INSTALLATION, OPERATION

AND

MAINTENANCE MANUAL FOR

HAYDEN INDUSTRIAL HEAT EXCHANGERS

 INSTALLATION, OPERATION
& MAINTENANCE MANUAL

Table of Contents
Page
WARRANTY
Limited Warranty 3
Limitation of Warranty and Liability 3
Safety Accessories Warning 4
General Safety Instructions 5

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Introduction 6
Description 6
Shipment and Receiving 6
Handling 7
Storage 7
Long-Term Preservation Process 8
General Information 9
Installation Instructions 9
Start-up 11
Maintenance 11
Bearings and Lubrication 12
Vibration 13
Trouble Shooting 15
Spare Parts 17
Factory Field Assistance 18

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Warranty
LIMITED WARRANTY

Hayden Industrial Products, San Bernardino, California, warrants that:

A. All Hayden Industrial parts are guaranteed to be free from defects of

workmanship and materials when applied within the scope of Hayden
Industrial approved applications. Merchandise found to be defective will
be repaired or replaced free of charge. No other warranty expressed or
implied is made. The manufacturer shall not be liable for any damage or
injury to property (other than the product itself) or any commercial loss or
damage.

B. Requests for return of defective merchandise must be submitted to the

factory. An RGA will be issued as authorization to return merchandise,
freight prepaid, for factory inspection and disposition. All replacements
are F.O.B. factory and will be made subject to factory inspection report, a
copy of which is available on customer request.

C. Requests to the factory for the above purposes shall be made within
twelve months from the date of original sale.

For warranty issues or questions, contact Hayden Industrial Customer Service at: 1-800-
854-4757 or [email protected].

LIMITATION OF WARRANTY AND LIABILITY

This warranty does not apply to Hayden Industrial products and parts which have
failed as a result of faulty installation or abuse, or incorrect connections or
alterations made by others, or use under abnormal operating conditions or
misapplication of the products and parts.

Hayden Industrial will not approve for payment any repairs made outside its
factory without prior written consent of its home office.

The foregoing shall constitute our sole and exclusive warranty and our sole and
exclusive liability and is in lieu of all other warranties, whether written, oral,
implied or statutory. There are no warranties which extend beyond the
description on the page hereof. Seller does not warrant that said goods and
articles are of merchantable quality or that they are fit for any particular purpose.
The liability of seller on any claim of any kind, including negligence, for any loss
or damage arising out of or connected with, or resulting from the sale and

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purchase of the products and parts covered by this proposal, acknowledgment,

order or from the performance or breach of any contract pertaining to such sale
or purchase, or from the design, manufacture, sale, delivery, resale, installation,
technical direction of installation, inspection, repair, operation or use of any
products or parts covered by this proposal, acknowledgement, order or furnished
by seller shall, in no case exceed the price allocable to the products or parts
thereof which give rise to the claim and shall terminate one (1) year after the
shipment of said products and parts.

In no event, whether as a result of breach of contract, or warranty or alleged

negligence, defects, incorrect advice or other causes, shall seller be liable for
special or consequential damages, including, but not limited to, loss of profits or
revenue, loss of use of the equipment or any associated equipment, cost of
capital, cost of substitute equipment, facilities or services, down time costs, or
claims of customers of the purchaser for such damages. Hayden Industrial
neither assumes nor authorizes any person to assume for it any other liability in
connection with the sale of its products and parts. Some states do not allow the
exclusion or limitation of incidental or consequential damages so all of the above
limitations or exclusions may not apply to you.

SAFETY ACCESSORIES WARNING

The responsibility for providing safety accessories for equipment supplied by

Hayden Industrial is that of the installer and user of this equipment. Hayden
Industrial sells its equipment with and without safety accessories, and
accordingly, it can supply such safety accessories upon receipt of order.

The user, in making its determination as to the appropriate safety accessories to

be installed, and any warning notices, should consider:
1) The location of the installation
2) The accessibility of employees and other persons to this equipment
3) Any adjacent equipment
4) Applicable building codes
5) Requirements of the Federal Occupational Safety and Health Act.

Users and installers of any Hayden Industrial equipment that includes fans or
blowers should read “RECOMMENDED SAFETY PRACTICES FOR AIR
MOVING DEVICES” which is published by Air Movement and Control
Association, 30 West University Drive, Arlington Heights, IL 60004.

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GENERAL SAFETY INSTRUCTION

1. Follow all local electrical and safety codes, the National Electrical Code
(NEC) and Occupational Safety and Health (OSHA) requirements.
2. Replace or repair any damaged mechanical parts or
electrical components immediately.
3. Keep all body parts (hands, feet) from coming into contact
with fan blades or drive components during operation.
4. Never exceed maximum operating conditions as outlined in
specifications

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Installation, Operation & Maintenance Manual

INTRODUCTION

The purpose of this manual is to aid in the proper installation and operation of
heat exchangers manufactured by Hayden Industrial Products. These
instructions are intended to supplement good general practices and are not
intended to cover detailed instructions or procedures, because of the wide variety
and types of units manufactured by Hayden Industrial.

It is the responsibility of the purchaser to assure that the installation and

maintenance of this equipment are handled by qualified personnel experienced in
such work and equipment. Contact your local representative for details.

Read instructions carefully before attempting to assemble, install, operate, or

service these Hayden Industrial heat exchangers. Protect yourself and others by
observing all information and additional instructions included with this equipment.
Failure to comply with instructions could result in personal injury and/or property
damage. Retain these instructions for future reference. For additional copies or
if there are any questions, please contact Hayden Industrial Products, Corona,
California.

DESCRIPTION

Hayden Industrial Temp-Troller heat exchangers are compact, lightweight units

that provide reliable temperature control of oils and a wide range of other highly
viscous fluids. Highly efficient heat transfer rates are obtained because Hayden
Industrial heat exchangers feature our proprietary Turbulator design. These
provide dependable fluid temperature control in compact packages.

The Temp-Troller unit provides a self-contained, air-moving device. The

integrated heat transfer assemblies contain fans and power sources to provide
airflow for the heat transfer unit.

SHIPMENT AND RECEIVING

Prior to shipment from Hayden Industrial, all products have been thoroughly
inspected and passed Quality Assurance requirements.

All equipment shipped from Hayden Industrial is boxed, skidded, or crated to fully
comply with railroad or trucking requirements. Inspect all shipments carefully for
damage.

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THE RECEIVER MUST NOTE ANY DAMAGE ON THE CARRIER’S BILL OF

LADING AND FILE A CLAIM IMMEDIATELY WITH THE FREIGHT COMPANY,
IN THE CASE OF ANY DAMAGE. Keep a record of all equipment received,
including inspection details and date of receipt, because of the possibility of
partial shipments.

If you receive damaged goods, contact your Hayden Industrial representative for
repair or replacement service.

HANDLING

Handle your equipment with care. Some units are provided with lifting lugs or
holes for easy handling. Others must be handled using nylon straps or well-
padded chains and cables, which protect the unit’s coating and housing.
Spreader bars should be used when lifting large units.

STORAGE

Units are to be stored in their original containers or equivalent protection and

should be kept in a clean, dry, protected warehouse where exercised control over
temperature, dust, dew point, shock and vibration is reasonably maintained.

A) Temperatures: between 50o F and 120o F.

B) Maximum relative humidity of 60%
C) Shock or vibration: 2 mils maximum to prevent bearings from brinelling.
Exceeding this limit will require vibration dampening material under the
units.

Motor bearings (and fan bearings on belt drive units) are to be greased at the
time of going into extended storage. Motor shaft (and fan shaft on belt drive
units) are to be manually rotated every month. Additional grease is to be added,
purging some of that in the bearing cavity every six (6) months.

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GREASE IN THE BEARINGS IS TO BE PURGED AT THE TIME OF REMOVAL

FROM STORAGE, MAKING SURE THAT AN AMPLE SUPPLY OF FRESH
GREASE IS IN EACH GREASE CAVITY. GREASE USED MUST BE
COMPATIBLE WITH THAT ALREADY IN MOTOR AND FAN BEARINGS.
Belts, on belt drive units, should be checked at the time of removal from storage
for proper belt tension. Tighten belts, if necessary. It is recommended that upon
installation, the vibration levels be checked to assure that the levels do not
exceed the levels set forth in this manual. (See Table 1).

Storage records complying with the above requirements should be maintained.

LONG-TERM PRESERVATION PROCESS

Hayden Industrial makes every effort to protect our heat exchanger units from
damage due to exposure to the elements prior to assembly, regardless of
environmental conditions. If storage of any heat exchanger extends beyond a 2
to 3 month period, additional steps are required to maintain the "like-new"
condition. Those additional steps are described below.

Process for Preservation prior to shipment from Hayden Industrial

facilities:
1) All bearings, shafts, and any other non-coated components on the heat
exchanger are to be coated with a protective lube (example, LU-777 Outdoor
Metal Protectant or equivalent).
2) Heat exchanger is internally protected with thin coating of Brayco 785
preservative oil. In the case of heat exchangers which were flushed and
hydro-tested with water a preservative mixed in with the water will provide a
thin coating of internal protection.
3) All flanges are sealed and shrink-wrapped
4) Entire heat exchanger is shrink-wrapped, and air vents taped to package for
air circulation during transport and storage.
Process for Long-Term Preservation post shipment:
1) Keep heat exchanger covered and protected from exposure to the elements.
2) Depending on actual long term storage conditions and packaging integrity it
may be necessary to periodically, every 2 to 3 months, inspect cooler and re-
apply protective lubricant as necessary to any non-coated surfaces where
protective lube coating may have degraded.
3) Do not open the heat exchanger flanges until installation is to begin.
4) Properly protect the heat exchanger internally from contaminants throughout
storage and installation.
Please contact Hayden Industrial for any additional information or details.

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GENERAL INFORMATION

1) Air cooled oil heat exchangers are built for operation with maximum oil
pressures of 300 PSI and temperatures of 350°F unless otherwise specified.

2) Air/Oil heat exchangers that are to be installed for utilization of waste heat for
space heating should be mounted 7 to 14 feet above the floor depending on
the structure, for proper heat distribution.

INSTALLATION INSTRUCTIONS

Hayden Industrial self-contained heat exchanger designs can be adapted to

various mounting locations. The most important consideration that must be
taken into account when deciding upon the location of a heat exchanger is
provision for the supply of air to the heat exchanger and removal of air from the
heat exchanger. The performance of the heat exchanger is dependent upon the
quantity and the temperature of the air entering the heat exchanger.

The units are adaptable for mounting in a well-ventilated indoor area. Care must
be taken to see that the temperature of the area does not build-up and to ensure
unrestricted airflow to and from the unit.

When installed outdoors, self-contained heat exchangers should be located so

that there is a free flow of air to and from the unit. Horizontal discharge units
require a minimum clearance of twice the width of the unit at the air inlet and
outlet. It is desirable to position the units so that the prevailing wind will blow into
the unit inlet. Wind deflectors or air discharge scoops may be mounted on the
discharge side to prevent the direct force of the wind from affecting the air
delivered at the propeller fan.

When units are located on the roof, it is best to mount the heat exchanger near
the edge with the intake facing away from the building, to minimize the possibility
of drawing super-heated air from the roof’s surface.

Supports for suspended units must be cross-braced for live load support to
prevent side sway.

Temp-Trollers should always be mounted to a flat, level, rigid structure. Shim

the unit where necessary. This will ensure permanent alignment and a smooth-
running, vibration-free unit, as well as minimizing maintenance costs.

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Units are supplied complete with headers and connections sized

for connecting to standard commercial pipe. Back-up wrenches
should be used on the fittings when making connections.

All piping practices used when installing self-contained heat exchangers should
be in accordance with the local building and safety codes.

A strainer located ahead of the heat exchanger inlet should

be installed to trap scale, dirt, or sludge that may be present
in piping and equipment, or that may accumulate with use
A thermostatic or spring loaded by-pass relief valve installed
ahead of the heat exchanger may be helpful to speed warm-up
and relieve the system of excessive pressures. All user
applied accessories should be considered in the original heat
rejection and piping calculations.

Connect motor only to a power supply of the same specifications as shown on

the motor nameplate. Voltage may vary + 10% of nameplate voltage. Follow
wiring diagram printed on motor nameplate or in terminal box. Before starting
motor, follow motor manufacturer recommendations. Observe operation carefully
after motor is started for the first time.

Connect unit to the system by means of suitable piping or hose,

using the appropriate fittings. Always use a back-up wrench
when tightening fittings.

Note: Ensure that the heat exchanger is in the circuit for a pressure lower than
that of the heat exchanger rating. The dry seal fittings should be lubricated with
a lubricant or a thread sealant (pipe thread – use Teflon type in hydraulic
systems). Check for air direction and for adequate air intake and discharge
areas around the heat exchanger.

Connect the power sources (AC, DC, or hydraulic) to the motor or the shaft in
case of a belt driver. Verify correct rotation of fan and air direction through the
heat exchanger. Hydraulic motors have a limitation of 200 PSI backpressure and
are bi-rotational. Maximum tip speed of fan blade is 16,000 feet per minute or
the limiting rotation of the fan.

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STARTUP:

Lock out the power source.

Place the heat exchanger on its rigid foundation or platform. Level the unit using
shims where necessary. Tighten all mounting bolts securely with lock nuts and
lock washers.

Tighten belts, if necessary. NOTE THAT ALL BOLTS, SETSCREWS AND

BELTS SHOULD BE TIGHTENED AGAIN AFTER TWO DAYS OF INITIAL
OPERATION.

Clearance should be checked around and between blade tips and the housing
before starting up. The fan should not strike the housing.

Unless the unit has been in storage for several months, no initial lubrication is
required. Motors have been pre-lubricated by the motor manufacturer and fan
bearings by the fan manufacturer.
Note that grease lines are NOT pre-loaded with grease at the factory. End user
MUST insure that all air is purged out of grease lines upon initial lubrication.

Arrows to show direction of rotation are attached to the fan housings or blades.

The fan should not need balancing, as it was balanced at the factory to be within
vibration levels before shipment. However, there are several things that may
cause vibration, such as rough handling in shipment and erection, weak
foundations, and alignments. It is recommended that the vibration levels be
checked with a vibration analyzer to verify that the vibration is within levels
recommended later in this manual. (See Table 1). During maintenance, fans
should be disconnected from their power source.

PRIOR TO START UP, THE END USER SHOULD FLUSH THE HEAT
EXCHANGER WITH A LIQUID COMPATIBLE WITH THE LIQUID THAT WILL
BE USED IN THE HEAT EXCHANGER DURING NORMAL OPERATIONS.
FLUSHING OF GAS HEAT EXCHANGERS IS NOT NECESSARY.

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MAINTENANCE:

Periodic inspection of all components is the key to good maintenance and

trouble-free operation. Frequency of inspection must be determined by the user
and is dependent upon the severity of the application. Prepare a maintenance
schedule and make sure it is strictly adhered to.

NEVER SERVICE OR ADJUST ROTATING EQUIPMENT WHILE IT IS IN

OPERATION. LOCK OUT THE POWER SOURCE BEFORE PERFORMING
MAINTENANCE.

Regular fan and oil heat exchanger maintenance should include the following
items and should be done after 10 to 15 days of operation and then at least once
a year or at more frequent intervals at the discretion of the end user.

1) Check the fan blade for any buildup of foreign material or wear from abrasion.
Both can cause excessive vibration, which will lead to damage of the fan
blade and other fan components. Replace the fan blade if excessive wear is
noticed. Carefully clean the fan blade of any foreign material.

2) Check belt drives for proper alignment, tension, and excessive wear.

3) Lubricate the fan and motor bearings.

4) Consult the trouble-shooting guide for excessive vibration or noise, insufficient

performance, or when the fan does not operate. (See Table 2).

5) Tighten all bolts and set screws.

6) Heat Transfer Surface:

Dirt and dust should be removed (recommended at least once a year) by
brushing the fins and tubes and blowing loose dirt off with a low pressure
(<150 PSI) air hose. Should the surface be greasy, the motor should be
removed and the fins and tubes brushed or sprayed with a mild alkaline
solution or a non-flammable degreasing fluid. Follow with a hot water rinse
and dry thoroughly. A steam cleaner may also be used effectively. Check for
damaged headers (manifolds) and tubes as they can reduce heat transfer
and increase pressure drop through the heat exchanger. Bent fins should be
straightened out with a fin comb.

7) Casing, Fan and Motor:

Dirt and grease should be removed from these parts. Rusty or corroded
surfaces should be sanded clean, primered, and repainted.

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BEARINGS AND LUBRICATION:

Selection of the correct bearing grease and greasing intervals depends on

several factors. Extreme high or low temperatures, dirty or damp surroundings,
and vibration exceeding 1 or 2 mils are all factors that will require more frequent
greasing or special greases.

The motor bearings and the fan bearings on the belt drive fans should be
greased at regular intervals. Motor manufacturers’ greasing instructions and
recommendations should be followed closely.
1) Avoid the use of a pressure greasing system, which tends to fill the bearing
chamber completely.
2) Do not over grease.
3) Use only 1 or 2 shots with a handgun in most cases.
4) Maximum handgun rating should be 40 psi.
5) Rotate bearings during lubrication where good safety practice permits.
NOTE: On motors with non-regreasable sealed bearings, no lubrication is
required for the life of the bearings.

The most frequent cause of bearing failure is not greasing often enough, using
an excessive quantity of grease, or using incompatible greases. Excessive
vibration, especially if the bearing is not rotating, will also cause bearings to fail.
Bearings must also be protected from water and moisture to avoid internal
corrosion.

In general, use a high quality medium consistency, ball bearing grease with a
polyurethane thickener such as Shell Dolium R grease.

IMPORTANT: Do not increase the fan speed before first contacting Hayden
Industrial. Arbitrarily speeding up the fan can cause motor
overload, failure, and potential fan blade failure.

VIBRATION:

Excessive fan vibration can be caused by many factors. ALL POSSIBLE

SOURCES OF EXCESSIVE VIBRATION MUST BE CHECKED OUT AND
CORRECTIVE ACTION TAKEN IMMEDIATELY TO CORRECT THE PROBLEM.
See the fan trouble-shooting chart (Table 2) for possible causes of excessive fan
vibration.
A vibration analyzer will be of great assistance in determining the amount of
vibration. The following values give an indication of the fan vibration condition.
Vibration readings should be taken on the fan bearings (if possible, on belt drive
fans), or motor (on direct drive fans). Horizontal, vertical, and axial readings
should be taken.

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TABLE 1

Vibration displacement in mils, “Double Amplitude”

Fan RPM Good Fair Slightly Rough

Rough
870 1.7 3.3 6.5 Above 6.5
1160 1.2 2.5 5.0 Above 5.0
1750 .75 1.5 3.5 Above 3.5
3450 .50 .9 2.0 Above 2.0

Interpolate for fan speeds other than show above. The fan should not be
operated unless the maximum vibration reading is in at least the “fair” range.

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TABLE 2

Trouble-Shooting Chart

PROBLEM POSSIBLE CAUSES

INADEQUATE COOLING - Lower flow rate of oil than design

- Lower air velocity than design
- Higher ambient temperature than
design
- Lower inlet oil temperature to inlet
air temperature than design
- Higher oil viscosity than design
- Undersized heat
exchanger/misapplication
- Clogged fins/damaged fins
- Bent return or header bends
- Higher elevation than design
EXCESSIVE PRESSURE DROP - Incorrect fluid – high viscosity
- Contaminants in heat exchanger
- Incorrect piping or fittings
INSUFFICIENT AIR - Incorrect (lower) voltage on electric
motors
- Low oil flows on hydraulic drives
- Incorrect pitch on fan blade
- Incorrect fan rotation
- Excessive air restriction (e.g.
louvers or ducting)
- Damaged finned section
- Buildup of foreign material on fins
- Higher elevation than design of heat
exchanger
- Buildup on fan blade
EXCESSIVE VIBRATION - Accumulation of material on fan
blade
- Worn or corroded fan blade
- Bent shaft
- Fan blade or sheaves loose on shaft
- Motor out of balance
- Fan blade out of balance
- Sheaves eccentric or out of balance
- Bearing or drive misalignment
- Mismatched belts
- Belts too loose or too tight

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TABLE 2 – CONTINUED

Trouble-Shooting Chart

PROBLEM POSSIBLE CAUSES

EXCESSIVE VIBRATION (Continued) - Loose or worn bearings

- Loose bearing bolts
- Loose fan mounting bolts
- Weak or resonant foundation
- Foundation not flat and level
- Structures not cross braced
- System pulsation (DANGER) – fan
operation in a stall
- Blades at different angles on
adjustable pitch fans
TOO MUCH AIRFLOW - Actual system is less restrictive to
flow than expected
- Fan speed higher than design
FAN DOES NOT OPERATE - Blown fuses
- Broken belts
- Loose pulleys
- Electricity turned off or not wired
properly
- Wrong voltage
- Motor too small and overload
protector has tripped circuit
- No oil flow to hydraulic motor
EXCESSIVE NOISE - Accumulation of material on fan
blade
- Worn or corroded fan blade
- Bent shaft
- Fan blade or sheaves loose on
shaft
- Fan blade hitting housing
- Fan blade out of balance
- Bearing or drive misalignment
- Mismatched belts
- Belts too loose or too tight
- Belts hitting guard
- Loose or worn bearings
- Belts worn
- Belts oily or dirty
- Defective or bad bearings

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TABLE 2 – CONTINUED

Trouble-Shooting Chart

PROBLEM POSSIBLE CAUSES

Excessive Noise (Continued) - Bearings need lubrication

- Loose bearing bolts
- Loose fan mounting bolts
- System pulsation or surge
- Electrical noise
- Noise from high velocity air system
Fan in stall condition (DANGER)
- Rattle of components in high
velocity airstream

It is recommended that the users and installers of this equipment familiarize

themselves with AMCA publication #201, “Fans and Systems”, and publication
#202 “Trouble-Shooting”, which are published by Air Movement and Control
Association, 30 West University Drive, Arlington Heights, IL 60004.

SPARE PARTS:

Spare parts are not needed for the first year of operation. If spare parts are
desired, then it is suggested that a spare motor and fan blade be ordered for
direct drive fans. For belt drive fans, in addition to the motor and fan blade, it is
suggested that a spare set of bearings, shaft, sheaves, and belts be ordered.

When ordering spare parts, specify the parts desired for the heat exchanger
model and part number, and if possible the serial number. Contact Hayden
Industrial for price and delivery.

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FACTORY FIELD ASSISTANCE

Hayden Industrial Products has assembled, for our customer’s benefit in dealing
with significant field issues, a highly qualified, dedicated team to handle
situations including:

 Shipping Damage
 Pressure Vessel Repair
 Structural Repair
 Cosmetic Issues
 Technical Support
 Warranty / Quality Issues

Requests for factory field assistance should be directed to:

Hayden Industrial Customer Service
1-800-854-4757 or [email protected].

Rev 7-17, Page 18

 Integral Horsepower
AC Induction Motors
ODP, WPI, WPII Enclosure
TEFC Enclosure
Explosion Proof

Installation & Operating Manual

2/07 MN400
 Table of Contents

Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Lubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Relubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Relubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐4
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5

MN400 Table of Contents i

Section 1
General Information

ii Table of Contents MN400

Section 1
General Information

Overview This manual contains general procedures that apply to Baldor Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or
attempt to perform maintenance procedures until you understand the Warning and Caution statements. A
Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution
statement indicates a condition that can cause damage to equipment.
Important: This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S NEMA Publication MG‐2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S The National Electrical Code
S Local codes and Practices

Limited Warranty
1. Most Baldor products are warranted for 18 months from the date of shipment to Baldor's customer from Baldor's
district warehouse or, if applicable, from Baldor's factory. Baldor Standard-E£ standard efficient motors are
warranted for 24 months. Standard-E is limited to three phase, general purpose, 1-200 HP ratings that fall under
the Energy Policy Act (EPAct). Baldor Super-E£ premium efficient motors are warranted for 36 months. Baldor
IEEE841 motors are warranted for 60 months. All warranty claims must be submitted to a Baldor Service Center
prior to the expiration of the warranty period.
2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the
warranty period if:
a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansas
or one of the Baldor Authorized Service Centers and
b. the purchaser gives written notification concerning the motor and the claimed defect including the date
purchased, the task performed by the Baldor motor and the problem encountered.
3. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith,
Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting
from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to
the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you.)
4. Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects in
material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill
Baldor's warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor's warranty repair
allowance. Baldor will not pay overtime premium repair charges without prior written authorization.
5. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid
unless first authorized in writing by Baldor.
6. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into
service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition
of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor
Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to
proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the
purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center's signed
service report to Baldor for further consideration.
7. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

MN400 General Information 1‐1

Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt installation, operation and maintenance of
electrical equipment.
Be sure that you are completely familiar with NEMA publication MG‐2, safety standards
for construction and guide for selection, installation and use of electric motors and
generators, the National Electrical Code and local codes and practices. Unsafe
installation or use can cause conditions that lead to serious or fatal injury. Only qualified
personnel should attempt the installation, operation and maintenance of this equipment.

WARNING: Do not touch electrical connections before you first ensure that
power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING: Be sure the system is properly grounded before applying power.
Do not apply AC power before you ensure that all grounding
instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes
must be carefully followed.
WARNING: Avoid extended exposure to machinery with high noise levels. Be
sure to wear ear protective devices to reduce harmful effects to
your hearing.
WARNING: This equipment may be connected to other machinery that has
rotating parts or parts that are driven by this equipment. Improper
use can cause serious or fatal injury. Only qualified personnel
should attempt to install operate or maintain this equipment.
WARNING: Do not by‐pass or disable protective devices or safety guards.
Safety features are designed to prevent damage to personnel or
equipment. These devices can only provide protection if they
remain operative.
WARNING: Avoid the use of automatic reset devices if the automatic restarting
of equipment can be hazardous to personnel or equipment.
WARNING: Be sure the load is properly coupled to the motor shaft before
applying power. The shaft key must be fully captive by the load
device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
WARNING: Use proper care and procedures that are safe during handling,
lifting, installing, operating and maintaining operations.
Improper methods may cause muscle strain or other harm.
WARNING: Before performing any motor maintenance procedure, be sure that
the equipment connected to the motor shaft cannot cause shaft
rotation. If the load can cause shaft rotation, disconnect the load
from the motor shaft before maintenance is performed. Unexpected
mechanical rotation of the motor parts can cause injury or motor
damage.
WARNING: Disconnect all electrical power from the motor windings and
accessory devices before disassembly of the motor. Electrical
shock can cause serious or fatal injury.
WARNING: Do not use non UL/CSA listed explosion proof motors in the
presence of flammable or combustible vapors or dust. These
motors are not designed for atmospheric conditions that require
explosion proof operation.

1‐2 General Information MN400

Section 1
General Information

Safety Notice Continued

WARNING: Motors that are to be used in flammable and/or explosive
atmospheres must display the UL label on the nameplate along with
CSA listed logo.

Specific service conditions for these motors are defined in

NFPA 70 (NEC) Article 500.
WARNING: UL Listed motors must only be serviced by UL Approved
Authorized Baldor Service Centers if these motors are to be
returned to a hazardous and/or explosive atmosphere.
Caution: To prevent premature equipment failure or damage, only qualified
maintenance personnel should perform maintenance.
Caution: Do not over-lubricate motor as this may cause premature bearing
failure.
Caution: Do not lift the motor and its driven load by the motor lifting
hardware. The motor lifting hardware is adequate for lifting only the
motor. Disconnect the load from the motor shaft before moving the
motor.
Caution: If eye bolts are used for lifting a motor, be sure they are securely
tightened. The lifting direction should not exceed a 20q angle from
the shank of the eye bolt or lifting lug. Excessive lifting angles can
cause damage.
Caution: To prevent equipment damage, be sure that the electrical service is
not capable of delivering more than the maximum motor rated amps
listed on the rating plate.
Caution: If a HI POT test (High Potential Insulation test) must be performed,
follow the precautions and procedure in NEMA MG1 and MG2
standards to avoid equipment damage.

If you have any questions or are uncertain about any statement or procedure, or if you
require additional information please contact your Baldor distributor or an Authorized
Baldor Service Center.

MN400 General Information 1‐3

Section 1
General Information

Receiving Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for
shipment. When you receive your motor, there are several things you should do
immediately.
1. Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part
number listed on your purchase order.
Storage If the motor is not put into service immediately, the motor must be stored in a clean, dry
and warm location. Several precautionary steps must be performed to avoid motor
damage during storage.
1. Use a “Megger” periodically to ensure that the integrity of the winding insulation
has been maintained. Record the Megger readings. Immediately investigate
any significant drop in insulation resistance.
2. Do not lubricate bearings during storage. Motor bearings are packed with
grease at the factory. Excessive grease can damage insulation quality.
3. Rotate motor shaft at least 10 turns every two months during storage (more
frequently if possible). This will prevent bearing damage due to storage.
4. If the storage location is damp or humid, the motor windings must be protected
from moisture. This can be done by applying power to the motors' space
heater (if available) while the motor is in storage.
Unpacking Each Baldor motor is packaged for ease of handling and to prevent entry of
contaminants.
1. To avoid condensation inside the motor, do not unpack until the motor has
reached room temperature. (Room temperature is the temperature of the room
in which it will be installed). The packing provides insulation from temperature
changes during transportation.
2. When the motor has reached room temperature, remove all protective wrapping
material from the motor.
Handling The motor should be lifted using the lifting lugs or eye bolts provided.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the
motor and additional equipment connected to the motor by this method. The
lugs or eye bolts provided are designed to lift only the motor. Never lift the
motor by the motor shaft or the hood of a WPII motor.
2. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by
inserting lifting lugs into holes on top of the cooling hood. These lugs are to be
used for hood removal only. A spreader bar should be used to lift the motor by
the cast lifting lugs located on the motor frame.
3. If the motor must be mounted to a plate with the driven equipment such as
pump, compressor etc., it may not be possible to lift the motor alone. For this
case, the assembly should be lifted by a sling around the mounting base. The
entire assembly can be lifted as an assembly for installation. Do not lift using
the motor lugs or eye bolts provided.

If the load is unbalanced (as with couplings or additional attachments)

additional slings or other means must be used to prevent tipping. In any event,
the load must be secure before lifting.

1‐4 General Information MN400

Section 2
Installation & Operation

Overview Installation should conform to the National Electrical Code as well as local codes and
practices. When other devices are coupled to the motor shaft, be sure to install protective
devices to prevent future accidents. Some protective devices include, coupling, belt
guard, chain guard, shaft covers etc. These protect against accidental contact with
moving parts. Machinery that is accessible to personnel should provide further protection
in the form of guard rails, screening, warning signs etc.
Location It is important that motors be installed in locations that are compatible with motor
enclosure and ambient conditions. Improper selection of the motor enclosure and
ambient conditions can lead to reduced operating life of the motor.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to
reduction of motor life.
1. Open Drip-Proof/WPI motors are intended for use indoors where atmosphere is
relatively clean, dry, well ventilated and non-corrosive.
2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are
present and in outdoor locations.
Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for
installations with high corrosion or excessive moisture conditions. These motors should
not be placed into an environment where there is the presence of flammable or
combustible vapors, dust or any combustible material, unless specifically designed for
this type of service.
Mounting The motor must be securely installed to a rigid foundation or mounting surface to
minimize vibration and maintain alignment between the motor and shaft load. Failure to
provide a proper mounting surface may cause vibration, misalignment and bearing
damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they
support. If these devices are used, be sure that they are evenly supported by the
foundation or mounting surface.
After installation is complete and accurate alignment of the motor and load is
accomplished, the base should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or
sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or
authorized Baldor Service Center for further information.
Alignment Accurate alignment of the motor with the driven equipment is extremely important.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment
manufacturer for more information. Mechanical vibration and roughness during
operation may indicate poor alignment. Use dial indicators to check alignment. The
space between coupling hubs should be maintained as recommended by the
coupling manufacturer.
2. End‐Play Adjustment
The axial position of the motor frame with respect to its load is also extremely
important. The motor bearings are not designed for excessive external axial thrust
loads. Improper adjustment will cause failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1.
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End‐Play
Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed
and load. However, belt slippage may occur during starting.
Caution: Do not over tension belts.
5. Sleeve bearing motors are only suitable for coupled loads.

MN400 Installation & Operation 2‐1

Section 1
General Information

Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet
into the foundation. This will maintain the correct motor position should motor removal be
required. (Baldor motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a
flat washer and lock washer under each nut or bolt head to hold the motor feet
secure. Flanged nuts or bolts may be used as an alternative to washers.
Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding
should conform to the National Electrical Code and local codes and practices.
Conduit Box For ease of making connections, an oversize conduit box is provided. The box can be
rotated 360q in 90q increments. Auxiliary conduit boxes are provided on some motors for
accessories such as space heaters, RTD's etc.
AC Power Connect the motor leads as shown on the connection diagram located on the name plate
or inside the cover on the conduit box. Be sure the following guidelines are met:
1. AC power is within r10% of rated voltage with rated frequency. (See motor name
plate for ratings).
OR
2. AC power is within r5% of rated frequency with rated voltage.
OR
3. A combined variation in voltage and frequency of r10% (sum of absolute values) of
rated values, provided the frequency variation does not exceed r5% of rated
frequency.
Performance within these voltage and frequency variations are shown in Figure 2‐2.

Figure 2‐1 Accessory Connections

One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).

Three thermisters are installed in windings and tied in series.

Leads are labeled T1 & T2.

Winding RTDs are installed in windings (2) per phase.

Each set of leads is labeled W1, W2, W3, W4, W5, & W6.

* One bearing RTD is installed in Drive endplate (PUEP), leads

are labeled RTDDE.
* One bearing RTD is installed in Opposite Drive endplate (FREP), leads
are labeled RTDODE.

* Note RTD may have 2-Red/1-White leads; or 2-White/1-Red Lead.

2‐2 Installation & Operation MN400

Section 1
General Information

Figure 2‐2 Typical Motor Performance VS Voltage Variations

+20
Maximum
Full ‐Load Torque
Current
+15
Changes in Motor Performance (%)

+10
Full ‐Load
Power Current
Factor
+5

Efficiency Efficiency
-5

-10

-15
Power
Maximum Factor
Torque
-20
-15 -10 -5 0 +5 +10 +15
Voltage Variations (%)

MN400 Installation & Operation 2‐3

Section 1
General Information

First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is
disconnected from the load and will not cause mechanical rotation of the motor shaft.
1. Make sure that the mechanical installation is secure. All bolts and nuts are tightened
etc.
2. If motor has been in storage or idle for some time, check winding insulation integrity
with a Megger.
3. Inspect all electrical connections for proper termination, clearance, mechanical
strength and electrical continuity.
4. Be sure all shipping materials and braces (if used) are removed from motor shaft.
5. Manually rotate the motor shaft to ensure that it rotates freely.
6. Replace all panels and covers that were removed during installation.
7. Momentarily apply power and check the direction of rotation of the motor shaft.
8. If motor rotation is wrong, be sure power is off and change the motor lead
connections. Verify rotation direction before you continue.
9. Start the motor and ensure operation is smooth without excessive vibration or noise.
If so, run the motor for 1 hour with no load connected.
10. After 1 hour of operation, disconnect power and connect the load to the motor shaft.
Verify all coupling guards and protective devices are installed. Ensure motor is
properly ventilated.
Coupled Start Up This procedure assumes a coupled start up. Also, that the first time start up procedure
was successful.
1. Check the coupling and ensure that all guards and protective devices are installed.
2. Check that the coupling is properly aligned and not binding.
3. The first coupled start up should be with no load. Apply power and verify that the
load is not transmitting excessive vibration back to the motor though the coupling or
the foundation. Vibration should be at an acceptable level.
4. Run for approximately 1 hour with the driven equipment in an unloaded condition.
The equipment can now be loaded and operated within specified limits. Do not exceed
the name plate ratings for amperes for steady continuous loads.
Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or
jog than by the same motor under full load. If it is necessary to repeatedly start or jog the
motor, it is advisable to check the application with your local Baldor distributor or Baldor
Service Center.
Heating ‐ Duty rating and maximum ambient temperature are stated on the motor name
plate. Do not exceed these values. If there is any question regarding safe operation,
contact your local Baldor distributor or Baldor Service Center.

2‐4 Installation & Operation MN400

Section 3
Maintenance & Troubleshooting

WARNING: UL Listed motors must only be serviced by UL Approved

Authorized Baldor Service Centers if these motors are to be
returned to a hazardous and/or explosive atmosphere.
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or
every 3 months, whichever occurs first. Keep the motor clean and the ventilation
openings clear. The following steps should be performed at each inspection:
WARNING: Do not touch electrical connections before you first ensure that
power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
1. Check that the motor is clean. Check that the interior and exterior of the motor
is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can
accumulate and block motor ventilation. If the motor is not properly ventilated,
overheating can occur and cause early motor failure.
2. Use a “Megger” periodically to ensure that the integrity of the winding
insulation has been maintained. Record the Megger readings. Immediately
investigate any significant drop in insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating
ability of a grease (over time) depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the severity of the operating
conditions. Good results can be obtained if the following recommendations are used in
your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Recommended grease for
standard service conditions is Polyrex EM (Exxon Mobil).
Equivalent and compatible greases include:
Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

Relubrication Intervals Recommended relubrication intervals are shown in Table 3‐1. It is important to realize
that the recommended intervals of Table 3‐1 are based on average use.

Refer to additional information contained in Tables 3‐2, 3‐3 and 3‐4.

Table 3‐1 Relubrication Intervals *
Rated Speed ‐ RPM
NEMA / (IEC) Frame Size 10000 6000 3600 1800 1200 900
Up to 210 incl. (132) ** 2700 Hrs. 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.
Over 210 to 280 incl. (180) ** 3600 Hrs. 9500 Hrs. 15000 Hrs. 18000 Hrs.
Over 280 to 360 incl. (225) ** * 2200 Hrs. 7400 Hrs. 12000 Hrs. 15000 Hrs.
Over 360 to 5800 incl. (300) ** *2200 Hrs. 3500 Hrs. 7400 Hrs. 10500 Hrs.
* Relubrication intervals are for ball bearings.
For vertically mounted motors and roller bearings, divide the relubrication interval by 2.
** For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.

MN400 Maintenance & Troubleshooting 3‐1

 Table 3‐2 Service Conditions
Severity of Service Hours per day Ambient Temperature Atmospheric
of Operation Maximum Contamination
Standard 8 40q C Clean, Little Corrosion
Severe 16 Plus 50q C Moderate dirt, Corrosion
Extreme 16 Plus >50q C* or Severe dirt, Abrasive dust, Corrosion, Heavy
Class H Insulation Shock or Vibration
Low Temperature <-29 q C **
* Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does
not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.
** Special low temperature grease is recommended (Aeroshell 7).
Table 3‐3 Relubrication Interval Multiplier
Severity of Service Multiplier
Standard 1.0
Severe 0.5
Extreme 0.1
Low Temperature 1.0

Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate.
In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use the
appropriate amount of grease for each bearing size (not the same for both).
Table 3‐4 Bearings Sizes and Types
Bearing Description
(These are the “Large” bearings (Shaft End) in each frame size)
Frame Size
Weight of Grease to Volume of grease
NEMA (IEC)
Bearing add * to be added
oz (Grams) in3 teaspoon
56 to 140 (90) 6203 0.08 (2.4) 0.15 0.5
140 (90) 6205 0.15 (3.9) 0.2 0.8
180 (100-112) 6206 0.19 (5.0) 0.3 1.0
210 (132) 6307 0.30 (8.4) 0.6 2.0
250 (160) 6309 0.47 (12.5) 0.7 2.5
280 (180) 6311 0.61 (17) 1.2 3.9
320 (200) 6312 0.76 (20.1) 1.2 4.0
360 (225) 6313 0.81 (23) 1.5 5.2
400 (250) 6316 1.25 (33) 2.0 6.6
440 (280) 6319 2.12 (60) 4.1 13.4
5000 to 5800 (315-450) 6328 4.70 (130) 9.2 30.0
5000 to 5800 (315-450) NU328 4.70 (130) 9.2 30.0
360 to 449 (225-280) NU319 2.12 (60) 4.1 13.4
AC Induction Servo
76 Frame 180 (112) 6207 0.22 (6.1) 0.44 1.4
77 Frame 210 (132) 6210 0.32 (9.0) 0.64 2.1
80 Frame 250(160) 6213 0.49 (14.0) 0.99 3.3
* Weight in grams = .005 DB
of grease to
be added
Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the
grease volume for the next larger size bearing.

3‐2 Maintenance & Troubleshooting MN400

 Caution: To avoid damage to motor bearings, grease must be kept free of dirt.
For an extremely dirty environment, contact your Baldor distributor or
an authorized Baldor Service Center for additional information.
Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease
already in the motor. Consult your Baldor distributor or an authorized service center if a
grease other than the recommended type is to be used.
Caution: Do not over-lubricate motor as this may cause premature bearing
failure.
With Grease Outlet Plug
1. With the motor stopped, clean all grease fittings with a clean cloth.
2. Remove grease outlet plug.
Caution: Over-lubricating can cause excessive bearing temperatures,
premature lubrication breakdown and bearing failure.
3. Add the recommended amount of grease.
4. Operate the motor for 15 minutes with grease plug removed.
This allows excess grease to purge.
5. Re‐install grease outlet plug.
Without Grease Provisions
Note: Only a Baldor authorized and UL or CSA certified service center can
disassemble a UL/CSA listed explosion proof motor to maintain it's
UL/CSA listing.
1. Disassemble the motor.
2. Add recommended amount of grease to bearing and bearing cavity. (Bearing
should be about 1/3 full of grease and outboard bearing cavity should be about
1/2 full of grease.)
3. Assemble the motor.
Sample Relubrication Determination
Assume ‐ NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient
temperature of 43q C and the atmosphere is moderately corrosive.
1. Table 3‐1 list 9500 hours for standard conditions.
2. Table 3‐2 classifies severity of service as “Severe”.
3. Table 3‐4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.

MN400 Maintenance & Troubleshooting 3‐3

Section 1
General Information

Table 3‐5 Troubleshooting Chart

Symptom Possible Causes Possible Solutions
Motor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,
as, single phasing at the starter. controls, etc.
Excessive humming High Voltage. Check input line connections.
Eccentric air gap. Have motor serviced at local Baldor service center.
Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in
(measured) with nameplate rating. motor or load.
Reduce load or replace with motor of greater capacity.
Single Phasing. Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Improper ventilation. Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build‐up on motor. Clean motor.
Unbalanced voltage. Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Rotor rubbing on stator. Check air gap clearance and bearings.
Tighten “Thru Bolts”.
Over voltage or under voltage. Check input voltage at each phase to motor.
Open stator winding. Check stator resistance at all three phases for
balance.
Grounded winding. Perform dielectric test and repair as required.
Improper connections. Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Bearing Over Heating Misalignment. Check and align motor and driven equipment.
Excessive belt tension. Reduce belt tension to proper point for load.
Excessive end thrust. Reduce the end thrust from driven machine.
Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.
Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.
Dirt in bearing. Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Vibration Misalignment. Check and align motor and driven equipment.
Rubbing between rotating parts and Isolate and eliminate cause of rubbing.
stationary parts.
Rotor out of balance. Have rotor balance checked are repaired at your
Baldor Service Center.
Resonance. Tune system or contact your Baldor Service Center
for assistance.
Noise Foreign material in air gap or Remove rotor and foreign material. Reinstall rotor.
ventilation openings. Check insulation integrity. Clean ventilation openings.
Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity and
new bearing. Repack with correct grease until cavity
is approximately 3/4 filled.

3‐4 Maintenance & Troubleshooting MN400

Suggested bearing and winding RTD setting guidelines
Most large frame AC Baldor motors with a 1.15 service factor are designed to operate
below a Class B (80qC) temperature rise at rated load and are built with a Class H
winding insulation system. Based on this low temperature rise, RTD (Resistance
Temperature Detectors) settings for Class B rise should be used as a starting point.
Some motors with 1.0 service factor have Class F temperature rise.
The following tables show the suggested alarm and trip settings for RTDs. Proper
bearing and winding RTD alarm and trip settings should be selected based on these
tables unless otherwise specified for specific applications.
If the driven load is found to operate well below the initial temperature settings under
normal conditions, the alarm and trip settings may be reduced so that an abnormal
machine load will be identified.
The temperature limits are based on the installation of the winding RTDs imbedded in
the winding as specified by NEMA. Bearing RTDs should be installed so they are in
contact with the outer race on ball or roller bearings or in direct contact with the sleeve
bearing shell.
Winding RTDs - Temperature Limit In 5C (405C Maximum Ambient)
Class B Temp Rise 3 80qC
Class F Temp Rise 3 105qC Class H Temp Rise 3 125qC
Motor Load (Typical Design)
Alarm Trip Alarm Trip Alarm Trip
3 Rated Load 130 140 155 165 175 185
Rated Load 140 150 160 165 180 185
to 1.15 S.F.
Note: S Winding RTDs are factory production installed, not from Mod-Express.
S When Class H temperatures are used, consider bearing temperatures and relubrication requirements.

Bearing RTDs - Temperature Limit In 5C (405C Maximum Ambient)

Bearing Type Anti-Friction Sleeve
Oil or Grease Alarm Trip Alarm Trip
Standard* 95 100 85 95
High Temperature** 110 115 105 110
Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise.
** High temperature lubricants include some special synthetic oils and greases.
Greases that may be substituted that are compatible with Polyrex EM (but considered as
“standard” lubricants) include the following:
- Texaco Polystar - Rykon Premium #2 - Chevron SRI #2
- Mobilith SHC-100 - Pennzoil Pennzlube EM-2 - Chevron Black Pearl
- Darmex 707 - Darmex 711 - Petro-Canada Peerless LLG
See the motor nameplate for replacement grease or oil recommendation.
Contact Baldor application engineering for special lubricants or further clarifications.

MN400 Maintenance & Troubleshooting 3‐5

3‐6 Maintenance & Troubleshooting MN400
Baldor District Offices Baldor District Offices Baldor District Offices
 BALDOR ELECTRIC COMPANY
World Headquarters
P.O. Box 2400 Fort Smith, AR 72901-2400
(479) 646-4711 Fax (479) 648-5792
www.baldor.com

¤ Baldor Electric Company Printed in USA

MN400 2/07
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 Motors | Automation | Energy | Transmission & Distribution | Coatings

Electric motors for explosive atmospheres

Instructions manual for installation, operation and maintenance of electric motors
(This page intentionally left blank)
 ENGLISH
1. INTRODUCTION
The installation, operation and maintenance of the motor must be always performed by qualified and authorized personnel using proper
tools and methods and following the instructions contained in the documents supplied with the motor.

The instructions presented in this document are valid for WEG motors with the following characteristics:
JThree-phase and single-phase induction motors (squirrel cage rotor); JThree-phase permanent magnet motors;

JThree-phase hybrid motors (squirrel cage rotor + permanent magnets);

These motors can be used in hazardous areas with the following types of protection:
JIncreased Safety – “Ex e”; JType of protection “n” - “Ex n”;

JFlameproof enclosure - “Ex d” or “Ex de”; JProtection by Enclosure (combustible dust) - “Ex t”;

JClass I Division 1; JClass I Division 2;

JClass II Division 1; JClass II Division 2.

Details of motor marking may be found on nameplate and product certification, which is part of the motor documentation. For reference, this manual
lists the certificate numbers for each type of protection and their nameplate markings. Furthermore, the applicable Standards may be found in
the product certification and at the “Installation, Operation and Maintenance Manual of Electric Motors for Use in Explosive Atmospheres” - code
50034162. This manual is available in the website www.weg.net.
The objective of this manual is to provide important information, which must be considered during the shipment, storage, installation, operation and
maintenance of WEG motors. Therefore, we advise to make a careful and detailed reading of the instructions contained herein before performing any
intervention on the motor. The noncompliance with the instructions informed in this manual and others mentioned in the website www.weg.net voids
the product warranty and may compromise the type of protection of the motor and still result in serious personal injuries and material damages.
Any component added to the motor by the user, for example, cable glands, thread plug, encoder, etc., must meet the type of
protection of the enclosure, the “equipment protection levels” (EPL) and the degree of protection of the motor, according to the
Standards indicated in the product certification.
Special Conditions for Safe Use
The sign “X” added to the certificate number, informed on the nameplate of the motor, indicates that the equipment demands
special conditions for installation, operation and/or maintenance, being those described in the certificate and the motor
documentation.
For reference, the chapter Certificates lists the certificate numbers for each type of protection and their nameplate markings.
The noncompliance with these requirements compromises the safety of the product and of the installation.
The correct classification of the installation area and ambient characteristics is user’s responsibility.
Electric motors have energized circuits and exposed rotating parts which may cause injuries to people.
2. SHIPMENT, STORAGE AND HANDLING
Check the conditions of the motor right after receiving. When any damage is noticed, this must be reported in writing to the transportation company,
and immediately communicated to the insurance company and to WEG. In this case, no installation job can be started before the detected problem
has been solved.
Check if the nameplate data match the invoice data, the environment conditions where the motor will be installed, the type of protection and EPL of
the motor. If the motor is not immediately installed, it must be stored in a clean and dry room protected against dust, vibrations, gases and corrosive
agents, with relative humidity not over 60%.
In order to prevent water condensation within the motor during the storage period, it is recommended to keep the space heater ON (if available). In
order to prevent oxidation of the bearings and ensure an even distribution of the lubricant, rotate the motor shaft at least once a month (at least five
turns), always leaving it in a different position. For bearings with oil mist lubrication systems, the motor must be stored horizontally with ISO VG 68
oil in the bearing, with the amount indicated in the motor manual available in the website and the shaft must be turned every week. If the motors
are stored for more than two years, it is recommended to change the bearings, or to remove, wash, inspect and relubricate them before the motor
is started. After this storage period, it is also recommended to change the start capacitors of single-phase motors since they loss their operating
characteristics.
Handle the motor always carefully in order to prevent impacts and damages to the bearings and always install the shaft
transportation/locking device (if supplied) when transporting the motor.
Use only the eyebolts to lift the motor. However these eyebolts are designed for the motor weight only. Thus never use these
eyebolts to lift the motor with additional loads coupled to it. The lifting eyebolts of the terminal box, fan cover, etc., are intended to handle
only these parts when disassembled from the motor.
Periodically and mainly before the initial star-up, measure the insulation resistance of the motor winding. Check the recommended values and the
measuring procedures in the website.
3. INSTALLATION
During the installation, the motors must be protected against accidental energization.
Check the motor direction of rotation, turning it without load before it is coupled to the load.
Remove the transportation devices and shaft locking device (if supplied) before starting the motor installation.
Motors must be only installed in places compatible with their mounting features and in applications and environments for which they are intended. It must be respected the
type of protection and the EPL of the motor, according to the classification of the area where the motor will be installed.
The motors with feet must be installed on bases duly planned in order to prevent vibrations and assure perfect alignment. The motor shaft must be properly aligned with
the shaft of the driven machine. Incorrect alignment, as well as improper belt tension, will certainly damage the bearings, resulting in excessive vibrations and even causing
the shaft rupture. The admissible shaft radial and axial loads indicated in the general manual of the website must be respected. Use flexible coupling whenever possible.
When motors are fitted with oil lubricated bearings or oil mist lubrication systems, connect the cooling and lubrication tubes (where provided).
For oil lubricated bearings, the oil level must be in the center of the sight glass.
Only remove the corrosion protection grease from the shaft end and flange immediately before the motor installation.
Unless specified otherwise in the purchase order, WEG motors are dynamically balanced with “half key” and without load (uncoupled). The driving elements, such as
pulleys, couplings, etc., must be balanced with “half key” before they are mounted on the shaft of the motors.
The motor must always be positioned so the drain hole is at the lowest position.
Motors supplied with rubber drain plugs leave the factory in the closed position and must be opened periodically to allow the exit of
condensed water. For environments with high water condensation levels and motor with degree of protection IP55, the drain plugs can be
mounted in open position.

Electric motors for explosive atmospheres | 3

For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position, being opened only during the
motor maintenance procedures.
The drain system of motors with Oil Mist lubrication system must be connected to a specific collection system.
The drain plugs of explosion proof motors cannot be removed during installation and maintenance procedures.
When provided with a breather-drain to certificate IECEx CSA 12.0005U, the motors are limited to Groups IIB, IIC and IIIC, an ambient
temperature of -55 °C to + 40 °C, temperature classification T5 to T2, and have a degree of protection of IP6X (for group IIIC).
Do not block the motor ventilation openings. Ensure a minimum clearance of ¼ of the diameter of the air intake of the fan cover from
the walls. The air used for cooling the motor must be at ambient temperature, limited to the temperature range indicated on the motor
nameplate (when not indicated, -20 °C to +40 °C must be considered).
Motors installed outdoors or in the vertical position require the use of additional shelter to protect them from water; for instance, use of a drip cover.
To prevent accidents, ensure that the grounding connection has been performed according to the applicable standards and that the shaft
key has been well-fixed fastened before the motor is started.
Connect the motor properly to the power supply by means of safe and permanent contacts, always considering the data informed on the
nameplate, such as rated voltage, wiring diagram, etc.
When motors are supplied with flying leads, they must be suitably connected to an appropriate terminal box required for the use condition
(type of protection).
When using terminals, all wires that form the stranded cable must be fastened inside the sleeve. The insulation of the accessories cables
must be kept up to 1 mm from the connector connection point.
For power cables and grounding system connections and terminal box assembly, the tightening torques indicated on Tables 1 and 2 must be
respected.
Table 1 - Tightening torques for fixing elements [Nm]
Type of protection of
Component M4 M5 M6 M8 M10 M12 M14 M16 M20
enclosure
Ex d Class 8.8/12.9 - 3.5 to 5 6 to 12 14 to 30 28 to 60 45 to 105 75 to 110 115 to 170 230 to 330
Terminal Box Cover
Class A2-70 / A4-70 - 3.5 to 5 6 to 8.5 14 to 19 28 to 40 45 to 60 75 to 100 115 to 170 225 to 290
Ex de Grounding 1.5 to 3 3 to 5 5 to 10 10 to 18 28 to 40 45 to 70 - 115 to 170 -
Ex d 1 to 1.5 2 to 4 4 to 6.5 6.5 to 9 10 to 18 15.5 to 30 - 30 to 50 50 to 75
Terminal block
1 to 1.5 2 to 4 4 to 6.5 6.5 to 9 5 to 9 10 to 15 - 20 to 30 -
Ex de Locking bolt for connection clamp - 3 to 7 4 to 8 7 to 11 - - - - -
Locking bolt for power cables - - - 2 to 6 6 to 10 - - - -
Ex n Terminal box cover - 3 to 5 4 to 8 8 to 15 18 to 30 25 to 40 30 to 45 35 to 50 -
Grounding 1.5 to 3 3 to 5 5 to 10 10 to 18 28 to 40 45 to 70 - 115 to 170 -
Ex t
Terminal block 1 to 1.5 2 to 4 4 to 6.5 6.5 to 9 10 to 18 15.5 to 30 - 30 to 50 50 to 75
Ex e Terminal block fixing bolts - 3 to 5 5 to 10 10 to 18 28 to 40 45 to 70 75 to 110 115 to 170 -

Table 2 - Tightening torques for cable glands and plugs [Nm]

Thread Material M16 M20 M25 M32 M40 M50 M63 M80
Plastic 3 to 5 3 to 5 6 to 8 6 to 8 6 to 8 6 to 8 6 to 8 6 to 8
Metric
Metallic 40 to 50 40 to 50 55 to 70 65 to 80 80 to 100 100 to 120 115 to 140 160 to 190
NPT NPT NPT NPT NPT NPT NPT NPT
Thread Material
1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3" 4"
Plastic - 5 to 6 6 to 8 6 to 8 6 to 8 6 to 8 6 to 8 6 to 8
NPT
Metallic 40 to 50 40 to 50 55 to 70 65 to 80 100 to 120 115 to 140 150 to 175 200 to 240

For power cables, switching and protection devices dimensioning, consider the rated motor current, the service factor, and the cable length, among
others. For motors without terminal block, insulate the motor terminal cables by using insulating materials that are compatible with the insulation
class informed on the nameplate. The minimum insulation distance between the non-insulated live parts themselves and between live parts and the
grounding must respect the Table 3.
Table 3 - Minimum insulation distance (mm)
Type of protection of the enclosure
Voltage
Ex e / Ex de Ex n/ Ex d/ Ex t
U ≤ 440 V 6 4
440 < U ≤ 690 V 10 5.5
690 < U ≤ 1000 V 14 8
1000 < U ≤ 6900 V 60 45
6900 < U ≤ 11000 V 100 70
11000 <U ≤ 16500 V - 105

Not-used cable inlet holes in the terminal box must be properly closed with certified plugs in order to assure the type of
protection, EPL and degree of protection indicated on the nameplate.
The cable entries used must be fitted with components (such as, cable glands and conduits) that meet the applicable standards
and regulations for each country. For “Ex d” motors, the conduit entries are permitted only for electrical equipment of group II.

The motor must be installed with overload protection devices. These protection devices can be integrated to the motor (such as thermistors in the
windings) or external protection devices, where the motor load is monitored by the nominal current. For three-phase motors, it is recommended to
install a phase failure protection device.
Motors driven by variable frequency drives must have their winding thermal protections connected. For other starting methods, the use of the thermal
protections is optional. When connected to the motor control circuit, the thermal protection must be used as simple apparatus into intrinsically safe
circuits.
Ensure the correct operation of the accessories (brake, encoder, thermal protection, forced ventilation, etc.) installed on the motor before it is started.

4 | Electric motors for explosive atmospheres

The temperature limits for alarm and tripping of the thermal protection can be defined according to the application, however they may not exceed the
values shown in Table 4.
Table 4 - Maximum temperature of actuation for thermal protections
Classified area marked on Classified area where product Maximum operating temperature (°C)
Component
nameplate will be installed Alarm Tripping
Ex d Ex d 130 150
Ex n Ex n 130 155
Ex t Ex t 120 140
Ex e Ex e - 110
Ex n 140 155
Winding Ex n + Ex t Ex t - 140
Ex d + Ex t Ex d 140 150
Ex t - 140
Class I Div. 1 Class I Div. 1 130 150
Class I Div. 2 Class I Div. 2 130 155
Class II Div. 1 Class II Div. 1 120 140
Bearings All All 110 120
Notes:
1) The quantity and type of thermal protections installed in the motor are infomed in the additional nameplates included on it.
2) In case of calibrated thermal protection (for example, Pt-100), the monitoring system must be set at the operation temperature indicated on Table 4.
In “Ex e” motors application, the thermal protection device, in case of overload or locked rotor, must actuate with time delay according to the
current and track the external power cables. The “tE” time indicated in the motor nameplate can not be exceeded. The “Ex e” motors, submitted to
acceleration time conditions greater than 1,7 x “tE” time, must be protected with protection devices against overcurrent.

Motors fitted with Automatic Thermal Protectors will reset automatically as soon as the motor cools down. Thus, do not use
motors with Automatic Thermal Protection in applications where the auto-reseting of this device may cause injuries to people or
damage to equipment. If the Automatic Thermal Protector trips, disconnect the motor from the power supply and check the cause
why the thermal protector trips.
For more information about the use of variable frequency drives, you must follow the instructions in the motor manual in the website and in the
manual of the variable frequency drive.

4. OPERATION
During operation, do not touch the non-insulated energized parts and never touch or stay too close to rotating parts.
Ensure that the space heater is always OFF during the motor operation.

The rated performance values and the operating conditions are specified on the motor nameplate. The voltage and frequency variations of the power supply should
never exceed the limits established in the applicable standards.
Occasional different behavior during the normal operation (actuation of thermal protections, noise level, vibration level, temperature and current increase) must always
be assessed by qualified personnel. In case of doubt, turn off the motor immediately and contact the nearest WEG service center.
Do not use roller bearings for direct coupling. Motors fitted with roller bearings require a minimum radial load to ensure a proper operation.
For motors fitted with oil lubrication or oil mist systems, the cooling system must be ON even after the machine is OFF and until the machine is at complete standstill.
In case of failure in the lubrication and/or cooling system, turn the motor OFF immediatly.
After complete standstill, the cooling and lubrication systems (if any exist) must be switched OFF and the space heaters (if available) must be switched ON.
In case of doubts, turn the motor OFF immediately and contact the nearest WEG authorized service Center for explosive atmospheres.
5. MAINTENANCE
Before any service is performed, ensure that motor is at standstill, disconnected from the power supply and protected against
accidental energization. Even when the motor is stopped, dangerous voltages may be present in space heater terminals.
Motor disassemble during the warranty period must be performed by a WEG authorized service center for Explosive Atmospheres only.
For motors with permanent magnet rotor (lines WQuattro and Wmagnet), the motor assembly and disassembly require the use of proper
devices due to the attractive or repulsive forces that occur between metallic parts. This job must be only performed by a WEG Authorized
service center specifically trained for such an operation. People with pacemakers cannot handle these motors. The permanent magnets
can also cause disturbances or damages to other electric equipment and components during maintenance.
Motors with flameproof enclosures and explosion proof enclosures, wait at least 60 minutes for frame sizes IEC 71 up to 200 and NEMA
143/5 up to 324/6 and at least 150 minutes for frames sizes IEC 225 up to 355 and NEMA 364/5 to 586/7 to open the terminal box and/or
disassemble the motor.
Motors with degree of protection greater than IP55 are supplied with a sealing product on joints and fixing bolts. Before assembly the components
with machined faces (for example, terminal box cover of Flameproof motors), clean these surfaces and apply a new layer of this product.
For Flameproof motors joints only the following products can be used: Lumomoly PT/4 (manufacturer: Lumobras – for ambient temperature ranging
from -20 °C to +80 °C) or Molykote DC 33 (manufacturer: Dow Corning – for ambient temperature ranging from -55 °C to +80 °C)). For motors with
other types of protection, use Loctite 5923 (manufacturer: Henkel) on joints.
For Flameproof motors, special care should be taken with the machined surfaces of the flame path. These surfaces must be free of burrs, scratches,
etc. that reduce the flame path length and increase the gap. The gaps between terminal boxes and the respective terminal box covers should not
exceed the values specified in Table 5.
Table 5 - Maximum gap between terminal box and terminal box cover for flameproof enclosures
Flat joint Cylindrical joint
Product line Frame size
Gap (max) Lenght (min) Gap (max) Lenght (min)
IEC 90 to 355
W21Xd 0.05 mm Under request Not available
NEMA 143 to 586/7
IEC 71 and 80 Not available 0.15 mm 12.5 mm
W22Xd
IEC 90 to 355
0.075 mm 6 mm 0.15 mm 19 mm
NEMA 143 to 586/7

For terminal box cover mounting, please follow the tightening torques indicated on Table 1 for fixing bolts.
In case of replacement of a fixing bolt, it is necessary to keep its dimensions and quality of material. For flameproof motors, the yield stress of the fastener elements of
motor and terminal boxes enclosures must be at least equal to class 12.9 for carbon steel bolts and class A2-70 or A4-70 for stainless steel bolts.
Motors which may have a potential risk of electrostatic charge accumulation, supplied duly identified, must receive proper cleaning and maintenance interventions, i.e.
with the use of a damp cloth, avoiding electrostatic discharges.
For Protection by Enclosure motors (groups I and/or III), the maximum permissible dust layer on the motor enclosure is five millimeters (5 mm).
Regularly inspect the operation of the motor, according to its application, and ensure a free air flow. Inspect the seals, the fastening bolts, the bearings, the vibration and
Electric motors for explosive atmospheres | 5
noise levels, the drain operation, etc.
The lubrication interval is specified on the motor nameplate (more information in the website www.weg.net).
6. ADDITIONAL INFORMATION
For further information about shipment, storage, handling, installation, operation and maintenance of electric motors, access the website www.weg.net.
For special applications and operating conditions (for example, smoke extraction motors, totally enclosed air over (TEAO), motors for high thrust
applications, motors with brake) refer to the manual in the website or contact WEG.
When contacting WEG, please, have the full description of the motor at hand, as well as the serial number and manufacturing date, indicated on the
motor nameplate.
7. WARRANTY TERMS
WEG Equipamentos Elétricos S/A, Motors Business Unit (“WEG”), offers warranty against defects in workmanship and materials for its products for a
period of 18 months from the invoice date issued by the factory or distributor/dealer, limited to 24 months from the date of manufacture.
Motors of the HGF Line are covered for a period of 12 months from the invoice date issued by the factory or distributor / dealer, limited to 18 months
from the date of manufacture. The paragraphs above contain the legal warranty periods. If a warranty period is defined in a different way in the
commercial/technical proposal of a particular sale, that will supersede the time limits set out above. The warranty periods above are independent
of the product installation date and the startup. If any defect or abnormal occurrence is detected during machine operation, the customer must
immediately notify WEG in writing about the occurred defect, and make the product available for WEG or its Authorized Service Center for the period
required to identify the cause of the defect, check the warranty coverage, and perform the proper repairs. In order for the warranty to be valid, the
customer must be sure to follow the requirements of WEG’s technical documents, especially those set out in the product Installation, Operation and
Maintenance Manual, as well as the applicable standards and regulations in force in each country. Defects arising from the inappropriate or negligent
use, operation, and/or installation of the equipment, non-execution of regular preventive maintenance, as well as defects resulting from external
factors or equipment and components not supplied by WEG, will not be covered by the warranty. The warranty will not apply if the customer at its
own discretion makes repairs and/or modifications to the equipment without prior written consent from WEG. The warranty will not cover equipment,
components, parts and materials whose lifetime is usually shorter than the warranty period. It will not cover defects and/or problems resulting from
force majeure or other causes not imputable to WEG, such as, but not limited to: incorrect or incomplete specifications or data supplied by the
customer; transportation, storage, handling, installation, operation and maintenance not complying with the provided instructions; accidents; defects
in the construction works; use in applications and/or environments for which the machine was not designed; equipment and/or components not
included in the scope of WEG supply. The warranty does not include disassembly services at the buyer’s premises, product transportation costs and
travel, lodging and meal expenses for the technical staff of the Service Centers, when requested by the customer. The services under warranty will
be provided exclusively at WEG authorized Service Centers or at one of its manufacturing plants. Under no circumstances will the warranty services
extend the equipment warranty period. WEG’s Civil Liability is limited to the supplied product; WEG will not be liable for indirect or consequential
damages, such as losses of profit and revenue losses and alike which may arise from the contract signed between the parties.
8. EC DECLARATION OF CONFORMITY
WEG Equipamentos Elétricos S/A WEG (Nantong) Electric Motor Manufacturing CO., LTD.
Av. Prefeito Waldemar Grubba, 3000 No. 128# - Xinkai South Road, Nantong Economic & Technical
89256-900 - Jaraguá do Sul – SC – Brazil, Development Zone, Nantong, Jiangsu Province - China,
and its authorised representative established in the European Community,
WEGeuro – Industria Electrica SA
Contact person: Luís Filipe Oliveira Silva Castro Araújo
Rua Eng Frederico Ulrich, Apartado 6074
4476-908 – Maia – Porto – Portugal
hereby declare that the products:
WEG induction motors and components for using in these motors, with types of protection:
Flameproof Enclosure “d” or “de”
IEC frames 71 to 355 (three-phase) and NEMA frame 61 (single and three-phase)
...............
Increased Safety “e”
IEC frames 63 to 630 (three-phase)
...............
type of protection “n”
IEC frames 63 to 630 and NEMA frames 143 to 9610 (three-phase)
...............
and dust ignition protection by enclosure “tD” ou “t”
IEC frames 63 to 630 and NEMA frames 143 to 9610 (three-phase)
...............
when installed, maintained and used in applications for which they were designed, and in compliance with the relevant installation standards and
manufacturer’s instructions, comply with the requirements of the following European Directives and standards where applicable:
Directives:
ATEX Directive 94/9/EC
Machinery Directive 2006/42/EC**
EMC Directive 2004/108/EC (inductions motors are considered inherently benign in terms of electromagnetic compatibility)
Standards:
EN 60079-0:2009, EN 60079-1:2007, EN 60079-7:2007, EN 60079-15:2010*,
EN 60079-31:2009, EN 60204-1:2006/AC:2010 and EN 60204-11:2000/AC:2010
* Electric motors designed for use with a voltage rating higher than 6,600 V complies with EN 60079-15:2005.
** Low voltage electric motors are not considered under the scope and electric motors designed for use with a voltage rating higher than 1,000 V are
considered partly completed machinery and are supplied with a
Declaration of Incorporation:
The products above cannot be put into service until the machinery into which they have been incorporated has been declared in conformity with the
Machinery Directive.
A Technical Documentation for the products above is compiled in accordance with part B of annex VII of Machinery Directive 2006/42/EC.
We undertake to transmit, in response to a reasoned request by the national authorities, relevant information on the partly completed machinery
identified above through WEG authorised representative established in the European Community. The method of transmission shall be electronic or
physical method and shall be without prejudice to the intellectual property rights of the manufacturer.

CE marking in: 1996

Milton Oscar Castella
Engineering Director
Jaraguá do Sul, March 15th, 2013
A list of the EC-Type Examination Certificates covered by the Declaration of Conformity is shown in chapter Certificates.

6 | Electric motors for explosive atmospheres

 Motors | Automation | Energy | Transmission & Distribution | Coatings

Low and high voltage electric motors

Instructions manual for installation, operation and maintenance of electric motors
(This page intentionally left blank)
 ENGLISH
1. INTRODUCTION
The installation, operation and maintenance of the motor must be always performed by qualified personnel
using proper tools and methods and following the instructions contained in the documents supplied with the
motor.
The instructions presented in this document are valid for WEG motors with the following characteristics:
Three-phase and single-phase induction motors (squirrel cage rotor);
J

Three-phase permanent magnet motors;

J

Three-phase hybrid motors (squirrel cage rotor + permanent magnets);

J

The objective of this manual is to provide important information, which must be considered during the shipment,
storage, installation, operation and maintenance of WEG motors. Therefore, we advise to make a careful and detailed
study of the instructions contained herein before performing any procedures on the motor. The noncompliance with
the instructions informed in this manual and others mentioned on the website www.weg.net voids the product
warranty and may cause serious personal injuries and material damages.
Electric motors have energized circuits and exposed rotating parts which may cause injuries to people.

2. SHIPMENT, STORAGE AND HANDLING

Check the conditions of the motor immediately upon receipt. When any damage is noticed, this must be reported in
writing to the transportation company, and immediately communicated to the insurance company and to WEG. In
this case, no installation job can be started before the detected problem has been solved.
Check if the nameplate data matches the invoice data and the environmental conditions in which the motor will be
installed. If the motor is not immediately installed, it must be stored in a clean and dry room protected against dust,
vibrations, gases and corrosive agents, and with relative humidity not exceeding 60%.
In order to prevent water condensation within the motor during the storage period, it is recommended to keep the
space heater ON (where provided). In order to prevent oxidation of the bearings and ensure an even distribution of
the lubricant, rotate the motor shaft at least once a month (at least five turns), always leaving it in a different position.
For bearings with oil mist lubrication systems, the motor must be stored horizontally, independently from the
mounting configuration, with ISO VG 68 oil in the bearing, (the amount is indicated in the motor manual available on
the website www.weg.net) and the shaft must be turned weekly. If the motors are stored for more than two years,
it is recommended to change the bearings, or to remove, wash, inspect and relubricate them before the motor is
started. After this storage period, it is also recommended to change the start capacitors of single-phase motors
since they loss their operating characteristics.
Handle the motor always carefully in order to prevent impacts and damages to the bearings and
always install the shaft transportation/locking device (if supplied) when transporting the motor.
Use only the eyebolts to lift the motor. However these eyebolts are designed for the motor
weight only. Thus never use these eyebolts to lift the motor with additional loads coupled
to it. The lifting eyebolts of the terminal box, fan cover, etc., are intended to handle only these parts
when disassembled from the motor. Additional information regarding the maximum allowable
angle-of-inclination is indicated in the general manual available on the website www.weg.net.
Periodically and mainly before the initial star-up, measure the insulation resistance of the motor winding.
Check the recommended values and the measuring procedures in the website.

3. INSTALLATION
During the installation, the motors must be protected against accidental energization.
Check the motor direction of rotation, turning it without load before it is coupled to the
load.
Remove the transportation devices and shaft locking device (if supplied) before starting the motor installation.
Motors must be only installed in places compatible with their mounting features and in applications and
environments for which they are intended.
Those motors with feet must be installed on bases duly planned in order to prevent vibrations and assure perfect
alignment. The motor shaft must be properly aligned with the shaft of the driven machine. Incorrect alignment, as
well as improper belt tension, will certainly damage the bearings, resulting in excessive vibrations and even causing
the shaft to rupture. The admissible shaft radial and axial loads indicated in the general manual of the website must
be respected. Use flexible coupling whenever possible. When motors are fitted with oil lubricated bearings or oil mist
lubrication systems, connect the cooling and lubrication tubes (where provided).
For oil lubricated bearings, the oil level must be in the center of the sight glass.

Low and High Voltage Electric Motors | 3

Only remove the corrosion protection grease from the shaft end and flange immediately before the motor
installation.
Unless specified otherwise in the purchase order, WEG motors are dynamically balanced with “half key” and
without load (uncoupled). The driving elements, such as pulleys, couplings, etc., must be balanced with “half
key” before they are mounted on the shaft of the motors.
Observe the correct assembly position of the drains as indicated in the manual on the website www.weg.net
Do not cover and block the motor ventilation openings. Ensure a minimum clearance of
¼ (25%) of the diameter of the air intake of the fan cover from the walls. The air used for
cooling the motor must be at ambient temperature, limited to the temperature indicated on
the motor nameplate.
Motors installed outdoors or in the vertical position require the use of additional shelter to protect
them from water; for instance, use of a drip cover.
To prevent accidents, ensure that the grounding connection has been performed according to the
applicable standards and that the shaft key has been securely fastened before the motor is started.
Connect the motor properly to the power supply by means of safe and permanent contacts, always
considering the data informed on the nameplate, such as rated voltage, wiring diagram, etc.
For power cables, switching and protection devices dimensioning, consider the rated motor current, the
service factor, and the cable length, among others. For motors without terminal block, insulate the motor
terminal cables by using insulating materials that are compatible with the insulation class informed on the
nameplate. The minimum insulation distance between the non-insulated live parts themselves and between
live parts and the grounding must be: 5.5 mm for rated voltage up to 690 V; 8 mm for voltages up to 1.1 kV;
45 mm for voltages up to 6.9 kV; 70 mm for voltages up to 11 kV and 105 mm for voltages up to 16.5 kV.
In order to assure the degree of protection, unused cable inlet holes in the terminal
box must be properly closed with blanking plugs having and equal or higher degree of
protection to that indicated on the motor nameplate.
The motor must be installed with overload protection devices. For three-phase motors, it is recommended
to install a phase failure protection device. When motor is fitted with temperature-monitoring devices in the
stator windings and/or bearings, they must be connected during the operation and even during tests.
Ensure the correct operation of the accessories (brake, encoder, thermal protection, forced ventilation, etc.)
installed on the motor before it is started.
Motors fitted with Automatic Thermal Protectors will reset automatically as soon as
the motor cools down. Thus, do not use motors with Automatic Thermal Protection in
applications where the auto-reseting of this device may cause injuries to people or damage
to equipment. Motors fitted with Manual Thermal Protectors require manual reset after they
trip. If the Automatic Thermal Protector or the Manual Thermal Protector trip, disconnect the motor
from the power supply and investigate the cause of the thermal protector tripping. Wmagnet motors
must be driven by WEG variable frequency drives only.
For more information about the use of variable frequency drives, follow the instructions in the motor manual
on the website www.weg.net and in the manual of the variable frequency drive.

4. OPERATION
During operation, do not touch the non-insulated energized parts and never touch or stay
too close to rotating parts.
Ensure that the space heater is always OFF during the motor operation.
The rated performance values and the operating conditions are specified on the motor nameplate. The
voltage and frequency variations of the power supply should never exceed the limits established in the
applicable standards.
Occasional different behavior during the normal operation (actuation of thermal protections, noise level,
vibration level, temperature and current increase) must always be assessed by qualified personnel. In case
of doubt, turn off the motor immediately and contact the nearest WEG service center.
Do not use roller bearings for direct coupling. Motors fitted with roller bearings require radial load to ensure
their proper operation.
For motors fitted with oil lubrication or oil mist systems, the cooling system must be ON even after the
machine is OFF and until the machine is at complete standstill.
After complete standstill, the cooling and lubrication systems (if any exist) must be switched OFF and the
space heaters must be switched ON.

4 | Low and High Voltage Electric Motors

5. MAINTENANCE
Before any service is performed, ensure that motor is at standstill, disconnected from
the power supply and protected against accidental energization. Even when the motor is
stopped, dangerous voltages may be present in space heater terminals.
If motors are fitted with capacitors, discharge them before any handling or service is performed.
Motor disassembly during the warranty period must be performed by a WEG authorized service
center only.
For motors with permanent magnet rotor (lines WQuattro and Wmagnet), the motor assembly and
disassembly require the use of proper devices due to the attracting or repelling forces that occur
between metallic parts. This work must only be performed by a WEG Authorized service center
specifically trained for such an operation. People with pacemakers cannot handle these motors.
The permanent magnets can also cause disturbances or damages to other electric equipment and
components during maintenance.
Regularly inspect the operation of the motor, according to its application, and ensure a free air flow. Inspect
the seals, the fastening bolts, the bearings, the vibration and noise levels, the drain operation, etc.
The lubrication interval is specified on the motor nameplate.

6. ADDITIONAL INFORMATION
For further information about shipment, storage, handling, installation, operation and maintenance of electric
motors, access the website www.weg.net.
For special applications and operating conditions (for example, smoke extraction motors, totally enclosed
air over (TEAO), motors for high thrust applications, motors with brake) refer to the applicable manual on the
website www.weg.net or contact WEG.
When contacting WEG, please, have the full description of the motor at hand, as well as the serial number
and manufacturing date, indicated on the motor nameplate.
7. WARRANTY TERM
WEG Equipamentos Elétricos S/A, Motors Business Unit (“WEG”), offers warranty against defects in workmanship
and materials for its products for a period of 18 months from the invoice date issued by the factory or distributor/
dealer, limited to 24 months from the date of manufacture.
Motors of the HGF Line are covered for a period of 12 months from the invoice date issued by the factory or
distributor / dealer, limited to 18 months from the date of manufacture.
The paragraphs above contain the legal warranty periods.
If a warranty period is defined in a different way in the commercial/technical proposal of a particular sale, that will
supersede the time limits set out above.
The warranty periods above are independent of the product installation date and the startup.
If any defect or abnormal occurrence is detected during machine operation, the customer must immediately notify
WEG in writing about the occurred defect, and make the product available for WEG or its Authorized Service
Center for the period required to identify the cause of the defect, check the warranty coverage, and perform the
proper repairs.
In order for the warranty to be valid, the customer must be sure to follow the requirements of WEG’s technical
documents, especially those set out in the product Installation, Operation and Maintenance Manual, as well as the
applicable standards and regulations in force in each country.
Defects arising from the inappropriate or negligent use, operation, and/or installation of the equipment, non-
execution of regular preventive maintenance, as well as defects resulting from external factors or equipment and
components not supplied by WEG, will not be covered by the warranty.
The warranty will not apply if the customer at its own discretion makes repairs and/or modifications to the
equipment without prior written consent from WEG.
The warranty will not cover equipment, components, parts and materials whose lifetime is usually shorter than
the warranty period. It will not cover defects and/or problems resulting from force majeure or other causes not
imputable to WEG, such as, but not limited to: incorrect or incomplete specifications or data supplied by the
customer; transportation, storage, handling, installation, operation and maintenance not complying with the
provided instructions; accidents; defects in the construction works; use in applications and/or environments for
which the machine was not designed; equipment and/or components not included in the scope of WEG supply.
The warranty does not include disassembly services at the buyer’s premises, product transportation costs and
travel, lodging and meal expenses for the technical staff of the Service Centers, when requested by the customer.
The services under warranty will be provided exclusively at WEG authorized Service Centers or at one of its
manufacturing plants. Under no circumstances will the warranty services extend the equipment warranty period.
WEG’s Civil Liability is limited to the supplied product; WEG will not be liable for indirect or consequential
damages, such as losses of profit and revenue losses and alike which may arise from the contract signed
between the parties.

Low and High Voltage Electric Motors | 5

8. EC DECLARATION OF CONFORMITY
WEG Equipamentos Elétricos S/A WEG (Nantong) Electric Motor Manufacturing CO., LTD.
Av. Prefeito Waldemar Grubba, 3000 No. 128# - Xinkai South Road, Nantong Economic & Technical
89256-900 - Jaraguá do Sul – SC – Brazil, Development Zone, Nantong, Jiangsu Province - China,

and its authorised representative established in the European Community,

WEGeuro – Industria Electrica SA
Contact person: Luís Filipe Oliveira Silva Castro Araújo
Rua Eng Frederico Ulrich, Apartado 6074
4476-908 – Maia – Porto – Portugal

hereby declare that the products:

WEG induction motors and components for using in these motors:

Three-phase
IEC frames 63 to 630
Nema frames 42, 48, 56 and 143 to 9610
……………
Single-phase
IEC frames 63 to 132
Nema frames 42, 48, 56 and 143 to 215
……………

when installed, maintained and used in applications for which they were designed, and in compliance with
the relevant installation standards and manufacturer’s instructions, comply with the requirements of the
following European Directives and standards where applicable:

Directives:
Low Voltage Directive 2006/95/EC*
Regulation (EC) No 640/2009*
Directive 2009/125/EC*
Machinery Directive 2006/42/EC**
EMC Directive 2004/108/EC (inductions motors are considered inherently benign in terms of
electromagnetic compatibility)

Standards:
EN 60034-1:2010/ EN 60034-2-1:2007/EN 60034-5:2001/A1:2007/ EN 60034-6:1993/
EN 60034-7:1993/A1:2001/ EN 60034-8:2007/ EN 60034-9:2005/A1:2007/ EN 60034-11:2004/
EN 60034-12:2002/A1:2007/ EN 60034-14:2004/A1:2007/ EN 60034-30:2009,
EN 60204-1:2006/AC:2010 and EN 60204-11:2000/AC:2010

CE marking in: 1996

* Electric motors designed for use with a voltage rating higher than 1,000 V are not considered under the scope.
** Low voltage electric motors are not considered under the scope and electric motors designed for use with
a voltage rating higher than 1,000 V are considered partly completed machinery and are supplied with a
Declaration of Incorporation:

The products above cannot be put into service until the machinery into which they have been incorporated
has been declared in conformity with the Machinery Directive.
A Technical Documentation for the products above is compiled in accordance with part B of annex VII of
Machinery Directive 2006/42/EC.

We undertake to transmit, in response to a reasoned request by the national authorities, relevant information
on the partly completed machinery identified above through WEG authorised representative established in
the European Community. The method of transmission shall be electronic or physical method and shall be
without prejudice to the intellectual property rights of the manufacturer.

Jaraguá do Sul, April 10th, 2013 Milton Oscar Castella

Engineering Director

6 | Low and High Voltage Electric Motors

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