Caterpillar® C N Electric Motors Installation and Removal Guide. {5927} Caterpillar

Caterpillar® C N Electric Motors Installation and Removal Guide. {5927}

Usage:

Electric Motor: CN1566 (S/N: RJ31-UP); CN2086 (S/N: RJ41-UP); CN2586 (S/N: RJ51-UP); CN3086 (S/N: RJ61-UP); CN3586 (S/N: RJ71-UP); CN4086 (S/N: RJ81-UP); CN5086 (S/N: RJ91-UP)

Introduction

This Special Instruction provides information for the installation and removal of Caterpillar C N Electric Motors.

The Caterpillar CN electric motor is an asynchronous induction squirrel cage motor that has been designed to meet the gas compression industry requirements.

The motors are configured with the most common options seen today for gas compression applications. Those options include an over-sized shaft to match industry leading compressors, sleeve bearings, class F insulation, space heater, and WPII enclosures.

Caterpillar CN electric motors have many other customer options. Blower cooling, differential current transformers, surge arrestors, F1 or F2 terminal box mounting, oil sump heaters, and stainless steel air filters are among these options.

Proper motor selection and installation are vital for dependable performance and a long, trouble-free life.

This Special Instruction will help the reader make knowledgeable choices of electrical motor equipment and designs to build installations that perform reliably. In addition, the information presented in this Special Instruction will aid in the planning through customer acceptance phases of a project.

Some technical data is included in this Special Instruction, while other data can be found elsewhere within the Caterpillar technical documentation system.

All the information provided will be updated periodically. Dealers can obtain current motor information by accessing the Caterpillar Technical Marketing Information System (TMI). Always check this system for the most current motor data available.

The installer has the responsibility to consider and avoid possibly hazardous conditions which could develop from the systems involved in the specific electric motor installation.

The suggestions in this Special Instruction regarding avoidance of hazardous conditions apply to all applications and are of a general nature, since only the installer is familiar with the details of a particular installation.

The suggestions provided in this Special Instruction are general examples only, and are in no way intended to cover every possible hazard in all installations.

Use this Special Instruction table of contents as a checklist of subjects affecting on-site compression installations.

Referring to this index during preliminary planning avoids the effort and expense of after-installation changes.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Ground the equipment. Improper grounding will result in electrical current paths that are uncontrolled and unreliable. Uncontrolled electrical circuit paths can result in damage to the equipment. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

General Safety Information

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Product Specific Safety Information

General safety regulations, specific agreements made for each work site and safety precautions shown in this document must always be observed.

Electric machines have dangerous live and rotating parts and may have hot surfaces. Do not climb on the motor. All work performed, including but not limited to transportation, storage, installation, connection, commissioning, operation, and maintenance, must be carried out by responsible skilled personnel. Improper handling may result in serious personal injury and significant damage to the equipment.

Air-cooled models are designed for ambient temperatures from 0° C (32° F) up to 40° C (104° F).

Air-cooled models are also designed for operation at altitudes that are less than or equal to 1000 m (3280 ft) above sea level.

Note: Check the motor rating plate, for specific equipment elevation and temperature.

Field conditions must conform to all rating plate markings. Operating outside of rated conditions can result in equipment damage or shortened equipment life.

Do not install equipment outdoors unless rated IP23 or better.

Note: For more information on altitude effects refer to the "Altitude Considerations" section of this document.

Transport and Storage Safety

If damage to the product is noticed after delivery, immediately report this damage to the transport company. If necessary, stop the installation and commissioning.

Lifting eyes are dimensioned for the weight of the motor. Do not apply extra loads. Remove shipping braces, such as bearing locks or vibration dampers, before commissioning, and always keep and store such items for future use.

Ensure the use of correct lifting eyes. If necessary, use suitable, adequately dimensioned means of transport, for example, rope guides.

When storing machines, make sure that the location is dry, dust free, and vibration free, as there is danger of bearing damage at rest.

Measure insulation resistance before commissioning. If the values are less than or equal to 1 KΩ per volt of rated voltage, then the winding must be dried.

Always follow the manufacturer instructions. Long-term storage procedures must be given thorough consideration. For proper storage instructions, refer to the Operation and Maintenance Manual, SEBU8852, "CN1566, CN2086, CN2586, CN3086, CN3586, CN4086, and CN5086 Electric Motors", Storage..

Installation Safety

Take care of even support, solid foot or flange mounting, and exact alignment. Avoid resonances with rotational frequency and double mains frequency as a result of assembly. Turn the rotor after proper bearing lubrication and listen for abnormal slip noises. Check direction of rotation in uncoupled state.

Follow the coupling manufacturer instructions when mounting or removing couplings or other drive elements and always cover any rotating part with a touch guard.

Avoid excessive radial and axial bearing loads. Always refer to the coupling manufacturer documentation.

Make sure that the cooling ventilation is not obstructed, and that heated air is not ingested into the cooling system.

Always position the motor so that any heated exhaust air cannot be ingested by, or from, other machines.

Electrical connection Safety

Ensure that the equipment is stopped and properly locked out before performing any work. All work must be performed by a qualified technician. Before starting work, make sure that the following safety rules are strictly followed:

De-energize and discharge any stored energy in the windings
Provide safeguards against re-energizing
Verify safe isolation from supply
Connect to earth and short
Cover or provide barriers against neighboring live parts
De-energize auxiliary circuits (for example, anti-condensation heaters)

General Information

This Special Instruction contains information on the transport, storage, installation, commissioning, operating, and maintenance of Caterpillar rotating electrical motors manufactured for gas compression applications. This guide provides information regarding all aspects of operation, maintenance, and supervision of the motor. Careful study of this Special Instruction and other related documentation, before any actions are taken, is necessary to ensure proper functionality and long lifetime of the motor.

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NOTICE

Some customer-specific items may not be included in this guide. Additional documentation can be found in the motor installation drawings, Application and Installation Guide, LEBW0049, and Operation and Maintenance Manual, SEBU8852. These instructions must be followed to ensure safe and proper installation, operation, and maintenance of the motor. All those instructions must be brought to the attention of anyone who installs, operates, or maintains this equipment. Improper installation, operation, or maintenance may void the warranty of the equipment. The information in this document may sometimes be of a general nature and applicable to multiple motors. Where a conflict exists between the contents herein and the actual motor supplied, the user must make an engineering judgment as to what to do. If any doubt exists, contact Caterpillar. The safety precautions presented in the Safety Instructions at the beginning of the manual must always be observed. Safety depends the awareness, concern, and prudence of all personnel who operate and service motors. While it is important that all safety procedures be observed, care near machinery is essential - always be observant of the environment. To avoid accidents, safety measures and devices required at the installation site must be in accordance with the instructions and regulations stipulated for required safety at work. This requirement applies to general safety regulations of the country in question, specific agreements made for each work site, safety instructions included in this manual, and separate safety instructions delivered with the motor.

Limitation of Liability

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NOTICE

In no event shall Caterpillar be liable for direct, indirect, special, incidental, or consequential damages of any nature or kind arising from the use of this Special Instruction, nor shall Caterpillar, Inc. be liable for incidental or consequential damages arising from use of any software or hardware described in this Special Instruction. The warranty issued covers manufacturing and material defects. The warranty does not cover any damage to the motor, personnel, or to a third party, by the improper storage, incorrect installation, or operation of the motor. The warranty conditions are defined according to the Caterpillar electric motor warranty statement. All warranties issued are not valid, if the operation conditions of the motor are changed or any changes in the construction of the motor, or repair work to the motor, have been made without prior written approval from Caterpillar.

Documentation

All equipment documentation should be read carefully before any actions are taken. An operations and maintenance manual is delivered with each motor.

Note: Product documentation is available to the ordering customer. For copies of these documents, contact your local Caterpillar Dealer.

In addition to this "Special Instruction", each motor will have dimensional drawings, electrical connection diagrams and a data sheet. At a minimum, the following information will be included:

Mounting and outline dimensions of the motor
Motor weight and load on the foundation
Location of lifting eyes of the motor
Instrumentation and location of accessories
Bearing oil and lubricant requirements
Main and auxiliary connections

Note: Some customer-specific items may not be included in this Special Instruction. Additional documentation will be found in the project documentation. If there is conflict between this Special Instruction and the additional documentation of the motor, the additional documentation will prevail.

Units of Measure

The units of measurement used in this Special Instruction are based on both the SI (Metric) system and the US (English) system.

Checks Upon Arrival and Unpacking

There are several tasks to be performed prior to the start of any of the installation procedures for the equipment.

Checks Upon Arrival

The motor and the entire package must be inspected immediately upon arrival.

Any transport damage must be photographed and reported immediately, within less than one (1) week after arrival, if any transport insurance is to be claimed.

Evidence of careless handling must be checked and reported immediately. Report any such damage to the transport company and the supplier, within 30 days (as specified in the Warranty Bulletin).

Note: A motor that is not to be installed immediately upon arrival, must not be left without supervision or without protective precautions. Refer to Operation and Maintenance Manual, SEBU8852, "Storage" for more detailed information.

Checks Upon Unpacking

Place the motor on a flat, vibration-free surface, ensuring that handling of any other goods is not hindered.

After all packaging materials have been removed, check that the motor is not damaged and that all accessories are included. Tick off the accessories on the packing list which is enclosed. If there is any suspected damage or if accessories are missing, take photographs and immediately report to the supplier.

Note: For correct recycling and disposal of the packaging material. Refer to Operation & Maintenance Manual, SEBU8852, "Decommissioning and Disposal" for more detailed information about recycling of packaging materials.

Installation Instructions for Main Terminal Box and Cooler Parts

These instructions apply when the machine is delivered on site with disassembled main components, such as the main terminal box or cooler parts. Refer to the dimensional drawing included in the project documentation for the correct positions of the parts. All bolts, nuts, and washers are included in the delivery.

Mechanical assembly should be done only by experienced personnel.

Electrically active parts such as stator cables should be installed by qualified technicians only.

Safety instructions must be observed at all times.

Note: To ensure that all warranty terms agreed in the purchase order contract of this project are not invalidated, read and carefully follow the "Safety Instructions" listed at the beginning of this "Special Instruction".

Installation of the Main Terminal Box

The main terminal box may be delivered with the machine in a separate box-slide package.

To install the main terminal box, perform the steps in the following procedure:

Open the package and lift the main terminal box using a suitable lifting device and cables.
Note: The main terminal box has "lifting eyes" that must be used for this purpose.
Check that all connection parts are free of dust and dirt.
Prepare the delivered bolts and washers for installation.
Lift the main terminal box directly onto the machine frame, over the position where the main terminal box has to be connected.
Note: See the dimensional drawing included in the project documentation.
Note: For NEMA main terminal boxes only, pull the stator cables though the sealing membrane.
Connect the main terminal box with the screws delivered with the machine frame. Make sure that the isolation sealing is available to the connection surface of the machine housing.
Tighten all screws with max. 20 Nm. Refer to the Operation and Maintenance Manual, SEBU8852, General Construction - Check for tightening torques.

For NEMA main terminal boxes only, after mechanically connecting the main terminal box to the machine housing, the stator cables are connected to the terminals.

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Illustration 1	g03877544
Stator cable connections for NEMA main terminal boxes (A) Screw connector M12 steel (B) Screw Connector M16 brass (C) Round terminal DIN 46223 / Screw M10 steel (1) Screw M12 steel (2) Hex nut M12 steel (3) Screw M16 bronze (4) Hex nuts M16 brass

To connect the stator cables to the terminals on NEMA main terminal boxes, perform the steps in the following procedure:

Check the markings of the stator cables and the terminals.
Connect the stator cables to the corresponding terminals according to the cable markings (U1, V1, W1, or L1, L2, L3). See the electrical connection diagram for more information.
Tighten the preinstalled screws with max. 80 Nm. (see Appendix Typical main power cable connections). Refer to the Operation and Maintenance Manual, SEBU8852, General Construction - Check for tightening torques.

Installation of the Cooler Parts

If the cooler, or parts of the cooling system are delivered separately, such part or parts require on-site installation.

To install the separate cooler system parts, perform the steps in the following procedure:

Open the cooler or cooler parts package and lift the parts using a suitable lifting device and cables.
Note: The cooler or cooler parts package has "lifting eyes" that must be used for this purpose.
Check that all connection parts are free of dust and dirt.
Check the correct installation positions from the dimension drawing delivered with the project documentation.
Note: See the dimension drawing included in the project documentation.
Check that all connection parts, bolts, washers, and nuts are included in the delivery.
Lift the cooler or cooler parts to the correct position, and connect all with the delivered installation parts. Make sure that all sealing parts are installed at the correct locations.
Tighten all screws with max. 80 Nm. Refer to the Operation and Maintenance Manual, SEBU8852, General Construction - Check for tightening torques.

Installation and Alignment

This section of this Special Instruction provides guidance and advice on the procedures to be followed for a safe and correct installation of a Caterpillar C N Electric Motor.

General Installation Information

Good planning and preparation will result in simple and correct installation, and will also assure a safe running condition with maximum accessibility.

Standards for the connecting and using electrical equipment in hazardous areas must be considered, specifically, national standards for installation. Refer to Standard IEC Publication 60079-14.

Note: General and local work safety instructions must be followed during installation.

Note: Ensure the protection of the motor while working nearby.

Note: Do not use the motor as a welding earth ground.

Foundation Design

The following list of requirements must be given serious consideration when planning and executing all work related to laying down the foundation:

The design of the foundation should assure safe running conditions with maximum accessibility. Sufficient free space should be left around the motor to ensure easy access for maintenance and monitoring. The cooling air should flow to and away from the motor without obstruction. Ensure that other nearby equipment does not heat the motor intake cooling air or any other external components such as bearings.
The foundation must be strong, rigid, flat, and free from external vibration. The possibility of motor resonance with the foundation must be verified. To avoid motor resonance vibrations, the foundation natural frequency together with motor must not be within a ±20% range of the running speed frequency.
A concrete foundation is preferred, however, a correctly designed steel construction is also acceptable. Anchoring the foundation, air provision, water, oil, and cable channels, and the location of grouting holes, must be considered prior to construction. The position of the grouting holes and the height of the foundation must agree with the corresponding dimensions on the provided dimensional drawing.
The foundation shall be designed to permit 2 mm (0.07874 inch) shim plates under the feet of the motor, to ensure an adjustment margin, and facilitate future installation of a replacement motor. Motor shaft height and foundation feet location have manufacturing tolerances, which are compensated with the 2 mm (0.07874 inch) shim plates.

Note: The calculation and design of the foundation, as well as the grouting operation, are outside the scope and responsibility of Caterpillar. The customer, or a third party, is responsible for all such responsibilities.

Forces to the Foundation

The foundation and mounting bolts must be dimensioned to withstand sudden torque loads, rotor lock torque, short circuit loads and must consider any and all local, state, and federal seismic loads. Sudden mechanical torque can occur every time the motor is started, or is at short circuit. The short circuit force is a gradually damped sine wave that changes direction. Refer to the motor dimensional drawing for information about the magnitude of sudden mechanical torque forces.

Machine Preparations Before Installation

Follow the steps in the next procedure, to prepare the motor for installation:

Remove the transport locking device when applicable, and store such for future use. Refer to Operation & Maintenance Manual, SEBU8852, "Transport Information"" for the disassembly details.
Verify that the grease available is according to the specification on the bearing plate. Refer to Operation & Maintenance Manual, SEBU8852, "Bearing Plate" for information on recommended grease types.

Note: The following procedure applies strictly to "Sleeve-Type" Bearing installations:

Fill the sleeve bearings with an appropriate oil. For suitable oils, refer to Operation & Maintenance Manual, SEBU8852, "Bearing Plate" for information on recommended oil types.
Note: Sleeve bearings are always delivered without oil.
Remove the anti-corrosive coating on the shaft extension, and motor feet with a Caterpillar approved solvent.
Check that the drain plugs at the lowest part of both ends of the motor are in open position. Refer to "Drain Plugs".

Insulation Resistance Measurements

Before a motor is started the first time, after a long period of standstill or general maintenance work, the motor insulation resistance must be measured. This procedure includes measuring the stator windings and all auxiliary devices.

Disassembly of the Transport Locking Device

Some machines, and all machines with sleeve or roller bearings, have transport locking devices installed.

For machines with sleeve or cylindrical roller bearings, the transport locking device is made of a steel bar. The steel bar comes attached to both the bearing shield on the "D" end and to the end of the shaft extension.

Remove the transport locking device prior to installation.

The shaft extension has to be cleaned of any anti-corrosive coating, and the locking device should be stored for future use.

Note: To avoid bearing damages, the transport locking device must be fitted to the motor whenever the motor is moved, transported, or stored. Refer to the Operation and Maintenance Manual, SEBU8852 for further protective measures prior to transport.

Drain Plugs

The motors are equipped with drain plugs at the lowest part of the motor. The drain plugs are designed and constructed to keeps dust outside while letting condensation water to drain out.

The drain plugs should always be open, so that half the plug is inside and half of the plug is outside.

The drain plug is opened by pulling the plug out from the frame.

Note: In AMA/AMI 560-630 machines, the drain plug (M12 screw) is opened from 6 mm (0.2362 inch) to 12 mm (0.4724 inch) for normal drainage.

For horizontal machines, two drain plugs are fitted at both ends of the motor.

For vertical machines, two drain plugs are fitted to the lower end shield.

Note: The main terminal box has one drain plug at the lowest part of the box which has to be closed during operation.

Installation on a Concrete Foundation

The motor delivery does not normally include installation, shim plates, mounting bolts, foundation plate set, or sole plate set. Those items are delivered according to special orders. If new fixing holes need to be drilled, contact the Caterpillar Dealer for information to ensure suitability.

General Preparations

Before starting the installation procedures, consider the following:

Provide sheet steel material for shimming the motor. Possible alignment adjustments require shims with thicknesses of 1 mm (0.03937 inch), 0.5 mm (0.01968 inch), 0.2 mm (0.00787 inch), 0.1 mm (0.00394 inch), and 0.05 mm (0.00197 inch)
Provide a recoil hammer, adjusting screws or hydraulic jacks for axial and horizontal adjustments
Provide dial indicator gauges, preferably a laser optical analyzer, to achieve accurate, and precise alignment of the motor
Provide a simple lever arm for turning the rotor during alignment
With outdoor installations, provide sun and rain protection to eliminate measuring errors during installation.

Note: Machines are delivered with jacking screws for vertical adjustment at each foot.

Foundation Preparations

A good, solid, and reliable foundation is a key factor for a successful installation and long trouble-free service life of the motor.

Foundation and Grouting Hole Preparations

Foundation studs or sole plates are used when the motor is anchored to a concrete foundation.

The following points must be considered when preparing the foundation:

The upper part of the foundation must be swept or vacuum cleaned
Walls of the grouting holes must have rough surfaces to give a good grip. Walls of the grouting holes must be washed and rinsed free from pollution and dust. Any oil or grease must be removed by chipping away small slices of the concrete surfaces
Check that the position of the grouting holes and the height of the foundation agree with corresponding measurements on the drawing provided
Attach a steel wire on the foundation to indicate the center line of the motor. Mark also the axial position of the motor.

Foundation Studs or Sole Plate Preparations

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Illustration 2	g03868416
Typical foundation stud assembly (1) Sole plate (2) Stud (3) Flange (4) Nut (5) Jack screw (6) Fix screw (7) Shim (8) Support plate (9) Taper pin (10) Jack screw

If shims and foundation studs are part of the delivery, such will be delivered as separate items, and must be assembled on site.

Note: To ensure that the foundation studs will attach to the concrete, the studs must be unpainted, and free from pollution and dust.

To assemble the foundation anchor studs (2), or sole plate sets (1), the motor must be suspended above the floor by a crane. Refer to Illustration 2 for a view of a typical foundation stud assembly.

Follow the steps in the procedure bellow, to assemble the foundation stud or sole plate set:

Clean the parts protected by an anti-corrosive coating with a Caterpillar approved solvent.
Screw the greased leveling screws into the foundation anchor studs (2), or sole plates (1).
Wrap a layer of tape around the upper part of the foundation anchor studs.
Note: The tape prevents the stud upper part from being stuck in the concrete, enabling retightening of the stud after the concrete sets.
Fit the foundation anchor studs (2) into the sole plate or plates (1) so that the top of the foundation anchor studs (2) are 1 mm (0.04 inch) to 2 mm (0.08 inch) above the upper surface of the nuts (4).
Fit the anchor flange (3) and the lower nut (4) to the foundation anchor studs (2). Bridge the anchor flange (3) to the foundation anchor studs (2) by welding and tighten the nuts (4). If the bridging cannot be done, lock the anchor flange (3) between two nuts (4).
After the assembly of the sole plates (1) is done, the motor should be lifted and suspended above the floor. The motor feet, side, and bottom surfaces of the sole plate sets (1), and foundation anchor studs (2), must be cleaned with white spirits.
Mount the assembled foundation anchor studs (2) or sole plate sets (1) under the motor feet with the fix screws (6) and anchor flanges (3). Center the fix screws (6) in the hole of the motor by wrapping paper, cardboard, or tape, on the fix screws (6) upper part.
Place the 2 mm (.08 inch) shim (7) between the foot and the sole plates (1). Fasten the sole plates (1) tightly against the foot with the fix screws (6).
Place the support plate (2) under the jack screw (5).
Check the space between the sole plates (1) and the foundation anchor studs (2). Ensure that the space is tight, and free of concrete. If concrete penetrates through this space and up to the foundation anchor studs (2), the retightening cannot be done.

Installation of the Motor

Slowly let down the motor and place the motor onto the foundation. Make a rough horizontal alignment using the previously installed steel wire and the marking of the axial location. Use the leveling screws to make a rough vertical alignment. Required positioning accuracy is within 2 mm (0.8 inch).

Alignment of the Motor

The alignment of the motor can now be performed. Refer to "Alignment".

Grouting

The grouting of the motor into the foundation is an important part of the installation. Strictly follow the instructions of the grouting compound supplier.

Use high-quality non-shrinking grouting materials to avoid future difficulties with the grouting.

Cracks in the grouting compound, or a poor attachment to the concrete foundation, cannot be accepted.

Final Installation and Inspection

Follow the steps in the next procedure to perform the final installation and inspection:

After the concrete has set, lift the motor from the foundation and retighten the foundation anchor studs (2).
Lock the nuts (4) by bridging or hitting sufficiently hard with a center punch.
Lift the motor back on the foundation and tighten the foundation anchor studs (2).
Check the alignment to ensure that the motor will run with only the permissible vibration.
If necessary, adjust the alignment with shims, and then complete the doweling according to the holes in the feet at the motor "D" end.

Doweling of the Motor Feet

The motor has one dowel hole per foot at the "D" end. Deepen the holes by drilling through to the steel foundation. After that, the holes are tapered with a reaming tool. Suitable tapered pins are fitted to the holes to ensure the exact alignment, and to allow easier reinstallation after any possible removal of the motor. Do not dowel until the unit has been run for 1 week and the alignment has been rechecked.

Covers and Enclosures

Complete the coupling installation by attaching both coupling halves to each other, according to the coupling manufacturer instructions.

Note: The coupling must be covered with a touch guard.

After the motor has been installed, aligned, and all accessories added, check that no tools or foreign objects were left inside the enclosures. Also, clean any dust or debris.

Check that all sealing strips are intact when installing the covers.

Store the alignment and assembly accessories together with the transport locking devices for future use.

Alignment

To ensure a long and satisfactory lifetime of both the motor and the driven machine, both need to be properly aligned to each other. The radial and angular deviation between the two shafts of the machines must be minimized. The alignment must be performed with great caution because alignment errors will lead to both bearing and shaft damages.

Before starting the alignment procedure, install the coupling in accordance to the recommendations and specifications of the coupling manufacturer.

The coupling halves of both the driving and driven machines must be bolted together loosely at first. The coupling halves must be able to move freely, regarding each other, during the alignment procedure.

Note: The following text refers to installations on both concrete and steel foundations. Shimming is not necessary in a concrete foundation, if the alignment and grouting procedures were done correctly.

Rough Leveling

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Illustration 3	g03869534
Vertical positioning of motor foot (1) Foundation (2) Shim (3) Motor foot (4) Fixing bolt (5) Jacking screw

To facilitate the alignment and enable the mounting of shims, jacking screws are fitted to the feet of the motor. Refer to Illustration 3, vertical positioning of motor foot.

The motor is left standing on the jacking screws. Ensure that the motor stands on all 4 feet, on a plain parallel within 0.1 mm (0.004 inch) or better. If the required tolerance is not achieved, the frame of the motor will be twisted or bent, leading to bearings or other parts damage.

Rough Adjustment

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Illustration 4	g03869652
Positioning of bracket plates (1) Bracket with adjusting screw

To facilitate the alignment in axial and transversal directions, place bracket plates with adjusting screws at the corners. Refer to Illustration 4, positioning of bracket plates.

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Illustration 5	g03869672
Mounting of the bracket plate (1) Bracket with adjusting screw (2) Expansion bolt

Bracket plates are placed against the foundation edge and tied down with expansion bolts. Refer to Illustration 5, mounting of the bracket plate.

Move the motor by using the adjusting screws. Adjust the screws until the motor shaft center line and the driven machine center line are roughly aligned. The desired distance between the coupling halves must also be reached during this adjustment. Leave all adjusting screws lightly tightened for now.

Note: The mounting of the bracket plate shown in Illustration 5 shows the bracket plate mounted onto a concrete foundation. Place a similar bracket plate on steel foundations.

Rough Adjustment for Bearing Type Sleeves With Axial Float

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Illustration 6	g03871192
Markings on shaft and running center pointer (1) Running center (2) Pointer (3) Outer seal (4) Rotor end float limits

The sleeve bearing in the "D" end is equipped with a pointer for showing running center, which is marked with a groove on the shaft. There are also grooves on the shaft for rotor mechanical end float limits. The position is correct when the tip of the pointer is in line with the machined running center groove on the shaft. Refer to Illustration 6 for the location of the markings on shaft and running center pointer. Notice that the running center is not necessarily the same as the magnetic center, as the fan may pull the rotor from the magnetic center.

Correction for Thermal Expansion

Running temperatures have a considerable influence on the alignment, and must be considered during the alignment.

The motor temperature is lower during installation than under operating conditions.

For this reason, the shaft center will be higher, or further away from the feet, during operation than during standstill. Under those conditions, heat compensated alignment may become a necessity .

Use of heat compensated alignment will depend on the driven machine operating temperature, coupling type, distance between machines, or such other variables.

Thermal Expansion Upward

Thermal expansion of the distance between the feet and the shaft center of the electrical motor can be calculated according to the following formula:

ΔH = a x ΔT x H where

ΔH - Thermal expansion [mm]

a - 10 x 10^-6K^-1

ΔT - 40 K

H - Shaft height [mm]

Note: Consider the thermal expansion of the driven machine in respect to the electrical motor to define the total thermal expansion.

Thermal Axial Growth

The thermal axial expansion must be considered, if the axial movement of the non-drive ("N") end bearing is locked. Refer to the dimensional drawings to determine which end is locked.

The expected axial thermal expansion of the rotor is proportional to the length of the stator frame. This thermal expansion can be calculated according to the following formula:

ΔL = a x ΔT x L where

ΔL - Thermal expansion [mm]

a - 10 x 10^-6K^-1

ΔT - 50 K (for AMA, AMB, AMK, AMI), 80 K (for AMH, HXR, M3BM, M3GM)

L - Frame length [mm]

Note: These calculations only generate approximated values.

Note: Make sure that continuous free axial movement is possible between the coupling halves (excluding rigid couplings). Free axial movement is necessary to prevent axial thermal expansion of the motor shaft, which could damage the bearings.

Final Alignment

The final alignment is made with dial gauges, although there is other and more exact measuring equipment on the market. The reason for using dial gauges in this text is to provide some alignment theory.

Note: Measurements should be made only after proper shimming, and with all fixing bolts properly tightened. The final alignment measurements should always be recorded for future reference.

Run-Out of the Coupling Halves

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Illustration 7	g03871291
Measuring the run-out at the coupling halves

The alignment procedure starts by measuring the run-out of the coupling halves. The measurement will show any inaccuracy of the shaft and/ or coupling halves.

Perform the steps in the following procedure, to measure the run-out of the coupling half, with respect to the bearing housing of the motor:

Place the gauges according to Illustration 7, for measuring the run-out at the coupling half.
Place the gauges in a similar way, to check the run-out of the coupling half of the driven machine with respect to the bearing housing.

Note: A simple lever arm is needed to turn a rotor of a sleeve-bearing motor. The admissible run-out error is less than 0.02 mm (0.0008 inch).

Note: Sleeve bearings must be filled with oil before turning.

Parallel, Angular, and Axial Alignment

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Illustration 8	g03871319
Definition of misalignment (1) Δr - Parallel Misalignment (2) Δb - Angular Misalignment (3) Δa - Axial Misalignment

After the motor has been roughly positioned as described in "Rough Leveling" and in "Rough Adjustment for Bearing Type Sleeves With Axial Float", the final alignment can start.

The final alignment must be performed with great caution. Failure to do so can result in serious vibrations that can damage both the driving motor and the driven machine.

The alignment is done in accordance with the recommendations given by the coupling manufacturer. Parallel, angular, and axial alignment of the motor is required. Any references to common practice, or standard publications are to be used for reference only. All final alignments are subject to the coupling manufacturers recommendations.

Note: Any references to common practices or standard publications are to be used for reference only. All final alignments are subject to the coupling manufacturers recommendations.

Some standard publications give recommendations for coupling alignment. Refer to BS 3170:1972 "Flexible couplings for power transmission".

In common practice, parallel and angular misalignment should not exceed 0.05 mm (0.002 inch) to 0.10 mm (0.004 inch). Axial misalignment should not exceed 0.10 mm (0.004 inch). Refer to Illustration 8 for a graphic definition of misalignment. The corresponding run-out is from 0.10 mm (0.004 inch) to 0.20 mm (0.08 inch) for parallel and angular misalignment.

Alignment

The alignment of the motor is performed according to these guidelines:

The motor should stand on the jacking screws provided
Rotate the rotor and check the axial end float. Refer to "Rough Adjustment for Bearing Type Sleeves With Axial Float"

Note: Sleeve bearings must be filled with oil before turning.

Once the two guidelines above have been followed, perform the steps in the following procedure:

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Illustration 9	g03871355
Alignment check with gauges (1) Radial alignment (2) Angular alignment

Mount the alignment equipment. If gauges are used, adjust the dial gauge in such way that approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets to eliminate the possibility of sag. Refer to Illustration 9.
Measure and note readings for parallel, angular, and axial misalignment in four different positions. Measure at the top, bottom, right, and left, 90° apart, while both shafts are turned simultaneously. Record all the readings.
Align the motor vertically by turning the jacking screws or by jacking with hydraulic jacks. To facilitate the alignment in the vertical plane, jacking screws are fitted to the feet of the horizontal motor. Refer to Illustration 3. The alignment accuracy of the motor is sometimes affected by the thermal expansion of the frame. Refer to "Correction for Thermal Expansion"
Measure the distance between the bottom of the motor feet and the bed plate. Make corresponding solid blocks or wedges, or reserve the necessary amounts of shims.
Fit the solid blocks or shims under the motor feet. Slacken the jacking screws and tighten the fixing bolts.
Check the alignment again. Make corrections if necessary.
Draw up a record for future checks.
Retighten nuts and lock the nuts by tack welds or hitting sufficiently hard with a center punch
Dowel the feet of the motor for easy future reinstallation. Refer to "Doweling of the Motor Feet".

Permissible Misalignment

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Table 1
Coupling Information		Permissible Misalignment
Diameter	Type	Parallel - Δr	Angular - Δb	Axial - Δa
100 mm (3.94 inch) to 250 mm (9.84 inch)	Rigid Flange	0.02 mm (0.001 inch)	0.01 mm (0.0004 inch)	0.02 mm (0.001 inch)
	Gear	0.05 mm (0.002 inch)	0.03 mm (0.001 inch)	0.05 mm (0.002 inch)
	Flexible	0.10 mm (0.004 inch)	0.05 mm (0.002 inch)	0.10 mm (0.004 inch)
250 mm (9.84 inch) to 500 mm (19.69 inch)	Rigid Flange	0.02 mm (0.001 inch)	0.02 mm (0.001 inch)	0.02 mm (0.001 inch)
	Gear	0.05 mm (0.002 inch)	0.05 mm (0.002 inch)	0.05 mm (0.002 inch)
	Flexible	0.10 mm (0.004 inch)	0.10 mm (0.004 inch)	0.10 mm (0.004 inch)

Permissible misalignment data

Definite alignment tolerances are impossible to state, as the many factors that have an influence on the calculations. Too large tolerances will cause vibration and may possibly lead to bearing or other damages.

Is recommended to aim for as narrow tolerances as possible. Maximum permissible misalignments are shown in Table 1. For definitions of misalignment types, refer to Illustration 8.

Note: All final alignment tolerances are subject to the coupling manufacturers recommendations.

Care After Installation

If the motor will not be in operation for any period after being installed, refer to Operation & Maintenance Manual, SEBU8852, "Storage" for either short or long-term storage options. Remember to rotate the shaft 10 revolutions at least every 3 months, and that self-lubricated bearings must be always filled with oil. If any external vibration is present, the shaft couplings must be opened and suitable rubber blocks must be placed under the feet of the motor.

Note: Rolling or sleeve bearings will both be damaged by external vibrations. External vibrations will damage both the bearing rolling surfaces, or the bearing sliding surfaces, and therefore shorten the bearings lifetimes.

Mechanical and Electrical Connections

Mechanical and electrical connections are made after the installation and alignment procedures. The mechanical connections include the connection of air ducts, water tubes, and oil supply system where applicable.

The electrical connections include the connection of main and auxiliary cables, earthing cables and possible external blower motors.

To determine proper actions, refer to the dimensional drawing , the connection diagram, and the data sheet provided with the motor.

Note: Additional installation holes or threads must never be drilled through the frame. Such actions will damage the motor.

Cooling Air Connections

Motors designed for cooling airflow to and/or from the motor with air ducts have connection flanges as specified in the dimensional drawing.

Clean the air ducts thoroughly before connecting any to the motor, and check for possible obstructions in the ducts. Seal the joints with appropriate gaskets. After all the ducts have been connected, check all the duct connections for possible air leaks.

Sleeve Bearing Oil Supply (If Equipped)

Machines with flood lubrication system are equipped with oil pipe flanges, and possibly with pressure gauges and flow indicators. Install all necessary oil pipes and connect the oil circulating units.

Install the oil supply system near the motor in equal distance from each bearing. Before connecting the pipes to the bearings, test the oil supply system by flowing rinsing oil through the pipes. After the test, remove and clean the oil filter.

The oil container should be constructed so that no pressure can enter the oil return piping from the container towards the bearing.

Install and connect the oil inlet pipes to the bearings. Install the oil outlet pipes downwards from the bearings at a minimum angle of 15°, which corresponds to a slope of 250 mm (9.84250 inch) to 300 mm (11.81100 inch) per foot.

The oil level inside the bearing will increase if the slope of the pipes is too small. The oil will flow too slowly from the bearing to the oil container, and will result in oil leaks or disturbances in the oil flow.

Note: Do not drill holes through the frame during the installation of the pipes or any other equipment, as serious damage to the motor will occur.

Fill the oil supply system with appropriate oil with correct viscosity. Refer to the dimensional drawing for the correct type of oil and viscosity. If in doubt about the cleanness of the oil, use a 0.01 mm (0.00039 inch) mesh, to filter unwanted debris from the oil.

Turn on the oil supply, and check the oil circuit for possible leaks prior to starting the motor. The normal oil level is obtained when half of the oil sight glass is covered.

Note: The bearings are delivered without lubricant, and running the motor without lubricant will result in immediate bearing damage.

Vibration Transducers Mounting

To mount the vibration transducers, perform the steps in the following procedure:

Disconnect the cables from the detached vibration transducers.
Remove the shield plugs from the tapped mounting holes on the end shield of the motor.
Protect the mounting surfaces against rust with a suitable anti-corrosion agent.
Mount the vibration transducers to the tapped mounting holes. The tightening torque depends on the transducer type being used.
Connect the cables to the vibration transducer.

Electrical Connections

The safety information in Safety Instructions at the beginning of the manual must always be observed.

The electrical installation must be thoroughly planned, before taking any actions. Study the connection diagrams received with the motor before starting the installation work.

Verify that the supply voltage and the frequency are the same as the values indicated on the rating plate of the motor.

The network voltage and frequency should be within given limits according to the applicable standard. Note the rating plate markings and connection diagram in the terminal box. Refer to the motor "Performance Data Sheet" for additional information.

Note: Prior to any installation work, separate the incoming cables from the supply network, and connect the cables to a protective earth ground.

Note: Check all rating plate data, especially for the voltage and winding connections.

Safety

All electrical work must be carried out only by skilled persons. The following safety rules must be applied:

De-energize all equipment, including auxiliary equipment
Verify all stored energy has been discharged
Provide safeguard against re-energizing the equipment
Verify that all parts are isolated from the respective supply
Connect all parts to protective earth and short the circuits
Cover or provide barriers against live parts in the surrounding area
If the secondary circuit of the current transformer is extended, make sure that the circuit does not become an open-circuit while in use

Main Terminal Box Options

The inside of the main terminal box must be free from dirt, moisture, and foreign debris. The box, cable glands, and unused cable entrance holes must be closed against both dust and water intrusions.

The main terminal box is equipped with a drain plug at the lowest part of the box. During transportation and storage, the plug should be in the open position, meaning half the plug is inside and the other half is outside. During operations, the plug should be kept in closed or shut position, but should be opened from time to time. If the box is turned after delivery, the drain plug function must be checked and possibly repositioned to the lowest part of the box.

Some main terminal boxes can be turned in 90 degrees steps. Before turning a terminal box, check that the length of the cables between the stator winding and the terminal box is sufficiently long.

Delivery Without a Main Terminal Box

If the motor is delivered without a main terminal box, the stator connection cables must be covered with earthed protective structure before commissioning. The structure must have the same or higher enclosure classification and hazardous area certifications as the motor.

To avoid cable failure, stator connection cables must be shortened, to minimize free movement of the cables. The supplier of the terminal arrangement is responsible for ensuring that adequate stator connection cable supports are used. The stator connection cable arrangement has to be spacious, to avoid overheating of the cables. Stator connection cables must not touch sharp corners. The minimum bending radius of stator connection cable is six times the cable outer diameter.

Insulation Distances of Main Power Connections

Connections of the main power cables must be designed to withstand demanding operation conditions where insulators can be subjected to dirt, humidity, and surge voltages. To ensure lasting and trouble-free running, ensure that the length of the insulation and creep distances are sufficient for the job.

The minimum insulation and creep distances should be equal to, or exceed, the demands set by:

Local requirements
Standards
Classification rules
Hazardous area classifications

Insulation and creep distances apply both for insulation distances between two different phases, and for insulation distances between one phase and earth. The air insulation distance is the shortest distance through air between two points with different electrical potential voltages. The surface creep distance is the shortest distance along surfaces next to each other, between two points with different electrical potential voltages.

Main Power Cables

The size of the input cables has to be adequate for the maximum load current and in accordance with local standards. The cable terminals have to be of appropriate type and of correct size. Connections to all devices must be checked.

The main power cable connections should be tightened correctly to ensure reliable operation. Refer to the Operation and Maintenance Manual, SEBU8852 for further information.

Protection Types for All Hazardous Areas

For Ex type motors, the cable glands, or the cable bushings for supply cables must be Ex certified. Glands or bushings are not included in the manufacturer delivery.

Prior to installation, check that the incoming cables are separated from the supply network Also check that the cables are connected to protective earth ground.

The stator terminals are marked with letters U, V, and W, according to IEC 60034-8 or T1, T2, and T3 according to NEMA MG-1. The neutral terminal is marked with "N" (IEC) or with "T0" (NEMA). Stripping, splicing, and insulating of the high-voltage cables must be performed in accordance with instructions by the cable manufacturer.

The cables must be supported so that no stress is applied to the bus bars in the terminal box.

Always check the phase sequence from the connection diagram.

Auxiliary Terminal Box

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Illustration 10	g03873987
Typical auxiliary terminal box

Auxiliary terminal boxes are attached to the frame of the motor according to accessories and customer needs. Refer to the motor dimensional drawings for details about the positions on the auxiliary terminal boxes on the motor.

Auxiliary terminal boxes are equipped with terminal blocks and cable glands. Refer to Illustration 10. The maximum sizes of the conductors are normally limited to 2.5 mm (0.09843 inch), and the voltage is limited to 750 V. The cable glands are suitable for cable sizes from 10 mm (0.39370 inch) to 16 mm (0.62992 inch) in diameter.

Note: For Ex type motors, cable glands or cable bushings for supply cables must be Ex type certified. Glands or bushings are not included in the manufacturer delivery package.

Auxiliaries and Instruments Connections

Connect the instruments and auxiliary equipment according to the connection diagram.

Note: Study the connection diagram delivered with the motor carefully before connecting any cables. The connection and functioning of accessories must be checked before first-time power-up of the motor, and also before commissioning.

Note: Correspondingly label all accessory terminals which are normally under voltage when the motor is switched off.

External Blower Motor Connections

The external blower motor is normally a three-phase asynchronous motor. A connection box is located on the frame of the blower motor. The external blower motor rating plate shows the voltage and frequency to be used. The direction of rotation of the fan is indicated by an arrow plate on the flange of the main motor.

Note: Visually check the direction of rotation of the external blower motor (fan) before starting the main motor. If the blower motor is running in the wrong direction, the phase sequence of the blower motor must be changed.

Earth Ground Connections

The motor frame, main terminal box, auxiliary terminal box, and associated equipment must be connected to protective earth ground. The connections to protective earth ground and power supply must be able to protect the motor frame from harmful or dangerous electrical potential voltages. Always mark the motor and terminal boxes with earth ground symbols according to relevant national standards.

Note: Before the first time the motor is connected to the voltage supply, all earth groundings must be carried out according to local regulations. The warranty does not cover destroyed bearings due to improper earth grounding or cabling.

Requirements for Motors Fed by Frequency Converters

In compliance with EMC Directive 89/336/ EEC, as amended by 93/68/EEC, AC motors fed from a frequency converter must be installed with screened cables as specified below:

Main Cables

The main supply cable between the motor and the frequency converter must be a symmetrical three-conductor screened cable.

This requirement is in order to fulfill the radiated emission requirements stated in the generic emission standard for industrial environment, EN 50081-2.

Earth Grounding of Main Cables

Compliance with EMC directives requires high-frequency earth grounding of the main cable. This is achieved by 360° earth grounding of the cable screens at the cable entries in both the motor and the frequency converter. The earth grounding at the motor is implemented with the EMC ROX SYSTEM cable transits for shielded installations.

Note: 360° high-frequency earth grounding of cable entries is made in order to suppress electromagnetic disturbances. In addition, cable screens must be connected to protective earth ground, to meet safety regulations.

Auxiliary Cables

Auxiliary cables must also be screened to meet EMC requirements. Special cable glands must be used for the 360° high-frequency earth grounding of the cable screens at the cable entries.

Note: For information on other equivalent cables, contact your local a Dealer Customer Support representative.

Commissioning and Start-Up

A commissioning report is a vital tool for future service, maintenance, and fault finding.

The commissioning is not to be considered finalized before an acceptable commissioning report has been documented and filed.

The commissioning report must be available in warranty requests, to obtain warranty for the motor.

For more information, contact Caterpillar Dealer Customer Support.

Mechanical Installation Checks

Check alignment of the motor prior to commissioning:

Go through the alignment report and ensure that the motor is accurately aligned. Refer to "Alignment" for details. The alignment protocol should always be included in the commissioning report.
Check that the motor is properly anchored to the foundation.
Check for cracks in the foundation and the general condition of the foundation.
Check the tightness of the mounting bolts.
Check that the lubrication system is commissioned and is running before the rotor is turned.
If possible, turn the rotor by hand, making sure that the rotor turns freely and that no abnormal sounds can be heard.
Check the assembly of the main terminal box and cooling system.
Check the oil supply connections and check for leaks when running.
Check pressure and flow for the oil system.

Insulation Resistance Measurements

Before a motor is started after a long period of standstill, or for general maintenance work, the motor insulation resistance must be measured. Refer to Operation & Maintenance Manual, SEBU8852, "Winding Insulation Resistance - Test" for details.

Electrical Installation Checks

The power cables can be permanently connected to the terminals in the main terminal box after the stator insulation resistance has been measured. Refer to Operation & Maintenance Manual, SEBU8852, "Winding Insulation Resistance - Test" for details.

Check connection of power cables:

Check that the cable lug bolts are tightened with proper torque.
Check that the power cables are correctly routed.
Check that the power cables are stress-relieved correctly.
Check that the connections of the auxiliary equipment are correct.

Note: If anti-condensation heaters without self-regulation are turned on immediately after the motor is shut down, take suitable measures to control the inside motor housing temperature. Anti-condensation heaters can only operate within a temperature controlled environment.

Control and Protection Equipment

The motor is equipped with temperature detectors to be connected to a temperature monitoring and protection system. Refer to the motor dimensional drawing, and connection diagram for the location and type, as well as the settings, for the temperature detectors.

The temperature alarm level for the resistance temperature detectors (RTD, Pt-100) should be set as low as possible.

The level can be determined based on the test results, or the operating temperatures developed.

The temperature alarm can be set 10° C (50° F) higher than the operating temperature of the motor during maximum load at the highest ambient temperature.

If a two-function temperature monitoring system is used, the lower level is normally used as an alarm level and the higher as a trip level.

Note: In case the motor trips, the reason must be found and eliminated before the motor is restarted. If there is an alarm, find the reason and correct the situation. Refer to Operation and Maintenance Manual, SEBU8852.

Stator Windings Temperatures

The stator windings are manufactured according to temperature rise class F, which has a temperature limit of 155° C (311° F). A high temperature will age the insulation and shorten the lifetime of the winding. Thorough consideration should be made when deciding the temperature trip and alarm levels for the stator windings.

Resistance Temperature Detectors

For determining the maximum temperature settings, refer to the connection diagram delivered with the motor. Refer to the method described in "Control and Protection Equipment" for the recommended settings for the temperature alarm.

Bearing Temperature Control

The bearings can be equipped with temperature detectors for monitoring the bearing temperatures. The viscosity of the grease or oil used will diminish as a function of higher temperatures. When the viscosity falls below a certain limit, lubrication of the bearing will cease, the bearing will fail, and shaft damage will result.

Bearing temperatures must be monitored continuously. If a bearing temperature starts to rise, the motor must be immediately shutdown, as a bearing temperature rising usually indicates an imminent bearing failure.

Resistance Temperature Detectors

For determining the recommended maximum temperature settings, refer to the connection diagram delivered with the motor. Is recommended to apply the method described in "Control and Protection Equipment", when setting the temperature alarm.

Protection Equipment

The motor must be protected against various disturbances, faults, and overloading that might damage the motor. The protection must be in accordance with the instructions and regulations for each country where the motor is used.

The motor parameter values for relay settings are found in the document "Motor Performance Data", included in the documentation provided with the motor.

Note: Caterpillar is not responsible for adjusting the protection equipment at the site.

First-Start Test

The first-start test is a standard procedure after the installation and alignment procedures are finished, the mechanical and electrical connections are made, the commissioning procedure is gone through, and the protective devices are active.

Note: If possible, the first-start test is performed with uncoupled couplings between the driving motor and the driven machine. The load on the motor must be as small as possible.

Precautions Before the First-Start Test

A visual inspection of the motor and all attached equipment must be made before the first-start test. Verify that all necessary tasks, and all alignments and adjustments, have been performed.

Before beginning the first-start test, the following checks and measures must be made:

The sleeve bearing oil reservoirs and oil supply systems are filled with recommended oil to the correct level and the oil supply system is turned on.
The rotor is turned by hand, and is verified that no abnormal noises are heard from the bearings. To turn a rotor with sleeve bearings, a simple lever arm is needed.
The oil supply systems are filled with recommended oil to the correct level. The oil supply system is turned on.
The cabling, cables, and bus bar connections are verified to be according to the connection diagram.
All the earth grounding connections and earth grounding devices are verified.
The starting, control, protection, and alarm relays of each device, are inspected.
The insulation resistance of the windings and other equipment are verified.
The motor covers are assembled, and the shaft seals are tightly fitted in.
The motor and the environment are cleaned, vacuumed, or swept.

Starting

The first-start should last only about one (1) second, during which the direction of rotation of the motor is verified. The direction of rotation of possible external blower motors must also be verified. Verify also that the rotating parts do not touch any stationary parts.

Note: If the motor does not have an axial locating bearing, and the motor is started uncoupled, is normal that the shaft will move axially before stabilizing. Standard Cat CN motors will have an axial locating bearing at the drive end.

Direction of Rotation

The objective of the first starting is to check the direction of rotation of the motor.

The motor should turn in the same direction as is shown with an arrow located on the frame or the fan cover.

The direction of rotation of the external blower motor is indicated by an arrow near the blower motor.

The motor may only be operated in the specified direction of rotation. The direction of rotation is indicated on the marking plate. Refer to Operation & Maintenance Manual, SEBU8852, "Plate Locations and Film Locations".

Motors suitable for reversing operation are labeled with a double-headed arrow on the rating plate, and on the frame.

If the desired direction of rotation is different from the one specified on the motor, the cooling fans, in inner and/or outer cooling circuit, must be changed, and the stamp on the rating plate.

To alter the direction of rotation, interchange the power supply phases.

First-Time Running of the Motor

After a successful first-start test, the coupling between the driving motor and the driven machine should be coupled, and the motor can be restarted.

Supervision During the First-Time Running of the Motor

During running first coupled run of the motor and driven equipment, verify that the whole system functions as expected. Frequently monitor vibration levels, temperature of the windings and bearings and other equipment. If the whole system functions as expected, the motor can be left running for a longer time.

Check the operating load of the motor by comparing the load current with the value given on the rating plate of the motor.

Record the temperature readings given by the temperature detectors placed in the windings and possibly in the bearings. Check the temperatures frequently to ensure that the temperatures remain below the limits. Continuous temperature monitoring is highly recommended.

Note: If no RTDs are available for monitoring, the surface temperature of the bearing area must be measured. The bearing temperature is approximately 10° C (50° F) higher than a surface temperature.

If there are any deviations from expected normal operation, such as elevated temperatures, noise, or vibration, shut down the motor. Find and correct the reason or cause for the deviations before starting the motor again. If necessary, consult the manufacturer, or consult with Caterpillar Dealer Customer Service personnel.

Note: Never disengage any protective or safety devices.

Checks During Running of the Motor

Close surveillance of the motor should be performed over the first several days of running the motor. Monitor for abnormal changes in vibration, temperature, sound, or current draw.

Bearings

The rotating electrical motors manufactured by Caterpillar are equipped with either rolling or sleeve bearings.

Motors with Rolling Bearings

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Illustration 11	g03875662
Lubrication channel through bearing arrangements of horizontal motors (1) "D" end (2) "N" end

With a new motor, or with a motor out of service for more than 2 months, inject new grease into the bearings immediately after start-up.

New grease must be injected when the motor is running. Inject new grease until old grease, or excess new grease, discharges through the lubrication channel in the bearing housing bottom. Refer to Illustration 11 for an example of lubrication channels through bearing arrangements of horizontal motors.

The temperature of the bearings will initially increase because of the excess grease. After few hours, the excess grease will be discharged through the lubrication valve and the temperature of the bearing will return to normal running temperature.

Note: Make sure to always keep bearings adequately lubricated. Do not exceed 12 months between lubrication intervals. Refer to Operating & Maintenance Manual, SEBU8852, "Maintenance Interval Schedule" for more specific information.

The type of original grease used is found on the bearing plate on the motor. Refer to Operation & Maintenance Manual, SEBU8852, "Bearing Plate" for recommended types of grease to use with rolling bearings.

After the motor has been running for several hours, measure the vibrations or SPM-values from the SPM-nipples, if available. Record the values for future reference.

Motors with Sleeve Bearings

Verify that no rotating parts rub against any stationary parts. Verify through the oil sight glass that the oil level inside bearing is correct. The correct oil level is in the middle of the oil sight glass. However, as long as the oil level is within the oil sight glass, the level is acceptable.

Checking the temperature and the oil level of the bearings continuously in the beginning isparticularlyimportant with self-lubricating bearings.

If the temperature of the bearing suddenly rises, the motor should be stopped immediately. The reason for the temperature rise must be found and repaired before the motor is started again.

If no logical reason is found from the measurement equipment, opening the bearing is recommended, and that the condition must be verified.

If the motor is under warranty, Caterpillar Dealer Customer Support must always be contacted before any action is taken.

For self-lubricating bearings, the rotation of the oil ring is verified through the inspection window on top of the bearing. If the oil ring is not rotating, the motor must be stopped immediately, as a stopped oil ring will result in bearing failure.

For flood-lubricated motors, the oil supply pressure is adjusted with the pressure valve and orifice. The normal supply pressure is 125 ± 25 kPa (18.13 ± 3.63 psi). A normal oil supply pressure gives the right flow of oil to the bearing.

Using higher supply pressure gives no additional benefit, but can cause bearing oil leakages. Refer to Operation & Maintenance Manual, SEBU8852, "Bearing Plate" for information about the specified rate of oil flow for these bearings.

Note: The lubrication system should be constructed so that the pressure inside the bearing is equal to the local atmospheric pressure. Air pressure entering the bearing from either inlet or outlet oil pipes will cause bearing oil leakages.

Vibrations and Noise

High or increasing vibration levels indicate changes in the motor condition. Normal levels vary greatly depending on the application, type, and foundation of the motor.

Some typical reasons that might cause high vibration or noise levels are:

Alignment
Air gap
Bearing wear or damage
Vibration from connected machinery
Loose fastenings or anchor bolts
Rotor unbalance
Couplings

Refer to Operation & Maintenance Manual, SEBU8852, "General Construction - Check" for more detailed information about detecting and addressing vibration-related issues.

Temperature Levels

The temperatures of the bearings, stator windings, and cooling air should be checked when the motor is running.

The winding and bearing temperature may not reach a stable temperature until after 4 to 8 hours of operation, when running at full load.

The stator winding temperature depends on the load of the motor. If full load cannot be obtained during or soon after commissioning, the present load and temperature should be noted and included in the commissioning report.

For recommended settings for alarm and trip levels, refer to the main connection diagram.

Heat Exchangers

Prior to start, check that the connections are tight and there is no leakage in the system. After running the motor for some time, the cooling system should be checked.

Verify that the cooling fluid and air, as applicable, are circulating without any obstruction.