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AMG Series
ABB AMG Series User Manual
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Manual for
Induction Motors and Generators
ABB
2
Table of Contents
Default Chapter
10
Table of Contents
10
Chapter 1 Introduction
16
General Information
16
Important Note
16
Limitation of Liability
17
Documentation
17
Documentation of the Machine
17
Information Not Included in Documentation
18
Units Used in this User's Manual
18
Identification of the Machine
18
Serial Number of the Machine
18
Rating Plate
18
Chapter 2 Transport and Unpacking
21
Protective Measures Prior to Transport
21
General
21
Bearing Plate
21
Lifting the Machine
23
Lifting a Machine in a Seaworthy Package
23
Lifting a Machine on a Pallet
24
Lifting an Unpacked Machine
25
Turning a Vertically Mounted Machine
26
Checks Upon Arrival and Unpacking
27
Check Upon Arrival
27
Check Upon Unpacking
27
Installation Instructions for Main Terminal Box and Cooler Parts
27
Installation of Main Terminal Box
27
Installation of Cooler Parts
28
Storage
28
Short Term Storage (Less than 2 Months)
28
Long Term Storage (more than 2 Months)
29
Rolling Bearings
30
Sleeve Bearings
32
Openings
33
Inspections, Records
33
Chapter 3 Installation and Alignment
34
General
34
Foundation Design
34
Forces to the Foundation
35
Flanges for Vertically Mounted Machines
35
Machine Preparations before Installation
35
Insulation Resistance Measurements
35
Disassembly of the Transport Locking Device
36
Coupling Type
36
Assembly of the Coupling Half
36
Balancing of Coupling
36
Assembly
37
Belt Drive
37
Drain Plugs
37
Installation on Concrete Foundation
38
Scope of Delivery
38
General Preparations
38
Foundation Preparations
38
Foundation and Grouting Hole Preparations
38
Foundation Studs or Sole Plate Preparations
38
Erection of Machines
40
Alignment
40
Grouting
40
Final Installation and Inspection
40
Dowelling of the Machine Feet
40
Covers and Enclosures
41
Installation on Steel Foundation
41
Scope of Delivery
41
Check of Foundation
41
Erection of Machines
41
Alignment
41
Final Installation and Inspection
41
Doweling of the Machine Feet
41
Covers and Enclosures
42
Installation of Flange Mounted Machines on Steel Foundation
42
Alignment
42
General
42
Rough Levelling
43
Rough Adjustment
43
Correction for Thermal Expansion
45
General
45
Thermal Expansion Upwards
45
Thermal Axial Growth
46
Final Alignment
46
General
46
Run-Out of the Coupling Halves
46
Parallel, Angular and Axial Alignment
47
Alignment
48
Permissible Misalignment
49
Care after Installation
50
Chapter 4 Mechanical and Electrical Connections
51
General
51
Mechanical Connections
51
Cooling Air Connections
51
Cooling Water Connections
51
Air-To-Water Coolers
51
Water Cooled Frames
51
Sleeve Bearing Oil Supply
52
Connection of Purging Air Pipe
53
Mounting of Vibration Transducers
53
Electrical Connections
53
General Information
53
Safety
54
Insulation Resistance Measurements
54
Main Terminal Box Options
55
Delivery Without Main Terminal Box
55
Insulation Distances of Main Power Connections
55
Main Power Cables
55
Secondary Cables for Slip Ring Connections
56
Auxiliary Terminal Box
56
Connection of Auxiliaries and Instruments
57
Connection of External Blower Motor
57
Earth Connections
57
Requirements for Machines Fed by Frequency Converters
58
Main Cable
58
Earthing of Main Cable
58
Auxiliary Cables
58
Chapter 5 Commissioning and Start-Up
59
General
59
Check of Mechanical Installation
59
Insulation Resistance Measurements
59
Check of Electrical Installation
59
Control and Protection Equipment
60
General
60
Stator Winding Temperature
60
Resistance Temperature Detectors
61
Thermistors
61
Bearing Temperature Control
61
General
61
Protection Equipment
61
First Test Start
62
General
62
Precautions before First Test Start
62
Starting
63
Direction of Rotation
63
Starting of Machines with Slip Rings
63
Starting of Ex P Machines
63
Running the Machine the First Time
64
Supervision During the First Run
64
Checks During Running of the Machine
64
Bearings
64
Machines with Rolling Bearings
65
Machines with Sleeve Bearings
66
Vibrations
66
Temperature Levels
66
Heat Exchangers
67
Slip Rings
67
Shut down
67
Chapter 6 Operation
68
General
68
Normal Operating Conditions
68
Number of Starts
68
Supervision
69
Bearings
69
Vibrations
69
Temperatures
69
Heat Exchanger
70
Slip Ring Unit
70
Follow-Up
70
Shut down
70
Chapter 7 Maintenance
71
Preventive Maintenance
71
Safety Precautions
71
Maintenance Program
72
Recommended Maintenance Program
74
General Construction
75
Main Supply Connection
75
Stator and Rotor
76
Auxiliaries
76
Slip Ring Unit
77
Lubrication System and Bearings
77
Cooling System
78
Maintenance of General Constructions
79
The Tightness of Fastenings
79
Vibration and Noise
80
Vibrations
81
Measurement Procedures and Operational Conditions
81
Classification According to Support Flexibility
82
Evaluation
82
Maintenance of Bearings and Lubrication System
83
Sleeve Bearings
84
Oil Level
84
Bearing Temperature
84
Lubrication of Sleeve Bearings
84
Lubrication Oil Temperature
84
Control of the Lubricant
85
Recommended Control Values for the Lubricating Oil
85
Oil Qualities
85
Oil Change Schedule for Mineral Oils
86
Rolling Bearings
87
Bearing Construction
87
Bearing Plate
87
Re-Greasing Intervals
87
Re-Greasing
88
Bearing Grease
89
Bearing Maintenance
90
Bearing Insulation and Bearing Insulation Resistance Check
90
Procedure
90
Cleanliness of Bearing Insulation
92
Maintenance of Stator and Rotor Windings
93
Particular Safety Instructions for Winding Maintenance
93
The Timing of the Maintenance
94
The Correct Operating Temperature
94
Insulation Resistance Test
94
Conversion of Measured Insulation Resistance Values
95
General Considerations
96
Minimum Values for Insulation Resistance
96
Stator Winding Insulation Resistance Measurement
97
Rotor Winding Insulation Resistance Measurement
98
Insulation Resistance Measurement for Auxiliaries
99
The Polarization Index
99
Other Maintenance Operations
100
Maintenance of Slip Rings and Brush Gear
100
Care of Slip Rings
100
Standstill Period
100
Wear
100
Care of Brush Gear
100
Brush Pressure
101
Maintenance of Cooling Units
101
Maintenance Instructions for Machines with Open Air Cooling
101
Cleaning of Filters
102
Maintenance Instructions for Air-To-Water Heat Exchangers
102
Maintenance Instructions for Air-To-Air Heat Exchangers
102
Air Circulation
102
Cleaning
103
Maintenance of External Blower Motors
103
Repairs, Disassembly and Assembly
104
Chapter 8 - Trouble Shooting
105
Trouble Shooting
105
Mechanical Performance
106
Lubrication System and Bearings
107
Lubrication System and Rolling Bearings
107
Lubrication System and Sleeve Bearings
108
Thermal Performance
110
Thermal Performance, Open Air Cooling System
110
Thermal Performance, Air-To-Air Cooling System
111
Thermal Performance, Air-To-Water Cooling System
112
Thermal Performance, Rib Cooled
113
Oil Leakage of Sleeve Bearings
114
Oil
114
Sleeve Bearings
115
Bearing Verification
115
Oil Container and Piping
116
Oil Container and Piping Verification
116
Use
117
Use Verification
118
Electrical Performance, Excitation, Control and Protection
121
Protection Trips
121
Pt-100 Resistance Temperature Detectors
121
Slip Rings and Brushes
123
Brush Wear
123
Brush Sparking
123
Thermal Performance and Cooling System
124
Chapter 9 After Sales Support and Spare Parts
125
After Sales
125
Site Services
125
Spare Parts
125
Support and Warranties
125
Support for Service Centers
125
After Sales Contact Information
125
Spare Parts for Rotating Electrical Machines
126
General Spare Part Considerations
126
Periodical Part Replacements
126
Need of Spare Parts
126
Selection of the most Suitable Spare Part Package
127
Typical Recommended Spare Parts in Different Sets
127
Operational Spare Part Package
127
Recommended Spare Part Package
128
Capital Spare Parts
128
Operational Spare Part Package
128
Recommended Spare Part Package
129
Capital Spare Parts
129
Operational Spare Part Package
130
Recommended Spare Part Package
131
Capital Spare Parts
131
Order Information
131
Chapter 10 Recycling
132
Introduction
132
Average Material Content
132
Recycling of Packaging Material
132
Dismantling of the Machine
133
Separation of Different Materials
133
Frame, Bearing Housing, Covers and Fan
133
Components with Electrical Insulation
133
Permanent Magnets
134
Hazardous Waste
134
Land Fill Waste
134
Commissioning Report
135
Typical Position of Plates
145
Typical Main Power Cable Connections
146
4
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ABB AMG Series Specifications
General
Rated Power
0.18 to 1000 kW
Frequency
50 Hz / 60 Hz
Protection Class
IP55, IP56, IP65
Engine Type
Induction Motor
Power Output
0.18 - 1000 kW
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