ABB LIMITED

L.V. MOTORS
Plot Nos. 5 & 6, 2nd Phase
Peenya Industrial Area, Bangalore - 560 058.

TEST CERTIFICATE

INSP F03C
Certified that the following 3 phase induction
motor has passed all the routine test as per
IS325 - 1996 and other relevent standards and
found O.K.

Type S.No.

kW/hp rpm

Duty Hz.

Volts Amp.

Conn. Enlco. Ins.Cl.

IP 55
Tested by: for ABB Limited

Date:
 CONTENTS

TOPICS PAGE
Reception 1
Storage 1
Pre-Installation Checks
- Insulation Resistance
Installation & Commissioning 3
- Foundation & Mounting
- Drain Holes
- Motor Alignment
- Fitting Half Coupling/pulley
- Slide Rails & Belt Drives
- V- Belt coupling
- Direct Connected coupling
- Vibrations
Motor Protection 10
Electrical Connection 10
- Terminal Box
- Earthing
- Direction of Rotation
- Reduced Voltage Starting
- Voltage and Frequency Variation
- Connections
- Precautions
- Thot Time
Operation with Inverters 13
Maintenance 14
- Cleaning
- Checks
- Drying Motor
- Reassembly
Bearing 16
- Bearing Mounting
- Bearing Removal
- Lubrication
- Grease valve Lubrication
- Relubrication chart
Troubleshooting Chart 20
 RECEPTION
• On receipt of the motor, please check for transit damage, if any.
!
• Unpack motor carefully and check motor for breakage and missing
!
parts. Check all data on the rating plate to see that they correspond
to your order. Make a special point of checking voltage, and the
connection method. (i.e. star or delta)
!
• If any damage to the motor is observed obtain a damage certificate
from the transporter within 24 hours.
• Please report damage, if any to ABB local office through whom the
!
motor has been purchased within 48 hours in order to observe the
time limit for filing claims.
!
• while reporting damage please mention motor serial number and if
possible the document no. for quicker response.
• Turn shaft by hand to check free rotation.
!
STORAGE
If the motor is not installed immediately the following storage method
has to be employed:
Motor to be stored indoors in a clean any dry atmosphere. Keep
covered to eliminate airborne dust and dirt. Cover openings for
ventilation, conduit connections, etc. to prevent entry of undesirable
elements (e.g. rodents). The temperature of the store room should be
kept 5°C above ambient temperature and as constant as possible as
temperature swings cause condensation. To prevent bearing damage
the storeroom should be free from vibration.
Machined parts should have a protective coat of rust inhibitor during
storage period. In case of long storage, periodic examination should
be carried out and fresh inhibitor should be applied where necessary.
In case of storage for a long period, the spare bearing should be given
a coating of light oil or grease and packed in polythene bags for
protection against moisture.
Anti-condensation heaters, if fitted, should be energised if motor is
idle.
Once per month, rotate shaft several turns to distribute grease in the
bearings as it tends to settle at the bottom of the housings. If the unit
has been stored more than a year add grease before start up.
Do not roll or drag motor on floor. Avoid jerks and jolts to increase the
life of the bearings. Do not keep a totally enclosed fan cooled motor in
vertical position with external cover as base.

1
 CAUTION
Eyebolts are intended for lifting of motor only. These lifting devices
must never be used when lifting or handling the motor with other
equipment's (i.e. pumps, gear boxes, fans or other driven
equipment) as a single unit. Eyebolt lifting capacity ratings is
based on a lifting alignment coincident with the center line.

PRE-INSTALLATION CHECKS
Inspect the name plate details and ensure that: the voltage and
frequency correspond to that of the supply. HP & rpm correspond to
that of the driven machine.
Remove the anti-corrosion agent on shaft with kerosene/thinner. Do
not use sandpaper or scraper.
INSULATION RESISTANCE
Measure the insulation resistance using a 500 V Megger as per IS
4029.The following formula gives a rough estimate of reference value
for insulation resistance :
Insulation resistance R ³
20±U/ 1000+2P (MOhms.)
U= Voltage (V)
P= Rated output of the motor (kW)
(highest output for a multispeed motor)
R= Calculated insulation resistance at 25°C
The formula applies at 25°C ambient temperature. If the temperature
is clearly different, the value must be revised with the factor given in
the nomogram in Fig. 1

Fig. 1
3.0
2.0

1.0

0.5
0.4
0.3
0.2

0.1
20 40 60 80°C

2
Example: at + 60°C ambient temperature the insulation resistance is
only about 30% of the value at + 25°C

Note : Always measure the insulation resistance before the first

starting from the beginning of the supply mains to detect possible
damages on the cables, wrong connections etc.

WARNING
Windings should be discharged immediately after measurement
to avoid the risk of electric shock.

In case the insulation resistance values are low, then the motor should
be dried according to IS 900-1992.
If this value is very low on account of adverse weather conditions or
long storage, we recommend that the motor be examined by our local
authorised service center.

INSTALLATION & COMMISSIONING

Accurate and careful installation of the motor is of prime importance.

CAUTION
Rotating parts such as pulleys, couplings, external fans and shaft
extensions should be permanently guarded.
Disconnect and lock out before working on motor or driven
equipment.

The motor should be installed where it can obtain adequate ventilation

and clean dry air. The clearance between the fan cover and any barrier
should be a minimum of 30 mm upto frame 200.
For higher frames this should be at least 85 mm.
If the air contains dust, moisture or corrosive gases the equipment
should be appropriately protected or else supplied with pure air
through special pipes or ducting. The motor should be accessible for
inspection and repairs.
FOUNDATION & MOUNTING
Foundation must be flat, even, sufficiently rigid and free from vibration.
They should be designed as to avoid the occurrence of vibration due to
resonance. A cast concrete foundation is therefore recommended. If it
is a metal foundation it should be painted to avoid corrosion.
The foundation must be stable enough to withstand the forces that can

3
 arise in the event of a three phase short circuit. The short circuit torque
is primarily a sinusoidal oscillation, and thus can have both positive
and negative values. The stress on the foundation can be calculated
with the aid of details in the data tables of the motor catalogue and the
formula below:
F= 0.5 x g x m + 4 x M... / A (N)
Where F = stress per side, N
g = acceleration due to gravity, 9.81 m/s
m = Weight of motor, kg
M... = maximum torque, Nm
A = Lateral distance between the holes in the motor feet.
The dimension is taken from the dimension drawing and is expressed
in meters.
(Please refer to ABB technical catalogue for values)
The foundation should be dimensioned to give a large enough
resonance distance between the natural frequency of the installation
and any interference frequency.
Before mounting the motor see that motor feet are cleaned.
Foundation students or a baseplate should be used to secure the
motor. Bolt the foundation studs to the feet of the motor firmly. Align the
motor directly using appropriate means.
In the case of the flange motors, care should be taken to ensure that
the motor has a snug fit in the recess and the mounting screws are
uniformly tightened.
For foot mounted motors to be fixed on the wall a support should be
provided for the mounting feet from below.
DRAIN HOLES
When mounting the motors, make sure that the drain holes face
downwards when the mounting designation is different from the
standard, See Fig 2. Rotate the endshields so that these holes are no
longer between the mounting feet, but at the lowermost point of the
motor. In case of vertical mounting, the upper plug must be hammered
in completely and grease plug should be positioned in such a way that
grease can be applied easily. In very dusty environments or when the
motor is in such a position that water can run into the motor both plugs
should be hammered home.
MOTOR ALIGNMENT
Correct motor alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions. As soon as any

4
vibrations or bearing failures are observed, there is every reason to
suspect alignment is faulty and a check therefore to be made.
Temperatures have a considerable Influence and should therefore be
considered during the alignment. The machine temperature is lower

Fig. 2

during erection than under operating conditions. For this reason shaft
centre is going to lie higher during operating conditions. It may be
necessary to use compensating alignment. Mounting instruction from
manufacturers of pumps, gear units etc. often state the vertical and
lateral displacement of the shaft at operating temperature. It is
important to bear in mind this information to avoid the vibration and
other problems in service.
FITTING HALF COUPLING / PULLEY
The driven member (Pulley, coupling half) must be balanced with a
half key. The members should be keywayed and balanced on a
smooth shaft. Clean keyway and make sure the key is fitting properly
on the sides of the keyway in both shaft and coupling or pulley. The key
should have clearance at the top and should not fit tightly on top and
bottom faces.
It is recommended that the couplings or pulley should be heated to a
temperature of about + 125°C in an oil bath for a sufficient length of
time to get uniform temperature and then slid on to the shaft extension
of the motor. The coupling half can be locked with an end washer. If the
coupling half / pulley is drilled for a tighter than a push fit, it must be
heated to around 150°C.
Please ensure that, once pressed on members fit tightly. They should
be pressed firmly against the shaft shoulder. If the hub of the member
is short in relation to the shaft end, the difference in length should be
adjusted by placing a distance piece in front of the shaft shoulder. A
coupling shaft which is mounted on the shaft with a push fit and is then
keyed on can be pushed on by hand along about half the shaft
extension. A special tool or a fully threaded bolt, a nut, and a piece of
flat iron can be used to press the pulley against the collar of the shaft. 5
 Bearings of the motor will get damaged when a hammer is used to
drive the coupling or pulley on to the shaft extension of the motor.
Should force be applied to fit the pulley or coupling on shaft, it is
desirable that non drive end bearing bracket is removed and shaft is
supported so that the hammer or pressure blows are not borne by the
bearings.
a1

a2

Fig. 3
Mounting accuracy of half coupling: check that the clearance b is less
than 0.05mm and that the difference a1 to a2 is less than 0.05 mm
also. See Fig. No 3.
When investigating whether the shafts are parallel, measure the
distance X between the outer edges of the coupling halves at one point
on the circumference with a feeler gauge. See Fig 4. Then turn at the
same time both the coupling halves 90° so that the relative position of
the shafts are not altered, and measure again at exactly the same
point. The coupling halves are then turned 180° and 270° and further
measurements are made.

Fig. 4

The difference between the largest and smallest X- dimension must

not exceed 0.05 mm (0.002 in) for normally occurring coupling
dimensions.
When checking the shafts stand opposite one another, place a straight
steel rule parallel with the shafts on the turned circumference of one of
the coupling halves then measure the play between the rule and the
circumference of the other half in four positions as previously. The

6
difference between the highest and lowest value must not exceed 0.05
mm (0.002 inch).

Fig. 5

The best tools for obtaining a perfect alignment are a couple of dial
gauges fitted as shown in Fig. 5. They are placed on each coupling half
and point in different directions, one axially and the other radially. By
slowly rotating the shafts and reading off at the same time deflections,
one can obtain an idea of whether any adjustments should be made in
the axial or radial direction. The coupling halves should loosely be
bolted together so that they move easily when the shafts are turned.
SLIDE RAILS AND BELT DRIVES
If belt or rope drive is used, install the motor in such a manner that it
can be shifted on its base (e.g. on slide rails) to obtain correct belt
tension. The lower belt part should be pulling. Align so that the centre
of the motor's belt pulley is exactly opposite the centre of the
corresponding pulley, see Fig 6.

Fig. 6

Fasten the motor to the slide rails as shown in the Fig. 7. Place the
slide rails horizontally on the same level. Check that the motor shaft is
parallel with driven, or driving shaft. The slide rails should have the
screw in opposite directions so that the screw which is nearest the belt

7
 Fig. 7

is between the motor and the driven machine, See Fig 8. Make certain
that the upper surface of the slide rails lie horizontally in the
longitudinal direction.

Fig. 8

The position in the lateral direction determines the driven shaft. After
the alignment is completed, grout the foundation bolts and slide-rails
with concrete.
V-BELT COUPLING
1. Select proper belts and sheaves, do not over belt. Excessive belt
load will damage bearings.
2. Align pulleys carefully to avoid axial thrust on motor bearing. The
drive sheave on the motor should be positioned toward the motor
so it is as close to the bearing.
3. When adjusting the belt tension, make sure the motor is secured
by all mounting bolts before tightening belts.
4. Pulleys that are too small or too wide may damage the bearings or

8
 the shaft. Arrange the drive such that the slack side of the belt is
uppermost. Avoid vertical drives. Fast and loose pulley drives
should be arranged such that the drive is on the fastest pulley
when the belt is nearest to the motor.
5. Adjust belt tension to belt manufacturers recommendations.
Excessive tension will decrease bearing life.
DIRECT CONNECTED COUPLING
1. Flexible or solid shaft couplings must be properly aligned for
satisfactory operation. Use flexible type couplings which will
accommodate small inaccuracies in alignment between the motor
and the driven member. Ensure that the shaft does not project
beyond the face of the coupling and that there is a small amount of
axial clearance between the faces of the two halves of the
couplings so that the motor bearings are not subjected to end
thrust.
2. On flexible couplings, the clearance between the ends of the shaft
should be accordance with the coupling manufacturer's
recommendations for end play and limited travel in coupling.
3. Misalignment and Run-Out between the direct connected shafts
will cause increased bearing loads and vibration even when the
connection is made by means of a flexible coupling. Excessive
misalignment will decrease the bearing life. Proper alignment, as
per the specification of the coupling being used in critical. Electrical
machines must always be carefully aligned, particularly when
coupled direct to a driven machine. Faulty alignment along with
bearing failures cause vibrations and fractured shaft extensions.
As soon as any vibrations or bearing failures are observed, there is
every reason to suspect alignment is faulty and a check is
therefore to be made.

WARNING
Excessive belt tension will damage bearings and cause shaft
breakage.

Do not exceed the maximum belt forces (i.e. radial bearing

loading) stated in the relevant product catalogues.

Clean the space between the ribs of the TEFC motor. Dust can have a
harmful effect if it is allowed to settle on the windings, to enter the
bearings, or to collect in the ventilating passages over a period of time.
Therefore motor should be cleaned with compressed air or blower
periodically depending on the atmospheric conditions on the site.

9
 Be sure rotor turns freely when disconnected from the load. Any
foreign matter in the air gap must be removed.
If the drive end of the motor faces upward, ensure that the water is
prevented from entering the upper bearing.
The cable and air ducts must be arranged so as to facilitate the
connection of the cables.
VIBRATIONS
The maximum level of vibrations as measured as per IS12075-1987
are:
Max. Vibration velocity, mm/s rms as per IS 12075-1987 are:
POLE Frame 71-132 Frame 160-225 Above Frame 225
2P 1.8 2.8 4.5
4P-8P 1.8 1.8 2.8
If the machine vibrates even after proper alignment on an amply sized
foundation, this could be caused by incorrectly balanced pulley,
coupling shaft or similar, fitted to the shaft. Other causes could be a
weak foundation structure generating vibrations.
MOTOR PROTECTION
Fuses alone do not protect a motor against single phasing or
overloading. Fuses protects the supply lead but not the motor. Use a
reliable starter with proper protection devices to protect the motor
against faulty operating conditions. We recommend the use of over
load setting, under voltage relay, single phasing preventer, motor
protection relays.
ELECTRICAL CONNECTION

WARNING
1. Disconnect power before working on motor or driven
equipment. It is necessary to make sure that rotor of the motor
can neither be energised electrically nor start to rotate by any
other means.
2. Motors with automatic thermal protectors will automatically
restart when the protector temperature drops sufficiently. Do
not use motors with automatic thermal protectors in
applications where automatic restart will be hazardous to
personnel or equipment.
3. Motor with manual thermal protectors may start unexpectedly
after protector trips. If manual protector trips, disconnect motor
from power line. After the protector cools it can be reset and
power may be applied to motors.

10
 4. Discharge all capacitors before servicing motor.
5. Never attempt to measure the rise of temperature by touch.
Temperature rise must be measured by thermometer,
resistance temperature detector, embedded detector or
thermocouple. The temperature of the outlet of the motor may
be hot to touch during normal operation.
6. Electrical repair should be performed by trained and qualified
personnel only.
7. Failure to follow instruction and safe electrical procedure could
result in serious injury or death.
8. If safety guards are required, be sure that guards are in use.
9. Prior to commissioning it is important to check that the
incoming cables are separated properly. The cables should be
grounded.

TERMINAL BOX
Beside the main winding and earthing terminals the terminal box can
also contain connections for thermistors, space heaters or PT 100
resistance element.
Before closing the terminal box ensure that:
- Interior of the terminal box is clean and free of cable residue.
- All terminals and screws and bolts are firmly tightened.
- All sealing surfaces have adequate contact.
- Unused cable entries must be closed.
EARTHING
Clean the area underneath the earthing terminal and smear it with
petroleum jelly before making earthing connections. Two separate
earthing screws (painted green) are provided for earthing. Connect
the protective earth conductor to the terminal located in the terminal
box, and on the motor body.
DIRECTION OF ROTATION
As standard, the motors are connected in a clockwise rotation as
determined from the drive end. In the case of motors designed for
operation in one direction only the direction of rotation is indicated by
an arrow plate, See Fig 9.

fig. 9

11
 Changing rotation: Before the motor is coupled to the load, determine
proper rotation by jogging or bumping. Apply power to the motor for a
short period of time, enough to get the motor shaft to rotate a slight
amount to observe the shaft rotating direction. To reverse the rotation
interchange any two of the three line leads.
REDUCED VOLTAGE STARTING
Motors used on reduced voltage starting, should be carefully selected
on power supply limitations and driven load requirements. The motor's
starting torque will be reduced when using reduced voltage starting.
The eclipsed time on the start step should be kept as short as possible.
VOLTAGE AND FREQUENCY VARIATION
If voltage and frequency are within the following range, motors will
operate, but with somewhat different characteristics than obtained
with correct name plate values.
Voltage: 10% of the value stamped on the name plate. 3 Phase
systems should be balanced within 2%. A small voltage imbalance will
cause a significant current unbalance. Please see that the full load
current does not exceed the name plate current and is balanced in all
three phases.
Frequency: 5% of the value stamped on the name plate.
Voltage and frequency together: Within 10% (providing frequency
variation is less than 5%) above or below values stamped on the name
plate.
CONNECTIONS
Connect the motor terminals as per connection diagram provided at
the terminal box cover. The terminal plate is normally equipped with
6/3 terminals. In direct starting the motor can be used in two different
L1 W2 U2 V2
W2 U1

W1 U2 U1 V1 W1
L3 L2 L1 L2 L3
V2 V1
Connection

L1
U1

U2
V2
W2 U1 V1 W1
L3 W1 V1 L2 L1 L2 L3
Y Connection
fig. 10

connections as in Fig. 10. In the event that a star-delta starter is used

no links are required on the terminal plate, and all 6 terminals are
connected to the corresponding terminals of the starter.
12
PRECAUTIONS
The supply cables should be of adequate size to carry the full load
current (current density not greater then 4 Amp/mm) and also large
enough to carry the starting current without excessive voltage drop.
The starting current for DOL starting will be 6 to 7 times full load current
at rated voltage in case of squirrel cage motors.
Use proper size of line current protection and motor controls as
required by Indian Electricity Rule. Recommended use is 115% of full
load amps at 40°C and service factor of 1.0. Do not use protection with
larger capacities than recommended. Three phase motors must have
all three phase protected.
Space heaters (if provided) should be switched ON when the motor is
not running and OFF before starting the motor.
Leave the motor disconnected from the load for the initial start; it is
desirable to operate the motor without load for about an hour to test for
any localised heating in bearing and windings.
Check for correct and balanced voltage and current at the motor
terminals.
T hot TIME
T hot time by definition is the permissible time for a motor with rotor in
locked condition. For the setting of certain electronic relays, T hot times
are required. This is available form the T hot times in ABB technical
catalogue.

CAUTION
Too many starts and over-loading of the motor will overheat the
windings and reduce the life of the insulation.

OPERATION WITH INVERTERS

When a squirrel cage motor is used with an inverter the following must
be done.
1. Always check
a. The motor and inverter rating
b. Insulation level of motor
c. Earth connection of motor and the driven equipment

2. Check if the motor will be operating at high speeds:

a. Bearing type and lubrication
b. Fan characteristics

13
 c. Critical speeds
d. Maximum torque

3. Check if the motor will be operating at low speeds:

a. Bearing type and lubrication
b. Motor's cooling system
c. Magnetic noise

In frequency converter applications motor frame external earthing

must be used for equalising the potential between the motor frame
and the driven machine, unless the two machines are mounted on
the same metallic base. For motor frame sizes above 280, use
0.75 x 70 mm flat conductor or at least two 50 mm round
conductors. The distance of the round conductors must be at least
150 mm from each other.
This arrangement has no electrical safety function purpose is to
equalise the potentials. When the motor and the gearbox are mounted
on a common steel fundament, no potential equalisation is required.

Potential equalisation
Plate/strip Cables/wires

V1
U1 W1
PE
3 -M 0.75 mm 150 mm

70 mm
Driven machinery min 50 mm

To comply with EMC-requirements, use only cables and connectors

approved for this purpose. (See instructionfor frequency converters.)

MAINTENANCE
CLEANING
Inspect the motor at regular intervals. Keep the exterior and interior of
the motor free from dust, oil and moisture. Dust can have a very
harmful effect. Motor should be blown out periodically depending on
the atmospheric conditions of the site. Make sure there is free
ventilation air flow. Use safe solvent (e.g. Carbon tetra chloride- CTC)
to remove any gummy accumulations of dirt in air passages.

14
WINDING
Keep clean to prevent layer of dust from acting as a heat insulator,
holding moisture or chemical particles or from starting abrasive action
on insulation. Inspection is required regularly, depending on
conditions around the motor. Open motors in dusty locations should
be avoided. To clean windings, vacuum clean or blow out with air.
Clean gummy dirt with a safe solvent (e.g. white petroleum, lactra
clean). Revarnish coils if varnish has got removed.
CHECKS
Insulation resistance should be checked regularly between phases
and phase to earth terminals.
- Inspect earthing terminals and clean regularly.
- Check the condition of shaft oil seals and replace if necessary.
- Check the condition of connections and mounting and assembly
bolts.
DRYING MOTOR
Motor installed outside or in a humid environment can be fitted with
space heaters to prevent the insulation resistance dropping during idle
periods. An element rated 50/100 W provides enough heat for a motor
upto 355 frame. In small low-voltage squirrel cage motors the stator
winding can be used to heat the motor when it is idle. For this, a single-
phase voltage of about 10% of the rated voltage of the motor is
connected to two of the terminals for a small duration.
RE-ASSEMBLY
The motors must be assembled in a dust free, dry and clean location.
Provide a fresh coat of bearing grease to all the machined mating
surfaces for motors with IP55 protection. Unmachined surfaces
should have rubber gaskets in good condition mounted carefully to
achieve correct sealing. During reassembly all fasteners that are used
on the exterior of the motor are provided with a coat of suitable loctite
sealant available in the market, to prevent ingress of water and dust
through tapped holes. When assembling the shaft oil seal ensure that
they are fitted properly.
(For other maintenance tips refer to our troubleshooting chart)
FANS
The axial locking of thermoplastic fans is provided with built-in tounges
which engage in the groove of the shaft. Thermoplastic fans have two
openings for the insertion of puller arms so that the pulling force can
directly act on the fan-hub.

15
 For removal of fans only a proper puller is to be used. Hammering is
strictly not permitted since the same can damage fans. In case of fans
with built in tounges for axial locking, the same should temporarily held
in lifted up position at the time of removal.
Metallic fans are axially locked with separate circlip. These fans are
best removed by engaging the puller arms on the outer rim of the fan.
In case of the larger fans the tapped holes provided on the hub can be
used.
BEARINGS
BEARING MOUNTING
When a bearing is mounted on a shaft, cold or hot mounting may be
used. Cold mounting is only suitable for small bearings. For hot
mounting, the bearing is heated in an oil bath or with a special heater
or with an induction heater. It is then pressed on to the shaft with a
mounting sleeve that fits the inner ring of the bearing or with the help of
other specialised tools for the purpose. Grease-filled bearing which
usually have sealing plates or shield plates, should not be heated.
BEARING REMOVAL
In many instances bearings have to be removed. Regrettably it often
happens that bearings that are perfect before removal for inspection
or cleaning are damaged during removal or mounting. It is good
practise only to remove bearings when strictly necessary. Instead of
removal bearing inspections must be done be checking for unusual
noise, scoring marks vibration measurement, bearing temperature
(see Fig.11), inspection of spent grease (for any change in colour),
grease leakage and SPM monitoring. Removal of small and medium
sized bearings does not present any difficulty. They are usually
removed by using conventional pullers. Reusable bearings having
interference fit on the shaft have to be removed by attaching the puller
jaws to the inner ring of the bearing. If it is necessary to attach puller
arms on the outer ring of the bearing, then the bearing must be rotated
during withdrawal to avoid damage to the bearing. When bearings are
removed from the motor wrap them in a polythene with grease
immediately, if partially dismantled, keep them free from dirt/corrosive
atmosphere. The removal of large bearings is more complicated. For

Fig. 11

16
example they can be removed cold with the aid of hydraulic pullers. It
is a good idea to get expert advice before attempting the removal of
large bearings.
Bearings that have been removed should be reused only if they show
no signs of damage and provided they are thoroughly cleaned
beforehand. For cleaning bearings use proper cleaning agent e.g.
white spirit or CTC, and wear gloves for protection. The cleaned
bearing must be free from foreign bodies.
Removal of bearings or inner rings which are not to be re-used is
facilitated by heating them with gas or welding torch.
FOR INFORMATION:
Motors provided with Roller bearings on the drive End side have very high
dynamic capacity. As per bearing manufacturers the roller bearing
performs satisfactorily only when it is physically loaded to approximately
1-2% of its dynamic capacity. In view of this, the roller bearing may not run
smooth when the motor is run uncoupled.
It is advisable not to run the motor with roller bearings in uncoupled
condition.
By far the commonest type of fault to affect electric motors is bearing
damage. Experts estimate that although more secure bearing
housings and more reliable high capacity bearings have been
introduced, bearing defects still account for around three quarters of
all motor faults. The main reasons for bearing failure are poor
alignment of the motor and driving machine, badly balanced coupling,
vibrating or weak foundations and the like. Faults of this type give rise
to pulsating forces which reach the bearing valve shaft and can cause
the bearing to wander. This means that the outer ring of the bearing
starts to rotate in it's seating, leading to failure.
When a belt pulley or coupling is being fitted and, unfortunately, also
when the bearings are being changed, it often happens that a hammer
or tin sledge is used. This results in indentations in the bearing races.
These relatively small marks are enlarged during the rotation of the
bearing and will result eventually in severe flaking. The danger of such
handling of bearing cannot be sufficiently over-emphasised. Among
other reasons for bearing failure is overtensioning of the belts, which
damages bearings and may even lead to shaft fracture, and failure to
observe the lubrication instructions for the motor and duty in question,
which may lead to bearing running dry and failing.
There are now objective methods for monitoring condition of ball and
roller bearings based on the techniques of condition monitoring at
regular intervals or vibration analysis. These methods allow the life
reserve of bearings to be better utilised and replacements to be
planned in good time.

17
 LUBRICATION
The motors are provided with single row deep groove ball bearings on
both ends. The complete type designation of each bearing is stamped
on the motor rating plate, including bearing sizes and radial clearance
class. The lubrication used in the bearings is Lithium complex grease
(IOC Servoplex LC3 or equivalent)
GREASE VALVE LUBRICATION
The principle of valve lubrication is that while the motor is running the
grease is forced in behind the bearing and so through it, See Fig
12.The old grease is forced out through the gap on a rotating disk
which carries the excess grease out through an opening in the outer
bearing cover. The grease that remain in the outlet opening serves as
a seal against the entry of dust. The advantages of grease valve

Fig. 12
lubrication is that the grease can be changed with the motor in service,
and that the bearing can never be over lubricated. A plate stating the
lubrication intervals is attached to every motor with grease valve
lubrication. It is important to follows these instructions. The stated
intervals are for a motor installed in a normal environment. If the place
is particularly dusty or wet the intervals should be shorter.
Relubrication procedure:
- Remove grease outlet plug if fitted.
- Press fresh grease into the bearing until all old grease has been
forced out.
- Let the motor run 1-2 hours to ensure that all excess grease is
forced out of the bearing. Close the grease outlet plug if fitted.
Re grease motors while running. If this is not possible, lubrication can
be carried out while the machine is at a standstill. In this case, use only

18
half the quantity of grease, then run the motor for a few minutes at full
speed. When the motor has stopped, the remaining quantity of grease
can be forced in until the old grease has been replaced. After 1-2
running hours close the grease outlet plug (if fitted).
The grease outlet plug must be removed permanently with automatic
lubrication.
If the machine is filled with a lubrication information plate, follow the
values given, otherwise use the valves in table below.

RELUBRICATION CHART

BEARING GREASE RELUBRICATION

FRAMES QTY. INTERVAL(HRS)
DS NDS GM DS NDS
Hx71 6203ZZ 6202ZZ - - - -
Hx80 6204ZZ 6203ZZ - - - -
Hx90 SL 6205ZZ C3 6205ZZ C3 - - - -
Hx100 L 6306ZZ C3 6206ZZ C3 - - - -
Hx112 MA 6307ZZ C3 6206ZZ C3 - - - -
Hx132 SM 6308ZZ C3 6307ZZ C3 - - - -
Hx160 ML 6309ZZ C3 6308ZZ C3 - - - -
HX+180 ML 6310ZZ C3 6309ZZ C3 - - - -
HX+200 ML 6312ZZ C3 6311ZZC3 - - - -
- -
- -
- -
HX+225 SM 6313 C3 6312 C3 23 20 3200 (2P) 3600 (2P)
6500 (4P) 6700 (4P)
8500 (6P) 8700 (6P)
8500 (8P) 8700 (8P)
HX+250 M 6315 C3 6313 C3 30 23 2400 (2P) 3200 (2P)
6100 (4P) 6500 (4P)
8100(6P/8P) 8500(6P/8P)
HX+280 SM 6316 C3 6315 C3 35 30 2000 (2P) 2400 (2P)
6000 (4P) 6100 (4P)
8000 (6P) 8100 (6P)
15100 (8P) 15300 (8P)
M2BA315 SM ML 2P 6316 C3 6316 C3 35 35 1000 (2P) 1000 (2P)
M2A315 SM ML 4…8P 6319 C3 6316 C3 45 35 3000 (4P) 3500 (4P)
2500 (6P) 6000 (6P)
2500 (8P) 6000 (8P)
M2BA355 SM ML 2P 6319 C3 6319 C3 45 45 800 (2P) 800 (2P)
M2BA355 SM ML 4…8P 6322 C3 6319 C3 60 45 2200 (4P) 5000 (4P)
2500 (6P) 5000 (6P)
4000 (8P) 5000 (8P)

19
 The above table is prepared for horizontally mounted motors.
Lubrication intervals for vertical motors are about half of the above
values.

The grease amount in the table is used if small quantities of fresh

grease are replaced at regular intervals as above.

As an alternative, when the machine is provided with grease

escape values, fresh grease may be pressed into the bearings until
the old grease is totally replaced.

High speed operation i.e. inverter applications, or lower speed with

heavy loading will require shortened lubrication intervals.

Typically a doubling of speed will require reduction of lubrication

intervals to approx. 50% of values in the table.

TROUBLE SHOOTING CHART

TROUBLE CAUSE WHAT TO DO
Motor fails to start Blown fuses Replace fuses with proper
type and ratings.

Overload trips Check and reset overload

in starter.

Improper power supply Check to see that power Supply

agrees with motor name plate
and load Factors.

Improper line connection Check connections withdiagram

supplied with motor.

Open circuit in winding or Indicated by humming sound

control switch when switch is closed. Check
for loose wiring connections.
Also, ensure that all control
contacts are closing.

Mechanical failure Check to see if motor and drive

turn freely. Check bearings and
lubrication.

Short circuited stator Indicated by blown fuses.

Motor must be rewound.

Poor stator coil connection Remove end shields, locate with

test lamps
20
 Rotor defective Look for broken bars
and/or end rings

Motors may be over loaded Reduce load.

Motor stalls One phase may be open Check lines for open phase.

Wrong application Change type or size.

Consult manufacturer.

Overload Reduce load.

Low voltage Ensure the name plate voltage

is maintained. Check connection.

Open circuit Fuses blown, check

overload relay, stator and
push buttons.

Motors runs and Power failure Check for loose connections to

then dies down line, fuses and control.

Motor does not Not applied properly come Consult supplier for proper
Up to speed type.

Voltage too low at motor Use higher voltage or

terminals because of line transformer terminals or reduce.
drop load Check connections. Check
conductors for proper size.

Starting load too high Check load motor is

supposed to carry at start.

Broken rotor bars or loose Look for cracks near the

rotor. rings. A new motor may be
required, as repairs are
usually temporary.

Open primary circuit. Locate fault with testing

device and repair.

Motor takes too Excessive load Reduce load

long to accelerate
and/or draws
high amp
Low voltage during start Check for high resistance.
Adequate wire size.

21
 Defective squirrel cage Replace with new rotor.
rotor

Applied voltage too low Increase power tap.

Wrong rotation Wrong sequence of phases Reverse connections at

motor or at switchboard.

Motor overheats Overload Reduce load.

while running
underloaded

Frame vents may be Open vent holes and check

clogged with dirt and for a continuous stream of
prevent proper ventilation air from the motor.
of motor.

Motor may have one phase Check to make sure that all
open leads are well connected.

Grounded coil Locate and repair.

Unbalanced terminal Check for faulty leads,

Voltage connections and
transformers.

Motor vibrates Motor misaligned Realign.

Weak support Strengthen base.

Coupling out of balance Balance coupling.

Drive equipment Rebalance driven

unbalanced equipment.

Defective bearings Replace bearings.

Bearings not in line Line up properly.

Balancing weights shifted Rebalance motor.

Contradiction between Rebalance coupling or

balancing of rotor and motor.
coupling (half key-full key)

Polyphase motor running Check for open circuit.

single phase.

22
 Excessive end play Adjust bearing or add shim.

Scrapping noise Fan rubbing fan cover Remove interference.

Fan striking insulation Clear fan.

Loose on bedplate Tighten holding bolts.

Noisy operation Rotor unbalance Rebalance.

Hot bearings Bent or sprung shaft Straighten shaft.

general

Excessive belt pull Decrease belt tension.

Pulleys too far away Move pulley closer to motor

Bearing.

Pulley diameter too small use larger pulleys.

Misalignment Correct by realignment of drive.

Hot bearings ball Insufficient grease Maintain proper quality of

grease in bearing.

Deterioration of grease of Remove old grease, wash

lubricant contaminated bearings thoroughly in
kerosene and replace with
new grease.

Excess lubricant Reduce quantity of grease,

bearing should not be more
than ½ filled.

Overload bearing Check alignment, side and

end thrust.

Broken ball or rough races Replace bearing, first clean

housing thoroughly.

23
 Marketing Offices
Marketing Offices: Branch :
Northern Regional Office : Chandigarh
4th Floor, NBCC Tower Tel : 0172-606093
15, Bhikaji Cama Place Fax : 0172-600678
New Delhi - 110 066 e-mail : [email protected]
Tel : 011-26186000, 26183974
Fax : 011-26197592, 26184035 Jaipur
e-mail : [email protected] Tel : 0141-2383208, 2381624
Eastern Regional Office : Fax : 0141-2383887
9, Lala Lajpat Rai Sarani e-mail : [email protected]
(Elgin Road), 3 & 4 Floor
Calcutta - 700 020 Kanpur
Tel : 033-22479162, 22478015 Tel : 0512-2554558
Fax : 033-22472427,22801309 e-mail : [email protected]
e-mail : [email protected]
Western Regional Office : Baroda
Asea House, Dr.S.B.Path Tel : 0265-2642141, 2644904
Old Goa Street, Ballard Estate Fax: 0265-2638911
Mumbai - 400 038 e-mail : [email protected]
Tel : 022-26730852, 26730964
Fax : 022-26730965 Pune
e-mail : [email protected] Tel : 020-4016251-52
Southern Regional Office : Fax: 020-4016255
Sona Towers, 71, Millers Road e-mail : [email protected]
Bangalore - 560 052
Tel : 080-2256315, 2256316 Hyderabad
Fax : 080 - 2204272 Tel : 040-27675988,27660795
e-mail : [email protected] Fax: 040-27607580
Chennai Regional Office : e-mail : [email protected]
Century Plazza, 3rd Floor, 3C, 3D & 3F
561-562, Mount Road, Tenyampet Coimbatore
Chennai - 600 018 Tel : 0422-432431
Ph: 044-24340201, 24340203 Fax: 0422-432431
Fax : 044-24340282 e-mail : [email protected]
e-mail : [email protected]
Central Regional Office :
H-21, Anupam Nagar,
(Near T.V.Tower)
Raipur - 492001
Tel : 0771-506016-18
Fax : 0771-5053391
 Service Centres
EAST : M/s. United Commercial Agencies
• CALCUTTA Mr. H.Advani
M/s.Avo Engineers Fancy Market, Shop No.3,
Mr. N.K.Dutta Morland Road, Opp. Zoola Maidan
138, Belaighatta Road Mumbai - 400011
Calcutta - 700 015 Ph : 022 - 3092582, 3013788 (O)
Ph : 033-2448826 4012557 (R) Fax : 022 - 3013788
• MAHESHTALA M/s. Saini Electricals
M/s. Electrical Services CIDCO, Service Indl. Plot No. 89,
Mr.Abhijit Banerjee Sector - 1, Shiravana Village, Nerul
Banerjee Para, Meheshtala New Mumbai - 400706
24 Paraganas (S) Ph : 022 - 7709073, 7710146
Ph : 033 - 4525146, M : 9831080921 E-mail : saini 1 @ vsnl.com
• BHILAI M/s. Bhavin Electricals
M/s Paramr Rewinders Mr. Nanjibhai
Mr.C.K.Paramar Sanganwa Chowk, Parekh Street
3-B, LIght Indl.Area, Rajkot - 360 001
Bhilai - 490026, M.P. Ph : 0281 - 222502
Ph : 0788 - 381592 (o) • SURAT
Fax : 0788 - 310478 (P.P.) M/s. Narmada Electricals Pvt. Ltd.
WEST Plot No. 4108, Road No. 4/41,
• AHMEDABAD GIDC, Esatae, Sachin,
M/s. Renovate Winding Works Distt. Surat - 394230
Mr. Arun Asnikar Ph : 870958, 872312
2016, GIDC, Phase IV NORTH
Opp. Ratnadeep Industries • FARIDABAD
Ahmedabad - 382455, Gujarat M/s. Prakash Electric Works
Ph : 079 - 5834955 (O), 5391352 (R) Mr. Om Prakash
• ANKLESHWAR Opp. Plot No. 2,
M/s. Narmada Electricals Pvt. Ltd. Whirlpool India, Sector - 25,
C1/B-3419 GIDC, Estate, Faridabad - 121 004
Near P.C. Chokdi, Ph : 0129 - 5230181, 5239142 (O)
Ankleshwar - 393002 Fax : 0129-5442065
Ph : 21197, 50455 (R) • JAIPUR
• BARODA M/s.Saini Electric Works
M/s. Allied Elect. Engg.Co. Mr. Satyanaryana Saini
Mr. Haribhai Thaker Ksheer Sagar Hotel, Motilal Atal Road,
358 GIDC, Makarpura, Jaipur - 302 001
Baroda - 390 010, Gujarat Ph n: 0141 - 360 204 (O), 200955 (R)
Ph : 0265 - 6443740, 640740 (O) Fax : 0141-200955
654343 (R), Fax : 0265 - 644716 M/s. Saggar Electrical Traders
• MUMBAI Mr.Kamlesh Kumar
M/S. Dol Electric Co. Pvt. Ltd. Opp. Industries Estate, Millerganj,
Mr. Suresh Dol Ludhiana - 141003, Punjab
Plot No. R-598, MIDC, TTC, Rabale Ph : 0131 - 534639, 538892 (O)
Navi Mumbai - 400071
Ph : 022 - 7692237 (O)
5334570, 5363127 (R)
Fax : 022 - 7691693
• MOHALI M/s. Banaglore Electrical Works
M/s. Pratap Heavy Electrical Engineers Mr. A.K. Mahesh
Mr. S.P. Singh 14th, Koramangala Industrial Layout
D-2, Industrial Estate, SAS Nagar, 5th Block, 4th 'C' Cross, Koramangala,
Mohali, Punjab Bangalore - 560 095
Ph : 0172-265706, 9814912668 (M) Ph : 080 - 5531831, 5534254 (O)
• NEW DELHI Fax : 080 - 5532402(O)
M/s. Aggarwal Engineering Co. 080-7832110(W), FAX : 080-7834937
(Motor Spares) 9845056057 (M)
Mr. S.K. Aggarwal E-mail : [email protected]
B-70/29, Lawrence Road, Ind. Area. • CHENNAI
DSIDC Complx, M/s Cheneleces Electricals
New Delhi - 110 006 Mr. Ranganathan
Ph : 011 - 7187520 / 7182384 (O) 4/492, Rajajaji Street,
7187520 (R) Fax : 011 - 3552393 Moover Nagar, Polichulur
M/s. New Universal Electric Works Chennai - 600074
Mr. Avtar Singh Ph : 044-2362594(O)
686, Farash Khana, G.B.Road, • COIMBATORE
New Delhi - 110 006 M/S. Siva Electricals Service
Ph : 011 - 3950506 (O) Mr. M.Parameswaran 156,
Fax : 011 - 5133660 Fourth Street Gandhipuram
• PATIALA Coimbatore - 641 012
M/s. India Electric Works Ph : 0422-499287 (O), 423667 (R)
Mr. Lalli • KOCHI
D-292, Industrial Focal Point M/s P.K. Babu Kutty
Patiala, Punjab 32/492,
Ph : 0175 - 359083, 229757 St.Johan Baptist Church Building
M : 9814019666 Palarivattom
Fax : 0175 - 213524 Kochi - 682025
E-mail : [email protected] Ph : 0484-340832
SOUTH • SECUNDERABAD
• BANGALORE M/s. Shree Satguru Electrical Works
M/s. Kashyap Electricals Mr. Ramprakash
Mr. N.Satish Shop No.23, Sterling Apartments,
No.2, 6th B, Cross Distillary Road, Ranigung-
Treveni Road, K.N. Extension Secunderabad
Yeshwanthpur Ph : 040 -7544446, 9849012553 (M)
Bangalore - 560022 Fax : 040 - 7542200
Ph : 080 - 3378751 Fax : 080 - 3570850
 WARRANTY
We guarantee the Electric Motor against
defective material and workmanship of 18
Months from the date of invoice or 12 Months
from the date of commissioning which ever is
earlier. Under this guarantee, we undertake to
replace or repair at our option the motor or any
defective parts thereof that need replacement
or repair by reason of defective material or
workmanship within the warranty period
provided that, if we so require, the motor/parts
are sent to our works as we may determine, at
the buyer's expense.

This warranty will lapse if the motor is opened

or its parts are tampered with by unauthorised
persons. Under no circumstances we
undertake liability for indirect or consequential
loss or damage of any nature.

NOTE: The card alongwith the attached Test

Certificate must be produced at the time of
lodging complaints.