent
Drive system bad set.
Set drive current

Reset the position of the brushes,
Brushes displaced from the neutral zone.
obeying the dent.
Motor runs too fast and Interrupted field circuit or field rheostat with Remedy the interruption. Adjust the
oscillates when facing load. excessive resistance resistor correctly
Series winding, auxiliary, wrongly connected Check the connection and correct it
Test voltage and current Eliminate

Overload
overload
Check cooling direction of rotation.
Volume of coolant air is not sufficient. Clean air and/or filter ducts. Substitute
Unusual heating in service filters if necessary.
Short circuit in the armature and field Check the windings and welding points.
windings. Repair coils.
Open inspection cover beside the fan. Close it.
Excessive grease. Remove excess.
Bad or incorrect grease. Relubricate with correct grease.

Unusual heating of the rolling
bearings.
Bearings in poor condition. Replace rolling bearing.
Decrease speed or remove excessive

Excessive speed or load.
load.

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ANOMALY POSSIBLE CAUSES CORRECTION
Machine, undercut mica and break the edges

Ovalized commutator.
of the lamellas
Very dirty commutator surface. Clean commutator.
Formation of grooves on the commutator

Adequate the brushes considering load.
surface.
Lower mica and break the edges of the
Insulation between protruding blades (mica).
lamellas
Insufficient pressure on the brushes. Check, if necessary, contact WEG.
Little contact between the brush terminal and Retighten the fixing bolts of the brush
brush holder. terminals.
Sparking on the brushes
when the motor faces load.
Worn brushes. Replace by other of the same type.
Make sure that only brushes of the specified

Inadequate type of brush.
type considering the load are used.
Broken brush edges. Replace brushes.
Sand the brush and mold it according to the

Brushes are not well seated.
commutator curve.
Brushes stuck in their compartments. Check the dimensional tolerance of brushes.
Brushes out of the neutral zone. Adjust them obeying the dent.
Short-circuit among commutator blades Identify the short circuit and eliminate it.
Check the quadrature of the brush holder.

Sparking on all the brushes
Error in the distribution of brushes. Unequal Check uniformity of the air-gap of the
and on some arms of the
distribution of current. Bad contacts. commutation poles.
brush holder.
Retighten the bolts.
Clean commutator and all brush holders. If
Impure particles get loose from the brushes
Projection of sparks. necessary, adequate the type of brush
or blades and catch fire.
considering the load.
Sparking of the brushes
Overload Adjust the values of allowable overload.
when the load increases.
Sparking on the brushes
when rotation increases * Excessive rotation. Adjust speed correctly.
excessively.
Blackening of certain
Contact WEG.
blades.
ATTENTION
The motors referenced herein are improved constantly, so the information in this manual is subject to change
without notice.

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11 WARRANTY
These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up date
or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation
expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do
not give Warranty extension, unless otherwise expressed in writing by WEG.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed
or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG
nor to assume for WEG any other liability in connection with any of its products.
In case this happens without WEG's authorization, Warranty is automatically cancelled.
LIABILITY
Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled
"Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or negligence
of the purchaser in connection with or arising out of the testing, use, operation, replacement or repair of any
product described in this quotation and sold or furnished by the company to the purchaser.
WEG Group - Energy Business Unit

Jaraguá do Sul - SC - Brazil
Phone: 55 (47) 3276-4000
energia@weg.net
www.weg.net
1013.03/0709

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NOTES

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WEG Group - Energy Business Unit

Jaraguá do Sul - SC - Brazil
Phone: 55 (47) 3276-4000
energia@weg.net
www.weg.net

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Motors | Automation | Energy | Transmission & Distribution | Coatings

Installation, Operation and Maintenance Manual

10061218 – DC Motors – D Series | 1

2 l 10061218 – DC Motors – D Series

Installation, Operation and Maintenance Manual

Document Number: 10061218

10061218 – DC Motors – D Series | 3

4 l 10061218 – DC Motors – D Series

WEG EQUIPAMENTOS ELÉTRICOS S.A.

10061218 – DC Motors – D Series | 5

6 l 10061218 – DC Motors – D Series

2 GENERAL INSTRUCTIONS .................................................................................12

3 RECEIVING, STORAGE AND HANDLING .............................................................13

10061218 – DC Motors – D Series | 7

4.5 COOLING ....................................................................................................................................... 22

8 l 10061218 – DC Motors – D Series

7.12.1.1 Lubrication instruction .........................................................................................................44

8 MOTOR DISASSEMBLY AND ASSEMBLY ...........................................................52

10 ANOMALIES, CAUSES AND SOLUTIONS ............................................................57

10061218 – DC Motors – D Series | 9

10 l 10061218 – DC Motors – D Series

SPECIFIES A DIRECT CURRENT MACHINE

CODE OF THE ND-ENDSHIELD AND COMMUTATOR TRACKS

1.2 SAFETY WARNINGS IN THIS MANUAL

10061218 – DC Motors – D Series | 11

All qualified personnel must also observe: 2.5 OPERATING CONDITIONS

12 l 10061218 – DC Motors – D Series

3 RECEIVING, STORAGE AND HANDLING

 When lifting a package (or container), the correct ATTENTION

10061218 – DC Motors – D Series | 13

3.2.4.1 Storage location 3.2.4.2 Separate parts

In case outdoor storage is unavoidable, the motor must be

14 l 10061218 – DC Motors – D Series

10061218 – DC Motors – D Series | 15

3.2.4.9 Preparation for commissioning 3.2.4.10 Inspections and records during

3.2.4.9.3 Checking the insulation resistance

Before operating the motor, the insulation resistance must

Before installing and operating the motor, the brushes

Follow the remaining procedures described in item

16 l 10061218 – DC Motors – D Series

3.2.4.11 Maintenance plan during storage

.1: Storage plan

10061218 – DC Motors – D Series | 17

3.3.1 Handling of horizontal motors

Figure 3.1: Handling of horizontal motors

Handling of horizontal motors must be performed as

Figure 3.2: Handling of vertical motors

18 l 10061218 – DC Motors – D Series

When motor is not immediately operated, it must be

10061218 – DC Motors – D Series | 19

Table 4.2: Insulation resistance referential limits in electric

Insulation resistance value Insulation evaluation

2MΩ or less Bad

Coefficient of insulation resistance variation Kt40ºC

4.3.4 Minimum insulation resistance

If the measured insulation resistance is below 100MΩ at

4.3.5 Conversion of measured values

The insulation resistance must be kept at 40°C. If the

The protection devices against overheating are installed on

4.4.1.1 Temperature sensors

20 l 10061218 – DC Motors – D Series

4.4.1.4 Temperature and ohm resistance of the thermoresistors PT100

When lifting a package (or container), the correct ATTENTION

Before starting operation, you must check if the motor