YY2YKK&YKS

Series high voltage

three phase asynchronous
electric motors

Operating And Maintenance Manual

Wolong Electric Huai ' an QingJiang Motor Co., Ltd.

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 CONTENT
1. General introduction ............................................................................1

2. Mounting ................................................................................................4

3. Preparation and trial run before operating .......................................5

4. Trial run with load ................................................................................7

5 .Tend and protection ..............................................................................7

6. Check and maintenance during operating terms ..............................7

7. Assistant devices ....................................................................................8

8. Failures and solution ............................................................................8

9. Attentions ...............................................................................................9

Appendix ..................................................................................................10

Drying process .........................................................................................10

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1. General introduction

1.1 This manual is applicable for Y series, YKK series and YKS series high voltage
three phase asynchronous electric motors produced by Huaian welling Qingjiang motor
manufacturing co., Ltd. This manual introduces mounting, stockpiling, transporting,
trial operating, operating, checking, maintenance and failures removing, and gives
some suggestion for correctly operating.
1.2 There are important data for operating and rated data on nameplate. Concerning
IPcooling type, mounting type, terminal box position ,matching size , connecting
and other technical data, they are in outline drawings or documents along with motors.
Please read the documents and data on nameplate carefully.
1.3 Please mount and operate according to outline drawings and manual, under which
our guarantee works. If any accident or any question please contact us.
1.4 Key parts introduction
1.4.1 These motors are designed for multipurpose, applicable for general-purpose
equipments under every situation. These kinds of motors are constructed by normal
parts and special parts, main parts are rotor, stator, bearing, terminal box,
endshield and cooler.
1.4.2 Stator and parts
Main partsFrame, stator core, stator coil. Frame is a rigid chest welded with
several armor plates. Stator core is consisted of insulated cold-rolled silicon
sheets. The plates on the end of the lamination and ribs on the back strengthen
lamination. Stator coils are embedded in stator core slots and then through VPI
process under vacuum and high pressure. There are three leading-out wires from stator
generally. Customer can ask 4 or 6 leading wires. They are marked in terminal box
with U,V,W or U1,V1,W1,neutral mark with N or U2,V2,W2.
1.4.3 Rotor and parts
Main partsRotor core, shaft, rotor bar or cast aluminum rotor. Rotor core
is consisted of insulated cold-rolled silicon sheets. The plates on the end of the
lamination and ribs on the back strengthen lamination.
1.4.3.1There is two kinds of rotor winding, cast aluminum and rotor bar, which are
embedded in rotor core slots firmly. Connection between copper bar and end collar
adopts intermediate frequency induction weld.
1.5 Ventilation
All motors adopts self ventilation .normal cooling type: safe rain proof,
climate proof, pipe cooling ,total closed air water cooling, total closed air
air cooling. When motors adopt pipe cooling, which guarantee the pressure inside
of the motor is higher than that in the room, forced cooler fan should be power
on to prevent air pressure from reducing. Necessary wind quantity can be calculated
by following formula:
P
Q
C.
Note

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QNecessary wind quantity ( m / s )

Cair specific heat at constant volume, C=1.1 when the ambient temperature
is 40.

permitted temperature-rise of cooling air. Generally =20K

P Total loss (kW)

2. Mounting

2.1Every motors have to pass electric and mechanic test before delivery, then get
qualification certificate and packaged. There are some documents along with motors
inside package, and also for spare parts as customers request (charge). If there
is damage on package when you receive the motors, please inform transportation
department and Huaian welling Qingjiang motor manufacturing Co.Ltd,ask
representative and open package together. If some damage on motors, please contact
Transportation Company.
2.2 Generally there are 4 lifting lugs, through which the motors can be lifted. If
no stand bar, please keep 60-degree included angle between rope and horizon. Lifting
without lifting lugs is forbidden.
2.3 Please put the motors in dry, clean warehouse before mounting. Please dont
use plastic cloth to cover motors for long time, instead you can use paulin.If motors
with heater, please keep the heater power on to prevent dew and humidity. If long-term
stock, periodic insulation resistance test is necessary. The min stock temperature
is 5.
2.4 Preparations before mounting:
Mounting procedure must be very strict, because motors performances largely
depend on his regulating and stability of base. So please check the following items
before mounting to avoid failures during operating.
2.4.1 Appearance and mechanic checking, if any damage or any question please contact
us immediately.
2.4.2 Please find the centre of base in order to create centre line of base and base
elevation.
2.4.3 Check if the foot, cable, conduit, main lead and other establishments are in
the correct direction, right dimension according to outline drawings, to facilitate
mounting.
2.4.4 Check if the dimension, direction and height of the foot bolt, according to
outline drawing.
2.4.5Make some plane or cuniform sizing blocks to avoid deflection and facilitate
regulating balance during mounting.
2.5 Placing
Placing must be according to relative standard, following items should be
considered.
2.5.1Ambient temperature should not beyond 40, altitude not beyond 1000m, except
special requirements.

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2.5.2 Please pay attention to air inlets and air outlets to avoid that exhaust from
one motor being inbreathed into other motors.
2.5.3 Please make sure that there is enough space around the motors to facilitate
maintenance and cleaning.
2.6 Base
The base must be reliable, so that the vibration is smaller. The base is best
to adopt concrete. Make certain the location of foot bolts according to outline
drawings. The length of the bolts in the base should be 20-30 times longer than the
diameter of bolt. There should be extra space left in foot bolts to facilitate
adjusting.
2.7 Steel pad making and using
2.7.1The width of the pad must be the same with that of foot of the motor at least.
Fluting at the foot-bolt location is according to outline drawing.
2.7.2After centering in the vertical directioncheck the clearance between motor
and base or bases with feeler and note down them. Make several kinds of pads, which
should have 15mm left out, according to your measurement (Generally less-than-0.05mm
clearance has no need to be considered).Then insert these pads into the clearance,
fold the outer pads and mark the depth of penetration at this point permanently.
If several pads are needed to pile, please replace them with a thicker one.
2.8 After mounting, please adjusting with coupling if NU bearing; if sliding bearing
please considering axial clearance to prevent axial thrust from damaging motors.
2.8.1Concerning the centering between motors and drived machine, measure 4
four-different-direction points on the wheels of coupling with feeler to adjusting
it. The readings on the coupling must be the same (or the error within 0.04-0.05mm),
run the motor shaft together with drived machine shaft; 90 degrees as an interval,
get 4 records. Concerning concentricity between motor and drived machine, you can
mount 2 micrometer gauges, touching the side face of wheel of two half-couplings,
at one side of coupling. Regulate micrometer gauges and fix them, then run the shafts
of motor and drived machine together by 360 degrees. Readings on the two micrometers
have to be the same and also same with the original reading. Otherwise, you should
check if the gauges are flexible, if they are fastened, the result means
non-concentricity of two shafts. The difference of readings within the range of
0.04-0.05mm denotes concentricity.
2.8.2 After adjusting is finished, please fix motors and drived machine on base with
bolts. Then centering again to make sure there is no change in position. Here means
centering is finished. Insert location pins.

3. Preparation and trial run before operating

3.1After centering, the motors with Nu bearing can go to next step preparation,
because manufacturer has regulated all clearance before delivery. But concerning
the sliding-bearing motors, the bearing plates should be opened to check if there
are plastic pad which is to avoid shaft sliding to break the bearing bush; and check
if there are injuries in bearing bush. Relubricate according to the directive along
with the motors.

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3.2 Clean surrounding.
3.3Test insulation resistance of winding;
If the rated voltage of winding is 500-3000V, please use 1000V-megohmmeter; if

upon, please use 2500V-megohmmeter.

When the motors are under cold conditions, the value of the insulation resistance
should not be lower than the value calculated from the following formula:

R 4(1 U N )

Attention R insulation resistance under cold conditionM

U N rated voltageKV

When the motors are under cold conditions, the value of the insulation
resistance should not lower than the value calculated from the following formula
UN
R
1000 PN / 100

Attention R insulation resistance under cold conditionM

PN rated power (KW)

U N rated voltageV

If the insulation resistance does not meet the requirements, please dry it,
appendix as reference.
3.4Check the power supply voltage, and frequency conforms that on the nameplate.
Connect correctly. The rotate direction should be clockwise seeing from D-end if
no special requirements.
3.5 If there are temperature measurement equipments or heater, please connect it
according to outline drawing or connecting diagram.
3.6Please connect the earthing lead according to relative standards. If there are
no special requirements, the earthing plate is stainless. Make sure there is no paint
or other rubbish.
3.7 Check the regrease system.
If with NU bearings, the grease should take up 2/3 of bearing chamber. If with
vertical ball bearings, the grease should fill in the whole bearing chamber by force.
If with sliding bearings please regrease according to the requirements on the outline
drawing; if there is extrinsic cycle regrease system, check if the system is open
and under normal working condition. The clearance between bearing location and
bearing bush should be within 1%-1.5% of the diameter of bearing location.
3.8 Concerning YKS series total closed air-water cooling motors, please check if
cooling water quantity, pressure and temperature in the cooler conforms to that on
the outline drawing, and check if the system is open and under normal working

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condition.
3.9 Open the connection with drived machine. Run the shaft with handed operated tools
to make sure the rotation is free.
3.10 Close the switch and open immediately, in order to check if this motor can run
and check the rotate direction. If wrong direction, please correct the connection
and then restart it.
3.11Please pay attention to the noise, vibration and abnormal temperature rising
during 2 hours after start. Continually test the bearing temperature, if the
temperature of bearings increase sharply, please cut off the power immediately and
inspect the bearings. Normally the temperature of grease from outlets should be not
beyond 65, the sliding bearings not beyond 80, ambinent temperature not beyond
40, roll bearings not beyond 95.

4. Trial run with load

4.1Trial run with load is permitted if unload trial run succeed.

4.2Twice start is permitted with 5-minute interval under cold condition. Under hot
situation only once start is permitted.Definetion: Cold condition is that the
temperature difference between motors and ambient is not beyond 3; Hot condition
means motors is still hot after stop for while.

5 .Tend and protection

5.1 Following works have to be done after one month stop without move
5.1.1Concerning slid bearingsDischarge all grease and regrease.
5.1.2If ambient is very wet or big difference in temperature, which will bring dew
to the motors, please power on once or several times every month to lustrate humidity.
If there is heater, please power on the heater, and check the heaters performance
periodically.
5.1.3There must be antirust coat on exposed metal surface.
5.1.4 Give every controlling and drived equipment the stick to tell people the
relative performance and what should be done before restart.
5.2If the motors are moved to stock, please refer to 2.2 and 2.3.

6. Check and maintenance during operating terms

6.1Please keep the running motors clean; prevent water, oil and other sundries
getting into inside of the motors. Cleaning the inside of the motors with compressed
air is necessary once every month at least.
6.2Oil leakage is forbidden, because the oil on the winding will affect electric
performance. So we advise replace all lubrication after one-week running. Please
take oil samples to test periodically, if the color is growing dark, or the oil have
moisture, please replace it immediately. And at the same time the bearing lubrication
have to be replaced every half year.
6.3Concerning roller bearings please regrease according to bearing stick strictly.

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If wet or dusty ambient please regrease more often. And use coal oil or gasoline
to wash bearing before relubrication. The value of regrease should be two thirds
of oil chamber. Then make sure the rotor is easy to be turned after regreasing.
6.4 Check all bolts, specially the bolts on rotating part.
6.5The cooling air have to be clean and dry with not-more than 40 temperature.
Check the ventilation system often, if there is blockage.
6.6 Check the load at any moment. Long-term overload running will reduce longevity
even bring damage to motors.
6.7 Please note down the running records periodically.
6.8Concerning YKS series total closed air-water motors, after long-term employing,
the cooler will be eroded or rubbed, usually located at the extension joint position
between cooler and wainscots, leading water leaking or bad cooling. If there is,
please repair it immediately.
6.9 Concerning YKS series total closed air-water motors, after long-term employing,
the cooler pipes will be blocked, please clear it in time.

7. Assistant devices

7.1Temperature measuring device

According to customers requirements the temperature measuring devices could
be place at winding or bearing, or both; three or six could be placed in winding,
every phase with one or two. Every device has two or three terminals which are all
connected in terminal box. Usually this device is Pt100,means 100 at O . By the
way consumers must have the temperature controller own self.
7.2Heater
If customers require, we can place heaters or heater tapes inside of the motors,
with the voltage of 220V or 380V. Theirs terminals are all in the terminal box, also
could be in a separate terminal box if special requirements.

8. Failures and solution

8.1Motors cannot be started

The possible reasons are wrong connection, wrong voltage, open protection device,
failures in winding and overload or blocked load. Check if the connection is wrong.
Check if the voltage between terminals conforms to that on nameplate. Check if the
maximum relay or fuse is open. Check if the stator winding is open or short circuit,
earthing. Check if the rotor or load is blocked or froze. Check if load moment is
beyond the limit denoted in outline drawing. Check if there are failures in start
equipments.
8.2Motor fever
The possible reasons: over voltage or lower voltage, over load, overheat cooling
mediums, and short circuit in winding. Check if the power voltage conforms to that
on nameplate. Check if the load moment is bigger than that on outline drawing and
three phase electricity is balanced. Check if the cooling pipes are blocked and the
ambient temperature is beyond the standard. Check there is any heating unit around

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the air inlets. Check if the balance between three-phase electricity resistance.
8.3Bearing fever
8.3.1Sliding bearingPossible reasons are less lubrication, wrong lubrication type,
unclean lubrication, blocked oil rings, smaller clearance between bearing location
and bearing bush, deflected bearing bush and shaft current. Check the bearing type
conforms to that on outline drawing. Check if the oil level reaches the standard
position. Check if there is water and other impurities in oil. Check if the oil rings
are rough and flexible. Check if the clearance between bearing location and bearing
bush is within 1-1.5% of diameter of shaft. Check if there is shaft current through
bearing film. Check if the bearings undertake axial force.
8.3.2 Rolling bearings: possible reasonswrong lubrication, less lubrication,
impure lubrication, bend shaft, over axial force. Check if the type of lubrication
and value conforms to that on outline drawings. Check if the lubrication go bad and
if the shaft bend. Check if the coupling has axial force to push the motors.
8.4Oil leakage in sliding bearings: the possible reasons are; there are some crack
in bearing brackets, untotally sealed bearing caps, over oil pressure, too much
lubrication, less oil discharging, wrong lubrication. Please check if bearing
brackets are broken. Check if the bolts in bearing caps are fastened. Check if the
type of lubrication, the value, quantity and oil pressure meets the requirements
on outline drawings.
8.5Vibration
Possible reasons: unaligned axial line of equipment group, malposition base,
bend shaft, unbalanced coupling, big clearance between bearing location and bearing
bush, broken rotor copper bar. Please check if mounting is good. Check if how
unbalanced is coupling. Check if the copper bar is broken.
8.6 Low insulation resistance: possible reasons; unclean winding surface, too-much
wet air, dews on the surface of winding caused by big temperature changing, aging
insulation. Please clean inside of the motor. Check if there are mars on winding.
Dry motors (please refer to appendix).

9. Attentions

9.1 Guaranteed terms

Under the situation that mounting, operating and storage motors according to
this manual, our company guarantee one-year using term, two-year good performance
from transportation date. If there is damage or abnormal performance caused by bad
quality during quality guaranteed term, we will repair or change motor freely.
9.2According to customers request, we can send technical people to mount and adjust
on site (charge).
9.3 mounting and maintenance must be operated by special trained people according
to this manual strictly.
9.4 After repairing winding, there must be one-minute high voltage holding test.
Tested voltage can be calculated with following formal

U (2U N 1000) X 0.75

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 Attention U tested voltage (V)

U N rated voltage of winding (V)

Appendix

Drying process

If the insulation resistance does not meet requirements after long-term stop
or before primary start, drying process is needed. Generally you can process
according to one of following methods.
1. Stator electrifying method
1.1Stator electrifying method
Lock rotor, power on the same as that of normal starting, but with 10%-15% of
rated voltage, leading the current is only 50%-70% of the rated current. This heat
is cause by copper loss. (See fig 1)
1.2single-phase electrifying method
Please connect according to fig 2, which lead 50%-70% of the rated current in
winding. Please exchange the terminals during c or d connections are adopted in order
to make the winding heated averagely.
2.iron loss heating method
2.1stator iron loss heating method
Draw out rotor; enwind the stator with insulated wire with single-phase
AC-electricity. If the voltage of 220V, requested cylinder number can be calculated
from below forma:

10 5
W
S

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The current in wire I=SD 10 A

AttentionWcylinder number
2
Snet yoke area of stator core. ( cm S=Lh

Lnet length of stator core(cmL=(total length-total length

of ventilation)0.9
hyoke height of stator core.cm
Daverage diameter of stator-core yokecmD=outer diameter
of stator core- h
Operator gets the value of L, H, D himself.
The choosing of section of wire depends on the safe section flux.
If with voltage of 380V, the requested cylinder number is the result, gotten from
above formula, multiplied by 1.7. But divided for the current. (See fig 3).
2.2 Rotor iron loss heating method

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 Applied voltage is needed, under which the current flow through the shaft.
S
U
45
Required current I=10DA
AttentionI, S and D, please refer to 2.1
After this process, better effect on rotor than on stator.see fig 4
3. Process time depends on how wet the winding is and the temperature during process;
at least ten hours, some with several days. During this process, the insulation
resistance will go down at the beginning, then go back, finally go stable. If being
stable for 3-5hours, the drying process is finished.
4. Please note down the insulation resistance, the temperature of winding and ambient
during drying process. If iron loss or copper loss heating method is adopted, please
note down voltage and current in addition, and draw the insulation time curve and
temperature-time curve like fig 5. Attention: at the beginning the interval is half
hour, when the insulation resistance is stable, the interval is one hour.
5. Concerning the safety, please make sure earthing is no problem during drying
process.
6.The temperature of winding and iron core ,during drying process, should be kept
at 70 with thermometer ,90 with resistivity method or 80-85 PT100
thermometer .

a b c d
Fig l stator electrifying heating method Fig 2 single phase electrifying heating method

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Fig 3stator iron loss heating method(without rotor) Fig 4 rotor iron loss heating method

Insulation resistance
Temperature
temperature
Winding

resistance
Insulation
Drying time

Fig 5 typical insulation resistance and winding temperature to time curve

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