鼠笼电机安装和维修.doc

此文档收集于网络 如有侵权 请联系网站删除 精品文档 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR SQUIRREL CAGE MOTORS 鼠笼电机安装和维修说明鼠笼电机安装和维修说明 Contents目录目录Page 1 STRUCTURE 结构结构 2 1 1 General 概要 2 1 2 Bearings 轴承 2 1 3 Phase windings 相位绕组 2 2 INSTALLATION 安装安装 2 2 1 Receipt and storage 验受和存放 2 2 2 Location 位置 2 2 3 Driven machinery 驱动机械 2 2 4 Connection to main supply 电源联接 2 3 START UP 启动启动 2 3 1 Operational check 运转前检查 2 3 2 Insulation resistance 绝缘电阻 2 4 MAINTENANCE AND INSPECTION 维修行检查维修行检查 2 4 1 Periodic inspection 周期检查 2 4 2 Service of the bearings 轴承保养 2 5 REPAIRS 修理修理 2 5 1 Exceptional vibration 异常振动 2 5 2 Hints to determine the cause of winding damage 绕组损坏原因迹象 2 5 3 Disassembly of the motor 拆卸电机 2 5 3 1 Disassembly of N end 拆卸 N 端 2 5 3 2 Disassembly of D end 拆卸 D 端 2 5 4 Re assembly of the motor 重装电机 2 5 5 Recommended lubricants 推荐润滑剂 2 6 ORDERING SPARE PARTS 备件订货备件订货 2 此文档收集于网络 如有侵权 请联系网站删除 精品文档 1 STRUCTURE 结构结构 1 1General 概述概述 The squirrel cage motors used in Konecranes cranes are completely enclose motors Some motors contain one or two plugged drain holes These holes are located at the lowest points of the frame The stator frame and bearing shields are made of cast iron or aluminum alloy The fan located outside of the N bearing shield Figure 1 is made of aluminum alloy or plastic In larger motors the fan is made of steel KCI 鼠笼电机整个密封 一些电机下面有排水孔 定子框架和轴承室由铸铁合铝合金制成 铝合金或塑料风扇在 N 轴承室的外边 大电机的风扇是用钢制成 D END Driving end 驱动端N END Non driving end 从动端 1 Ball bearing 球轴承6 Terminal box 接线盒 2 End shield D end 驱动端轴承室7 Lifting eye bolt 吊点螺栓 3 Inside bearing cover 轴承内盖8 End shield N end 从动端轴承室 4 Rotor and shaft 转子和轴9 Fan 风扇 1234567891011 D endN end Figure 1 Totally enclosed squirrel cage motor without lubricating device 不带润滑装置并整个密封的鼠笼电机 此文档收集于网络 如有侵权 请联系网站删除 精品文档 5 Stator frame and stator10 Key 键 定子框架和定子11 Fan cover 风扇罩 Figure 2 Bearings in a motor with lubricating device 带润滑装置的轴承 1 2Bearings轴承 The motors are furnished with series 62 or series 63 ball bearings To fix the axial position of the rotor lock the bearings specified in the axial direction In motors M08 M24 lock the D bearing In motor M25 lock the N bearing 电机带有 62 或 63 系列球轴承 为了固定转子轴向位置 特别要轴向固定轴承 M08 M24 电机固定驱动端轴承 M25 电机固定从动端轴承 Motors M22 and M25 are supplied with a lubricating device Figure 2 For these motors the axial locking of the bearing is achieved by means of the grease valve disc There is a thread in the N grease valve disc of motor M25 The other grease valve discs are removed by pulling M22 M25 电机带有润滑装置 图 2 这些电机用油脂阀盘来轴向固定轴承 M25 电机从 动端上的油脂阀盘带有螺纹 其他电机的油脂阀盘靠用力拖拉来移动 1 3Phase windings 相位绕组相位绕组 The insulation class of the stator windings is stated in the rating plate The insulation class is typically class F Dynamo wire used in motors up to size M22 is IEC 182 1 and 182 2 grade2 Installation 123456 7 1 Grease valve disc 油脂阀盘 5 Grease nipple 油嘴 2 Outside bearing cover 轴承外盖 6 Inside bearing cover 轴承内盖 3 End shield 轴承室 7 Felt sealing strip 密封圈 4 Ball bearing 轴承 此文档收集于网络 如有侵权 请联系网站删除 精品文档 铭牌上标明了定子绕组的绝缘等级 典型绝缘等级是 F 级 M22 以下的电机的绕组线符合 IEC 182 1 和 IEC182 2 的 2 级标准 2 INSTALLATION 安装安装 2 1 Receipt and storage 验收和存放验收和存放 Inspect the motor immediately upon receipt Verify that there is no damage due to transport 收到电机后立即检查 保证电机在运输中无损坏 Verify that the rating plate values correspond to the order Verify that the power supply is compatible with the values specified on the rating plate 保证铭牌上的参数和定单上一致 保证电源和铭牌上的参数一致 If the motor is to be stored prior to installation it must be kept indoors at room temperature in order to keep the insulation dry If the motor is stored for more than six months manual rotation of the shaft is recommended every two months The rotation will distribute the oil in the bearing grease 电机必须存放在常温的室内来保持绝缘干燥 如电机存放超过 6 个月 应每 2 个月用手 转动一次轴使润滑脂布置均匀 WARNING 警告 警告 When lifting the motor use the lifting eye bolt on the stator frame Figure1 item7 or two lifting slings placed under the stator frame 起吊电机必须用吊点 2 2 Location 位置位置 If there are drain holes in the motor the motor must be mounted in the position specified on the rating plate 带有排水孔的电机必须按铭牌上所指示的位置安装 Ambient temperature must not exceed 40 oC unless otherwise stated in the order The flow of the cooling air must not be obstructed Expelled air must be freely discharged and it must not be directed back immediately 除非定单上游说明 环境温度不得超过 40 oC 空气必须流通以便电机散热 2 3 Driven machinery 驱动机械驱动机械 The rotor is balanced with a full length key in the keyway of the shaft extension Pulleys and couplings connected to the motor must be balanced without the use of a key 转子已是平衡的 外接的滑轮 联轴器等必须也是平衡的 Use solvent to clean the shaft ends and the contact faces of the flanges Note that the shaft ends and the contact faces of the flanges are treated against corrosion 用溶剂来清洗轴端和法兰的接触面 注意轴端和法兰的接触面经过防腐处理 此文档收集于网络 如有侵权 请联系网站删除 精品文档 CAUTION 注意注意 The solvent must not penetrate the bearings 溶剂不允许渗入轴承 WARNING 警告警告 To prevent damaging the bearings do not hammer or strike the shaft of the motor 为保护轴承 不允许锤击电机轴 2 4 Connection to main supply 接电源接电源 In motors M08 M16 the terminal box is located on top of the stator frame In motors M18 M25 the terminal box is located on the right hand side of the stator frame as shown on the D end motor Figure 3 The terminal box on motors M18 M25 may be moved to the opposite side of the frame by disassembling the motor section 5 3 and by turning the stator frame around 在 M08 M16 电机上 接线盒在定子框架顶部 在 M18 M25 电机上 接线盒在定子框架右 边 或转动定子框架使接线盒在左边 The terminal board strips are in the position corresponding to the type of connection stamped on the motor rating plate Figure 4 端子板的位置和电机铭牌上标示接线位置相对应 图 4 D endD end M08 M16M18 M25 Figure 3 Location of the terminal box 接线盒位置 W2U2V2 W1V1U1 W2U2V2 W1V1U1 L2L1L3L1L2L3 W2U2V2 W1V1U1 L2L1L3 Y connection Y 联接D connection D 联接Y D starting strips are removed Y D 联接 取走连接片 Figure 4 Position of the terminal board strips 端子板的位置 此文档收集于网络 如有侵权 请联系网站删除 精品文档 Motors with an output of 3 kW or less may have only three wires from the stator winding to the terminal box They are connected to terminals U1 V1 and W1 In this case the terminal board strips are removed 功率等于或小于 3KW 的电机可以只有 3 根从定子绕组到接线盒的 U1 V1 和 W1 这种 情况没有连接片 On two speed motors with two separate windings i e poles marked 2 8 or 2 8 the low speed winding is connected to terminals U1 V1 and W1 The high speed winding is connected to terminals U2 V2 and W2 Figure 5 Follow the wiring diagram provided with the motor for all other pole changing motors 带有两组绕组的双速电机 如极标记为 2 8 或 8 2 中 低速绕组和 U1 V1 及 W1 连在一 起 高速绕组和 U2 V2 及 W2 连在一起 图 5 其它的变极电机接线须按电机上的接线 图进行 3 START UP 启动启动 3 1 Operational check 运转前检查运转前检查 Before operating the motor check the following 运转电机前 检查下列 1 Free rotation of the rotor Verify that all temporary transport supports for the bearings if any have been removed 转子自由运转 转子自由运转 保证无任何临时轴承支架 2 Insulation resistance Check the insulation resistance in accordance with section 3 2 Check the insulation a few days before use since the winding may need drying 绝缘电阻 绝缘电阻 因为绕组需要烘干 应提前几天按 3 2 节检查绝缘 3 Direction of rotation of the motor The direction of rotation of the motor in accordance with section 2 4 is clockwise as viewed from the D end The direction of rotation may be reversed by interchanging any two main supply wires which connect to the pole screws U1 V1 W1 of the motor Verify that the direction of rotation of the motor corresponds to the W2U2V2 U1V1W1 2U12V12W1 1U11V11W1 High speed Low speed Figure 5 Connection of pole changing motor with two separate windings 双速电机接线 此文档收集于网络 如有侵权 请联系网站删除 精品文档 direction of the control commands Symmetrically installed bridge travelling machine units operating on different rails have opposite directions of rotation 电机旋转方向 电机旋转方向 根据 2 4 节 从 D 端看电机的旋转应是顺时针方向 交换任两极的接 线可改变旋转方向 保证电机的旋转方向和控制方向一致 对称在两根轨道上的大车 电机旋转方向应是相反的 4 Operating noise A loud growling sound from the motor indicates that the connection is faulty and the motor must be stopped immediately 噪音 噪音 如电机发出很大的噪声则表明接线有错 电机必须立即停止 5 Vibration The cause of any exceptional vibration in the motor must be determined 振动 必须查明异常振动原因 6 Load condition recommendation Measure the stator current from each phase Measure the speed of rotation with a tachometer or by slip measurement Compare the values obtained with the values specified on the rating plate 负荷状况 从每一相测量定子电流 用转速表或滑环表测量转子速度 比较测量值和 铭牌上标定值 7 Running temperature Running temperature Check the temperature after the first long term use The motor will reach it s final running temperature in approximately three to five hours after starting To check the temperature first feel the stator frame If the temperature of the stator frame feels as though it has exceeded 50 oC use a thermometer to obtain an accurate temperature reading Place the bulb of the thermometer in the bolt hole of the lifting eye or on the surface of the stator frame inside the terminal box The temperature rise of the winding must not exceed 100 oC in motors with F class insulation 运转温度 运转温度 第一次长时间运转后应检查温度 电机在 3 5 小时运转后达到最终温度 可用手触摸定子外壳来检查温度 如感觉温度超 50 oC 应用温度计来测量出精确的 温度 将温度计的的触头放在起吊螺丝孔内或接线盒内的外壳表面上 F 级绝缘电机 的绕组温度不允许超过 100 oC 3 2 Insulation resistance 绝缘电阻绝缘电阻 The most convenient method of evaluating the condition of the insulation is to measure the insulation resistance When the winding is clean and dry the insulation resistance is high A low insulation resistance value is usually the result of dampness or dirt 最简便的检查绝缘的方法是测量绝缘电阻 当绕组干净和干燥时 绝缘电阻高 而当绕组 潮湿和肮脏时 通常绝缘电阻低 The stator winding may be damp due to transportation conditions or storage of the motor in a cold damp or poorly ventilated location for a long period of time 由于电机运输和或长期存放在冷潮或通风差的地方 定子绕组可能会潮湿 Measure the insulation resistance with a 1000V M meter Take the reading when the test voltage of the meter has been connected to the winding for approximately one minute 用 1000V M 表测量绝缘电阻 当表和绕组连接大约一分钟后读数 此文档收集于网络 如有侵权 请联系网站删除 精品文档 The insulation resistance for a cool winding 10 to 40 oC should be at least 5M The insulation resistance for a warm winding over 40 oC should be at least 1M If the insulation resistance is lower the motor must be dried out 冷绕组 10 to 40 oC 的绝缘电阻至少应达到 5M 热绕组 大于 40 oC 的绝缘电阻至少应达 到 1M 如绝缘电阻比这低 必须烘干电机 The drying process is controlled by heat and ventilation Drying may be controlled in the following manner 烘干方法是加热和通风 有下列方式 1 Use a heater fan to blow hot air approximately 100 oC onto the windings inside the motor 用电吹风将热风 约 100 oC 吹在电机里的绕组上 2 The windings may be dried in an oven at a temperature of approximately 100 oC provided that there is reasonable ventilation If the temperature is increased slowly the evaporation of the moisture will not damage the windings 如通风较好 可在约 100 oC 的烘箱中烘干绕组 如温度增长缓慢 湿汽蒸发不会损 坏绕组 Initially as the temperature of the damp winding begins to increase the insulation resistance will decrease However as drying continues the resistance will begin to increase The drying may be stopped when the resistance no longer changes 一开始 绝缘电阻随着潮湿的绕组的温度升高而降低 但当烘干继续绝缘电阻将变大 当 电阻不变化时 可停止烘干 If the winding is dry and the insulation resistance is still too low the winding is dirty or damaged A dusty winding may be cleaned carefully The winding may only be washed by a specialist 如绕组已烘干 绝缘电阻还是太低 绕组就是肮脏或损坏了 肮脏的绕组可仔细清洁 只 有专家才能清洗绕组 4 MAINTENANCE AND INSPECTION 维修和检查维修和检查 4 1Periodic inspection 定期检查定期检查 Periodic inspection is recommended at intervals of two months 建议每两个月作一次定期检查 Check the following items 检查下列项目 1 Overheating cleanliness ventilation 过热 清洁 通风 2 Operating noise 噪音 3 Vibration 振动 4 Mountings 附件 此文档收集于网络 如有侵权 请联系网站删除 精品文档 Check the condition of the bearings by listening to them i e by means of a rod An even humming sound indicates that the bearing is working satisfactorily If a distinct rattling is heard the bearing is damaged 利用一根棒来听轴承的声音来检查轴承状况 均匀的嗡嗡声表示轴承状况良好 如听见明 显的咔嗒声则轴承坏了 必须立刻更换轴承 4 2 Service of the bearings The lubricating intervals for motors with a lubricating valve are as follows 带有油阀的电机加油间隔 horizontally mounted motors 7000 operating hours 水平安装电机 7000 工作小时 vertically mounted motors 3500 operating hours 垂直安装电机 3500 工作小时 Lubrication must be done while the motor is running to prevent grease from entering the motor 为防止油脂进入电机 加油必须在运转时进行 For all other motors the bearings must be cleaned and re lubricated in the following intervals 其他电机的轴承的清洁和换油间隔 one shift working5 years 一轴工作5 年 two shifts working4 years 二轴工作4 年 three shifts working3 years 三轴工作3 年 5 REPAIRS 修理修理 5 1 Exceptional vibration 异常振动异常振动 If there is exceptional vibration in the motor the cause must be determined i e as follows 如有异常振动 按下列步骤检查原因 1 Dismount the motor from the driven machinery Start the motor while it is on the bed plate and lift it by means of the lifting eye 将电机从驱动机械上拆下来 将它放在支座上时启动 然后利用吊点将它提升起来 CAUTION Do not start or stop the motor while it is suspended 注意 注意 不要让电机在悬挂时启动 If the motor no longer vibrates possible causes of the vibration are 如电机不再振动 则振动原因可能如下 twisted bedplate misalignment or eccentricity between the shafts 此文档收集于网络 如有侵权 请联系网站删除 精品文档 improper compression in the coupling pin bushing or an incorrect division of pins This is often the cause if the vibration increases with load a defect in the driven machinery 支座变形 轴心线不在一条线上 联轴节销套不正确的压缩或联轴节销不均匀布置 当振动随负荷增加而加大常是 这个原因 电机故障 2 If the motor continues to vibrate while suspended remove the coupling Place a full length key in the keyway and secure it with adhesive tape Repeat the test described above If the motor continues to vibrate there is an imbalance in the rotor If the motor does not vibrate there is an imbalance in the coupling 如电机在悬挂运转时继续振动 将联轴节拆下 将键放在键槽内并用胶布粘牢 然后 在一次按上述方法试验 如继续振动 则转子不平衡 如不振动 则联轴节不平衡 5 2 Hints to determine the cause of winding damage 绕组损坏原因迹象绕组损坏原因迹象 A winding which burned out due to overload is usually uniformly black and brittle 由于过载烧坏的绕组通常整个发黑和发脆 Cut off of one phase causes the other phases to darken in various stages 某一相的短路会引起其它相变黑 A short circuit due to an insulation defect usually burns only a few coil sections black There is also localized burning at the location of the defect 由于绝缘缺陷而引起的短路只引起缺陷部位的部分线圈烧黑 If a motor which has been running well becomes weak slip increases at a certain torque the defect is often in a cage winding The brazed joint in a copper or brass winding has failed or some bars in an aluminum winding are broken A defective brazed joint can usually be repaired The rotor must be replaced if a cast aluminum bar is broken 如一个电机运转良好 但容易在某一力矩是打滑 这常由鼠笼绕组缺陷引起 可能是铜接 点脱焊或铝合金棒损坏 铜接点脱焊可以修复 铝合金棒损坏则必须更换转子 5 3 Disassembly of the motor 电机拆卸电机拆卸 Typically it is not necessary to completely disassemble the motor 一般不必将电机完全拆开 When detaching the motor parts with an extractor protect the edges of the threaded hole at the shaft end from being damaged 当用提取器拆电机零件时 要保护好轴段上的螺纹孔 WARNING Never disassemble or re assemble the motor parts by hammering 此文档收集于网络 如有侵权 请联系网站删除 精品文档 警告 警告 不允许用锤击来拆卸和重装电机零件 5 3 1 Disassembly of N end 拆卸拆卸 N N 端端 1 Unscrew the fastening screws on the fan cover Remove the cover 松开风扇的固定螺栓 拆下风扇 2 Steel or aluminum fan Unscrew the locking screw 1 of the fan Pull the fan from the shaft with an extractor using the threaded holes 2 in the fan 钢和铝合金风扇 钢和铝合金风扇 松开风扇的固定螺栓 1 利用风扇上的螺孔 用提取器将风扇从 轴上取下来 Plastic fan Remove the retaining ring from the fan and pull the fan from the shaft 塑料风扇塑料风扇 取下安装挡圈 将风扇从轴上拖下来 3 Unscrew the fixing screws of the end shield Unscrew the fixing screws of the inside bearing cover if any 松开端盖的固定螺栓 松开内轴承盖 如果有 的固定螺栓 1 2 1 2 此文档收集于网络 如有侵权 请联系网站删除 精品文档 4 For motor M22 open the locking screw of the grease valve disc Remove the grease valve disc by pulling with an extractor in the threaded holes 2 in the ring For motor M25 remove the grease valve disc by unscrewing it counter clockwise 对 M22 型电机 松开油脂阀盘的锁紧螺栓 利用环上的螺孔 2 用提取器拖下油脂 阀盘 对 M25 型电机 反时针方向旋下油脂阀盘 5 Pull the end shield off For motors M20 and M25 do this by using an extractor in the threaded holes in the shield The bearing is to remain in the rotor shaft 拆下端盖 对 M20 和 M25 型电机 要利用端盖上的螺孔 2 用提取器将端盖拆下 WARNING When removing the end shield do not damage the ends of the stator windings 警告 当警告 当拆端盖时 不要损坏定子绕组 6 Pull the ball bearing from the shaft either 将轴承从轴上拖下来 5 3 2 Disassembly of D end 拆卸拆卸 D D 端端 1 Unscrew the fastening screws of the end shield Unscrew the fastening screws of the inner bearing cap and remove the outer bearing cap if any 松开端盖的固定螺栓 松开内轴承盖的固定螺栓 拆下外轴承盖 如果有 2 For motors M22 and M25 unscrew the locking screw 1 of the grease valve disc Remove the grease valve disc by using an extractor in the threaded holes 2 in the ring 对 M20 和 M25 型电机 松开油脂阀盘的锁紧螺栓 1 利用环上的螺孔 2 用提取器 拖下油脂阀盘 3 Remove the end shield and the bearing as described in sections 5 and 6 按 5 3 1 中的 5 6 节拆下端盖和轴承 4 Remove the rotor if necessary 必要时拆下转子 1 2 此文档收集于网络 如有侵权 请联系网站删除 精品文档 5 4 Re assembly of the motor 重新安装电机重新安装电机 1 Remove all of the old grease from the bearings Renew the grease in the lubrication channel if necessary Wash the old bearings Grease them lightly to prevent them from rusting 清除旧油脂 必要时更换润滑管道中油脂 清洗用过的轴承然后涂上一些油脂防锈 2 Replace the rotor if it was removed Heat the bearings to a temperature of 80 to 90 oC in an oil bath or in an oven Push the bearings onto the shaft 如转子已被拆下 应将它放回原处 轴承在油或炉里加热至 80 90 oC 后装到轴上 WARNING Use protective gloves when handling hot bearings Make sure to keep the gloves clean to prevent them from collecting dirt 警告 警告 安装热轴承时要用保护套 保护套要保持清洁 3 Use the appropriate lubricant as listed in section 5 5 to lubricate the bearings as follows 按下所示 用在 5 5 节中列出的合适的润滑脂来润滑轴承 Completely fill in the space between the inner and outer race of the bearing with grease 用润滑脂填满轴承内外圈之间的空间 If the bearing has a grease valve M22 M25 also fill the inside bearing cover with grease 如轴承有油脂阀 M22 M25 轴承盖内也要填满润滑脂 If there is no grease valve in the bearing fill the space in the inside and outside bearing cover half way with grease 如轴承没有油脂阀 轴承盖内只要填一半润滑脂 Lightly grease the sealing surfaces of the inside and outside bearing cover against the bearing housing and the shaft 内外轴承盖上和轴承座及轴接触的油封表面要抹点油脂 4 To install the grease valve discs heat both rings of motor M22 heat only the D ring of motor M25 to a temperature of approximately 100 oC Push them onto the shaft Replace the locking screws of the grease