BORGER. The unique Rotary Lobe Pump with MIP!Powerful Endurance. Unrivalled Maintenance Friendly. of Berger Pures mintenance and repair on GEECEEE We didn’t invent the Rotary Lobe Pump, we made something special of it Today Boerger isthe leading manufacturer of elastomer coated Rotary Lobe Pumps. Your decision for Boerger contains patented technology, unrivalled maintenance friendliness and customized solutions ~ at ‘every location, for every fluid, in all sectors of the industry. As diversified and individual your application is, {a5 numerous isthe variety of components and materials of construction of our pump design, Each pump incorporates a customized solution based on the teamwork between the customer ‘and our engineering department. Rotor shapes and materials are chosen based on the characteristics of the pumped fluid. Different rubber, pla rotor materials are available. and metal Because of the rotor variety Boerger pumps are often prime choice in a variety of industries: Construction industry; mining; chemical, cera- ‘mic and oil industry; pulp and paper; wastewa- ter, sludge and biosolids; marine and cl spill industry; food processing; sugar and star industry; soap, grease and cil mills breweries; waste recycling: ete.We do not let you wait! Downtime and maintenance cast time and ‘common to Boerger ~ You take charge of your money, As litle time as possible should be maintenance and repair costs, Our MIP-Design spent on maintenance, By following this philo- is a unique advantage: MIP [Maintenance In ‘Sophy Boorger Rotary Lobe Pumps improve Placed allowss the quick and convenient continuously. replacement ofall fluid wetted parts without The result: An extramely powerful, robust removal of pipes, drives or ether components ‘and unrivalled maintenance friendly pump. of the pump unit by your own staff ‘Allwear and tear parts are extremely rigid, Rotors with individually replaceable rotor tips durable and very inexpensive. Expensive main- or readjustable lobes reduce the repair costs tenance contracts, complicated repairs are not especially with abrasive fluids. Boerger didn’tinvent the Rotary Lobe Pump, but made something special of it: The {ow ene consumption next to the maintenance friendly MIP-Design reduces the life cycle cost af your Boerger pump, The drive, base and flange arrangement possibilities are unlimited, for example trailers with pump / diesel engine configuration are manufactured in our own, facilites. Take us apart!BORGER. Boerger, LLC 1749 NE Harding Street Minneapolis, MN 55413 Usa, Toll Free 877-726-3743, Fox 612-931-8769 ‘wurw.boerger-purmps.com america@boerger-pumps.com 290 1490 wsgpm 0.600 Th a = WL = contnaous Operation Bl = Discontinuous OperationOPERATING AND MAINTENANCE MANUAL FOR BORGER ROTARY LOBE PUMPS FL 518 FL 776 FL 1036 Code No.: 4 1st Modification* Date: nnn 4 2nd Modification*: Date: nnn 4 3rd Modification* Date: 4 Date of Shipment: To: *) Please modify Code with changes to the pump (see 9.1) File: BEDI-FL-7-1-02-E-0 1 Valid from: 07/15/02Operating and Maintenance Manual Table of Contents BORGER - Rotary Lobe Pumps Models FL 518, FL 776, FL 1036 BORGER ROTARY LOBE PUMPS (BARE SHAFT PUMP).. 1.1 CONSTRUCTION OF THE ROTARY LOBE PUMP....... 1.2 FLANGES 1.3 DRIVE SPECIFICATION. 1.4 ASSEMBLY OF AGGREGATE..... . COMPLETE BORGER ~ AGGREGATE. 2.1 STANDARD DESIGN 2.2 LUBRICANT LEVEL AND CHANGE INSTALLATION IN THE PIPE SYSTEM ... START UP o..c.ccoe ecsnceene essscseiee D 4.1 START UP REPORT MAINTENANCE AND CONTROL .. 5.1 DISASSEMBLY OF QUICK RELEASE COVER AND FLANGES 5.2 CLEANING OF THE ROTARY LOBE PUMP... 5.3 DANGER OF FROST. 5.4 STORAGE INFORMATION. TROUBLESHOOTING.. 6.1 PROBLEM/ HELP... . 6.2 EXCHANGE OF LINEAR ROTOR TIPS 6.3 EXCHANGE OF SCREW RoTor TIPS. 6.4 EXCHANGE OF LINEAR ROTORS. 6.5 EXCHANGE oF SCREW ROTORS 6.6 EXCHANGE OF MIP RADIAL LINERS (OPTIONAL FEATURE) EXCHANGE OF MECHANICAL SEAL 7.1 EXCHANGE OF MECHANICAL SEAL 7.2 ADJUSTMENT OF THE AXIAL TOLERANCE OF THE ROTORS 7.3 GLAND PACKING 7.4 SPECIAL PUMP CONSTRUCTIONS SPARE PARTS LIST ... SPARE PARTS REGARDING THE CODE NUMBER ... 9.1 Cope NUMBER 9.2 SPARE PARTS LIST File: BEDI-FL-7-15-02-E-0 Valid from: 07/15/021. BORGER Rotary Lobe Pumps (Bare Shaft Pump) 1.1 Construction of the Rotary Lobe Pump BORGER Rotary Lobe Pumps of the FL Series are designed on a modular basis. Gear unit, axial wear plates, cover and mechanical seals remain the same throughout the series. The material of the fluid wetted parts of the pump unit should be adapted to the chemical and physical conditions of the fluid. The Code Number represents the parts used in the pump unit. Safety Opanin donet clove @ 11 Fill Breather Timing Gear oi! Gauge DeivingSehatt (top oF bottom 4 Cover Oi Drain R112" Timing Gear File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02Intermediate Chamber Timing Gear Pump Chamber 1.2 Flanges The fiange material is usually galvanized steel or stainless steel. Gaskets (see 9.2 Spare Parts List Pos. 25) have to be installed between the pump casing and the flanges. The material of the gaskets should be adapted to the chemical and physical conditions of the fluid. 1.3. Drive Specification The BOERGER Rotary Lobe Pump needs a drive unit with suitable rotation speed and torque. The design of the drive unit (rotation speed and power) depends on the hydraulic conditions (i.e. capacity, pressure, viscosity) of the application. 1.4 Assembly of Aggregate The Rotary Lobe Pump and the drive unit must be assembled free of distortion. The pump shaft and drive shaft have to be connected with a suitable coupling including guard for protection. After assembly of the pump aggregate on the foundation and in the pipe system the alignment of the coupling has to be controlled as part of the warranty. Follow also Operation and Maintenance Manual of Drive U Shaft Diameter of FL-Series: ‘Shaft-Design Diameter ‘Standard, DIN 748_|48 mm (1.89) PTO = Profile 13/8" File: BEDI-FL-7-15-02-6-0 4 Valid from: 07/15/022. Complete BORGER — Aggregate 24 Standard Design Rotary Lobe Pump and drive (standard: helical geared motor) fitted on common base (twist-free), made from galvanized steel, incl. elastic coupling and coupling guard. Also possible is an overhead mounted drive and a variable speed drive. The base of the aggregate has to be fastened on an even foundation, 1.) BORGER Rotary Lobe Pump 2.) Elastic coupling 3.) Coupling Guard Hes 4) veto ae s 5) V-Belt - - 6) VeBelt Guard . 7.) Motor 8) Gear Reduction Unit Ace=, la ©) Variable Speed Drive | | (I 10.) Base E = 11) Flanges n File: BEDI-FL-7-15-02-E-0 5 Valid from: 07/15/022.2 Lubricant Level and Change Before start up of the pump unit check oil level of timing gear at the oil gauge. The oil level must be at the middle of the oil gauge. The oil of the timing gear has to be exchanged after 250 hours of operation, after that every six months for continuous working units and at least once a year for discontinuous working units. The fluid level in the intermediate chamber must be at the level of the top shaft. The top opening of the intermediate chamber must remain open to the environment and must be protected against dirt with our plastic stopper (see parts list Pos. 69). Submersible units must be equipped with a sensor for monitoring of the mechanical seal The functions of the intermediate chamber are 1. Lubrication and cooling of the mechanical seals and rotor/shaft connection 2. Detection of seal failures 3. Buffer zone to the sealed timing gear Check oil of intermediate chamber with every rotor change. When changing mechanical seals the intermediate chamber has to be flushed and cleaned with water before fill up of new oil Atten Please check if the factory site filled oil types and/or listed oil types of the pump unit are allowable with the environmental regulations at the application site. If need please consult factory. Oil quantity depending on model! Rotary Lobe Pump _ [Timing Gear Intermediate Chamber Model Oil quantity Lubricant quantity FL 518 App. 5.6 liter (1.48 gal) | App. 4.1 liter (1.08 gal) FLT76 App. 5.6 liter (1.48 gal) |App. 4.1 liter (1.08 gal) FL 1036 pp. 5.6 liter (1.48 gal) | App. 1.9 liter (0.5 gal) Factory site used oil types: Timing Gear: Mobilgear 630 Intermediate Chamber: MOBIL AMBREX 68 Attached is a list of factory approved oil types for BOERGER Rotary Lobe Pumps: File: BEDI-FL-7-1-02-E-0 6 Valid from: 07/15/02Oil Types Timing Gear a ac aa a a Lubricant Types Intermediate Chamber TE, | [Owe noe] Yan Or alternative a mixture of Glysantine and water Attention: Oil level must be at the middle of the oil gauge! Oil level and oil change for drive follow instruction of Operation and Maintenance Manual of the drive unit. File: BEDI-FL-7-1-02-E-0 7 Valid from: 07/15/023. Installation in the Pipe System The BOERGER Rotary Lobe Pumps are self-priming under certain conditions. To prevent cavitation install the pump with flooded suction or only with a small suction lift. With larger suction lifts and/or long suction pipes control, if the NPSH available of the system is higher in comparison to the required NPSH of the pump. The required NSPH value must be at least a 0.5 m under the NPSH available to prevent cavitation. With suction lifts over 2 m it is required to install a check valve at a suitable position in the pipe system. Especially in pump installations with gaseous fluids it is important to prevent air bubbles on the suction side of the pump. If this is not practicable, install an air release valve close to the pump at a suitable position in the pipe system. This ensures a trouble free start up of the pump aggregate. Install compensators (follow the mounting instruction of the compensator manufacturer) between pump flanges and system especially with thin-walled pipes. Also consider loads caused by changing physical conditions (i.e. temperature), Connection flanges or valves are not allowed to load the pump unit. Before start up check and if needed correct the alignment of the coupling. Uneven foundation surfaces have to be corrected with spacers. Recommended Maintenance Space File: BEDI-FL-7-1-02-E-0 8 Valid from: 07/15/02Start Up + Check Lubricant Levels (see 2.2) * Check that flange and pipe connections are sealed and not leaking. infinite variable rotating flanges (i.e. mobile pumps) check the tightness of the ‘* Check of all installed appurtenances in addition to the pump aggregate (.e. VFDs, dry running protection, pressure gauges etc.) ‘* Start of drive unit for rotation direction check. ‘* Prevent dry running longer than one minute in the start up phase. Fluid is needed for cooling of the pump. + Do not operate pump in hose systems out supervision! ‘+ The BORGER Rotary Lobe Pump can operate in either direction. Check if rotation direction fits your needs. Top shaft rotates counterclockwise. Top shaft rotates clockwise. Fluid flows in direction of arrow. Fluid flows in direction of arrow. Change rotation direction of the drive or change to the other driving shaft of the pump (if suitable) to reverse flow. © Opening of valves. ‘+ After a short time the Rotary Lobe Pump is displacing the nominal capacity. The pressure is not allowed to rise over the permissible pressure of the pipe system and of the Rotary Lobe Pump and shall not overioad the drive unit. The top opening of the intermediate chamber must remain open to the environment and must be closed for dirt protection with our plastic stopper. The closing oft he top opening cause damages on the gear wheels and the bearings File: BEDI-FL-7-1-02-E-0 9 Valid from: 07/15/024.1 Start Up Report Customer: Start Up Report BOReS R Contact: Phone # Rep: em] hak | Remar Date [Signature ‘Bump used as por ‘igi sii {ater tng on foundation jfted corecty | SiPi protaction davies tod leorrecty and checked ! [ali evel oF dive waa correct ibveather opened “oie oF Sycranising a" | ailive oF anench camber lorect.pusged wit pase ‘pug eny aivaives ossed lal pressure se Ping saa, Inoige normal [arranged #8 per operating | "7atcheck fo Amp ea land atte 15 minutes of leperation i Pumps with special construction may route adalitional inspections. We racommand to stock waat parts for important pumps. File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 105. Maintenance and Control Before every start up check lubricant levels. | addition to the lubricant has to be changed in the named periods. (see 2.2), 5.1 Disassembly of Quick Release Cover and Flanges Following are precautions before disassembly of quick release cover and flanges: + Disconnect geared motor from power or remove drive from pump unit. * Close suction and discharge valves. ‘+ Loosen ring nuts of the quick release cover equally app. 5 mm and move the cover slowly of the pump casing. Pressure may still exist inside the pump. Cautior Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. 5.2 Cleaning of the Rotary Lobe Pump Remove quick release cover of the pump (see 5.1). Clean pump and flanges with suitable cleansing agent. Let the pump casing dry and use metal surface protection (i.e. grease) suitable for the rubber material of the rotors. Do not use grease with EPDM or SBR rotors. 5.3 Danger of Frost The pump and pipe system must be secured against frost. As a supplement BORGER can deliver a heated quick release cover. Attention: _ Frozen fluid pieces from the pipe system can cause wear inside the pump, especially at the rubber - coating of the rotors. 5.4 Storage Instructions Instructions for storage and recommissiong of Rotary Lobe Pumps Please refer to these instructions if Rotary Lobe Pumps are stored prior to commissioning. With following these instructions you will protect the pump and avoid damage from humidity and corrosion. Actions are required for long-term storage only. As the requirements depend on the kind of storage and the environmental conditions it cannot be said from which time on these instructions are valid A longer storage prior to commissioning does not extend the time of warranty. File: BEDI-FL-7-1-02-E-0 "1 Valid from: 07/15/025.41 54.14 54.1.2 54.1.3 5.4.2 5.4.3 54.31 5.4.3.2 5.5 5.6 5.7 5.8 5.8.1 5.82 5.8.3 5.84 File: BEI Actions prior to storage The flanges as well as the further openings to the pump have to be closed by using the transport-covers. If these are no longer available please use other suitable humidity controlled protections. Possible surface damages from transport handling should be repaired, at the galvanised as well at painted surfaces. The storage room should be dry and ventilated. The temperature should not exceed 5 to 40 °C. In case of storage outside this temperature area the actions described under item 2 and 3 are required for short-term storage already. Actions during storage time Itis advised to rotate the pump shaft approximately every half year. This is to lubricate the upper gearwheel and the mechanical seals. Actions prior to commissioning Prior to commissioning it is advised to check for easy rotation of the pump shaft. In case of doubt the rotors and seal should be disassembled and reassembled as per operating instructions. The pump should be rotated by hand or by short tipping of the motor switch. An easy rotation of the pumps must be ensured. In case of storage longer than two years, or in case of abnormal storage temperatures, the lubricants should changed prior to commissioning. Please refer to the operating instructions. Remove all covers and protections. Install the pump aggregates as per operating instructions. Actions for taking pumps out of order Ifit becomes necessary to take a pump out of order for a limited period please contact us for instructions as the actions depend on the individual use of the pump. If possible empty and clean the pump and use corrosion protection agent for non-coated steel parts. Before re-commissioning it is advisable to check the easy rotation of the shafts in the mechanical seals. If necessary disassemble and reassemble the seal as per instructions. The pump should be rotated by hand or by short tipping of the motor switch. An easy rotation of the pumps must be ensured DI-FL-7-15-02-E-0 12 Valid from: 07/15/025.9 Storage of drives 5.9.1. For storage and recommissioning of drives please follow the instructions of the. manufacturers. 5.10 Storage of spare parts 5.10.1 For the storage of spare parts please follow item 1 to 5 of this information. 5.10.2 Elastomeres must be stored dry and light protected (UV-radiation must be avoided). File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 136. Troubleshooting 6.1 Problem / Help Pump does not start after shut down Possible problem Help ‘+ Solids have settled inside the pump after shut down. ‘+ Rotors are swollen and are tight to the. pump casing. + Long fibers, foil or plastics are blocking the pump. ‘* Axial rotor tolerance misaligned + Power and/or torque too weak, drive too small Pump does not self prime Possible problem Cleaning of pump (see 5.2) Check temperature and chemical ‘compounds of fluid. Change rotor toa suitable rubber material Cleaning of pump and suetion flange (see 5.1), pian the installation of a Mutti- chopper Adjust axial rotor tolerance (see 7.2) Change to bigger drive Help ‘+ Rotation direction wrong of the drive + Suction pipe blocked * Suction connection leaky * Air bubble inside the pump or pipe system ‘+ Rubber coating of rotors destroyed File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 ‘Change rotation direction of the drive Cleaning of suction pipe Check gasket and tightness of connections Fill up pump with fluid or release air out of the system Replace rotors 14Pump cavitates Possible Problem Help ‘* Rotation speed too high: The cavities inside the pump are not filled (cavitation). ‘* Solid is blocking suction side ‘+ Decrease rotation speed and/or increase suction - pressure + Remove solid Qil leakage at the top of the intermediate chamber Possible Problem Help ‘* O-rings of the mechanical seal are damaged ‘Mechanical seal defect ‘* Replace the o-rings of the mechanical seal (see 7.1/7.2) + Change of mechanical seal (see 7.1/7.2) Technical information mechanical seal The single acting mechanical seals used in BOERGER Rotary Lobe Pumps consist of each two seal faces positioned against each other. The mechanical seals are quenched with the fluid (standard: hydraulic oil) in the intermediate chamber. With capillary and centrifugal force created by the rotation the oil is forced between the seal faces and lubricates the seal gap and removes developing heat from the mechanical seal. Pumped fluid is not needed to lubricated and/or cool the mechanical seal, If the mechanical seals had to be opened during maintenance it is recommended to exchange the mechanical seal, even if the wear limit has not been reached. File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 156.2 ») 4) Exchange of Linear Rotor Tips ‘Shut down pump unit and close valves surrounding the pump (see 5.1). Loose ring nuts (1) of the quick release cover equally app. 5 mm and move the cover slowly of the pump casing. Eventually pressure still can exist inside the pump. Clean or flush the pump casing. Caution: Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. Remove T-Plug (6) of the rotor tip (i. with screwdriver). Loose the socket head cap screw (7) of the clamp and pull the rotor tip (11) off the rotor body (12). If necessary remove the socket head cap screw and front clamp wing. The clamp base is machined with an internal 12 mm thread were you can screw in a 12 mm. puller to remove the rotor tip. Hint: ‘Screw (7) and front clamp wing (8) can be removed to make place for a puller (M12, can be delivered as a special tool) screwed to the clamp base (9). Unscrew the base of the clamp off the old rotor tip (11) and screw the clamp base to the new rotor tip. Screw the two clamp wings (8 and 10) and the clamp screw (7) slightly together with the clamp base (9) Push the rotor tip (11) on the rotor body (12) and tighten the socket head cap screw (7) (see 6.3) using following torques. ‘+ Torque: 70 Nm for standard screws + Torque: 40 Nm for stainless steel screws If applicable push on the spacer sleeve over the head of the socket head cap screw. Then drive in the new T-Plug (use a hammer). Align the T-Plug with the surfaces to avoid areas where solids or fibers could be collected. If necessary cut or grind the T-Plug. Rotate rotor to control tolerances. Control the cover O-ring and tighten the quick release cover (2) with the wear plate to the pump casing with the ring nuts (1), Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump. File: BEDI-FL-7-1-02-E-0 16 Valid from: 07/15/026.3 Exchange of Screw Rotor Tips a) Shut down pump unit and close valves surrounding the pump (see 5.1) b) Loosen ring nuts of the quick release cover equally and move the cover slowly of the pump casing. Pressure may still exist inside the pump. Clean or flush the pump casing Caution: — Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. °) Remove T-Plug (1) of the rotor tip (i.e. with screwdriver) and if applicable the spacer sleeve pushed over the head of the socket head cap screw (2). The screw rotor tips not meshed to the other rotor can now be replaced in turn. Please see illustration d) Open the clamp by using a 10 mm hexagon head socket wrench. After turning the screw (2) counter clockwise app. 5 ~ 8 revolutions please check if the back clamp wing is loose. Otherwise knock slightly to the screw head by using a suitable diving wrench. When the clamp is open the screw rotor tip can be removed. If necessary remove the socket head cap screw and front clamp wing. The clamp base is machined with an internal 12 mm. thread were you can screw in a 12 mm puller to remove the screw rotor tip. Hint: ‘Screw (2) and front clamp wing can be removed to make place for a puller (M12, can be delivered as a special tool) screwed to the clamp base. ) Preparation of the new screw rotor tip (4): Remove the clamp base from the worn screw rotor tip and fit it to the new one by regarding the tightening torque Screw Type Tightening torque Tightening torque ‘Socket head cap screw M8 | Socket head cap screw M10 Model FL 518 Model FL776 / FL(A) 1036 / FLA 1540 Socket head cap screw |25 Nm 50 Nm | ‘Standard Socket head cap screw |20 Nm 40 Nm Stainless Steel Tab. 07 Tightening torques for clamp base connection to screw rotor tip File: BEDI-FL-7-1-02-E-0 17 Valid from: 07/15/02Push the screw rotor tip (4) on the rotor body and tighten the socket head cap screw (2) Using following torques. * Torque: 50 Nm for standard screws * Torque: 40 Nm for stainless steel screws Attention: — Regard tips with clockwise and counter clockwise thread! Repeat steps 3 to 6 until all necessary screw rotor tips are replaced. 9) Check easy motion of the rotors, if necessary, correct the alignment of the tips. h) If applicable push on the spacer sleeve over the head of the socket head cap screw. Then drive in the new T-Plug (use a hammer). Align the T-Plug with the surfaces to avoid areas where solids or fibres could be collected. If necessary cut or grind the T-Plug i) Control the cover O-ring and tighten the quick release cover with the wear plate to the pump casing with the ring nuts. i) Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump. File: BEDI-FL-7-15-02-6-0 18 Valid from: 07/15/0264 Exchange of Rotors type FL a) Shut down pump unit and close valves surrounding the pump (see 5.1). b) —_Loose ring nuts (1) of the quick release cover equally app. 5 mm and move the cover (2) slowly of the pump casing. Eventually pressure still can exist inside the pump. Clean or flush the pump casing, Caution: Remaining pressure in the pump can splash fluid out of the gap be tween pump casing and cover. Cover gap with suitable rag. °) Open the socket head cap screw (3), which holds the rotor in axial position on the shaft, by using a 17 mm hexagon head socket wrench. (The shafts may be locked to each other by pushing a dull tool between the rotors!) d) Take out the cover disks (4) and refit the two socket head cap screws (3). ) _ Pull off the rotors by using the special BORGER tool (see spare parts list Pos. 90 / 91). D) Check (if necessary replace) and oil the O-rings (5) and (8). 9) _Oilthe shafts and push on the new rotors. Screw the grub screws into the threaded bores (6) at the front of the rotors. h) Unscrew the two screws (3) and refit the cover disks (4). i) ‘Screw in the socket head cap screws (3) with the sealing washer (9) and tighten them with a torque wrench. ‘+ Torque 200 Nm for standard screws ‘+ Torque 200 Nm for stainless steel screws i) Check easy motion of the rotors, if necessary, correct the alignment of the rotors. k) Control the cover O-ring and tighten the quick release cover with the wear plate to the pump casing with the ring nuts. } Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump. File: BEDI-FL-7-15-02-6-0 19 Valid from: 07/15/0265 Exchange of Screw Rotors For additional information see 6.4. Remove tip, Turn rotor to Remove the tip Turn rotor back 60° shown position and remove it Prior to removing the screw rotors pull off one of the tips which is not meshed to the other rotor (see illustration). Then tum the rotors counter clockwise 120° Now you can remove the rotors as described under 6.4. For refitting use the same procedure reverse. File: BEDI-FL-7-1-02-E-0 20 Valid from: 07/15/026.6 Exchange of MIP Radial Liners (Optional Feature) 1. Disassembly of MIP Radial Liners a) — Shut down pump unit and close valves surrounding the pump (see 5.1). b) Loosen ring nuts (3) of the quick release cover equally app. 5 mm and move the cover (4) slowly of the pump casing. Pressure may still exist inside the pump. Clean or flush the pump casing Caution: Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. c) Remove the axial wear plate (5). d) Now open the clamps (2) holding the MIP Radial Liners (6) in position by loosening the screws (1). Attention: Check the CU-Rings and replace them if necessary. e) The MIP Radial Liners (6) can now be removed. 2 Disassembly of MIP Radial Liners a) Clean the pump casing from any particles, if necessary remove one of the rotor tips (see Pos. 6.3). b) Push the MIP Radial Liners (6) into the pump casing symmetrically. c) Now fasten the MIP Radial Liners (6) by equally alternate tightening of the clamps (2). Observe an equal tolerance at both sides of the flange openings. d) Check easy motion of the rotors, if necessary, correct the alignment of the MIP Radial Liners. e) Control the cover O-ring and tighten the quick release cover with the wear plate to the pump casing with the ring nuts. f) Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump. File: BED-FL-7-15-02-E-0 24 Valid from: 07/15/02Exchange of Mechanical Seal 4 ) Drain the fluid from the intermediate chamber through the oil drain (11). b) Remove the rotors as described under 6.4 . », ES °) Remove the feather key (9) from the groove. Unscrew the holding ws ein bush with thread (2) by using the special BOERGER tool (spare Bee part list Pos. 95). d) Remove the mechanical seal rings (4) with O-rings (5) from the holding bush with thread (2) and from the stationary holding bush (8). Clean and oil the O-ring seats of the holding bushes. Flush the intermediate chamber for cleaning purpose. ) Push the O-rings (5) onto the new mechanical seal rings (4). Press one seal ring (4) into the stationary bush (8) and the other into the holding bush with thread (2). For this, operation is a also a special tool available (spare part list Pos. 95). Oy Screw the holding bush with thread (2) onto the shaft until aligned with the wear plate (7), then tum it backwards app. 1/6 revolution. The holding bush projects app. 0,3 mm to the wear plate. Ensure that one groove of the bush (2) is aligned with the groove on the shaft for the feather key (see 7.2). 9) Place the feather key (9) into the aligned grooves of the holding bush with thread (2) and of the shaft h) Check (replace if necessary) and oil the O-ring (1). Clean and oll the counter surfaces for the rotors. i) Refit the rotors (see 6.4), i) Fill fluid (see 2.2) into the intermediate chamber through the oil inlet opening (10) (minimum to the level of the top shaft). Close intermediate chamber with plastic stopper (spare part list Pos. 69) for dirt protection. File: BEDI-FL-7-1-02-E-0 22 Valid from: 07/15/027.1 Adjustment of the axial Tolerance of the Rotors 1 Remove the lobes as described under 6.4. 2 Take the feather key (9) out of the shaft groove. 3 a) The rotors are too tight to the quick release cover: & Turn the holding bush with thread (2) clockwise 1/6 revolution until the next groove is aligned with the shaft groove by using the special BOERGER, tool (spare part list Pos. 93). b) The rotors are too tight to the rear wear plate (7): Turn the holding bush with thread (2) counter clockwise 1/6 revolution until the next groove is aligned with the shaft groove by using the special BOERGER tool (spare part list Pos. 93) Do not unscrew the threaded bush (2) more than 1/6 turn! Danger of fluid leakage from the intermediate chamber! 4 Place the feather key (9) into the aligned grooves of the holding bush with thread (2) and of the shaft. 5 Refit the rotors (see 6.4 and/or 6.5) 7.3 Gland Packing Please refer to separate operation and maintenance instructions. 7.4 Special Pump Constructions Please refer to separate operation and maintenance instructions. File: BEDI-FL-7-1-02-E-0 23 Valid from: 07/15/028. Spare Parts List The Spare Parts List contains position number referring to the explosion drawing, the name of the part, material, article number (important for spare part orders) and quantity per pump. The BOERGER Rotary lobe pump is furnished with fluid wetted parts according to the code number (see 9.1). Exchange of Rotor Tips 1 to 12 rotor tips Pos. No.: 92 Exchange of Mechanical Seal 1x. mechanical seal Pos. No. 18 4x O-ring 67 x4 Pos. No. 3 2x O-ring 110x3 Pos. No, 33 Exchange of wear plates 1x. front wear plate Pos. No, 10 2x_ rear wear plate Pos. No, 1 4x O-ring 67 x 4 Pos. No, 34 4x O-ting 1176 x9 Pos. No, 30 8x countersunk screw; M8 x 20 Pos. No.: 52 Exchange of fluid wetted parts 1x pump casing Pos. No, 5 2x_ rotor body, 4 — 12 x rotor tips Pos. No, 9.4,9.2 4-12 sels of clamps Pos. No.: 9.3 1x front wear plate Pos. No, 10 2x. rear wear plate Pos. No, 4 2x_ holding bush with thread Pos. No, 13 2x_ stationary holding bush Pos. No, 14 2x_ mechanical seal Pos. No. 18 2x. cover disk Pos. No.: 24 2x. gasket Pos. No, 25 1x O-ring 1176 x 9 Pos. No, 30 4x O-ring 67 x 4 Pos. No. 34 2x O-ring 110x3 Pos. No. 33 8X countersunk screw M8 x 20 Pos. No, 52 2x_ socket head cap screw M20 x 50 Pos. No, 64 2x. sealing washer A 21 x 26 Pos. No, 74 Optional 2x_ radial casing liners (no pump casing req.) Pos. No.: 156 4x_ clamps Pos. No. 159 4x Cu-ting Pos. No, 158 As special tools use the withdrawal tool for tri-lobe rotors (Pos. No. 90), the special tool for the holding bush (Pos. No. 95) and the special tool for the mechanical seal (Pos. No. 93). File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 24Spare Parts regarding the Code Number 9.1 Code Number The code number stamped to the pump nameplate identifies all fluid wetted parts the pump is furnished with. The code number is also recorded on the cover page of this operation and maintenance manual. To decode the pump code, refer to the attached code table on the next page. 9.2 Spare Parts List The attached spare parts list is universal and contains all available combinations. Please use the pump code for identification. Please order required spare parts at (please mention the article numbers): BOERGER LLC PO Box 3949 Minneapolis, MN 55403 USA E-m america@boerger-pumps.com 612 331 - 8765 612 331 - 8769 File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02 25File: BEDI-FL-7-15-02-E-0 Valid from: 07/15/02 Material / Design [Code Number 26eal ATC Um psa 27 File: BEDI-FL-7-1-02-E-0 Valid from: 07/15/02SPARE PARTS LIST FL-Pumps 6/01 material 1 ‘gear case ‘ASTM A4® | 10008 2 gear case cover ASTM Aga | A10108 3 bearing cap open ASTMAd® | A10218 4 bearing cap closed ‘ASTM Ade | A10228 5 pump casing FL 518 astm aga | 830018 pump casing FL 776 ASTM Ads | 830118 pump casing FL 1036 ASTM Ade | 830214 pump casing FL 518, stainless steel St. Steel | 830038 Pump casing FL 776, stainless steel St. Steel | 830138 pump casing FL 1036, stainless stee! St. Steel | 830234 pump casing FL $18, MIP ‘ASTM A48 | 840470 pump casing FL 776, MIP asTM Ass | 840480 Pump casing FL 1036, MIP ‘ASTM A48 | 840490 pump casing FL 518, stainless steel, MIP St. Steel | 830241 pump casing FL 776, stainless steel, MIP St Steel | 830251 pump casing FL 1036, stainless steel, MIP St. Steel | 830261 8 pump casing cover ASTM A536 | 831008 ta linear rotor body, FL§18, 3-lobe ASTM As36 | 70404 linear rotor body, FL 776, 3-lobe ‘ASTM A836 | 70504 linear rotor body, FL 1036, 3-4obe ‘ASTM A536 | 70604 linear rotor body, FL518, 3-lobe st. Steel | c70414 linear rotor body, FL776, 3-lobe St Steet | c70514 linear rotor body, FL 1036, 34obe St Steel | 70614 9.18 screw rotor body, FL 518, cow ‘ASTM A536 | R2010L9 ‘screw rotor body, FL 818, cw ‘ASTM A836 | R2010R9 ‘screw rotor body, FL 776, cow ‘ASTM A536 | R2110L9 screw rotor body, FL 776, cw ASTM A836 | R2110R9 screw rotor body, FL 1036, cow ‘ASTM A836 | R2210L9 screw rotor body, FL1036, cw ASTM A536 | R2210R9 ‘screw rotor body, FL 518, cow St. Steel_ | R2310L9 screw rotor body, FL 518, ow St. Steel_ | R2310R9 screw rotor body, FL 776, cow St.Steel_| R2320L9 ERSA-FL-22-6-01-USA-0 28SPARE PARTS LIST FL-Pumps material 6/01 ‘crew rotor body, FL. 776, cw st steel | Ras20r0] - | 1 sorew rotor body, FL 1036, cow st Stee! | Rassau9] - | - | 1 sorew rotor body, FL 1036, ew St Stee!_| R2330R9 ~ 4 92a linear rotor tp, 3-lobe, short guna | eas] 6 | - | 12 linear rotor tip, 3-lobe, short Bunan | 72a} 6 | - | 12 linear rotor tip, 3-lobe, short epom | r7zsis| 6 | - | 12 linear rotor tp, 3-tobe, short rem | R72ata | 6 | - | 12 linear rotor tip, 2-lobe, short st steet_| R72713 | 6 12 linear rotor tip, lobe, long suna_| Rvs} - | 6 | - linear rotor tip, Hobe, long Bunan | 72523 {| - | 6 | - linear rotor tip, -lobe, long epom | R72533 | - | 6 linear rotor tip, abe, long Fem | rvs] - | 6 linear rotor tip, $-obe, long St Steel | R72573 6 [| - 9.28 screw rotor tip, FL 518, cow Buna_| rsorre| 3 | - | - sorew rotor tip, FL 518, ew Buna_| Raozore| 3 | - screw rotor tip, FL 518, cow Bunan | Raorae| 3 | - | - serew rotor tip, FL 818, ow Bunan [Raozare[ 3 | - screw rotor tip, FL 518, cow epom | raotms]| 3 | - | - sorew rotor tip, FL 518, ow epom [rsozire[ 3 | - | - sorew rotor tip, FL 518, cow Fem | Raotao| 3 | - screw rotor tip, FL 518, ow Fem | Rsozre| 3 | - | - sorew rotor tip, FL 776, cow Buna_| Rare] - | 3 screw rotor tip, FL776, ow Buna_|ratzoro| - | 3 | - sorew rotor tip, FL 776, ecw BunaN | Rattas| - | 2 screw rotor tip, FL 776, ow Bunan [rotzrof - | 3 | - sorew rotor tip, FL 776, cow epom | ratio] - | 3 serew rotor tip, FL776, ow epom [roiziro] - | 3 | - serew rotor tip, FL776, cow rem [ratiae| - | 3 screw rotor tip, FL 776, ow rpm [rsizre| - | 3 | - screw rotor tip, FL 1036, cow suna_[raztos| - | - | 3 sorew rotor tip, FL 1036, ew Buna Razaoref - | - | 3 screw rotor tip, FL 1036, cow aunan [Raatasf - [| - | 3 ERSA-FL-22-6-01-USA0 29SPARE PARTS LIST FL-Pumps 6/01 material screw rotor tip, FL 1036, ow Buna-N | Ra223R0| - - 3 screw rotor tip, FL 1036, cow epom | R2ito | - - 3 screw rotor tip, FL 1038, ew epom | Razairo| - 3 screw rotor tip, FL 1036, cow Fem | Raaiao | - - 3 screw rotor tip, FL 1036, ow Fem | Razno] - 3 93 clamp for linear rotor tip, complete astmas7o| z73014 | a6 | a6 | 812 clamp for linear rotor tip, complete, ststee! st steel | 273024 | a6 | 46 | a2 93a sorew for clamp, M 10 x 90 astmas7o| z7a2ta | aie | aie | 812 screw for clamp, M 10 x 90, stainless steel st.steel_| 273224 | 46 | 46 | a2 9.3b screw for clamp, M10 x 25 astm as7o| z73414 | a2 | ana | 16124 screw for clamp, M 10 x 25, stainless steel st.Steel_| 273424 | a2 | ant2 | 16/24 9.36 T-plug for linear rotor tip, PU R777 | aie | 46 | 416 T-plug for linear rotor tip prre | r72776 | ae | 46 | 416 9.3d spacer sleeve for near rotor tip st.steel | 73777 | - | 46 | - 9.3s| clamp for screw rotor tip, FL518, complete | ASTM AS70| zeoo09 | 6 - : clamp for screw rotor tip, FL776, complete | ASTMAS70| Zatooa | - 6 ‘clamp for screw rotor tip, FL 1036, complete _| ASTM A570| ze2009 |_- : 6 clamp for screw rotor tip, FL 518, complete st.Steel_[ zaotoa | 6 - - clamp for screw rotor tip, FL 776, complete st steel | zei109 | - 6 - ‘clamp for screw rotor tip, FL 1036, complete st. Steel | za2i0a | - - 6 9.3t screw for clamp, FL 518, M 10 x 70 10.9 z90009 | 6 - - screw for clamp, FL 776, M 10x 110 10.9 za1o09 | - 6 screw for clamp, FL 1036, M 10 x 130 10.9 z92009 | - - 6 screw for clamp, FL 518, M10 x 70 St Steel | zaoo19 | 6 - - screw for clamp, FL 776, M 10 x 110 st.steel | zoio1a | - 6 screw for clamp, FL 1036, M 10 x 130 st.Steel | z92019 | - - 6 9.3u screw for clamp, FL 518, M 8 x 20 10.9 z90s09 | 12, screw for clamp, FL 776 / FL 1036; M10x20 10.9 zoisoo | - | 12 | 12 screw for clamp, FL 518, M8 x 20 st.stee! | zoosia | 12 | - screw for clamp, FL 776 / FL 1036; M10x20 ststeel | zoisia | - | 12 | 12 93v T-plug for screw rotor tip, FL 518 PU zassso | 6 | 6 6 T-plug for screw rotor tip, FL 518 ptre | zssa99 | 6 | 6 6 ERSA-FL-22-6-01-USA-0 30SPARE PARTS LIST FL-Pumps 6/01 material 9.30) spacer sleeve for screw rotor tip, FL 518 st Stee! | zaosoo | 6 - spacer sleeve for screw rotor tip, FL 776 st Steel | ze1509 | - 6 - spacer sleeve for screw rotor tip, FL 1036 St. Steel | za2509 | - = 6 oa complete rubber rotor 2-lobe BunaN | Ra2ioo | 2 : 10 cover protection plate, hardened steel xar 500 | B3t018 | 1 1 1 cover protection plate, stainless steel st. Steel | e3toze | 1 1 1 1" axial casing protection plate, hardened ste! aisi4i4o | B3t0s8 | 2 | 2 2 axial casing protection plate, stainless steel st.steel | eatoas | 2 | 2 2 12.4 radial casing liners, FL 518 xar400 | B41t80 | 2 - radial casing liners, FL 776 xar4o0 | Batt90 | - 2 ~ radial casing liners, FL 1036 xaR400 | B41200 | - - 2 radial casing liners, FL 518, stainless stee! st steel | Bat2t0 | 2 radial casing liners, FL 776, stainless steel st Steel | 841220 | - 2 radial casing liners, FL 1036, stainless stee! st Steel | 841230 | - - 2 122 clamping part FL 518 astmas7o| Baiza0 | 4 | 4 4 ‘clamping part FL 776 astmas7o| 841250 | 4 | 4 4 clamping part FL 1036 astmas7o| Baiz60 | 4 | 4 4 123 socket head cap srew; M10 x 50 pinoi2 | zs1299 | 4 | @ 8 124 sealing washer, A10x16 cu zsi29 | 4 | 8 8 13 stationary holding bush for pos. 11; d= 131 aisito4s | vaszig | 2 | 2 2 stationary holding bush for pos. 11; d= 131 st. steel | p3s224] 2 | 2 2 stationary holding bush without pos.11;d=167 | aisi1045 | pastos | 2 | 2 2 14 holding bush with thread, stee! aisitoas | vasi1a | 2 | 2 2 holding bush with thread, stainless ste! st.steel | pastza | 2 | 2 2 15 ‘mechanical seal, cast iron; O-ring, Buna-N castiron | 035008 | 2 | 2 2 mechanical seal, cast iron; O-ring, EPDM castiron | D3so14 | 2 | 2 2 ‘mechanical seal, cast iron; O-ring, FPM castiron | 035024 | 2 | 2 2 mechanical seal, cast iron; O-ring, PTFE castiron | 035067 | 2 | 2 2 mechanical seal, Sic/Sic, O-ring, Buna-N SicfBuna-N | D3s018 | 2 | 2 2 ‘mechanical seal, Sic/Sic, O-ring, EPDM sicepom | p3sosa | 2 | 2 2 ‘mechanical seal, Sic/Sic, O-ring, FPM SiciFPM | 035134 2 2 mechanical seal, Sic/Sic, O-ring, PTFE siciptFE | p3so77 | 2 | 2 2 ERSA-FL-22-6-01-USA-0 34SPARE PARTS LIST FL-Pumps 6101 material O-ring; 72,6 x 6,5 BunaN | 036237 | 4 | 4 4 O-ring; 72,5 x 6,5 epom | vasza7 | 4 | 4 4 O-ring; 72,5x 6,5 FPM pass7 | 4 | 4 4 O-ring; 72,5x 6,5 prre | oasze7 | 4 | 4 4 16 driving shaft, FL 518 aisi4i40 | ws0st4 | 12 | - - driving shaft, FL776 aisi4140 | wsoata | - v2 | - driving shaft, FL 1036 aisi4140 | wsoa24 | - ~ | 12 7 short shaft, FL 518 aisiai4o | wsosta | 10 | - - short shaft, FL 776 aisi4i4o | wso014 | - | 10 | - short shaft, FL 1036 aisi4140 | ws0024 | - - | 10 18 shaft with SAE-profile, FL 518 aisi4i4o | wasota | 2 - shaft with SAE-profile, FL 776 aisi4i4o | wso1ta | - 2 - shaft with SAE-profile, FL 1036 aisi4140 | wso124 | - - 2 [shaft with SAE-specialprofile: FL 1036, 1 3/4",20 sec.| alsi4140 | wso131 | - - 2 19 gear wheel with groove, linear gear design aisi4i4o | erz104 | 2 | 2 2 24 cover disc, steel St 50 astmas7o| c7osos | 2 | 2 2 cover disc, stainless steel st.stee! | c7osta | 2 | 2 2 25 gasket, FL 518 Bunan | Feto1s | 2 - - gasket, FL 518 epom | Fe1o4 | 2 - - gasket, FL 518 FPM Fatoaa | 2 gasket, FL 518 prre | Fetosa | 2 gasket, FL 776 BunaN | Fetozs | - 2 - gasket, FL 776 epom | Fettas | - 2 - gasket, FL 776 FPM Feii44 | 2 gasket, FL 776 prre | rettsa | - 2 - gasket, FL 1036 BunaN | Faiz | - - 2 gasket, FL 1036 epom | Feiza4 | - - 2 gasket, FL 1036 FPM Feizaa | - = 2 gasket, FL 1036 prre | retzsa | - - 2 30 Ovring; 1176 x 9 Buna-N | 035408 | 1 1 1 O-ring; 1176 x 9 epom | 035424 | 1 1 1 ‘O-ring; 1176 x 9 FPM o3sai8 | 1 1 1 ERSA-FL-22-6-01-USA-0 32SPARE PARTS LIST FL-Pumps 6/01 material O-ring; 1176 x 9 pre | 036428 | 1 1 1 31 (O-ring, 67 x 4 BunaN | 036808 | 4 | 4 4 (O-ring, 67 x 4 epom | ossaza | 4 | 4 4 ‘O-ring, 67 x4 FPM ossaia | 4 | 4 4 Oring, 67 x4 prre | o3ses7 | 4 | 4 4 33 O-ring, 110 x3 BunaN | 036708 | 2 | 2 2 Oring, 110x3 epom | o3572 | 2 | 2 2 O-ring, 110 x3) FPM oss7ig | 2 | 2 2 O-ring, 110 x3 prre | oas7a7 | 2 | 2 2 36 oll seal, 55x88x10 AS Bunan | steia7 | 12 | 12 | 12 37 double-lip oil seal, 80x100x12 DUO Bunan | stesos | 2 | 2 2 double-lp oil seal, 80x100x12 DUO FPM siesta | 2 | 2 2 40 cylindrical roller bearing pinsat2 | stato | 2 | 2 2 44 self-align roller bearing ones | st4o0s | 2 | 2 2 42 hardened sleeve, 70x80x25 pin s405 | stez0s | 2 | 2 2 43 hardened sleeve, 50X55X20 pinsa0s | steoos | 12 | 12 | 12 44 ‘supporting ring, 60x75x3 pingss | steots | 2 | 2 2 46 feather key, B18x11x60 pin esas | siz304 | 2 | 2 2 50 cover nut, M 20 pinsez | zs1208 | 4 | 4 4 52 ‘countersunk screw; M8x20; stainless steel pin 7901 | zaaz0s | 8 | 8 8 53 screw stud, M 20x55, ong39 | zattos | 4 | 4 4 55.4 dowel pin, 16x32 pin 7978 | zs3308 | 2 | 2 2 55.2 dowel pin, 16x60 pin 797s | z37208 | 2 | 2 2 56 hexagon head screw; M 12x30 oiness | z37308 | 24 | 28 | 32 87 hexagon head screw; M 12x30 oiness | za7308 | 4 | 4 4 57 hexagon head screw; M 12x35 pines | zs7e08 | 8 | 8 8 58 socket head cap screw, M 10x20 pine12 | za7zos | 12 | 12 | 12 59 ‘socket head cap screw, M 12x55 pine12 | za7aos | 12 | 12 | 12 60 liting eye bolt, M20 pin seo | zs7908 | 1 1 1 62 feather key, 14x9x100 pinesss | zasios | 172 | 12 | 12 63 feather key, 14x9x93 pin esas | zaei14 | 2 - feather key, 14x9x100/56 pin esas | z3e124 | - 2 : ERSA-FL-22-6-01-USA-0 33SPARE PARTS LIST FL-Pumps 6101 Pos. name material | article quantity FL 518] FL 776 feather key, 14x9x100/118 pin esas | zsei34 | - : 64 socket head cap screw, M 20x50 (10.9) oinoi2 | zssiaa | 2 | 2 socket head cap screw, M 20x50 (stainless steel) | DING12 | zaeisa | 2 | 2 65 oll gauge, brass, R1" brass | ztesos | 1 1 66 oil drain screw, inspection chamber; R 1/ oingos | zto308 | 2 | 2 o7 air vent screw, R1/2" brass | ziotos | 1 1 69 stopper B182 PE zio4os | 1 1 70 sealing washer, A 33 x 39 cu 22208 | 2 | 2 74 sealing washer, A 21 x 26 cu K22588 | 3 | 3 7 circlip J 150 pina72 | K22808 | 2 | 2 78 gear case locking screw, R oing10 | ziacos | 1 1 80 sealing compound (tube 50 ml) u22308 | 1 1 sealing compound (tube 250 ml) u22208 | 1 1 20 withdrawal tool for rotor body ‘astmas7o| uzzeos | 1 1 93, special tool for mechanical seal astm as7o| uzzes4 | 1 1 95 Special tool for holding bush ASTM As70| uz2e64 | 1 1 ERSA-FL-22-6-01-USA-0@ GEI-M1023 Motors Motor Installation And Maintenance Instructions SKSxxxA TExxxx Horizontal AC Motors SKSxxxDTExxxx Horizontal AC Motors SKSxxxJTExxxx Horizontal AC Motors SKExxxATExxx Horizontal AC Motors 143-449 Frame Sizes NEMA Epact & Energy Saver Premium Open Drip Proof SKEXxxBTExxxx Horizontal AC Motors SKEXxxKTExxxx Horizontal AC Motors SKSxxxSTExxxx Horizontal AC Motors 143-326 Frame Sizes NEMA Energy Efficient Totally Enclosed Fan Cooled Standard and Severe Duty (Including Epact & Energy Saver)GEI-M1023 Safety Precautions a High voltage and rotating parts of electrical machinery can cause Warning | sorious or fatal Injury. Only ‘qualified personne! should perform motor installation, oporation, and_maintenance. Famniliarization with NEMA MG2 Safety Standard for Construction and Guide for Selection, Installation, and Use of Fractional and Integral Motors, the National Electrical Code and sound local practices Is recommended. For equipment covered by this Instruction book, it is Important to observe safety precautions to protect personnel from possible injury. Personnel should be instructed to: © Avoid contact with energized circuits. Dis- ‘connect all power sources before attempting ‘maintenance or repair. ‘© Avoid contact with rotating parts and be ‘sure that the shaft key Is fully captive before the motor is energized. ‘* Avoid bypassing or rendering inoperative any safeguards or protective devices. + Avoid use of automatic-reset thermal protection where unexpected starting of ‘equipment might be hazardous to personnel. * Avoid contact with capacitors until sate discharge procedures have been followed. + Act with care and in accordance with pre- scribed procedures in handling, fitting, installing, operating and maintaining equip- ‘ment. © The eyebolt provided with this motor is Intended for lifting only the motor. The ‘motor eyebolt must not be used to lift the ‘motor plus additional equipment. Failure to observe this precaution could result in personal injury. If the provided eyebolt is used to lift the motor, it must be securoly tightened and the direction of the lift must not exceed a 15° angle with the shank of the eyebolt. Improper eyebolt installation or substitution may result in serious injury to personnel or damage of property. Precautions should also be taken to minimize potentially hazardous overloads due to sudden acceleration, deceleration or impact forces Safe maintenance practices and qualified personnel are imperative. Before initiating maintenance procedures, be sure that: © Equipment connected to the shaft will not cause mechanical rotation. © Main machine windings and all accessory devices associated with the work area are disconnected from electrical power sources. If high potential insulation test is required, procedures and procautions outlined In NEMA Standard MG-1 and MG-2 should be followed. Failure to proporly ground motor may causo serious injury to personnel. Grounding should bo in accordance with the National Electrical Code and consistent with sound local practice. ‘These instructions do not purport io cover all of the details or variations in equipment nor to provide for every possible ‘contingency 10 be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes. the maiter should be referred to the General Electric Company. ‘© Copyright 2007 General Electric CompanyGEL-M1023 Table of Contents i i Power Supply and Connections 1, Wiring and Grounding. ..0nnnn 2. Allowable Voltage and Frequency 2 Vacuums and Compressed Air Cleaning wo. 4. Cleaning with Water and Detergent. 4. Cleaning with Solveas... s. : ©. viaton and Bearings BRESCSINI SSS coc meee MIVA NANAHUUN DD ADDNGEL-M1023 143-449 Frame Horizontal AC Motors; Open Drip Proof and Totally Enclosed Fan Cooled |. RECEIVING, STORAGE, HANDLING AND UNPACKING A. Receiving Each shipment should be carefully inspected upon arrival. Any damage should be reported promptly to the carrier and a claim filed. The nearest GE sales office can provide additional guidance, B. Storage If the machine will not be put into service immediately, certain precautions should be taken to protect the machine while in storage. It_is recommended that the machine be placed under cover in a clean, dry location. During storage, windings should be protected fiom excessive moisture by some safe and reliable method of heating, such as space heaters, to keep the temperature of the windings a few degrees above the temperature of the surrounding air. It is recommended that the machine be inspected at periodic intervals, the windings meggered, and a log kept of pertinent data, (Refer to Operation section.) Any significant drop in insulation resistance should be investigated, Precautions are taken by the factory to guard against corrosion. ‘The machined parts are coated to prevent rust during shipment. If the equipment is to be stored, examine the parts carefully for rust and moisture and re-coat where necessary. Grease-lubriceted machines have the bearings greased at the factory with the cavity approximately 50% full. Rotate the shaft of all two-bearing machines 10- 20 revolutions at two-month intervals. C. Lifting Lifting lugs or eyebolts on the motor ara designed for handling the motor Waring _| only. They are not to be used to lift the motor plus additional equipment such as pumps, compressors, or other driven ‘equipment. In the case of assemblies on a common base, lugs or eyabolts provided on the motor are not to be used to lift the assembly and base. The assembly should bo lifted by 2 sling around the base or by other lifting means Provided on the base. in the case of unbalanced Joads (such as couplings or other attachments), ‘additional slings, or other effective means should be used to prevent tipping. Failure to ‘observe these precautions may result damage to the equipment, injury to personn Lor both. Before lifting the motor, ensure the eyebolt shoulder is completely seated against the motor frame boss. Eyebolt should only be tightened by hand. The angle of lift must not exceed a 15 degree angle with respect to the shank of the eyebolt, D. Unpacking If the machine or machine parts have been exposed to low temperatures, unpack it only after it has reached the temperature of the room in which it will be unpacked or located; otherwise condensation will occur.GEIM1023 I. INSTALLATION a Coupling, belt and chain guards should be instellod as needed to Wemies _| protect against accidental contact with moving parts. Machines accessible to personnel should be further guarded by sereening, guard rails, etc., to prevent them from coming in contact with the equipment. Fallure to observe these precautions may result | in injury to personnel. A. Location 1. Open drip proof motors are used in Weather-protected locations where moisture is limited to dripping water at less than 15° from the vertical 2. Standard enclosed motors are used where they are exposed to dirt, moisture, and most outdoor conditions. 3. Severe-duty enclosed motors are used in highly corrosive or excessively moist areas. B. Mounting Mount motors securely on a firm, flat base. If necessary, grout in larger motors. Motors can be mounted per the chart shown below. For vertical mounting, check with the GE representative for recommendations. The standard transition and/or sliding bases are suitable for floor mounting. For other locations, check with the GE representative for recommendations. (Note: ODP (IP22) motors become Open Guarded (IP20) motors when wall. or ceiling mounted) Remove drain plugs from the frame or end shields of enciosed motors used outdoors or in other high EX moisture areas. C. Alignment 1. Direct Coupling Align motors accurately. For direct drive, use flexible couplings if possible. For drive recommendations, consult drive or equipment manufacturers or GE. Accurate mechanical alignment is essential for successful operation. For base assembly and motor mounting, the bolts must be carefully tightened to prevent changes in alignment and possible damage to the equipment. It is recommended that a washer be used under each nut or bolt head to get a secure hold on the motor fect; or as an alternative, flanged nuts or bolts may be used. Use bolts that are a minimum Grade 5 or ISO 8.8. (Refer to Table 2). The recommended tightening torques for SAE (Grade 5) bolts, ar ISO 8.8 bolts can be found in Table 3. Table 2: Bolt Grade Designations 1so8.8 ‘Table 3: Mounting Bolt Torques ‘Recommended Torque Bolt Size in FLb (N-M) Inch (Metris) [Mi Maia aM | 7 | Cs 516 (8) | 14 19) | 218) 3 io) | 25 Gay | 37 (50) % tz | 6 (i) | 9 22) se (ais) | 120 (163) | 180 (244) 3/420) _| 210 (285) | 320 (433) Note: For hardware that is less then SAE Grade 5, use 50% of the above recommended tightening torques. There are no ID marks on bolts that are less than SAE Grade 5.GEL-M1023 2. End-Play Adjustment The axial position of the motor frame with respect to the load is important. The bearings furnished with these motors are not designed to take any extemal axial thrust load unless specifically requested by the purchaser. 3. Belt Drive The applications of pulleys, sheaves, sprockets and gears on motor shafts are shown in NEMA MG1-14.07. For more information on allowable sheave sizes refer to the AC Motor Selection and Application Guide, GET-6812. Align the sheaves carefully to avoid axial thrust on the bearings. Belt tension should just prevent slippage when the motor is running at full load. Excessive belt tension causes unnecessary load on the bearings. This may be especially true on high-inertia loads where belts may be tightened to prevent squealing and slipping during acceleration, On drives of this type, the belts should be allowed to slip during acceleration to prevent the possibility of overloading the motor bearings. Please refer to Table 4 for v-belt sheave diameter information. The belt spoods should not exceed 6,000 feet per minute unless D. Power Supply and Connections 1. Wiring and Grounding Where unexpected starting would | be dengerous to personnel, do not | Electrical Code and consistent with sound | fecal practices. Failure to observe these precautions may result in damage to the | equipment, injury to personnel, or both. Stator winding connections should be made as shown on the connection diagram or in accordance with the wiring diagram attached to the inside of the conduit box cover. ‘The motor frame may be grounded by attaching a ground strap from a known ground point to the bronze-grounding bolt in the conduit box or on motor frame. 2. Allowable Voltage and Frequency The power supply must agree with the nameplate voltage and frequency. The motors will operate (but with characteristics somewhat different from nameplate values) on line voltages within +10% of nameplate value and frequency within 15%, and a combined variation not to exceed +10%. Motors identified as “useable at 200V” will not operate full loads on line voltages below 190V. Motors will not meet NEMA MG-1 performance standards (including efficiency) when operated at 200V. 3. Position of the Conduit Box When mounting conditions permit, the conduit box may be rotated so that entrance can be made upward, downward, or from either side.GEL-M1023 Ml, OPERATION A. Prior to Starting Wf the motor has been stored in a a damp location, dry it out thoroughly warming _| before operating. Before energizing ‘the motor for the first time or after an extended shut down, it is advisable to check Insulation resistance, power supply and mechanical \sulation Resistance Before measuring insulation resistance, the machine must be at standstill and all windings to be tested must slectrically connected to the frame and to ground for 2 time sufficient to remove all residual electrostatic charge. Failure fo obsorve those procautions may result in injury to personnel, damage to the equipment or both, | In accordance with established standards, the ‘Then the air temperature may be raised to 150°C- 15°C, +5°C. Continue to heat until the insulation resistance is constant for a one-half hour period. 2. Enclose the motor with canvas or similar covering, leaving a hole at the top for ‘moisture to escape. Insert heating units or lamps and leave them on until the insulation resistance is constant for a one-half hour period. 3. With the rotor locked mechanically, and using approximately 10% of rated voltage, pass a current through the stator windings. Increase the current gradually until the winding temperature reaches 90°C, Do not exceed this temperature. Maintain a temperature of 90°C unti] the insulation resistance becomes constant for a one-half hour period C. Steps Prior to Initial Start | Be sure that ‘motor is not running and the powor supply is | recommended minimum insulation resistance for | _Wemies | disconnected. the stator winding when measured with a 500 volt DC direct indicating ohmmeter with self contained power supply (megger), is 2s follows: Roo Where R, is the recommended minimum insulation resistance in megohms at 40°C of the entire stator winding obtained by applying direct potential to the entire winding for one minute. sMQ NOTE: See IFFE Recommended Practice for Testing Insulation Resistance of Rotating Machines, Publication No. 43, for more complete information. If the insulation resistance is lower than this value, it is advisable to eliminate the moisture in one of the following ways: 1, Dry the part in an air circulating oven with the air surrounding the part at 110°- 15°C, +5°C until the part has been above 90°C or at least four hours. 1, Do not flush out anti-friction bearings. The bearing grease supplied is sufficient for initial operation. 2, Whenever possible, examine the machine for loose objects or debris which may have accumulated and remove any foreign material. 3. Ifpossible, tum the rotor by hand to be sure that it rotates freely. 4, Check all connections with the connection diagram. Check all accessible factory made connections for tightness to make sure none has become loose during shipment. 5. When the driven machine is likely to be damaged by the wrong direction of rotation, it is best to uncouple the drive from its load during the initial start and make certain that it rotates in the cortect direction. If it is necessary to change rotation, interchange any two line/supply leads.GEI-M1023, D. Initial Start 1. After inspecting the machine carefully, make the initial start by following the regular sequence of starting operations in the control instructions. 2. At initial start, the rate of rise of the bearing temperature is more indicative of trouble than of total temperature. When starting a machine for the first time, the bearing temperature should be observed for a minimum of two hours. If at any time the rate of temperature rise exceeds 2°C/minute, shut down the machine immediately and make an investigation of the lincup conditions. 3. Check motor operation under load for an initial period of at least one hour to observe whether any unusual noise or hot spots develop. 4, In the event of excessive vibration or unusual noise, disconnect the machine from the load and check the mounting and alignment, 5. Space heaters (when supplied) should be de-energized during motor operation. 6. Check the operating current against the nameplate value. Do not exceed the value of nameplate amperes times service factor (if any) under steady continuous load. NOTE: 208 Volt system: When a 230/460 Volt motor with nameplate which states “usable at 200V, Hp, Amps, |.0SF” is operated on @ 208 Volt system, the motor slip will increase approximately 30% and the motor locked-rotor, pull-up and breakdown torque values will be reduced by approximately 20 to 30%. Therefore, it should be determined by the user that the motor will start and accelerate the connected load without injurious heating and that the breakdown torque is adequate for the application. E. Jogging and Repeat Starts Reposted starla andlor Joge af a inductlon motors greatly reduce the cazten _| life of the winding insulation. Theat produced by each acceleration or jog much more than dissipated by the motor under full load. if it Is necessary to repeatedly start or Jog a motor, it is advisable to check the sation with the local GE sales office. F. Heating Use a thermometer or thermocouple to determine temperature. If there is any doubt about the safe operating temperature, take the temperature of the part in question and confer with the nearest GE sales office. Give full details, including all nameplate information. Overheating of the machine may be caused by improper ventilation, excessive ambient temperature, dirty conditions, excessive current due to overload or unbalanced a-c voltage. IV, MAINTENANCE a ‘Before tnftating maintenance procedures, disconnect all power Waring _| sources to the machine and any accessories. For machines equipped with surge capacitors do not handle capacitor until discharged by a conductor simultaneously touching all terminals and leads, including ground. This discharge conductor should be insulated for handling. Replace all normal grounding connections prior to operating. Failure to observe these precautions may result Jn injury to personnel. A. General Cleanliness Inspect the motor at regular intervals, depending on service. Keep the motor cleaned and the ventilation openings clear. In addition to the daily observation of the overall condition, it is recommended that a general inspection routine be set up to periodically check the following items:‘+ General Cleanliness * Insulation and Windings ‘© Lubrication and Bearings The interior and exterior of the machine should be kept free from dirt, oil, grease and conducting dust. Oily vapor, paper, or textile dusts may build up and block off ventilation. Any of these contaminants can lead to early motor failure. B. Insulation and Windings 1. General To obtain long life and satisfactory operation of insulated windings, they should be kept clean from dirt, oil, metal particles, and other contaminants. A variety of satisfactory and acceptable methods are available for keeping equipment clean. The choice of method will depend greatly on time, availability of equipment, and on the insulation system, However, vacuum and/or compressed air cleaning with nonmetallic hose tips should precede cleaning with water and detergent or solvents. Tight adhering dirt will require agitation by gentle brushing or wiping. a fective To prevent injury to eyes and respiratory organs, safety glasses and sultable ventilation or other julpment should be used. nd Compressed air should be used to remove loose dirt and dust from air passages such as air ducts. Suction should be used to remove dirt and dust particles from windings to avoid driving particles into the windings and damaging the f Care must be taken to make sure that 6 Ser Se Caution excessive air pressure is not used. Generally 2 pressure of not more than 30 psi is recommended. a Operator must not use compressed | air to remove dirt or dust from his warming | person or clothing. GEI-M1023 3. Cleaning with Water and Detergent This method is very effective in cleaning windings when used with a low-pressure steam Jenny (maximum steam flow 30 psi and 90°C) To minimize possible damage to varnish and insulation, a fairly auton _| neutral non-conducting type of & ‘be taken to ‘detergent, such as Dubious Flow, should be used. A pint of detergent to 20 gallons of water is recommended. If a steam jenny is not available, the cleaning solution may be applied with warm water by a spray gun. After the cleaning operation, the windings should be rinsed with water or low- pressure steam. It is advisable to dry the windings. Refer to Insulation Resistance section for instructions on how to proceed. 4. Cleaning with Solvents ‘Many cleaning fluids are flammable and/or toxic. To prevent injury to personnel and property, care should avoid flames, sparks, ote. Safety glasses should be used and contact with the skin should be avoided. The area should be ‘well ventilated or protective equipment should be used. J Although cleaning with water and detergent is the preferred method, solvent cleaning may be used when heat drying facilities are not available. Mineral spirits are recommended for use as the cleaning solvent. Solvent cleaning of silicone- insulated windings, leads, and space heaters is not recommended. | Mineral spirits should be used only In a well-ventilated area that is free wana _| from open flames. Avoid prolonged ‘exposure to vapor. Failure to observe these tions may result in onnel. Windings cleaned with solvent should be dried thoroughly by circulation of dry air before voltage is applied.5. Revamishing Windings After several cleanings with water and detergent, it may be necessary to revamish the windings. This varnish is available from the General Electric Company or a GE Authorized Service Shop. C. Lubrication and Bearings 1. Anti-Friction Bearing Relubrication and Maintenance ‘The grease used as a lubricent in grease- lubricated anti-friction ball bearings loses. its lubricating ability over a period of time. For a given bearing construction and assembly, the lubricating ability of a grease with age depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates, and the severity of operating conditions. As a result, it is mot possible to accurately predetermine when new grease must be added. Good results can be obtained if the gencral recommendations are followed as stated in this instruction book. GEI-M1023 ‘The primary function of grease is to supply the essential lubricating oil from the sponge-like reservoir of its soap structure, Grease-lubricated anti-friction ball bearings consume only a small amount of lubricant. This lubricant must always be present to avoid rapid wear and bearing failure. However, excessive or too frequent lubrication may damage the motor. Ball bearing motors are adequately lubricated at the factory. Motors with grease fittings should be Relubricated in accordance with these instructions to provide maximum bearing life. To obtain optimum results, Chevron SRI-2 (General Electric Specification D6A2C23) or compatible grease should be used for relubrication, unless special grease is specified on the motor nameplate. Regreasing frequency should be in accordance with the Table 5. If in doubt, refer to GE. The procedure below must be followed for safe and effective regreasing. (Note: Motors with frame sizes from 143 to 286 contain shielded bearings and cannot be regreased). Table 5: Recommended Frequency of Regreasing Lubjication Interval (Years) Type of Service _Typical Examples HP Range Horizontal Mount Easy Valves, door openers, portable floor | 50-100 4 sanders, motor operating infrequently | 200-350 3 (one hour per day) ‘Standara ‘Machine tools, air conditioning | __50— 100 TS apparatus, conveyors (one or two| 200-350 1 shifts), "garage compressors, reltigeration machinery, oil wall pumps, water pumps, wood working machinery Severs Noior for fans, machine tools, M-G| 50-700 Tmo8, sets, etc. (that run 24 hours a day, 365 | 200-350 6 mos. days a yer), coal and mining machinery. motors subject to severe vibration, steel mill machinery. Vary Severe | Dirty, vibraling applications, whore end | 60-100 Tos. of shaft is hot (pumps and fans), high | 200-350 3 mos. ambient temperature 10GEL-M1023 2. Recommended Frequency of Regreasing Recommended Regreasing Procedure: ‘Relubrication should be performed with the motor stationary and disconnected from the power ‘Source. Extreme caution must be exercised to avoid contact with rotating parts or electrical wiring if the motor must be relubricated while running. Failure to observe these precautions may result in damage to the equipment, injury to. | porsonnel, or both. a, Rum the motor until warm, ». Stop the motor and disconnect it from the power supply. ¢. Clean dirt and debris from around the inlet lubrication fitting and the grease relief plug. 4. Clear the opening and relief tube of hardened grease. This may be accomplished with a twisted wire brush or sturdy pipe cleaner. NOTE: a standard 10,000-psi, 16-ounce grease gun delivers approximately 0.04 02. of grease with each pump, and a 24-ounce gun delivers approximately 0.06 oz. of grease. ¢. While the motor is still warm, add grease with a hand-operated grease gun until grease has been added to about 50-65% of the grease cavity volume listed in Table 6 £ Restart the motor, and resume operation. Since this method of greasing anti-friction bearings tends to purge the housing of used grease over a period of time, removal of all ‘grease should be required infrequently. A GE authorized Service Shop can clean the bearing cavity and replace the bearings and grease when the motor is removed from service for ‘maintenance or reconditioning. a Warranty may be voided if internal maintenance or repairs are not warning _| performed by @ GE authorized ‘service shop. D. Anti-Friction Bearing Maintenance 1. Removal Even though high-quality design and workmanship are incorporated in a bearing, it sometimes becomes necessary to remove the bearing for maintenance. jure t observe the foregoing| It is for this reason that the following instructions instructions for regreasing may result | are included. in grease leakage andor bearing To avoid demage to equipment, Table 6: Bearing Regreasing Data for ODP Drive End Bearing Poles Regreasing Bearing Size | Cavity Size (07, 2 | on 28 4 28 2 psa 2 < z 4 | esiaNUsTe sors_|_2 [2 soot 14 | 6312Care must be taken to avoid |e See SS 8 i eS a Extreme care is required in the | | disassembly of a machine for bearing caution | removal. in addition, the surfaces of | the shaft bearing fit and the bearing itself must | be protected during and after disassembly operations. For TEFC motors, anti-friction bearings may be removed from the motors by the following procedures. For ODP motors, start bearing removal with step d 2, Remove bolis securing fan cover. ’. Remove the snap ring that secures the fan to the shaft extension. cc. Remove the fan from the shaft extension by employing a gear pulley. d. If the motor has bearing caps, remove the hex head bearing cap screws, adjacent to the ‘motor hub, which hold the outer bearing caps at both ends. e. Remove the hex head bolts on the outer flange of the end shields, which hold the end shields on the frame. Then remove the end shields. £. Carefully draw out the rotor, being careful not to damage any of the intemal windings or machined surfaces. GEIM1023 Ifit is desirable to reuse the bearing, apply Bearing puller to the inner rings only. Reuse of bearings Is not & recommended due to risk of bearing cwéen | damage or contamination during handling. | 2, Reassemb! To prevent injury to eyes, safety waning | 9lass0s should bo used. J Cleanliness is important when working with bearings. Before reassembling a bearing, all bearing and machined surfaces should be thoroughly cleaned with suitable solvent, Examine the machined fits of the end-shield, cartridge, slinger, and grease cap for burrs. It is important that these surfaces be smooth. Reassembly of the bearing should be performed in the following manner: 2, Inspect the bearing housing and related parts for foreign material. Clean if necessary. b. The machined fits and critical surfaces of the end-shield, bearing housing, bearing cep and bearings should be firee of all nicks, scratches or | “Table 7: Bearing Cap Bolt Torque Requirements for ODP & TEFC | : =, [_Retommended Torque in FL (NM) Frame Size | Bolt Size ‘Minimum Torque Maximum Torque TaTasT AS2T/184T Not ‘Not ‘Not 213T/215T | Applicable Applicable Applicable 2ST RIOT 320T Me 14 (19) 18.7 (25) 360T ‘MIO 28 (38) 375 (50.7) 400/440T M10. 28 (38) 37.5 (50.7) Table 8: End Shield Bolt Torque Requirements ‘Bort | Recomm Torqusia FELD GNM) | 5 | Recommended Torque in FtL> Frame Size | El for ODP Enclosure Size | OM) for TERC Enclosure Min Toroue | Max, Torque Tin. Torque Max. Torgue aaTi4sT_ | MS 227 34.1) ms_| 37017 | 123066) 182T/184T MB 8.7117) 12.3 (16.6) MIO 14(19) 18.725) asTaisr | ms_| 72 | 76@03) | mio | 31@.7 | 76193) 2s0T/280T Mi2 49.3 (66.8) 65.8 (89.2) MI2 49.3 (66.8) 65.8 (89.2) 320T M12 49.3 (66.8) 65.8 (89.2) M12 49.3 (66.8) 65.8 (89.2) 360T [win 493668) | 658892) | NA | NA NA 400T/440T M16 126.6 (171.5) 168.8 (228.8) NIA NIA NAIf any polishing is done, care should be taken to avoid a deposit of metal dust in and around the bearing assembly c. The intemal surface of the bearing housing should be coated with a thin film of the recommended grease. The shaft and shaft fit of the grease housing and grease cap should also receive a very light coating of the recommended grease, These precautions, although not absolutely essential, will guard against corrosion of the critical surfaces. d, Heat the bearing in oil to a temperature between 50°C and 125°C (122°F to 257°) and place it on the shaft. Hold it against the shaft shoulder until the bearing cools. , Mount the drive end end-shield and outer bearing cap to the shaft. Refer to Table 7 for bolt torque requirements. (Note: Motor frame sizes 143 to 286 do not have bearing caps). £ Mount the opposite drive end end shield to the stator fame. Refer to Table 8 for recommended bolt torques. GELM1023 . Insert the rotor into the stator with appropriate tools. Carefully insert the rotor shaft ‘through the opposite drive end end shield. h, Assemble the outer bearing cap at the ‘opposite drive end. (Note: Motor frame sizes 143 to 286 do not have bearing caps). i. For TEFC motors, assemble the fan, snap- ring, grease pipes and fan cover. j- Mount the drive end end shield to the stator frame. Refer to Table 9 for motor shaft endplay. ior Endpy Range for ODP & TH meses Shaft Bala Gach) lca Minima | Mari rare tt tos [ras ca tas7 286 ass — 05 '320/360/400/440 _ | None (Locked Bearings) Y. OPERATIONAL DIFFICULTIES Some operating difficulties may occur, and their causes are given in Table 10 and should be corrected as soon as possible. Table 10: Trouble Shooting Chart Mocied Pats riieuy ‘Whatto Check wees “oraeag Taton of aang REBUT Enoaseve caren ‘Unbalancee AC eurant Inpropererrstiaea versaton Excesove embionttorperste Shor ered ol er wnings Diy wedegs ‘Untalneed veto Bernas ‘Overeating ‘Calbraton of easing nature ough ural Maignmant ‘ronstvn eran of mal 28g ‘Sha corer Excestve cineca grase ‘ern out or cy grace Unslarce Meaigrment Improper er ote funcation Nemuntorm a gop Rating pats Tor Faun Resistance er Isuaton Damages bong _ ‘Notre, oft mel paride, Gl or ther contaminants on fhe dated ‘wodlras Woeravettage Excossve erperauce Netage sues Mechel damage cessive. wraton wh resutan ‘mechanical damage 13Vi. FAILURE a ‘An extreme overload or electrical fallure may result in heating or Wamiey__| arcing which can cause the insula- Won to give off noxious fumes. All power should be removed from the motor circult as Precaution even though the cireult has overload protection. Personnel should not approach the ‘motor until adequate ventilation of the area has purged the air of fumes. When covers of a ‘motor are romoved after 2 failure, care should be observed fo avold breathing fumes from Inside the motor. Preferably, timo should be allowed for the motor or generator to coo! ‘bofore attempting any examination or repair. Failure to observe these precautions may result in injury to personnel. a ‘equipment electrically energized | waning _| because electric shock could result in serfous or fatal Injury. in caso of fire, disconnect all power and use a carbon dioxide extinguisher to quench the flame. Before operating any motor after a suspected failure, it Water should not be applied to any should be inspected fordamage. __ Vil, REPAIR Only qualified personnel using the materials ‘and processes for which the motor was designed should make repairs, To protect the warranty during the warranty period, all repairs must be made in a GE Service Shop or GE approved repair facility. Many repairs can be easily performed with only assembly operations if GE replacement parts are available. If major repairs aro undertaken (such as rewinding a stator), proper facilities should be available and suitable precautions observed. 4 GEIM1023 When burning off old insulation materials or when welding near wemira _| insulation during re-winding, ade- quate ventiiation must be provided to avoid exposing personnel to noxious fumes. ‘Combustion of exhaust must be complete and | adequately vented to the outside atmosphere in compliance with acceptable standards. | Exposure of personnel to alr-bome inorganic fibers must be avoided by adequate ventilation or by wetting the remaining Insulation components following the burning off of the ‘organic materials. Failure to observe these precautions may result in injury to personnel. VIIL RENEWAL PARTS The use of only GE renewal parts is recommended. When ordering, specify model number and serial number of motor (complete nameplate data is desirable). Specify quantity ‘and describe part. For information and service, rofer to the nearest GE Sales Office or GE Authorized Service Shop.Reader Comments jeneral Electric pany We welcome comments and suggestions lo make this publication more useful. GBI-M1023 GE Motors ‘At: Indust Engnooring ‘Technical Publeatons Edtor 1080 Sinney Ave, Bldg 26-2 Fort Wayne IN 46802-4332 Fax: 260-439-3881 (GE intemal DC: 8380-2661) "YourNane Todays Date TTnceded how can we contact you? "Your Companys Name and Adis Tob Sie Fah. GE Requlsion No. Phone No, "Your Job Funsiioa/How Vou Use This Publieation | Publication No EMail Fabieatn ines /Reviioa Dats] Adress General Rating Excellent Good Fair Poor Afltonal Comments Contents ° Qo Q Oo Organization o 6 6 6 ‘Technical Accuraey 9 ¢ 9 9 = Clay 2 ¢ 9 9 Completeness gs 8 8 8 Drawings /F we 2 ¢ 89 9 Referencing 6 6 0 6 Readability o 6 060 6 = could be expanded on, and such) Specific Suggestions (Correction, information tht. PageNo. Comments Other Comments (What you lke, whet could be added, how to improve, nd such.) Overall Grede (Compared to publications fom other manufacturers of sinilar products, how do you rte this publication”) © Superior Ocomparble Inferior © Donotimew Comment Detach and fax or mal tothe address noted above.GEI-M1023 Fold here and close with staple or tape. esate Place Stamp GE MOTORS INDUSTRIAL ENGINEERING 1635 BROADWAY FORT WAYNE IN 46802 USA 16