DriveIT Low Voltage Motors

Manual for M3000 and M2000 Ranges

Installation, operation and

maintenance manual GB 3
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Example of the Declaration of Conformity
given by ABB.

EC Declaration of Conformity

The Manufacturer :- (Name and address of the manufacturer)

hereby declares that

The Products :- (Product identification)

are in conformity with provisions of the following Council Directives :

Low Voltage Directive 73/23/EEC (amended by 93/68/EEC),

and, as components, with the essential requirements of the following :

EMC Directive 89/336/EEC (amended by 92/31/EEC and 93/68/EEC), regarding the intrinsic
characteristics to emission and immunity levels,

and are in conformity with :

EN 60 034-1

Additional Information :-

By design, the machines, considered as components, comply with the essential requirements of

Machinery Directive 98/37/EEC provided that the installation be correctly realised by the manufacturer
of the machinery (for example : in compliance with our Installation Instructions and EN 60 204 “Electri-
cal Equipment of Industrial Machines”).

Certificate of Incorporation (Directive 98/37/EEC, Art 4.2 and Annex II, Sub B) :

The machines above must not be put into service until the machinery into which they have
been incorporated have been declared in conformity with the Machinery Directive.

Year of CE marking : CE00.

Signed by ..................................................

Title ...........................................................

Date ..........................................................

Translations into other languages are available from

ABB.

2 ABB / Low Voltage Motors / Manual 11-2002

Installation, operation and
maintenance manual

List of Contents

1. General 4. Maintenance

2. Installation 5. Environmental Requirements

3. Operating 6. Motor trouble shooting chart

1. General Validity
The instructions are valid for the following ABB electrical
NOTE! machine types, in both motor and generator operation.
These instructions must be followed to ensure safe
and proper installation, operation and maintenance of series MT*, MBT*, MXMA,
the motor. They should be brought to the attention of series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*, M2F*/
anyone who installs, operates or maintains this M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,
equipment. Ignoring the instruction may invalidate the M2V*/M3V*
warranty.
in frame sizes 56 - 400.
Declaration of Conformity There is a separate manual for e.g. Ex motors ‘Low
voltage motors for hazardous areas: Installation, opera-
Declarations of Conformity with respect to the Low tion and maintenance Manual’ (Low Voltage Motors/
voltage Directive 73/23/EEC amended by Directive 93/ Manual for Ex-motors).
68 EEC are issued separately with individual machines.
Additional information is required for some machine
The Declaration of Conformity also satisfies the types due to special application and/or design
requirements of a Declaration of Incorporation with considerations. Additional information is available for the
respect to the Machinery Directive 98/37/EEC, Art 4.2 following motors:
Annex II, sub B - roller table motors
- water-cooled motors
- open drip proof motors
- smoke venting motors
- brake motors
- permanent magnet motors

ABB / Low Voltage Motors / Manual 11-2002 3

2. Installation Direct-on-line or star/delta starting
The terminal box on standard single speed machines
normally contains 6 winding terminals and at least one
Putting into service (starting) earth terminal.

Reception check Earthing must be carried out according to local

Immediately upon receipt check the machine for external regulations before the machine is connected to the
damage and if found, inform the forwarding agent without supply voltage.
delay.
The voltage and connection are stamped on the rating
Check all rating plate data, especially voltage and plate.
winding connection (star or delta). The type of bearing is
specified on the rating plate of all motors except the Direct-on-line starting (DOL):
smallest frame sizes. Y or D winding connections may be used.
e.g. 660 VY, 380 VD indicates Y-connection for 660 V
Remove transport locking if employed.Turn shaft by and D-connection for 380 V.
hand to check free rotation.
Star/Delta starting (Y/D) :
Do not exceed permissible loading values of bearings The supply voltage must be equal to the rated voltage of
stated in the product catalogue. the machine in D-connection.
Remove all connection links from the terminal block.
Motors equipped with roller bearings: Running the
motor with no radial force applied to the shaft may For two-speed, single phase and special machines,
damage the roller bearing. supply connection must follow the instructions inside the
terminal box.
Motors equipped with angular contact bearing:
Running the motor with no axial force applied in the right If direct-on-line starting lasts for more than 10 seconds
direction to the shaft may damage the angular contact or Y/D starting more than 30 seconds, consult ABB
bearing. Sales Office or see the publication ‘The Motor Guide'
(also available on the internet on www.abb.com/
Motors equipped with regreasing nipples: motors&drives).
When starting the motor for the first time, or after long
storage of the motor, apply the specified quantity of Terminals and direction of rotation
grease until new grease is forced out of the grease Direction of rotation is clockwise when viewing the shaft
outlet. face at the machine drive end, when the line phase
For details see section “Manual lubrication" on page 8. sequence L1, L2, L3 is connected to the terminals as
shown in the figure 1.
Insulation resistance check
Measure insulation resistance before commissioning and To alter the direction of rotation, interchange the
when winding dampness is suspected. connection of any two line cables.

Resistance, measured at 25°C, shall exceed the If the machine has a uni-directional fan, ensure that the
reference value, i.e. 10 M ohm (measured with 500 V dc direction of rotation is according to the arrow marked on
Megger) the machine.
WARNING
Windings should be discharged immediately after
Handling
measurement to avoid risk of electric shock.

Insulation resistance reference value is halved for each Storage

20°C rise in ambient temperature. The machine should always be stored indoors, in dry,
vibration free and dust free conditions.
If the reference resistance value is not attained, the
winding is too damp and must be oven dried. Unprotected machined surfaces (shaft-ends and flanges)
Oven temperature should be 90°C for 12-16 hours should be protected with anti-corrosive treatment.
followed by 105°C for 6-8 hours.
It is recommended that shafts be rotated periodically by
Drain hole plugs, if fitted, must be removed and closing hand to prevent grease migration.
valve, if fitted, must be opened during heating.
Anti condensation heaters, if fitted, should preferably be
Windings drenched in seawater normally need to be energised.
rewound.
The characteristics of electrolytic capacitors, if fitted to

4 ABB / Low Voltage Motors / Manual 11-2002

single-phase motors, will require “reforming” following Installation
periods of storage exceeding 1-2 years.
Contact ABB Sales Office for details. Cooling
Normal ambient temperatures should not exceed 40°C
Transportation (marine standard +45 or +50°C) if standard performance
Machines fitted with cylindrical-roller and/or angular is to be achieved. Check that the motor has sufficient
contact bearings must be fitted with locking devices airflow. Ensure that no nearby equipment, surfaces or
during transport. direct sunshine, radiate additional heat to the motor. For
more information about higher ambient temperatures and
Lifting cooling, see “the Motor Guide” or contact ABB Sales
Lift the motor using the lifting lugs only, if not otherwise Office.
stated in the separate lifting instruction.
Foundation
The center of gravity of motors with the same frame The purchaser bears full responsibility for preparation of
may vary due to different outputs, mounting arrange- the foundation.
ments and auxiliary equipment.
Metal foundations should be painted to avoid corrosion.
Check that eyebolts or the lifting lugs integrated with the
motor frame are undamaged before lifting. Damaged Foundations must be even, and sufficiently rigid to
lifting lugs must not be used. withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
Lifting eyebolts must be tightened before lifting. If to resonance.
needed the position of the eyebolt must be adjusted with
suitable washers. Foundation studs
Bolt the foundation studs to the feet of the motor and
Ensure that proper lifting equipment is used and that the place a 1-to-2 mm shim between the stud and the feet.
sizes of the hooks are suitable for the lifting lugs.
Align the motor directly using appropriate means.
Care must be taken not to damage auxiliary equipment Grout the studs with concrete, check alignment and drill
and cables attached to the motor. holes for locating pins.

Machine weights Drain holes

Total machine weight can vary within the same frame Always check that open drain holes face downward.
size (center height) depending on different output,
mounting arrangements and added features. In extremely dusty environments, all drain holes should
be closed.
The following table shows estimated maximum weights
for machines in their basic versions as a function of Alignment
frame material. Correct alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions.
The actual weight of all our motors is stated on the
rating plate except the smallest frame sizes. Slide rails and belt drives
• Fasten the machine to the slide rails as shown in
Aluminium Cast iron Steel figure 2.
Frame Weight Add. Weight Weight • Place the slide rails horizontally on the same level.
size kg for brake kg kg • Check that the machine shaft is parallel with driven, or
driving, shaft.
56 4.5 - - -
63 6 - - - • Any belt must be tensioned according to the supplier's
71 8 5 13 - instructions.
80 12 8 20 -
90 17 10 30 - WARNING
100 25 16 40 - Excessive belt tension will damage bearings and
112 36 20 50 - can cause shaft breakage.
132 63 30 90 -
160 110 55 175 -
180 160 65 250 - Do not exceed the maximum belt forces (i.e. radial
200 220 - 310 - bearing loading) stated in the relevant product
225 295 - 400 - catalogues.
250 370 - 550 -
280 405 - 800 600
315 - - 1300 1000
355 - - 2300 2200
400 - - 3500 3000

ABB / Low Voltage Motors / Manual 11-2002 5

 This arrangement has no electrical safety function; the
Connection
purpose is to equalise the potentials. When the motor
Normal machine design has the terminal box on top with and the gearbox are mounted on a common steel
cable entry possible from both sides. fundament, no potential equalisation is required.

Some machines are available with top mounted terminal Potential equalisation
boxes rotatable 4 x 90°, and some with side mounted
terminal boxes. V1
U1 W1 Plate/strip Cables/wires
Availability of these solutions is described in the product PE
3~M
catalogues.
0.75 mm > 150 mm

Unused cable entries must be closed. 70 mm

Driven machinery 2
min 50 mm

As well as main winding and earthing terminals, the

terminal box can also contain connections for To comply with EMC-requirements, use only cables and
thermistors, standstill heating elements, bimetallic, connectors approved for this purpose. (See instruction
switches, or PT 100 resistance elements. for frequency converters.)

WARNING The highest permissible rotational speed of a cast iron

Voltage may be connected at standstill inside the motor used in variable speed drive (M2BA/M3BP) must
terminal box for heating elements or direct not exceed maximum permissible speeds as stated in
winding heating. the figure below or the speed stamped on the rating
plate. For information on the highest permissible rota-
Connection diagrams for auxiliary elements are found tional speed for other motor sizes and types, please
inside the terminal box cover. contact ABB. Bearing lubrication should follow the
directions mentioned later.
WARNING
The capacitor in single-phase motors can retain Frame Speed r/min
a charge that appears across the motor terminals, size 2 pole 4 pole
even when the motor has reached standstill. 280 3600 2600
315 3600 2300
355 3600 2000
Connection for variable speed drive 400 3600 1800
If there is uncertainty concerning the suitability of the
Variable speed drives cause higher voltage stresses motor for the variable speed drive, please contact ABB.
than the sinusoidal supply on the winding of the motor
and may cause high frequency shaft voltages and WARNING
bearing currents. Therefore the winding and the bearing The maximum operating temperature of the
insulation of the motor as well as the filter at the con- grease and bearings must not be exceeded.
verter output must be dimensioned according to "Selec-
tion rules for VSD applications/Insulation" (3GZF500930-
2), available on request from ABB. Balancing

In variable speed drives the motor (Pn > 30 kW) must The rotor of the machine is dynamically balanced.
be cabled by using shielded symmetrical cables and
As standard, balancing has been carried out using half
cable glands providing 360° bonding (also called EMC
key, and the shaft is marked with a RED tape, with the
glands). More information can be found in ABB’s manual
text “Balanced with half key”.
“Grounding and cabling of the drive system”
(3AFY61201998).
To avoid vibration the coupling-half or pulley must be
balanced with half key after the keyway has been
In frequency converter applications motor frame
machined.
external earthing must be used for equalising the
potential between the motor frame and the driven
In the event of balancing with full key the shaft is
machine, unless the two machines are mounted on the
marked with a YELLOW tape, with the text “Balanced
same metallic base.
with full key”.
For motor frame sizes above IEC 280, use 0.75 x 70
In case balancing without key, the shaft is marked with
mm flat conductor or at least two 50 mm² round conduc-
a BLUE tape, with the text “Balanced without key".
tors. The distance of the round conductors must be at
least 150 mm from each other.

6 ABB / Low Voltage Motors / Manual 11-2002

3. Operating 4. Maintenance
Use Maintenance and lubrication
Operating conditions General inspection
The machines are intended for use in industrial drive - Inspect the machine at regular intervals.
applications. - Keep the machine clean and ensure free
Normal ambient temperature limits are -20° to +40°C. ventilation airflow.
Maximum altitude 1000 m above sea level. - Check the condition of shaft seals (e.g. V-ring) and
replace if necessary.
Safety considerations - Check the condition of connections and mounting
The machine is intended for installation and use by and assembly bolts.
qualified personnel, familiar with relevant safety - Check the bearing condition by listening for
unusual noise, vibration measurement, bearing
requirements.
temperature, inspection of spent grease or SPM
bearing monitoring.
Safety equipment necessary for the prevention of * When changes of condition occur,
accidents at the installation and operating site must be dismantle the machine, check the parts
provided in accordance with the local regulations. and replace if necessary.

WARNING Lubrication
Small motors with supply current directly
switched by thermally sensitive switches can WARNING
start automatically. Beware of all rotating parts!
Points to observe
1. Do not use the machine to step on. WARNING
2. The temperature of the outer casing of the Grease can cause skin irritation and eye
machine may be hot to the touch during normal inflammation. Follow all safety precautions
operation. specified by the manufacturer.
3. Some special machine applications require
special instructions (e.g. using frequency
converter supplies). Machines with permanently greased bearings
4. Lifting lugs must only be used for lifting the motor. Bearings are usually permanently greased bearings of
They must not be used to lift the motor when it is either Z or 2Z types.
attached to other equipment. Bearing types are specified in the respective product
catalogues and on the rating plate of all our motors
Assembly and dismantling except smaller frame sizes.

General As a guide, adequate lubrication for sizes up to 180 can

Dismantling and assembly of machines must be carried be achieved for the following duration, according to L1
out by qualified personnel using only suitable tools and (i.e. that 99 % of the motors are sure to make the
working methods. All repairs must be carried out interval time) at ambient temperature of 25°C. For duties
according to the standard IEC-60079-19. with ambient temperatures higher than 25°C, see the
respective product catalogue.
Bearings
Frame size Poles Duty hours
Special care should be taken with the bearings.
These must be removed using pullers and fitted by 56-80 2-8 for life
heating or using special tools for the purpose. How 90-112 2-8 40 000
132 2 31 000
to replace bearings is described in detail in a separate
132 4-8 40 000
instruction leaflet available from ABB Sales Office.
160 2 23 000
160 4-8 40 000
Fitting coupling halves and pulleys 180 2 19 000
Coupling halves and pulleys must be fitted using suitable 180 4-8 40 000
equipment and tools that do not damage the bearings.
Depending on application and load conditions, see
Never fit a coupling half or pulley by hammering into applicable product catalogue.
place or remove it using a lever pressed against the
body of the machine. Hours of operation for vertical motors are half of the
above values.
Mounting accuracy of coupling half :
check that the clearance b is less than 0.05 mm and
that the difference a1 to a2 is also less than 0.05 mm.
See figure 3.

ABB / Low Voltage Motors / Manual 11-2002 7

Motors with regreasing nipples Lubrication intervals and amounts
Frame Amount 3600 3000 1800 1500 1000 500-900
Lubrication information plate and general lubrication size of grease r/min r/min r/min r/min r/min r/min
advice g/bearing
Ball bearings
If the machine is fitted with a lubrication information Lubrication intervals in duty hours
plate, follow the given values. 112 10 10000 13000 18000 21000 25000 28000
132 15 9000 11000 17000 19000 23000 26500
On the lubrication information plate, regreasing intervals 160 25 7000 9500 14000 17000 21000 24000
180 30 6000 8000 13500 16000 20000 23000
with regard to mounting, ambient temperature and speed 200 40 4000 6000 11000 13000 17000 21000
of rotation can be defined. 225 50 3000 5000 10000 12500 16500 20000
250 60 2500 4000 9000 11500 15000 18000
ABB policy is to have reliability as a vital issue in 280 70 20001) 35001) 8000 10500 14000 17000
1) 1)
bearing lubrication intervals. That is why we follow the 315 90 6500 8500 12500 16000
1) 1)
355 120 4200 6000 10000 13000
L1-principle. 400 120 1) 1)
4200 6000 10000 13000
1) 1)
400 M3BP 130 2800 4600 8400 12000
Manual lubrication Roller bearings
Regreasing while motor is running Lubrication intervals in duty hours
- Remove grease outlet plug or open closing valve if 160 25 3500 4500 7000 8500 10500 12000
fitted. 180 30 3000 4000 7000 8000 10000 11500
- Be sure that the lubrication channel is open 200 40 2000 3000 5500 6500 8500 10500
225 50 1500 2500 5000 6000 8000 10000
- Press the specified amount of grease into the bearing. 250 60 1300 2200 4500 5700 7500 9000
- Let the motor run 1-2 hours to ensure that all 280 70 10001) 20001) 4000 5300 7000 8500
excess grease is forced out of the bearing. 315 90 1) 1)
3300 4300 6000 8000
1) 1)
Close the grease outlet plug or closing valve if fitted. 355 120 2000 3000 5000 6500
1) 1)
400 120 2000 3000 5000 6500
1) 1)
400 M3BP 130 1400 2300 4200 6000
Regreasing while motor is at a standstill
1)
Values for IEC sizes 280 to 400 in certain motor types (3600 and
Regrease motors while running. If this is not possible,
3000 r/min), please see the next page.
lubrication can be carried out while the machine is at a
standstill.
- In this case, use only half the quantity of grease, then Factors influencing the lubrication intervals
run the motor for a few minutes at full speed. Lubrication intervals for vertical machines are half of the
- When the motor has stopped, press the rest of the above values.
specified amount of grease into the bearing.
- After 1-2 running hours close the grease outlet plug or The lubrication intervals are based on bearing operating
closing valve if fitted. temperature 80°C (ambient temperature of about + 25°).
Note! An increase in the ambient temperature raises the
Automatic lubrication temperature of the bearings correspondingly. The values
The grease outlet plug must be removed permanently should be halved for 15°C increase in bearing temper-
with automatic lubrication or open closing valve if fitted. ature and may be doubled for 15°C degrease in bearing
temperature.
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the
equipment. WARNING
The maximum operating temperature of the
grease and bearings must not be exceeded.
We recommend only the use of electromechanical
systems. Contact your local ABB Sales Office.
Lubricants
The amount of grease per each lubrication interval WARNING
stated in the table should be doubled if an automatic Do not mix different types of grease.
regreasing system is used. Incompatible lubricants may cause bearing
damage.
If 2-pole motors are being automatically regreased, the
note (NOTE!) concerning lubricant recommendations When regreasing, use only special ball bearing grease
given for 2-pole motors in the chapter Lubricants shall be with the following properties:
followed. - good quality grease with lithium complex soap and with
mineral- or PAO-oil
- base oil viscosity 100-160 cST at 40°C
- consistency NLGI grade 1.5 - 3 *)
- temperature range -30°C - +120°C, continuously.

*) For vertical mounted motors or in hot conditions a

stiffer NLGI grade is recommended.

8 ABB / Low Voltage Motors / Manual 11-2002

Grease with the correct properties is available from all The following grease can be used:
major lubricant manufacturers.
• FAG L69 (polyurea base)
Admixtures are recommended, but a written guarantee • Klüber Klüber quiet BH 72-102 (polyurea base)
must be obtained from the lubricant manufacturer • SKF LGHP2 (polyurea base)
especially concerning EP admixtures, that admixtures
do not damage bearings or the properties of lubricants at If other lubricants are used, check with the manufacturer
the operating temperature range. that the qualities correspond to those of the above
mentioned lubricants, or if the compatibility of the
WARNING lubricant is uncertain, contact your local ABB Sales
Lubricants containing EP admixtures are not Office.
recommended in high bearing temperatures in
frame sizes 280 to 400. Frequency converter drives
Higher speed operation, e.g. in frequency converter
applications, or lower speed with heavy load will require
If the ambient temperature is below -25°C or above shorter lubrication intervals. Consult your local ABB
+55°C, or bearing temperature is above 110°C, consult Sales Office in such cases.
ABB Sales Office regarding suitable grease.
Typically a doubling of speed will require a reduction of
The following high performance grease can be used lubrication intervals to approx. 40 % of values tabulated
above.
• Esso Unirex N2, N3 or S2 (lithium complex base)
• Mobil Mobilith SHC 100 (lithium complex base)
• Shell Albida EMS 2 (lithium complex base) WARNING
• SKF LGHQ 3 (lithium complex base) The constructional maximum speed of the motor
• Klüber Klüberplex BEM 41-132 (special lithium must not be exceeded.
base)
Suitability of bearings for high speed operation must be
• FAG Arcanol TEMP90 (calsium polyurea base)
checked.
• FAG Arcanol TEMP110 (lithium complex base)

Lubrication intervals for other grease fullfilling the Spare parts

required properties, contact your local ABB Sales When ordering spare parts, the full type designation and
Office. product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
Lubrication intervals and amounts, 2-pole,
number, this should also be given.
IEC frame sizes 280 and 400
Frame Amount 3600 3000 Rewinding
size of grease r/min r/min
g/bearing
Rewinding should always be carried out by qualified
Ball bearings
repair shops.
Lubrication intervals in duty hours
280 M2B*, M2C*, M3B* 35 2000 3500
315 M2B*, M2C*, M3B* 35 2000 3500 Smoke venting and other special motors should not be
355 M2B*, M2C* 45 1200 2000 rewound without first contacting ABB.
355 M3B* 35 1200 2000
400 M2B*, M2C* 45 1200 2000
400 M3B* 40 1000 1600
5. Environmental requirements
Roller bearings
Lubrication intervals in duty hours
280 M2B*, M2C*, M3B* 35 1000 1800
Noise levels
315 M2B*, M2C*, M3B* 35 1000 1800
355 M2B*, M2C* 45 600 1000 Most of our motors have a sound pressure level not
355 M3B* 35 600 1000 exceeding 82 dB(A) refer to 50 Hz sinusoidal supply
400 M2B*, M2C* 45 600 1000 conditions, tolerance ± 3 dB(A).
400 M3B* 40 500 800

Values for specific machines can be found in the

NOTE! relevant product catalogues.
Always use high speed grease for high speed machines
and some other models, e.g. M2BA 355 and 400 2-pole For sound pressure levels for 60 Hz sinusoidal supply
machines, where the speed factor is higher than 400 000 and with non-sinusoidal supplies, contact ABB Sales
(calculated as Dm x n where Dm = average bearing Office.
diameter, mm; n = rotational speed, r/min).
Sound pressure levels for all machines having separate
cooling systems and for series M2F*/M3F*, M2L*/M3L*,
M2R*/M3R*, and M2BJ/M2LJ are indicated in separate
Manuals.

ABB / Low Voltage Motors / Manual 11-2002 9

These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please contact
the nearest ABB Sales Office.

Motor trouble shooting chart

Your motor service and any trouble shooting must be handled by qualified persons with proper tools and equipment.

TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor
rating plate and load factor.
Improper line connections Check connections with diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is
switch closed. Check for loose wiring connections. Also,
ensure that all control contacts are closed.
Mechanical failure Check to see if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end bells, locate with test lamp.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult manufacturer.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained.
Check connection.
Open circuit Fuses blown, check overload relay, stator and push
buttons.
Motor runs and then Power failure Check for loose connections to line, fuses and
dies down control.
Motor does not come Not applied properly Consult supplier for proper type.
up to speed Voltage too low at motor terminals Use higher voltage or transformer terminals or
because of line drop reduce load. Check connections. Check conductors
for proper size.
Starting load too high Check load motor is supposes to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Adequate wire size.
high amp Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while Overload Reduce load.
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous stream
clogged with dirt and prevent proper of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well
connected.
Grounded coil Locate and repair.
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.

10 ABB / Low Voltage Motors / Manual 11-2002

 TROUBLE CAUSE WHAT TO DO
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor
rotor and coupling
(half key – full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing fan cover Remove interference.
Fan striking insulation Clear fan.
Motor loose on bedplate Tighten holding bolts.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
Hot bearings general Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Hot bearings ball Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in
contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be
more than 1/2 filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing thoroughly.

ABB / Low Voltage Motors / Manual 11-2002 11

 Figure 1. Connection diagram
Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio

Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figur 2. Remdrift
Kuva 2. Hihnakäyttö

70 ABB / Low Voltage Motors / Manual 11-2002

 Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshälften und
Riemenscheiben
Figure 3. Montage des demi-accouplements et des
poulies
Figura 3. Montaje de mitades de acoplamiento y
poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus

ABB / Low Voltage Motors / Manual 11-2002 71