Certified that this 3 phase inductionmotor has passed all the routine test as perIS/IEC 60034-1 and other relevent standards andfound O.K.

Frame ____________________

Motor Sr. No. ______________

HP___________________ VOLT______________

EFF. CLASS____________ M. TYPE____________

Tested by : for ABB India Limited

Date :

ABB INDIA LTD.Factory : 32, Industrial Area, N.I.T. Faridabad-121 001

(Haryana) INDIA

INSP F03C

3G1J1_ _ _ 000 _ _ _ _ _ _ _

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Low Voltage MotorsInstallation, operation and maintenance manualContents Page1. General ................................................................................... 4

1.1 Validity ................................................................................. 42. Installation ................................................................................. 5

2.1 Putting into service (standing) ......................................... 52.1.1 Reception check ...................................................... 52.1.2 Insulation resistance check ................................... 52.1.3 Direct-on-line or star/delta starting ....................... 62.1.4 Terminals and direction of rotation ........................ 6

2.2 Handling .............................................................................. 72.2.1 Storage ...................................................................... 72.2.2 Transportation .......................................................... 72.2.3 Lifting ......................................................................... 72.2.4 Machine weights ..................................................... 8

2.3 Installation .......................................................................... 82.3.1 Cooling ....................................................................... 82.3.2 Foundation ................................................................ 92.3.3 Alignment ................................................................ 102.3.4 Slide rails and belt drives ..................................... 10

2.4 Connection ....................................................................... 102.4.1 Connection for variable speed drive ................... 11

2.5 Balancing .......................................................................... 123. Operating ............................................................................... 13

3.1 Use ................................................................................. 133.1.1 Operating conditions ............................................. 13

3.2 Safety considerations .................................................... 133.2.1 Points to observe ................................................... 13

3.3 Assembly and dismantling ............................................. 133.3.1 General ................................................................... 133.3.2 Bearings .................................................................. 143.3.3 Fitting coupling halves and pulleys ..................... 14

4. Maintenance .......................................................................... 144.1 Maintenance and lubrication .......................................... 14

4.1.1 General inspection ................................................ 144.1.2 Lubrication .............................................................. 154.1.3 Machines with permanently greased bearings . 154.1.4 Motors with regreasing nipples ........................... 164.1.5 Lubrication intervals and amounts ...................... 184.1.6 Lubricants ............................................................... 194.1.7 Frequency converter drives ................................ 204.1.8 Spare parts ............................................................. 214.1.9 Rewinding ............................................................... 21

5. Environmental requirements .......................................... 215.1 Noise levels .................................................................... 21

6. Troubleshooting ................................................................ 22

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Marketing Offices :North14, Mathura Road, Faridabad - 121003Tel. : +91 129 - 2275592, 2279627Fax : +91 129 - 2275019ChandigarhABB India Ltd.SCO-13, 14, 15, 3rd Floor, Sec.34ATel. : +91 172 2606375Fax : +91 172 2601618JaipurTel. : +91 141 2744024Fax : +91 141 2744027LucknowTel. : +91 522 2209436Fax : +91 522 2209478LudhianaTel. : +91 161 5082395Fax : +91 161 5082396DehradunTel. : +91 135 2760654Fax : +91 135 2760655EastABB India Ltd.Omega Building, 17th FloorBengal Intelligent Park, Block EP & GPSector-V, Salt Lake City,Kolkatta-700091Tel. : +91 9748419377Raipur4th & 5th Floor, Maruti HeightsAamanaka, G.E. RoadRaipur - 492 099Tel. : +91 771 4701016-18Fax : +91 771 4701019BhubaneshwarTel. : +91 674 2541062Fax : +91 674 2540985JamshedpurTel. : +91 657 2224016Fax : +91 674 2540985GuwahatiTel. : +91 9435731532WestMumbaiABB HouseDr. S.B. Path, Ballard EstateMumbai - 400 038Tel. : +91 22 56318231-39Fax : +91 22 56318276-77

BhopalABB India Ltd.Plot No. 34, Sector-A,Next to Bhopal Medical Centre,Indrapuri, Raisen Road,Bhopal - 462023Tel. : +91 755 6463601-08Fax : +91 755 2550397PuneTel. : +91 20 25881503-06Fax : +91 20 56016255VadodaraTel. : +91 265 2642141-42Fax : +91 265 2638911AhemadabadTel. : +91 79 22871478NagpurTel. : +91 9822737622IndoreTel. : +91 9981123166SouthEmbassy Star, 1st Floor,No. 8, Place Road, Vasanth Nagar,Bangalore - 560 052Tel. : +91 80 22949779/815Fax : +91 80 22949808ChennaiCentury PlazaNo. 3C, 3D, 3F, 3rd Floor561/562, Anna Salai, TeynampetChennai - 600 018Tel. : +91 44 27340201 - 203Fax : +91 44 24340282CoimbatoreTel. : +91 422 2313415Fax : +91 422 2313415HyderabadTel. : +91 40 27906736, 13, 14, 15Fax : +91 40 27906648KochiTel. : +91 484 3942600Resident Manager :Tel. : +91 94471 37264VisakhapatnamTel. : +91 891 2538188

1. GeneralNOTE!These instructions must be followed to ensure safe andproper installation, operation and maintenance of themotor. They should be brought to the attention of anyonewho installs, operates or maintains this equipment.Ignoring the instruction may invalidate the warranty.

1.1 Validity

The instructions are valid for the following ABB electrical

machine types, in both motor and generator operation.

series HX*, MT*, MBT*, MXMA,

series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*, M2F*/M3F*,

M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,

M2V*/M3V*

in frame sizes 71 - 250.

There is a separate manual for e.g. Ex motors ‘Low voltage

motors for hazardous areas: Installation, operation and

maintenance Manual’ (Low Voltage Motors/Manual for

Ex-motors).

Additional information is required for some machine types

due to special application and/or design

considerations. Additional information is available for the

following motors:

– roller table motors

– water-cooled motors

– open drip proof motors

– smoke venting motors

– brake motors

– permanent magnet motors

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2. Installation2.1 Putting into service (starting)2.1.1 Reception checkImmediately upon receipt check the machine for externaldamage and if found, inform the forwarding agent withoutdelay.

Check all rating plate data, especially voltage and windingconnection (star or delta). The type of bearing is specified on the rating plate of all motors except the smallestframe sizes.

Remove transport locking if employed.Turn shaft by handto check free rotation. Do not exceed permissibleloading values of bearings stated in the productcatalogue.

Motors equipped with roller bearings: Running the motorwith no radial force applied to the shaft may damage theroller bearing.

Motors equipped with angular contact bearing : Runningthe motor with no axial force applied in the right directionto the shaft may damage the angular contact bearing.

Motors equipped with regreasing nipples: When startingthe motor for the first time, or after long storage of themotor, apply the specified quantity of grease until greaseis forced out of the grease outlet. For details see section“Manual lubrication” on page 16.

2.1.2 Insulation resistance checkMeasure insulation resistance before commissioningand when winding dampness is suspected.

Resistance, measured at 25°C, shall exceed thereference value, i.e. 10 M ohm (measured with 500 V dcMegger)

WARNINGWindings should be discharged immediately aftermeasurement to avoid risk of electric shock.

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Insulation resistance reference value is halved for each 20°Crise in ambient temperature.If the reference resistance value is not attained, the winding istoo damp and must be oven dried. Oven temperature shouldbe 90°C for 12-16 hours followed by 105°C for 6-8 hours.Drain hole plugs, if fitted, must be removed and closingvalve, if fitted, must be opened during heating.Windings drenched in seawater normally need to berewound.

2.1.3 Direct-on-line or star/delta startingThe terminal box on standard single speed machinesnormally contains 6 winding terminals and at least oneearth terminal.Earthing must be carr ied out according to localregulations before the machine is connected to the supplyvoltage.The voltage and connection are stamped on the rating plate.

Direct-on-line starting (DOL):Y or D winding connections may be used.e.g. 660 VY, 380 VD indicates Y-connection for 660 V andD-connection for 380 V.

Star/Delta starting (Y/D):The supply voltage must be equal to the rated voltage ofthe machine in D-connection.Remove all connection links from the terminal block.For two-speed, single phase and special machines,supply connection must follow the instructions inside theterminal box.If direct-on-line starting lasts for more than 10 seconds orY/D starting more than 30 seconds, consult ABB Sales Officeor see the publication ‘The Motor Guide’ (also available onthe internet on www.abb.com/ motors & drives).

2.1.4 Terminals and direction of rotationDirection of rotation is clockwise when viewing the shaftface at the machine drive end, when the line phasesequence L1, L2, L3 is connected to the terminals asshown in the figure 1.

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To alter the direction of rotation, interchange theconnection of any two line cables.If the machine has a uni-directional fan, ensure thatthe direction of rotation is according to the arrowmarked on the machine.

2.2 Handling2.2.1 StorageThe machine should always be stored indoors, in dry,vibration free and dust free conditions.Unprotected machined surfaces (shaft-ends andflanges) should be protected with anti-corrosivetreatment.It is recommended that shafts be rotated periodicallyby hand to prevent grease migration.Anti condensation heaters, if fitted, should preferablybe energised.The characteristics of electrolytic capacitors, if fittedto single-phase motors, wil l require “reforming”following periods of storage exceeding 1-2 years.Contact ABB Sales Office for details.

2.2.2 TransportationMachines fitted with cylindrical-roller and/or angularcontact bearings must be fitted with locking devicesduring transport.

2.2.3 LiftingLift the motor using the lifting lugs only, if not otherwisestated in the separate lifting instruction.The center of gravity of motors with the same framemay vary due to di f ferent outputs, mount ingarrangements and auxiliary equipment.Check that eyebolts or the lifting lugs integrated withthe motor frame are undamaged before l i f t ing.Damaged lifting lugs must not be used.Lifting eyebolts must be tightened before lifting. Ifneeded the position of the eyebolt must be adjustedwith suitable washers.

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Ensure that proper lifting equipment is used and thatthe sizes of the hooks are suitable for the lifting lugs.Care must be taken not to damage auxiliary equipmentand cables attached to the motor.

2.2.4 Machine weightsTotal machine weight can vary within the same framesize (center height) depending on different output,mounting arrangements and added features. Thefollowing table shows estimated maximum weightsfor machines in their basic versions as a function offrame material.The actual weight of all our motors is stated on therating plate except the smallest frame sizes.

2.3 Installation2.3.1 CoolingNormal ambient temperatures should not exceed 40°C(marine standard +45 or +50°C) i f standardperformance is to be achieved. Check that the motorhas suff ic ient air f low. Ensure that no nearbyequipment, surfaces or direct sunshine, radiateadditional heat to the motor. For more information

Framesize

Cast IronWeight Kg.

56 -63 -71 1380 2090 30100 40112 50132 90160 175180 250200 310225 400250 550

Table 1

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about higher ambient temperatures and cooling, see“the Motor Guide” or contact ABB Sales Office.

2.3.2 FoundationThe purchaser bears full responsibility for preparationof the foundation.Metal foundations should be painted to avoid corrosion.Foundations must be even, and sufficiently rigid towithstand possible short circuit forces. They shall bedimensioned as to avoid the occurrence of vibrationdue to resonance.

Before mounting the motor, the foundation surface forthe shims or for the feet must be clean from thick paint,paint drops and dirt. Then it should be checked inorder to discover any height differences between theindividual foot locations. Also, the smoothness withineach footpr int area has to be checked. Therequirements are noted in the figure below.

Foundation studsBolt the foundation studs to the feet of the motor andplace a 1-to-2 mm shim between the stud and thefeet. Align the motor directly using appropriate means.Grout the studs with concrete, check alignment anddrill holes for locating pins.

Drain holesAlways check that open drain holes face downward.In extremely dusty environments, all drain holesshould be closed.

Note! Heightdifference shall notexceed ± 0, 1 mmreffered to any othermotor foot location

Foot location

Ruler

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2.3.3 AlignmentCorrect alignment is essential to avoid bearing failures,vibrations and possible fractured shaft extensions.

2.3.4 Slide rails and belt drives– Fasten the machine to the slide rails as shown in

figure 2.– Place the slide rails horizontally on the same level.– Check that the machine shaft is parallel with driven,

or driving, shaft.– Any belt must be tensioned according to the

supplier’s instructions.

WARNINGExcessive belt tension will damage bearings and cancause shaft breakage.

Do not exceed the maximum belt forces (i.e. radialbearing loading) stated in the relevant productcatalogues.

2.4 ConnectionNormal machine design has the terminal box on topwith cable entry possible from both sides. Somemachines are available with top mounted terminalboxes rotatable 4 x 90°, and some with side mountedterminal boxes.Availability of these solutions is described in theproduct catalogues.Unused cable entries must be closed.As well as main winding and earthing terminals, theterminal box can also contain connect ions forthermistors, standstill heating elements, bimetallic,switches, or PT 100 resistance elements.

WARNINGVoltage may be connected at standstill inside theterminal box for heating elements or direct windingheating.

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Connection diagrams for auxiliary elements are foundinside the terminal box cover or in additional labelson the frame of the machine.

WARNINGThe capacitor in single-phase motors can retain acharge that appears across the motor terminals, evenwhen the motor has reached standstill.

2.4.1 Connection for variable speed driveVariable speed drives cause higher voltage stressesthan the sinusoidal supply on the winding of the motorand may cause high frequency shaft voltages andbearing currents. Therefore the winding and thebearing insulation of the motor as well as the filter atthe converter output must be dimensioned accordingto “Selection rules for VSD applications/Insulation”(3GZF500930-2), available on request from ABB.

In variable speed drives the motor (Pn > 30 kW) mustbe cabled by using shielded symmetrical cables andcable glands providing 360° bonding (also called EMCglands). More information can be found in ABB’smanual “Grounding and cabling of the drive system”(3AFY61201998).

In frequency converter applications motor frameexternal earthing must be used for equalising thepotential between the motor frame and the drivenmachine, unless the two machines are mounted onthe same metallic base.

For motor frame sizes above IEC 280, use 0.75 x 70mm flat conductor or at least two 50 mm2 roundconductors. The distance of the round conductors mustbe at least 150 mm from each other.

This arrangement has no electrical safety function;the purpose is to equalise the potentials. When themotor and the gearbox are mounted on a commonsteel fundament, no potential equalisation is required.

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To comply with EMC-requirements, use only cables andconnectors approved for this purpose. (See instructionfor frequency converters.)

WARNINGThe maximum operating temperature of the grease andbearings must not be exceeded.

2.5 BalancingThe rotor of the machine is dynamically balanced.

As standard, balancing has been carried out using halfkey, and the shaft is marked with a RED tape, with thetext “Balanced with half key”. In case of motors deliveredwithout any tape defining the type of balancing, thesemotors are also balanced with half key.

To avoid vibration the coupling-half or pulley must bebalanced with half key after the keyway has beenmachined.

In the event of balancing with full key the shaft is markedwith a YELLOW tape, with the text Balanced with fullkey”.

In case balancing without key, the shaft is marked witha BLUE tape, with the text “Balanced without key”.

Potential equalisation

>150 mm0.75 mm

70 mm

min 50 mm2Driven machinery

U1V1

W 1P E

3 ~ M

Plate/strip Cables/wires

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3. Operating3.1 Use3.1.1 Operating conditionsThe machines are intended for use in industrial driveapplications.Normal ambient temperature limits are -20° to +40°C.Maximum altitude 1000 m above sea level.

3.2 Safety considerationsThe machine is intended for installation and use byqualif ied personnel, famil iar with relevant safetyrequirements.Safety equipment necessary for the prevention ofaccidents at the installation and operating site must beprovided in accordance with the local regulations.

WARNINGSmall motors with supply current directly switched bythermally sensitive switches can start automatically.

3.2.1 Points to observe1. Do not use the machine to step on.2. The temperature of the outer casing of the machine

may be hot to the touch during normal operation.3. Some special machine appl icat ions require

special instructions (e.g. using frequency convertersupplies).

4. Lifting lugs must only be used for lifting the motor.They must not be used to lift the motor when it isattached to other equipment.

3.3 Assembly and dismantling3.3.1 GeneralDismantl ing and assembly of machines mustbe carried out by qualif ied personnel using onlysuitable tools and working methods. Al l repairs

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must be carr ied out according to the standardIEC-60079-19.

3.3.2 BearingsSpecial care should be taken with the bearings. Thesemust be removed using pullers and fitted by heating orusing special tools for the purpose.How to replace bearings is described in detail in a separateinstruction leaflet available from ABB Sales Office.

3.3.3 Fitting coupling halves and pulleysCoupling halves and pulleys must be fitted using suitableequipment and tools that do not damage the bearings.Never fit a coupling half or pulley by hammering intoplace or remove it using a lever pressed against thebody of the machine.Mounting accuracy of coupling half :check that the clearance b is less than 0.05 mm andthat the difference a1 to a2 is also less than 0.05 mm.See figure 3.

4. Maintenance4.1 Maintenance and lubrication4.1.1 General inspection– Inspect the machine at regular intervals.– Keep the machine clean and ensure free ventilation

airflow.– Check the condition of shaft seals (e.g. V-ring) and

replace if necessary.– Check the condition of connections and mounting

and assembly bolts.– Check the bearing condition by listening for unusual

noise, vibration measurement, bearing temperature,inspection of spent grease or SPM bearing monitoring.

* When changes of condit ion occur,dismantle the machine, check the partsand replace if necessary.

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4.1.2 Lubrication

WARNINGBeware of all rotating parts.

WARNINGGrease can cause skin i r r i tat ion and eyeinf lammation. Fol low al l safety precaut ionsspecified by the manufacturer.

4.1.3 Machines with permanently greased bearingsBearings are usually permanently greased bearingsof either Z or 2Z types.

Bearing types are specified in the respective productcatalogues and on the rating plate of all our motorsexcept smaller frame sizes.

As a guide, adequate lubrication for sizes up to 200can be achieved for the following duration, accordingto L1 (i.e. that 99 % of the motors are sure to make theinterval time) at ambient temperature of 25°C. Forduties with ambient temperatures higher than 25°C,see the respective product catalogue.

Frame size Poles Duty hours

71-80 2-8 for life90-112 2-8 40 000132 2-8 40 000160 2-8 40 000180 2-8 40 000200 2 27 000200 4 40 000

Table 3

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Depending on application and load conditions, seeapplicable product catalogue.

Hours of operation for vertical motors are half of theabove values.

Motors with roller bearings have considerably shortergrease l ife. For continuous operation regreasingnipples should be considered.

4.1.4 Motors with regreasing nipplesLubrication information plate and general lubricationadvice

If the machine is fitted with a lubrication informationplate, follow the given values.

On the lubrication information plate, regreasing intervalswith regard to mounting, ambient temperature andspeed of rotation can be defined.

During the first start or after a bearing lubrication it mayappear a temporary temperature rise, appr. 10-20hours. ABB policy is to have reliability as a vital issue inbearing lubrication intervals. That is why we follow theL1-principle.

A. Manual lubricationRegreasing while motor is running

– Remove grease outlet plug or open closing valve iffitted.

– Be sure that the lubrication channel is open.

– Press the specified amount of grease into thebearing.

– Let the motor run 1-2 hours to ensure that all excessgrease is forced out of the bearing. Close thegrease outlet plug or closing valve if fitted.

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Regreasing while motor is at a standstill

Regrease motors while running. If this is not possible,lubrication can be carried out while the machine is ata standstill.

– In this case, use only half the quantity of grease,then run the motor for a few minutes at fullspeed.

– When the motor has stopped, press the rest ofthe speci f ied amount of grease into thebearing.

– After 1-2 running hours close the grease outletplug or closing valve if fitted.

B. Automatic lubricationThe grease outlet plug must be removed permanentlywith automatic lubrication or open closing valve iffitted.

Some motors may be equipped with a collector for oldgrease. Follow the special instructions given for theequipment.

We recommend only the use of electromechanicalsystems. Contact your local ABB Sales Office.

The amount of grease per each lubrication intervalstated in the tables 4-5 should be doubled if anautomatic regreasing system is used.

If 2-pole motors are being automatically regreased,the note (NOTE!) concerning lubr icantrecommendations given for 2-pole motors in thechapter Lubricants shall be followed.

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112 10 10000 13000 18000 21000 25000 28000

132 15 9000 11000 17000 19000 23000 26500

160 25 7000 9500 14000 17000 21000 24000

180 30 6000 8000 13500 16000 20000 23000

200 40 4000 6000 11000 13000 17000 21000

225 50 3000 5000 10000 12500 16500 20000

250 60 2500 4000 9000 11500 15000 18000

Table 4

Frame Amount 3600 3000 1800 1500 1000 500-900size of grease r/min r/min r/min r/min r/min r/min

g/bearing

Ball bearingsLubrication intervals in duty hours

4.1.5 Lubrication intervals and amounts

160 25 3500 4500 7000 8500 10500 12000

180 30 3000 4000 7000 8000 10000 11500

200 40 2000 3000 5500 6500 8500 10500

225 50 1500 2500 5000 6000 8000 10000

250 60 1300 2200 4500 5700 7500 9000

Table 5

Factors influencing the lubrication intervalsLubrication intervals for vertical machines are half ofthe above values.

Frame Amount 3600 3000 1800 1500 1000 500-900size of grease r/min r/min r/min r/min r/min r/min

g/bearing

Roller bearingsLubrication intervals in duty hours

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The lubricat ion intervals are based on bearingoperating temperature 80°C (ambient temperature ofabout + 25°). Note! An increase in the ambienttemperature raises the temperature of the bearingscorrespondingly. The values should be halved for 15°Cincrease in bearing temperature and may be doubledfor 15°C decrease in bearing temperature.

WARNINGThe maximum operating temperature of the greaseand bearings must not be exceeded.

4.1.6 Lubricants

WARNINGDo not mix different types of grease.Incompatible lubricants may cause bearing damage.

When regreasing, use only special ball bearing greasewith the following properties:– 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 end of scale is recommended.Grease with the correct properties is available fromall major lubricant manufacturers.Admixtures are recommended, but a written guaranteemust be obtained from the lubricant manufacturerespecially concerning EP admixtures, that admixturesdo not damage bearings or the properties of lubricantsat the operating temperature range.

WARNINGLubricants containing EP admixtures are notrecommended in high bearing temperatures in framesizes 280 to 450.

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If the ambient temperature is below -25°C or above+55°C, or bearing temperature is above 110°C, consultABB Sales Office regarding suitable grease.The following high performance grease can be used– Esso Unirex N2, N3 or S2 (lithium complex base)– Mobil Mobilith SHC 100 (lithium complex base)– Shell Albida EMS 2 (lithium complex base)– SKF LGHQ 3 (lithium complex base)– Klüber Varilub PKS2

(special lithium base)– FAG Arcanol TEMP110 (lithium complex base)– IOC Servoplex LC3 (lithium complex base)Lubrication intervals for other grease fullfilling therequired properties, contact your local ABB SalesOffice.

NOTE!Always use high speed grease for high speed machinesand some other models, e.g. M2 BA 355 and 400 2-polemachines, where the speed factor is higher than400 000 (calculated as Dm x n where Dm = averagebearing diameter, mm; n = rotational speed, r/min).

The following grease can be used:– FAG L69 (polyurea base)– Klüber Klüber quiet BH 72-102 (polyurea base)– Lubcon Turmogrease PU703 (polyurea base)

I f other lubr icants are used, check with themanufacturer that the qualities correspond to thoseof the above mentioned lubricants, or if the compatibilityof the lubricant is uncertain, contact your local ABBSales Office.

WARNINGEspecially in high rotational speed (the speedfactor > 400000) over greasing may cause damage.

4.1.7 Frequency converter drivesHigher speed operation, e.g. in frequency converterapplications, or lower speed with heavy load willrequire shorter lubrication intervals. Consult your localABB Sales Office in such cases.

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Typically a doubling of speed will require a reductionof lubrication intervals to approx. 40 % of valuestabulated above.

WARNINGThe constructional maximum speed of the motormust not be exceeded.

Suitability of bearings for high speed operation mustbe checked.

4.1.8 Spare partsWhen ordering spare parts, the full type designationand product code, as stated on the rating plate, mustbe specified. If the machine is stamped with a serialmanufacturing number, this should also be given.

For more information, please visit our web sitewww.abb.com/partsonline.

4.1.9 RewindingRewinding should always be carried out by qualifiedrepair shops.

Smoke venting and other special motors should notbe rewound without first contacting ABB.

5. Environmental requirements5.1 Noise levelsMost of our motors have a sound pressure level notexceeding 82 dB(A) refer to 50 Hz sinusoidal supplyconditions, tolerance 3 dB(A).

Values for specific machines can be found in therelevant product catalogues.

For sound pressure levels for 60 Hz sinusoidal supplyand with non-sinusoidal supplies, contact ABB SalesOffice.

Sound pressure levels for al l machines havingseparate cooling systems and for series M2F*/M3F*,M2L*/M3L*, M2R*/M3R*, M2BJ/M3BJ and M2LJ/M3LJare indicated in separate Manuals.

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6. TroubleshootingThese instructions do not cover all details or variations in equipmentnor provide for every possible condition to be met in connection withinstallation, operation or maintenance. Should additional informationrequired, please contact the nearest ABB Sales Office.

Motor troubleshooting chartYour motor service and any troubleshooting must be handled byqualified persons with proper tools and equipment.

TROUBLE CAUSE WHAT TO DOMotor 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 ratingplate and load factor.

Improper line Check connections with diagramconnections supplied with motor.Open circuit in winding Indicated by humming soundor control switch when switch is closed. Check

for loose wiring connections.Also, ensure that all controlcontacts are closed.

Mechanical failure Check to see if motor and driveturn freely. Check bearings andlubrication.

Short circuited stator Indicated by blown fuses. MotorPoor stator coil connection must be rewound. 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 Power failure Check for loose connections tothen dies down line, to fuses and to control.

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TROUBLE CAUSE WHAT TO DO

Motor does not Not applied properly Consult supplier for proper type.come up to speed Voltage too low at motor Use higher voltage or

terminals because of line transformer terminals or reducedrop load. Check connections. Check

conductors for proper size.Starting load too high Check load motor is supposed

to carry at start.Broken rotor bars or Look for cracks near the rings.loose rotor A new rotor may be required,

as repairs are usually temporary.Open primary circuit Locate fault with testing device

and repair.Motor takes too Excessive load Reduce load.long to accelerate Low voltage during start Check for high resistance.and/or draws Adequate wire size.high amp Defective squirrel cage Replace with new rotor.

rotorApplied voltage too low Get power company to

increase power tap.Wrong rotation Wrong sequence of Reverse connections at motor

phases or at switchboard.Motor overheats Overload Reduce load.while running Frame or bracket vents Open vent holes and checkunderloaded may be clogged with dirt for a continuous stream of air

and prevent proper from the motor.ventilation of motorMotor may have one Check to make sure that allphase open leads are well connected.Grounded coil Locate and repair.Unbalanced terminal Check for faulty leads,voltage connections and transformers.

Motor vibrates Motor misaligned Realign.Weak support Strengthen base.Coupling out of balance Balance coupling.Driven equipment Rebalance driven equipment.unbalancedDefective bearings Replace bearings.

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Bearings not in line Line up properly.Balancing weights shifted Rebalance motor.Contradiction between Rebalance coupling or motor.balancing of rotor andcoupling(half key-full key)Polyphase motor running Check for open circuit.single phaseExcessive 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 fitsor bearing.

Rotor unbalance Rebalance.Hot bearings ball 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.Insufficient grease Maintain proper quality of

grease in bearing.Deterioration of grease Remove old grease, washor lubricant contaminated bearings thoroughly in kerosene

and replace with new grease.Excess lubricant Reduce quantity of grease,

bearing should not be morethan 1/2 filled.

Overloaded bearing Check alignment, side andend thrust.

Broken ball or rough Replace bearing, first cleanraces housing thoroughly.

TROUBLE CAUSE WHAT TO DO

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Figure 2. Belt driveBild 2. RiementriebFigure 2. Glissières at entrainements à courroieFigura 2. Carriles tensores y correasFigura 2. Slitte tendicinghia e puleggeFigur 2. RemdriftKuva 3. Hihnakäytto

Figure 3. Mounting of half-coupling or pulleyBild 3. Anbau von Kupplungshälften und RiemenscheibenFigure 3. Montage des demi-accouplements et des pouliesFigura 3. Montaje de mitades de acoplamiento y poleasFigura 3. Montaggio di semigiunti e puleggeFigur 3. Montering av kopplinshalvor och drivskivorKuva 3. Kytkinpuolikkaan ja hihnapyörän asennus

Figure 1. Connection diagramBild 1. AnschlußdiagramFigure 1. ConnectionFigure 1. ConexionFigure 1. CollegamentoFigure 1. Anslutning diagramKuva 1. Kytkentäkaavio

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Service CentresEAST

WEST BENGALM/s. Kar Bros. ElectricP/6, Garfa East End Row,(Near SD-4 Bus Stand,Opposite Sushila Pharmacy)Kolkata - 700078Ph. : 033-24182339, M : 9433430378

M/s. Ma-kali Engineering WorksMr. Chayan Dey : 943367242434, 35/2, Dharanidhar Mullick Lane,Howrah - 711 101Ph. : 033-26415405, 26534727E-mail : enggmakali@yahoo.com

JHARKHANDM/s. Hindustan Electricals WorksMr. P. Chatterjee : 09431112665Gowala Para Road, Jugsalai,Jamshedpur - 831006Ph. : 0657-2293039E-mail : hewbkc@rediffmail.com

ASSAMM/s. Basar and SonsMr. Aurobindo Basar :09435112476 / 08876512474A K Azad Road, Rehabri,Guwahati - 781 008Ph. : 0361-2606618 / 2472096E-mail : basarandsons@gmail.com

ORISSAM/s. Pratap Electrical WorksMr. Pratap Mohanty :Plot No. A/2, Mancheswar IndustrialEstate 3-B, Bhubaneswar - 751010Mob.: 09437013324 / 09338223076Ph. : 0674-2582463E-mail : pratapelectricalworks@yahoo.com

CHATTISGARHM/s. Unique RewindersMr. Rajesh Pandya : 09827401142Ganjpara, Banstal, RaipurE-mail : uiquerewinders@rediffmail.com

M/s. Adak ElectricalsMr. Tarun Adak : 9830041267Halderpara, P.O. Jote, Shibrampur,Mahestala, Kolkata - 700 141, TinsukiaPh. : 033-24880091/1398/1632Fax : 033-24880220E-mail : tkadakceew@gmail.com

M/s. Pioneer ElectricalsMr. Bishwanath Ghosh38, Rani Rashmoni Path,City Centre, DurgapurPh. : 0343-2391035, Mob.: 9434757716

BIHARM/s. ENGICOMr. Ravindra : 09835012292 /9546730599North Chandmari Road, Kabari Gali,Kankarbagh, Patna - 800 020 (Bihar)E-mail : aewpatna@sancharnet.in

TINSUKIAM/s. Roy Electric WindersMr. Nabendu Roy : 09435135159Nau Pukhuri Road, Tinsukia - 786 125E-mail : royelectric@rediffmail.com

CHATTISGARHM/s. Parmar RewindersMr. Neeraj Parmar : 09826182352Light Industrial Area, Bhilai - 490026Ph.: 0788-2286339E-mail : parmarrewinders@yahoo.co.in

M/s. New Electrical Engineering WorksMr. Gopal Patel : 09826111666New City Plaza, Kotra Road,Raigarh - 496001Ph.: 07762-232126E-mail : dnew-electricals@yahoo.co.in

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WEST MUMBAIM/s. B R BrothersMr. Rikin Padia :09869006529 / 022-6715089Sabuwala Compound,Budhiya Jadhav Wadi,Opp. ETP Center,Near L & T Gate No. 7Saki Vihar Road, Powai,Mumbai - 400072E-mail : brbrothers1@rediffmail.com

AHMEDABADM/s. Amee ElectricalsMr. Devendra Yadav30, Madhav Estate,Nr. Jay Yogeshwar School,Sardar Patel Ring Road,Odhav, AhmedabadPh. : 079-30918720, Mob.: 9825270627

GANDHIDHAMM/s. Vishal ElectricalsMr. Deobhai : 09825226547Plot No. 330, Ward No. 12-BGandhidam - Kutch(Near Bank of Baroda)

AURANGABADM/s. Satish Electrical WorksMr. Dharmendra SoniM.I.D.C. Ranjangaon Road,Pandharpur, Waluj,Aurangabad - 431136Ph. : 0240-2554089, Mob. : 9850055388

NAGPURM/s. S.G. Engg.Mr. Sanjay KhandelwalS-65, M.I.D.C. NagpurPh. : 0240-232091Mob. : 9823063314

PUNEM/s. Excellent Elecrical CorporationMr. N A Mallik : 09822620408692/4B/4 Alka House, Opp. Century EnkaColony No. 2, Bhosari - Pune - 411 039E-mail : eec@pn2.vsnl.net.in

MUMBAIM/s. Gelstar Engg. ServicesMr. F. Mendonca : 09821167015EL 62, Electronic Zone,Mahape, TTC Ind. Area,Navi Mumbai - 400 710Ph. : 022-32985927 / 0923187633E-mail : gelstar31@rediffmail.com

JAMNAGARM/s. Excel Technical ServicesMr. Suni PatelPlot No. 508, GIDC Phase-ll, Near VishalChowk, Odhav Ringh Road Char,Jamnagar - 4Ph. : 0288-3205447, Mob.: 9825265447

KOLHAPURM/s. Transcoll ElectricalsMr. Ashok Gaikwad / GuravP.B. Road, Near Neelam Hotel, Opp.Maruti Motors Sai Service Station MIDC,Shirili, Kolhapur - 416 122Ph. : 0230-2468342, Mob. : 09823172341E-mail : trans_coil@yahoo.co.in

NAGPURM/s. Akshay Laxmi Electrical ServicesMr. Mandavkar : 0888884458213/67, Butibori MIDC, Nagpur - 440 010(Maharashtra)Mob. : 09881462241E-mail : akshay_laxmi@gmail.com

PUNEM/s. ACE Contractors & EngineersMr. L. FernandisBarne Building, Opp. Padumjee PaperMill, Thergaon, Chinchwad, Pune-411033Ph. : 020-27274038, Mob. : 9822330334

SURATM/s. Kerala Electric CompanyMr. Mohandass : 9327332244Plot No. 832/2A/13, Road No. 8, G.I.D.C.,Sachin - 394230E-mail : keralaelectric@yahoo.co.in

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SOUTH BANGALOREM/s. Rajamane & Hegde ServicesMr. ShudhakarWhitefield Road, Mahadevapura Post,Bangalore - 560048Ph. : 080-28524252, Mob: 9900592264

CHENNAIM/s. Ponni Electrical WorksMr. P. Santosh KumarNo. 31, Jawaharlal Nehru Main Road,Ekkatuthangal,Chennai - 97Ph. : 044-22320229, Mob : 9444028084

MANDAPETAM/s. Sri Lakshmi Electrical WorksMr. GovindarajD. No. 17-1-24, Alamuru Road,MandapetaPh. : 08855-232471, Mob : 9396536771

HYDERABADM/s. S.V. ElectricalsMr. V. SrinivasShed No. 1A, Type-III, APIIC,Industrial Estate, Prasanth Nagar,Kukatpally, Hyderabad - 500072Mob : 9848028003

CENTRAL INDOREM/s. C. NigudkarMr. C. Nigudkar43, Raoji Bazar Main Road Juni,Indore - 452001Ph. : 0731-2361773, Mob : 9826043248

RAIPURM/s. Unique RewindersMr. Balu BhaiGanj Para, Banstall,Raipur (C.G.)Ph. : 0771-2527395, Mob : 9827401142

RAIPURM/s. Parmar RewindersMr. Pammu Parmar3-B, light Industrial Area, Bhilai (C.G.),H.O. Station Road, RaipurPh. : 0778-2393592, Mob : 9826182352

KOCHIM/s. Genmot ElectricalsMr. K.G. Dileep Singh24/253, Vaikom Mohammed Basheer RoadKoonamthai East, Changampuzha NagarP.O. Kochi - 682 033Ph. : 0484-2540551, Mob: 9846202253

COIMBATOREM/s. Shiva Electrical ServiceMr. M. Parameswaran156, 4th Street GandhipuramCoimbatore-541 012Ph. : 0422-2482101, Mob : 9843248210

VIZAGM/s. S.V. Ramchandra Engineering WorksMr. RaviBlock-B, Plot No. 47,Autonagar, VisakhapatnamPh. : 0891-2516502, Mob : 9393126698

SECUNDERABADM/s. Shree Satguru Electrical WorksMr. SekharShop No. 41/A, Bansilalpet,Near Jabbar Building, Behind Bible House,Secunderabad - 500003Ph. : 040-27544446, Mob : 9885312554

BHOPALM/s. Bharat EnterprisesMr. M.Y. Khan2, Bhojpal Market, Chhola Road,Near Vishal Shadi Hall, Bhopal - 462001Ph. : 0755-2745833, Mob : 9425011833

RAIGARHM/s. New Electrical Engineering WorksMr. Gopal PatelNear City Plaza, Kotra Road,RaigarhPh. : 07762-232126, Mob : 9826111666

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MOHALIM/s. HSB Electro Hi-Tech Pvt. Ltd.Mr. I. P. SinghC-142, Indus. Area, Phase - VII,S.A.S. Nagar, Mohali - 160057Ph. : 0172-2360204, Mob: 9414046955

JAIPURM/s. SBR Saini Electric WorksMr. Satyanarayan Saini314, Behind Sangam Tower RotaryClub Marg, Charch Road, JaipurPh. : 0141-2360204, Mob : 9414046955

JAIPURM/s. Alpha EngineersMr. Anoop ParakhH-178, Malviya Industrial Area, Phase-ll,Jaipur - 302017Mob. : 9829009569E-mail : anoop_prakash@hotmail.com

UDAIPURM/s. Power RewindingMr. Dinesh ShrimaliG-36A, M.I.A. (Ext.) Road No. 12,Udaipur, RajasthanPh. : 0294-2491683, Mob : 9928082716

JODHPURM/s. Hari Om Electrical & RewindersMr. Balmukund GoyalNear Kumharon ka Mandir, 1st ‘B’ RoadSardarpur, Jodhpur - 342003Ph. : 0291-2611181, Mob : 9414247815

KANPURM/s. Narindra ElectricalMr. Amarjeet Singh21B-2, Dada Nagar, KanpurPh. : 0512-22133475Mob : 9235721531

LUDHIANAM/s. Jyoti ElectricalsMr. Manmohan SinghPlot No. 8A, Industrial Area A Extrn.Ghora Road, Ludhiana - 141003Ph. : 0161-5084201, Mob : 09876716964

KOTAM/s. New Shakti RewindersMr. Dilip Kr. Mewara111, Pliwal Compound Chhawani, KotaPh. : 0744-2362729Mob. : 9235721531 . HARIDWARM/s. United ElectricalsMr. D.K. Verma1, Ranipur More, P.O. Rishikul,Haridwar, U.A.Ph. : 0512-2213475Mob. : 9235721531

UDAIPURM/s. Shakti Electric & Engg. WorksMr. Dinesh SutarS-63, Road No. - 2, M.I.A. Madri,Udaipur - 313003Ph. : 0294-2490519, Mob : 9829064519

LUCKNOWM/s. Pratap ElectricalsMr. Amrit Singh562/32, Ramgarh Colony,Kanpur Road, LucknowPh. : 0522-2436979, Mob. : 9839279661

BHIWADIM/s. National Electric WorksMr. Parvez BaigPlot No. J-1160 B, RIICO Industrial Area,Bhiwadi, Distt. Alwar, RajasthanMob. : 9414224040E-mail : nationalelectricworks9@gmail.com

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SOUTH BANGALOREM/s. Rajamane & Hegde ServicesMr. ShudhakarWhitefield Road, Mahadevapura Post,Bangalore - 560048Ph. : 080-28524252Mob. : 9900592264

HUBLIM/s. Rajamane & Hegde ServicesMr. SuryavamshiUnit - ll, C-31, Industrial Estate,Gokul Road, Hubli - 580030, HubliPh. : 0836-22321158, Mob : 9900592267

THRISSURM/s. S.S. Electrical IndustriesMrs. Remy / Mr. SebiPadavarad, Ollur No. 493/A,Near KSEB Sub Station, Thrissur-68030Ph. : 0487-2352558Mob. : 9526825739

CHENNAIM/s. VG ElectricalsMr. Rajakumar134/1, Thilagar Street, Saligramam,Chennai - 600093Ph. : 044-23761973, Mob : 9841639994

COIMBATOREM/s. Siva Electrical ServicesMr. ParameshwaranNo. 1NA, Annayappa Counter Street, NearShabari Kitchen Service, ManikaranpalayamRoad, Nallapalayam, Coimbatore - 641006Ph. : 0422-2482101, Mob. : 9843248210

HYDERABADM/s. S.V. ElectricalsMr. V. SrinivasShed No. 1A, Type-III, APIIC,Industrial Estate, Prasanth Nagar,Kukatpally, Hyderabad - 500072Ph. : 040-23078001, Mob. : 9848028003

BANGALOREM/s. Kokatnur Electric Co.Mr. ArunNo. 50, Byaraveswara Industrial Estate,Andra Halli Main Road, Heggana Halli,Near Peenya ll Stage, Bangalore-560091Ph. : 080-28367532, Mob: 9986506453 / 52

COCHINM/s. ElectrocomMr. JosephNo. 29/2577-B, Poonithura,Near Pettah Jh., Cochin - 682038Ph. : 0484-2303103, Mob : 9847378066

CHENNAIM/s. Santhi EnterprisesMr. DevrajNo. 69, Mount Road, Ellis Road,Chennai - 600002Ph. : 044-43568430 / 28516330Mob. : 9840224866

PONDICHERRYM/s. VG ElectricalsMr. KumarNo. 157 A, 100 Feet Road, Next to HotelSunway Marapalam, PondicherryPh. : 044-23761973, Mob : 9843045559

MADURAIM/s. Jothi ElectricalsMr. EshwaranJothi Electrical Industries No. 2, RCStreet, Palangantham, Madurai - 3Ph. : 0452-2371763 / 6454333Mob : 9787761000 / 9842171763

HYDERABADM/s. Sri Sai Electrical WorksMr. MuralikrishnaNo. 25-40/31/2, East Anand Bagh,Malkajgiri, Hyderabad - 500072Ph. : 040-27242868, Mob : 9848072218

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MANDAPETAM/s. Sri Lakshmi Electrical WorksMr. GovindrajD. No. 17-1-24, Alamuru Road,MandapetaPh. : 08855-232471Mob : 9396536771 / 8978444999

VIJAYWADAM/s. Sri Venkata Krishan Electrical WorksMr. ShivaprasadD. No. 9-64-25, Syed Gulab Street,Kothapet, VijayawadaPh. : 0866-2567830Mob : 8885221689 / 9391854848

CENTRAL INDOREM/s. C. NigudkarMr. C. Nigudkar43, Raoji Bazar Main Road Juni,Indore - 452001Ph. : 0731-2361773, Mob : 9826043248E-mail : prabhat_nigudkar@yahoo.co.in

REWAM/s. Singh Electrical WorksPlot No. 57, Udyog Vihar,Chorahata Rewa, MPMr. Pankaj Singh : 9827520714E-mail : singh_ele@rediffmail.com

VISHAKHAPATNAMM/s. S.V. Ramchandra Engineering WorksMr. Krishna MohanBlock-B, Plot No. 47, Autonagar,VisakhapatnamPh. : 0891-2516502, Mob : 9441920165

BHOPALM/s. Ashok Electrical WorksMr. AshokMain Road, Misrod, Bhopal-462001,Ph. : 0755-4289245, Mob. : 9826399245E-mail : aew_bpl@yahoo.co.in