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Summary of Contents for ABB DC Machines DMI
- Page 1 DC Machines Operating and Maintenance Instructions...
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Page 3: Table Of Contents
Contents Safety 1. General ...........4 5. Electrical connection and 2. Intended use ..........4 commissioning ........5 instructions 3. Transport, storage .........4 6. Operation ..........5 4. Installation ..........4 7. Maintenance and servicing ....5 Machine General ............6 Grouting-in ..........7 description General storage General ............10 Vibrations ...........10 Condensation ..........10 Shaft end protection ........10... -
Page 4: Safety Instructions
All operations serving transport, connection, taken into account. commissioning and periodic maintenance must To guarantee trouble-free operation the ABB be carried out by skilled, responsible techni- documentation must be followed. cal personnel (note EN 60034; EN 50110-1/VDE 0105). -
Page 5: Electrical Connection And Commissioning
(VDE 0530), i.e. voltage ± 5%, or an unfavour- brush monitors), strictly follow the correspond- able form factor resulting from the type of ing instructions. In case of doubt, consult ABB. converter used, leads to increased heating and For machines with brakes, check satisfactory shortens the life of the machine. -
Page 6: Machine Description
Machine description Technical data The exact type designation and the most im- portant technical data are shown on the rating on rating plate plate located on the terminal box. Figure 1. Rating plate for DMI machine. -
Page 7: Grouting-In
Machine description Type of motor Field exciter voltage, alternative operation Motor number (specific for each motor) Field exciter current, alternative Rating and performance standard operation Mounting arrangement Open row Thermal class/Temperature rise Method of cooling Motor weight (without cooling device) Degree of protection Converter and/or AC supply data Valid temp. - Page 8 Machine description Description of Part Part Part Description Description Description parts Outer bearing cover, N-end Pressure finger spring Counterweight, D-end Retaining ring, N-end Pressure finger Inspection cover, complete with gasket (state position and type) Brush Grease-sling disc, N-end Terminal box, complete Grease retaining ring, N-end Stator, complete Gasket Stator frame Bearing, N-end Box bottom plate Inner bearing cover, N-end Main field coil Mounting rail Main field coil insulation Grease nipple, N-end...
- Page 9 Machine description...
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Page 10: General Storage Precautions
General storage precautions General Special attention must be given to machines Condensation, corrosive gases and vibrations which are to be stored for a long period of time should be avoided. before commissioning. Caution Lift all brushes and wrap protective paper around the commutator. Condensation Condensation in a machine may lead to maintain a constant temperature. -
Page 11: Foundation
Avoid resonances in the operating speed range tors which are not controlled by ABB. Caution The foundation must be dimensioned in such a way that its own natural frequency, including the motor weight, does not correspond to those disturbing frequencies which normally exist in a thyristor-fed DC machine. -
Page 12: Machine Installation
Machine installation Checks before - DMI-motor - Check that the rating plate is in accordance with the order starting - Accessories in separate packages installation - Maintenance Instruction, including “Declaration of Incorporation” and “EC Declaration of Conformity” Inspection It is recommended to check that: R Air ducts, if needed, are free from foreign matter which could be sucked into the ma- R The erection site is clean... -
Page 13: Machines
Machine installation Alignment of Good alignment ensures safe operation and long To ensure correct alignment of the machine, machine life. Check the misalignment between the place suitable metal shims between machine feet direct coupled coupling flanges after the machine has been in- and mounting blocks. -
Page 14: Alignment Of V-Belt Drive
Machine installation Alignment of The drive should be arranged in such a way that feet and positioned in such a way that the the lower belts are the driving ones, i. e. so that tensioning screws are diagonally opposite each V-belt drive the slack is in the upper belts. -
Page 15: Terminal Diagram
Machine installation Terminal Terminal diagram for DMI 180-280, standard design (shunt wound machine). diagram Motor Generator Pressure switch Filter monitor A1 A2 F1 F2* + - + - - + + ”Pressure on” ”Filter dirty” Supply lead Supply lead ”Pressure off” ”Filter not dirty”... - Page 16 Machine installation Terminal Terminal diagram for DMI 315 – 400, standard design (shunt wound machine). diagram Fig. 10 Terminal diagram. * Formerly designated F4. Changed to F2 according to IEC 60034-8.
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Page 17: Commissioning
Don’t seal air ducts to the motor with products containing silicone, as silicone oil particles will adhere to the surface of the commutator and cause high brush wear. Caution It is advisable to contact ABB if there are any abnormal observations Checks during Check the following points during the start-up: R that no unusual bearing noise is heard. -
Page 18: Observation And Maintenance
Observation and maintenance General Careful maintenance is the best insurance However, the needs for maintenance can vary against failures and interruption of operation. widely depending on local conditions. The The maintenance schedule shown below is the schedule is therefore to be regarded as a guide result of many years of experience. -
Page 19: Insulation
Insulation resistance Measuring of Example The measurement should be done with a 500 V insulation In the winding of a 750 V motor, the insulation megger. resistance has been measured as 100 MΩ at resistance It is not practical to state a definite minimum 6 °C. -
Page 20: Brushes And
A critical factor for achieving good surface condition commutation is the correct choice of brush – Brushes: grade, wear/1000h, condition grade. ABB has many years of experience in the of the contact surfaces, wedging effect selection of suitable types. Nevertheless, the (lateral wear) brush grade may have to be changed if unex- –... -
Page 21: Poor Brush Contact
As the ideal current load depends on the brush grade, ABB should be consulted in Scratched contact surface such cases. Cement dust or similar hard particles can scratch the commutator surface. -
Page 22: Brush Wear
Use only one brush grade per DC machine. Commutation problems and consequential damage to machines equipped with different type of brush grade than the original type or the type suggested by ABB is not covered by warranty. Bedding-in A medium-coarse emery cloth is used for bed- After bedding-in, the commutator and the brush ding-in the carbon brushes. -
Page 23: Commutator
If the commutator surface is rough, it is If the patina is of poor quality, ABB recommends essential to check the operating conditions removing it completely. such as current loading, and environmental If the surface is burnt to the extent that craters conditions. -
Page 24: Bearings
Figure 17. Disassembling a bearing using a purpose-designed extractor. Assembling • Fill the bearing with grease. Note! Use only • Carefully clean bearings and the inside of the grease that fulfils ABB requirements, see bearing covers. page 25. • Then place the inner bearing cover on the •... -
Page 25: Lubrication
After machine and may cause serious contamination. the surplus grease has run out of the bearing Use only high quality grease equivalent to ABB housing, the temperature should reach normal grease. Lubrication... -
Page 26: Cleaning
Cleaning General The most important factor in preventive main- free from dust, oil and other matter which can tenance is that everything is clean. The ma- come from the driven object or which can enter chine itself and the surroundings must be kept through ventilation openings, etc. -
Page 27: Filter
Filter Fans with air Machines which have fans with air filters must Remove the inlet protection screen and fit a be checked at regular intervals and the filters clean filter. filters must be exchanged when necessary. Remark Note that the filter material has a different structure on each side. The side with the coarser structure must be placed outward. -
Page 28: Speed Control Installing The Speed Control Device
Speed control device Mounting the speed control device 1. Split the coupling (1) into three parts (A). 2. Make sure that grease and dirt are removed from the shaft hole. 3. Mount the part from the coupling (1a) inside the rotor shaft and tighten it with a screwdriver. -
Page 29: Device
Speed control device For POG, REO and TDP speed control devices: 7. For shaft heights 180-280; assemble the adapter (2) on the bearing cover with four bolts and washers (3+5). Tightening torque M6 10Nm with a dynamometric wrench. For shaft heights 315-400; assemble the adapter (2) on the bearing cover with four bolts and washers (3+7). -
Page 30: Heat Exchangers General
IP 54 on the windings, so affecting the ground insula- or IP 55, according to customer request. tion level. ABB recommends users to follow all maintenance instructions described previously and to clean the motor regularly by opening all covers and vacuuming out all dust not held by the filtering material. - Page 31 Heat exchangers Note! Do not lift the motor and heat exchanger by the heat exchanger’s lifting eyes. Figure 18. Mounting of heat exchanger for DMI 180-280.
- Page 32 Heat exchangers DMI 315 and 400 prepared for IC 666 and IC 4. Place the heat exchanger on top of the DMI 86W heat exchangers are delivered with pre- machine and joint the heat exchanger at the mounted gaskets (item 1), set screws (item 2), flat point set screws of the DMI machine washers (item 3 and 4), spacers (item 5 and 6) (item 2).
- Page 33 Heat exchangers Specific information about air/water heat Water connection of air/water heat exchanger exchangers with air inlet at N-end (standard) 1. Water connection on right side 3. Water connection on left side (seen from (seen from D-end) towards N-end. D-end) towards N-end. Label on cooling coil shows the in- and outlet of water depend- 2.
- Page 34 Heat exchangers Water connection of air-water heat exchanger with air inlet at D-end 1. Water connection on left side (seen from 3. Water connection on right side (seen from D-end) towards D-end. D-end) towards D-end. Label on cooling coil shows the in- and outlet of water depend- 2.
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Page 35: Equipment Of Heat Exchangers
Heat exchangers 1. Remove screws holding the cooling coil and the cover. 2. Slide the coil out of the housing and rotate as shown above. 3. Slide the coil into the housing and replace the screws. 4. Replace the cover at the opposite side. Figure 22 Changing the water connection direction 1. -
Page 36: Before Starting
Heat exchangers Before starting • The water supply pipe system must be • The water flow must be regulated to obtain flushed out before coil is connected. water flow indicated on data plate of the heat exchanger. • Pressure tests of pipe system, after coil is connected, must not exceed test pressure •... - Page 37 Verification: Only to be done by trained personnel from Samson. If done wrongly, the thermostat might be destroyed Adjustment: Contact ABB PT100, Inor RNT8 Function: For measuring the temperature of the cooling air Verification:...
- Page 38 Verification: Readings should say “Zero” when the valve is shut. Compare with the other flow sensor/meter when valve is opened Adjustment: Contact ABB Leakage water detector, SIE07065 Function: Top- and side-mounted heat exchangers: If a water leakage occurs or if there is condensation inside the heat exchanger, water will be evacuated through the leakage air filter canal and an alarm goes off.
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Page 39: Maintenance Of Motors With Heat Exchangers
Heat exchangers Terminal diagram for heat exchangers 11, 12, 13: HUBA 604 — FILTER GUARD — TERMINAL 3 LIVE AT INCREASING PRESSURE — ALARM—CLOGGED FILTER 21, 22, 23: TRAFAG MST 9515 — THERMOSTAT IN COLD AIR — TERMINAL 3 LIVE AT INCREASING TEMPERATURE —... - Page 40 For information regarding over the cooling coil and the filter). Use filter paint contact ABB. type EU3 according to Eurovent 4/5 or similar filter with efficiency 85% according to Ashrae Check fan motor (Figure 24, item 10) for unusual 52-76.
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Page 41: Dismantling And Reassembling
Dismantling and reassembling Dismantling R Make sure the machine and fan motor are R Unscrew the fixing bolts which tie stator and electrically disconnected. end shield together at the N-end. R Remove air ducts (if present at installation), R Remove the end shield at the N-end. Do not disconnect coupling or V-belts and dismantle damage the main gasket between end shield the machine from the foundation. -
Page 42: Spare Parts Recommended Spare Parts
Spare parts Recommended Number of identical motors spare parts 2 – 4 5 – 9 10 – Brushes (number of sets) – – 9 10 – Brush gear Bearings (number of sets) Set of armature coils + resp. commutating coils Armature, complete + main field coil + resp. commutating coils 1 *) Motor, complete *) Also two compensating windings incl. slot insulations and slot keys when the machine has compensating windings. Remark Please state when ordering: motor type, motor serial number and part number. -
Page 43: Faults And Mechanical
Post-mounted coupling adversely Rebalance rotor with coupling affecting rotor balance Damage to rolling bearings Overheating immediately after Too much grease filled Fill and press in only the prescribed starting or regreasing amount of grease (See rating plate). Overheating automatically disappears after some time Overheating after long period of Bearing cover seals rubbing Remachine bearing cover, replace operation damaged seals Scraping, rubbing or knocking Change bearing (cause to be noises in bearing determined by specialists) Whistling sounds in grease Bearing is dry Inject grease lubricated bearings Damage on bearing cage Replace bearing Formation of indentations when Vibrations being transferred to Isolate motor from external vibration or machine stationary bearings from external source keep rotor turning continuously Formation of indentations when Electric current flowing through the Consult ABB machine in operation bearing... -
Page 44: Electrical
Faults and remedies Electrical Fault Possible cause Remedy Motor will not start at no load No armature voltage Check supply Armature coils burnt out or short- Clear short-circuit (generally circuited only possible in specialist’s or manufacturer’s workshop) Brushes not making proper contact Check pressure and position of brushes, replace worn brushes No excitation voltage Check supply Open circuit in field winding Remedy open circuit Interturn short-circuit in the armature Repair in workshop winding Short-circuit between commutator Check commutator and eliminate short segments Motor will not accept load Overload Check current input and eliminate overload Voltage decreasing Check supply Motor overspeeding and hunting Brushes displaced from neutral zone in Set brush-bracket to mark under load under load opposite direction to rotation position Fault in field circuit Eliminate fault... -
Page 45: Commutation
Reset neutral position ) Asymmetry between the brush holder studs Correct the distance between the studs ) Commutating pole flux too high Increase commutating pole air gap ) Commutating pole flux too low Decrease commutating pole air gap ) Excessive no load operation Use suitable brushes, reduce the number of brushes ) Dirt and oil on the commutator Clean the commutator and identify cause ) Abrasive dust on the brush surfaces Remove the brushes and brush them clean ) Overload Reduce the load 9) Vibrations Check the alignment, rebalance if necessary 10) The armature winding is damaged Repair, rewind if necessary 11) Inadequate ventilation Trace the causes, then consult ABB if necessary 1) Current density at the brushes is too low Reduce the number of brushes 1) Current surges Choose suitable brush types 1) The air is too damp Let in fresh air, select suitable brushes 1) The air is too dry Let in fresh air, select suitable brushes 1) Dust or sand suspended in the air Fit filters and eliminate the causes 1) Gases or acids in the air (*) Let in fresh air, select suitable brushes 1) Excessive brush friction Reduce brush pressure, make use of non-abrasive brushes 19) Brushes not adapted to the commutator Adapt the brushes perfectly, as previously shown 0) Different brush types Use brushes of the same type 1) The commutator is stained when the... -
Page 46: Ec Directives Declaration Of Incorporation
EC Directives Declaration of Incorporation... -
Page 47: Ec Declaration Of Conformity
EC Directives EC Declaration of Conformity... - Page 48 ABB Automation Technologies DC Motors SE-1 0 Västerås, Sweden Telephone: + (0)1 90 00 Telefax: + (0)1 9 1 www.abb.com/motors&drives...
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