User Manuals: ABB HXR Series High Voltage Motors

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ABB HXR Series Manual

ABB HXR Series Manual (147 pages)

for Induction Motors and Generators

Brand: ABB | Category: Engine | Size: 2 MB

Table of Contents

Table of Contents
10
Chapter 1 Introduction

16
- General Information
  16
- Important Note
  16
- Limitation of Liability
  17
- Documentation
  17
- Identification of the Machine
  18
  - Serial Number of the Machine
    18
  - Rating Plate
    18
Chapter 2 Transport and Unpacking

21
- Protective Measures Prior to Transport
  21
  - General
    21
  - Bearing Plate
    21
- Lifting the Machine
  23
- Turning a Vertically Mounted Machine
  26
- Checks Upon Arrival and Unpacking
  27
  - Check Upon Arrival
    27
  - Check Upon Unpacking
    27
- Installation Instructions for Main Terminal Box and Cooler Parts
  27
  - Installation of Main Terminal Box
    27
  - Installation of Cooler Parts
    28
- Storage
  28
  - Short Term Storage (Less than 2 Months)
    28
  - Long Term Storage (more than 2 Months)
    29
  - Rolling Bearings
    30
  - Sleeve Bearings
    32
  - Openings
    33
- Inspections, Records
  33
Chapter 3 Installation and Alignment

34
- General
  34
- Foundation Design
  34
  - Forces to the Foundation
    35
  - Flanges for Vertically Mounted Machines
    35
- Machine Preparations before Installation
  35
  - Insulation Resistance Measurements
    35
  - Disassembly of the Transport Locking Device
    36
  - Coupling Type
    36
  - Assembly of the Coupling Half
    36
    
    Balancing of Coupling
    36
    
    Assembly
    37
  - Belt Drive
    37
  - Drain Plugs
    37
- Installation on Concrete Foundation
  38
  - Scope of Delivery
    38
  - General Preparations
    38
  - Foundation Preparations
    38
    
    Foundation and Grouting Hole Preparations
    38
    
    Foundation Studs or Sole Plate Preparations
    38
  - Erection of Machines
    40
  - Alignment
    40
  - Grouting
    40
  - Final Installation and Inspection
    40
    
    Dowelling of the Machine Feet
    40
    
    Covers and Enclosures
    41
- Installation on Steel Foundation
  41
  - Scope of Delivery
    41
  - Check of Foundation
    41
  - Erection of Machines
    41
  - Alignment
    41
  - Final Installation and Inspection
    41
    
    Doweling of the Machine Feet
    41
    
    Covers and Enclosures
    42
  - Installation of Flange Mounted Machines on Steel Foundation
    42
- Alignment
  42
  - General
    42
  - Rough Levelling
    43
  - Rough Adjustment
    43
  - Correction for Thermal Expansion
    45
    
    General
    45
    
    Thermal Expansion Upwards
    45
    
    Thermal Axial Growth
    46
  - Final Alignment
    46
    
    General
    46
    
    Run-Out of the Coupling Halves
    46
    
    Parallel, Angular and Axial Alignment
    47
    
    Alignment
    48
    
    Permissible Misalignment
    49
- Care after Installation
  50
Chapter 4 Mechanical and Electrical Connections

51
- General
  51
- Mechanical Connections
  51
  - Cooling Air Connections
    51
  - Cooling Water Connections
    51
    
    Air-To-Water Coolers
    51
    
    Water Cooled Frames
    51
  - Sleeve Bearing Oil Supply
    52
  - Connection of Purging Air Pipe
    53
  - Mounting of Vibration Transducers
    53
- Electrical Connections
  53
  - General Information
    53
  - Safety
    54
  - Insulation Resistance Measurements
    54
  - Main Terminal Box Options
    55
    
    Delivery Without Main Terminal Box
    55
  - Insulation Distances of Main Power Connections
    55
  - Main Power Cables
    55
  - Secondary Cables for Slip Ring Connections
    56
  - Auxiliary Terminal Box
    56
    
    Connection of Auxiliaries and Instruments
    57
    
    Connection of External Blower Motor
    57
  - Earth Connections
    57
  - Requirements for Machines Fed by Frequency Converters
    58
    
    Main Cable
    58
    
    Earthing of Main Cable
    58
    
    Auxiliary Cables
    58
Chapter 5 Commissioning and Start-Up

59
- General
  59
- Check of Mechanical Installation
  59
- Insulation Resistance Measurements
  59
- Check of Electrical Installation
  59
- Control and Protection Equipment
  60
  - General
    60
  - Stator Winding Temperature
    60
    
    Resistance Temperature Detectors
    61
    
    Thermistors
    61
  - Bearing Temperature Control
    61
    
    General
    61
  - Protection Equipment
    61
- First Test Start
  62
  - General
    62
  - Precautions before First Test Start
    62
  - Starting
    63
    
    Direction of Rotation
    63
    
    Starting of Machines with Slip Rings
    63
    
    Starting of Ex P Machines
    63
- Running the Machine the First Time
  64
  - Supervision During the First Run
    64
  - Checks During Running of the Machine
    64
  - Bearings
    64
    
    Machines with Rolling Bearings
    65
    
    Machines with Sleeve Bearings
    66
  - Vibrations
    66
  - Temperature Levels
    66
  - Heat Exchangers
    67
  - Slip Rings
    67
- Shut down
  67
Chapter 6 Operation

68
- General
  68
- Normal Operating Conditions
  68
- Number of Starts
  68
- Supervision
  69
  - Bearings
    69
  - Vibrations
    69
  - Temperatures
    69
  - Heat Exchanger
    70
  - Slip Ring Unit
    70
- Follow-Up
  70
- Shut down
  70
Chapter 7 Maintenance

71
- Preventive Maintenance
  71
- Safety Precautions
  71
- Maintenance Program
  72
  - Recommended Maintenance Program
    74
    
    General Construction
    75
    
    Main Supply Connection
    75
    
    Stator and Rotor
    76
    
    Auxiliaries
    76
    
    Slip Ring Unit
    77
    
    Lubrication System and Bearings
    77
    
    Cooling System
    78
- Maintenance of General Constructions
  79
- Maintenance of Bearings and Lubrication System
  83
  - Sleeve Bearings
    84
    
    Oil Level
    84
    
    Bearing Temperature
    84
  - Lubrication of Sleeve Bearings
    84
    
    Lubrication Oil Temperature
    84
    
    Control of the Lubricant
    85
    
    Recommended Control Values for the Lubricating Oil
    85
    
    Oil Qualities
    85
    
    Oil Change Schedule for Mineral Oils
    86
  - Rolling Bearings
    87
    
    Bearing Construction
    87
    
    Bearing Plate
    87
    
    Re-Greasing Intervals
    87
    
    Re-Greasing
    88
    
    Bearing Grease
    89
    
    Bearing Maintenance
    90
  - Bearing Insulation and Bearing Insulation Resistance Check
    90
    
    Procedure
    90
    
    Cleanliness of Bearing Insulation
    92
- Maintenance of Stator and Rotor Windings
  93
- Maintenance of Slip Rings and Brush Gear
  100
  - Care of Slip Rings
    100
    
    Standstill Period
    100
    
    Wear
    100
  - Care of Brush Gear
    100
    
    Brush Pressure
    101
- Maintenance of Cooling Units
  101
- Repairs, Disassembly and Assembly
  104
Chapter 8 - Trouble Shooting

105
- Trouble Shooting
  105
- Oil Leakage of Sleeve Bearings
  114
  - Oil
    114
  - Sleeve Bearings
    115
  - Bearing Verification
    115
  - Oil Container and Piping
    116
  - Oil Container and Piping Verification
    116
  - Use
    117
  - Use Verification
    118
- Electrical Performance, Excitation, Control and Protection
  121
  - Protection Trips
    121
  - Pt-100 Resistance Temperature Detectors
    121
- Slip Rings and Brushes
  123
  - Brush Wear
    123
  - Brush Sparking
    123
- Thermal Performance and Cooling System
  124
Chapter 9 After Sales Support and Spare Parts

125
- After Sales
  125
  - Site Services
    125
  - Spare Parts
    125
  - Support and Warranties
    125
  - Support for Service Centers
    125
  - After Sales Contact Information
    125
- Spare Parts for Rotating Electrical Machines
  126
  - General Spare Part Considerations
    126
  - Periodical Part Replacements
    126
  - Need of Spare Parts
    126
  - Selection of the most Suitable Spare Part Package
    127
  - Typical Recommended Spare Parts in Different Sets
    127
    
    Operational Spare Part Package
    127
    
    Recommended Spare Part Package
    128
    
    Capital Spare Parts
    128
    
    Operational Spare Part Package
    128
    
    Recommended Spare Part Package
    129
    
    Capital Spare Parts
    129
    
    Operational Spare Part Package
    130
    
    Recommended Spare Part Package
    131
    
    Capital Spare Parts
    131
  - Order Information
    131
Chapter 10 Recycling

132
- Introduction
  132
- Average Material Content
  132
- Recycling of Packaging Material
  132
- Dismantling of the Machine
  133
- Separation of Different Materials
  133
  - Frame, Bearing Housing, Covers and Fan
    133
  - Components with Electrical Insulation
    133
  - Permanent Magnets
    134
  - Hazardous Waste
    134
  - Land Fill Waste
    134
- Commissioning Report
  135
- Typical Position of Plates
  145
- Typical Main Power Cable Connections
  146

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