Cat 135 400 kW - 3-phase motor dksWaW653-12-4 Operating Manual

The 135 / 400 kW - 3-phase motor dksWaW65/3-12-4 (according to ATEX instruction) Operating manual Information sheet 1003258

version 4 version 2

BREUER - MOTOREN ELEKTROMASCHINENFABRIK Rensingstrasse 10 44807 Bochum Tel.: 0234/90 42 6-0 Fax: 0234/53 28 80 Internet: www.breuer-motoren.de

Operating Instructions for three-phase AC motors Order No.: 000-90-00-006

Edition: 09/05

Table of Contents

Table of Contents............................................................................................ 1 A. General.........................................................................................................................2 A.1 General information on these operating instructions ...............................................2 A.2 General safety information ......................................................................................2 A.3 Safety-relevant terms and expressions ...................................................................2 A.4 Transport, storage ...................................................................................................3 B. Assembly......................................................................................................................4 B.1 Safety information....................................................................................................4 B.2 Installation ...............................................................................................................5 B.3 Connection ..............................................................................................................7 B.4 Insulation test ..........................................................................................................8 B.5 Commissioning ........................................................................................................9 C. Operation ...................................................................................................................10 C.1 Safety Instructions.................................................................................................10 C.2 Switching on / off ...................................................................................................10 C.3 Operating intervals ................................................................................................10 D. Servicing ....................................................................................................................10 D.1 Safety instructions .................................................................................................10 D.2 Inspections ............................................................................................................11 D.3 Repairs..................................................................................................................12 D.4 Replacement parts ................................................................................................14

Order No. 000-90-00-006-V4 Page 1 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

A. General A.1 General information on these operating instructions These operating instructions and the relevant data sheet are intended to assist you in using the 3-phase motor safely, properly and economically.

By following the information in these instructions, you will: ♦ increase the reliability and extend the working life of the 3-phase motor ♦ avoid dangers ♦ avoid repairs and breakdown times These operating instructions, the relevant data sheet and the certificate issued must: ♦ be available at all times during installation, operation, maintenance and repair work ♦ be read, understood and applied by any and all persons carrying out work on the 3-phase motor.

The machines dealt with here are components of high-voltage electrical plant for stationary and mobile applications. They are constructed in accordance with the recognised rules of technology. However, improper handling or incorrect use may still create danger to life and limb of the user or other persons, or adversely affect the operation of the machine or other equipment. Please therefore observe all safety information in these operating instructions and the relevant data sheet.

A.2 General safety information The “U” symbol following the certification number specifies that this certificate may not be confused with a certificate issued for a device or protection system. This partial certification may only be used as the basis for the certification of a device or protection system.

If there is an “X” following the certification number, attention is drawn to special requirements for the safe use of the device or protection system in the appendix to this certification.

The symbols “U” and “X” are not used simultaneously.

Inset threads, into which cable bushes or guides are screwed by means of a screw-in thread must conform to the minimum requirements of EN 50018, Section 5.3 (Table 3) in conjunction with Appendix C.2.2..

Gap surfaces forming a pressure-tight seal must be so designed that their average peak-to-valley value does not exceed Ra6,3 µm. The surfaces must be of bright metal and level.

The permanent usage temperature of adhesives, e.g. Loctite ... used for the possible gluing of threads as anti-loosening protection must be at least 100 °C. The prohibition relating to the working of unqualified persons on high-voltage electrical equipment is published for example in DIN VDE 0105 or IEC 364 (German IEE Regulations).

A.3 Safety-relevant terms and expressions DANGER / WARNING / CAUTION Disregard of such a sign may lead to serious injury or even death, and/or may lead to substantial damage being caused.

Information: Draws attention to a specific technical connection, which may not be readily seen by trained personnel.

Order No. 000-90-00-006-V4 Page 2 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

Qualified staff: are persons who, on the basis of their training, experience, the instructions they are given and their knowledge of the relevant standards, regulations, accident prevention instructions and operating conditions, are delegated by those responsible for the safety of the plant to undertake the duties necessary in its operation and to recognise possible sources of danger and to avoid them.

Other necessary qualifications are a knowledge of first-aid treatment and familiarity with the location and use of locally-available emergency equipment.

The observation of all other transport, installation, operation and servicing instructions, and technical data is equally indispensable for avoiding breakdowns or faults which themselves can directly or indirectly cause serious personal injury or damage to property.

A prerequisite of the reliable and safe operation of the machine is appropriate care in transport, storage, installation and assembly, as well as care in operation and maintenance.

It is assumed that all work on the machine will be carried out by qualified personnel trained to work on these motors and/or monitored by responsible specialists.

The machines dealt with here are components of high-voltage electrical plant for stationary and mobile applications. They are constructed in accordance with the recognised rules of technology. However, improper handling or incorrect use may still lead to a reduction in performance or create danger to the user. Please therefore observe all safety information in these operating instructions and the relevant data sheet.

The prohibition relating to the working of unqualified persons on high-voltage electrical equipment is published for example in DIN VDE 0105 or IEC 364 (German IEE Regulations).

WARNUNG It is taken for granted that all workings on the machine are carried out by qualified staff and controlled by responsible specialists.

The personnel must be thoroughly acquainted with all warnings and maintenance measures, in accordance with these operating instructions.

The following operating instructions incorporate generally-valid details, and safety instructions to be followed in respect of the frequency converter motors of the BREUERMOTOREN GmbH Co. KG. Due to the wide variety of motor types manufactured, there are special instructions to be observed in the case of some motor types.

There are summarised in a special data sheet relating to the individual motor types, and must be observed in addition to these general instructions, in order to avoid damage and sources of danger.

A.4 Transport, storage WARNUNG The motors may only be lifted by the lifting-points provided. The lifting-gear selected must be chosen in accordance with the gross weight of the motor (see Data sheet).

Any additional lifting eyes which may be present, e.g. on ventilator cowls, are only suitable for lifting the individual parts concerned.

For motors provided with transport security devices for the bearings, these are only to be removed when the motor is installed in the machine in its place of use.

If the motor is not commissioned immediately, it must be stored in a dry room, not subject to vibrations.

The cooling ducts of water-cooled motors are flushed through with an anti-corrosion emulsion. The water connections are sealed.

To avoid condensation gathering inside the motor when it is stored, the motor must not be subjected to large variations in temperature.

Order No. 000-90-00-006-V4 Page 3 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

B. Assembly B.1 Safety information WARNUNG

Please observe the "General safety information" most carefully.

Usage information for installation parts

End of line units The short-circuit current of the protection or monitoring device supplying the power must not exceed 33 mA .

Bushes (according to Spare part List) Bushes must be fitted into electrical equipment in such a way that they are secured against turning and selfloosening.

Cable and lead guides (according to Spare part List) Cable and lead guides must be fitted into electrical equipment in such a way that they are secured against turning and self-loosening.

For the installation of cable and lead guides with intermediate adapters – and where the required tightening moments are not specified – the screw-in bush must be screwed firmly into the intermediate adapter, and the screws of the fixing clamps tightened firmly, using the suitable tools.

The flange fixing screws of the cable and lead guides must end in blind holes.

Cable bushes (according to Spare part List) Cable bushes must be fitted into electrical equipment in such a way that they are secured against turning and self-loosening. Max. tightening moment 60 Nm. Damaged bushes must be replaced.

Unused cables must be laid to connection terminals, and may not be simply cut off.

Cable guides (according to Spare part List) Cable guides may only be used for the fixed laying of cables. The cables must be securely attached, so that they are protected against tension and twisting.

Connecting clamps (according to Spare part List) Connecting clamps may only be attached by means of the corresponding combination screws. The tightening moment may not exceed a maximum of 0.4 Nm. Connecting clamps must be fitted into electrical equipment in such a way that they are secured against turning and self-loosening. For the installation of a single 2-pole mini-clamp, a special part is provided for protection against twisting. This must be fitted to the grooved side of the mini-clamp.

Order No. 000-90-00-006-V4 Page 4 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

B.2 Installation B.2.1 Conditions of use Observe the conditions of use, technical data as shown on the rating plate and technical documentation.

If the motor is to be operated where fire-damp may occur, or in other locations at risk of explosion, check before installing whether the existing permit (see data sheet) complies with legal requirements in the country of use.

The assessment of hazard of explosion of any operating location is exclusively the preserve of the authorities responsible.

For installation in territories where VDE guidelines are applicable, the following must be observed ♦ for machines protected against fire-damp for use in mines prone to fire-damp (group I), regulations as laid down in DIN VDE 0118 (Installation of electrical equipment under ground), the Electrical equipment permit (mining) regulations (ElZulBergV) and §4 of the Explosion Protection Ordinance (Directive 94/9/EG) ♦

for motors protected against explosion (groups IIA, IIB, IIC) for use in locations at risk of explosion, the Installation regulations DIN VDE 0165 (Installation of electrical equipment in locations at risk of explosion).

For installation in other countries, the appropriate national standards and installation regulations apply.

B.2.2 Lubrication For lubrication, use only lithium grease of class 3 consistency, and a drip-point of over 175°C. For necessary lubrication measures, see data sheet.

If the time between delivery of the motor and its commissioning exceeds two years, the bearings must be relubricated.

Information: Toxicological advice: the lubricant should not be allowed to remain in contact with the skin for a long period. Any lubricant which gets into the eyes should immediately be thoroughly rinsed out with plenty of clean water. If any lubricant should be swallowed, do not induce vomiting; consult the doctor immediately.

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Operating instructions for three-phase AC motors

B.2.3 Cooling B.2.3.1 Air-cooled motors For air-cooled motors, it must be ensured that the cooling air can flow unhindered both in and out. Hot exhaust air must not be taken in again. Particular care must be taken that the air inlets are kept clear. From any wall, the spacing should be at least 50 cm. Extensive deposits must not be allowed to form on the cooling fins to guarantee adequate heat dissipation.

B.2.3.2 Liquid-cooled motors The coolant inlet and outlet are both marked on the motor. When connecting up the cooling system, theses marking must be observed with care. It is essential the cooling system shut-off tap be located before the motor, in order to avoid pressure banking up.

As a rule, there are safety valves at the coolant inlet (operating pressure see data sheet), to protect the cooling system from damage if the inlet pressure becomes too high.

In the case of some motors designed for use in specific machines, it has been necessary to omit the safety valve for space reasons. In these cases, it is the responsibility of the customer to arrange for the location of a safety valve in the auxiliary pipework in the immediate vicinity of the motor. Operating pressure must be in accordance with that shown in the data sheet.

If the cooling water can be expected to be dirty or have an undesirable composition (scale/sulphur content), the water flow rate through the machine must be checked at least 1x per month, and compared with the specification curve (see data sheet). In the event of variances, the cooling ducts must be cleaned.

To prevent soiling and damage in the cooling system, the coolant must be chemically neutral, and nonaggressive, with a pH value ≅7. In addition, the coolant must be free of coarse pollutants (≤ 0,25 mm); where appropriate, additional filters which must be cleaned regularly must be added in series.

If the motor is to be dismantled underground, the cooling circuit must be flushed out, flushed through with a preservation agent for transport and filled with an anti-freeze agent for storage.

The amount of coolant required and its maximum permitted inlet temperature are to be obtained from the data sheet. An inlet temperature below 15°C should be avoided on account of the danger of condensation forming. After switching the motor off, the cooling water must be allowed to continue flowing for a further 5 min., in order to avoid the build-up of heat in the converter motor.

B.2.4 Balancing Rotors manufactured since June 1996 are, in accordance with DIN ISO 8821 (balance quality stage Q2,5) basically dynamically balanced with half-length parallel keys. Next to the motor number in this case the letter ‘H’ is stamped into the end of the shaft at the power take-off side. If this identification mark is not present (i.e. in the case of motors manufactured before the above date), the rotors will have been balanced with standard parallel keys.

When selecting the coupling, it must be ensured that the type of balance matches that of the rotor.

B.2.5 Noise emission When running under no-load conditions, the motors emit a noise pressure level of between 75 dB(A) (watercooled) and 85 dB(A) (air-cooled) at a distance of 1 metre. At the place of installation, the level will depend heavily on type of installation and conditions of the environment itself, so that the actual noise behaviour in operation can only be established on site.

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Operating instructions for three-phase AC motors

B.2.6 Assembly conditions Where feather keys are part of the consignment, these are as a rule only secured against becoming dislodged in transit.

In the case of motors with two shaft ends, where a take-off is only fitted at one end, the unused feather-key is to be secured against being thrown out. The length of the key is to be selected according to the type of balancing (see B.2.4).

Tightening the coupling must only be carried out with the assistance of the thread in the shaft-end, or by other device also avoiding blows or jars on the shaft. The motor must be carefully adjusted when being attached to the machine.

The motors may only be installed in machines of the appropriate design for their type (see data sheet).

B.3 Connection B.3.1 General Before commencement of connecting work, compare the available power supply with details given on the rating plate. The connecting cabling is to be suitable for the nominal current and the conditions existing on site, e.g. ambient temperature, type of cable-laying.

A connecting clamp is available in the terminal space as well as on the outside of the cabinet, of corrosionresistant material, for the earthing conductor connection.

The connecting operations may only be carried out by qualified personnel trained to work on these motors.

B.3.2 Clamp marking a) Power connections (motor voltage) see data sheet

b) Monitoring devices see data sheet Every motor must, in accordance with DIN VDE 0118 and/or DIN VDE 0165, be protected by a currentdependent cut-out switch (also see data sheet) or a similarly-effective device as per DIN VDE 0660 on all phases against overheating.

If the permit number of an explosion-protected motor has an affix "B" or "X", then special measures are to be undertaken in agreement with the test certificate (see data sheet).

B.3.3 Direction of Rotation When the L1, L2 and L3 power supply lines are connected to U, V and W respectively, then a clockwise rotation results when viewed from the output side. By exchanging two leads then an anti-clockwise rotation can be achieved.

All motors must be protected against undue heating by an electric guard circuit (see Information Sheet) which meets the relevant DIN VDE 0118 or DIN VDE 0165 norm, or must be protected by a similar device on all phases with meets the DIN VDE 0660 norm. Interlocking protective devices are required for each setting position for polarity-reversible motors.

If the certification number of motors protected against explosion is supplemented with a ‘B’ or an ‘X’, then specific steps in accordance with the inspection certificate are to be carried out (see Information Sheet).

B.3.4 Monitoring CAUTION Monitoring in accordance with special certification of the registration authority, as well as in accordance with the Installation regulations for "Underground plant”.

Order No. 000-90-00-006-V4 Page 7 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

B.3.5 Final preparations Before closing the junction-box, the following points must be checked ♦ The current- and control-leads must all be connected in accordance with the wiring diagrams shown in the data sheet and attached to the inside of the door to the junction-box. ♦ The interior of the junction-box must be thoroughly clean. ♦ All connecting clamps, including those not in use, must be fully tightened. ♦ Air-gaps between current-carrying components and between current-carrying components and the cabinet must correspond with the regulations valid in the country of use. Particular attention must be paid to loose upstanding ends of wires. ♦ All connecting supply cables must be open to access, and the cable insulation must not be damaged. ♦ Corresponding to the type of protection indicated in the certificate, unused lead-in ports must be non-detachable closed by means of those seals certified for this purpose. Detaching may only be effected be means of tools. ♦ All seals and sealing surfaces of the junction-box must be properly engineered to maintain the protection necessary. The sealing surfaces must be clean and slightly lubricated. The sealing rings designed for the junction-box lid must be present, and no gap is permitted on account of these between the sealing surfaces. ♦ With regard to the type of protection, the mode of cable laying and the permissible cable diameter, the cable glands have to be chosen applicatively and to be fitted according to the rules.

B.4 Insulation test Before initial commissioning as well as after longer periods stored or out of action, insulation resistance of the windings against earth must be established.

WARNING During, and immediately after, this measurement, any of the clamps may be carrying dangerous voltages and must not be touched.

With any connected power leads, make certain that no power supply can be fed.

Observe the operating instructions of the insulation meter being used.

Insulation resistance measurements on low-voltage machines are in general only to be carried out with a measurement voltage of 500V. Exceptionally, a measurement voltage of 1,000V may be applied, but only to new windings, and then only if the insulation resistance has previously been measured with a maximum measurement voltage of 500V and there has been no drop below the permitted value.

When measuring, the final resistance value must be awaited, which for high-tension machines will take about 1 minute.

The lowest insulation resistance for new, cleaned or renovated windings, using a measurement voltage of 500V, amounts to 50MΩ.

Dry, as-new windings have insulation resistances between 100MΩ and 2000MΩ, sometimes even higher.

If the insulation resistance registers less than 50MΩ, this may be caused by damp and/or dirt. The cause must be established, and the winding dried if necessary.

INFORMATION: Note that after cleaning and drying windings whenever necessary, the insulation resistance of warm windings is reduced. Correct measurement of the insulating resistance can only be carried out once the winding has cooled down to a room temperature of about 20 to 30°C.

Order No. 000-90-00-006-V4 Page 8 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

B.5 Commissioning B.5.1 Preparation After installation and assembly or repair, check to make sure that ♦

installation and operating instructions are in agreement with the details shown on the rating plate (voltage, phase supply, frequency, switch, build, protection type, cooling system etc.; see also data sheet if appropriate).

♦

the machine is correctly installed and connected.

♦

the power take-off elements have correct adjustments, according to their purpose.

♦

the minimum insulation resistance values are respected – this applies also after longer intervals in operation.

♦

the machine has been connected in consideration of the intended direction of rotation.

♦

the cooling air inlet is not obstructed.

♦

the coolant is flowing.

♦

all fixing bolts and connecting elements, and all electrical connections, are pulled up tight.

♦

earth- and equipotential connections are in good order.

♦

any additional accessories (temperature monitoring of the windings or bearings etc.) are correctly connected and in working order.

♦

all guards, shields etc., for moving or live components are in place and operative; where there is a second, unused shaft end, its feather key is secured against being thrown out.

♦

any available external ventilators are operational and are connected in consideration of the prescribed direction of rotation and do not disturb the balance of the machine when in operation.

INFORMATION: This list cannot be regarded as exhaustive. Further checks, tests etc., may be necessary in accordance with the attached data sheet, or depending on the specific circumstances.

B.5.2 Switching on After assembly or after commissioning the following steps are recommended for normal operation: ♦ start up the machine without any load, close the circuit breaker and do not switch off early if possible. Particularly for high-voltage machines start-up cut-offs with lower revolutions are to be restricted to the absolutely necessary extent in order to avoid switch over voltages. ♦ Check mechanical operation for noises and oscillations on the bearings and bearing plates. ♦ Switch off the machine in cases of imbalanced operation or abnormal noises and establish the cause when machine has stopped. ♦ If the mechanical operation is better immediately after switching off, this points to magnetic or electrical causes. Otherwise a mechanical problem exists, e.g. imbalance of the electrical machines or the working machine, inadequate alignment of the machine setting. ♦ With problem-free operation, exert load on the machine. Check balance, voltage readings, current, read and document performance. As far as is possible, read and document the respective values of the working machine. ♦ Monitor and document the temperature of the bearings and windings, etc. until the point of inertia, as far as is possible with the available measurement devices.

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Operating instructions for three-phase AC motors

B.5.3 Switching off Open circuit breaker and allow the machine to run down freely

C. Operation C.1 Safety Instructions WARNING: Follow the ‘General Safety Instructions’ in Section A.2 exactly and observe the required specialised knowledge when working with high-voltage machines.

Covers which prevent contact with live or rotating parts or which are required for the correct ventilation, and therefore correct cooling, must not be opened during operation.

The run-up or block times may be between a maximum of 8 to 10 sec. when the machine is in operation.

The start up or blockades time at motors with auxiliary PTC control could be max 8 – 12 sec.

The over-current trips used for monitoring the motor must be set to the rated current setting as well as to the max. time (8 to 10 sec.) until the triggering of the over-current trip with blocks (6x Inom.). The reset time must be approx. 2 min. when the trip device has been activated.

INFORMATION: Note: The responsibility for the correct setting of the over-current trip is with the customer!

Non-compliance invalidates all guarantee claims.

C.2 Switching on / off It is assumed that the switching on and off normally occurs in a fully automatic way.

WARNING Abnormalities as compared with normal operation, e.g. higher current consumption, high temperature, vibration, unusual noises or smells, warning from the temperaturemonitoring device etc.) are a signal that something is out of order. To avoid any breakdowns or faults which themselves can directly or indirectly cause serious personal injury or damage to property, the responsible service personnel must be notified without delay.

If in any doubt, immediately switch-out the motor affected!

C.3 Operating intervals When there are longer operating intervals, the machine must regularly – say once a month – be operated briefly, or at least the bearings must be turned.

When motors are taken out of service for a more extended period, appropriate anti-corrosion measures must be taken, and for preservation, mothballing and keeping dry.

After longer operating intervals, it is recommended the measures in Section B.5 should be undertaken in accordance with the length of time out of use, to the extent considered advisable.

D. Servicing D.1 Safety instructions Please respect scrupulously the "General safety instructions" in Section A.2 and the specialist knowledge essential for working on high-tension electrical plant and equipment.

Before commencement of any work on the machines, and in particular before opening the covers of working parts, it must be ensured that the machine or plant is disconnected from power in accordance with regulations. Remember there may be subsidiary or emergency power supplies as well as the mains!

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Operating instructions for three-phase AC motors

Since parts of the motor may be hot, safety gloves must be worn.

The usual "5 Safety rules” go like this (e.g. according to DIN VDE 0105): ♦ Switch out ♦

Secure against being re-energised

♦

Make sure there is no residual current

♦

Connect to earth and fix short-circuit clamps (for voltages over 1,000V)

♦

Barrier off or cover nearby working parts

D.2 Inspections D.2.1 General Careful and regular servicing, inspections and overhauls are all necessary to recognise possible sources of failure in advance and correct them before they can do any extensive damage.

Since operating conditions vary very considerably, only a general idea of service intervals can be given.

Actual service intervals will have to be tuned to the exigencies of the operating location – incidence of dust and dirt, frequency of switching in, operating load etc.

In cases of failure, or other exceptional occurrence, which indicate an electrical or mechanical overload (e.g. overload, short circuit etc.), the appropriate inspections must be carried out immediately.

D.2.2 Flushing out the cooling ducts in water-cooled motors If because of pollution or unfortunate composition of the cooling water, the diameter of the cooling water ducts becomes so reduced by scale that the specified water-flow can no longer be reached, the cooling water ducts must be cleaned without delay.

Diluted caustic or acid solutions can be used can be used for cleaning the cooling ducts. The solution is pumped through the ducts using an external pump. Under no circumstances should high pressure (> 30 bar) be used for cleaning, since this will cause permanent damage, and thus a reduction in the cooling performance. The cleaning operation must be allowed to continue until all deposits and sediments are completely removed. In the event of complete blockage of the cooling circuit, solution must continue to be pumped through until the blockage is removed.

After this, the cooling ducts are to be rinsed through and neutralised.

Our recommendation for cleaning: 10% scale solvent WBD 177 or 50% citric acid Xi; R36. The relevant safety data sheets and delivery addresses should be requested separately.

WARNING The regulations for the handling of chemicals must be observed.

INFORMATION

ON THE DISPOSAL OF SOLVENTS:

Solvents must not be disposed of together with normal household waste, and must not be allowed to get into the drainage system.

Scale solvent: to Eck-code 06 01 02 Citric acid: Chemical-physical treatment, special waste incineration

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Operating instructions for three-phase AC motors

D.2.3 Inspections The inspections must cover whether ♦ the foundations have suffered any subsidence or cracks, ♦

the adjustment of the machine is still within permitted tolerances,

♦

all fixing bolts for mechanical and electrical connections are tight,

♦

the insulation resistances of the windings are sufficiently large,

♦

any bearing insulations fitted are not bridged,

♦

cables, leads and insulation components, where accessible, are in good condition and display no signs of discolouration.

When running, the following checks must be made: ♦ that the technical data laid down are being maintained (current consumption, temperature of the windings, bearings, coolant etc.), ♦

that there are no leakages of oil, lubricant or water,

♦ that the machine's operating smoothness and noise of the bearings has not worsened.

As a rule, it is not necessary to dismantle the machine for a normal inspection. Dismantling is normally necessary for the first time when cleaning or renewing the bearings.

INFORMATION This list cannot be regarded as exhaustive. Further checks, tests etc., may be necessary in accordance with the attached data sheet, or depending on the specific circumstances.

Any faults, inaccuracies or alterations noted during the inspection must be corrected without delay.

D.2.4 Routine lubrication For routine lubrication periods see data sheet.

D.3 Repairs D.3.1 Permitted repairs For alterations and repairs to mining machinery, the Electrical equipment permit (mining) regulations (ElZulBergV) or the Mining regulations relating to electrical equipment (BVOE; §118 with attendant instructions as to installation) apply, and to all other plant at hazard of explosion the regulations of the "Directions concerning electrical equipment in places at hazard of explosion" (ElexV or ExVO).

When repair work or alterations affect the explosion protection, they should whenever possible be carried out by the original manufacturer. When this work is carried out in repair shops, the motor must be identified with an additional plate showing the date on which and the place at which the work was carried out, as well as the exact nature and extent of the work. In addition, the work must be approved by a recognised specialist who must sign a test certificate for his acceptance of the work.

Technical details of the machine must correspond with the details shown on the certificate. If alterations are to be carried out, it must be ascertained whether these are permitted within the framework of the version manufactured, or whether the certificate will require extension of range. For this it will be necessary to make enquiries of the manufacturer. If extensive alterations are undertaken without endorsement of the certificate, the certificate shown on the testing-plate loses its validity!

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Operating instructions for three-phase AC motors

D.3.2 Dismantling Dismantling the frequency converter and of its attendant electronic componentry is prohibited. It is obligatory to make contact with the manufacturer.

Normal drawings and parts lists do not include any details of types or measurements of fixing elements or similar; therefore care must be taken when dismantling to identify each item for purposes of re-assembly.

For dismantling centred parts, use an extractor-screw or other suitable implement.

Before forcing off bolted components, replace two of the upper fixing bolts by over-length set-screws or bolts, so that they can carry the weight of the part after its removal.

Machines built vertically can be dismantled in the horizontal plane.

CAUTION where bearings are arranged in the vertical The centrings in the shaft-ends (DIN 332) have inset threads; this means that lifting screws in accordance with DIN 580 are unsuitable, as too few turns of thread would grip.

The machines only have narrow gaps at the shaft exits. For this reason, before removing the bearing end-plate, have a support ready for the shaft end, to avoid damage occurring to the gap surfaces due to oblique position of the rotor.

Make certain the pieces are correctly marked for re-assembly to ensure maintaining the protection type, in particular when for routine maintenance a number of machines of a similar type may be dismantled at the same time.

D.3.3 Re-assembly Seals When re-assembling, make sure all sealing surfaces are in proper order. They must be undamaged, bright metal and lubricated. Installing additional seals at the pressure-tight seal is only permitted where so designed (e.g. sealing rings).

If sealing elements are installed, these must be checked over, and if no longer in proper order, they must be replaced.

Screw locking devices Screws mounted together with safety, sprung and/or power spreading elements (e.g. safety plates, locking washers etc.) must be reinstalled with identical elements in good order. Positive-fitting safety elements must as a general rule be replaced.

Order No. 000-90-00-006-V4 Page 13 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

Operating instructions for three-phase AC motors

Tightening moments Torque (Nm, with a tolerance of ±10%) for a thread sized

Case 1 Case 2 Case 3

M4 1.2 1.3 3.3

M5 2.5 2.6 6.5

M6 4.0 4.5 11.2

M8 8.0 10 27

M10 13 20 55

M12 20 34 94

M16 40 83 230

M20 160 470

M24 280 800

Torque - case 1 for electrical connections where the permitted torque is restricted by the screw material and/or the composition of the insulators.

Torque - case 2 for screws of property classes from 5.6, or for screws in components with limited strength (e.g. aluminium), Torque - case 3 for screws of property class 8.8, but only when used in components of matching strength (e.g. grey cast iron, steel or cast steel).

Installation instructions For work on the installation site after assembly, observe the details given in Section B.2 ...

D.4 Replacement parts With the exception of standardised, commercially-available parts, only original spare parts are to be used.

When ordering spares, please give the exact designation of the parts and always quote the motor type and its serial number. The motor type and serial number are to be found on the rating plate.

The designation of the parts should correspond with that shown in the spare parts list, where this is available.

In the case of a number of spare parts, for organisational and technical reasons, it is necessary to supply certain components as complete working units.

Commercially-available standard parts may be obtained, paying attention to similar type, measurements and property class, from the trade.

Where roller-bearings are concerned, in addition to the bearing designation, the adjustment code for the bearing type is required. Both markings can be read from the built-in bearing.

Appendix

: see data sheet

Order No. 000-90-00-006-V4 Page 14 of 14 Printing date: Apr. 06 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 234/90426-0 Telefax: +49 234/532880

BREUER - MOTOREN GmbH & Co. KG Rensingstrasse 10

44807 Bochum Tel.: +49 (0) 234 90426-0 Fax: +49 (0) 234 90426-777 E-Mail: info @breuer-motoren.de

Information sheet to the operating manual for 3-phase motors dksWaW65/3-12-4 Order-no.:

010-90-00-056-V2

Date of issue: June 2008

Contents Contents .......................................................................................................1 A. Short description of the motor...........................................................................2 B. Parameter.........................................................................................................2 C. Connection diagram for motor monitor .............................................................3 D. Special Requirements for Safe Use..................................................................4 E. Intended Application .........................................................................................4 enclosure: .....................................................................................................................4 F. Dimension sheet ...............................................................................................4 G. Spare part list....................................................................................................4 H. Drawing for spare part list.................................................................................4

Order-no.: 010-90-00-056-V2 Page 1 printed: 23.06.2008 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 (0) 234 90426-0 Telefax: +49 (0) 234 90426-777

Information sheet to the operating manuel dksWaW65/3-12-4

A. Short description of the motor The motor is designed with the protection class „pressure-proof enclosure“ for use underground. This motor is equipped with cooling water ducts in the jacket of the housing and in the shaft for cooling.

B.

Parameter

Model Rated power Rated current Rated frequency Insulation class Type of operation

: dksWaW65/3-12-4 : 135 / 400 kW Rated voltage : 1000 V : 155 / 267 A Rated revolutions : 490 / 1485 min-1 : 50 Hz Power factor cos ϕ : 0,57 / 091 :H : S1 und S4 – 50% - 350//60 c/h – FI=1,35

Version : IMB5 Cooling type : water Inlet temperature : 30 °C Threshold pressure of the pressure release valve : 30 bar

Total weight Bearing grease Rated flow

Re- grease after

: approx. 8000 hours

Dimension sheet Spare part list

: 010-06-10-03-1003258-04-00 : 010-99-00-044

: 3900 kg : LGHP 2/1 : 15 l/min

Approval-No. Protection class

: BVS 04 ATEX E 266 X / N1 : I M2 EEx dI

Motor monitoring Assembled temperature monitor Winding : 2x6 170 °C Water monitoring : 2x1 70 °C

: PTC resistors bearing : 2x1 100 °C

Supply openings For the main connection For the control

: 54235.03-… : 54235.01-…

Order-no.: 010-90-00-056-V2 Page 2 printed: 23.06.2008 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 (0) 234 90426-0 Telefax: +49 (0) 234 90426-777

Information sheet to the operating manuel dksWaW65/3-12-4

C.

Connection diagram for motor monitor Kaltleiter PTC-resistor

Pt100

060-95-xx-026

Order-no.: 010-90-00-056-V2 Page 3 printed: 23.06.2008 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 (0) 234 90426-0 Telefax: +49 (0) 234 90426-777

Information sheet to the operating manuel dksWaW65/3-12-4

D.

Special Requirements for Safe Use

In addition to the protective motor switch, the motor has to be directly monitored by the thermistors mounted in the stator windings in connection with a triggering device certified authority. The certificate is part of the operation manual.

The used screws for mounting the bearing shields, bearing covers DE and NDE and the connection box cover are exclusively manufactured from material A70, A80 or 8,8.

In case mine water is used (very high concentration of salts and particulate materials), the cooling function could be restrained after a certain running period due to the emissions of the salts. In particular, those motors are concerned which are equipped with a meander-type cooling system (refer to the operation manual B.2.3 Cooling system) These cakings have to be removed locally by regular rinsing of the cooling ducts. (refer to the operation manual D.2.2 Cleaning of the cooling ducts of water-cooled motors).

E. Intended Application The operating safety of the three-phase a. c. motor is ensured only in case of its intended application!

Intended application means that the following points have to be respected and to be met: • Interferences which could affect the safety have to be immediately remedied by specialized staff correspondingly trained and instructed.

• Only authorized staff is allowed to operate the three-phase a. c. motor. Those persons must have read and understood the instruction manual.

• The certificate is part of the operation manual.

Each other application which does not meet these points is not considered to be the intended application. The manufacturer will not assume liability for damages resulting from this. The risk for this is solely borne by the user. This also applies for constructive modifications of any kind (unless they are certified) like for example to carry out additional bore holes or mounting of unsuitable spare parts.

enclosure: F.

Dimension sheet

G.

Spare part list

H.

Drawing for spare part list

Order-no.: 010-90-00-056-V2 Page 4 printed: 23.06.2008 This document is allowed to be distributed only complete and unmodified Rensingstr. 10 44807 Bochum Telefon: +49 (0) 234 90426-0 Telefax: +49 (0) 234 90426-777

BREUER

-

MOTOREN

D 44807 Bochum spare part list type

spare part list no.

dksWaW65/3-12-4

010-99-00-044

rating

drawing-no.

135/400 kW; 1000V

010-80-E0-025

item-no.

sheet

1003258

1/4

item 1 1a 1b 1c

quant.

1 24 24 1

designation flange end shield hex. socket head cap plug DIN 912; M12x35; 8.8 spring ring DIN 7980; 12 O-ring 647x5; NBR70 Shore

order-no.

0214740 0202172 0202290 0202591

2 2a 2b

1 8 8

end cap AS inside hex. head screw DIN 933, M10x25; 8.8 spring ring DIN127; A10

0205963 0202075 0202285

3 3a 3b 3c 3d 3e

1 8 8 1 1 1

end cap AS outside hex. socket head cap plug DIN 912; M10x25; 8.8 spring ring DIN 7980; 10 rotary shaft seal 125x150x12 BA rotary shaft seal 125x150x12 BA O-ring 200x3; NBR70 Shore

0200377 0202156 0202287 0202778 0202780 0202521

4 4a

1 1

bushing DE O-ring 104x3; NBR70 Shore

0211284 0202471

5

1

roller bearing NU2222 C3

2002985

6 6a

1 1

shaft with rotor shaft without rotor

1003864 1003865

7 7a

1 1

stator core with winding stator core without winding

1004437 1004438

8 8a 8b 8c

1 21 21 1

end shield BS hex. socket head cap plug DIN 912; M10x25; 8.8 spring ring DIN 7980; 10 O-ring 430x5; NBR70 Shore

0223197 0202156 0202287 0202570

9 9a 9b

1 8 8

end cap BS inside hex. head screw DIN 933; M10x30; 8.8 spring ring DIN 127; A10

0200638 0202077 0202285

10 10a 10b 10c 10d

1 8 8 1 1

end cap BS outside hex. head screw DIN 933; M10x25; 8.8 spring ring DIN 127; A10 O-ring 228x3; NBR70 Shore rotary shaft seal 78x100x12

0200755 0202075 0202285 0212930 0202727

spare part list no.: 010-99-00-044

page 1 / 3

spare part list dksWaW65/3-12-4, 135/400kW; 1000V

010-99-00-044

item 11 11a

quant. designation 1 bushing BS 2 V-ring WVA-0075

order-no.

0211269 0202608

12 12a 12b

1 1 1

roller ball bearing 6320 C3 supporting ring DIN 988; SS100 retaining ring DIN 983; AK100

0202929 0223198 0202673

13 13a 13b

1 6 6

connection flange hex. socket head cap plug DIN 912; M8x25; 8.8 spring ring DIN 7980; 8

0139315 0202143 0202284

14 14a 14b 14c

1 12 12 1

cooling water chamber hex. head screw DIN 933; M8x25; 8.8 spring ring DIN 127; A8 O-ring 180x5; NBR70 Shore

0139275 0202062 0202281 0202513

15 15a 15b

1 2 3

sealing bush O-ring threaded pin DIN 916; M8x10; 10.9

0139880 0211160 0211165

16

1

sliding ring seal

0211151

17

1

sliding ring seal

0211152

18 18a 18b

1 7 7

cover plate hex. socket head cap plug DIN 912; M10x25; 8.8 spring ring DIN 7980; 10

0216990 0202192 0202287

19 19a 19b 19c 19d 19e

1 2 2 1 1 1

crossing piece hex. socket head cap plug DIN 912; M12x55; 8.8 spring ring DIN 7980; 12 indication plate “water connection in” *) over pressure valve seal ring

0213380 0202177 0202290 0211064 0206637 0200533

20 20a 20b 20c

1 2 2 1

crossing piece hex. socket head cap plug DIN 912; M12x55; 8.8 spring ring DIN 7980; 12 indication plate “water connection out ” *)

0200563 0202177 0202290 0211066

21 21a 21b 21c

3 6 6 12

high-pressure tube screw together screw together clamp

0203021 0203018 0203022 0203022

22 23

1 1

cable gland blind cover

1003885 0210576

item

quant. designation

order-no.

spare part list-no.: 010-99-00-044

page 2 / 3

spare part list dksWaW65/3-12-4, 135/400kW; 1000V

010-99-00-044

25 25a 25b

2 10 10

guard hex. socket head cap plug DIN 912; M10x20; 8.8 spring ring DIN 7980; 10

0217262 0202154 0202270

26 26a 26b 26c 26d

1 6 6 1 1

cover for pressure proof enclosure hex. socket head cap plug DIN 912; M10x30; 8.8 spring ring DIN 7980; 10 O-ring 345x3; NBR70 Shore indication plate „pressure prood enclosure“ *)

0215502 0202158 0202270 0215719 0211047

27 27a 27b 27c 27d 27e

1 6 6 1 1 1

cover for connection box hex. socket head cap plug DIN 912; M10x30; 8.8 spring ring DIN 7980; 10 O-ring 440x3; NBR70 Shore indication plate „connection box chamber“ *) communion sign *)

0215501 0202158 0202270 0215090 0211048 0211080

30 30a 30b

4 8 8

earthing plate hex. head screw DIN 933; M8x25; 8.8 spring ring DIN 127; A8

0212527 0224170 0202281

31 31a 31b

6 6 6

cable hole safety plate connection terminal

0210338 0202404 0210602

32 32a

4 4

cable hole safety plate

0210352 0202397

33 33a

4 4

cable hole safety plate

1003895 0202397

34 34a 34b 34c

1 2 2 1

plate hex. head screw DIN 933; M6x16; 8.8 spring ring DIN 127; A6 indication plate “PTC resistor” *)

0200779 0202048 0202278 0223172

35 35a 35b

4 4 4

connection terminal hex. socket head cap plug DIN 84; M3x12; 5.8 spring ring DIN 7980; 3

0223141 0202121 0217720

36 36a 36b

4 4 4

connection terminal hex. socket head cap plug DIN 84; M3x12; 5.8 spring ring DIN 7980; 3

0210630 0202121 0202273

40 1 indication plate “PTC resistor” *) 41 2 rating plate *) 42 2 test plate *) *) with grooved pins spare part list-no.: 010-99-00-044

0211076 0211119 0211128 Wie /23.06.2008 page 3 / 3

torque-current-diagram dksWaW65/3-12-4, 135 / 400 kW 157 / 267 A, 1000 V, 492 / 1486 rpm 8000

2000

7000

1750 I 4p

6000

1500 Md 4p

5000

1250

4000

1000

3000

750

I/A

t / Nm

Md 12p

I 12p 2000

500

1000

250

0 0

250

500

750

1000

1250

0 1500

n / rpm

BREUER-MOTOREN Bochum, 07.03.2005

drawing no: 010-65-00-026