Ami800 Abb

ABB Automation Products GmbH
Large Drives & Machines

Dept.: APR/AVL
Wallstadter Strasse 59
D - 68526 Ladenburg
Coversheet
Final-Documentation
Customer: Coperion GmbH
Project: Shenhua Yulin PP //

Main drive for ZSK320
Tag.-No. A-401
Serial-No. 8130002869
ABB Project-No.: 246658 242 660
CST Order-No.: 112/46327196

CST Commission No.: 64052731
Language: english
Motor Type AMI 800L4L BSXYM, 9.700 kW
Rev. 01 20.03.2014
Index of tag numbers
Project Shenhua Yulin PP
Aggregate Main motor
Manufacturer Coperion Client

item no. tag no. tag no.
(for tag plates)
Aggregate
Main motor A201 A-401
Main motor cooler W201 E-401
Main motor space heater A201-E1 E1
Terminal boxes
Main terminal box A201.10 1310-PAJBP4331
Space heater terminal box A201.11 1310-PAJBP4301
Current transformer terminal box A201.16 A-401.16
Analog signal terminal box (Flow meters) A201.44 1310-NSJBP4301
Vibration monitoring terminal box A201.45 1310-NSJBP4319
Thermal sensors terminal box (PT100) A201.46 1310-NRJBP4301
Binary signal terminal box (leakage detectors) A201.81 1310-NEJBP4301
Instruments
Oil flow bearing DE FT20101 1310-FT4302
Oil flow bearing NDE FT20102 1310-FT4303
Water flow heat exchanger FT20185 1310-FTI4305
Leakage heat exchanger 1 LS20185 1310-LSH4303
Leakage heat exchanger 2 LS20186 1310-LSH4324
Pressure indication oil supply bearing DE PI20101 1310-PI4305
Pressure indication oil supply bearing NDE PI20102 1310-PI4306
Key phasor proximity probe SE20171 1310-SE4301
Key phasor proximity transmitter ST20171 1310-ST4301
Temperature 1 winding TE20111 1310-TE4301
Temperature bearing NDE TE20121 1310-TE4307
Temperature bearing DE TE20122 1310-TE4308
Temperature heat exchanger warm air TE20180 1310-TE4311
Temperature heat exchanger cold air NDE TE20181 1310-TE4312
Temperature heat exchanger cold air DE TE20182 1310-TE4313
Temperature indication bearing DE TI20123 1310-TI4309
Temperature indication bearing NDE TI20124 1310-TI4310
Shaft vibration X DE proximity probe ZE20171 1310-ZE4301
Shaft vibration Y DE proximity probe ZE20172 1310-ZE4302
Shaft vibration X NDE proximity probe ZE20173 1310-ZE4303
Shaft vibration Y NDE proximity probe ZE20174 1310-ZE4304
Shaft vibration X DE proximity transmitter ZT20171 1310-ZT4301
Shaft vibration Y DE proximity transmitter ZT20172 1310-ZT4302
Shaft vibration X NDE proximity transmitter ZT20173 1310-ZT4303
Shaft vibration Y NDE proximity transmitter ZT20174 1310-ZT4304
POS. PARTS WEIGHT (kg) J (kg*m2)
SHAFT
1 ALBERO
3620 75
IRON CORE+WINDING+PLATES
2 LAMIERE+BARRE+ANELLI C.TO C.TO
5630 875
TOTALE 9250 950
TORSIONAL STIFFNESS K1 29755

RIGIDEZZA TORSIONALE K2 54027
(kNm/rad) TOTAL 19188
SHAFT MATERIAL ST442S - 25CrMo4

MATERIALE ALBERO (UNI EN 10083)
YIELD STRESS
400 N/mm2
LIMITE DI SNERVAMENTO
TENSILE STRESS
600 N/mm2
CARICO DI ROTTURA
MODULUS OF ELASTICITY
211000 N/mm2
MODULO DI ELASTICITA'
Classifying code or document type
ABB SpA PERFORMANCE DATA OF MOTOR

MV Induction Machines
Department/Author Date of issue Lang. Rev. date Our ref.
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Customer ref. Saving Ident Rev./Changed by Pages
COPERION x Shenhua Yulin PP A 1/10
Driven Machine : Extruder

Motor type code AMI 800L4L BSXYM
Motor type Squirrel cage Motor
Mounting designation IM 1001
Protected by enclosure IP 55
Method of cooling IC 81W
Insulation Class F
Standards IEC
Ambient temperature, max. 40 °C
Cooling water temp 30 °C
Altitude, max. 1125 m.a.s.l.
Duty type S1
Temp. rise Class B (RES)
Connection of stator winding Star
Rated output 9700 kW
Voltage 10000 V ±7 %
Frequency 50 Hz
Speed 1492 rpm
Current 634 A
Relat. starting current 4.4 ( max 5.0 ) (*)
Relat. starting torque 0.6
Relat. maximum torque 1.8
Rated torque 62077 Nm
Load characteristics Load % Current A Efficiency % Power Factor
100 634 97.4 0.91
75 469 97.5 0.92
50 315 97.2 0.91
Direction of rotation CW seen from DE
Sound pressure level: (sinus supply, no load) 82 dB(A), tol. + 3 dB(A), 1 m
Weight of rotor 9250 kg
Total weight of Motor 32970 kg
Inertia rotor / load 950kgm² / 234 kgm²
Bearings Sleeve forced lubricated
Maximum stalling time 6.5 / 5.0 s (cold/warm) (U=100%)
Starting time 4.4 s (U=100%)
11.5 s (U=70 %)
Number of consec. starts 3 / 2 (cold/warm)
Maximum number of starts 1000 / year
Warm-up time constant 63 min
Cool-down time constant 168 min
This performance data is preliminary.
All Motor data is subject to tolerances in accordance with IEC(except (*))
ABB SpA
MV Induction Visiting Address Postal Address Telephone Telefax
Machines v.le dell'Industria, 18 v.le dell'Industria, 18 39 02 90341 39 02 90347272
Vittuone (MI) Vittuone (MI)
Italy
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
©Copyright 2012 ABB

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Motor type code: AMI 800L4L BSXYM

Rated output 9700 kW Power Factor 0.91
Voltage 10000 V ±7 % Rated torque 62077 Nm
Frequency 50 Hz Relat. starting current 4.4
Speed 1492 rpm Relat. starting torque 0.6
Current 634 A Relat. maximum torque 1.8
Torque and Current as a Function of Speed
4 2
3 1.5
I/In T/Tn
2 1
1 0.5
0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/ns
I, U=100% I, U=75% I, U=70% Load Torque

T, U=100% T, U=75% T, U=70%
ABB SpA
Italy

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Time - Current and Thermal Limit Curves
10,000
1,000
100
Time [s]
10
0.1
1 2 3 4
Stator current / Rated current
Thermal capability, running (cold) Thermal capability, locked (cold) Time-current, U = 100%
Thermal capability, running (w arm) Thermal capability, locked (w arm) Time-current, U = 70%
ABB SpA
Italy

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Speed vs. time
0.9
0.8
0.7
0.6
Speed
0.5
0.4
0.3
0.2
0.1
0
0 1 2 3 4 5 6 7 8 9 10 11 12
Time
Direct on line start from cold Direct on line start from w arm
70% reduced volt. start from cold 70% reduced volt. start from w arm
ABB SpA
Italy

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2-Phase Short Circuit
12 12
11 11
10 10
9 9
8 8
7 7
6 6
5 5
4 4
3 3
2 2
1 1
I/In 0 0 T/Tn
-1 -1
-2 -2
-3 -3
-4 -4
-5 -5
-6 -6
-7 -7
-8 -8
-9 -9
-10 -10
-11 -11
-12 -12
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
t [ms]
Phase Current Ia Phase Current Ib Phase Current Ic Torque

Equation
ABB SpA
Italy

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3-Phase Short Circuit
12 6
11 5.5
10 5
9 4.5
8 4
7 3.5
6 3
5 2.5
4 2
3 1.5
2 1
1 0.5
I/In 0 0 T/Tn
-1 -0.5
-2 -1
-3 -1.5
-4 -2
-5 -2.5
-6 -3
-7 -3.5
-8 -4
-9 -4.5
-10 -5
-11 -5.5
-12 -6
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
t [ms]

Equation
ABB SpA
Italy

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Direct On Line Start
12 6
11 5.5
10 5
9 4.5
8 4
7 3.5
6 3
5 2.5
4 2
3 1.5
2 1
1 0.5
I/In 0 0 T/Tn
-1 -0.5
-2 -1
-3 -1.5
-4 -2
-5 -2.5
-6 -3
-7 -3.5
-8 -4
-9 -4.5
-10 -5
-11 -5.5
-12 -6
0 50 100 150 200 250 300 350 400 450 500
t [ms]

Equation
ABB SpA
Italy

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Auto Reclosing
18 18
16 16
14 14
12 12
10 10
8 8
6 6
4 4
2 2
I/In 0 0 T/Tn
-2 -2
-4 -4
-6 -6
-8 -8
-10 -10
-12 -12
-14 -14
-16 -16
-18 -18
0 50 100 150 200 250 300 350 400
t [ms]

Equation
ABB SpA
Italy

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Airgap torque at start from standstill
Te(t) = M0(1 + e -t/1 e-t/2) - M1 (cos(t - ) e -t/1 + cos(t + ) e -t/2)
M0 = 0.595 ; M1 = 4.59 ; 1 = 10.7 s ; 2 = 0.0198 s ;  = 1.44 rad
Maximum value of torque 5.11 * TN, when t = 134 ms ( = 2f, f = supply freq.)
Airgap torque at 3-phase short circuit at terminals
Te(t) = M0 e -t/0 - M1 e -t/1 sin t
M0 = -0.574 ; 0 = 0.0567 s ; M1 = 5.23 ; 1 = 0.0286 s;  = 309 rad/s
Maximum value of torque -4.92 * TN, when t = 5 ms
Airgap torque at 2-phase short circuit at terminals
Te(t) = M00 ( 1 - e-t/0) + (M0 + M2 e -t/2) sin 2t - M1 e -t/1sin t
M00 = 0.163 ; M0 = 1.36 ; M1 = 4.93 ; M2 = 3.58 ; 0 = 0.202 s ; 1 = 0.0718 s ; 2 = 0.00836 s; 

= 312 rad/s
Airgap torque at high speed automatic reclosing
Te(t) = M0 e -t/0 + ( M1 e -t/1 + M2 e -t/2 ) cos( t - ) + M00
M0 = -10.4 ; M1 = 5.21 ; M2 = 0 ; M00 = 0.151 ; 0 = 0.0188 s ; 1 = 0.302 s; 2 = 10 s ;  = 0.146

rad ;  = 302 rad/s
High speed automatic reclosing time t = 0.2 s
ABB SpA
Italy

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Running
Stator resistance R1 (120 °C) 0.03921  Rotor resistance R2' (100 °C) 0.06567 
Stator reactance X1 1.4255  Rotor reactance X2' 0.7275 
Magnetizing reactance Xm 68.22  Iron loss resistance RFe 2.37 k
Starting
Stator resistance R1 (40 °C) 0.03037  Rotor resistance R2' (40 °C) 0.24618 
Stator reactance X1 1.2339  Rotor reactance X2' 0.7108 
X1 R1 X 2’ R2 ’ / s
UN RFe Xm
3
ABB SpA
Italy
Instrumentslist for project SHENHUA YULIN PP, Main drive motor
Motor: AMI 800 L4L BSXM

ITABB 8130002869.01
Item Position at Outline drawing Pieces Type Manufacturer Range

M517080
1 Bearing DE (insulated) 12 1 EMZLB 22-280 RENK
2 Bearing NDE (insulated) 13 1 EMZLQ 22-280 RENK
3 Water leakage detector 18 1 ASH/V/GN-1-V/U-L65/08-1-SVK27/10/A-HH-EXIAG KSR Kübler
4 Water flow meter 17 1 H250 RR M40 ESK1- Ex Krohne 5,7 - 57,0m³/h
6 Oil flow meter bearing 26 2 H250 RR M40 ESK - Ex Krohne 0 - 20 l/min
7 PT100 Winding inside 2 6 UM--413338PZ2BS SYNFLEX ITALIA SRL
8 Surge Arrester on RTD inside 2 6 PT4-Ex(I) 24DC-ST Phoenix Contact
PT100 inside Bearing DE TS-CVO-RTD TERMICS
9 8 2
PT100 inside Bearing NDE TS-CVO-RTD TERMICS
10 PT100 Cold-/Hot-Air 19 & 20 3 TS-CVO-RTD TERMICS
11 Space heater 3 1 1~ 220V / 2x300W / 50 Hz F.A.T.I.
12
13 Key Phasor and Proximity Probe housing 22 & 23 5 31000 -28-05-30-017-02-02 Bently Nevada
14 Bently Nevada proximitor sensor Inside pos. 22 & 23 5 330105-02-12-05-02-05 Bently Nevada
15 Ext. cable proximity probe and key phasor 5 330130-045-00-00 Bently Nevada
16 BN transducer inside 4 5 330180-51-05 BN Bently Nevada
17 Oil manometer 25 2 233.50.100 Wika 0 - 0,16MPa
18 Bearing thermometer 9 2 TMI 100A - AMX Rueger 0 - 160°C
19 Current transformer inside 1 3 AOC 105 (50/1A 5P10 5VA 50Hz) F.T.M.
20 Surge Arrester inside 1 3 MWD11 ABB
21 Surge Capacitor inside 1 3 2GUS031803A9 ABB
14.03.2014 Rev. A
Magnetic Float Switches / Stainless steel - with oval flange
Type ASH/PA/SO-V/..-L../12-1/SB40/15/A ASH/V/SO-V/..-L../12-1/SVK44/15/A
Material quality: Stainless steel / Polyamide / Buna 1.4404 / 1.4435 / 1.4571 ( 316L / 316Ti )
Electrical connection: Connector Hirschmann DIN 43650 Connector Hirschmann DIN 43650
Process connection: Standard oval flange 80 x 50 mm, Polyamide Standard oval flange 80 x 50 mm
Guide tube: Ø 12 mm ( optional Ø 14 mm ) Ø 12 mm ( optional Ø 14 mm )
1003
Length of instrument: ≤ 5000 mm ≤ 5000 mm*

Float: SB40/15/A Ø 40 mm SVK44/15/A Ø 44 mm
Specific gravity: ≥ 700 kg/m3 ≥ 800 kg/m3
Design pressure: -0 bar ... 0,5 bar -1 bar ... 1 bar
Design temperature: -10°C ... 80°C -30°C ... 180°C
Ingress protection class: IP 65 IP 65
Mounting position: Vertical +/-30° Vertical +/-30°
Level switch function
Function: Normally open / S Normally open / S

Switching capacity: 230 V / 1.0 A / 100 VA 230 V / 1.0 A / 100 VA
Maximal number of contacts: 2 pieces 2 pieces
Function: Normally closed / O Normally closed / O

Maximal number of contacts: 2 pieces 2 pieces
Function: Change over / U ( only without temp. switch ) Change over / U ( only without temp. switch )
Maximal number of contacts: 1 piece 1 piece
Option temperature probe / Page 112
Temperature probe: - -
Norm: - -
Option temperature switch / Page 112
Function: Normally closed or normally open Normally closed or normally open

Switching capacity: Page 112 Page 112
Accuracy / Hysteresis: Page 112 Page 112
Temperature / Grading: Page 112 Page 112
Minimum measures
ASH/PA/SO-V/..-L../12-1/SB40/15/A
L1: ≥ 50 mm
U: 50 mm
Contact distance: ≥ 20 mm
81
Float distance: ≥ 45 mm
51
Approvals / Certificates
L1 = ...
PED / BV / SIL1
L1 = ...
Minimum measures
L2 = ...
L2 = ...
ASH/V/SO-V/..-L../12-1/SVK44/15/A
L = ...
L = ...
L1: ≥ 35 mm
U: 45 mm
Contact distance: ≥ 20 mm
Float distance: ≥ 70 mm
U = ...
U = ...
Approvals / Certificates
ATEX / PED / GOST / GL / BV / ABS / SIL1

Screw-hole circle Ø 55 mm, 2 Bores Ø 6,4 mm Screw-hole circle Ø 55 mm, 2 Bores Ø 6,4 mm
The magnetic float switches are based on a modular design and can be arranged individually.
Type key page 62 - 65
* ATEX-design = if length of instrument ≥ 4000 mm please choose different material quality for guide tube and float
Heinrich Kübler AG
76 Ruessenstrasse 4 | CH-6340 Baar | Phone +41 (0)41 766 62 62 | Fax +41 (0)41 766 62 63 | E-Mail info@kubler.ch | Internet www.kubler.ch
TD_H250_M40_en_060709_R01_PRT.book Page 1 Monday, November 16, 2009 10:04 AM
H250 /M40 Technical Datasheet
Variable area flowmeter

• Sturdy construction for high pressure, temperature and media resistance
• Universal Ex concept: Ex i and Ex d
• Modular scalability – from mechanical to fieldbus
© KROHNE 11/2009 - 4000685601 - TD-H250-M40-R01-R01-en

CONTENTS H250 /M40
1 Product features 3
1.1 The standard solution for the process industry............................................................... 3

1.2 Options and variants......................................................................................................... 5
1.3 Operating principle........................................................................................................... 7
2 Technical data 8
2.1 Technical data................................................................................................................... 8

2.2 Dimensions and weights ................................................................................................ 14
2.3 Measuring ranges........................................................................................................... 17
3 Installation 25
3.1 Intended use ................................................................................................................... 25

3.2 Installation conditions .................................................................................................... 26
3.2.1 Tightening torques ................................................................................................................ 27
3.2.2 Magnetic filters ..................................................................................................................... 28
3.2.3 Heat insulation ...................................................................................................................... 29
3.2.4 Float damping ....................................................................................................................... 30
3.2.5 Pointer damping.................................................................................................................... 30
4 Electrical connections 31
4.1 Safety instructions.......................................................................................................... 31

4.2 Electrical connection indicator M40............................................................................... 32
4.2.1 Indicator M40 - limit switches .............................................................................................. 32
4.2.2 Current output ESK4A........................................................................................................... 35
4.3 Grounding connections................................................................................................... 38
4.4 Protection category ........................................................................................................ 38
5 Order form 39
2 www.krohne.com 11/2009 - 4000685601 - TD-H250-M40-R01-R01-en

Product features
H250 /M40 PRODUCT FEATURES 1
1.1 The standard solution for the process industry

The all-metal variable area flowmeter H250 is used for flow measurement of conductive and
non-conductive liquids, gases and vapours.
1 Limit switch
2 4...20 mA output
3 With LCD, flow counter, electronic limit switches and pulse output
4 Fieldbus - Profibus PA or Foundation Fieldbus
11/2009 - 4000685601 - TD-H250-M40-R01-R01-en www.krohne.com 3

1 PRODUCT FEATURES H250 /M40
Highlights
• Simple, low-cost installation: Measure and display without auxiliary power supply
• Universal Ex concept: Ex i and Ex d
• Modular scalability – from mechanical to fieldbus
• Any installation position: vertical upward, horizontal, vertical downward
• Robust measuring tube construction for high process temperatures and extreme operating
pressures
• Choice of material: Stainless steel, hastelloy®, titanium, Monel, PTFE/TFM etc.
• Many connection variants: flanged, screwed, clamped, weld-on ends etc.
• Extended measuring range: up to100:1
• High application safety, even with extremely low flows
Industries
Can be used in all industrial sectors, for example:
• Chemicals
• Petrochemicals
• Pharmaceuticals
• Machinery
• Food & Beverage
• Oil & Gas
• Iron, Steel & Metals
• Power plants
• Paper & Pulp
• Water & Wastewater
Applications
• Continuous gas and liquid measurement
• Measurement of non-conductive media
• Industrial burner controlling
• Compressor monitoring
• Dry-run protection of pumps

1.2 Options and variants

FOOD & PHARMA (H250 F)
The only EHEDG-certified variable area
flowmeter approved for used in the food
and pharmaceuticals industry.
Smooth stainless steel surfaces with a
surface roughness of ≤ 0.8 µm or 0,6 µm
on parts exposed to the media make it
difficult for deposits to take hold and are
very easy to clean.
Combined with a design featuring no dead
spaces or stagnation zones, micro-
organisms have no chance to adhere and
multiply.
The measuring devices can be cleaned
(CIP) and sterilised (SIP) in place.
Suitable connections and FDA conforming
materials for the food and pharmaceutical
industry are available.
PTFE/ceramic liner for aggressive media

All wetted parts are made of PTFE or
ceramic and can thus be used for almost
all acids and alkalis.
Depending on the choice of material, the
measuring device can be used up to a
maximum temperature of 70°C / 158°F
(PTFE) or 250°C / 482°F (ceramic).

1 PRODUCT FEATURES H250 /M40
Versions for special installation positions (H250H / H250U)

Variable area flowmeters typically feature
a vertically positioned measuring cone
through which the medium flows from
bottom to top, lifting a float against the
weight.
If the installation structure does not permit

otherwise, versions for horizontal or
inverted (from top to bottom) installation
positions are used.
The missing reset force of the variable
area float weight is replaced by a spring.
Version with extended measuring range 100:1

The normal measuring range of the H250
measuring device is 10:1.
A measuring range of 100:1 can be
achieved by inserting a spring which, from
a defined float travel, acts as a restoring
force in addition to the weight.
This eliminates the need for an additional
device for minimal volumes.

1.3 Operating principle

The H250 flowmeter operates on the variable area measuring principle. The measuring unit
consists of a metal cone in which a float can move freely up and down. The medium flows
through the flowmeter from bottom to top. The float adjusts itself so that the buoyancy force F1
acting on it, the form drag F2 and its weight F3 are in equilibrium: F3 = F1 + F2
1 Indication principle M40 magnetic coupling

2 Magnetic coupling sensors
1 For the indicator, the flow-dependent height of the float in the measuring unit is transmitted
by means of a magnetic coupling and displayed on a scale.
2 For a built-in signal converter (ESK4), the flow-dependent height of the float in the measuring
unit is detected by the S1 and S2 magnetic field sensors and electronically processed.
Operating principle of H250H and H250U
Figure 1-1: Operating principle H250H and H250U

1 H250H - horizontal flow direction
2 H250U - flow direction from top to bottom
The flowmeter operates based on a modified float measuring principle. The guided float adjusts
itself so that the flow force acting on it is in equilibrium with the opposing spring force. The flow-
dependent position of the float in the measuring unit is displayed on a scale by means of a
magnetic coupling.

Technical data
2 TECHNICAL DATA H250 /M40
2.1 Technical data

• The following data is provided for general applications. If you require data that is more
relevant to your specific application, please contact us or your local representative.
• Additional information (certificates, special tools, software,...) and complete product
documentation can be downloaded free of charge from the website (Download Center).
Measuring system
Application range Flow measurement of liquids, gases and vapors
Operating method / measuring principle Variable area measuring principle
Measured value
Primary measured value Float position
Secondary measured value Operating and standard volumetric flow
Measuring accuracy
Directive VDI / VDE 3513, sheet 2 (qG = 50%)
H250 /RR /HC /F 1.6%
H250/C (Ceramic, PTFE) 2.5%
H250H, H250U, H250 (100 : 1)
Operating conditions
Temperature
Max. operating temperature TS -196..+300°C / -321...+572°F
Pressure
Max. operating pressure PS Depending on the version, up to 400 bar / 5802 psig 1
Max. test pressure PT Pressure equipment directive 97/23/EC or AD 2000-HP30
Min. required operating pressure 2 times greater than pressure loss (see measuring ranges)
Protection category
According to EN 60529 and NEMA250 IP 66/67, NEMA 4/4X/6
Float damping during gas measurement recommended:
DN15...25 / ½"...1" Operating pressure <0.3 bar / 4.4 psig
DN50...100 / 2"...4" Operating pressure <0.2 bar / 2.9 psig
Installation conditions as per VDI/VDE 3513 Sheet 3

Inlet run ≥ 5 x DN
Outlet run ≥ 3 x DN
1 higher operating pressures on request

H250 /M40 TECHNICAL DATA 2
Materials
Device Flange / raised face Measuring Float Float stop / Ring orifice
tube guide
H250 /RR CrNi steel 1.4404 CrNi steel 1.4404 1 -
Stainless Steel massive 1
H250/HC CrNi steel 1.4571 with Hastelloy® C4 (2.4610) -
Hastelloy® plated Hastelloy® C4
(2.4610) 1
H250/C CrNi steel 1.4571 PTFE or Al2O3 Al2O3 Al2O3
Ceramic/PTFE with TFM/PTFE liner 2 with FFKM gasket and PTFE
H250/F - Food CrNi steel 1.4435 -
1 CrNi steel 1.4571 on request, for clamp connection CrNi steel 1.4435
2 TFM/PTFE liner (electrically non-conductive)
H250/C - DN100 / 4" only PTFE

H250/F: wetted surfaces Ra ≤0.8 μm, optional ≤0.6 μm
Other options:
• Special materials on request: e.g. SMO 254, titanium, 1.4435
• Float damping: ceramic or PEEK
• Gasket for devices with female thread as insert: O-ring FPM / FKM
Temperatures
For devices to be used in hazardous areas, special temperature ranges apply. These can be
found in the separate instructions.
Temperatures H250/M40 - mechanical indicator without power supply

Float liner Product temperature Ambient temperature
[°C] [°F] [°C] [°F]

H250/RR Stainless Steel -196...+300 -321...+572 -40...+120 -40…+248
H250/RR screw fitting -196...+300 -321...+572 -20…+120 -4…+248
H250/HC Hastelloy® C4 -196...+300 -321...+572 -40...+120 -40…+248
H250/C PTFE PTFE -196...+70 -321...+158 -40...+70 -40…+158
H250/C Ceramic PTFE -196...+150 -321...+302 -40...+70 -40…+158
H250/C Ceramic TFM / -196...+250 -321...+482 -40...+120 -40…+248
Ceramic
H250 H/U Stainless Steel -40...+100 -40…+212 -20…+90 -4…+194
Minimum ambient temperatures Tamb. with electrical components
Version [°C] [°F]

ESK4, ESK4-FF, ESK4-PA -40 -40
ESK4-T 1 -40 -40
Limit switch NAMUR -40 -40
3-wire limit switch -25 -13
1 Decreasing display contrast out of the temperature range 0...60 °C / 32..140°F.

Temperatures H250/M40 - with electrical components [°C]

Tamb. < +40 °C Tamb. < +60 °C
EN ASME Version with Standard HT Standard HT

DN15, ½", 1" ESK4, ESK4-FF, ESK4-PA +200 +300 +180 +300
DN25
ESK4-T +200 +300 +80 +130
Limit switch NAMUR +200 +300 +200 +300
3-wire limit switch +200 +300 +130 +295
DN50 2“ ESK4, ESK4-FF, ESK4-PA +200 +300 +165 +300
ESK4-T +180 +300 +75 +100
DN80, 3“, 4" ESK4, ESK4-FF, ESK4-PA +200 +300 +150 +250
DN100
ESK4-T +150 +270 +70 +85
Temperatures H250/M40 - with electrical components [°F]

Tamb. < +104°F Tamb. < +104°F 1
EN ASME Version with Standard HT Standard HT

DN15, ½", 1" ESK4, ESK4-FF, ESK4-PA 392 572 356 572
DN25
ESK4-T 392 572 176 266
Limit switch NAMUR 392 572 392 572
3-wire limit switch 392 572 266 563
DN50 2“ ESK4, ESK4-FF, ESK4-PA 392 572 165 572
ESK4-T 356 572 167 212
DN80, 3“, 4" ESK4, ESK4-FF, ESK4-PA 392 572 302 482
DN100
ESK4-T 302 518 158 185
1 if there are no heat insulation measures, a heat-resistant cable is necessary (continuous

operating temperature of the cable to be used: +100°C)
Abbreviation
HT High-temperature version
ESK4 Current output 2-wire 4…20 mA
ESK4-T ESK4 Basic with LCD, binary status outputs, digital counter and pulse output.
ESK4-FF FOUNDATION FIELDBUS interface (pending)
ESK4-PA PROFIBUS PA interface (pending)

Cable glands
Cable gland Material Cable diameter
M 20x1.5 Standard PA 8...13 mm 0.315...0.512"
M20 x 1.5 Nickel-plated brass 10...14 mm 0.394...0.552"
Limit switch
Terminal connection 2.5 mm2
Limit switch I7S23,5-N SJ3,5-SN 1 SJ3,5-S1N 1 SB3,5-E2
SC3,5-N0
NAMUR yes yes yes no
Connection type 2-wire 2-wire 2-wire 3-wire
Switching element NC contact NC contact NO contact PNP NO contact
function
Nominal voltage U0 8 VDC 8 VDC 8 VDC 10...30 VDC
Pointer vane not detected ≥ 3 mA ≥ 3 mA ≤ 1 mA ≤ 0.3 VDC
Pointer vane detected ≤ 1 mA ≤ 1 mA ≥ 3 mA UB - 3 VDC
Continuous current - - - max. 100 mA
No load current I0 - - - ≤ 15 mA
1 safety oriented
Current output ESK4

Terminal connection 2.5 mm2
Power supply 14...30 VDC
Min. power supply for HART® 20 V DC, load ≤ 250 Ohm
Measuring signal 4.00...20.00 mA = 0...100% flow value in 2-wire technology
Power supply influence <0.1%
Dependence on external resistance <0.1%
Temperature influence <5 µA / K
Max. external resistance / load 650 Ohm (30 VDC)
Min. load for HART® 250 Ohm
ESK4 HART® configuration

Manufacturer name (code) KROHNE Messtechnik (69 = 45h)
Model name ESK4 (214 = 0xD6)
HART® protocol revision 5.9
Device revision 1
Physical layer FSK
Device category Transmitter without galvanic isolation

ESK4 process variable

Values [%] from full-scale Signal output [mA]
range
Over range +102.5 (±1%) 20,24...20.56
Device error identification > 106.25 >21.00
Max. current consumption 131.25 25
Multi-drop operation 4.5
ESK4-FF in preparation
ESK4-PA in preparation
ESK4-T with LCD, binary inputs and outputs and digital counter
Binary output
Two binary outputs Galvanically isolated
Mode Switch output NAMUR or open collector
Configurable as Switch contact or Opener/NO contact or
Pulse output max. 10 pulses / s
NAMUR switch output
Power supply 8 VDC
Signal current > 3 mA switching value not < 1 mA switching value
reached; reached
Switch output, open collector
Power supply 5...30 VDC
Pmax 500 mW
Continuous current max. 100 mA
No load current I0 ≤ 1 mA
Pulse output
Ton configurable from 50...500 ms
Toff depending on flow rate
Pulse value configurable in flow units e.g. 5 pulses / m3
Reset input
Binary input Galvanically isolated
Mode Reset counter
Configurable as active Hi / active Lo
Voltage level 5...30 VDC
Current consumption ≤ 1 mA
Ton (active) ≥500 ms

Approvals (pending)
Standard Display Marking
ATEX / M40 mechanical II2GD IIC
IECEx II3GD IIC
M40 electrical II2G Ex ia IIC T6, II3G Ex nA IIC T6
II2D tD IIC T6, II3D IP66 T65°C
FM M40 IS/I/1/ABCD;T6
FM-C NI/I/2/ABCD;T6
IS/I, II, III/1/A-G
NI/II/2/ABCD
XP/I/1/ABCD;T6
DIP/II,III/1/EFG/T6
Nepsi M40 Ex ia IIC T1-T6
Ex nA II T1-T6
Ex d IIC T1...T6

2.2 Dimensions and weights

Dimensions H250/M40
Front view Side view with heating High-temperature
a b d h
[mm] ["] [mm] ["] [mm] ["] [mm] ["]

All nominal sizes 138 5.44 250 9.85 160 6.30 150 5.91
ISO 228 300 11.82
H250/C - 3"/300 lbs 300 11.82
EN ASME c e Øf g j
[mm] ["] [mm] ["] [mm] ["] [mm] ["] [mm] ["]
DN15 ½" 94 3.70 114 4.49 20 0.79 100 3.94 197 7.76
DN25 1" 94 3.70 125 4.92 32 1.26 106 4.18 208 8.19
DN50 2" 107 4.22 139 5.48 65 2.56 120 4.73 222 8.75
DN80 3" 107 4.22 155 6.11 89 3.51 145 5.71 238 9.38
DN100 4" 107 4.22 164 6.46 114 4.49 150 5.91 247 9.73
ISO 228 ISO 228 H250/F H250/F

female thread female thread Clamp connection Screw connection
screwed welded DIN 11851
1
1 Stainless steel 1.4435 - EHEDG tested - wetted surfaces Ra ≤ 0.8 / 0.6 µm

Weights
H250 with heating
Nominal size EN 1092-1 Flange connection Ermeto connection
EN ASME [kg] [lbs] [kg] [lbs] [kg] [lbs]

DN15 ½" 3.5 7.7 5.6 12.6 3.9 8.6
DN25 1" 5 11 7.5 16.5 5.8 12.8
DN50 2" 8.2 18.1 11.2 24.7 9.5 21
DN80 3" 12.2 26.9 14.8 32.6 13.1 28.9
DN100 4" 14 30.9 17.4 38.4 15.7 34.6
H250/C [Ceramic / PTFE] Screw connect.

Nominal size EN 1092-1 ASME 150 lbs ASME 300 lbs DIN 11864-1
EN ASME [kg] [lbs] [kg] [lbs] [kg] [lbs] [kg] [lbs]
DN15 ½" 3.5 7.7 3.2 7.1 3.5 7.7 2 4.4
DN25 1" 5 11 5.2 11.5 6.8 15 3.5 7.7
DN50 2" 10 22.1 10 22.1 11 24.3 5 11
DN80 3" 13 28.7 13 28.7 15 33.1 7.6 16.8
DN100 4" 15 33.1 16 35.3 17 37.5 10.3 22.7
Process connections
Standards Conn. dim. Pressure rating
Flanges (H250/RR /HC /C) EN 1092-1 DN15...150 PN16...250
ASME B16.5 ½...6" 150...2500 lbs
JIS B 2220 15…100 10...20K
Clamp connections (H250/RR /F) DlN 32676 DN15...100 10...16 bar
ISO 2852 Size 25...139.7 10...16 bar
Screw connections (H250/RR /HC /F) DIN 11851 DN15...100 25...40 bar
SMS 1146 1...4" 6 bar / 88.2 psig
Female thread welded (H250/RR /HC) ISO 228 G½...G2" ≥ 50 bar / 735
psig
ASME B1.20.1 ½…2" NPT
Female thread (H250/RR /HC) ISO 228 G½…2" ≤ 50 bar / 735
with insert, FPM gasket and union nut psig
ASME B1.20.1 ½…2" NPT
Thread connection aseptic (H250/F) DIN 11864 - 1 DN15…50 PN40
DN80…100 PN 16
Flange aseptic (H250/F) DIN 11864 - 2 DN15…50 PN40
DN80…DN100 PN 16
Meters (H250/RR /HC) with heating:
Heating with flange connection EN 1092-1 DN15 PN40
ASME B16.5 ½" 150 lbs / RF
Heating pipe connection for Ermeto - E12 PN40
Higher pressure ratings and other connections on request

Bolts and tightening torques
For measuring devices with PTFE liner or ceramic liner and PTFE raised face, tighten the flange
threads with the following torques:
Nominal sizes EN
Nominal size Bolts Tightening torques
acc. to EN 1092-1 Quantity x size [Nm] [lb-ft]

DN15 PN40 1 4 x M 12 9.8 7.1
DN25 PN40 2 4 x M 12 21 15
DN50 PN40 2 4x M16 57 41
DN80 PN16 2 8x M16 47 34
DN100 PN16 2 8x M16 67 48
1 standard connections; other connection on request
2 standard connections; other connections on request
Nominal size ASME

Nominal size Bolts (Quantity x size) Tightening torques
acc. to ASME B 16.5 150 lbs 300 lbs [Nm] [lb-ft]

½" 150 lbs / 300 lbs 1 4x ½" 4x ½" 5.2 3.8
1" 150 lbs / 300 lbs 1 4x ½" 4x 5/8" 10 7.2
2" 150 lbs / 300 lbs 1 4x 5/8" 8x 5/8" 41 30
3" 150 lbs / 300 lbs 1 4x 5/8" 8x ¾" 70 51
4" 150 lbs / 300 lbs 1 8x 5/8" 8x ¾" 50 36
1 standard connections; other connections on request
Low pressure resistance (vacuum) H250/C

Max. process temperature +70°C (+158°F) +150°C (*302°F) +250°C (+482°F)
Min. operating pressure
Nominal size float lining [mbar [psia] [mbar [psia] [mbar [psia]
abs.] abs.] abs.]
DN15...DN100 PTFE PTFE 100 1,45 - - - -
DN15...DN80 ceramic PTFE 100 1,45 250 3,63 - -
DN15...DN80 ceramic TFM / 100 1,45 100 1,45 100 1,45
ceramic

2.3 Measuring ranges

H250/RR - Stainless Steel, H250/HC - Hastelloy®
Measuring span 10 : 1; flow values 100%
Water Air Max. pressure loss
Float TIV CIV DIV TIV TIV DIV TIV TIV CIV DIV
Alu Alu
Nominal Cone [l/h] [m3/h] [mbar]

size
DN15, ½" K 15.1 18 25 - 0.42 0.7 - 12 21 26 -
K 15.2 30 40 - 0.7 1 - 12 21 26 -
K 15.3 55 63 - 1 1.5 - 12 21 26 -
K 15.4 80 100 - 1.7 2.2 - 12 21 26 -
K 15.5 120 160 - 2.5 3.6 - 12 21 26 -
K 15.6 200 250 - 4.2 5.5 - 12 21 26 -
K 15.7 350 400 700 6.7 10 18 1 12 21 28 38
K 15.8 500 630 1000 10 14 28 1 13 22 32 50
K 15.8 - - 1600 2 - - 50 2 - - - 85
DN25, 1" K 25.1 480 630 1000 9.5 14 - 11 24 32 72
K 25.2 820 1000 1600 15 23 - 11 24 33 74
K 25.3 1200 1600 2500 22 35 - 11 25 34 75
K 25.4 1700 2500 4000 37 50 110 1 12 26 38 78
K 25.5 3200 4000 6300 62 95 180 1 13 30 45 103 3
DN50, 2" K 55.1 2700 6300 8400 58 80 230 1 8 13 74 60
K 55.2 3600 10000 14000 77 110 350 1 8 13 77 69
K 55.3 5100 16000 25000 110 150 700 1 9 13 84 104
DN80, 3" K 85.1 12000 25000 37000 245 350 1000 1 8 16 68 95
K 85.2 16000 40000 64000 280 400 1800 1 9 16 89 125
DN100, 4" K105.1 19000 63000 100 000 - 550 2800 1 - - 120 220
1 P >0.5 bar
2 with TR float
3 300 mbar with damping (gas measurement)
Reference condition:
Water 20°C
Air 20°C - 1.013 bar abs.
Remarks:
• Air measurement - TIV float: heating not possible.
• The indicated pressure losses are valid for water and air at maximum flow rate.
• Other flow ranges on request.
• Conversion of other media or operating data is performed using the calculation method in
accordance with VDI /VDE Directive 3513.

H250/RR - Stainless Steel, H250/HC - Hastelloy®

Water Air Max. pressure loss
Float TIV CIV DIV TIV TIV DIV TIV TIV CIV DIV
Alu Alu
Nominal Cone [gph] [scfm] [psig]

size
DN15, ½" K 15.1 4.76 6.60 - 0.26 0.43 - 0.18 0.31 0.38 -
K 15.2 7.93 10.6 - 0.43 0.62 - 0.18 0.31 0.38 -
K 15.3 14.5 16.6 - 0.62 0.93 - 0.18 0.31 0.38 -
K 15.4 21.1 26.4 - 1.05 1.36 - 0.18 0.31 0.38 -
K 15.5 31.7 42.3 - 1.55 2.23 - 0.18 0.31 0.38 -
K 15.6 52.8 66.0 - 2.60 3.41 - 0.18 0.31 0.38 -
K 15.7 92.5 106 185 4.15 6.20 11.2 1 0.18 0.31 0.41 0.56
K 15.8 132 166 264 6.20 8.68 17.4 1 0.19 0.32 0.47 0.74
K 15.8 - - 423 2 - - 31.0 2 - - - 1.25
DN25, 1" K 25.1 127 166 264 5.89 8.68 - 0.16 0.35 0.47 1.06
K 25.2 217 264 423 9.30 14.3 - 0.16 0.35 0.49 1.09
K 25.3 317 423 660 13.6 21.7 - 0.16 0.37 0.50 1.10
K 25.4 449 660 1057 22.9 31.0 68.2 1 0.18 0.38 0.56 1.15
K 25.5 845 1057 1664 38.4 58.9 111 1 0.19 0.44 0.66 1.51 3
DN50, 2" K 55.1 713 1664 2219 36.0 49.6 143 1 0.12 0.19 1.09 0.88
K 55.2 951 2642 3698 47.7 68.2 217 1 0.12 0.19 1.13 1.01
K 55.3 1347 4227 6604 68.2 93.0 434 1 0.13 0.19 1.23 1.53
DN80, 3" K 85.1 3170 6604 9774 152 217 620 1 0.12 0.24 1.00 1.40
K 85.2 4227 10567 16907 174 248 1116 1 0.13 0.24 1.31 1.84
DN100, 4" K105.1 5019 16643 26418 - 341 1736 1 - 1.76 3.23
1 P >7.4 psig
2 with TR float
3 4.4 psig with damping (gas measurement)
Water 68°F
Air 68°F - 14.7 psi
Remarks:
• Air measurement - TIV float: heating not possible.

H250/C - Ceramic/PTFE
Flow rate Max. pressure loss
Water Air Water Air
Liner / PTFE Ceramic Ceramic PTFE Ceramic Ceramic

Float
Nominal Cone [l/h] [m3/h] [mbar]

size
DN15, ½" E 17.2 25 30 - 65 62 62
E 17.3 40 50 1.8 66 64 64
E 17.4 63 70 2.4 66 66 66
E 17.5 100 130 4 68 68 68
E 17.6 160 200 6.5 72 70 70
E 17.7 250 250 9 86 72 72
E 17.8 400 - - 111 - -
DN25, 1" E 27.1 630 500 18 70 55 55
E 27.2 1000 700 22 80 60 60
E 27.3 1600 1100 30 108 70 70
E 27.4 2500 1600 50 158 82 82
E 27.5 4000 1 2500 75 290 100 100
DN50, 2" E 57.1 4000 4500 140 81 70 70
E 57.2 6300 6300 200 110 80 80
E 57.3 10000 11000 350 170 110 110
E 57.4 16000 1 - - 284 - -
DN80, 3" E 87.1 16000 16000 - 81 70 -
E 87.2 25000 25000 - 95 85 -
E 87.3 40000 1 - - 243 - -
DN100, 4" E 107.1 40000 - - 100 - -
E 107.2 60000 1 - - 225 - -
1 special float
Water 20°C
Remarks:

H250/C - Ceramic/PTFE
Flow rate Max. pressure loss
Water Air Water Air
Liner / Float PTFE Ceramic Ceramic PTFE Ceramic Ceramic
Nominal Cone [gph] [scfm] [psig]

size
DN15, ½" E 17.2 6.60 7.93 - 0.96 0.91 0.91
E 17.3 10.6 13.2 1.12 0.97 0.94 0.94
E 17.4 16.6 18.5 1.49 0.97 0.97 0.97
E 17.5 26.4 34.3 2.48 1.00 1.00 1.00
E 17.6 42.3 52.8 4.03 1.06 1.03 1.03
E 17.7 66.0 66.0 5.58 1.26 1.06 1.06
E 17.8 106 - - 1.63 - -
DN25, 1" E 27.1 166 132 11.2 1.03 0.81 0.81
E 27.2 264 185 13.6 1.18 0.88 0.88
E 27.3 423 291 18.6 1.59 1.03 1.03
E 27.4 660 423 31.0 2.32 1.21 1.21
E 27.5 1056 1 660 46.5 4.26 1.47 1.47
DN50, 2" E 57.1 1057 1189 86.8 1.19 1.03 1.03
E 57.2 1664 1664 124 1.62 1.18 1.18
E 57.3 2642 2906 217 2.50 1.62 1.62
E 57.4 4226 1 - - 4.17 - -
DN80, 3" E 87.1 4227 4227 - 1.19 1.03 -
E 87.2 6604 6604 - 1.40 1.25 -
E 87.3 10567 1 - - 3.57 - -
DN100, 4" E 107.1 10567 - - 1.47 - -
E 107.2 15850 1 - - 3.31 - -
1 special float
Water 68°F
Air 68°F - 14.7 psi
Remarks:

H250H - Horizontal installation position

EN ASME Cone Flow rate Flow rate Pressure loss

Water [l/h] Air [Nm3/h] [mbar]
DN15 ½ K 15.1 70 1.8 195

K 15.2 120 3 204
K 15.3 180 4.5 195
K 15.4 280 7.5 225
K 15.5 450 12 250
K 15.6 700 18 325
K 15.7 1200 30 590
K 15.8 1600 40 950
K 15.8 2400 60 1600
DN25 1" K 25.1 1300 35 122
K 25.2 2000 50 105
K 25.3 3000 80 116
K 25.4 5000 130 145
K 25.5 8500 220 217
K 25.5 10000 260 336
DN50 2" K 55.1 10000 260 240
K 55.2 16000 420 230
K 55.3 22000 580 220
K 55.3 34000 900 420
DN80 3" K 85.1 25000 650 130
K 85.2 35000 950 130
K 85.2 60000 1600 290
DN100 4" K 105.1 80000 2200 250
K 105.1 120000 3200 340
Water 20°C
Remarks:
• Conversion to other media or operating data in accordance with VDE /VDI Directive 3513

H250H - Horizontal installation position


Water [gph] Air [scfm] [psig]
DN15 1/2" K 15.1 18.5 1.12 2.87

K 15.2 31.7 1.86 3.00
K 15.3 47.6 2.79 2.87
K 15.4 74.0 4.65 3.31
K 15.5 119 7.44 3.68
K 15.6 185 11.2 4.78
K 15.7 317 18.6 8.68
K 15.8 423 24.8 14.0
K 15.8 634 37.2 23.5
DN25 1" K 25.1 343 21.7 1.79
K 25.2 528 31.0 1.54
K 25.3 793 49.6 1.71
K 25.4 1321 80.6 2.13
K 25.5 2245 136 3.19
K 25.5 2642 161 4.94
DN50 2" K 55.1 2642 161 3.53
K 55.2 4227 260 3.38
K 55.3 5812 360 3.23
K 55.3 8982 558 6.17
DN80 3" K 85.1 6604 403 1.91
K 85.2 9246 589 1.91
K 85.2 15851 992 4.26
DN100 4" K 105.1 21134 1364 3.68
K 105.1 31701 1984 5.00
Water 68°F
Air 68°F - 14.7 psi
Remarks:

H250U - Vertical installation position

Flow direction from top to bottom

Water [l/h] Air [Nm3/h] [mbar]
DN15 ½" K 15.1 65 1.6 175

K 15.2 110 2.5 178
K 15.3 170 4 180
K 15.4 260 6 200
K 15.5 420 10 220
K 15.6 650 16 290
K 15.7 1100 28 520
K 15.8 1500 40 840
DN25 1" K 25.1 1150 30 97
K 25.2 1800 45 85
K 25.3 2700 70 92
K 25.4 4500 120 115
K 25.5 7600 200 172
DN50 2" K 55.1 9000 240 220
K 55.2 15000 400 230
K 55.3 21000 550 240
Water 20°C
Remarks:

H250U - Vertical installation position

Flow direction from top to bottom

Water [gph] Air [scfm] [psig]
DN15 ½" K 15.1 17.2 0.99 2.57
K 15.2 29.1 1.55 2.62
K 15.3 44.9 2.48 2.65
K 15.4 68.7 3.72 2.94
K 15.5 111 6.20 3.23
K 15.6 172 9.92 4.26
K 15.7 291 17.4 7.64
K 15.8 396 24.8 12.3
DN25 1" K 25.1 304 18.6 1.42
K 25.2 476 27.9 1.25
K 25.3 713 43.4 1.35
K 25.4 1189 74.4 1.69
K 25.5 2008 124 2.53
DN50 2" K 55.1 2378 149 3.23
K 55.2 3963 248 3.38
K 55.3 5548 341 3.53
Water 68°F
Air 68°F - 14.7 psi
Remarks:

Installation
H250 /M40 INSTALLATION 3
3.1 Intended use

The variable area flowmeters are suitable for measuring gases, vapours and liquids.
The devices are particularly suitable for the measurement of:

• Water
• Hydrocarbons
• Corrosion protection agents and lubricants
• Chemicals and additives
• Solvents
• Superheated steam
• Food, beverages and tobacco
• Air
• Industrial gases
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
Responsibility for the use of the measurement devices with regard to suitability, intended use
and corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
Do not use any abrasive media containing solid particles or highly viscous media.

3 INSTALLATION H250 /M40
3.2 Installation conditions

When installing the device in the piping, the following points must be observed:
• The variable area flowmeter must be installed vertically (measuring principle). Flow direction
from bottom to top. For installation recommendations please refer also to VDI/VDE 3513
Sheet 3.
H250Hs are installed horizontally and H250U devices are installed vertically with the flow
direction from top to bottom.
• A straight unimpeded inlet run of ≥ 5x DN upstream of the device and a straight outlet run of
≥ 3x DN downstream of the device are recommended.
• Screws, bolts and gaskets are to be provided by the customer and must be selected in
accordance with the pressure rating of the connection or the operating pressure.
• The inside diameter of the flange deviates from the standard dimensions. Flange seal
standard DIN 2690 can be applied without any limitation.
• Align the gaskets. Tighten the nuts with the tightening torques of the appropriate pressure
rating.
For devices with PTFE liner or ceramic liner and PTFE raised faces, see chapter "Tightening
torques".
• Control devices are to be positioned downstream of the measuring device.
• Shutoff devices are preferably to be positioned upstream of the measuring device.
• Before connecting, blow or flush out the pipes leading to the device.
• Pipes for gas flow need to be dried before the device is installed.
• Use connectors suitable for the particular device version.
• Align the pipes centrically with the connection bores on the measuring device so they are free
of stresses.
• If necessary, the piping has to be supported to reduce the vibrations transmitted to the
measuring device.
• Do not lay signal cables directly next to cables for the power supply.

Take special note of the installation position for the H250H with horizontal flow
direction:
In order to comply with thermal parameters and measuring accuracy, H250H flowmeters for
horizontal installation are to be installed in the pipeline so that the display is located on the side
of the measuring tube. The maximum medium and ambient temperatures indicated as well as
the measuring accuracy are based on lateral installation of the display.
3.2.1 Tightening torques

For measuring devices with PTFE liner or ceramic liner and PTFE raised face, tighten the flange
threads with the following torques:
Nominal size acc. to Bolts Max. torque
EN 1092-1 ASME B16.5 EN ASME EN 1092-1 ASME 150 lbs

1092-1
DN PN Inches lbs 150 lbs 300 lbs Nm ft*lbf Nm ft*lbf

15 40 ½" 150/300 4 x M 12 4 x ½" 4 x ½" 9.8 7.1 5.2 3.8
25 40 1" 150/300 4 x M 12 4 x ½" 4 x 5/8" 21 15 10 7.2
50 40 2" 150/300 4 x M 16 4 x 5/8" 8 x 5/8" 57 41 41 30
80 16 3" 150/300 8 x M 16 4 x 5/8" 8 x ¾" 47 34 70 51
100 16 4" 150/300 8 x M 16 8 x 5/8" 8 x ¾" 67 48 50 36

3.2.2 Magnetic filters

The use of magnetic filters is recommended when the medium contains particles which can be
influenced magnetically. The magnetic filter is to be installed in the flow direction upstream of
the flowmeter. Bar magnets are positioned helically in the filter to provide optimal efficiency at
low pressure loss. All of the magnets are coated individually with PTFE to protect against
corrosion. Material: 1.4571
Magnetic filters
1 Type F - fitting part with flange - overall length 100 mm

2 Type FS - fitting part without flange - overall length 50 mm

3.2.3 Heat insulation

The indicator housing may not be heat-insulated.
The heat insulation 3 may only reach as far as the housing fastening 4.
1 Standard indicator M40

2 Indicator with HT extension
The heat insulation 1 may only reach to the rear of the housing 2. The area of the cable entries
3 must be freely accessible.
Figure 3-1: Insulation - cross section

3.2.4 Float damping

Float damping is characterised by high standstill times and self-centering. The damping sleeve
is made of high performance ceramic or PEEK, depending on the medium and the application.
Float damping can also be retrofitted for the user (see Service).
Use of damping
• Generally when CIV and DIV floats are used for gas measurement.
• For TIV floats (H250/RR and H250/HC only) with an operating primary pressure:
Nominal size according to Operating primary pressure
EN 1092-1 ASME B16.5 [bar] [psig]

DN15 ½" ≤0.3 ≤4.4
DN25 1" ≤0.3 ≤4.4
DN50 2" ≤0.2 ≤2.9
DN80 3" ≤0.2 ≤2.9
DN100 4" ≤0.2 ≤2.9
3.2.5 Pointer damping

The pointer system with its magnetic system basically contains pointer damping. An additional
eddy current brake is advantageous for fluctuating or pulsing flows. The eddy current brake
magnets surround the pointer vane without touching it, damping its movement. The result is a
pointer position that is considerably calmer, and there is no distortion of the measured value. A
clamp screw holds it in place securely. The eddy current brake can be retrofitted without having
to recalibrate and while in operation (see Service).

Electrical connections
H250 /M40 ELECTRICAL CONNECTIONS 4
4.1 Safety instructions

All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!
Observe the national regulations for electrical installations!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.

4 ELECTRICAL CONNECTIONS H250 /M40
4.2 Electrical connection indicator M40

4.2.1 Indicator M40 - limit switches
The M40 indicator can be equipped with a maximum of two electronic limit switches. The limit
switch functions as a slot sensor which is operated inductively through the semicircular metal
vane belonging to the measuring pointer. The switching points are set using the contact pointers.
The position of the contact pointer is indicated on the scale.
Limit switch module
1 Min. contact
2 Max. contact
3 Locking screw
4 Maximum pointer
5 Connection terminal
The connecting terminals have a pluggable design and can be removed in order to connect the
cables. The built-in limit switch types are shown on the indicator.
Electrical connection of the limit switches

Contact MIN MAX
Terminal no. 1 2 3 4 5 6
Connection 2-wire NAMUR - + - +
Connection 3-wire + DC - + DC -

Limit switch connection terminals
1 2-wire limit switch NAMUR

2 3-wire limit switch
3 Terminal connection min contact
4 Terminal connection max contact
5 3-wire load
6 NAMUR isolated switching amplifier
7 3-wire power supply
Limit setting
Figure 4-1: Limit switch settings

1 Contact pointer MAX
2 Contact pointer MIN
3 Locking screw
Setting is carried out directly via contact pointers 1 and 2:

• Slide the scale away
• Loosen the locking screw 3 slightly
• Slide the scale back to the latching point
• Set contact pointers 1 and 2 to the desired switching point
After setting has been carried out: Fix the contact pointers with the locking screw 3.

Switch contact definition
1 MIN contact
2 MAX contact
3 Pointer vane with switching vane
If the pointer vane enters the slot, an alarm is triggered. If the pointer vane lies outside the slot
sensor, a wire break also causes the alarm to be triggered.
The 3-wire limit switch does not have any wire break detection.
Definition MinMin - MaxMax
1 MIN 2 contact or MAX 1 contact

2 MIN 1 contact or MAX 2 contact
Current consumption in the position shown:

Contact Type Current
MIN 1 NAMUR ≤ 1 mA
MIN 2 NAMUR ≤ 1 mA
MAX 1 NAMUR ≥ 3 mA
MAX 2 NAMUR ≥ 3 mA

4.2.2 Current output ESK4A

The connecting terminals of the ESK4 have a pluggable design and can be removed in order to
connect the cables.
ESK4 connection
1 ESK4A current output

2 Power supply 14...30 VDC
3 Measuring signal 4...20 mA
4 External load, HART® communication
Power supply M40 with electrical isolation
The circuitry for connection to other devices such as digital evaluator units or process control
equipment must be designed with special care. In some circumstances, internal connections in
these devices (e.g. GND with PE, ground loops) may lead to impermissible voltage potentials,
which can compromise the function of the device itself or a connected device. In such cases a
protected extra-low voltage (PELV) is recommended.
1 Terminal connection
2 Converter supply isolator with electrical isolation
3 Power supply (see supply isolator information)
4 Measuring signal 4...20 mA
5 External load, HART® communication

Power supply
The supply voltage must be between 14 VDC and 30 VDC. This is based on the total resistance of
the measuring loop. To determine this, add up the resistances of each component in the
measuring loop (not including the device).
The required supply voltage can be calculated using the formula below:
Uext. = RL.24 mA + 14 V
where
Uext. = the minimum supply voltage and
RL = the total measuring loop resistance.
The power supply has to be able to supply a minimum of 30 mA.
HART® communication
When HART® communication is carried out with the ESK4, the analogue measured data
transmission (4...20 mA) is not impaired in any way.
Exception for multidrop mode. In multidrop mode, a maximum of 15 devices with HART® function
can be operated in parallel, whereby their current outputs are switched inactive
(I approx. 4.5 mA per device).

Load for HART® communication

For HART® communication a load of at least 230 ohm is required.
The maximum load resistance is calculated as follows:
Use a twisted two-core cable to prevent electrical interference from impeding the DC output
signal.
In some cases a shielded cable may be necessary. The cable shield may only be earthed
(grounded) at one place (on the power supply unit).
Configuration
The ESK can be configured via HART® communication. DD (Device Descriptions) for AMS 10.1
and PDM 5.4 - PACTwareTM version 3.6.0.2 as well as a DTM (Device Type Manager) are available
for configuration. They can be downloaded free of charge from our website.
The current flow rate can be transmitted using the integrated HART® communication. A flow
counter can be configured. Two limit values can be monitored. The limit values are assigned
either to flow values or to the counter overflow.
Self monitoring - Diagnostics

During both start-up and operation, a wide variety of diagnostic functions are performed
cyclically in the ESK4, in order to guarantee function reliability. When an error is detected, a
failure signal (high) is activated (current> 21 mA, typically 22 mA). In addition, more detailed
information can be requested via HART® (CMD#48). The failure signal is not activated for
information and warnings.
Diagnostic functions (Monitoring):

• Plausibility of FRAM data
• Plausibility of ROM data
• Working range of internal reference voltages
• Signal detection of the measuring range of the internal sensors
• Temperature compensation of the internal sensors
• Calibration based on the application
• Plausibility of counting value
• Plausibility of physical unit, system and selected unit

4.3 Grounding connections
1 Grounding connection in the indicator

2 External grounding connection
The grounding wire may not transfer any interference voltage.

Do not use this grounding wire to ground any other electrical devices.
4.4 Protection category

The measuring device meets all requirements of protection category IP66/67.
After all servicing and maintenance work on the measuring device, the specified protection
category must be ensured again.
Therefore it is essential to observe the following points:

• Use only original gaskets. They must be clean and free of any damage. Defective gaskets must
be replaced.
• The electrical cables used must be undamaged and must comply with regulations.
• The cables must be laid with a loop 3 upstream of the measuring device to prevent water
from getting into the housing.
• The cable feedthroughs 2 must be tightened.
• Close the unused cable feedthroughs using blanking plugs 1.
1 Use blanking plugs if no cable is routed through

2 Tighten cable feedthrough firmly
3 Lay the cable in a loop

Order form
H250 /M40 ORDER FORM 5
You can help us to assist you as quickly as possible by giving us a few items of information.
Then please fax this page to the appropriate sales associate. We will then contact you as soon as
possible.
Device data
Connection type:
Nominal connection size:
Pressure rating:
Raised face:
Material of pipeline:
Indicator options: K1 1
K2 2
ESK4
ESK4-T
ESK4-FF*
ESK4-PA*
Approvals* : None ATEX / IEC-Ex FM / FMc NEPSI
1 1 limit switch
2 2 limit switches
* in preparation
Rating data
Product:
Operating pressure: Absolute Overpressure
pressure
Rated pressure:
Operating temperature:
Rated temperature:
Density: Standard Operating
density density
Viscosity:
Measuring range:
Comments:
Contact data
Company:
Contact person:
Telephone number:
Fax number:
E-mail:

K K
KROHNE product overview

• Electromagnetic flowmeters
• Variable area flowmeters
• Ultrasonic flowmeters
© KROHNE 11/2009 - 4000685601 - TD-H250-M40-R01-R01-en - Subject to change without notice.
• Mass flowmeters
• Vortex flowmeters
• Flow controllers
• Level meters
• Temperature meters
• Pressure meters
• Analysis products
• Measuring systems for the oil and gas industry
• Measuring systems for sea-going tankers
Head Office KROHNE Messtechnik GmbH

Ludwig-Krohne-Str. 5
D-47058 Duisburg (Germany)
Tel.:+49 (0)203 301 0
Fax:+49 (0)203 301 10389
info@krohne.de
The current list of all KROHNE contacts and addresses can be found at:
www.krohne.com
Document kind Document identity Revision
Accessories 3AAM100011 F
Owner organization Document type Date of revision (yyyy-mm-dd) Status Page(s)
Motors and Generators Machine Description Document 2013-06-19 Valid 1(5)

Division/Department Prepared by Approved by Security level
DMMG/PID Emidio Norcini Karita Forss Internal
Winding temperature control
Motor type Inspected by Date Motor type Inspected by Date

X AMA Eerik Kinnunen 2010-10-10 X AMLi Piero Bodini 2013-06-19
AMC AMS
AMD AMZ
AMG DMI
AMGe M3
X AMI Eerik Kinnunen, Piero Bodini 2010-10-10 X HXR Eerik Kinnunen 2010-10-10
X AMKi Piero Bodini 2013-06-19
Note! This document covers product families that are marked with “X”. Restrictions to the scope of the document have been described in the body text.
Table of Contents
1 Purpose ......................................................................................................................................................... 1
2 General ......................................................................................................................................................... 1
2.1 Technical data ........................................................................................................................................ 1
2.2 Typical alarm and trip values in normal operating conditions ................................................................. 2
3 Solutions for Machines according to IEC ....................................................................................................... 2
3.1 Standard design ..................................................................................................................................... 2
3.2 Optional design ...................................................................................................................................... 2
3.3 On request design .................................................................................................................................. 3
4 Solutions for Machines according to NEMA .................................................................................................. 3
4.1 Standard design for this purpose ........................................................................................................... 3
4.2 Optional design ...................................................................................................................................... 3
4.3 On request design .................................................................................................................................. 3
5 Normative references .................................................................................................................................... 3
6 Definitions of available solutions ................................................................................................................... 4
1 Purpose
This Machine Description Document is meant to describe the standard and optional designs of ABB electrical
machines related to the topic of the document title. The document is internal by nature, intended mainly for the
use of ABB employees who need to explain to a third party the technical details of an offer.
2 General
RTDs are fitted in the slot of form wound stators (embedded temperature detector [ETD]) for measuring the
temperature of stator windings. Usable for 3- and 4-wire system. Figure 2 describes the difference between 3-
and 4-wire connection. Voltage range U ≤ 15,2kV.
2.1 Technical data

Following technical information apply to the components:
- Dielectric strength min. 5 kV (50 or 60 Hz) for 1 minute for standard sensor. Dielectric strength min. 3,2
kV (50 or 60 Hz) for 1 minute for sensors with shielded cables available as optional.
- IEC 60034-1: Withstand voltage test, 1500V AC, 50 Hz, for 1 minute. Tested to the machine frame.
- Measuring current max. 10 mA
- Teflon insulated flexible wires 4×0.24 mm2 (AWG#24), contained in a common teflon sheath.
- Standard: IEC 60751 class B
- ATEX approved for zone 1 and zone 21
Copyright 2010 ABB.
Accessories Valid 3AAM100011 F
Winding temperature control 2010-10-30 2(5)
- Usable temperature
o -60...+180˚C for safe area
o -20...+180˚C for hazardous area.
Figure 1. Pt-100 sensor for measuring temperature in form wound stator winding.
Figure 2. Usable connections for a 4-wire RTD.
2.2 Typical alarm and trip values in normal operating conditions
See maintenance manual.
3 Solutions for Machines according to IEC
3.1 Standard design

Standard sensors are with following variables:
- Type of sensor material: Pt100
- 1- Length of sensor (L2):
o 200 mm for AMA, AMI ≤ 630
o 50 mm for HXR,AMI ≥ 710, AMKi, AMLi, AML
- Cable without shield
- 2- Length of sensor (L2):
o 200 mm for AMI ≥ 710, AMKi, AMLi, AML
- Cable with shield
- Suitable for safe and hazardous areas
Standard designs are described in Table 1 with bold text.
3.2 Optional design

Optional designs include different amounts of RTDs and shielded cables for certain sensor types. Table 1
includes descriptions of standard and optional solutions. Sensor material always is Pt-100 in these solutions.
Copyright 2010 ABB
3.3 On request design

On request available are also single RTD sensors of types Pt-120, Pt-1000, Cu-10 and Ni-120. However, these
types aren’t suitable for explosion hazardous areas and are not available with shielded cables or for AMA
machines.
4 Solutions for Machines according to NEMA
4.1 Standard design for this purpose

Standard sensors are with following variables:
- Length of sensor (L2) 200 mm
- Cable without shield
- Suitable for safe and hazardous areas
Standard designs are described in Table 1 with bold text.
4.2 Optional design

Optional designs include different amounts of RTDs and shielded cables for certain sensor types. Table 1
includes descriptions of standard and optional solutions. Sensor material always is Pt-100 in these solutions.

On request available are also single RTD sensors of types Pt-120, Pt-1000, Cu-10 and Ni-120. However, these
types aren’t suitable for explosion hazardous areas and are not available with shielded cables or for AMA
machines.
5 Normative references
Standard IEC 60034-1 – “Rotating electrical machines – Part: Rating and performance
ANSI/NEMA MG 1 – “Motors and Generators”
IEC 60751 – "Industrial platinum resistance thermometer sensors”
6 Definitions of available solutions

Table 1. Available solutions.
Pt-100 Shield
Quantity
Code For machine type Title wiring for
[pcs]
type cable
AMI RTD's (Pt-100) in stator
AMKi/AMLi/AML windings, 6 pcs, 4-wire,
ST-PT100-SET1EX 3+3 4-wire no
unshielded, safe and hazardous
HXR areas.
AMA/AMI RTD's (Pt-100) in stator
HXR areas. (Standard design)
AMI, RTD's (Pt-100) in stator
HXR areas.
AMA/ AMI RTD's (Pt-100) in stator
AMKi /AMLi/AML windings, 12 pcs, 3-wire,
HXR areas.
ST-PT100-SET5EX 3+3 4-wire yes
shielded, safe and hazardous
HXR areas.
AMA/ AMI RTD's (Pt-100) in stator
AMKi /AMLi/AML windings, 6 pcs, 3-wire,
HXR areas.
HXR areas.
AMA/AMI RTD's (Pt-100) in stator
HXR areas.
Revision history
Rev. Date Prepared by Division/ Description
(yyyy-mm-dd) Department
B 2006-05-10 Antti Kuitunen FIDRI/PID Creation version
C 2010-01-10 Raija Ekblom FIDRI/PID Revised for AMA560-630.
D 2010-07-01 Raija Ekblom FIDRI/PID Revised for AMA 400-500 and AMI400-500.
E 2010-10-01 Emidio Norcini DMMG Revised for AMKi, AMLi and AMI 710-
Jan Knuts DMMG/PID Published
F 2012-10-16 E.Norcini DMMG/PID Added ”i” to AMK on the table of "Motor types" page 1.
Page 1 - par. 2 : modified voltage range: from 15 kV to 15,2kV
Page 2 - par. 3.1 :
for a sensor with length (L2) and cable without shield :
- about 50 mm for HXR,AMI ≥ 710, AMKi, added AMLi, AML.
For a sensor with length (L2) and cable with shield, added :
200 mm for AMI ≥ 710, AMKi, AMLi, AML.
Added machine type “AML” on table 1 page 4

Antifriction bearing temperature control

X AMA Eerik Kinnunen 2010-10-10 X AMLi Piero Bodini 2013-06-19
AMC AMS
AMD AMZ
AMG DMI
AMGe M3
X AMKi Piero Bodini 2013-06-19
Table of Contents
1 Purpose..........................................................................................................................................................1
2 General…………………………………………………………………………………………………………….…….1
2.1 Technical data……………………………………………………………………………………….………………..1
2.2 Typical alarm and trip values in normal operating conditions…………………………………………..…….….3
3 Solutions for Machines according to IEC ……………………………………………………………………….……3
3.1 Standard design for thispurpose…………………………………………………………………………….…...3
3.2 Optional design...................................................................................................................................... 3
3.3 On request design ................................................................................................................................. 3
4 Solutions for Machines according to NEMA .................................................................................................. 3
4.1 Standard design .................................................................................................................................... 3
4.2 Optional design...................................................................................................................................... 3
4.3 On request design ................................................................................................................................. 3
5 Normative references ................................................................................................................................... 3
6 Definitions of available solutions ................................................................................................................... 4
1 Purpose
2 General
To be fitted near the outer ring of antifriction bearings for measuring the temperature of bearing. Usable for 3- and
4-wire system. Figure 2 describes the difference between 3- and 4-wire connections.
2.1 Technical data
 Dielectric strength min 1 kV (50 or 60 Hz) for 1 minute

 Degree of protection IP56
 Insulation test voltage 500 V at room temperature
 Measuring current max. 10 mA
Copyright 2010 ABB.
Antifriction bearing temperature control 2010-10-30 2(5)
 Teflon insulated flexible wires, each 0.24 mm2 (AWG#24), contained in a common teflon sheath. The
cable is equipped with braided shield. If not specified, the shield is not connected to the terminal block in
the terminal box (see fig. 2)
 Standard: IEC 751 class B
 Hazardous area versions ATEX approved for zone 1 and zone 21
 Temperature range -40...+180˚C (hazardous area) and -60...+180˚C (in safe area).
Figure 1: Pt-100 sensor for measuring temperature in antifriction bearings.
Figure 2: Usable connections for a 4-wire RTD.
For AMI ≥ 710 – AMLi ≥ 560 – AMKi 400- 450- 500,on request is available Pt100 Exi execution, with 6-wire
connection (see figure 3)
Type code: TS-CVO-RTD

CASTELVERDE - CR S.N. XXXXX XX XX
ITALY
1G EEx ia IIC T6
0032 TÜV 05 ATEX 2931X
Figure 3 : Pt100 sensor for measuring temperature in antifriction bearings

3 Solutions for Machines according to IEC
3.1 Standard design for this purpose

Standard design is with following parameters:
 Sensor type Pt-100
 Cable with shield
 One sensor per bearing
3.2 Optional design

Optional designs include different amounts of RTD and RTDs for explosion hazardous areas. Table 2 includes
descriptions of standard and optional solutions. In these solutions sensor material always is Pt-100 and the cable
is shielded.

On request available are also single RTD sensors of types Pt-120, Pt-1000, Cu-10 and Ni-120. These types aren’t
suitable for explosion hazardous areas.
On request available for antifriction temperature measurement there are also thermocouples of types K, T, J and
E. These types aren’t suitable for explosion hazardous areas.
4 Solutions for Machines according to NEMA
4.1 Standard design

Standard design is with following parameters:
 Sensor type Pt-100
 Cable with shield
 One sensor per bearing
4.2 Optional design

Optional designs include different amounts of RTD and RTDs for explosion hazardous areas. Table 2 includes
descriptions of standard and optional solutions. In these solutions sensor material always is Pt-100 and the cable
is shielded.

On request available are also single RTD sensors of types Pt-120, Pt-1000, Cu-10 and Ni-120. These types aren’t
suitable for explosion hazardous areas.
On request available for antifriction temperature measurement there are also thermocouples of types K, T, J and
E. These types aren’t suitable for explosion hazardous areas.
Table 1: Normative references.
Standard IEC 60034-1 – “Rotating electrical machines – Part: Rating and performance

Table 2: Available solutions.
Qua
Pt-100 Safe or
ntity
Code For machine type Title wiring Hazardous
[pcs
type area
]
AFB- AMI 400÷1000 RTD's (Pt-100) in antifriction bearings,
PT100- 1 pc / bearing, 4-wire, shielded, safe 2 4-wire Safe
HXR
SET1 areas
PT100- 1 pc / bearing, 4-wire, shielded, 2 4-wire Hazardous
HXR
SET1EX hazardous areas
PT100- 1 pc / bearing, 3-wire, shielded, safe 2 3-wire Safe
SET2 HXR areas
PT100- 1 pc / bearing, 3-wire, shielded, 2 3-wire Hazardous
HXR
AFB- AMI 400÷1000 Duplex RTD's (Pt-100) in antifriction
PT100- bearings, 1 pc / bearing, 4-wire, 2 4-wire Safe
HXR
SET3 shielded, safe areas
PT100- bearings, 1 pc / bearing, 4-wire, 2 4-wire Hazardous
HXR
SET3EX shielded, hazardous areas
PT100- bearings, 1 pc / bearing, 3-wire, 2 3-wire Safe
HXR
PT100- bearings, 1 pc / bearing, 3-wire, 2 3-wire hazardous
HXR
PT100- 2 pcs / bearing, 4-wire, shielded, safe 4 4-wire Safe
HXR
SET5 areas
PT100- 2 pcs / bearing, 4-wire, shielded, 4 4-wire Hazardous
HXR
PT100- 2 pcs / bearing, 3-wire, shielded, safe 4 3-wire Safe
SET6 HXR areas
PT100- 2 pcs / bearing, 3-wire, shielded, 4 3-wire Hazardous
HXR
PT100- bearings, 2 pcs / bearing, 4-wire, 4 4-wire Safe
HXR
PT100- bearings, 2 pcs / bearing, 4-wire, 4 4-wire Hazardous
HXR
PT100- bearings, 2 pcs / bearing, 3-wire, 4 3-wire Safe
HXR
PT100- bearings, 2 pcs / bearing, 3-wire, 4 3-wire Hazardous
HXR
Revision history
A ? ? ? Document created
B 2006-05-10 Antti Kuitunen FIDRI/PID
C 2010-01-10 Raija Ekblom FIDRI/PID Revised for AMA560 and 630.

D 2010-07-01 Raija Ekblom FIDRI/PID Revised for AMA 400-500 and AMI 400-500.
E 2010-10-01 Jan Knuts DMMG/PID Updated Product family applicability table for AMK. Removed AMK from table 2.
F 2012-12-18 E.Norcini DMMG/ITABB Inspection corrected ; Inserted PT100 for AMI≥710,AMLi,AMKi (pag 2) ; Updated
Product family applicability (pag 4).

Sleeve bearing and cooling air temperature control

X AMA Eerik Kinnunen 2010-10-10 X AMLi Piero Bodini
AMC AMS
AMD AMZ
AMG DMI
AMGe M3
X AMKi Piero Bodini
Table of Contents
1 Purpose ..................................................................................................................................................... ...1
2 General…………………………………………………………………………………………………………….….…2
3 Normative Reference…………………………………………………………………………………………….…….3
4 Definitions of evailable solutions………………………………………………………………………………………4
1 Purpose
machines related to the topic of the document title. The document is internal by nature, intended mainly for the use
of ABB employees who need to explain to a third party the technical details of an offer.
2 General
For measuring temperature in sleeve bearings and cooling air. Usable for 3- and 4-wire system. Figure 2 describes
the difference between 3- and 4-wire connections.
Technical specification:
- Dielectric strength min 1 kV (50 or 60 Hz) for 1 minute
- Degree of protection IP56
- Insulation test voltage 500 V at room temperature
- Teflon insulated flexible wires, each 0.24 mm2 (AWG#24), contained in a common teflon sheath. The cable
is equipped with braided shield. If not specified, the shield is not connected to the terminal block in the
terminal box.
- Hazardous area versions ATEX approved for zone 1 and zone 21
- Temperature range -40...+180˚C (hazardous area) and -60...+180˚C (in safe area)
- Typical alarm and trip values in normal operating conditions: See maintenance manual.
Sleeve bearing and cooling air temperature control 2010-10-30 2(7)
Figure 1. Pt-100 sensor for sleeve bearing and cooling air temperature measurement.
Figure 2. Usable connections for a 4-wire RTD.

Standard solution has following parameters:
- Cable with shield
- L1 = 210 mm.
- 3-wire connection
Optional designs include different amounts of RTDs, duplex RTDs and RTDs for explosion hazardous areas.
Tables 1 and 2 include descriptions of standard and optional solutions. In these solutions sensor material always is
Pt-100 and the cable is shielded.
On request available are also single RTD sensors of types Pt-120, Pt-1000, Cu-10, Ni-120 and duplex Ni-120.
These types aren’t suitable for explosion hazardous areas. On request available for sleeve bearing temperature
measurement there are also thermocouples of types K, T, J and E. These types aren’t suitable for explosion
hazardous areas.
For AMI ≥ 710 – AMLi ≥ 560 – AMKi 400- 450- 500,on request is available Pt100 Exi execution, with 6-wire
connection (see figure 2) :
Figure 2 – Pt100 sensor for sleeve bearing temperature measurement for Exi execution
Standard IEC 60034-1 – “Rotating electrical machines – Part: Rating and performance. For bearing
temperature measurement.

Table 1. Solutions for sleeve bearing shell and oil sump temperature measurement.
Qu
anti Pt-100 Safe or
Code For machine type Title ty wiring Hazardous
[pc type area
s]
SB-PT100- AMI 400 ÷1000 RTD's (Pt-100) in sleeve bearing shell, 1
2 4-wire Safe
SET1 HXR pc / bearing, 4-wire, shielded, safe areas
AMI 400 ÷1000 RTD's (Pt-100) in sleeve bearing shell, 1
SB-PT100-
pc / bearing, 4-wire, shielded, hazardous 2 4-wire Hazardous
SET1EX HXR
areas
2 3-wire Safe
SET2 HXR pc / bearing, 3-wire, shielded, safe areas
SB-PT100-
pc / bearing, 3-wire, shielded, hazardous 2 3-wire Hazardous
SET2EX HXR
areas
AMI 400 ÷1000 Duplex RTD's (Pt-100) in sleeve bearing
SB-PT100-
shell, 1 pc / bearing, 4-wire, shielded, safe 2 4-wire Safe
SET3 HXR
areas
SB-PT100-
shell, 1 pc / bearing, 4-wire, shielded, 2 4-wire Hazardous
SET3EX HXR
hazardous areas
SB-PT100-
shell, 1 pc / bearing, 3-wire, shielded, safe 2 3-wire Safe
SET4 HXR
areas
SB-PT100-
shell, 1 pc / bearing, 3-wire, shielded, 2 3-wire Hazardous
SET4EX HXR
hazardous areas
AMI 400 ÷1000 RTD's (Pt-100) in sleeve bearing oil sump,
SB-PT100-
1 pc / bearing, 4-wire, shielded, safe 2 4-wire Safe
SET5 HXR
areas
SB-PT100-
1 pc / bearing, 4-wire, shielded, 2 4-wire Hazardous
SET5EX HXR
hazardous areas
SB-PT100-
1 pc / bearing, 3-wire, shielded, safe 2 3-wire Safe
SET6 HXR
areas
SB-PT100-
1 pc / bearing, 3-wire, shielded, 2 3-wire Hazardous
SET6EX HXR
hazardous areas
SB-PT100-
oil sump, 1 pc / bearing, 4-wire, shielded, 2 4-wire Safe
SET7 HXR safe areas
SB-PT100-
oil sump, 1 pc / bearing, 4-wire, shielded, 2 4-wire Hazardous
SET7EX HXR hazardous areas
SB-PT100-
oil sump, 1 pc / bearing, 3-wire, shielded, 2 3-wire Safe
SET8 HXR
safe areas
SB-PT100-
oil sump, 1 pc / bearing, 3-wire, shielded, 2 3-wire Hazardous
4 4-wire Safe
SET9 HXR pcs / bearing, 4-wire, shielded, safe areas
SB-PT100- AMI 400 ÷1000 RTD's (Pt-100) in sleeve bearing shell, 2 4 4-wire Hazardous
Qu
anti Pt-100 Safe or
Code For machine type Title ty wiring Hazardous
[pc type area
s]
SET9EX pcs / bearing, 4-wire, shielded, hazardous
HXR
areas
4 3-wire Safe
SET10 HXR pcs / bearing, 3-wire, shielded, safe areas
SB-PT100-
pcs / bearing, 3-wire, shielded, hazardous 4 3-wire Hazardous
SET10EX HXR
areas
SB-PT100-
shell, 2 pcs / bearing, 4-wire, shielded, 4 4-wire Safe
SET11 HXR
safe areas
SB-PT100-
shell, 2 pcs / bearing, 4-wire, shielded, 4 4-wire Hazardous
SET11EX HXR
hazardous areas
SB-PT100-
shell, 2 pcs / bearing, 3-wire, shielded, 4 3-wire Safe
SET12 HXR
safe areas
SB-PT100-
AMI 400 ÷1000 shell, 2 pcs / bearing, 3-wire, shielded, 4 3-wire Hazardous
SET12EX
HXR hazardous areas
SB-PT100-
2 pcs / bearing, 4-wire, shielded, safe 4 4-wire Safe
SET13 HXR
areas
SB-PT100-
2 pcs / bearing, 4-wire, shielded, 4 4-wire Hazardous
SET13EX HXR
hazardous areas
SB-PT100-
2 pcs / bearing, 3-wire, shielded, safe 4 3-wire Safe
SET14 HXR
areas
SB-PT100-
2 pcs / bearing, 3-wire, shielded, 4 3-wire Hazardous
SET14EX HXR
hazardous areas
SB-PT100-
oil sump, 2 pcs / bearing, 4-wire, shielded, 4 4-wire Safe
SET15 HXR safe areas
SB-PT100-
oil sump, 2 pcs / bearing, 4-wire, shielded, 4 4-wire Hazardous
SB-PT100-
oil sump, 2 pcs / bearing, 3-wire, shielded, 4 3-wire Safe
SET16 HXR
safe areas
SB-PT100-
oil sump, 2 pcs / bearing, 3-wire, shielded, 4 3-wire Hazardous
Table 2: Solutions for cooling air temperature measurement

Pt-100 Safe or
For machine
Code Title wiring Hazardous
type
type area
CA-PT100- RTD's (Pt-100) in warm and cold cooling air, 4-wire,
AMI 400 ÷1000 4-wire Safe
AMI 400 ÷1000 4-wire Hazardous
Pt-100 Safe or
For machine
Code Title wiring Hazardous
type
type area
CA-PT100- Duplex RTD's (Pt-100) in warm and cold cooling air,
SET3 4-wire, shielded, safe areas
SET3EX 4-wire, shielded, hazardous areas
AMA / AMI 3-wire Safe
SET4 3-wire, shielded, safe areas
SET4EX 3-wire, shielded, hazardous areas
Revision history
A 2005-08-18 Antti Kuitunen FIDRI/PID Document created.
B 2006-05-10 Antti Kuitunen FIDRI/PID Revised.
C 2010-01-10 Raija Ekblom FIDRI/PID Revised for AMA560 and 630.

D 2010-07-01 Raija Ekblom FIDRI/PID Revised for AMA 400-500.
E 2010-10-01 Emidio Norcini DMMG Removed applicability for AMK and AMI ≥ 710.
Jan Knuts DMMG/PID Published.
F 2012-12-18 E.Norcini DMMG/ITABB Inspection corrected ; Inserted PT100 for AMI≥710,AMLi,AMKi (pag 2) ; Updated
Product family applicability (pag 4/5/6).
Accessories 3AAM100013 B
Electrical Machines Machine Description Document 2006-05-10 Valid 1(8)

FIDRI/PID Antti Kuitunen Heikki Vepsäläinen Internal
Sleeve bearing and cooling air temperature control

X AMA Eerik Kinnunen 2006-05-29 AML
AMC AMS
AMD AMZ
AMG DMI
AMGe M3
X AMI Gunnar Porsby 2006-05-11 X HXR Eerik Kinnunen 2006-05-29
X AMK Eerik Kinnunen 2006-05-29
Table of Contents
1 Purpose ............................................................................................................................................................1
2 General .............................................................................................................................................................1
2.1 Technical specification ..............................................................................................................................2
2.2 Typical alarm and trip values in normal operating conditions ...................................................................2
3 Machines according to IEC ..............................................................................................................................3
3.1 Standard design ........................................................................................................................................3
3.2 Optional design .........................................................................................................................................3
3.3 On request design .....................................................................................................................................3
4 Machines according to NEMA ..........................................................................................................................3
4.1 Standard design ........................................................................................................................................3
4.2 Optional design .........................................................................................................................................3
4.3 On request design .....................................................................................................................................3
5 Normative references .......................................................................................................................................3
6 Definitions of available solutions ......................................................................................................................4
1 Purpose
2 General
For measuring temperature in sleeve bearings and cooling air. Usable for 3- and 4-wire system. Figure 2
describes the difference between 3- and 4-wire connection.
This MDD supersedes following documents:
- PIF 2a-5225 – HXR Machines “Resistance temperature detector (RTD) Pt-100 sensor for measuring
sleeve bearing temperature in safe and explosion hazardous areas”
- PIF 2b-5225 – AMA Machines “Resistance temperature detector (RTD) Pt-100 sensor for measuring
sleeve bearing or cooling air temperature in safe and explosion hazardous areas”
 Copyright 2006 ABB
Accessories Valid 3AAM100013 B
2.1 Technical specification
- Dielectric strength min 1 kV (50 or 60 Hz) for 1 minute

- Degree of protection IP56
- Insulation test voltage 500 V at room temperature
- Teflon insulated flexible wires, each 0.24 mm2 (AWG#24), contained in a common teflon sheath. The
cable is equipped with braided shield. If not specified, the shield is not connected to the terminal block
in the teminal box.
- Hazardous area versions ATEX approved for zone 1 and zone 21
- Temperature range -40...+180˚C (hazardous area) and -60...+180˚C (in safe area)
Figure 1: Pt-100 sensor for sleeve bearing and cooling air temperature measurement.
Figure 2: Usable connections for a 4-wire RTD.
Alarm and trip values for cooling air are case-specific.
3 Machines according to IEC
3.1 Standard design

- Cable with shield
- L1 = 210 mm.
3.2 Optional design

Tables 1 and 2 include descriptions of standard and optional solutions. In these solutions sensor material
always is Pt-100 and the cable is shielded.

These types aren’t suitable for explosion hazardous areas.
On request available for sleeve bearing temperature measurement there are also thermocouples of types K, T,
J and E. These types aren’t suitable for explosion hazardous areas.
4 Machines according to NEMA
4.1 Standard design

- Cable with shield
- L1 = 210 mm.
4.2 Optional design

Tables 1 and 2 include descriptions of standard and optional solutions. In these solutions sensor material
always is Pt-100 and the cable is shielded.

These types aren’t suitable for explosion hazardous areas.
On request available for sleeve bearing temperature measurement there are also thermocouples of types K, T,
J and E. These types aren’t suitable for explosion hazardous areas.
Standard IEC 60034-1 – “Rotating electrical machines – Part: Rating and performance. For bearing
temperature measurement.

Table 1: Solutions for sleeve bearing shell and oil sump temperature measurement.
For Pt-100 Safe or

Quantity
Code machine Title wiring hazardous
[pcs]
type type area
AMA
AMI RTD's (Pt-100) in sleeve bearing
SB-PT100-SET1 shell, 1 pc / bearing, 4-wire, shielded, 2 4-wire safe
AMK safe areas
HXR
AMA
SB-PT100-SET1EX shell, 1 pc / bearing, 4-wire, shielded, 2 4-wire hazardous
AMK hazardous areas
HXR
AMA
SB-PT100-SET2 shell, 1 pc / bearing, 3-wire, shielded, 2 3-wire safe
AMK safe areas
HXR
AMA
SB-PT100-SET2EX shell, 1 pc / bearing, 3-wire, shielded, 2 3-wire hazardous
AMK hazardous areas
HXR
AMA
AMI Duplex RTD's (Pt-100) in sleeve
SB-PT100-SET3 bearing shell, 1 pc / bearing, 4-wire, 2 4-wire safe
AMK shielded, safe areas
HXR
AMA
SB-PT100-SET3EX bearing shell, 1 pc / bearing, 4-wire, 2 4-wire hazardous
AMK shielded, hazardous areas
HXR
AMA
SB-PT100-SET4 bearing shell, 1 pc / bearing, 3-wire, 2 3-wire safe
HXR
AMA
SB-PT100-SET4EX bearing shell, 1 pc / bearing, 3-wire, 2 3-wire hazardous
HXR
AMA
AMI RTD's (Pt-100) in sleeve bearing oil
SB-PT100-SET5 sump, 1 pc / bearing, 4-wire, 2 4-wire safe
HXR
AMA
SB-PT100-SET5EX sump, 1 pc / bearing, 4-wire, 2 4-wire hazardous
HXR
AMA
SB-PT100-SET6 sump, 1 pc / bearing, 3-wire, 2 3-wire safe
HXR
AMA
SB-PT100-SET6EX sump, 1 pc / bearing, 3-wire, 2 3-wire hazardous
HXR
AMA
SB-PT100-SET7 safe
AMK bearing oil sump, 1 pc / bearing, 4- 2 4-wire
wire, shielded, safe areas
HXR
AMA
SB-PT100-SET7EX hazardous
AMK bearing oil sump, 1 pc / bearing, 4- 2 4-wire
wire, shielded, hazardous areas
HXR
AMA
AMI
SB-PT100-SET8 Duplex RTD's (Pt-100) in sleeve
AMK bearing oil sump, 1 pc / bearing, 3- 2 3-wire safe
HXR
AMA

SB-PT100-SET8EX
bearing oil sump, 1 pc / bearing, 3- 2 3-wire hazardous
AMK wire, shielded, hazardous areas
HXR
AMA
SB-PT100-SET9
AMK shell, 2 pcs / bearing, 4-wire, 4 4-wire safe
shielded, safe areas
HXR
AMA
SB-PT100-SET9EX
AMK shell, 2 pcs / bearing, 4-wire, 4 4-wire hazardous
shielded, hazardous areas
HXR
AMA
SB-PT100-SET10
AMK shell, 2 pcs / bearing, 3-wire, 4 3-wire safe
HXR
AMA
SB-PT100-SET10EX
AMK shell, 2 pcs / bearing, 3-wire, 4 3-wire hazardous
HXR
AMA
SB-PT100-SET11 safe
AMK bearing shell, 2 pcs / bearing, 4-wire, 4 4-wire
HXR
AMA
HXR
AMA
SB-PT100-SET12 safe
HXR
AMA
SB-PT100-SET12EX
AMK bearing shell, 2 pcs / bearing, 3-wire, 4 3-wire hazardous
HXR
AMA
SB-PT100-SET13 safe
AMK sump, 2 pcs / bearing, 4-wire, 4 4-wire
HXR
AMA
SB-PT100-SET13EX
AMK sump, 2 pcs / bearing, 4-wire, 4 4-wire hazardous
HXR
AMA
SB-PT100-SET14 safe
HXR
AMA
HXR
AMA
SB-PT100-SET15
AMK bearing oil sump, 2 pcs / bearing, 4- 4 4-wire safe
HXR
AMA
SB-PT100-SET15EX bearing oil sump, 2 pcs / bearing, 4- 4 4-wire hazardous
AMK wire, shielded, hazardous areas
HXR
AMA
SB-PT100-SET16
AMK bearing oil sump, 2 pcs / bearing, 3- 4 3-wire safe
HXR
AMA
SB-PT100-SET16EX
AMK bearing oil sump, 2 pcs / bearing, 3- 4 3-wire hazardous
HXR
Table 2: Solutions for cooling air temperature measurement
For Pt-100 Safe or

Code machine Title wiring hazardous
type type area
AMA
RTD's (Pt-100) in warm and cold cooling air, 4-
CA-PT100-SET1 AMI 4-wire safe
AMK
AMA
CA-PT100-SET1EX AMI 4-wire hazardous
AMK
AMA
AMK
AMA
AMK
AMA
Duplex RTD's (Pt-100) in warm and cold cooling
air, 4-wire, shielded, safe areas
AMK
AMA
air, 4-wire, shielded, hazardous areas
AMK
AMA
air, 3-wire, shielded, safe areas
AMK
AMA
air, 3-wire, shielded, hazardous areas
AMK
3300 5mm Transducer
Bently Nevada* Asset Condition Monitoring
Description
Transducer System
The 3300 5mm Proximity Transducer System consists of:
• a 3300 5 mm probe 1, 2
• a 3300 XL extension cable (ref 141194-01)
• a 3300 XL Proximitor* Sensor 3, 4, 5 (ref 141194-01)
When combined with a 3300 XL Proximitor Sensor and XL extension cable, the
system provides an output voltage that is directly proportional to the distance
between the probe tip and the observed conductive surface. The system can
measure both static (position) and dynamic (vibration) data. Its primary use is in
vibration and position measurement applications on fluid-film bearing machines,
as well as Keyphasor* measurement and speed measurement applications6.
The system provides an accurate, stable signal output over a wide temperature
range. All 3300 XL Proximity Transducer Systems achieve this level of
performance with complete interchangeability of probe, extension cable, and
Proximitor sensor, eliminating the need for individual component matching or
bench calibration.
Proximity Probe
The 3300 5 mm probe improves upon previous designs. A patented TipLoc*
molding method provides a more robust bond between the probe tip and the
probe body.
Connectors
The 3300 5mm probe and 3300 XL extension cable have corrosion-resistant,
gold-plated brass ClickLoc* connectors. These connectors require only finger-
tight torque (connectors will "click"), and the specially engineered locking
mechanism prevents the connectors from loosening. The connectors require no
special tools for installation or removal.
You can order 3300 5mm Probes and XL Extension Cables with connector
protectors already installed, or we can supply the connector protectors
separately for installation in the field (such as when you must run the cable
through restrictive conduit). We recommend connector protectors for all
installations to provide increased environmental protection7.
Specifications and Ordering Information

Part Number 172036
Rev. G (09/09)
Page 1 of 15
Notes:
1. A 5mm probe uses smaller physical packaging and provides the same linear range as a
3300 XL 8mm probe (ref 141194-01). The 5mm probe does not, however, reduce the
sideview clearances or tip-to-tip spacing requirements as compared to an XL 8 mm probe.
IYou should use the 5mm probe when physical (not electrical) constraints preclude the use
of an 8mm probe, such as mounting between thrust bearing pads or other constrained
spaces. When your application requires narrow sideview probes, use the 3300 XL NSv*
probe and extension cable with the 3300 XL NSv Proximitor Sensor (refer to Specifications
and Ordering Information p/n 147385-01).
2. XL 8 mm probes provide a thicker encapsulation of the probe coil in the molded PPS
plastic probe tip to produce a more rugged probe. The larger diameter of the probe body
also provides a stronger, more robust case. We recommend the use of XL 8mm probes
when possible to provide optimal robustness against physical abuse.
3. A 3300 XL Proximitor Sensor is available and provides many improvements over the
non-XL version. The XL sensor is electrically and mechanically interchangeable with the
non-XL version. Although the packaging of the 3300 XL Proximitor Sensor differs from its
predecessor, its design allows you to usea 4-hole mounting base to fit it t in the same 4-
hole mounting pattern and to fit within the same mounting space specifications (when the
application observes the minimum permissible cable bend radius). Consult Specifications
and Ordering Information (p/n 141194-01) or our sales and service professional for more
information.
4. Us of XL components with 3300 5mm Probes will limit system performance to the
specifications for the non-XL 3300 system.
5. The factory supplies Proximitor Sensors that are calibrated by default to AISI 4140 steel.
Calibration to other target materials is available upon request.
6. If you are considering using this transducer system for tachometer or over-speed
measurements, consult www.ge-energy.com/bently for the application note regarding the
use of eddy current proximity probes for over speed protection.
7. We provide silicone tape i with each 3300 XL extension cable. You can use this tape
instead of connector protectors. We do not recommend silicone tape in applications
which will expose the probe-to-extension cable connection to turbine oil.

Part Number 172036
Rev. G (09/09)
Page 2 of 15
Table 2: Extension Cable DC Resistance
Specifications
Resistance from Resistance from
Unless otherwise noted, the following specifications Length of
Center Conductor to Outer Conductor to
are for a proximity transducer system between +18 Extension
Center Conductor Outer Conductor
°C and +27 °C (+64 °F to +80 °F) with a -24 Vdc Cable
(RCORE) (Ω) (RJACKET) (Ω)
power supply, a 10 kΩ load, an AISI 4140 steel
target, and a probe gapped at 1.27 mm (50 mils). 3.0 0.66 ± 0.10 0.20 ± 0.04
Electrical 3.5 0.77 ± 0.12 0.23 ± 0.05
XL Proximitor 4.0 0.88 ± 0.13 0.26 ± 0.05

Sensor Input 4.5 0.99 ± 0.15 0.30 ± 0.06
Accepts one noncontacting 3300
7.0 1.54 ± 0.23 0.46 ± 0.09
5 mm Proximity Probe and XL
Extension Cable. 7.5 1.65 ± 0.25 0.49 ± 0.10
Power 8.0 1.76 ± 0.26 0.53 ± 0.11

Requires -17.5 Vdc to -26 Vdc at 8.5 1.87 ± 0.28 0.56 ± 0.11
12 mA maximum consumption.
Operation at a more positive
voltage than -23.5 Vdc can result Note: Outer conductor refers to the shielded conductor that is
in reduced linear range. attached to the connector, not the armor braid.
Supply Extension cable

Sensitivity capacitance
Less than 2 mV change in output 69.9 pF/m (21.3 pF/ft) typical.

voltage per volt change in input Field Wiring
voltage.
Recommend using 3-conductor
Output shielded triad cable 0.2mm to
resistance 1.5mm (16 AWG to 24 AWG). 305
50 Ω metres (1,000 feet) maximum
length between 3300 XL Proximity
Table 1: Probe DC Resistance Transducer and monitor. Consult
Performance Specification
Resistance from the Center
155687 for signal rolloff at high
Probe Length (m) Conductor to the Outer Conductor
frequencies when using longer
(Ω)
field wiring lengths or external
0.5 7.45 ± 0.50 safety barriers located some
distance from the monitoring
1.0 7.59 ± 0.50
system.
1.5 7.73 ± 0.50 Linear Range
2.0 7.88 ± 0.50 2 mm (80 mils). Linear range
5.0 8.73 ± 0.70 begins at approximately 0.25 mm
(10 mils) from target and is from
9.0 9.87 ± 0.90 0.25 to 2.3 mm (10 to 90 mils).
Recommended
Gap Setting
1.27 mm (50 mils).

Part Number 172036
Rev. G (09/09)
Page 3 of 15
Incremental at least 50 mm (2 in) or greater.
Scale Factor Care should be taken to maintain
minimum separation of
7.87 V/mm (200 mV/mil) ±6.5%
transducer tips, generally at least
typical, including
40 mm (1.6 in) for axial position
interchangeability error when
measurements or 38 mm (1.5 in)
measured in increments of 0.25
for radial vibration measurements
mm (10 mils) over the linear
to limit cross-talk to 50 mV or less.
range.
Radial vibration or position
Deviation from measurements on shaft
best fit straight diameters smaller than 76.2 mm
line (DSL) (3 in) will generally result in a
change in scale factor. Consult
Less than ±0.038 mm (±1.5 mil)
Performance Specification
typical deviation from best fit
155687 for additional information.
straight line.
Effects of 60 Hz
Probe
Magnetic Fields
Temperature
Up to 300 Gauss
Stability
(typical) See Table 3.
Over probe temperature range of Table 3: Output Voltage in Mil (pk-pk)/Gauss (5-metre
-35 °C to +177 °C (-31 °F to +350 System)
°F), the incremental scale factor
remains within ±10% of 7.87 XL
XL Ext.
V/mm (200 mV/mil) and the Gap Proximitor Probe
Cable
deviation from the best fit straight Sensor
line remains within ±0.076 mm 10 mil 0.0119 0.0004 0.0004
(±3 mils).
50 mil 0.0131 0.0014 0.0014
Frequency
Response 90 mil 0.0133 0.0045 0.0045
0 to 10 kHz: +0, -3 dB, with up to Electrical

305 metres (1000 feet) of field Certification
wiring.
Complies with the European CE
Minimum mark.
Target Size
15.2 mm (0.6 in) diameter
(flat target).
Shaft Diameter
Minimum
50.8 mm (2 in)
Recommended
minimum
76.2 mm (3 in)
When gapped at the center of the
linear range, the interaction
between 2 separate transducer
systems (cross-talk) will be less
than 50 mV on shaft diameters of
Part Number 172036
Rev. G (09/09)
Page 4 of 15
Europe
Hazardous Area Approvals 3300 XL
Proximitor
Note: Multiple approvals for hazardous areas certified by
Sensor, ia:
Canadian Standards Association (C/US) in North America
and by Baseefa for Europe and IEC Ex. II 1 G EEx ia IIC T4/T5. EC
certificate number
Table 4: Field Wiring Limitations: BAS99ATEX1101, when installed
L/R
per drawing 141092.
Gas
Type Capacitance Inductance
Grou Ratio 3300 XL
Approval: (µF) (mH)*
p (μH/Ω) Proximitor
Sensor, nA:
ATEX
and IEC IIC 0.078 0.99 29.2 II 3 G Ex nA II T4/T5. EC
Zone 0/1 certificate number Baseefa
IIB 0.645 7.41 117.0 07ATEX0189X, when installed per
IIA 2.144 15.6 234.0 drawing 140979.
CSA Div A
1 and 0.070 1.0 29.2 T5 @ Ta= -35 °C to +85 °C
B
C 0.600 5.0 117.0 T4 @ Ta= -51 °C to +100 °C.
D 2.09 11.0 234.0
CSA Div
All 0.460 100.0 N/A
2
North America
3300 XL
Proximitor
Sensor and 3300 XL 8mm
probe, ia: probe, ia:
Ex ia IIC T4/T5; Class I Zone 0 or II 1 G EEx ia IIC, Temperature
Class 1 Division 1; Groups A, B, C, Classification per table 4-5, EC
and D, when installed with certificate number
intrinsically safe zener barriers BAS99ATEX1099 when installed
per drawing 141092 or when per drawing 142491.
installed with galvanic isolators. 3300 XL 8mm
Certificate number 1109248(LR probe, nA:
26744-222) II 3 G EEx nA II, Temperature
3300 XL Classification per table 4-5, EC
Proximitor certificate number
Sensor and BAS99ATEX3098 when installed
probe, nA: per drawing 142491.
Ex nA IIC T4/T5 Class I Zone 2 or IEC Ex
Class I, Division 2, Groups A, B, C, 3300 XL
and D when installed without Proximitor
barriers per drawing 140979. Sensor, ia
T5 @ Ta = -35 °C to +85 °C. IECEx BAS04.0055X
T4 @ Ta= -51 °C to +100 °C. Ex ia IIC T4 (-51°C ≤ Ta ≤ +100°C) /
Certificate number 1109248(LR T5 (-35ºC ≤ Ta ≤ +85ºC)
26744-222)
Part Number 172036
Rev. G (09/09)
Page 5 of 15
Terminal Block Hazardous Area
Connections Conditions of
Safe Use:
Ui= -28V Ci = 0
Ii= 140mA Li =10µH
ATEX: Follow the conditions of
Pi= 0.84W
safe use included on the
3300 XL Declaration of Conformance sent
Proximitor with each product.
Sensor, nA:
Canadian Standards Association
IECEx BAS04.0057X (CSA):
Ex nA II T4 (-51°C ≤ Ta ≤ +100°C) / Division 1 (Intrinsically
T5 (-35°C ≤ Ta ≤ +85°C) safe): Install per Bently Nevada
drawing 141092.
Ui = -28V
Division 2 (non-Incendive):
3300 XL 8mm
Install per Bently Nevada drawing
and 3300 5mm
140979.
Eddy Current
Probes, ia: IECEx
IECEx BAS04.0056 Zone 0 (Intrinsically safe): The
Proximitor® Sensor must be
Ex ia IIC Temperature
installed to minimize the risk of
Classification per table 5.
impact or friction with other
Ui = -28V Ci = 1.5 nF metallic surfaces.
Li = 140 mA Li = 200 µH
Pi – 0.84 W Zone 2 (non-Incendive): The
probe must be supplied from a
3300 XL 8mm
voltage-limited source.
and 3300 5mm
Eddy Current
Probes, nA
Compliance and Certifications
IECEx BAS04.0058X
EMC:
Ex nA II for Zone 2 Temperature
Classification per table 5. European Community Directives:
EMC Directive 2004/108/EC
Table 5: Probe Ex ia and Ex nA Temperature Standards:

Classification EN61000-6-2
Temperature Ambient Temperature EN61000-6-4
Classification (Probe Only)
American
T1 -51ºC to +232ºC Bureau of
Shipping (ABS)
T2 -51ºC to +177ºC Type Approval
T3 -51ºC to +120ºC Certification Number:
T4 -51ºC to +80ºC 09-HS446965B-PDA
T5 -51ºC to +40ºC

Part Number 172036
Rev. G (09/09)
Page 6 of 15
Hole Size
Mechanical 0.218 to 0.222 in
Probe Tip Hole Depth
Material 0.376 to 0.750 in
Polyphenylene sulfide (PPS). Tap Size
Probe Case #3
Material
AISI 303 or 304 stainless steel
(SST). Recommended
case hole and
Probe Cable tap size for
75Ω triaxial, fluoroethylene M8x1 case
propylene (FEP) insulated probe Drill Size
cable in the following lengths: 0.5,
1, 2, 5, or 9 metres (1.6, 3.3, 16.4, 7.5mm
or 29.5 feet). Hole Size
System Length 7.625 to 7.72 mm
5 or 9 metres (16.4 or 29.5 feet) Hole Depth
including extension cable.
12 to 24 mm
Extension Cable
Material Tap Size
75 Ω triaxial, fluoroethylene M8x1
propylene (FEP) insulated. Probe case
Probe and torque
Extension Cable 5.1 N·m (45 in·lb) recommended
Armor
7.3 N·m (65 in·lb) maximum
Flexible AISI 302 or 304 SST with
FEP outer jacket Connector-to-
connector
5mm Probe torque
Tensile Strength
Recommended
222 N (50 lbf) probe case to probe torque
lead. 222 N (50 lbf) probe lead to
extension cable connectors. See Table 5.
Connector Table 5: Recommended Torque
material
Connector Type Tightening Instructions
Gold-plated brass or gold-plated
beryllium copper. 2 3300 XL gold "click" type
Finger tight
connectors
Recommended
case hole and 1 non-XL stainless steel
Finger tight plus 1/8 turn
tap size for 1/4- connector and 1 3300 XL
using pliers
28 case connector
Maximum
torque
Drill Size
0.565 N•m (0.42 ft•lbf)
0.213 in
Part Number 172036
Rev. G (09/09)
Page 7 of 15
Minimum Cable Note: It is the responsibility of the customer or user to ensure
Bend Radius that all liquids and gases are contained and safely
controlled should a proximity probe. leak In addition,
25.4 mm (1.0 in).
solutions with high or low pH values may erode the tip
Weight assembly of the probe causing media to leak into
surrounding areas. Bently Nevada LLC will not be held
Total System
responsible for any damages resulting from leaking 3300
0.71 kg (1.6 lbm), typical. 5 mm proximity probes. In addition, Bently Nevda LLC will
not replace 3300 5mm proximity probes under the service
3300 5mm Probe
plan due to probe leakage.
323 g (11.39 oz).
Patents:
XL Extension
Cable One or more components or
procedures described in the
34 g/m (0.4 oz/ft) following patents apply to this
103 g/m (1.5 oz/ft) (armored) product: 5,016,343; 5,126,664;
5,351,388; and 5,685,884.
XL Proximitor
Sensor
246 g (8.7 oz) Ordering Information
Environmental Limits 3300 5 mm Proximity Probes
Probe 330171 3300 5 mm Probe, 1/4-28 UNF thread, without
Temperature armor
Range: 330172 3300 5 mm Probe, 1/4-28 UNF thread, with armor
-35 °C to +177 °C (-31 °F to +351 Part Number-AXX-BXX-CXX-DXX-EXX
°F)
A: Unthreaded Length Option
Note: Exposing the probe to temperatures below –
Note: Unthreaded length must be at least 0.8 in less than the
34 °C (-30 °F) may cause premature failure of the
case length.
pressure seal.
Order in increments of 0.1in
Extension Cable
Length configurations:
Temperature
Maximum unthreaded length:
Range:
8 8 = 8.8 in
-51° C to +177° C (-60° F to +351° Minimum unthreaded length:
F) for standard extension cable. 0 0 = 0.0 in
ref 141194-01 Example: 0 4 = 0.4 in
B: Overall Case Length Option

Order in increments of 0.1 in
Threaded length configurations:
Probe Pressure: Maximum case length:
3300 5 mm probes are designed 9 6 = 9.6 in
to seal differential pressure Min. case length:
between the probe tip and case. 0 8 = 0.8 in
The probe sealing material Example: 2 4 = 2.4 in
consists of a fluorocarbon O-ring. C: Total Length Option
We do not pressure test probes 05 0.5 metre (1.6 feet)
10 1.0 metre (3.3 feet)
prior to shipment. Contact our
20 2.0 metres (6.6 feet)
custom design department if you
50 5.0 metres (16.4 feet) 1
require a test of the pressure seal
90 9.0 metres (29.5 feet)
for your application.
Part Number 172036
Rev. G (09/09)
Page 8 of 15
D: Connector Option Phenolic Probe Mounting Bracket
01 Miniature coaxial ClickLoc
connector with connector The phenolic mounting bracket is recommended if
protector, standard cable additional electric isolation from the mounting
02 Miniature coaxial ClickLoc location is required (as in some generator and
connector, standard cable electrical motor bearing locations). The -02 option is
E: Agency Approval Option supplied with 2 10-24 UNC-2A mounting screws. The
00 Not required -03 option is supplied with 2 M5 x 0.8-6g mounting
05 Multiple Approvals screws. The mounting screws have pre-drilled holes
for safety wire.
3300 5mm Proximity Probes, Metric
27474 -AXX
330173 3300 5 mm Probe, M8 x 1 thread, without armor
A: Thread size
330174 3300 5 mm Probe, M8 x 1 thread, with armor
02 1/4-28
Part Number-AXX-BXX-CXX-DXX-EXX 03 M8 x 1
A: Unthreaded Length Option 75Ω ClickLoc Connector Kit
Note: Unthreaded length must be at least 20 mm less than the 330153-AA
case length.
75Ω ClickLoc Connector Kit for 3300 series probes and
Order in increments of 10 mm. extension cables. Each kit contains 1 color-coded sleeve
Length configuration: per connector.
Max. unthreaded length: 2 3 = 230
A: Kit Type
mm
02 1 ClickLoc male connector for
Min. unthreaded length: 0 0 = 0.0
3300 XL 5mm and 8mm
mm
extension cable.
Example: 0 6 = 60 mm.
03 1 ClickLoc female connector
B: Overall Case Length Option
for 3300 XL 5mm and 8mm
Order in increments of 10 mm.
extension cable.
Metric thread configurations:
04 1 ClickLoc male connector for
Maximum length:
3300 5mm probe.
2 5 = 250 mm
Minimum length:
0 2 = 20 mm
Accessories
Examples: 0 6 = 60 mm. 02120015
C: Total Length Option
05 0.5 metre (1.6 feet) Bulk field wire. 1.0 mm2 (18
10 1.0 metre (3.3 feet) AWG), 3-conductor, twisted,
20 2.0 metres (6.6 feet) shielded cable for connections
50 5.0 metres (16.4 feet) 1 between Proximitor Sensor and
90 9.0 metres (29.5 feet) monitor.
Probe Accessories 03200006
Aluminum probe mounting bracket Silicone self-fusing tape.
The aluminum probe threaded mounting bracket is 9.1-metre (10-yard) roll of silicone
the standard mounting bracket for most 3300 5 mm tape to protect connectors. It is
probe installations. The -02 option is supplied with 2 easy to install and provides
10-24 UNC-2A mounting screws. The -03 option is excellent electrical isolation and
supplied with 2 M5 x 0.8-6g mounting screws. The protection from the environment.
mounting screws have pre-drilled holes for safety It is not recommended for use
wire. inside the casing of the machine.
137492 -AXX
A: Thread size
02 1/4-28
03 M8 x 1
Part Number 172036
Rev. G (09/09)
Page 9 of 15
provide environmental protection
of connectors.
40113-03
03800001
Connector Protector Kit.
Connector Protector Kit for 3300 75Ω Coaxial Female Connector
5mm probes, including connector Protector. Placed onto 3300 5mm
protectors and installation tools. probe leads; attaches to the male
connector protector on the
136536-01
extension cable to provide
Connector Protector Adapter. environmental protection of
Makes connector protector kits connectors.
purchased prior to 1998
163356
compatible with ClickLoc
extension cable connectors. Connector Crimp Tool Kit.
Includes 1 set of multi-connector
40180-03
inserts and connector installation
Connector Protectors. Package instructions. Compatible only
containing 10 pairs of 75Ω with 330153 connector kits or
Coaxial Connector Protectors. with probes shipped in 2003 or
later with ClickLoc connectors
03839410
uninstalled. Supplied with
75Ω Triaxial/95 ohm Coaxial carrying case.
Male Connector Protector.
Placed onto the extension cable;
attaches to the female connector
protector on the 5 mm probe to

Part Number 172036
Rev. G (09/09)
Page 10 of 15
Graphs
Figure 1 - Typical 3300 5 mm probe and 1 metre of cable at high and low temperatures (XL Proximitor Sensor and XL extension
cable are at 25°C)

Part Number 172036
Rev. G (09/09)
Page 11 of 15
Figure 2 - 3300 5 metre XL Proximitor Sensor at high temperatures (3300 5mm probe and XL extension cable at 25° C)
Dimensional diagrams

Part Number 172036
Rev. G (09/09)
Page 12 of 15
1. Probe tip, 5.2 mm [0,21 in] diameter
2. 11.1 mm [7/16 in] for 1/4-28 threads, 13.0 mm [0.51 in] for M8 thread. See Note 3.
3. Case thread
4. 5.6 [7/32] wrench flats for 1/4-28 threads, 7.0 [0.28] for M8 threads
5. 75Ω cable, 2.8 mm [0.11 in] maximum outside diameter, 7.6 mm [0.3 in] outside diameter of armor, 9.0 mm [0.35 in] maximum
diameter of armor ferrule.
6. Miniature male coaxial connector, 7.23 mm [0.285 in] maximum outside diameter “D”
7. 3.2 [0.13 in]
8. Unthreaded length “A”
9. Case length “B”
10. 6.0 mm [0.235 in] maximum
11. Total length “C”, =30%, -0%. See Note 8.
Figure 3 - 3300 5 mm Proximity Probes, Standard Mount3
330171, 1/4-28 UNF-2A, without armor7

330172, 1/4-28 UNF-2A, with armor6
330173, M8X1 thread, without armor7
330174, M8X1 thread, with armor6

Part Number 172036
Rev. G (09/09)
Page 13 of 15
1. 12 mm [0.40 in] maximumd diameter
2. 36.3 mm [1.43 in] maximum
3. 51.1 mm [2.01 in] maximum
4. Connector protector (fluorosilicone material)
Figure 4 - Installed Connector Protectors
1. 7.2 mm [0.25 in] maximum diameter

2. Miniature male coaxial connector
3. FEP or PFA coated armor. Armor length is 300 mm [11.8 in] less than cable length. See Note 6.
4. 75Ω cable, 3.7 mm [0.15 in] maximum outside diameter, 3.9 mm [0.16 in] maximum diameter for FluidLoc* cable, 7.6 mm [0.30
in] maximum outside diameter or armor, 9.0 mm [0.35 in] maximum diameter of armor ferrule.
5. Stainless steel ferrules, 8.4 mm [0.33] diameter
6. Miniature female coaxial connector
7. Cable length, +20%, -0%
Figure 5 - 3300 XL Extension Cable
330130, 3300 XL Extension Cable (FEP armor and insulation)
Notes:
1. All dimensions are in millimetres (inches) unless otherwise noted.
3. Standard mount 5 mm probes supplied with 13 mm or 7/16-in lock nut.
5. Letters inside quotation marks refer to probe ordering options.
6. Stainless steel armor is supplied with FEP outer jacket for standard probes, PFA outer jacket for ETR probes.
Part Number 172036
Rev. G (09/09)
Page 14 of 15
7. FEP jacket is standard non-armored portion of the cable for standard probes, PFA jacket on non-armored portion
for ETR probes.
8. Probes ordered with 5 or 9 metre integral cables have a length tolerance of +20%, -0%.
9. Five metre probes are designed for use with the five metre Proximitor Sensor only.
Add notes for missing numbers, even if it is something like “Deleted” or “Note removed”, or renumber the notes in the
document.
* denotes trademarks of Bently Nevada, LLC, a wholly owned subsidiary of General Electric Company.
© 2005 – 2009 Bently Nevada LLC. All rights reserved.

1631 Bently Parkway South, Minden, Nevada USA 89423
Phone: 775.782.3611 Fax: 775.215.2873
www.ge-energy.com/bently
All rights reserved.

Part Number 172036
Rev. G (09/09)
Page 15 of 15
Mechanical
Pressure Measurement
Bourdon Tube Pressure Gauges

Stainless Steel Series
Model 232.50/233.50, without/with Liquid Filling
WIKA Data Sheet PM 02.02
Applications
 With liquid-filled case for applications with high dynamic

pressure pulsations or vibrations
 For gaseous and liquid aggressive media that are
not highly viscous or crystallising, also in aggressive
ambience
 Process industries: chemical/petro-chemical, power
stations, mining, on and offshore, environmental tech-
nology, machine building and plant construction
Special Features
 Excellent load-cycle stability and shock resistance

 All stainless steel construction
 German Lloyd, Gosstandart and DVGW approval
 Scale ranges up to 0 … 1600 bar
Bourdon Tube Pressure Gauge Model 232.50
Description Pressure limitation

NS 63: Steady: 3/4 x full scale value
Design Fluctuating: 2/3 x full scale value
EN 837-1 Short time: full scale value
Nominal size in mm NS 100, 160: Steady: full scale value
63, 100, 160 Fluctuating: 0.9 x full scale value
Short time: 1.3 x full scale value
Accuracy class
NG 63: 1.6 Operating temperature
NG 100, 160: 1.0 Ambient: -40 ... +60 °C without liquid filling
-20 ... +60 °C gauges with glycerine filling
Scale ranges
Medium: +200 °C maximum without liquid filling
NS 63: 0 ... 1 to 0 ... 1000 bar
+100 °C maximum with liquid filling
NS 100: 0 ... 0.6 to 0 ... 1000 bar
NS 160: 0 ... 0.6 to 0 ... 1600 bar Temperature effect
or all other equivalent vacuum or combined pressure and When the temperature of the measuring system deviates
vacuum ranges from the reference temperature (+20 °C):
max. ±0.4 %/10 K of full scale value
Ingress protection
IP 65 per EN 60 529 / lEC 529
WIKA Data Sheet PM 02.02 ·∙ 02/2009 Page 1 of 2
Data Sheets showing similar devices:

Stainless steel series; model 232.30; see data sheet PM 02.04
Standard version Options
Process connection  O ther process connection
Stainless steel 316L (NS 63: 1.4571),  A  ssembly on diaphragm seals see product review DS
lower mount (LM) or lower back mount (LBM) 1)  M  onel pressure system (model 26X.50, not with NS 160
NS 63: G ¼ B (male), 14 mm flats back connection)
NS 100, 160: G ½ B (male), 22 mm flats  Pressure system stainless steel 1.4571
 Surface or panel mounting flange, stainless steel
Pressure element  Panel mounting flange, stainless steel, polished
Stainless steel 316L,  Triangular bezel, stainless steel, polished, with clamp
< 100 bar: C-type  Ambient temperature -40 °C: silicon oil filling
≥≥ 100 bar: helical type  Switch contacts (see data sheet AC 08.01)
 Pressure gauge with electrical output signal,
Movement see Model PGT23.100/160, data sheet PV 12.04
Stainless steel  Version per ATEX Ex II 2 GD c
Dial
Standard version
Aluminium, white, black lettering,
NS 63 with pointer stop pin Lower mount (LM)
≤≤ 16 bar with compensating valve
> 16 bar without compensating valve
Pointer
Aluminium, black
1520806.03
Case
Stainless steel, with pressure relief in case top (NS 63) or in
case back (NS 100 and 160),
ranges ≤ 0 ... 16 bar with compensating valve to vent case
Window: Laminated safety glass (NS 63: Polycarbonate)
Bezel ring: Cam ring (bayonet type), stainless steel
Liquid filling (for Model 233.50): Glycerine 99.7 % Lower back mount (LBM) 1)
≤≤ 16 bar with compensating valve
1520814.03
> 16 bar without compensating valve
Special versions
Gauges for ammonia plants (NS 100 and 160)
With temperature scale for refrigerant R 717 (NH3) in °C,
scale ranges: -1 ... 0 ... 15 bar or -1 ... 0 ... 26 bar
Dimensions in mm
NS Dimensions in mm Weight in kg
a b b1 b2 D1 D2 e f G h±1 SW Model 232.50 Model 233.50
63 9.5 33 33 57 63 62 11.5 - 1) G¼B 54 14 0.16 0.20
100 15.5 49.5 49.5 83 101 99 17.5 30 G½B 87 22 0.60 0.90
160 15.5 49.5 3) 49.5 2) 83 2) 161 159 17.5 50 G½B 118 22 1.10 2.00
Process connection per EN 837-1 / 7.3 2) Plus 16 mm with pressure ranges ≥ 100 bar
1) NS 63: Centre back pressure entry (CBM) 3) Plus 16 mm with pressure range 1600 bar
Ordering information
Model / Nominal size / Scale range / Connection size / Connection location / Options
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
9019723 02/2009 GB
Page 2 of 2 WIKA Data Sheet PM 02.02 ·∙ 02/2009
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
Operating 1. Safety device is fitted to a pressure gauge, it must
Instructions GB WARNING!
be protected against being blocked by debris
and dirt. With safety pressure gauges (see dial
Before installation, commission- symbol k) it must be ensured that the free space
ing and operation, ensure that the behind the blow-out back is at least 15 mm.
Pressure Gauges appropriate pressure gauge has After mounting, set the compen-
been selected in terms of measur- sating valve (if available) from
ing range, design and suitable wetted material CLOSE to OPEN.
(corrosion) for the specific measuring conditions. With models 4 and 7, do not open the flange
Examples: In order to guarantee the measuring accuracy mounting screws.
and long-term stability specified, the corre-
sponding load limits must be observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the gauge is not sufficiently rigid for
manager are permitted to install, maintain and vibration-free mounting, a pipe-support bracket
service the pressure gauges. should be used to secure it (possibly via a flexi-
Model 732.14, ble capillary). If vibration cannot be prevented
Overpressure safety For hazardous media such as oxygen, acety-
through suitable installation, liquid-filled gauges
up to 400 bar lene, flammable or toxic gases or liquids, and
should be used. The instruments should be
Model 432.36, refrigeration plants, compressors, etc., in
protected against coarse dirt and wide fluctua-
Overpressure safety addition to all standard regulations, the appro-
tions in ambient temperature.
up to 400 bar priate existing codes or regulations must also be
followed.
Model 213.40 3. Permissible ambient and operating
After an external fire, pressure media can leak temperatures
out, particularly at soft solder joints. All gauges
must be checked and, if necessary, replaced When mounting the pressure gauge it must be
before recommissioning the plant. ensured that, taking into consideration the influ-
Non-observance of the respective regulations ence of convection and heat radiation, no devia-
Notes in accordance with Pressure Equipment can result in serious injury and/or damage to tion above or below the permissible ambient and
Directive 97/23/EC equipment. medium temperatures can occur. The influence
of temperature on the display accuracy must be
The pressure gauges are "pressure accessories"
2. Mechanical connection observed.
in accordance with Article 1, Paragraph 2.1.4
The volume of the pressure bearing housings of In accordance with the general technical regula-
WIKA pressure gauges is < 0.1 L 4. Storage
tions for pressure gauges (e.g. EN 837-2). When
The pressure gauges carry CE marking for Fluid screwing the gauges in the force required for
Group 1G in accordance with Annex 2, Table 1 The pressure gauge should be kept in its original
this must not be applied through the case or packing until installation. The gauge should be
when their permissible working pressure terminal box, rather only through the spanner
exceeds 200 bar protected from external damage during storage.
flats provided for this purpose (using a suitable Storage temperature range: -40 ... +70 °C.
Pressure gauges that do not carry the CE mark tool). Protect the gauges from humidity and dust.
are manufactured in accordance with Article 3,
Paragraph 3 "Sound engineering practice". Mounting with 5. Maintenance / Repairs
Applied standards spanner
EN 837-1 Bourdon tube pressure gauges, dimensions, The instruments are maintenance-free. Checks
metrology, requirements and testing should be carried out on a regular basis to
EN 837-2 Selection and installation recommendations Correct sealing of pressure gauge connections ensure the measuring accuracy of the pressure
for pressure gauges with parallel threads  must be made using gauge. The checks or recalibrations must be
EN 837-3 Diaphragm and capsule pressure gauges, suitable sealing rings, sealing washers or WIKA carried out by qualified skilled personnel with
dimensions, metrology, requirements and profile seals. The sealing of tapered threads (e.g. the appropriate equipment.
testing NPT threads) is made by providing the thread When dismounting, close the compensating
Specifications: see data sheet on www.wika.de  with additional sealing material such as, for valve (if available).
example, PTFE tape (EN 837-2).
Subject to technical modifications. WARNING!
© WIKA Alexander Wiegand SE & Co. KG 2009 Residual media in dismounted
Spanner flats Sealing by pressure gauges can result in a risk
2408976.03 02/2010
WIKA Alexander Wiegand SE & Co. KG the thread  to personnel, the environment and
Sealing face  equipment. Take sufficient precau-
Alexander-Wiegand-Straße 30
63911 Klingenberg • Germany tionary measures.
Tel. (+49) 93 72/132-0 The torque depends on the seal used. Connect-
Fax (+49) 93 72/132-406 ing the gauge using a clamp socket or a union
E-Mail info@wika.de nut is recommended, so that it is easier to
www.wika.de orientate the gauge correctly. When a blow-out
Testreport according to EN 10204 - 2.2
Werkszeugnis nach EN 10204 - 2.2
Page 1 / 1
Seite
Customer: Certificate No.
WIKA Italia S.R.L. & C. S.A.S. 01345414
Kunde: Via G. Marconi, 8 Zeugnis-Nr.
20020 ARESE (Mi)
Italien Date
15.01.2014
Datum
Customer Order No. Customer Part. No. Order Date

PO00047734 57198209 03.01.2014
Kundenbestellnummer Kunden Artikel-Nr. Bestelldatum
Order No. / Item Part No. Quantity

21263540/1 0752.02 2,00
Auftrags-Nr. / Pos. Artikel-Nr. Menge
Model Serial number Scale range

233.50 0...0,16 MPa
Typ Seriennummer Anzeigebereich
Class Tag No.

1.0
Klasse Messstellen-Nr.
We herewith certify that above mentioned unit(s) complied with state-of-the-art

technology at the time of supply. The order specifications were adhered to. The
quality of the unit(s) was confirmed by the Quality Management System.
The following materials have been employed for wetted, metallic components:
1.4404/316L
The class accuracy of the aforementioned unit(s) complies with class 1.0.
We herewith certify ingress protection IP 65 provided by the enclosure

according to EN / IEC 60529.
Hiermit bescheinigen wir, dass vorgenannte Einheit(en) zum Zeitpunkt des

Inverkehrbringens, dem Stand der Technik entsprochen haben.
Die Bestellvorgaben wurden eingehalten. Die Qualität der Einheit(en) wurde im
Rahmen des Qualitätsmanagement-Systems sichergestellt.
Für medienberührte, metallische Bauteile wurden folgende Werkstoffe eingesetzt:

1.4404/316L
Die Anzeigegenauigkeit der vorgenannten Einheit(en) entspricht der Klasse 1.0.
Hiermit bescheinigen wir die Schutzart IP 65 durch umhüllende Bauteile

nach EN / IEC 60529.
Inspection Representative (MP-PG)

Abnahmebeauftragter Ralf Groß 45
This document was created automatically and needs no signature.

Dieses Dokument wurde automatisch erstellt und gilt ohne Unterschrift.
WIKA Alexander Wiegand SE & Co. KG Phone: +49 9372 132/0

Alexander-Wiegand-Str. 30 Fax Inland: +49 9372 132/406
63911 Klingenberg E-Mail: info@wika.de
Germany Internet: www.wika.de
https://www.phoenixcontact.com/us/products/2839486
Surge protection base element - PT 4-EX(I)-BE - 2839486

Please be informed that the data shown in this PDF Document is generated from our Online Catalog. Please find the complete data in the user's
documentation. Our General Terms of Use for Downloads are valid
(http://download.phoenixcontact.com)
Base element for protective plug PT with protective circuit for a 4-core floating EEx ia signal circuit. Nominal
voltage: 24 V DC, for mounting on NS 35/7.5 and NS 35/15, housing width: 17.5 mm
Product Features
Plugs can be checked with CHECKMASTER
Maximum ease of maintenance thanks to the two-piece design
Base element remains an integral part of the installation
Tailored to the special requirements of intrinsically safe circuits
Consistent plug-in signal circuit protection
Impedance-neutral disconnection of plug for test and maintenance purposes
Key commercial data

Packing unit 1 pc
Weight per Piece (excluding packing) 55.25 GRM
Custom tariff number 85363010
Country of origin Germany
Technical data
Dimensions
Height 89.8 mm
Width 17.7 mm
Depth 52 mm
Horizontal pitch 1 Div.
Height 90 mm
Width 17.7 mm
Depth 65.5 mm
Ambient conditions
3/12/14 Page 1 / 6

Technical data
Ambient conditions
Ambient temperature (operation) -40 °C ... 85 °C
Degree of protection IP20
General
Inflammability class according to UL 94 V0
Color blue
Standards for air and creepage distances VDE 0110-1
IEC 60664-1
EN 60079-11
Mounting type DIN rail: 35 mm
Type DIN rail module, two-section, divisible
Number of positions 4
Protective circuit
Surge protection fault message None
Connection data
Connection method Screw connection
Connection type IN Screw terminal blocks
Connection type OUT Screw terminal blocks
Screw thread M3
Tightening torque 0.8 Nm
Stripping length 8 mm
Conductor cross section stranded min. 0.2 mm²
Conductor cross section stranded max. 2.5 mm²
Conductor cross section solid min. 0.2 mm²
Conductor cross section solid max. 4 mm²
Conductor cross section AWG/kcmil min. 24
Conductor cross section AWG/kcmil max 12
Standards and Regulations

Standards/regulations EN 61643-21
EN 60079-0
EN 60079-11
EN 60079-26
EN 61241-0
EN 61241-11
Conformity / approvals
ATEX  II 1 G Ex ia IIC T4...T6
3/12/14 Page 2 / 6

Technical data
Conformity / approvals
 II 1 D Ex iaD 20 IP6x T85 °C...135 °C
Classifications
eCl@ss
eCl@ss 4.0 27140201

eCl@ss 4.1 27130801
eCl@ss 5.0 27130801
eCl@ss 5.1 27130801
eCl@ss 6.0 27130803
eCl@ss 7.0 27130803
eCl@ss 8.0 27130803
ETIM
ETIM 2.0 EC000472

ETIM 3.0 EC000472
ETIM 4.0 EC000472
ETIM 5.0 EC000472
UNSPSC
UNSPSC 6.01 30212010

UNSPSC 7.0901 39121610
UNSPSC 11 39121610
UNSPSC 12.01 39121610
UNSPSC 13.2 39121620
Approvals
Approvals
Approvals
GOST
Ex Approvals
INMETRO
3/12/14 Page 3 / 6

Approvals
Approvals submitted
Approval details
GOST
Accessories
Accessories
Marker pen
Marker pen - X-PEN 0,35 - 0811228
Marker pen without ink cartridge, for manual labeling of markers, labeling extremely wipe-proof, line thickness 0.35 mm

Marker pen - B-STIFT - 1051993
Marker pen, for manual labeling of unprinted Zack strips, smear-proof and waterproof, line thickness 0.5 mm

Shield connection
Shield connection - SSA 5-10 - 2839512
Shield fast connection for conductor diameters 5 - 10 mm. Potential connection cable: 200 mm, black

3/12/14 Page 4 / 6

Accessories
Shield connection - SSA 3-6 - 2839295
shield fast connections for conductor diameter 3 - 6 mm. Potential connection cable: 200 mm, black

Terminal marking
Zack marker strip - ZB 5 :UNBEDRUCKT - 1050004
Zack marker strip, Strip, white, Unlabeled, Can be labeled with: Plotter, Mounting type: Snap into tall marker groove, For
terminal block width: 5.2 mm, Lettering field: 5.1 x 10.5 mm

Zack Marker strip, flat - ZBF 5:UNBEDRUCKT - 0808642
Zack Marker strip, flat, Strip, white, Unlabeled, Can be labeled with: Plotter, Mounting type: Snap into flat marker groove,
For terminal block width: 5 mm, Lettering field: 5.1 x 5.2 mm

Zack marker strip - ZB 5,8:UNBEDRUCKT - 2715209
Zack marker strip, Strip, white, Unlabeled, Can be labeled with: Plotter, Mounting type: Snap into tall marker groove, For
terminal block width: 5.8 mm, Lettering field: 5.75 x 10.5 mm

Required add-on products
Surge protection connector - PT 4-EX(I)-24DC-ST - 2839253
PT protective connector with protective circuit for a 4-wire floating Ex-i signal circuit. Nominal voltage: 24 V DC

3/12/14 Page 5 / 6

Accessories
Drawings
Dimensioned drawing
90
44,8
65,5
51,5
The figure shows the complete module consisting of a base element and connector
© Phoenix Contact 2013 - all rights reserved

http://www.phoenixcontact.com
3/12/14 Page 6 / 6
Surge Capacitors
Specialty Capacitors

Type 2GUS
Surge capacitors are designed to modify the steep

fronted waves and prevent damage to the turn-to-
turn insulation of rotating machines and transformers.
It is advisable to use surge arresters together with
the surge capacitor units to form a comprehensive
protective package (please contact your ABB sales
representative for further information). Standard rat-
ings and dimensions are shown here; however, special
requirements can be accommodated on an extended
lead-time.
The 2GUS capacitors are built for the most demanding
conditions and offer:
High transient voltage withstand
Long life design
Low loss dielectric
Rugged construction
STANDARD FEATURES SPECIFICATIONS

All-film low loss dielectric Low-loss polypropylene film and
Faradol Non-PCB insulating fluid aluminum foil
Indoor or outdoor mounting Non-PCB dielectric fluid—
FARADOL 800
Mount in any position: upright, side, or inverted
Discharge resistors to reduce the
Internal discharge resistors
residual voltage to less than 50 V
Hermetically sealed unit in 5 minutes of de-energization
Designed for indoor/outdoor use
with an ambient temperature range
of -40°C to +50°C
Stainless steel case
ANSI 70 light gray paint
APPLICATIONS
Surge protection for:
Large motors and generators
MV switchgear and motor control centers
Large transformers
Power Quality
All ABB products are IndustrialIT enabled.

Contact your ABB Sales Representative or visit our website at www.abb.com.
Specialty Capacitors

SPECIFICATIONS
Standard Design Dimensions and Weights
All dimensions and weights are approximate. Dimensions are specified in inches (mm).
Reference
Rated No. of µ Per Figure
A B Weight
Voltage Poles Pole Inches (mm) Inches (mm) Lbs. (kg)
2GUS031803A1 7200/4160 3 0.500 2 8.23 (209) 10.25 (260) 48 (22)
2GUS031801A2 7200 1 0.500 3 6.26 (159) 9.45 (240) 30 (14)
2GUS031801A3 13,800 1 0.250 3 7.24 (184) 9.45 (240) 34 (15)
2GUS031801A4 24,000 1 0.130 3 10.20 (259) 10.66 (271) 47 (21)
2GUS031801A5 24,000 1 0.083 3 15.12 (384) 10.66 (271) 66 (30)
2GUS031801A6 14,400 2 0.500 4 11.18 (284) 10.66 (271) 55 (25)
2GUS031803A7 4160/2400 3 0.500 1 7.64 (194) 4.84 (123) 34 (15)
2GUS031803A9 13,800/7960 3 0.250 2 12.76 (324) 10.25 (260) 59 (26)
2GUS031801A15 13,800 1 0.750 3 11.18 (284) 9.45 (240) 49 (22)
Figure 1 Figure 2
4.5 4.5 16.89 (429.01)
(114.3) (114.3)
1.12
B (28.45) B
A
A
13.5 (342.9)
15.625 (396.88) 13.5 (342.9)
5.51 15.625 (396.88) 5.51
17.008 (432.00)
(140.00) (140.00)
17.008 (432.00)
Figure 3 Figure 4
8.66 8.66
(219.96) 1.772 (219.96) 1.772
(45.00) (45.00)
B B
A A
13.5 (342.9)
Power Quality
13.5 (342.9)
15.825 (401.96) 5.51
15.825 (401.96) 5.51
(140.00)
17.008 (432.00) 17.008 (432.00) (140.00)
All ABB products are IndustrialIT enabled.

Contact your ABB Sales Representative or visit our website at www.abb.com.
ABB
Sistema di verniciatura “C3” (7FA) UVT-600093 C

Painting System “C3”
ABB BU 4130 Machines Specifica tecnica 2007-11-09 1(7)

Technical Specification
ITIND/DMPB-DMTF Davide Tacconi / Livio Vignati Piero Bodini External
Sistema di verniciatura “C3”

Painting System “C3”
Indice Table of Contents
1 Obiettivo 1 Purpose
2 Istruzioni su igiene e sicurezza 2 Health and safety Instructions
2.1 Materiali impiegati 2.1 Used materials
2.2 Dispositivi di protezione individuale 2.2 Individual protection devices
2.3 Misure di igiene e sicurezza 2.3 Health and safety precautions
2.4 Documentazione 2.4 Documents
2.5 Smaltimento dei rifiuti 2.5 Waste disposal
3 Riferimenti 3 References
4 Ambiente, corrosività, categoria e durabilità 4 Typical environment, corrosivity category
5 Trattamento superficiale and durability
6 Sistema di verniciatura 5 Surface treatment
7 Colore finale 6 Painting system
8 Verniciatura 7 Final color
8.1 Mani di fondo e intermedie 8 Painting work
8.2 Verniciatura finale 8.1 Priming and Intermediate coating
9 Controllo qualità 8.2 Final painting
9.1 Manutenzione del registro di ispezione 9 Quality control
9.2 Misurazione dello spessore della vernice 9.1 Keeping an inspection record
9.2 Measuring the Thickness of the Paint
Diritti riservati sul documento e tutte le informazioni in esso contenute. La riproduzione, uso e divulgazione a terzi sono severamente vietati senza previa autorizzazione.
 Copyright 2007 ABB.
ABB Library Document Kind Name
UVT 600093 C
Sistema di verniciatura “C3” / Painting system “C3” 2007-11-09 2(7)
1 Obiettivo 1 Purpose
Queste istruzioni di lavoro descrivono il sistema di These work instructions have the purpose to describe
verniciatura standard “C3” applicato alle macchine the standard Painting System “C3” applied to ABB
elettriche ABB di cui al titolo del documento. electrical machines related to the document title.
Il presente documento si basa sulla Specifica Tecnica This document is based on ABB Technical
ABB 3AAM700306. Specification 3AAM700306
2 Istruzioni su igiene e sicurezza 2 Health and Safety Instructions
2.1 Materiali impiegati 2.1 Used Materials

a) Primer epossidico bi-componente a) Two-component epoxy primer
b) Finitura acrilica b) Acrylic Top Coat
c) Diluenti per vernici c) Paint diluents
2.2 Dispositivi di protezione individuale 2.2 Individual protection devices

d) Scarpe di sicurezza d) Protective shoes
e) Guanti di sicurezza e) Protective gloves
f) Grembiule f) Apron
g) Occhiali di sicurezza g) Protective glasses
h) Maschera h) Mask
i) Tappi per le orecchie i) Ear plug
2.3 Misure di igiene e sicurezza 2.3 Health and safety precautions

j) Le attività che prevedono l’impiego di aria j) All blowing operations by compress air
compressa e vernice devono essere and painting must be done in apposite
eseguite in ambienti specifici ed a porte room with closed doors
chiuse.
k) Usare dispositivi di protezione idonei k) Use apposite protection devices during
durante il trattamento delle superfici; surfaces treatment;
l) Lavorare a distanza da sorgenti di calore; l) Work far from heat sources;
m) Non è consentito fumare, bere o tenere m) Smoking, drinking, eating and food
alimenti nell’area di lavoro; storage is not allowed on work site;
n) Evitare il contatto accidentale della pelle con n) Avoid any skin contact with painting
vernici e solventi; in caso di contatto materials or solvents; in case of
accidentale risciacquare con acqua accidental contact wash with running
corrente; water;
o) In caso di inalazione o ingestione, rivolgersi o) Contact company medical service in
al servizio medico in azienda. case of inhalation or ingestion.
2.4 Documentazione 2.4 Documents

Schede tecniche e di sicurezza del materiale. Technical and safety material data sheet
2.5 Smaltimento dei rifiuti 2.5 Waste disposal

Il materiale di scarto ed i rifiuti devono essere Materials scraps and wastes must be
gestiti conformemente alle disposizioni managed according to actual government rules
nazionali sui rifiuti speciali attualmente in for special wastes.
vigore.
Diritti riservati sul documento e tutte le informazioni in esso contenute. La riproduzione , uso e divulgazione a terzi sono severamente vietati senza previa autorizzazione.
UVT 600093 C
3 Riferimenti 3 References
ISO 8501-1 ISO 8501-1 Preparation of steel substrates before
application of paints and related
products -- Visual assessment of
surface cleanliness.
ISO 8503 ISO 8503 Preparation of steel substrates before
application of paints and related
products – Surface roughness
characteristics of blast-cleaned steel
substrates.
ISO 12944 ISO 12944 Paints and varnishes -- Corrosion
protection of steel structures by
protective paint systems. Parts 1, 2, 3,
!"#$%& 4, 5, 6, 7, 8
4 Ambiente, corrosività, categoria 4 Typical environment, corrosivity

e durabilità category and durability
Il sistema di verniciatura “C3” si presta alla maggior Paint system “C3” it is suitable for most industrial
parte delle atmosfere industriali, interne ed esterne atmospheres, indoor and outdoor (atmospheres with
(atmosfere a moderato inquinamento ed ambiente moderate pollution and aggressive ambient). The
aggressivo). Il sistema di verniciatura soddisfa i criteri painting systems fulfil the requirements specified in
indicati nella seguente tabella: the table below:
Caratteristiche ambientali tipiche Categoria di corrosività

Durabilit / Durability
Corrosion category
Typical environment characteristics (according to ISO 12944-2)
(according to ISO 12944-2&5)
Atmosfere interne ed esterne urbane ed
industriali, con moderato inquinamento da
anidride solforosa.
Aree costiere a bassa salinità
C3 H
Urban and industrial indoor and outdoor
atmospheres with moderate sulphur dioxide
pollution.
Coastal areas with low salinity.
5 Trattamento superficiale 5 Surface treatment

La preparazione viene eseguita secondo la The preparation is done according to Technical
Specifica Tecnica UVT600053. Specification UVT600053.
Prima della sabbiatura e verniciatura, rimuovere Welds are carefully cleaned from spatters and
con cura residui di saldatura. Prima della holes before blast cleaning and painting. Any oil
verniciatura, rimuovere eventuali contaminazioni and grease contamination shall be removed
da grasso e olio. Prima della sabbiatura, abradere before the paint applications. Layers with a hard
gli strati con una superficie dura (ad esempio le surface (e.g. flame-cut surfaces of thick plates)
superfici tagliate a fiamma di piastre spesse). are abraded before blast cleaning.
UVT 600093 C
6 Sistema di verniciatura 6 Painting System

Lettera rif. Numero
Mano Tipo di vernice 1)
di mani Specifica Tecnica vernice
NDFT
Coating ref. Paint type Number Paint Technical Spec.
letter of coats
A1 Fondo epossidico bi- componente 80 m 1

Colore: Grigio chiaro RAL 7035 (o simile)
3AAM700310 – EP primer
2-component epoxy primer
A2 Color: light grey RAL 7035 (or similar) 60 m 1
Mano di finitura acrilica (1)

D 40 m 1 3AAM700313 – AY top coat
Acriylic topcoat (1)
NDFT TOTALE (2) 180 m

1) Qualora il colore a specifica non sia disponibile in acrilico, usare vernice poliuretanica per la verniciatura finale delle macchine
assemblate. Vedi specifiuca Tecnica “3AAM700315” - PUR top coat” per le informazioni sul prodotto.
In case the specified color is not available in Acrylic, polyurethane can be used for final painting of the assembled machines.
See the Technical Spec. “3AAM700315” - PUR top coat” for product information
2) NDFT = spessore nominale film asciutto / Nominal Dry Film Thickness
NOTA: Solitamente la mano secondo il riferimento REMARK: Usually the coat of primer acc. to Coating
“A1” è già applicata sui componenti prima ref “A1” is already applied as minimum on
dell'
assemblaggio, conformemente al quanto the components before the assembly,
prescritto da UVT 600053. Controllare lo according to UVT 600053. Check the paint
spessore della vernice e completare per thickness and complete to guarantee
garantire il riferimento della mano “A1”. Coating ref “A1”.
Trattamenti superficiali più leggeri, secondo A1, Lighter surface treatment including the coating A1 can
possono essere utilizzati per le superfici che non sono be used for the surfaces that are not in touch with the
a contatto con l'
aria esternamente alla macchina. Lo machine’s external air. The minimum thickness of
spessore minimo di queste superfici rivestite deve such coated surfaces shall be 80 m (NDFT).
essere 80 m (NDFT). List of such surfaces is below and if the lightened
Qui di seguito un elenco di queste superfici; se il surface treatment is used on any other surfaces, there
trattamento superficiale leggero viene usato su shall be made part-wise written agreement about the
qualunque altra superficie, i componenti devono issue with ABB.
essere concordati per iscritto con ABB.
Superfici interne delle carcasse Surfaces inside frames of the machines
Superfici delle chiusure cuscinetto interni alla Surfaces of the machines’ bearing shields that
macchina leave inside the machine
Superfici interne dello scambiatore di calore Surfaces inside heat exchanger housing of an
per le macchine con raffreddamento aria-aria air-air and air-water cooled machines
e aria-acqua.
Fans that leave inside the frames of the
Ventilatori interni delle macchine machines
Superfici interne delle scatole morsetti Surfaces inside the terminal boxes
Prodotti dello stesso fornitore di vernici devono essere The same paint supplier’s products shall be used for
utilizzati per tutto il sistema di verniciatura. the whole paint system.
UVT 600093 C
7 Colore finale 7 Final color

Colore standard della mano superiore: blu ABB Standard top coat colour is ABB blue:
- Mûnsell : 8B 4.5/3.25 (riferimento al - Mûnsell : 8B 4.5/3.25 (referring to the
sistema americano di American colour designation
attribuzione dei colori) system)
- NCS 4822-B 05 G : (NCS = sistema a colore - NCS 4822-B 05 G : (NCS = Natural Colour
naturale) System)
- RAL : L’esatto codice RAL non è - RAL : Exact RAL-code is not available
disponibile per il blu ABB; un for ABB Blue; a similar colour in
colore simile con codice RAL è the RAL-code is the RAL
RAL 5010. 5010.
Il colore finale può essere variato in base a specifiche Final colour can be changed according to specific
richieste del cliente. In tal caso il colore deve essere customer requests in this case the colour needs to be
indicato nell'ordine di acquisto. specified in the purchase order.
8 Verniciatura 8 Painting work

Verniciare attenendosi alle istruzioni della scheda di Painting is performed according to the instructions in
prodotto del produttore della vernice. Applicare la the paint manufacturer' s product data sheet. Paints
vernice con pistola a spruzzo airless ad alta are applied by airless high-pressure spraying, making
pressione, prestando attenzione alle superfici di very attention to the all surfaces that are difficult to
difficile accesso, quali bordi, angoli, saldature ed access, for example edges, corners, welds and
angoli nascosti. In caso di oggetti piccoli e difficili da hidden corners. A brush is used for hard-to-spray and
spruzzare, si può usare un pennello. small objects.
Tutte le superfici esterne della macchine sono All external surfaces of the machines are painted
verniciate, ad eccezione delle seguenti: estremità except the followings: shaft end, machined surfaces
degli alberi, superfici rettificate sui piedi della on the machine’s feet, contact surfaces on earthing
macchina, superfici a contatto dei componenti di components, titanium, copper, brass, plastic, stainless
messa a terra, superfici in titanio, rame, ottone, steel, chrome-plated, nickel-plated surfaces.
plastica, acciaio inossidabile, cromate e nichelate.
Surfaces on the parts that must remain free of paint
Proteggere le superfici dei componenti da non shall be protected with a plastic film, masking tape or
verniciare con una pellicola di plastica, del nastro screw. After painting work, the unpainted steel and
adesivo o viti. Dopo la verniciatura, le superfici in cast iron surfaces shall be protected with anti-
acciaio e ghisa rimaste scoperte devono essere corrosion oil.
protette con olio anti-corrosione.
Part that
must be
painted
(DE/NDE
sides)
Parte da
dipingere (lati
DE/NDE)
UVT 600093 C
NOTA: La parte della chiusura esterna del cuscinetto REMARK: the part of the outer bearing cover in touch
a contatto con l’aria deve essere verniciata, ma non with external air must be painted – not the shaft end.
l’estremità dell’albero.
I prodotti dello stesso fornitore di vernici devono The same paint supplier’s products shall be used for
essere utilizzati per tutto il sistema di verniciatura. the whole paint system.
I giunti spegnifiamma delle macchine AMD non Flameproof joints for Ex-d machines and enclosures
devono essere verniciate, in accordo a quanto are not be painted, according to Ex standards
prescrito dalle normative Ex. requirement.
All’interno delle macchine si applica un trattamento A reduced surface treatment is used inside the
superficiale ridotto. machines.
I tubi in acciaio inossidabile collegati a quelli in Pipes made of stainless steel connected to carbon
carbonio sono verniciati in modo che la vernice si steel are painted in such a way that the paint overlaps
sovrapponga all’acciaio inossidabile di 50 mm. the stainless steel by 50 mm.
8.1 Mani di fondo ed intermedie 8.1 Priming and Intermediate Coating

Subito dopo la preparazione della superficie, i Parts of the machines are sprayed with primer
componenti della macchina vengono sottoposti a immediately after surface preparation. Nominal dry
verniciatura con mano di fondo. Lo spessore film thickness of the primer is according to tables of
nominale del film asciutto è indicato nelle tabelle della section 6.
sezione 6.
Le parti attive (ad esempio rotore e statore) sono
Active parts (such as rotor and stator) are painted with
verniciate con speciali mani di fondo. Le vernici sono
special selected primers. The paints are accurately
sottoposte a test rigorosi ed accurati per garantirne la
and rigorously tested to guarantee compatibility with
compatibilità con il sistema isolante. Le mani di fondo
insulation system. The primers don’t change
non cambiano in base al sistema di verniciatura
depending on the selected painting system.
prescelto.
8.2 Verniciatura finale 8.2 Final painting

Dopo l’assemblaggio finale, la superficie esterna della After final assembly, the external surface of the
macchina è sottoposta a finitura come descritto nella machine is finished according to section 6.
sezione 6.
9 Controllo qualità - Misurazione 9 Quality control - Measuring the

dello spessore della vernice Thickness of the Paint
Controllare la qualità della verniciatura ed il rispetto The quality of paintwork and fulfilment of the required
dello spessore della mano. Eseguire le ispezioni in coat thicknesses will be monitored. Inspections will be
base al presente documento ed allo standard ISO performed in accordance with this document and ISO
12944. Una sintesi dei risultati deve essere riportata 12944 standard. A summary of the results will be
nel registro di ispezione della verniciatura. included in the painting inspection record.
9.1 Manutenzione del registro di 9.1 Keeping an Inspection Record

ispezione
Il registro di ispezione garantisce che la verniciatura Purpose of keeping an inspection record is to ensure
anticorrosiva sia conforme all’accordo, alle istruzioni that anti-corrosive paintwork conforms to the
ed agli standard. L’ispettore deve inserire tutte le agreement, instructions and standards. The inspector
proprie osservazioni, commenti e correzioni nel must enter all of his observations, comments and
registro di ispezione, che può essere compilato a repairs into the painting inspection record, which can
mano o elettronicamente. be fulfilled either by computer or manually.
E’ possibile redigere un unico registro di ispezione A single combined inspection record can be prepared,
contenente tutti gli elementi inseriti nella stessa containing all parts included into the same order
posizione dell’ordine. position.
UVT 600093 C
Il registro di ispezione deve essere consegnato ad The inspection record must be delivered to ABB
ABB insieme agli altri documenti di controllo qualità together with other quality control documents of the
del componente/dei componenti. Il registro di part(s). The inspection record shall be also stored in
ispezione deve essere conservato dal fornitore per 24 supplier’s archives minimum for 24 months following
mesi dalla verniciatura. the paint job.
9.1 Manutenzione del registro di 9.1 Keeping an Inspection Record

ispezione
Il registro di ispezione garantisce che la verniciatura Purpose of keeping an inspection record is to ensure
anticorrosiva sia conforme all’accordo, alle istruzioni that anti-corrosive paintwork conforms to the
ed agli standard. L’ispettore deve inserire tutte le agreement, instructions and standards. The inspector
proprie osservazioni, commenti e correzioni nel must enter all of his observations, comments and
registro di ispezione, che può essere compilato a repairs into the painting inspection record, which can
mano o elettronicamente. be fulfilled either by computer or manually.
E’ possibile redigere un unico registro di ispezione A single combined inspection record can be prepared,
contenente tutti gli elementi inseriti nella stessa containing all parts included into the same order
posizione dell’ordine. Il registro di ispezione deve position. The inspection record must be delivered to
essere consegnato ad ABB insieme agli altri ABB together with other quality control documents of
documenti di controllo qualità del componente/dei the part(s). The inspection record shall be also stored
componenti. Il registro di ispezione deve essere in supplier’s archives minimum for 24 months
conservato dal fornitore per 24 mesi dalla verniciatura. following the paint job.
9.2 Misurazione dello spessore della 9.2 Measuring the Thickness of the Paint
vernice
Per le strutture prive di un disegno di misurazione For structures with no defined measuring drawing, the
definito, misurare lo spessore della mano in modo da coating thickness should be measured in such a way
farsi un’idea che sia la più completa possibile per that as comprehensive a picture as possible is
l’intero rivestimento. Per le strutture con un disegno obtained of the entire coating. For structures with a
di misurazione definito, misurare lo spessore della defined measuring drawing, the coating thickness
mano nelle aree indicate da quest’ultimo. Lo spessore must be measured based on the areas defined in the
minimo consentito della mano, in qualunque punto di measuring drawing. The permitted minimum coating
misurazione, è l’80% dello spessore nominale (limite thickness at any individual measuring point is 80% of
superiore 300%. ISO 12944-5). the nominal coating thickness (upper limit 300%. ISO
12944-5).
ABB ABB S.p.A.
ABB Discrete Automation and Motion Division
Quality Control Plan – Inspection and Testing Plan
WBS & Q.C.P. Reference Quantity Document Revision
8130002869.01 1 2Q 10400 0
Three phase asynchronous motor
AMI800L4LBSXYM 9700 kW 10000 V 50 Hz

Customer Plant Motor item number
ABB GERMANIA Shenhua Yulin PP

Reference design specifications
Customer to receive certifications as per QCP
Revision Date Mods. Implemented Written Checked Approved
0 05/08/2013 Issue BARENGHI VANZINI MURRU
Inspection Dept. Inspection site
a Supplier representative Supplier

□
b ABB Quality Control ● ABB
c External facility
d Customer representative
Type of action
W Witness point N Inspection without issuing certificate
H Hold point R Certificate review
C Inspection with issuing of certificate D Certificate of conformity
Certifications supplied conform to procurement and manufacturing specifications as guarantee of performance requested.
Q.C.P. and I.T.P.
ABB WBS & Q.C.P Reference

8130002869.01
Document
2Q 10400
Rev.
0
Type of action
Operation
Subject of inspection Quantity Type of inspection Reference standard
Inspection Inspection
ABB
site facility ABB Client
Supplier
SHAFT
1. 1 Heat analysis EN 10083 □ a C R R
Forged rod
1 1. 2 Mechanical properties UVT 600322 □ a C R R
25CrMo4 (St 442 S)
1. 3 Ultrasonic test UVT 600113 □● a C R R
ROTOR
2. 1 Heat analysis UN 600002 □ a C R R
Drawn rotor bars

- 2. 2 Brinell hardness UN 600002 □ a C R R
Cu ETP
2. 3 Dimensional and form check UQ 600148 □ a C R R
Rotor balancing 1 3. 1 Balance test HTAG 20023 □● b - C R
STATOR
HTAY 620220 - HTAY 620221

4. 1 Insulation tests after impregnation ● b - C R
UVT 600224
HTAY 620220 - HTAY 620221

Stator dielectric test 1 4. 2 Voltage test after cables connection ● b - C R
UVT 600224
HTAY 620220 - HTAY 620221

4. 3 Phase resistance test ● b - C R
UVT 600224
RING
5. 1 Heat analysis UQ 600061 □ a C R R
5. 2 Brinell hardness UQ 600061 □ a C R R
5. 3 Electrical conductivity UQ 600061 □ a C R R

S/C ring forgings 2
5. 4 Liquid penetrant inspection UQ 600186 □ a C R R
5. 5 Ultrasonic test UQ 600187 □ a C R R
5. 6 Dimensional inspection Drawing □ a C R R
MECHANICAL COMPONENTS
6. 1 Ultrasonic inspection of white metal adhesion UNI ISO 4386/1 classe B □ a C - R

Sleeve bearings 2
6. 2 Dimensional inspection Drawing □ a C - R
Q.C.P. and I.T.P.
ABB WBS & P.C.Q. Reference

8130002869.01
Document
2Q 10400
Rev.
0
Quantity Type of action

REF. Inspection
Operation Request Type of inspection Reference standard Inspection site ABB
Test facility ABB Client
[Attended] Supplier
ROUTINE TESTS
Winding, heater and thermo-resistor (cold) resistance

7. 1 1[1] R1 IEEE 112 par. 5.4 ● bd - C W
test
7. 2 1[1] R2 Insulation resistance maesurement (cold) IEEE 43 ● bd - C W
7. 3 1[1] R3 Axial play check Drawing ● bd - C W
7. 4 1[1] R4 No-load test IEEE 112 par. 5.5 ● bd - C W
7. 5 1[1] R5 No-load vibration test IEC 60034-14 ● bd - C W
7. 6 1[1] R6 Short circuit test with locked rotor IEEE 112 par. 7.2 ● bd - C W
IEEE 43
7. 7 1[1] R7 Insulation resistance measurement ● bd - C W
IEC 60204-1
IEC 60034-1 par. 9.2

7. 8 1[1] R9 High voltage test ● bd - C W
IEC 60060-1 par.6
7. 9 1[1] R10 Visual inspection Drawing ● bd - C W
TYPE TESTS AND SPECIAL
IEC 60034-1 par.8

8. 1 1[1] T1 Temperature rise test with double frequency method ● bd - C W
IEC 60034-29 par. 6.2.4
8. 2 1[1] T6 Starting torque/current test with locked rotor IEEE 112 par. 7.2 ● bd - C W
8. 3 1[1] T7 Shaft voltage test IEEE112 par. 8.4 ● bd - C W
8. 4 1[1] T8 Polarization index IEEE 43 par. 5.4 ● bd - C W
8. 5 1[1] T9 Overspeed test IEC 60034-1 par. 9.7 ● bd - C W
FFT (Fast Fourier Transform) analysis of no-load

8. 6 1[1] S3 IEC 60034-14 ● bd - C W
vibration
No-load noise test at nominal frequency by octave band

8. 7 1[1] S5 IEC 60034-9 ● bd - C W
analysis
INSPECTIONS FINISHED ENGINE
9.1 1[1] Final inspection Drawing ● bd - C W
9. 2 1 Conformity tests (MCIR) IQU405 ● b - C R

Q.C.P. and I.T.P.

8130002869.01
Doc. Rev.
2Q 10400 0
PROCEDURES
STATOR WINDING TESTS DURING PRODUCTION
A number of intermediate inspection tests are to be carried out during stator winding construction, the results of
which are given in the "Inspection Certificate".
- Dimensional check and coil voltage test

- Ground insulation test with coils installed
- Insulation test across turns with coils installed
- Pre-impregnation ground insulation test
- Pre-impregnation insulation test across turns
- Phase resistance test (using milliohmeter)
- Post-impregnation insulation resistance test
- Ground insulation test after wiring-up
- Insulation resistance test
- Phase resistance test (using milliohmeter)
Tests as per procedures HTAY 620220/620221, UVT 600224
The tests listed hereunder may be carried out on customer request.

A. Sample coil test - UVT 600703, IEC 60034-15, API541 para. 4.3.4.2
B. tanδ test (for motors Un> 5000V) - HTAE 60017, STD IEEE 286, API 541 para. 4.3.4.3
C. Spray test - UVT 600128, API541 para. 4.3.4.4, NEMA MG-1 para. 20.18
D. Loop test - UVT 60098, API 541 para. 4.3.4.1
R1 – RESISTANCE TEST (COLD)
Test purpose
- Stator winding resistance test
- Rotor winding resistance test (AMK-AML only)
- Check for operation of any temperature sensors
- Anti-condensate or preheat resistance test (if applicable)
Procedure
Check interlinked phase resistance (U-V / U-W / V-W) using voltammeter test method. Check winding
temperature using multimeter and temperature sensors (PT-100, thermocouples). If temperature sensors are
not envisaged use ambient temperature.
Use results obtained to calculate average phase resistance.
Using a multimeter, monitor anti-condensate or preheat resistance.

Note: This test may be carried out prior to tests requiring attendance.
References
STD IEEE 112 para. 5.4
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R2 – INSULATION RESISTANCE TEST (COLD)
Test purpose
Check winding insulation resistance
Procedure
Check insulation resistance across component under test and motor frame.
Test to be carried out on the components listed hereunder.
- Stator winding (voltage as per table below)
- Rotor winding (AMK and AML only, voltage as per table below)
Acceptance criteria
Winding insulation resistance (correct at 40°C) after 1 minute ≥ 100MΩ.
References
Ref. IEEE 43
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R3 - AXIAL PLAY CHECK
Test purpose
Correctly position the rotor relative to the bearings
Procedure
Start the motor and run by inertia at low speed. Push rotor from DE and if possible from NDE determining total
bearing end play relative to bearing abutment.
Run motor at rated voltage and frequency and determine rotor end play relative to bearings; if minimum footprint
drawing requirements are not met reposition bearings.
All motors shall have either of the references given hereunder for shaft positioning on assembly.
- Distance between surface with red mark and step on shaft
- Thumbwheel or arrow as reference for groove in shaft
R4 - NO-LOAD TEST
Test purpose
Check direction of rotation, monitor current and losses in no-load condition.
Procedure
On motor starting check for correct direction of rotation. If the test is carried out after heat test, proceed
immediately with it, otherwise leave the motor running for one hour minimum. Take different voltage readings at
eight points (from 110% of rated voltage reduced by 10% at each point).
For each point record:
- Voltage
- Current
- Power consumption
- Power factor
Plot current and power curves versus voltage.
Using the loss separation method obtain readings for:
- No-load current
- Total loss in no-load condition
- Copper losses
- Mechanical losses
- Core losses
At end of test record temperature readings for winding and bearings.
Note: For inverter supplied motors, test may be carried out at voltage and frequency different from normal
operating points. Parameters used for test are calculated keeping induction constant.
References
Q.C.P. and I.T.P.

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R5 - VIBRATION TEST (NO-LOAD)
Test purpose
No-load vibration test
Procedure
Vibration test shall be carried out with motor resting or restrained on rigid foundation, running in no-load
condition and supplied at rated voltage and frequency. Readings shall be taken on both bearings in horizontal,
vertical and endwise positions. In some cases, where bearings are non accessible, readings shall be taken on
motor frame.
On motors running on plain bearings (bushings), for which there is a request to install or make provision for proxi
transducers, shaft vibration (DE and NDE) and runout at 200 - 300 rpm shall be tested.
Acceptance criteria
References
STD IEC 60034-14
R6 - SHORT CIRCUIT TEST WITH LOCKED ROTOR
Test purpose
Current and power factor test – Clamped rotor
Procedure
Test shall be carried out with the rotor positively clamped.
Depending on power supply used, motor shall be supplied at rated frequency and three different voltage ratings
with associated power consumption ratings (200% In, 150% In, 100% In). For each point record:
- Voltage
- Current
- Power consumption
- Power factor
References
Q.C.P. and I.T.P.

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R7 - INSULATION RESISTANCE MEASUREMENT
Test purpose
Monitor insulation resistance of winding, temperature sensors, anti-condensate or preheat resistors.
Procedure
Check insulation resistance across component under test and motor frame.Test to be carried out on the
components listed hereunder.
- Windings (voltage as per table below)
- Rotor winding (AMK and AML only, voltage as per table below)
- Temperature sensors (if applicable) at 500 Vdc
- Anti-condensate or preheat resistors (if applicable) at 500 Vdc
Acceptance criteria
Winding insulation resistance (correct at 40°C) after 1 minute ≥ 100MΩ.
Insulation resistance of temperature sensors and anti-condensate or preheat resistors ≥ 1MΩ.
References
Ref. IEEE 43 - IEC 60204-1
R9 - HIGH VOLTAGE TEST
Test purpose
Check ground insulation of windings and auxiliaries
Procedure
Apply voltage for 60 seconds across components under test and motor frame:
- Winding (2 times rated voltage + 1000 Vac)
- Temperature sensors at 1500 Vac (if applicable)
- Anti-condensate or preheat resistors installed in motor frame at 1500 Vac (if applicable).
For motors with accessible star point, voltage shall be applied to one phase at a time, with the other two
grounded, to be repeated for each phase (case B)
References
IEC 60034-1 para. 9.2, IEC 60060-1 para. 6
R10 - VISUAL INSPECTION
Test purpose
Visual inspection of auxiliaries
Procedure
Components to be visually inspected shall include:
- Serial number stamping
- Phase stamping on pins of main terminal unit
- Main and auxiliary units for correct position
- Electrical connections of main and auxiliaries terminal units
- Type, size and number of brushes (AML and AMK only)
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T1 - TEMPERATURE RISE TEST WITH DOUBLE FREQUENCY METHOD
Test purpose
Check warm-up temperature versus insulation class.
Procedure
Dual frequency heat test gives warm-up temperature even when the motor is not coupled to any load, therefore
to regenerate motor current use is made of two series-connected power supplies.
One power supply powers the motor at 50Hz and rated voltage (or referred to 50 Hz). The other power supply
generates voltage at a lower frequency. As the motor is supplied at two different frequencies, the first forces the
motor to accelerate, whereas the other, which is lower, tends to slow it down, such continuous changes having
the effect of increasing current consumption. By altering the secondary source parameters (voltage and
frequency), depending on the source in question, the motor rated current is obtained.Max. current for this test
shall be 800 Amps, motors of higher current ratings being subject to a no-load heat test to be used for returning
the rating of test under load (800Amps) to that of rated current.In some cases, at start of test, overloading may
be applied or cooling reduced, in order to shorten test time.The motor is brought to warm-up (when the
difference in ∆t of all temperature sensors is reduced by 2°C per hour).
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At this point, the motor shall be stopped and the resistance test repeated quickly to record the cooling curve.
Average winding temperature is calculated taking as reference the resistance when cold. ∆t (or “K”) defines the
temperature change between that of the component and the winding cooling air temperature.
The cooling curve is obtained after acquiring the 13 points. The time to be considered for reference purposes is
obtained depending on motor power rating.
If the time at resistance acquisition point 1 is below reference time, the reading taken is that of ∆t for the time
given in the table, otherwise use is made of the time at zero seconds.
For motors with power rating above 5000kW, reference time shall be considered to be 120 seconds.
Acceptance criteria
K (∆t) below value guaranteed in datasheet
References
IEC 60034-1 para. 8, IEC 60034-29 para. 6.2.4
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T6 - START TORQUE AND CURRENT WITH LOCKED ROTOR
Test purpose
Monitor motor starting torque and current
Procedure
Positively clamp rotor and possibly supply motor at rated frequency. Acquisition five test points with different
voltage readings, so as to obtain various current consumption values. Depending on the power supply used for
testing, run the first point at 300% of rated current, the second at 250%, up to the fifth point at rated value.
For each point record:
- Voltage
- Current
- Power consumption
- Power factor
Plot starting current and torque curves versus voltage and use loss parameters of no-load test to calculate:
- Start (break-away) current
- Starting torque
Note:
- When requested, this test also includes short circuit test
- This test is not significant for inverter controlled motors (VSD motors)
Acceptance criteria
Start (break-away) current +20% of rating guaranteed by datasheet
Starting torque +25/-15% of rating guaranteed by datasheet
References
T7 - SHAFT VOLTAGE TEST
Test purpose
Test for voltage across shaft ends
Procedure
Check shaft voltage during motor no-load running at rated voltage and frequency across shaft ends (DE and
NDE).
References
Q.C.P. and I.T.P.

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T8 - POLARIZATION INDEX
Test purpose
Polarization index test (PI)
Procedure
Test to be carried out on stator winding. Test voltage shall depend on motor rated voltage (see table below).
Apply voltage for 10 minutes and record insulation resistance after one minute and after ten minutes.
Acceptance criteria
Polarization index shall be considered acceptable if greater than 2. If R1min (correct at 40°C) is greater than
5000MΩ the index shall not be considered.
References
STD IEEE 43 para. 5.4 and 6.3
T9 - OVERSPEED TEST
Test purpose
Check strength under mechanical stress
Procedure
Test for two minutes with motor at no-load running at 20% over rated rpm.
Acceptance criteria
After overspeed test the machine shall not show signs of detectable permanent deformation.
References
IEC 60034-1 para. 9.7
S3 - ANALYSIS VIBRATION (NO-LOAD)
Test purpose
Check for critical frequencies
Procedure
This is the no-load vibration test. Using algorithm FFT (Fast Fourier Transform), plot the curves arranged by
frequencies. Resulting values may be used to check for possible critical vibration.
References
STD IEC 60034-14
S5 - NOISE LEVEL TEST (NO-LOAD)
Test purpose
Evaluate motor noise level
Procedure
Run test with motor running at no-load and rated voltage and frequencies. Depending on motor size the points
acquired shall be 8 or 16.From recorded data obtain total sound pressure and for each point the values
subdivided by frequency.
Acceptance criteria
Actual value smaller than that guaranteed by datasheet
References
IEC 60034-9
Installation and Maintenance Squirrel Cage Motors AMI 710…1000
ABB
Safety Instructions
AMA, AMB, AMC, AMI, AMH, AMK, AML, HXR
1 General  Cover or provide barriers against neighbouring live parts!

General safety regulations, specific agreements made for each work  De-energize auxiliary circuits (e.g. anti-condensation heating)!
site and safety precautions shown in this document must be Exceeding of limit values of zone A in EN 60034-1 / DIN VDE
observed at all times. 0530-1 - voltage ± 5%, frequency ± 2%, waveform and symmetry -
2 Intended use leads to higher temperature rise and affects the electromagnetic
Electric machines have dangerous live and rotating parts and may compatibility. Note rating plate markings and connection diagram in
have hot surfaces. All operations serving transport, storage, the terminal box.
installation, connection, commissioning, operation and maintenance The connection must be so made that permanent safe electrical
shall be carried out by responsible skilled persons (in conformity connection is maintained. Use appropriate cable terminals. Establish
with EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling and maintain safe equipotential bonding.
may cause serious personal injury and damage to property. Danger! The clearances between uninsulated live parts and between such
These machines are intended for industrial and commercial parts and earth must not be below the values of appropriate
installations as components as defined in the Machinery Directive standards and values possibly given in manufacturer’s
(MD) 89/392/EEC. Commissioning is prohibited until conformity of documentation.
the end product with this directive has been established (follow No presence of foreign bodies, dirt or moisture is allowed in the
particular local safety and installation rules as e.g. EN 60204). terminal box. Close unused cable entrance holes and the box itself
These machines comply with the harmonized series of standards in a dust- and watertight manner. Lock the key when the machine is
EN 60034 / DIN VDE 0530. Their use in hazardous areas is run without coupling. For machines with accessories, check
prohibited unless they are expressly designed for such use (follow satisfactory functioning of these before commissioning.
additional instructions). The proper installation (e.g. segregation of signal and power lines,
On no account, use degrees of protection  IP 23 outdoors. screened cables etc.) lies within the installer's responsibility.
Air-cooled models are typically designed for ambient temperatures 6 Operation
of -20°C up to +40°C and altitudes of  1000 m above sea level. Vibration severity in the "satisfactory" range (Vrms  4.5 mm/s)
Ambient temperature for air-/water-cooled models should be not according to ISO 3945 is acceptable in coupled-mode operation. In
less than +5°C (for sleeve-bearing machines, see manufacturer's case of deviations from normal operation - e.g. elevated temperature,
documentation). By all means, take note of deviating information on noises, vibrations - disconnect machine, if in doubt. Establish cause
the rating plate. Field conditions must conform to all rating plate and consult manufacturer, if necessary.
markings.
Do not defeat protective devices, not even in trial run. In case of
3 Transport, storage heavy dirt deposits, clean cooling system at regular intervals. Open
Immediately report damage established after delivery to transport closed condensate drain holes from time to time.
company. Stop commissioning, if necessary. Lifting eyes are Grease the bearings during commissioning before start-up.
dimensioned for the weight of the machine, do not apply extra loads. Regrease antifriction bearings while the machine is running. Follow
Ensure the use of correct lifting eyes. If necessary, use suitable, instructions on lubrication plate. Use right kind of grease. In case of
adequately dimensioned means of transport (e.g. rope guides). sleeve-bearing machines, observe time-limit for oil-change and if
Remove shipping braces (e.g. bearing locks, vibration dampers) equipped with oil supply system make sure the system is working.
before commissioning. Store them for further use.
7 Maintenance and servicing
When storing machines, make sure of dry, dust and vibration free
Follow manufacturer's operating instructions. For further details, see
location (danger of bearing damage at rest). Measure insulation
the comprehensive User´s Manual. Preserve these safety
resistance before commissioning. At values of  1k per volt of
instructions!
rated voltage, dry winding. Follow manufacturer's instructions.
4 Installation 8 Frequency converter
In frequency converter applications motor frame external
Make sure of even support, solid foot or flange mounting and exact
earthing must be used for equalising the potential between the
alignment in case of direct coupling. Avoid resonances with
rotational frequency and double mains frequency as a result of motor frame and the driven machine, unless the two machines are
mounted on the same metallic base. For motor frame sizes above
assembly. Turn rotor and listen for abnormal slip noises. Check
IEC 280, use 0.75 x 70 mm flat conductor or at least two 50 mm²
direction of rotation in uncoupled state.
round conductors. The distance of the round conductors must be at
Follow manufacturer’s instructions when mounting or removing
least 150 mm from each other.
couplings or other drive elements and cover them with a touch
This arrangement has no electrical safety function; the purpose is to
guard. For trial run without output elements, lock or remove the shaft
equalise the potentials. When the motor and the gearbox are
end key. Avoid excessive radial and axial bearing loads (note
manufacturer's documentation). The balance of the machine is mounted on a common steel fundament, no potential equalisation is
indicated as H = Half and F = Full key. With half-key models, the required.
coupling too, must be half-key balanced. In case of protruding,
Potential equalisation
visible part of the shaft end key, establish mechanical balance.
Make necessary ventilation and cooling system connections. The Plate/strip Cables/wires
ventilation must not be obstructed and the exhaust air, also of V1
U1 W1
neighbouring sets, not taken in directly. PE
3~M
0.75 mm > 150 mm
5 Electrical connection
70 mm
min 50 mm
All operations must be carried out only by skilled persons on the
Driven machinery
machine at rest. Before starting work, the following safety rules must
be strictly applied:
 De-energize! To comply with EMC-requirements, use only cables and connectors
 Provide safeguard against reclosing! approved for this purpose. (See instruction for frequency
 Verify safe isolation from supply! converters.)
 Connect to earth and short!
Safety and Ex-instructions-EN.doc ABB Electrical Machines 2003 1(2)

Additional Safety Instructions for Electrical IEC 60079-0; Std. concerning General Requirements for
Motors for Hazardous Areas Explosive Atmospheres
IEC 60079-2; Std. concerning Ex p protection
IEC 60079-7; Std. concerning Ex e protection
Note IEC 60079-15; Std. concerning Ex nA protection
IEC 61241-1-1 Std. concerning Dust Ignition Protection
These instructions must be followed to ensure safe and proper
installation, operation and maintenance of the motor. They should ABB machines (valid only for group II) can be installed in areas
be brought to the attention of anyone who installs, operates or corresponding to following marking:
maintains this equipment. Ignoring the instruction may invalidate the Zone (IEC) Category (EN) Marking
warranty.
1 2 Ex p, Ex pe, Ex e
Warning 2 3 Ex nA
Motors for hazardous areas are specially designed to comply with

Atmosphere (EN);
official regulations concerning the risk of explosion. If improperly
used, badly connected, or alter, no matter how minor, their reliability G – explosive atmosphere caused by gases
could be in doubt. D – explosive atmosphere caused by dust
Reception check
Standards relating to the connection and use of electrical apparatus
in hazardous areas must be taken into consideration, especially - Immediately upon receipt check the machine for external
national standards for installation. Only trained personnel familiar damage and if found, inform the forwarding agent without
with these standards should handle this type of apparatus. delay.
- Check all rating plate data, especially voltage, winding
Declaration of Conformity connection (star or delta), category, type of protection and
All ABB machines comply with: temperature marking.
- The Low Voltage Directive 73/23/EEC amended by Directive Notice following rules during any operations!
93/68/EEC
- EMC Directive 89/336/EEC, amended by Directives 92/31/EEC Warning !
and 93/68/EEC Disconnect and lock out before working on the machine or the
- Certificate of Incorporation with respect to the Machinery driven equipment. Ensure no explosive atmosphere is present while
Directive 89/392/EEC, amended by Directives 91/368/EEC, the work is in progress.
93/44/EEC and 93/68/EEC
- All ABB Ex-machines, which have a CE-mark on the rating Starting and Re-starting
plate comply with the ATEX Directive 94/9/EC - The maximum number of the sequential starts has been
Validity declared in machine’s technical documents.
These instructions are valid for the following ABB’s electrical motor - The new starting sequence is allowed after the machine has
types, when the machine is used in explosive atmospheres. cooled to the ambient temperature (-> cold starts) or to
operating temperature (-> warm starts).
Non-sparking Ex nA
- AMA Induction Machines, sizes 315 to 500 Earthing and Equipotentialing
- AMB, AMI Induction Machines, sizes 560 to 1000 - Check before starting that all earthing and equipotentialing
- HXR Induction Machines, sizes 315 to 560 couplings are effectively connected.
- AMC Induction Machines, sizes 800 to 1000
- Do not remove any earthing or equipotentialing cables, which
Increased safety Ex e has been assembled by the manufacturer.
- AMA Induction Machines, sizes 315 to 500
- AMB, AMI Induction Machines, sizes 560 to 1000 Clearances, creepage distances and separations
- HXR Induction Machines, sizes 315 to 560 - Do not make any removal or adjustment in terminal boxes,
- AMC Induction Machines, sizes 800 to 1000 which could decrease clearances or creepage distances
Pressurisation Ex pe, Ex p, between any parts.
- AMA Induction Machines, sizes 315 to 500 - Do not install any new equipment to terminal boxes without
- AMB, AMI Induction Machines, sizes 560 to 1000
asking for advises from ABB.
- HXR Induction Machines, sizes 315 to 560
- AMC Induction Machines, sizes 800 to 1000 - Be sure that air gap between rotor and stator is measured after
any maintenance for the rotor or bearings. The air gap shall be
Dust Ignition Protection (DIP)
- AMA Induction Machines, sizes 315 to 500 the same in any point between stator and rotor.
- AMB, AMI Induction Machines, sizes 560 to 1000 - Centralise the fan to the centre of the fanhood or the air guide
- HXR Induction Machines, sizes 315 to 560 after any maintenance. The clearance shall be at least 1% of
- AMC Induction Machines, sizes 800 to 1000 the maximum diameter of the fan and in accordance with
(Additional information may be required for some machine types standards.
used in special applications or with special design.) Connections in terminal boxes
Conformity - All connections in main terminal boxes must be made with Ex-
As well as conforming to the standards relating to mechanical and approved connectors, which are delivered with the machine by
the manufacturer. In other cases ask an advice from ABB.
electrical characteristics, motors designed for explosive
atmospheres must also conform to the following IEC or CENELEC - All connections, in auxiliary terminal boxes, as marked
standards: intrinsically safe circuits (Ex i) must be connected to proper
safety barriers.
EN 60079-0; General norm concerning explosion-proof
material. Note !
EN 60079-2; Std. concerning Ex p protection
EN 60079-7; Std. concerning Ex e protection If there are any conflicts between this instruction and user manual,
EN 60079-15; Std. concerning Ex nA protection this document is prevailing.
EN 61241-1-1 Std. concerning Dust Ignition Protection
Safety and Ex-instructions-EN.doc ABB Electrical Machines 2003 2(2)

Squirrel Cage Motors AMI
Table of Contents
Chapter 1 Introduction ................................................................................................................................................................... 1

1.2 Operative range and intended application ............................................................................................................................ 1
1.3 Information on electromagnetic compatibility ..................................................................................................................... 1
1.4 Required qualifications for erection and operating personnel .............................................................................................. 1
Chapter 2 Safety instructions ......................................................................................................................................................... 2
2.1 Safety.................................................................................................................................................................................... 2
2.2 Site conditions ...................................................................................................................................................................... 2
2.3 Prerequisites ......................................................................................................................................................................... 2
2.4 Contraindications ................................................................................................................................................................. 3
Chapter 3 Storage and transport ..................................................................................................................................................... 4
3.1 Inspection of delivery ........................................................................................................................................................... 4
3.2 Oil lubricated bearings ......................................................................................................................................................... 4
3.3 Rotor transport lock .............................................................................................................................................................. 4
3.4 Turning a vertical motor to the horizontal position ........................................................................................................ 5
3.5 Storage of the motor ............................................................................................................................................................. 9
3.5.1 Short term storage of crated motor ................................................................................................................................ 9
3.5.2 Long term storage of crated motor ................................................................................................................................ 9
3.5.3 Short term storage of uncrated motor .......................................................................................................................... 10
3.5.4 Long term storage of uncrated motor .......................................................................................................................... 11
3.5.5 Space heater................................................................................................................................................................. 11
3.5.6 Prevention of corrosion damage an air-water coolers ................................................................................................. 11
Chapter 4 Preparing for commissioning ....................................................................................................................................... 12
4.1 Removing the rotor transport lock ...................................................................................................................................... 12
4.1.1 Motors with anti-friction bearings ............................................................................................................................... 12
4.1.2 Motor with sleeve bearings ......................................................................................................................................... 12
4.2 Mounting the coupling hub ............................................................................................................................................ 12
4.2.1 Cylindrical-bore coupling hub with a feather key ....................................................................................................... 13
4.2.2 Cylindrical-bore coupling hub with a shrink fit (plain or stepped seat) ...................................................................... 14
4.2.3 Taper-bore coupling hub with a shrink fit ................................................................................................................... 15
4.3 Installing the motor ............................................................................................................................................................ 15
4.3.1 Prerequisites for installation ........................................................................................................................................ 15
4.4 Foundation.......................................................................................................................................................................... 17
4.4.1 Grouting ...................................................................................................................................................................... 17
4.4.2 Installation of motor with soleplates ........................................................................................................................... 17
4.5 Aligning to driven equipment ............................................................................................................................................. 18
4.5.1 Influence of the axial position of the rotor on motor alignment .................................................................................. 18
4.5.2 Motors with guide bearings (anti-friction or special sleeve bearing design) ............................................................... 18
4.5.3 Increase in shaft height due to thermal expansion ....................................................................................................... 19
4.5.4 Alignment procedure ................................................................................................................................................... 20
4.5.5 Tightening torque for the anchor bolts ........................................................................................................................ 21
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4.5.6 Alignment report ......................................................................................................................................................... 21
4.5.7 Additional information for vertical motors.................................................................................................................. 22
4.5.8 Bearings ....................................................................................................................................................................... 22
4.5.9 Anti-friction bearings .................................................................................................................................................. 22
4.5.10 Sleeve bearings .......................................................................................................................................................... 22
4.5.11 Bearing temperature monitoring ................................................................................................................................ 24
4.6 Mounting the ventilation unit ............................................................................................................................................. 25
4.6.1 AMI 710 motors .......................................................................................................................................................... 25
4.6.2 AMI 800…1000 motors .............................................................................................................................................. 25
4.6.3 Air-to-water cooler ...................................................................................................................................................... 25
4.7 Electrical connections......................................................................................................................................................... 25
4.7.1 Insulation resistance .................................................................................................................................................... 25
4.7.2 Cable penetration plate on the terminal box ................................................................................................................ 27
4.7.3 Terminals, preparing for connection ........................................................................................................................... 28
4.7.4 Cleaning the terminals ................................................................................................................................................. 28
4.7.5 Measures to prevent oxidation and corrosion .............................................................................................................. 28
4.7.6 Stud terminals .............................................................................................................................................................. 28
4.7.7 Bar terminals ............................................................................................................................................................... 29
4.7.8 Fully insulated connectors ........................................................................................................................................... 30
4.7.10 Earthing ..................................................................................................................................................................... 31
4.7.11 Earth brushes ............................................................................................................................................................. 31
Chapter 5 Commissioning ............................................................................................................................................................ 32
5.1 Sleeve bearings with forced oil lubrication ........................................................................................................................ 32
5.2 Direction of rotation ........................................................................................................................................................... 32
5.3 Air to water coolers ............................................................................................................................................................ 33
5.3.1 General ........................................................................................................................................................................ 33
5.3.2 Prevention of corrosion damage on air-to-water coolers ............................................................................................. 33
5.4 Starting frequency .............................................................................................................................................................. 33
5.5 Starting, operation, shut-down ........................................................................................................................................... 34
5.6 Continuous monitoring during operation ........................................................................................................................... 34
5.7 Check list ............................................................................................................................................................................ 35
5.7.1 Page 1 .......................................................................................................................................................................... 36
5.7.2 Page 2 .......................................................................................................................................................................... 37
5.7.3 Page 3 .......................................................................................................................................................................... 38
Chapter 6 Inspection and maintenance ......................................................................................................................................... 39
6.1 General ............................................................................................................................................................................... 39
6.2 Instrumentation................................................................................................................................................................... 40
6.3 Maintenance on sleeve bearings ......................................................................................................................................... 40
6.3.1 Oil change ................................................................................................................................................................... 40
6.3.2 Oil ring ........................................................................................................................................................................ 40
6.3.3 Oil leakage................................................................................................................................................................... 41
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6.3.4 Emergency running for motors with forced oil lubrication ......................................................................................... 41
6.3.5 Maintenance on a separate oil supply system (Lube oil or jacking oil supply) ................................................... 41
6.3.6 Maintenance plan for sleeve bearings ......................................................................................................................... 41
6.4 Maintenance on anti-friction bearings ................................................................................................................................ 42
6.4.1 Validity of the regreasing intervals, conversion .......................................................................................................... 42
6.4.2 Regreasing procedure .................................................................................................................................................. 43
6.4.3 Choice of lubricating grease ........................................................................................................................................ 43
6.4.4 Maintenance plan for anti-friction bearings on horizontal and vertical motors ........................................................... 44
6.5 Bearing monitoring instruments and bearing insulation ..................................................................................................... 46
6.5.1 Bearing temperatures ................................................................................................................................................... 46
6.5.2 Bearing condition monitoring by the shock-pulse method (SPM, only for anti-friction bearings) .................... 46
6.5.3 Bearing housing and shaft vibration ............................................................................................................................ 46
6.5.4 Bearing insulation........................................................................................................................................................ 48
6.6 Checking the cooling elements of heat exchangers ............................................................................................................ 48
6.6.1 Checking and replacing the sacrificial anodes on water coolers ................................................................................. 48
6.7 Maintenance plan for cage-induction motors ..................................................................................................................... 49
Chapter 7 Servicing and cleaning ................................................................................................................................................. 51
7.1 Servicing............................................................................................................................................................................. 51
7.1.1 Dismantling and reassembly........................................................................................................................................ 51
7.1.2 Service sleeve bearings ............................................................................................................................................... 51
7.1.3 Service of anti-friction bearings .................................................................................................................................. 52
7.1.4 Reconditioning work during servicing ........................................................................................................................ 52
7.2 Cleaning ............................................................................................................................................................................. 52
7.2.1 Mechanical dry cleaning.............................................................................................................................................. 52
7.2.2 Wet cleaning with cleaning agents .............................................................................................................................. 52
7.2.3 Cleaning the air-to-water cooler .................................................................................................................................. 53
7.3 Stocking of spare parts ....................................................................................................................................................... 55
Chapter 8 Dismantling and reassembly ........................................................................................................................................ 57
8.1 Safety instructions .............................................................................................................................................................. 57
8.2 Dismantling ........................................................................................................................................................................ 57
8.2.1 Coupling hub with a feather key ................................................................................................................................. 57
8.2.2 Coupling hub with a cylindrical shrink fit ................................................................................................................... 57
8.2.3 Coupling hub with a tapered shrink fit ........................................................................................................................ 59
8.2.4 Removing the ventilation unit from a horizontal motor .............................................................................................. 61
8.2.5 Weather protection units.............................................................................................................................................. 62
8.2.6 Removing the ventilation unit from a vertical motor .................................................................................................. 62
8.2.7 Weather protection unit ............................................................................................................................................... 64
8.2.8 Dismantling anti-friction bearings on horizontal motors ............................................................................................. 64
8.2.9 Dismantling anti-friction bearings from vertical motors ............................................................................................. 65
8.2.10 Dismantling sleeve bearings ...................................................................................................................................... 66
8.2.11 Space heater............................................................................................................................................................... 67
3BSM 008369, rev. G

Table of Contents
8.2.11.1 Rotor withdrawal .................................................................................................................................................... 68
8.3 Reassembly......................................................................................................................................................................... 69
8.3.1 Fitting the air guide rings ............................................................................................................................................ 69
8.3.2 Assembling anti-friction bearings ............................................................................................................................... 70
8.3.3 Assembling sleeve bearings ........................................................................................................................................ 72
8.4 Recommended tightening torque for bolts on the motor .................................................................................................... 74
Chapter 9 Trouble shooting .......................................................................................................................................................... 75
9.1 Operational faults on cage-induction motors ...................................................................................................................... 75
3BSM 008369, rev. G

Chapter 1 Introduction
Chapter 1 Introduction
• This installation and maintenance manual for the motor is a part of the main documentation for
the project.
• Actions shown in this manual are only to be performed by trained personnel authorized by the
user.
1.2 Operative range and intended application

Electric motors are components intended for application in high voltage industrial installations.
Due to the nature of their electrical and mechanical operating conditions, improper installation or
operation, as also insufficient maintenance, could introduce hazards which could lead to the most
severe bodily injury or damage to property. The technical data for the motor was determined with
due consideration to the standards and specifications agreed in the order. This data is shown on the
motor dimension drawing and in the test report. The motor may only be operated within the scope
of this data. In case of deviations the manufacturer must be contacted.
These instructions only consider those measures which must be observed when the motor is being
operated in its operative range and in its intended application. The applicable national, local and
plant regulations must also be taken into consideration.
1.3 Information on electromagnetic compatibility

The user must take the following precautionary measures during installation and operation in order
not to impair the electromagnetic compatibility.
The motor may only be connected to a power supply system which is properly earthed in
conformity with the applicable regulations.
Have technical modifications carried out by qualified personnel who, after completing the
modifications, can check that the electromagnetic compatibility has not been in adversely
influenced.
If it is necessary to replace possible anti-interference components, filters or screened cables, the
new parts must be identical to the originals.
1.4 Required qualifications for erection and operating personnel

Installation, operation, maintenance and repair work may only be carried out by mechanically and
electrically skilled personnel qualified and properly trained for this work. These persons must be
conversant with the motor, that is, they must have completely read and fully understand the
relevant chapters of these operating instructions.
3BSM 008369, rev. G 1-1

Chapter 2 Safety instructions
2.1 Safety
The machine is manufactured and intended for use only as prescribed by this manual.
Modification, alteration, or lack of maintenance procedures as described in the labeling,
may adversely affect the safety and efficacy of this device. The manufacturer is not
responsible for malfunctions that comprise safety as a result of alteration, use of non ABB
replacements parts, neglect or misuse.
Replacements parts may vary from those shown in this manual. Should you have questions on
those parts please contact ABB Automation Technologies AB.
The actual appearance of the machine may vary from the illustration in this manual.
Should pre-owned ABB equipment be purchased and reconditioned, the equipment should not
be used until testing and analysis demonstrate that the equipment meets the original or upgraded
specifications.
The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety
hazards. The recommended precautions and procedures of the manufacturers should be
followed.
2.2 Site conditions

This motor is to be used on a site with conditions according to ABB´s Technical Specification
“Site conditions and applicable standards” (included in binder “Users Manual”).
2.3 Prerequisites
The operator must:
• be proficient in the application of the machine and electricity.
• be thoroughly trained in the skills and have the knowledge required to operate this machine.
• be thoroughly familiar with the contents of this manual and other operator´s manuals that
deals with the machine and accessory devices that may be used with this machine.
• be fully qualified and trained in the operation of this machine and able to distinguish normal
from aberrant device behavior.
• never reset an alarm or trip until the reason for the alarm/trip has been located and necessary
correction has been made to make a safe restart of the machine.
• The motors are suitable for a wide range of mounting and operating conditions. These
variants greatly influence noise emission. With due consideration to all the factors involved,
noise levels for the work location can only be measured on the commissioned motor on site.
3BSM 008369, rev. G 2-2

2.4 Contraindications
The machine is not designed, sold or intended for any use except as indicated above.
Furthermore, it is not intended to be used outside of the machine specifications or limitations.
The machine must be in good working order.
3BSM 008369, rev. G 2-3

Chapter 3 Storage and transport
3.1 Inspection of delivery

The motor will be packed in a case or bolted to a wooden skid for transport. Unpacking
should be done carefully in order to avoid damage. The delivery should be checked against
the packing list for completeness.
The motor was checked in the factory and tested for faultless running.
NOTE: When the motor arrives at its destination a general check must be carried
out in order to determine possible transport damage as quickly as possible.
Any damage or deviations between delivery and packing list must be
entered in a report in cooperation with the responsible forwarder.
Should the motor have suffered damage during transport or installation, this must be
rectified before commissioning.
3.2 Oil lubricated bearings

Motors with oil lubricated bearings will be transported without oil filling.
NOTE: Anytime the motor is to be transported, the lubrication oil must first be
drained from the bearings, otherwise it could ingress through the seals to
the inside of the motor.
3.3 Rotor transport lock

In order to prevent vibration arising during transport from causing bearing damage, a rotor
transport lock is fitted which blocks the rotor axially.
3BSM 008369, rev. G 3-4

WARNING - Heavy lift

Whenever the motor is to be lifted, the lifting equipment must have adequate lifting
capacity. The weight of the motor is given on the rating plate. When two or more
motors are mounted on a common bedplate, this machine set may neither be lifted nor
transported as a single unit.
In case of special designs, contact ABB.
When a motor is equipped with a ventilation unit, under no circumstances may the
motor plus ventilation unit be lifted together using the lifting lugs on the ventilating
unit (see figure 3-1). When lifting the motor, always use all four lifting lugs provided
on the motor itself.
Figure 3-1 Lifting the motor
3.4 Turning a vertical motor to the horizontal position

As a general rule vertical motors of big size are generally transported in horizontal
position. Vertical transport is possible on request as option.
Vertical motors that are packed for transport in the horizontal position, they must never be
stored in the horizontal position. However, it is permitted to turn a vertical motor to the
horizontal position for short periods in special cases were this is necessary due to space
limitation during installation. In such a case the following procedure is to be followed:
1. The ventilation unit exchanger must be removed before beginning.
2. Should the access opening be too narrow, it may be necessary to remove the main
terminal box.
3. Fit the rotor locking device.
4. Before beginning, figure 3-2 to figure 3-7 should be studied and the necessary slings
and blocks etc. be made ready.
3BSM 008369, rev. G 3-5

5. The whole turning process must be carried out slowly and smoothly avoiding swinging,
sudden shifts in suspension, or shock forces, which could be detrimental to the motor
bearings.
6. During the turning process ensure that the slings do not come into contact with junction
boxes or any other accessories fitted.
7. Follow the instructions given under figure 3-2 to figure 3-7.
8. The motor can be turned from the horizontal back to the vertical by following the
instructions in the reverse sequence.
Raise motor with slings arranged at the

four top lifting lugs and using two crane
hooks. All slings with same tension.
Figure 3-2
Gradually relieve tension of

slings on one side so that the
motor is suspended at one
side only.
Figure 3-3
3BSM 008369, rev. G 3-6

Remove slack slings

from top lifting lugs and
relocate to two bottom
lugs.
See figure 3-5
Figure 3-4
Slings now located on top and bottom lugs.

Weight of motor still taken up by slings on
top lugs only.
Figure 3-5
3BSM 008369, rev. G 3-7

Gradually tension slings on

bottom lugs and raise crane
hook while simultaneously
lowering the crane hook
with the slings on the top
lugs
Figure 3-6
Bring the motor into the horizontal position

and rest onto suitable blocks positioned
under the corners of the motor frame.
Figure 3-7
3BSM 008369, rev. G 3-8

3.5 Storage of the motor
3.5.1 Short term storage of crated motor

Storage < 6 month
Measures to be taken by customer or other part.
• The machine should be left in the crate.
• ABB strongly suggests forecasting the crate storage in an adequate indoor location, it
shall also be placed on a vibration-free, flat and well-drained surface. If the crate is to be
stored outdoors, the crate must be covered with a tarpaulin on the top extending at least
1 meter out from the crate to avoid direct rain on the crate..
• The crate should be kept dry, protected from rain and moisture.
Before commissioning the following items should be carried out:
• Visual external inspection of bearings and entering shaft
• Check insulation resistance in accordance with section 4.7.1
3.5.2 Long term storage of crated motor

Storage > 6 month
Long-term storage must be notified before delivery, so that the machine can be prepared
and packed for the actual condition. If an unscheduled long-term storage is needed, please
contact ABB.
ABB strongly suggests forecasting the machine storage in an adequate indoor location, it
shall also be placed on a vibration-free, flat and well-drained surface.
1. Remove top and sides of the wooden crate.
2. Open the plastic protection to allow for a good ventilation.
3. If cooler top is delivered separate, the cooler top must be mounted immediately on the
machine.
4. If the machine is prepared for air ducts, don’t remove the temporary transport covers.
5. The machine should be protected from rain and moisture. If the machine is to be stored
outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out
from the crate to avoid direct rain on the machine. If the machine is stored in a harsh
environment measures should be taken to protect it against dust and dirt.
6. To avoid condensation in the machine, the heating elements in main machine and
exciter must be connected according to the circuit diagram, included in the binder
“Users Manual”.
7. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc.
and touch up if necessary.
8. Measures should be taken to ensure that the heaters work properly at all time.
3BSM 008369, rev. G 3-9

9. If sleeve bearings, corrosion preventive oil should be filled in the bearings once every
12 month. Rotation of the rotor is not required.
10. The axial transport-locking device must always be mounted during transportation of the
machine.
• Visual external inspection of bearings and entering shaft.
• Visual inspection of exciter.
• Visual inspection of rotor and stator windings.
• The corrosion preventive oil in the bearings must be drained before rotation.
• Check insulation resistance in accordance with section 4.7.1.
3.5.3 Short term storage of uncrated motor

Storage < 6 month
1. Open the plastic protection to allow for a good ventilation.
2. If cooler top is delivered separate, the cooler top must be mounted immediately on the
machine.
3. If the machine is prepared for air ducts, don’t remove the temporary transport covers.
4. The machine should be protected from rain and moisture. If the machine is to be stored
outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out
from the crate to avoid direct rain on the machine and be placed on at least 100 mm high
rigid supports, as to make sure that no water can enter the machine from below. If the
machine is stored in a harsh environment measures should be taken to protect it against
dust and dirt.
5. To avoid condensation in the machine, the heating elements in main machine and
exciter must be connected according to the circuit diagram, included in the binder
“Users Manual”.
6. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc.
and touch up if necessary.
7. Measures should be taken to ensure that the heaters work properly at all time.
8. The axial transport-locking device must always be mounted during transportation of the
machine
3BSM 008369, rev. G 3-10

3.5.4 Long term storage of uncrated motor

Storage > 6 month
Long-term storage must be notified before delivery, so that the machine can be prepared
and packed for the actual condition. If an unscheduled long-term storage is needed, please
contact ABB.
Measures to be taken accordance with section 3.5.3 ” Short term storage of machine, < 9
month” and in accordance to below:
• If sleeve bearings, corrosion preventive oil should be filled in the bearings once every
12 month. Rotation of the rotor is not required.
• Visual inspection of exciter.
• Visual inspection of rotor and stator windings.
• The corrosion preventive oil in the bearings must be drained before rotation.
3.5.5 Space heater

NOTE: The motor space heater must be energized during the motor storage period.
Take care to connect up with the correct supply voltage as shown on the motor connection
diagram.
3.5.6 Prevention of corrosion damage an air-water coolers

In order to avoid corrosion damage, care should be taken to ensure that the water quality
and possible inhibitors or sacrificial anodes etc. are conform with that or those agreed upon
in the order.
When a motor is delivered, the cooler will have been drained but may not be completely
dry.
Should commissioning not be planned within 6 months after delivery, or if ever the motor
must be shut down for such a long period of time for other reasons, then the cooler must be
dried out in order to prevent corrosion. This can be done by removing the covers of both
water chambers and blowing through with warm air.
3BSM 008369, rev. G 3-11

Chapter 4 Preparing for commissioning
4.1 Removing the rotor transport lock

4.1.1 Motors with anti-friction bearings
Unscrew the locking bolt

(tagged with a red label) at the
D-end bearing by 5 mm and
relock using jam nut.
Figure 4-1 Rotor lock on motors with anti-friction bearings
4.1.2 Motor with sleeve bearings

Dismantle the whole rotor locking gear, bar and
studs, from the D-end.
Figure 4-2 Rotor lock on motors with sleeve bearings
4.2 Mounting the coupling hub

Torque transmission between the motor and the driven equipment is achieved by a
coupling, mounted to the motor shaft and having either a feather key or a shrink fit. The
form of shaft extension is shown on the binding motor outline drawing and could be one of
the following:
• Cylindrical with a feather key
3BSM 008369, rev. G 4-12

• Cylindrical with a shrink fit (plain or stepped)
• Tapered with a shrink fit.
CAUTION - Risk of personal injury

Handle hot couplings with care to avoid burns!
4.2.1 Cylindrical-bore coupling hub with a feather key

In general, the instructions issued by the coupling manufacturer are applicable for mounting
and removing a coupling. The motor rotor will have been balanced with a half-key.
Therefore, coupling parts must have been balanced on a mandrel, also with half-keys in
their keyways.
1. Clean shaft extension and coupling hub, check hub bore and slot for damage.
2. Check diameters of hub bore and shaft extension against drawings.
3. Check lengths of shaft extension, coupling hub and key.
4. When the coupling hub is shorter than the shaft extension and a spacer ring is not to be
fitted, then the length of key protrusion must be halved in order to avoid unbalance (see
Fig. 4-3).
Figure 4-3 Coupling fitted without a spacer ring
5. Under no circumstances may mating surfaces be coated with agents containing

molybdenum sulphide (e.g. Molykote or similar). Light oiling of the shaft and the hub
bore is recommended.
6. Heat coupling hub to 110 °C. Refer to section “Shrink couplings” for heating up and
mounting procedures.
CAUTION - Component damage

In the case of vertical motors, the coupling must be secured against slipping off.
3BSM 008369, rev. G 4-13

4.2.2 Cylindrical-bore coupling hub with a shrink fit (plain or stepped

seat)
1. Clean shaft extension and coupling hub, blow out oil channels, check hub bore for
damage.
2. Have following tools ready:
– two threaded studs
– two large lead hammers
– protective gloves
– wirerope slings or belts.
3. Measure shaft and bore. Document interference.
4. In case of a gear coupling, position sealing ring on the shaft beyond the coupling seat.
5. Lightly oil shaft extension with hydraulic oil (e.g. type HL 68). Do not use Molykote!
6. Heat coupling according to the Fig. 4-4:
– Check temperature before fitting
– The coupling hub should always be mounted by a two-man team.
Figure 4-4 Shrink temperature of coupling hub as a function of diameter
∆T Required shrink temperature of coupling hub

A Oil bath
B Induction oven
C Measured interference
D Diameter of shaft extension
7. After cooling, stress relieve the hub by injecting oil at about 1000 bar so long until oil
appears from between the shaft and hub at both ends.
3BSM 008369, rev. G 4-14

NOTE: In the case of stepped shrink seats, it is essential to leave the middle hole
open, otherwise the shrink fit will loosen and the coupling will be pushed
towards the end of the shaft.
4.2.3 Taper-bore coupling hub with a shrink fit

1. Clean shaft extension and coupling hub, blow out oil channels, check hub bore for
damage.
2. Have following tools ready:
– two threaded studs
– two large lead hammers
– protective gloves
– wire rope slings or belts.
3. Slip cold coupling hub onto the shaft. Document axial position of the hub and remove
again.
4. In case of a gear coupling, position sealing ring on the shaft beyond the coupling seat.
5. Set temporary stop at the definitive axial location of the coupling hub according to data
given by the responsible party.
6. Lightly oil shaft extension with hydraulic oil (e.g. type HL 68). Do not use Molykote!
7. Heat coupling according to figure 4-4:
– Check temperature before fitting
– The coupling hub should always be mounted by a two-man team.
8. After cooling, fit shaft-end nut or other locking device, and tighten up. Stress relieve the
hub by injecting oil at about 1000 bar so long until oil appears from between the shaft
and hub at both ends.

Before injecting oil, the shaft-end nut, or retaining disc, must be fitted to prevent the
coupling hub from jumping off the shaft.
9. Check shaft-end nut or retaining disc, retighten if necessary.
4.3 Installing the motor

Normally, the motor is installed on soleplates or a bedplate, which, together with the anchor
bolts are later concreted into the foundation.
4.3.1 Prerequisites for installation

The environmental conditions must correlate with those agreed in the order, e.g.:
• Altitude of plant
• Ambient temperature
3BSM 008369, rev. G 4-15

• Humidity
• Cooling water:
– Inlet temperature
– Pressure
– Flow rate
– Quality.
• Lube oil:
– Inlet temperature
– Pressure
– Flow rate
– Viscosity.
For details see labels on the motor.
The cooling air must be free of dust, oil, aggressive gases particularly ammonia, sulphur,
chlorine and silicone.
The motor must be installed on a solid foundation, which guarantees for plan-parallelism of
the machined surfaces of the motor feet of at least 0.1 mm.
After installation (driving and driven equipment), the running quality of the motor must be
at least “acceptable” according to ISO 3945.
The structural design of the foundation is not included in ABB´s undertaking and the
customer or a third party is therefore responsible for this. Furthermore, the grouting
operation is normally also outside ABB´s undertaking and responsibility.
The installation should be planned as early as possible.
NOTE: Pay attention to the direction of the cooling air.
In the case of open-ventilated motors it must be ensured that the air inlet and outlet
openings are not obstructed by ducts, piping or other objects. Warm exhaust air must not be
drawn back into the motor.

Air inlet and outlet openings are to be covered during the installation phase in order
to prevent the ingress of foreign matter into the motor. It is absolutely essential that
these covers are removed again before commissioning.
3BSM 008369, rev. G 4-16

4.4 Foundation

The concreting in of the motor soleplates or bedplate must be done by personnel
qualified for this work. The construction management is responsible to ensure this
work is carried out properly.
4.4.1 Grouting
When the motor has been properly aligned, its base elements are attached to the foundation
by grouting. Use only non-shrinking concrete for grouting to ensure proper adhesion
between the base frame and grouting. Make sure that the grouting fills properly the whole
space around and under the base element. Do not use a vibrator in order to avoid any
disturbance in the alignment.
After the grouting has set (cured), adjust vertically to the final elevation by putting shims
between the base frame and the base element. Check also the other alignments of the motor
and adjust, if necessary.
Non-shrink grout is recommended for the best results. For shaping and grouting, the
manufacturers instructions to be followed.
4.4.2 Installation of motor with soleplates

Normally, the motor is installed on soleplates with anchor bolts, which are to be concreted
into the foundation. Proceed as follows:
1. Check the prepared concrete foundation against the outline drawing, correct if
necessary.
2. Fasten soleplates (with at least 3 mm of shims between the mating faces) to the bottom
of the motor feet by means of the holding-down bolts. Ensure the bolts are centrally
positioned in their holes to permit later correction. The shims must be clean and free of
burrs.
3. Mark the location of the pads on the foundation. Place the pads in position and adjust
the height with special mortar so there will be a clearance of about 15 mm between the
bottom of the soleplates and the foundation. Align using a spirit level. Maintain the
specified setting time for the special mortar.
4. Suspend the motor on the crane and hang the anchor bolts centrally in their holes in the
sole plates. Screw the levelling bolts in until the bolt heads protrude about 10 mm below
the bottom edge of the soleplates. Position the slide plates onto the pads underneath the
bolt heads. Rest motor down.
5. Align motor, or driven equipment, to an accuracy of approx. 0.2 mm.
6. Grout in anchor bolts up to the level of the pads and permit the grouting to set.
7. Finish grouting foundation in conformity with the outline drawing or foundation plan.
Vibrate grouting beneath the soleplates and ensure there are no cavities.
8. The final tightening of the anchor bolts are to be done after the alignment. See section
4.5.4
3BSM 008369, rev. G 4-17

4.5 Aligning to driven equipment

NOTE: Careful alignment of the motor to the definitive installed driven equipment
is an indispensable prerequisite for smooth running.
4.5.1 Influence of the axial position of the rotor on motor alignment

4.5.1.1 Motors without a guide bearing (sleeve bearing designs)
The rotor of a motor with sleeve bearings, B or K shells, must be guided by the coupling of
the driven machine in such a way, that under no circumstances can a shaft shoulder come
into contact with an end face of a bearing shell.
B Shells at the D-end
The deviation between the magnetic and mechanical centers is given on the label figure 4-5
beside the shaft position indicator.
Figure 4-5 Shaft position label
As a general rule the shaft should be positioned in its mechanical centre. However, in order
to keep the axial force acting on the guide bearing of the driven equipment low, a shaft
displacement towards the magnetic centre is permitted so long that the clearance in the
coupling and thermal expansion do not result in contact between the shaft shoulder and the
bearing shell.
K-Shells with zero bearing play at the D-end
The axial position of a sleeve bearing with a K-shell is set in the factory, by inserting shims
or machining the seating face of the bearing endshield, so that the magnetic and mechanical
centers correlate.
The uncoupled motor can be operated for test runs in this condition. In operation, the driven
equipment must guide the rotor by way of a rigid coupling. The guide bearing on the driven
equipment must have zero clearance.
4.5.2 Motors with guide bearings (anti-friction or special sleeve bearing

design)
Motors with anti-friction bearings or A-shell type sleeve bearings can accept axial force
(refer to outline drawing for permissible values).
3BSM 008369, rev. G 4-18

Consequently, the driven machine must not provide for axial guidance. During alignment
the specified clearance between the coupling halves is to be ensured.
In the case of motors with anti-friction bearings, the axial clearance between the coupling
halves must be able to absorb the thermal expansion of the motor shaft.
4.5.3 Increase in shaft height due to thermal expansion

When assessing the vertical mismatch, the change in shaft height due to thermal expansion
must be taken into consideration.
Formula for growth in shaft height ∆h:
∆ h = Shaft height x Temperature rise x Factor
For the motor, a temperature rise of 20 and 30 K must be reckoned with.

For the driven equipment, the data from the manufacturer is applicable. When no data is
available, it will be assumed as being zero.
Permissible angular mismatch
Rigid coupling ∆ a= ±0.02 mm

Curved-tooth coupling ∆ a= ±0.05 mm
Flexible coupling ∆ a= ±0.1 mm
Figure 4-6 Angular mismatch
Permissible radial mismatch
Rigid coupling ∆ r= ±0.02 mm

Curved-tooth coupling ∆ r= ±0.05 mm
Flexible coupling ∆ r= ±0.1 mm
3BSM 008369, rev. G 4-19

Figure 4-7 Radial mismatch
4.5.4 Alignment procedure

1. Motors with sleeve bearings: Before the rotor may be turned, the bearings must be
lubricated with 0.1 – 0.2 l of oil.
Measure run-out at the largest diameter of the coupling hub. The run-out on the shaft
extension was measured in the factory and verified to be conform with the following tables:
Diameter of shaft extension Run-out tolerance of shaft

extension (=total deflection)
[mm] [µm]
> 30 - 50 25
> 50 - 80 30
> 80 - 120 35
> 120 - 180 40
> 180 - 250 45
> 250 - 315 50
> 315 - 400 55
The run-out on the coupling hub may not be much greater than these values. Document
measured values.

The motor is very heavy.
2. Measure angular mismatch ∆a and document result.

– Equalize vertical gap by inserting shims under the corresponding motor feet.
– Correct horizontal gap by moving motor laterally.
3. Measure radial mismatch ∆r and document result.
– Equalize vertical mismatch by inserting shims under all four motor feet. (Consider
change in shaft height due to thermal expansion).
3BSM 008369, rev. G 4-20

– Correct horizontal mismatch by moving motor laterally.
4. Repeat steps 3 and 4 until the permissible values have been attained.
4.5.5 Tightening torque for the anchor bolts
Motor type Bolt diameter [mm] Tightening torque [Nm]

AMI 710 M42 800
AMI 800 - AMI 900 M56 1900
AMI 1000 M64 2800
4.5.6 Alignment report

Enter the values for the aligned motor into the alignment report.
Figure 4-8 Alignment report
3BSM 008369, rev. G 4-21

4.5.7 Additional information for vertical motors

4.5.7.1 General
Radial mismatch (∆ r)
Vertical motors have a spigot seating on the mounting flange as standard design. Therefore,
radial alignment is not necessary, but a check is advisable.
Angular mismatch (∆ a)
The engine flange surface should be checked for perpendicular alignment against the shaft
end.
Table: Allowed values
Any correction required to match up with the counter-flange, for instance angular
misalignment, can be done by inserting shims between the flanges covering the greatest
area of flange face as possible. Presence of threaded holes on motor flange it’s optional for
some bigger and heavy motors, their scope is to lift the motor during the alignment
procedure and to make more easy shims positioning. These holes don’t have to be used for
leveling screws.
4.5.7.2 Vertical motors with sleeve bearings
To enable the rotor to be turned, the N-end thrust bearing must be relieved of load. This
requires that the rotor weight be taken up by suitable lifting equipment.
The radial clearance of the guide bearing at the N-end must be set as small as possible.
4.5.8 Bearings
4.5.9 Anti-friction bearings
The motor bearings will have been packed with lithium-soap grease in the factory.

Storing the motor over a period of several months can lead to oil leakage due to
separation from the bearing grease. In such a case, the outer bearing cover must be
dismantled to remove the grease with the oil residue.
Fresh grease must be injected, with the motor running, directly after starting up.
4.5.10 Sleeve bearings

Motors with sleeve bearings are delivered without oil in the bearings. When filling with oil,
the correct filling level is the middle of the sight glass. A higher level is not recommended
as oil could escape at the seals during operation.
In the case of bearings without a separate lube oil supply system, lubrication is provided by
the oil rings.
During longer periods of motor standstill, the weight of the rotor will press out the oil film
from between the bearing shells and the journals. The bearings will be dry!
Therefore, prior to the first commissioning, or before starting up after a longer period of
standstill, 0.1 to 0.2 l of oil must be poured over the bearings.
3BSM 008369, rev. G 4-22

4.5.10.1 Laying the oil pipes

NOTE: Only properly cleaned pipes are to be used for the lube oil lines.
In order to achieve stress-free connections, flexible compensating elements are to be
included in the field piping just before the connection flanges on the motor bearings. The
piping must be rigidly supported on the field side of the compensator.
The oil return lines must have a continuous downward gradient of at least 5% from the
connections on the motor bearings to the oil tank. Return lines are always to be kept as
short as possible. The free pipe section must never be less than that at the bearing outlet
points. Pipe bends should be avoided as far as possible. In order to avoid the danger of oil
build-up or overpressure in the bearings, syphons and bridge sections are forbidden (see
figure 4-9).
Observe information given on outline drawing!
The speed of the runback flow of the lubricant (referred to the pipe cross section) shall not
exceed 0.17m/s. Thus, only 70% of the cross section is filled under the most unfavorable
operation conditions, so that any oil mist present can be transported to the oil reservoir
along with the returning oil.
Branch connections are to be arranged in the flow direction.
The pipe sections must be large enough to ensure the following oil flow velocities:
• Oil supply (full pipe section), < 1.5 m/s
• Oil return lines (full pipe section), < 0.17 m/s.
Vertical drops in the line > 1 m are to be avoided in order to prevent the formation of oil
foam.
In the case of bearing seals with sealing air, suitable venting of the bearing housing must be
provided for. This can be done via the oil return pipe or by means of sufficiently sized vent
filters, which will prevent the escape of oil vapor.
4.5.10.2 Layout of oil supply system
Figure 4-9 Layout of oil supply system
1 Oil return line

2 Vent
3 Vent holes
3BSM 008369, rev. G 4-23

The oil tank must have a condensed water separator and, if required by the ambient
temperature, also a heater. Suitable inside protection against corrosion will enhance the
prevention of oil contamination. Do not fit any equipment such as filters or similar in the
return line as these will hinder the flow.
The oil return line should ideally enter the oil tank above the oil level (A). However,
should it submerge into the oil, then vent holes must be provided above the oil level to
allow oil-borne air to escape from the pipe (B).
The oil level in the tank must never, under any operating condition, be allowed to fall
below the location of the oil suction line.
Filters must block any particles larger than 15 – 25 [µm]. When necessary, for process
related reasons, switchable double filters must be used which can be cleaned during
operation, i.e. without switching off the oil supply.
Oil reservoirs
The capacity of oil reservoirs should be approximately eight times the quantity delivered
per minute. The lubricant content in small, very confined systems should not be less than
five times this amount. Small plants should have a settling chamber permitting the air
entrained in the oil to escape.
If the return pipes which lead into the oil reservoir dip into the lubricant, vent holes shall be
provided above the oil level (permitting the air entrained in the lubricant to escape).
The suction pipe of the pump shall be adequately vented and provided with an oil level
indicator. It shall be adequately distant from the bottom of the reservoir so as to prevent so
as to prevent any deposits being sucked up. The oil reservoir shall have a sloping base for
the oil to run off.

ABB will not accept any responsibility for oil leakage at the bearings when the above
mentioned conditions have not been fulfilled.
4.5.10.3 Monitoring of the oil supply system

The oil supply to each bearing should be monitored by a flow indicator. If the oil flow falls
below 70% of the nominal value the flow indicators should shut the motor down.
4.5.11 Bearing temperature monitoring

If the motor bearings are equipped with temperature monitors, the alarm and shutdown
values are to be set according to the connection diagram.
4.5.12 Bearing insulation
When both bearings are insulated, it should be ensured that the short-circuiting cable at the
D end is connected (see outline drawing).
In the case of anti-friction bearings ensure that all auxiliary connections to the bearings are
insulated (only use original parts from the motor manufacturer!)
3BSM 008369, rev. G 4-24

NOTE: The jumper cable may only be connected to the non-short-circuiting
position for measuring purposes.
4.6 Mounting the ventilation unit
4.6.1 AMI 710 motors

Motors of the series AMI will normally be delivered with the ventilation unit already
mounted.
See section 8.2.4 on page 60 for dismantling and reassemble instructions.
4.6.2 AMI 800…1000 motors

For AMI motors the ventilation unit will be removed for transport. See section 8.2.4 on
page 60 for dismantling and reassemble instructions.
4.6.3 Air-to-water cooler

Prior to commissioning, we recommend that the cooler be tested at the specified operating
pressure to determine possible transport damage and to check for leakage. Tighten up any
loose screws in the covers.
After the leakage test the cooler can be connected up and vented. This is done by removing
the vent plug from the connection-side water chamber and then slowly filling the cooler
until bubble-free water is expelled from the vent hole. Screw the vent plug back into
position. The cooler can then be put into operation. Only after this may the motor be started
up.
4.7 Electrical connections

Work on the terminal box is to be carried out with care. It could contain sensitive
equipment such as current transformers etc
4.7.1 Insulation resistance

The insulation resistance of the winding is an indication of the condition of the insulation.
The insulation resistance must be measured and documented before the motor is switched
on for the first time (before connecting the cables).
4.7.1.1 Minimum acceptable values of insulation resistance
The minimum acceptable values of insulation resistance are:
3BSM 008369, rev. G 4-25

a) For the stator winding:
R1min (20°C) ≥ 3x(1+Un) in MΩ

where Un = rated voltage of the motor in kV (line-to-line)
b) For a wound rotor winding:
R1min (20°C) ≥ 1xUn in MΩ;

where Un = rated voltage of the rotor kV (line-to-line)
c) For the resistance temperature detectors:
≥ 2000 MΩ
It is usual to apply a DC test voltage of 1000 to 5000 V.

The insulation resistance varies with the winding temperature. A temperature rise of 12 K
halves the value of the insulation resistance. When taking the measurement, in addition to
the insulation resistance, the test voltage, the winding temperature and the time / date are
also to be documented.
Figure 4-10 Minimum values of insulation resistance for stator windings

The insulation resistance is taken 1 min. after applying the test voltage. It is recommended
to extend the measurement and also take the 10 min. reading to determine the polarization
index (R10 min. / R1 min.). This data is very helpful at later diagnoses.
3BSM 008369, rev. G 4-26

Should the minimum permissible value not be obtained, then the winding must first be
cleaned if this is necessary, and afterwards dried out.
Winding with Y-connection
DC Voltage supply (Megger)
Figure 4-11 Measuring the whole winding
Example: Measuring phase W (all phases are to be

measured)
DC Voltage supply (Megger)
Figure 4-12 Phase-by-phase measurement
4.7.2 Cable penetration plate on the terminal box
Figure 4-13 Terminal box with cable penetration plate

The terminal box is fitted with a separate cable penetration plate, which has to be adapted to
the actual requirements of the plant (number and size of cable penetration). To remove the
cable penetration plate the terminal box lid (3) must first be lifted off, to do this remove the
earth strap (1) and bolts (2).
3BSM 008369, rev. G 4-27


Remove lid with care. Danger of bodily injury if lid is dropped. The lid is not normally
hinged.
Unscrew bolts (4) and remove the penetration plate (5).
4.7.3 Terminals, preparing for connection

The terminals may not be subjected to any forces from the weight of the incoming cables.
Strain relief must be arranged external to the terminal box to prevent such forces acting on
the terminals or the terminal box itself.
After removing screws (4) the penetration plate (5) may be removed.
NOTE: All electrical screwed connections accessible are to be checked and if
necessary tightened up as specified. Always use a torque spanner.
4.7.4 Cleaning the terminals

Any dirt, oil or grease on the terminals is to be cleaned off using mineral spirits or another
suitable solvent. Surface treated bar terminals (e.g. tinned, nickel or silver plated) may not
be cleaned mechanically.
4.7.5 Measures to prevent oxidation and corrosion

The contact surfaces of electrical connections are to be treated, depending on the
environmental conditions, as indicated in the table below:
Environment Measures
Indoors, dry environment None
Outdoors, humid or aggressive Apply a light coating of vaseline using clean cloths
environment
Table 4-1. Measures to prevent oxidation and corrosion

Should another inhibitor be used, the manufacturer’s instructions are to be followed.
4.7.6 Stud terminals

Stud terminals are designed for a max. current of 400 A.
The nominal torque for tightening the nuts is given in Tab. 4-2:
3BSM 008369, rev. G 4-28

Size of thread on stud Tightening torque [Nm]

M16 30 - 40
Table 4-2. Tightening torque for stud terminals
Figure 4-14 Stud terminal for max. 400 A / 11 kV (max. 2 cables per phase)
Figure 4-15 Stud terminal Ex e for max. 400 A / 11 kV (max. 1 cable per phase)
4.7.7 Bar terminals
Size of thread on stud Tightening torque [Nm]

M12 40
M16 80
Table 4-3. Tightening torque for dry or lightly greased bolts of property class 8.8.
Figure 4-16 Bar terminal for max. 1600 A / 4.2 kV (max. 4 cables per phase)
3BSM 008369, rev. G 4-29

Figure 4-17 Bar terminal for max. 2000 A / 11 kV (max. 4 cables per Phase)
4.7.8 Fully insulated connectors
Figure 4-18 Fully insulated connector for max. 400 A / 13.8 kV per connection
1 Winding lead with connector fitted

2 Connector for fitting to cable on site (supplied lose)
3 Shrink sleeve, shrunk into place on site after bolting up
4 Strain relief clamp
A Connectors as delivered
B Connectors ready for operation
Connecting up on site
1. Drill out hole in connector (2) for accepting the cable, according to Tab. 4-4
3BSM 008369, rev. G 4-30

2. Soft-solder field-side cable into the supplied connector (2)
3. Slip shrink sleeve (3) over the cable. Fit and bolt the two connectors together.
4. Move shrink sleeve (3) to its final position over the connection and shrink on with warm
air of approx. 140 °C
5. Secure cable in the strain relief clamp (4).
2
Cable section in mm 70 95 120 150 185 240 300 400
Hole diameter D in mm 11.3 13.5 15.2 16.7 18.4 21.1 23.7 27.0
Table 4-4.
4.7.9 Fastening the bolts for the terminal connectors
Size of thread Tightening torque[Nm]

M8 18 - 25
Table 4-5. Tightening torque for bolts for the terminal connectors
4.7.10 Earthing
WARNING - The motor housing must be earthed

The motor housing must be connected to the plant earthing system (for connection
points on the motor see outline drawing). All potential equalizing cables between the
motor housing and the parts fitted to it must be connected up. Any special (local)
requirements are also to be observed!
4.7.11 Earth brushes

NOTE: The brush tracks on the shaft must be bare and clean. The brushes must not
come into contact with solvents.
3BSM 008369, rev. G 4-31

Chapter 5 Commissioning
5.1 Sleeve bearings with forced oil lubrication

The bearings are connected to a separate oil supply system which must be in operation
before the motor is started up until after it is has been switched off and come to rest.
As a general rule the bearing oil inlet temperature must be between 20 °C and 50 °C.
5.2 Direction of rotation

Phase connections: Terminal designations according to IEC Recommendation 34-8:
For clockwise rotation when facing onto the drive end of the motor (figure 5-1):
L1-U1 / L2-V1 / L3-W1
For anti-clockwise rotation when facing onto the drive end of the motor (figure 5-2):
L1-W1 / L2-V1 / L3-U1
A corresponding label will be fastened to the inside of the terminal box. The motor outline
drawing will also show the planned direction of rotation.
Figure 5-1 Clockwise rotation Figure 5-2 Anti-clockwise rotation
3BSM 008369, rev. G 5-32

5.3 Air to water coolers
Figure 5-3 Figures of coolers
5.3.1 General
The coolers are provided with compensators to prevent the transfer of vibration between the
cooler and the piping system.
The agreed quality, quantity and inlet temperature of the cooling water must be maintained.
Larger foreign bodies in the cooling water must be filtered out to prevent ingress into the
cooler.
The water inlet flange is the bottom one of the two. This ensures that the cooler remains full
of water even after the system has been shut down. The cooling water flow rate should be
regulated so that the required cooling capacity is attained at full load.
The cooling capacity can be checked directly by measuring the cold air temperature (cold
air entering into the motor), generally 40 °C, or indirectly via the stator winding
temperature. The set values for the sensors are given on the connection diagram.
5.3.2 Prevention of corrosion damage on air-to-water coolers

In order to avoid corrosion damage, care should be taken to ensure that the water quality
and possible inhibitors or sacrificial anodes etc. are conform with that or those agreed upon
in the order.
5.4 Starting frequency

During the starting phase, the motor will be subjected to thermal and mechanical stressing.
Therefore, in order to avoid unnecessary damage the starting frequency agreed upon in the
order should be adhered to. Any changes must be explicitly approved by the manufacturer
3BSM 008369, rev. G 5-33

5.5 Starting, operation, shut-down

NOTE: Short power interruptions cause current and torque fluctuations.
Should the supply voltage at reclosure be in phase-opposition to the residual voltage, this
would mean high stressing for the gearbox and the driven equipment. This can be avoided
by providing suitable protection, otherwise the whole shaft train must be suitably
dimensioned for the stresses involved.
Step Activity Remarks
1 Switch off space heater When one is fitted
2 Switch on separate lube-oil system for sleeve For forced oil lubrication
bearings
3 Turn on water supply for air-to-water cooler When one is fitted
4 Switch on fan-motor for ventilation unit When one is fitted
5 Close stator circuit braker. Motor starts

(When the motor is to be started up via a
starting transformer, then this must be
interlocked with the circuit-breaker, so the
motor can not be switched on when the
starting transformer is in its operating
position).
6 Operation
7 Open stator circuit breaker Motor runs down
8 Set starting transformer to starting position When provided for starting
9 Switch-off fan-motor on ventilation unit When one is fitted
10 Turn off water supply to air-water cooler When one is fitted
11 Turn off lube-oil supply to sleeve bearings For forced oil lubrication
12 Switch on space heater When one is fitted
5.6 Continuous monitoring during operation

The motor will be monitored during operation by the field monitoring system. For further
inspections see Chapter 6 Inspection and maintenance.
In case of anything unusual of arising, the motor should be switched off and the cause
investigated in conformity with the trouble-shooting procedures given in Chapter 9 Trouble
shooting.
3BSM 008369, rev. G 5-34

5.7 Check list

The following checklist and protocols should be completed during commissioning and
returned to ABB together with the commissioning report after completed commissioning.
3BSM 008369, rev. G 5-35

5.7.1 Page 1
Customer: Name and company of responsible commissioning engineer:
Site name:
Serial number:
Order number: Date:
 First run up, date......................................................................

 Direction of rotation: clockwise (Seen from D-end)
 Direction of rotation: counterclockwise (Seen from D-end)
 No abnormal noise
Comments .....................................................................................................................................................
........................................................................................................................................................................
 Second run up (to full speed), date ........................................

Starting time .......................................... s
Retardation time .................................... min
Comments .....................................................................................................................................................
........................................................................................................................................................................
 Running unconnected, date ....................................................

Starting time .......................................... s
Retardation time .................................... min
Comments .....................................................................................................................................................
........................................................................................................................................................................
 Running of connected machine, date .....................................

Starting time .......................................... s
Retardation time ..................................... min
Comments .....................................................................................................................................................
........................................................................................................................................................................
Motor data
Output: kVA Power factor: Voltage: V

Frequency: Hz Speed: r/min Current: A
Excitation: V A Oil quality:
3BSM 008369, rev. G 5-36

5.7.2 Page 2
Site name:
Serial number:
Order number: Date:
Time Bearing temp. Inlet Oil Vibr. Winding Cooling Comments

(°C) (mm/s, µm) temp. (°C) air/water Vibrations, noise, etc.
D-side N-side (°C) (l/s) D- N- max min m3/h °C
side side
3BSM 008369, rev. G 5-37

5.7.3 Page 3
Site name:
Serial number:
Order number: Date:
Time Stator Load Comments

(MW) Vibrations, noise, etc.
(A) (cosϕ) (V)
3BSM 008369, rev. G 5-38

Chapter 6 Inspection and maintenance
6.1 General
Thorough and conscientious maintenance is the best foundation for high availability of the
plant.
WARNING - High voltage

This work involves the main circuits of the motor normally connected to the high
voltage supply net. Before you start to work:
1. Make sure the motor is disconnected from the high voltage net and the circuit breaker is
locked in the open position so it not accidentally (or otherwise) can be closed during
measurements.
2. Note also that capacitors can contain dangerous voltages, so be sure to ground all details
before you touch them.
The maintenance plans presented in the following are based on ABB’s many years of
experience. The given time intervals are based on continuous trouble-free operation and are
offered as reference values.
It is recommended to draw up a maintenance plan tailored for the plant in question and to
include deadlines.
The following influential factors must be taken into consideration:
• Actual periods of operation
• Environmental conditions (e.g. dirt deposits)
• Loading, switching frequency.
Inspections given in the maintenance plans Table 6-4. should ideally be carried out by the
same personnel to ensure that any deviations from the normal conditions will be recognized
quickly.
Regular plant inspection and recording of important operating quantities and events such
as:
• Oil levels
• Earth fault monitoring
• Temperatures
• Noise, vibration, discoloring, odors.
afford valuable information when seeking the cause of a fault.
It is essential that the cause of a fault (shutdown) is clarified before switching on again.
Also in the case of abnormal operating conditions such as an alarm, a short-circuit, an
overload etc., the cause should be determined and any corrective action necessary, carried
out without delay.
The actual maintenance work which is mostly carried out during planned periods of
shutdown can be divided up as follows:
3BSM 008369, rev. G 6-39

• Cleaning
• Replacing consumables
• Replacing wear and tear parts
• Elimination of recognized deficiencies.
6.2 Instrumentation
The set values for the monitoring instruments will normally have been agreed upon at the
time of the order (see connection diagram).
When this is not the case, then the values given in these instructions shall apply. The values
are to be set during commissioning and may not be changed without first consulting the
manufacturer.
6.3 Maintenance on sleeve bearings
6.3.1 Oil change

Oil qualities acc. to ABB´s drawing “Outline drawing”, included in the binder “Users
Manual”.
The oil is to be changed:
• After a specified fixed interval of time (see lube label).
Rule of thumb:,
– Oil-ring lubricated bearings, 8'000 hours
– Forced lubricated bearings, 20'000 hours
– Shorter intervals are necessary for frequent starting, high oil temperatures or
excessive oil contamination.
• Refer to the lube label for the oil change interval, viscosity, oil flow rate and quality
• Top up or change the oil only when the motor is at standstill.
Max. oil level during operation

Filling level
Min. oil level during operation
Figure 6-1 Oil level inspection at the sight glass
6.3.2 Oil ring

Correct functioning of the oil ring (i.e. uniform running and oil transport) can be checked at
the top oil sight glass.
3BSM 008369, rev. G 6-40

6.3.3 Oil leakage

In case of oil leakage, replacement seals should be made ready for fitting during the next
service.
6.3.4 Emergency running for motors with forced oil lubrication

Should the oil supply fail, the motor must be switched off immediately. All sleeve bearings
are equipped with an oil ring which permits the motor to run down safely. If the process
requires an emergency running time at rated speed, the manufacturer must be consulted.
6.3.5 Maintenance on a separate oil supply system

(Lube oil or jacking oil supply)
If the motor manufacturer’s scope of supply includes a separate oil supply system to
provide the motor with lube or jacking oil, then instructions for maintenance will be given
in a separate document.
6.3.6 Maintenance plan for sleeve bearings
Every two years
During service
Machine part Maintenance or inspection work
Quarterly
Annually
Monthly
Weekly
Sleeve bearings Check physical, chemical and Before first commissioning
mechanical properties of the lube oil.
If the recommended lube oil change
interval is to be increased, a regular
check on the oil is to be carried out at
least every 4 months.
Check condition of bearing oil
(discoloring, contamination) at sight

glass. Filter if necessary. Determine
cause and eliminate.
Read off temperatures at the provided

measuring points and record.
Measure machine vibration, by means 
of provided sensors or a portable
measuring instrument, and record.
Measuring points:
middle of bearing housing, horizontal
and vertical (see section 6.5.3 on page
45).
Check lube rings at top sight glasses for

uniform running and oil transport.
Check bearing seals for oil leakage and

clean off any dirt deposits.
3BSM 008369, rev. G 6-41

Every two years
During service
Quarterly
Annually
Monthly
Weekly
Sleeve bearings, Check bearing shell insulation (see

both insulated section 6.5.4 on page 47).
Change oil. 
Sleeve bearings Change wear and tear parts. If bearing After evaluation of the above
and separate oil parts are changed, change the oil after periodic checks and inspections
supply system for running for 3 hours to remove any metal
lube or jacking oil particles rubbed off during running in.
Check for rust. (see Chapter 7

Servicing and cleaning).
Clean filter on oil supply system. After indication from filter monitor
(optical/electrical)
Separate oil supply Check:
system for lube or - Oil supply system for proper
jacking oil functioning 
- Oil level and for loss oil on the
system incl. piping and fittings.
Check water piping for leakage. 

Oil-to-water cooler
(when provided) Check water pipes for deposits and

possible signs of corrosion.
Table 6-1. Maintenance plan on sleeve bearings
6.4 Maintenance on anti-friction bearings

All data such as bearing nos., grease quantities and regreasing intervals are given on the
lube labels fastened to the motor.
6.4.1 Validity of the regreasing intervals, conversion

• The regreasing intervals are given for the longest possible maintenance interval.
Regreasing may be carried out more frequently. In such a case the regreasing quantities
are to be reduced proportionally.
• When the motor is to be connected to a central lubrication system with continuous
regreasing, the grease quantities are to be converted proportionally.
• When the place of operation is very dirty the regreasing intervals are to be shortened.
• When the bearing temperature is higher than 70 °C, the regreasing interval must be
halved for every excessive 15K.
3BSM 008369, rev. G 6-42

6.4.2 Regreasing procedure

Regreasing may only be carried when the motor is running. Excessive grease will be guided
to the used grease container by the grease regulator thus preventing overgreasing of the
bearing. A temporary increase in bearing temperature may be observed during the
regreasing procedure.
This increase can be avoided by injecting the grease into the bearing slowly. The used
grease container should be checked at each regreasing and emptied when necessary.
6.4.3 Choice of lubricating grease

The bearings will have been packed with lithium-soap grease in the factory.
Only greases of the same soap basis may be used for regreasing. Should it be necessary to
change the grease quality (e.g. because of lower ambient temperatures) the bearings must
be dismantled and washed out, refer to separate section on service.
In case of doubt we recommend seeking advice from the grease manufacturer.
Lubricants
When regreasing, use only special grease with the following properties:
• good quality grease with lithium complex soap and with mineral- or PAO-oil.
• base oil viscosity 100-150 cST at 40oC.
• consistency NLGI grade 2 or 3
• temperature range -30oC - + 120oC, continuously
Grease with the correct properties is available from all the major lubricant manufacturers.
Recommended standard lubricants.

Manufacturer Quality Thickener Base oil Tempera- Kinematic Kinematic Consis-
ture range viscosity of viscosity of tency
[°C] base oil base oil [NLGI
[mm2/s, cSt [mm2/s, cSt scale]
at 40°C] at 100°C]
ESSO UNIREX N2 Li Mineral -30 to +165 115 12.2 2
ESSO UNIREX N3 Li Mineral -30 to +165 115 12.2 3
ESSO BEACON 2 Li Mineral -40 to +120 100 9.5 2
SKF LGMT 2 Li Mineral -30 to +120 92 9.6 2
MOBIL OIL Mobilux 2 Li Mineral -30 to +120 100 10.0 2
SHELL Alvania Grease G2 Li/Ca Mineral -25 to +140 100 11 2
SHELL Alvania Grease G3 Li/Ca Mineral -20 to +150 100 11 2
TEBOIL Multi-Purpose Li Mineral -30 to +110 110 10.5 2
Grease
BP Energrease LS 2 Li Mineral -30 to +110 92 9.5 2
STATOIL Uniway Li 42 Li Mineral -30 to +120 100 12.0 2
3BSM 008369, rev. G 6-43

Recommended high temperature greases.
Manufacturer Quality Thickener Base oil Tempera- Kinematic Kinematic Consis-
ture range viscosity of viscosity of tency
[°C] base oil base oil [NLGI
[mm2/s, cSt [mm2/s, cSt scale]
at 40°C] at 100°C]
ESSO UNIREX N3 Li-comp. Mineral -30 to +165 115 12.2 3
SKF LGHT 3 Li-comp. Mineral -30 to +150 110 13.0 3
MOBIL OIL Mobiltemp SHC 100 Inorga. Synthetic -40 to +200 100 12.5 2
SHELL Syntix 100 Li-comp. Synthetic -40 to +150 100 21.0 2
TEBOIL Syntex Grease Li-comp. Synthetic -40 to +140 150 20.0 2
STATOIL Uniway LiX 42 PA Li-comp. Polyalfa -35 to +150 100 18.0 2
CHEVRON SRI 2 Polyr. Mineral -30 to +150 115 14.0 2
NESTE Rasva 606 Li-comp. Synthetic -40 to +150 150 20.0 2
MOBIL OIL Mobilgrease 28 Clay Synthetic -54 to +177 30 5.7 2
SHELL AeroShell Grease 22 Microgel Synthetic -65 to +204 30.5 5.8 2
SKF LGLT 2 Lithium Synthetic -50 to +110 18 4.5 2
1) NLGI Grade = Grease Consistency Classification according to “NATIONAL

LUBRICATING GREASE INSTITUTE” (USA)
NLGI Grade 2 is normally used for 4-6 poles horizontal machines
NLGI Grade 3 is normally used for 8 and more poles horizontal machines and for vertical
machines.
REMARK : motors are lubricated in the factory with the following greases
2 pole horizontal motors : ESSO UNIREX N3
≥ 4 poles horizontal motors : MOBILUX EP2
vertical machines : ESSO UNIREX N3
motor for ambient temperature below –20°C: MOBILGREASE 28 – AEROSHELL GREASE 22
WARNING: some greases are not miscible with others.

In case of doubt, ask for compatibility to grease manufacturer.
For lubrication instructions please refer to maintenance for rolling bearings:
- Sheet N° DMPB 6245 for AMD machines;
- Sheet N° 1/7.15.12.04 for AMB - AMC – AMI - AML - AMLi machines.
3BSM 008369, rev. G 6-44

6.4.4 Maintenance plan for anti-friction bearings on horizontal and

vertical motors
Every two years
During service
Quarterly
Annually
Monthly
Weekly
Anti-friction Measure temperature at the provided

bearings measuring points and record.
Measure motor vibration using the
installed instruments or a portable
meter. Measuring points/directions: On

horizontal motors, on bearing housing
and vertical. On vertical motors, on
bearing endshield in two directions.
Take measurements of the bearing
condition by the shock-pulse method
(SPM) and record. Always do this at

the same speed and operating
conditions. (See section 6.5.2 on page
45).
Regrease the bearings. (Only when
the motor is running, see lube labels
on the motor).
Check bearing seals for loss of grease

and clean off any dirt deposits.
Replace wear and tear parts (bearings,

sliding or rubbing seals etc.).
Wash out bearing covers, labyrinth

seals etc. and renew grease filling.
Check for rust. (See Chapter 7

Servicing and cleaning).
Anti-friction Check insulation on bearing
bearings, when endshields. (See section 6.5.4 on page 
both insulated. 47).
Table 6-2. Maintenance plan for anti-friction bearings
Observe regreasing intervals given on the general arrangement drawing. In case of bearing
temperatures >70 °C and/or very dusty environments, the intervals for regreasing the
bearings and for emptying the used grease container must be shortened. When, for process
reasons, a motor is frequently at standstill, regreasing must be done at least once per year.
This is made necessary by the useful life of the grease, possible condensation in the bearing
enclosures etc.
3BSM 008369, rev. G 6-45

6.5 Bearing monitoring instruments and bearing insulation

The set values will normally have been agreed upon at the time of placing the order (see
connection diagram).
6.5.1 Bearing temperatures

When not agreed otherwise the set values for bearing temperature monitoring are:
Alarm 90 °C
Shutdown 100 °C
A sudden increase in bearing temperature compared with the normal operating temperature
is an indication of the development of damage. If necessary, the cause must be investigated
with the motor at standstill.
6.5.2 Bearing condition monitoring by the shock-pulse method

(SPM, only for anti-friction bearings)
All anti-friction bearings are equipped with measuring nipples, as a standard, for taking
readings with portable equipment. The measurements pick up the shock-pulses emitted
when the rolling elements pass over an unevenness in the raceway. The measuring
equipment converts this value into a so-called spike pulse with the unit “SV” (= Shock
Value).
The speed and the bearing diameter are decisive to allocate the measured values to one of
the ranges “good”, “average” or “poor”.
The SPM method is intended for trend measurement. Evaluation is only meaningful when
the records show the initial values taken during the trial runs in the plant and those of
following measurements taken periodically at the same speed and load conditions. (Never
take measurements directly after regreasing).
NOTE: During the trial runs, the values “good” and “average” are evaluated as
being acceptable.
After a certain running-in time the values can improve.
Starting with the initial values, further measurements indicate the trend. A rapid worsening
is a deciding factor in determining the time for a pending bearing change.
It follows, that a bearing condition diagnosis based on one single measurement can not be
made with SPM, but periodic comparison measurements must be taken under the same
conditions, whereby the differences in obtained values are the criteria for evaluation.
6.5.3 Bearing housing and shaft vibration

The limit values for bearing housing acc. to section 6.5.3.1 and shaft vibration acc. to
section 6.5.3.2.
These values are not valid for motors driving reciprocating compressors, diesel generators
or machines mounted on a foundation having a low natural frequency. For these machines,
values must be agreed upon with the customer at the time of the order.
3BSM 008369, rev. G 6-46

6.5.3.1 Bearing housing vibration

The applicable quantity is the rms value of the vibration velocity measured on the bearing
housing.
Veff
Alarm 4.5 mm/s
Trip 7.1 mm/s
6.5.3.2 Shaft vibration

According to standard IEC 60034-14 (2003), it is advisable to measure the shaft vibrations
only on machines with sleeve bearings; operating speed more than 1200 rpm and power
greater than 1000kW The vibration limits are usually established by agreement between
manufacturer and user. It is not possible to establish beforehand the vibration alarm and
stoppage values since these depend on the type of machine, rotation speed, stiffness of
rotor, operating conditions, etc. Useful reference guides for a monitoring program and the
methods to measure the shaft vibration are contained in ISO 7919-3 (1996) and ISO 7919-1
(1996)
The shaft vibration is to be measured by means of "non contact" probes place near the
bearings.
ALARM 100 µ P-P

SHUT-DOWN 125 µ P-P
Converting of vibration velocity Vrms to vibration amplitude Ŝ

To afford comparison with the measured values, the vibration amplitude Ŝ can be
calculated as follows (on the supposition that vibration is sinusoidal):
2 xVrms 2 Vrms V
S= = x ~ 0,225 x rms
ω 2 xπ f f
f = frequency of rotational speed (round/sec)

Vrms = vibration speed (mm/sec)
S = vibration amplitude 0-peak (mm)
Remark for motors running at less than 600 r.pm.
The limiting values shown in the a.m. nomograph have general validity for motors running
at 600 r.pm. and more (2 to 10 or 12 poles maximum). For motors running at less than 600
r.p.m. (12 poles and more) the suggested decisive limits is the vibration amplitude S with
the following values:
ALARM 320 µ P-P

SHUT-DOWN 500 µ P-P
3BSM 008369, rev. G 6-47

6.5.4 Bearing insulation

This work involves the main circuits of the motor normally connected to the high
voltage supply net. Before you start to work:
1. Make sure the motor is disconnected from the high voltage net and that the circuit
breaker is locked in the open position so it not accidentally (or otherwise) can be closed
during the measurements.
2. Note also that capacitors can contain dangerous voltages, so be sure to earth all details
before you touch them.
When both bearings are insulated, the condition of the bearing insulation can be measured
on the assembled motor. When taking the measurement, the short-circuit across the
insulation must be opened (switch jumper cable from steel bolt to insulation bolt).
Measuring instrument: megger
Evaluation: no signal
When only one bearing is insulated, the condition can only be assessed when the bearing or
bearing endshield is dismantled.
6.6 Checking the cooling elements of heat exchangers

Heavy deposits in the cooling tubes can considerably reduce the cooling effect, i.e. the heat
transfer. Depending on the degree of contamination, annular inspections could be
necessary. In the case of water coolers, if there is evidence of corrosion, the water analysis
should be repeated and replacement parts considered for a possible spare parts order.
6.6.1 Checking and replacing the sacrificial anodes on water coolers

Checking and replacing sacrificial anodes is described in section 7.2.3.5 on page 53.
3BSM 008369, rev. G 6-48

6.7 Maintenance plan for cage-induction motors
Every two years
During service
Quarterly
Annually
Monthly
Weekly
Temperature Follow up of temperatures at the
monitoring of the provided measuring points (e.g.

stator winding and RTD’s) by monitoring system
cooling air
Stator winding Measurement of insulation resistance
(see section 6.5.4 , Page 47). A
 
winding diagnosis is recommendable
after 3 years.
Bearings Refer to maintenance plans Table 6-1.
Page 42 and Table 6-2. , Page 44.
Complete Listen for unusual machine noise or
Machine changes in noise emission (e.g. 
rubbing or knocking noises).
Check all accessible places for rust
(see Chapter 7 Servicing and 
cleaning).
Connections for Check all cables and wires, and their
power supply, connections for condition, fastening

instrumentation and cleanliness.
and control
Earthing brushes Check extent of wear, ease of
(when such are movement in the holders, and brush
fitted) pressure. Clean contact surfaces of 
brushes and shaft with a fine polishing
cloth.
Air-to-water heat Check piping and cooler for leakage. 
exchanger
Check inside of cooling tubes for
possible deposits or signs of corrosion

(depending on water contamination
and water treatment).
Check sacrificial anodes (depending
on water contamination and water 
treatment).
Air-to-air heat Check inside of cooling tubes for

exchanger deposits.
Other ventilation Check filter for degree of 
units (e.g. IPW24 contamination. Clean or replace filter
weather protection after filter monitor responds
units). (depending on contamination of
ambient air).
3BSM 008369, rev. G 6-49

Every two years
During service
Quarterly
Annually
Monthly
Weekly
Coupling Check state of coupling alignment and

record values.
Maintenance on coupling according to
the manufacturer‘s instructions. Should
the vibration level increase carry out
check immediately or decrease
maintenance interval.
Foundation Check machine foundation bolts for

tightness.
Fastening bolts Check for tightness and condition of

locking elements.
Fan-motor on Regrease antifriction bearings. Check
ventilation unit, for rust and cleanliness (see section 
when such is fitted 7.1 on page 50).
Table 6-4. Maintenance plan for cage-induction motors
3BSM 008369, rev. G 6-50

Chapter 7 Servicing and cleaning
7.1 Servicing
Well planned and carefully carried out servicing helps to maintain high availability of the
plant and to avoid consequential damages.
7.1.1 Dismantling and reassembly

Detailed information on dismantling and reassembly are presented in Chapter 8,
Dismantling and reassembly, page 56.
7.1.2 Service sleeve bearings

Before filling the bearings with new oil, flush them out with a halogen-free solvent (e.g.
SANGOJOL, VARSOL or WHITE SPIRIT).
Following recommissioning, a bearing inspection after running for three hours is still the
best means of preventing damage and should not be ignored. (Refer to chapter 8, for
instructions on dismantling and reassembling). The important thing is to carry out servicing
at the right time.
The first service should be carried out after either 500 starts or 8000 hours of operation, but
not later than two years after commissioning. Afterwards, servicing is recommended at
intervals of 2 to 4 years. Services should be planned to utilize normal operational shut-
downs:
• Draw up the service plan in good time with ABB and if necessary with the insurance
company. The records taken and the observations made during regular maintenance
serve as an important basis for this.
• Reserve necessary workshop capacity.
• Ensure necessary tools and equipment are ready.
• Determine requirements for possible replacement parts, complement stock of spare
parts.
7.1.2.1 Inspection of the sliding surfaces of sleeve bearings
The condition of the contact surfaces indicates whether the bearing shells were correctly
fitted and are matched to the forces arising during operation. Indication is also given as to
whether the oil supply is sufficient.
Remove any imperfections in the load-bearing surfaces using a scraper (do not use emery
cloth!). Clean load-bearing surfaces until a white cloth remains clean!
7.1.2.2 Oil rings
Check roundness of oil rings with values given in Table 7-1 on page 51.
3BSM 008369, rev. G 7-51

Inside diameter of oil ring [mm] Permissible out-of-round

[mm] *)
(In accordance with DIN 322)
> 140 - 200 0.5 mm
> 200 - 280 0.6 mm
> 280 - 400 0.7 mm
> 400 - 500 0.8 mm
> 500 - 600 0.9 mm
> 600 - 760 1.0 mm
Table 7-1. *) Average value of two measurements displaced by 90°
7.1.3 Service of anti-friction bearings

If a lubricating grease of another soap base is to be used then the bearings must be washed
out with a halogen-free solvent (e.g. SANGOJOL, VARSOL or WHITE SPIRIT) prior to
filling with the new lubricating grease. This requires dismantling the bearings, refer to
chapter 8, for instructions on dismantling and reassembling. After the bearing components
have been cleaned, they should be greased immediately to prevent corrosion.
A rise in bearing temperature for a brief time after relubricating is insignificant as the
grease regulator quickly eliminates the initial overpressure and ejects excessive grease.
7.1.4 Reconditioning work during servicing

• Cleaning.
• Remove any signs of rust or burrs (in particular on the shaft seats, bearing shoulders and
bore of bearing endshields) by brushing off, or rubbing off using a whet stone (oil
stone) and then polish over.
• Check functional dimensions and if necessary correct by means of a suitable resurfacing
process (e.g. metal spraying).
• Where painting is not allowed, give blank surfaces a coating of a suitable rust inhibitor,
and protect them from moisture during possible periods of storage.
• Replace damaged wear and tear parts such as bearings, seals etc.
7.2 Cleaning
7.2.1 Mechanical dry cleaning

As a basic rule a mechanical process (scraper, vacuum cleaner with a soft nozzle or brush,
compressed air) should be carried out first. When using compressed air, care is to be taken
that dirt is not blown into the windings.
7.2.2 Wet cleaning with cleaning agents

Wet cleaning should only be carried out after an initial dry cleaning to avoid dirt from
being transported into the windings which would be potentially dangerous.
3BSM 008369, rev. G 7-52

WARNING - Danger of fire

Some technical liquids are very flammable. Use them with care. Do not smoke or have
a flame near the working place. Have a person prepared with a fire extinguisher at the
working place during the work. Also use a breathing mask during the task.
As the cleaning agent will become contaminated by dipping in the brush, prepare only
small quantities and replace as necessary. Prepare plenty of small, clean and lint-free
cleaning cloths.
Working on small areas in turn, apply the cleaning agent using a hard brush and then
immediately wipe over with a cleaning cloth. Change the cloths regularly.
7.2.3 Cleaning the air-to-water cooler

7.2.3.1 Cleaning interval
The degree of deposit build-up on the heat-exchanging surfaces of the cooler will depend
on the cleanliness and composition of the coolants. Heavy deposits can considerably affect
the cooling capacity making cleaning essential.
It is therefore recommended to inspect the cooler periodically and to clean when necessary
to prevent any deposits building up to form thick hard layers or even complete blocking of
the tubes. The deposits can be removed either mechanically or chemically, whereby
mechanical cleaning is the preferred method with consideration to corrosion. Should there
be any signs of corrosion, the water analysis should be repeated and the results considered
when ordering spare parts.
7.2.3.2 Dismantling
Drain the cooler and connected piping. Remove the bolts from the pipe flanges and those
from the cooler fastening flanges, and withdraw the cooling element from the cooler
housing.
The water chamber covers can be removed to enable cleaning the insides of the cooling
tubes.
When reassembling, ensure that the joint faces are clean, free of grease and dry. It is not
permitted to use sealing pastes or compounds etc. Clean the gaskets and ensure that they are
not damaged. Tighten up the bolts working on diagonally opposite pairs.
7.2.3.3 Cleaning the inside of the cooling tubes
Loose dirt can be flushed out by increasing the flow velocity (increasing the pressure up to
the test pressure).
Soft deposits can be removed by using a nylon tube brush. Fasten the brush to a rod and
push through the tubes.
High pressure water has proven to be effective for removing hard crusted deposits. High
pressure equipment can operate at pressures of up to 500 bar.
3BSM 008369, rev. G 7-53

Chemical cleaning agents must be chosen with great caution giving due consideration to
corrosion. It is advisable to consult the supplier in advance and obtain his confirmation that
the proposed product will not harm the tubes. Cleaning of the air water cooler to cooling
coil.
7.2.3.4 Cleaning the outside of the cooling tubes

The following methods can be applied depending on the kind of dirt deposits involved:
• Blowing down with compressed air.
• Swill with warm water or steam, adding a cleaning agent if the dirt is oily or sooty.
• Spray with high pressure water: Caution, adjust the pressure so that the cooling fins will
not be bent.

Adjust the pressure so that cooling fins will not be bent.
7.2.3.5 Sacrificial anodes (expendable anodes) for air-water coolers

When metals of different electrochemical potential are galvanically joined together, the
presence of an electrolyte, such as sea water for example, results in the formation of a
galvanic element and the electrochemical degradation of the baser metal. Controlled
degradation of a sacrificial anode prevents this degradation and produces a protective
coating on those parts made of copper alloy.
3BSM 008369, rev. G 7-54

Figure 7-1 Sacrifial anode
The pure iron sacrificial anodes (figure 7-1) are screwed into the bottom part of the cooler.
They should be checked at regular intervals, at least once per year. The cooler element need
not be emptied for this inspection, but the water pressure should be reduced.
The surface of an active sacrificial anode will show signs of its own material degradation
and also deposits of corrosion products. In case of excessive corrosion the water analysis
should be repeated. When the sacrificial anodes are dirty they must be cleaned.
When ordering replacement sacrificial anodes quote the motor type and serial number. Any
dirt accumulated during transport or storage is to be thoroughly cleaned off prior to fitting.
7.3 Stocking of spare parts

The following is a recommendation for the stocking of spare parts depending on the
machine type and its design.
This low investment can often prevent minor defects from developing into a more serious
situation.
For all kinds of machines, depending on its design
• 1 Set of bearing shells incl. oil rings and seals
• 1 Set of anti-friction bearings (type designation engraved in bearing)
• 1 Set of air filters
• 1 Set of earthing brushes and their holders
• Sacrificial anodes.
In the case of a single motor for a very important drive system or when there are several
identical motors in the plant, the following additional spare parts are also recommended:
• 1 Spare rotor
• 1 Spare slide-in stator
• 1 Spare slipring.
Orders for spare parts should be directed to our responsible representative quoting the
following data:
1. Motor for which the parts are intended.
3BSM 008369, rev. G 7-55

2. Type designation and serial number of the machine. (This data is given on the motor
rating plate. Please copy this data very carefully in order to avoid incorrect deliveries).
3. Quantities and names of the desired spare parts, Item Number. (when such is given) or
drawing or sheet number.
This data listed under points 1 – 3 is still to be given, even when spare parts are being
ordered based on a submitted example, otherwise it can be difficult to determine where the
parts belong. The motor type designation and serial number should also be quoted in all
correspondence.
Example for a spare parts order or request for quotation:
Machine type and Serial number.
3BSM 008369, rev. G 7-56

Chapter 8 Dismantling and reassembly
8.1 Safety instructions

When carrying out any work on electrical conductors the local rules and regulations
are to be observed. Non-observance of these could result in severest bodily injury or to
loss of life.
Prior to removing protection covers, ventilation units, bearing endshields etc. the
following points are to be conscientiously carried out:
1. Switch off all circuits feeding the motor such as the main power supply, auxiliary
systems for the monitoring equipment and any accessories fitted.
2. Ensure all power supplies to the motor are dead and secured against unauthorized
reconnection.
3. Disconnect the cables at the motor for the main power supply, monitoring equipment,
any accessories fitted and earthing.
8.2 Dismantling
First of all:
• uncouple the motor
• remove the holding-down bolts and any dowel pins fitted.
8.2.1 Coupling hub with a feather key

The coupling hub is to be removed cold using a puller. When necessary, it can be flame
heated to ease removal.
8.2.2 Coupling hub with a cylindrical shrink fit

1. Fit studs (1) and holding plate (2).
2. Connect all the tapped oil-injection holes in the hub to the pump with the high-pressure
hoses (5).
3BSM 008369, rev. G 8-57

NOTE: Do not damage the cone seals!
Under no circumstances may the tapped oil-injection holes in the coupling
hub be recut.

Support the coupling hub in the crane slings in such a way that it can not tip and slip
out.
3. Place a drip tray underneath the coupling hub.

4. Inject oil, ISO VG 68 (68 mm2/s at 40 °C), until the oil slots are full.
5. Maintain a constant pressure of max 1200 to 2000 bar at the middle connection, when
there is one, otherwise at the outer connection. When the pressure begins to fall,
maintain the max. pressure also at the other connections. After about 10 to 15 min oil
will emerge from each end of the shrink fit.
6. Change oil type to ISO VG 150 and repeat the whole procedure. Waiting time, at least
20 min.
7. Coupling hub with plain cylindrical shrink fit
Begin the removal process by producing a force of 45 t using the pump (8). Gradually
increase the force to max 65 t within 10 to 15 min. When the coupling hub begins to
move, continuously pump in more oil to maintain the full pressure and removal occurs
in one swift movement without interruption. In case of oil leakage, try changing to
cylinder oil, or clean the joint areas with acetone and seal with Araldite (AV 121 N).
1 Stud
2 Holding plate
3 Hydraulic jack
4 Oil pump
5 High-pressure hose
6 Pump support
7 Sling
8 Manometer
Figure 8-1
8. Coupling hub with a stepped cylindrical shrink fit
Begin the removal process by injecting oil into the connection (6) using the oil pump
(5).
This will force the coupling hub to move axially. Removal must occur in one smooth
movement without interruption. The oil pumps (1) must be maintained at full pressure
during the whole removal process.
3BSM 008369, rev. G 8-58

1 Oil pump
3 Pump support
4 Sling
5 Oil pump (pneumatic
or motor driven)
6 Connection nipple
7 Manometer
Figure 8-2
NOTE: If the stroke of the hydraulic jack is not long enough to pull the hub off in
one single operation, then interrupt the process while the last oil slot is still
on the shaft (approx. 70 mm of hub length). Insert a spacer and pull off the
remaining length of hub without further interruption.
NOTE: The pump (5) must be able to produce a pressure of at least 1000 bar.
8.2.3 Coupling hub with a tapered shrink fit

1. Loosen shaft-end nut, or locking device, so far to afford sufficient clearance for axial
movement of the coupling hub.
Insert a rubber or wooden spacer between coupling hub and the stop nut to avoid
damage of the thread in the nut.
3BSM 008369, rev. G 8-59


Shaft-end nut, or locking device, must never be completely removed because the
coupling hub can suddenly and unexpectedly break from its seat!
2. Connect injection hole, in the hub, to the oil pump (3) by means of the high-pressure
hose (2).
3. Place a drip tray underneath the coupling hub.
4. Inject oil, ISO VG 68 (68 mm2/s at 40 °C), until the oil slots are full.
5. Maintain a constant pressure of max 1200 to 2000 bar at the middle connection, when
there is one, otherwise at the outer connection. When the pressure starts to fall maintain
the max. pressure also at the other connections. After about 10 to 15 min oil will emerge
from each end of the shrink fit.
6. Maintain max oil pressure (1200 to 2000 bar) until the coupling hub slides up to its limit
of axial movement. In case of too much oil leakage, try changing to cylinder oil, or
clean the joint areas with acetone and seal with Araldite (AV 121 N).
1 Coupling hub
3 Oil pump
4 Manometer
5 Pump support
Figure 8-3
3BSM 008369, rev. G 8-60

8.2.4 Removing the ventilation unit from a horizontal motor

8.2.4.1 Air-to-water cooler
Drain cooling elements and piping. Disconnect flanges.
8.2.4.2 Air-to-air cooler
Figure 8-4
When provided, dismantle noise damping units from air inlet (1) and air outlet (2).
8.2.4.3 Motors type AMI 710
Figure 8-5
1. Dismantle cover (1) and air-guide ring (2). Remove circlip (5).
3BSM 008369, rev. G 8-61

2. Flame-heat fan (3) and pull off using an extractor.
3. Loosen 4 nuts (6) and remove fan cowling (4).
8.2.5 Weather protection units

8.2.5.1 All ventilation units

The ventilation unit is very heavy.
AMI 710
AMI 800…1000
Figure 8-6
Remove fastening bolts or nut (1) washers (2) and dampers (4) then lift off cooler with the
crane. Check seal (3), replace if necessary. Seal must be perfectly seated.
8.2.6 Removing the ventilation unit from a vertical motor

8.2.6.1 Air-to-water cooler
Figure 8-7
3BSM 008369, rev. G 8-62

1. Remove cover (1) and air-guide ring (2).
2. Loosen bolts (3) on tension element (4) and pull off fan (5).
3. Loosen nuts (6) and take off fan cowling (7).
Figure 8-8

The unit is very heavy.
4. Sling cooler (4) on crane and unscrew 4 fastening bolts (1).

5. Remove washers (2) and lift away cooler.
Figure 8-9
6. Before turning motor to the horizontal position lock rotor axially by means of locking
screws.
Instructions for turning the motor are given in section 3.4.
3BSM 008369, rev. G 8-63

8.2.7 Weather protection unit
8.2.8 Dismantling anti-friction bearings on horizontal motors

D and N ends
D-LAGER
N-LAGER
Figure 8-10
1. Remove circlips 1D, 1N.
2. Dismantle labyrinth covers 2D, 2N or cover plate 3N.
3. Pull off labyrinth rings 4D, 4N cold using an extractor. If necessary flame-heat to ease
removal.
4. Remove bearing covers 5D, 5N.
5. Unscrew bearing endshield fastening screws and pull off bearing endshields 6D, 6N
incl. outer rings of roller bearing.
6. Pull off inner ring of roller bearing cold using an extractor. If necessary flame-heat to
ease removal.
Only D-end
7. Loosen bolts 11D and remove bearing ring 7D incl. spacer rings (2 pcs.) 8D.
8. Pull off at ball bearing 9D cold using an extractor. If necessary flame-heat to ease
removal.
D + N ends
9. Remove bearing covers 10D, 10N from the shaft.
3BSM 008369, rev. G 8-64

8.2.9 Dismantling anti-friction bearings from vertical motors
Figure 8-11
Top bearing (N-end)

1. Turn motor to horizontal position (see Chapter 3.4 ).
2. Remove cover (1).
3. Remove ring (2) and 2 half-rings (3).
4. Pull off balance disc (4) cold using an extractor. If necessary flame-heat to ease
removal.
5. Unscrew fastening bolts from cover (5) and pull off bearing endshield.
6. Pull off angular contact ball bearing (7) cold using an extractor (one on motors type
AMB560 and 2 on larger motors). If necessary flame-heat to ease removal.
3BSM 008369, rev. G 8-65

Bottom bearing
Figure 8-12
1. Same as “Dismantling anti-friction bearing from horizontal motors”.
NOTE: Do not lose bearing prestress springs 15D!
8.2.10 Dismantling sleeve bearings
1. Cover 8. Lower half bearing housing

2. Seal cover 9. Motor seal
3. Upper half bearing housing 10. Spring
4. Bearing seal (4a and 4b) 11. Bearing endshield
5. Upper half bearing shell 12. Stopper
6. Lower half bearing shell 13. Oil drain hole
7. Lube ring
Figure 8-13
3BSM 008369, rev. G 8-66

1. Drain off oil.
2. Remove the cover (1) or the seal carrier (2).
3. Remove the bolts in the upper half of the bearing housing (3) and lift the upper half
away.
4. Remove the springs (10) on each bearing seal (4a,b) and remove the bearing seal.
5. Remove the bolts from the upper half of the bearing shell (5) and disconnect the
earthing cable.
6. Insert a lifting eyes and carefully lift the upper half of the bearing shell away.

7. Loosen the bolts holding together the lube ring (7) and remove the two halves (the lube
ring is made of brass in two halves, held together with bolts and cylindrical pins).
8. In order not to damage the bottom half of the bearing shell during removal, the rotor
must be carefully raised until the shaft just touches the bore of the motor seal (9).
9. Attach a lifting eye into the lower half of the bearing shell and draw the assembly
toward you so that is slides around the journal. Insert lifting eyes in the top of the
bearing shell and carefully lift lower bearing shell away. See figure 8-14.
Step 1 Step 2 Step 3

Figure 8-14

10. Screw eye bolt into bearing endshield (11), remove the bolts and lift carefully the
bearing endshield away by using a crane.
11. Remove the motor seal (9).
8.2.11 Space heater

1. On machines with 6 poles or more, an air guide ring is fitted, which must be removed.
2. Remove space heater.
3BSM 008369, rev. G 8-67

NOTE: The space heater can also be removed without taking off the bearing
endshield.
Remove access cover (1) and work from the side of the motor.
Figure 8-15 Removing the space heater
8.2.11.1 Rotor withdrawal

The rotor is very heavy.
NOTE: Do not damage the core or winding. Insert presspahn in stator bore.
1. Withdraw rotor with the help of an extension pipe (1).
2. Inside diameter of pipe must be matched to the shaft diameter. Protect shaft.
3. Before removing the internal fan, mark its circumferential location on the fan carrier
ring (so not to introduce unbalance at re-assembly).
4. For AMI motors, mark fans D and N. Remove N-end fan before withdrawing the rotor.
Do not interchange fans at reassembly!
3BSM 008369, rev. G 8-68

Figure 8-16
8.3 Reassembly
Reassemble the motor following the instructions given for dismantling in the reverse
sequence. (Rotor withdrawal Section 8.2.10 )
8.3.1 Fitting the air guide rings
Figure 8-17 AMB with shaft-mounted fan Figure 8-18 AMB 2-pole
1 Air-guide ring 3 Air-guide-ring (D+N)

2 Fastening screws 4 Bearing endshields (D+N)
3BSM 008369, rev. G 8-69

Figure 8-19 AMI

1. Ensure all bolts inside the motor are properly tightened up and provided with their
original locking elements.
2. In the case of AMI motors pay particular attention to the direction of rotation. Do not
interchange the fans.
3. Carefully insert rotor (see rotor withdrawal).
4. Fit ventilation unit.
8.3.2 Assembling anti-friction bearings
D-END N-END
Figure 8-20
1. Normally the bearings will be replaced by new ones.

2. Wash out bearing cover.
3. Carry out dimensional check on shaft and bore of bearing endshield.
4. Check seats for possible damage. When necessary smooth imperfections using emery
paper (coarseness P220).
5. Apply a light coating of oil to shaft and bore of bearing inner ring (only fill pores)
3BSM 008369, rev. G 8-70

6. Apply a coating of Wevopat 2000 to all seatings and spigot faces.
7. Grease quality for packing out and relubrication.
8. Clean lube holes in the bearing cover and bearing endshield. Important: Inject grease
through the lube channels until clean grease is discharged.
9. Fill bearing cover with grease and slide onto shaft: On vertical motors fix spring in
inner cover with grease.
10. Heat bearing to 115 °C in an oil bath and slide onto shaft. Flame-heat labyrinth and fit
into place.

Temperatures above 120 °C damage the bearings.
When necessary, exchange the O-ring (1) (Figure 8-21).
In the case of angular contact bearings, pay particular attention to correct location
(Figure 8-22).
11. Fill grooves in the labyrinth cover with special grease USBB 312 and fit parts.
Figure 8-21
Figure 8-22
3BSM 008369, rev. G 8-71

8.3.3 Assembling sleeve bearings

Before beginning, ensure that the shaft surfaces and the bearing components are clean.
When necessary exchange worn parts.
1. Assemble the motor seal (9) to the bearing endshield (11). Apply a thin coat of sealing
compound (WEVOPAT) to the contact surfaces between motor seal and bearing
endshield. Tightening torque according to table below:
Bearing size 9 11 14 18 22 28
Tightening torque (Nm) 89 89 215 420 725 1450
2. Assemble the bearing endshield to the motor housing. Apply a thin coat of sealing
compound (WEVOPAT) to the contact surfaces between bearing endshield and the
motor housing.

3. Assemble the lower half of the bearing housing (8) and the bearing endshield. Apply a
thin coat of sealing compound (WEVOPAT) to the contact surfaces between bearing
housing and the bearing endshield. Tightening torque according to table in point 1.
4. In order not to damage the lower half of the bearing shell during assembling, the rotor
must be carefully raised until the shaft just touches the bore of the motor seal (9).
5. Apply coating of oil (bearing lube oil) to faces of spherical seat and bearing contact
surfaces. Insert lifting eyes in the lower bearing shell over and onto the rotor shaft. Hold
onto the lifting eye and allow the shell to glide around the journal until the lower shell is
inserted. See figure 8-23.
Step 1 Step 2 Step3
Figure 8-23
3BSM 008369, rev. G 8-72


6. Lower the rotor shaft carefully into the bearing shell.

7. Check the distance between the bearing journal and the bearing shell with a feeler gauge
on front and rear end of the shell on both sides.
8. Assemble the lube ring. Apply “Loctice” to the bolts and tighten. Tightening torque
according to table below:
Bearing size 9 11 14 18 22 28
Tightening torque(Nm) 1.4 2.7
9. Oil shaft and bearing shell top-half (5) and set onto shaft.
10. Connect the earth cable.
11. Insert the bolts and tighten the bolts with a torque wren
NOTE: Check location of stop to prevent the bearing seal from turning. See figure 8-
13.
12. Coat joint faces and assemble the inner bearing seal (4b). Check location of the oil drain
hole (13) and the stopper (12) to prevent turning.
NOTE: Identification marks on the top and bottom shell halves must be identical and
on the same side.
13. Hand tighten joint-face fastening bolts in turn, working in a cross-wise sequence.
14. Clean the upper part of the bearing housing and apply thin coat of oil to the spherical
bearing seat.

15. Clean the horizontal joint of the upper and lower bearing housing carefully and apply a
thin coat of the sealing compound WEVOPAT.
16. Coat the contact surfaces between endshield and the upper bearing housing.
17. Tighten up flange bolts in top-half of bearing housing with torque specified in table
below. Lock bolts with Loctite.
3BSM 008369, rev. G 8-73

Bearing size 9 11 14 18 22 28
Tightening torque (Nm) 89 89 215 420 725 1450
18. Tighten up joint-face fastening bolts, in turn working in a cross-wise sequence, with the
torques given in table under point 17.
19. Prepare outer bearing seals as for the inner ones and set onto shaft, fit seal-carrier halves
(2). Tightening torque according to the table below.
Bearing size 9 11 14 18 22 28
Tightening Torque (Nm) 10.5 26
8.4 Recommended tightening torque for bolts on the motor

Recommended tightening torque for bolts, property class 8.8, slightly coated with oil.
NOTE: Do not use Molybdenum di-sulphide
Bolt size M8 M 10 M 12 M 16
Torque (Nm) 22.5 45 79 190
(lbft) 16.6 33 58 140
Bolt size M 20 M 24 M 30 M 36
Torque (Nm) 400 690 1390 2450
(lbft) 295 510 1022 1800
Bolt size M 42 M 48
Torque (Nm) 3800 5800
(lbft) 2800 4280
3BSM 008369, rev. G 8-74

Chapter 9 Trouble shooting
9.1 Operational faults on cage-induction motors

Instructions for determining the cause of abnormal behaviour or fault conditions on cage
induction motors and proposed corrective measures.
Should abnormal behaviour arise when starting or operating the motor, the cause should be
determined and eliminated immediately, whereby prompt action can often avoid serious
damage. In case of phenomena which can not be satisfactorily explained, we and our sales
offices are at your disposal for further clarification.
The following lists are offered as guidelines for trouble shooting.

The motor must be isolated from the power supply system prior to carrying out any
investigations. Even when switched off at the stator switch, previous isolation from the
power supply system is still necessary.
Fault Possible cause of fault Corrective action
Motor does not start, no noise Interruptions in at least two of Check fuses, supply cables
the supply lines and terminal connections
No voltage Check supply cables
Motor does not start, hums Interruption in one supply line Check supply cable and repair
Motor will not start under load, Load torque too high Correct driven equipment.
normal magnetic noise Uncouple motor and test at
no-load (Pay attention to
starting time and axial
guidance)
Supply voltage too low Measure supply voltage
Motor runs at no-load, stalls Break in a supply cable after Check supply cables
under load start-up
Rotor bars broken, sparking in Inspect rotor

air-gap
Soldered joints between bars

and cage rings loose (an
ammeter in the stator circuit
indicates periodic fluctuations)
3BSM 008369, rev. G 9-75

Motor overheats even at no- Stator wrongly connected (e.g. Correct connection according
load delta instead of star) to connection diagram
Supply voltage too high Measure supply voltage and

no-load current
Insufficient cooling as a result Clean air passages

of blocked air passages
Wrong direction of rotation for Check direction of rotation and

motors fitted with fans
unidirectional fans (angled
blades)
Motor overheats under load Motor is overloaded Check current input
Voltage too high or too low Measure voltage
Motor is single-phasing Check for break in supply

cables
Rotor is rubbing in the stator Check air-gap

bore
Local overheating in stator Short-circuits in stator winding Dismantle motor to afford

winding (individual coils will be too hot, detailed inspection, call in
singed appearance) specialist, when necessary
send motor or rotor to
Humming noise, emission of Rotor rubbing in stator bore manufacturer
smoke, signs of fire (when signs of fire in airgap),
broken or loose rotor bars
Motor speed decreases Motor too weak or load torque Decrease load torque
greatly at low load too high
Voltage dip too great Check supply voltage and

section of supply cables
Periodic fluctuation at Interruption in rotor circuit due Inspect rotor

ammeter in stator circuit (up to to broken or loose bars
about 6 times per second).
Dependent on slip
Motor emits abnormal noise Mechanical or electrical cause When cause is electrical,
noise will disappear when
motor is switched off, when
mechanical it will usually
decrease with decreasing
speed. Consult manufacturer
3BSM 008369, rev. G 9-76

Abnormally high bearing Axial force too high Determine cause and
temperature eliminate
High vibration from an
extraneous source
Bearing damaged or
insufficiently lubricated
Oil rings out-of-round or have

stepped lateral wear
Oil filling not correct

(level/grade) or oil is
contaminated
Vibration on rotor Bearings or coupling Check bearings, coupling,

damaged, fault on gearbox or gearbox and driven equipment
driven equipment
Change in state of balance, Check balance of components

cause could be on motor, and dynamically rebalance
coupling or driven equipment when necessary
Sinking of foundation, inferior Realign shaft train, rectify

foundation foundation
3BSM 008369, rev. G 9-77

 
3BSM 008369 rev.: G / June 2013
ABB S.p.A.
Headquaters and Sales Dept. Engineering Dept. and facility
Via Luciano Lama, 33 Viale dell’Industria, 18
20099 SESTO S. GIOVANNI 20010 VITTUONE
Milano – Italy Milano - Italy
Telephone +39 02 2414.1 Tel. +39 02 9034.1
Telefax +39 02 2414.3086 Fax. +39 02 9034.7272
www.abb.com/motors&drives
Suppliers’ declaration for products having preferential origin status
(according to (EU) No. 1207/2001 )
DECLARATION
I, the undersigned, declare that the goods listed on this document
ABB-Induction-Machine, Type _AMI800L4LBSXYM _(ITABB-Order-No. _8130002869.01_)
Orginate in European Community and satisfy the rules of origin governing

preferential trade with
Island (IS), Liechtenstein (LI), Norwegen (NO), Schweiz (CH)

Türkei (TR) (bei Einbindung der Türkei in die paneuropäische Kumulation)
Ägypten (EG), Albanien (AL) Algerien (DZ), Bosnien und Herzegowina (BA), Ceuta (XC), Chile
(CL), Färöer (FO), Israel (IL), Jordanien (JO), Kroatien (HR), Libanon (LB), Marokko (MA),
Mazedonien (MK), Melilla (XL), Mexiko (MX), Montenegro (ME), Palästinensische Gebiete (PS),
Republik Korea (KR), Serbien (XS), Südafrika (ZA), Tunesien (TN).
I declare that:
Cumulation applied with __________________________ (name of the country/ countries)
X No cumulation applied.
I undertake to make available to the customs authorities any further supporting documents they require.
ABB S.p.A, Vittuone/ Italy
_VITTUONE__19/03/2014__LUCA VANZINI__PROJECT MANAGER_ _

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ABB Automation Products GmbH

Large Drives & Machines

Customer: Coperion GmbH

Project: Shenhua Yulin PP //

CST Order-No.: 112/46327196

Motor Type AMI 800L4L BSXYM, 9.700 kW

Manufacturer Coperion Client

TOTALE 9250 950

TORSIONAL STIFFNESS K1 29755

SHAFT MATERIAL ST442S - 25CrMo4

ABB SpA PERFORMANCE DATA OF MOTOR

Driven Machine : Extruder

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Torque and Current as a Function of Speed

I, U=100% I, U=75% I, U=70% Load Torque

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Time - Current and Thermal Limit Curves

Stator current / Rated current

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Speed vs. time

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Phase Current Ia Phase Current Ib Phase Current Ic Torque

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

3-Phase Short Circuit

Phase Current Ia Phase Current Ib Phase Current Ic Torque

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Direct On Line Start

Phase Current Ia Phase Current Ib Phase Current Ic Torque

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

0 50 100 150 200 250 300 350 400

Phase Current Ia Phase Current Ib Phase Current Ic Torque

ABB SpA PERFORMANCE DATA OF MOTOR

Motor type code: AMI 800L4L BSXYM

Airgap torque at start from standstill

Te(t) = M0(1 + e -t/1 e-t/2) - M1 (cos(t - ) e -t/1 + cos(t + ) e -t/2)

M0 = 0.595 ; M1 = 4.59 ; 1 = 10.7 s ; 2 = 0.0198 s ;  = 1.44 rad

Airgap torque at 3-phase short circuit at terminals

Te(t) = M0 e -t/0 - M1 e -t/1 sin t

M0 = -0.574 ; 0 = 0.0567 s ; M1 = 5.23 ; 1 = 0.0286 s;  = 309 rad/s

Maximum value of torque -4.92 * TN, when t = 5 ms

Airgap torque at 2-phase short circuit at terminals

Te(t) = M00 ( 1 - e-t/0) + (M0 + M2 e -t/2) sin 2t - M1 e -t/1sin t

M00 = 0.163 ; M0 = 1.36 ; M1 = 4.93 ; M2 = 3.58 ; 0 = 0.202 s ; 1 = 0.0718 s ; 2 = 0.00836 s; 

Maximum value of torque -6.59 * TN, when t = 7 ms

Airgap torque at high speed automatic reclosing

Te(t) = M0 e -t/0 + ( M1 e -t/1 + M2 e -t/2 ) cos( t - ) + M00

M0 = -10.4 ; M1 = 5.21 ; M2 = 0 ; M00 = 0.151 ; 0 = 0.0188 s ; 1 = 0.302 s; 2 = 10 s ;  = 0.146

High speed automatic reclosing time t = 0.2 s

Maximum value of torque -11.7 * TN, when t = 8 ms