Basic Training

Basic Training
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Basic Training

Product catalog summary
Introduction
The document provides an extensive overview of electric motors, gear reducers, gearmotors, and AC & DC drives, focusing on their industrial and commercial applications. It begins with the history and principles of electric motors, emphasizing their significance in modern industry and the contributions of pioneers like Nikola Tesla.
General Motor Replacement Guidelines
This section highlights the importance of interchangeability and safety in motor replacement, emphasizing proper grounding and adherence to safety codes. Key factors for motor selection include nameplate data, mechanical characteristics, and electrical connections.
Major Motor Types
The document categorizes motors into AC single-phase, AC polyphase, and DC motors, describing the characteristics and applications of each type.
Mechanical Considerations
Details on enclosures, NEMA frame sizes, mounting types, and guidelines for belted applications are provided, stressing the importance of precise manufacturing for motor efficiency and longevity.
Electrical Characteristics and Connections
This section covers voltage, phase, current, frequency, horsepower, and other electrical parameters, discussing insulation classes, service factors, and the importance of proper wiring and motor starters.
Metric (IEC) Designations
IEC standards for enclosure protection, cooling, insulation, duty cycles, and mounting are explained, highlighting their global relevance.
Motor Maintenance
Guidelines for lubrication and maintenance intervals are provided to ensure optimal motor performance and longevity.
Common Motor Types and Typical Applications
Examples of AC and DC motor applications, such as elevator motors and industrial equipment, are discussed.
Gear Reducers and Gearmotors
The section explains different types of gear reducers and gearmotors, installation considerations, and maintenance practices.
Adjustable Speed Drives
Details on DC and AC drives, including encoders and motor/drive combinations, are provided, covering application factors and maintenance of electrical drives.
Engineering Data
Includes conversion tables and characteristics tables for temperature, mechanical, and electrical data.
Glossary
A glossary of terms is provided to aid understanding of technical jargon used throughout the document.
V-Belt Drives Overview
The document provides guidelines for the use of V-belt drives, emphasizing efficiency in torque transmission while minimizing bearing and shaft loads.
Key Guidelines
  • Sheave Diameter: Use the largest practical sheave diameter to reduce shaft stress and increase system efficiency.
  • Number of Belts: Use the fewest belts necessary to transmit required torque without slipping.
  • Sheave Location: Position sheaves close to support bearings to enhance bearing life.
  • Belt Tension: Maintain the lowest tension that prevents slipping, using a belt tension gauge for accuracy.
Technical Specifications
  • Sheave Rim Speed Formula: Shaft RPM x 3.14 x Sheave Diameter (in inches) / 12.
  • Belt Deflection: Proper deflection is calculated by dividing the belt span by 64, with force requirements detailed in Table 1.
Electrical Characteristics
  • Voltage and Frequency: Motors operate within 10% of nameplate voltage and 5% frequency variation.
  • Phase: Single-phase motors are common in residential and low-power applications, while three-phase motors are used in larger industrial settings.
  • Horsepower and Efficiency: Efficiency is a measure of useful work versus energy consumed, with formulas provided for calculating horsepower based on torque.
Additional Considerations
  • Insulation Class: Motors should be replaced with those of equal or higher insulation class to prevent premature failure.
  • Service Factor: Indicates overload capacity; replacement motors should match or exceed the original motor’s service factor.
  • Thermal Protection: Protectors prevent overheating and should not be bypassed.
  • Motor Starters: Include overload protection and may be full-voltage or reduced-voltage types.
Tables and Figures
Table 1 provides recommended sheave diameters, belt types, and numbers for various RPMs and horsepower ratings. Figures illustrate belt tensioning and deflection measurement techniques.
Motor Model Number Configuration
This section outlines the configuration of motor model numbers, detailing the significance of each position in the model number.
Frame and Enclosure Types
The document lists various frame sizes and types, including 48, 56, 143T, 145T, 182T, 184T, 213T, and 215T frames, and describes different enclosure types such as drip-proof, explosion-proof, fan-cooled, and weatherproof.
Motor Types and RPM
Different motor types are identified, including capacitor start, direct current, brushless DC, and three-phase motors.
IEC and NEMA Standards
The document compares IEC and NEMA standards, highlighting dimensional differences and protection indexes.
IEC Cooling, Insulation, and Duty Cycle Indexes
IEC designations for cooling (IC codes), insulation classes, and duty cycles are explained.
IEC Design Types and Mounting Designations
IEC Design N motors are compared to NEMA Design B, and IEC Design H to NEMA Design C.
Key Tables and Charts
The document includes tables comparing IEC and NEMA frame dimensions, horsepower ratings, and protection indexes.
Specifications and Maintenance
Motors, when properly selected and installed, can operate for many years with minimal maintenance.
Lubrication Procedure
Motors up to 10 HP are typically factory-lubricated for long-term operation under normal conditions without re-lubrication.
Relubrication Intervals Chart
The chart provides suggested relubrication intervals based on hours of service per year and motor HP range.
Motor Troubleshooting
Before performing service or maintenance, disconnect power and discharge all capacitors.
Common Motor Types and Applications
Different motor types are suited for various applications.
Gear Reducers and Gearmotors
The document provides detailed specifications and applications for various types of motors and gear reducers used in industrial and commercial settings.
Installation and Application Considerations
  • Mounting: Gear reducers are typically base-mounted, with various configurations available to suit application needs.
  • Output Speed and Torque: Key criteria for matching gear reducers to application requirements.
  • Overhung and Thrust Load: Considerations for bearing and shaft longevity, with specific calculations provided for overhung load.
  • Mechanical and Thermal Ratings: Define the maximum power transmission capabilities based on component strength and heat dissipation.
  • Service Factor: Adjusts reducer ratings relative to application load characteristics, critical for ensuring maximum reducer life.
Specifications and Procedures
The document discusses the specifications for gear reducers, emphasizing the importance of consulting manufacturers for input speeds under 900 RPM or above 3000 RPM.
Environmental Considerations
Gear reducers are designed for rugged use, but extreme heat and moisture can affect their longevity.
Service Factors
The document provides a table for service factor conversions based on duration of service and type of load.
Maintenance
Industrial gear reducers require minimal maintenance if filled with quality synthetic lubricant.
Adjustable Speed Drives
Adjustable speed drives allow for variable speed adjustments to match operating requirements.
DC and AC Drives
DC drives control motor speed by varying armature voltage, with types including SCR, regenerative SCR, and PWM drives.
Encoders and Integrated Motor/Drive Combinations
Encoders provide feedback for motion control systems, with rotary and linear types available.
AC Drive Application Factors
Key factors include torque requirements, speed control, and current capacity.
Drive Sizing and Power Supply
The document emphasizes the importance of sizing a drive based on the current required to provide the needed torque.
Control Complexity
Modern AC drives come with advanced features, including programmable functions and extensive input/output capabilities.
Environmental Factors
Drives are affected by heat, moisture, vibration, and dirt.
Motor Considerations
Pulse width modulated drives can produce voltage spikes that damage motor insulation.
Routine Maintenance
Routine maintenance includes checking for loose connections, cleaning heatsinks, and ensuring ventilation slots are clear.
Engineering Data
The document provides temperature conversion tables, electrical characteristics, and formulas for calculating amperes, kilowatts, and horsepower.
Glossary
A glossary of terms related to motors and drives is provided.
Specifications and Definitions
Includes definitions for terms like inch-pound, form factor, frame, frequency, full load amperes, horsepower, IEC, induction motor, insulation classes, and power factor.
Procedures and Testing
Includes high voltage tests, temperature tests, and thermal protector functions.
Components and Devices
Includes definitions for generators, inverters, rectifiers, relays, resistors, and transformers.
Motor Characteristics
Includes locked rotor current and torque, slip, speed regulation, and torque types.
Standards and Organizations
Includes NEMA, National Electric Code (NEC), and Underwriters Laboratories (UL).
Introduction
This document serves as a basic training manual for understanding the concepts and terminology associated with LEESON electric motors, gear drive products, and adjustable frequency drives.
Key Terminology
  • Vector Drive: An AC drive with enhanced processing capability for positioning accuracy and fast response to speed and torque changes.
  • Voltage: A unit of electromotive force that produces current in conductors.
  • Watt: The power required to maintain a current of 1 ampere at a pressure of one volt.
  • Winding: Refers to wrapping coils of copper wire around a core.
Important Information
This manual is intended for general introduction purposes only. Selection, application, and installation should be performed by qualified personnel.
Disclaimer
LEESON Electric disclaims any warranties or representations regarding the merchantability or fitness for a particular purpose of the goods sold.
Additional Resources
For more information, visit LEESON's website for downloadable literature, technical bulletins, and an interactive stock catalog.
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Catalog excerpts

Basic Training -1

INDUSTRIAL-DUTY & COMMERCIAL-DUTYElectric MotorsGear ReducersGearmotorsAC & DC Drives >

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Basic Training -4

XI. Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 XII. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Temperature Conversion Table Mechanical Characteristics Table Electrical Characteristics Table Fractional/Decimal/Millimeter Conversion VI. Metric (IEC) Designations . . . . . . . . . . . . . . . . . . . . . . .40 VII. Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 X. Adjustable Speed Drives . . . . . . . . . . . . . . . . . . . . . . . . .68 IEC Enclosure Protection Indexes IEC Cooling,...

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Basic Training -8

Electric motors are the versatile workhorses of industry. In many applica-tions, motors from a number of manufacturers can be used.Major motor manufacturers today make every effort to maximize interchangeability, mechanically and electrically, so that compromise does not interfere with reliability and safety standards. However, no manufacturer can be responsible for misapplication. If you are not certain of a replacement condition, contact a qualified motor distributor, sales office or service center. > Use safe practices when handling, lifting, installing, operating, andmaintaining motors and...

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Basic Training -9

Much of this information consists of standards defined by the NationalElectrical Manufacturers Association (NEMA). These standards are widely used throughout North America. In other parts of the world, the standards of the International Electrotechnical Commission (IEC) are most often used. > Nameplate data is the critical first step in determining motor replacement. Much of the information needed can generally be obtained from the name- plate. Record all nameplate information; it can save time and confusion. > Catalog number.ՕMotor model number. Frame. ՕType (classification varies from manufacturer...

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Basic Training -11

Alternating current (AC) induction motors are divided into two electricalcategories based on their power source single phase and polyphase (three phase). > Types of single-phase motors are distinguished mostly by the way they are started and the torque they develop. > motors have low starting torque, low cost, low efficiency,and no capacitors. There is no start switch. These motors are used on small direct drive fans and blowers found in homes. Shaded pole motors should not be used to replace other types of single-phase motors. > motorshave applications similar to shaded pole, except much higher...

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Basic Training -13

A heavy-duty polyphase motor with cast-iron frame. >

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Basic Training -15

DC motors can be operated from rectified alternating cur- rent of from low-voltage bat- tery or generator source.This is a low-voltage design,which includes external connection lugs for the input power.With the rear endshield removed, as in this view,the brush assemblies and commutator that form a DC motors elec- trical heart are clearly visible. > Speed reduction gearing is visible in this cutaway view of a parallel-shaft gearmotor.Shown is a small, sub-fractional horsepower gearmotor. -14- >

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Basic Training -16

Gearmotors may be either integral, meaning the gear reducer and motorshare a common shaft, or they may be created from a separate gear reducer and motor, coupled together. Integral gearmotors are common in sub-fractional horsepower sizes; separate reducers and motors are more often the case in fractional and integral horsepowers. For more on gear reducers and gearmotors, see Chapter IX. > A brakemotor is a pre-connected package of industrial-duty motor and fail- safe, stop-and-hold spring-set brake. In case of power failure, the brake sets, holding the load in position. Brakemotors are commonly...

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Basic Training -17

Totally Enclosed Non-Ventilated (TENV) > Totally Enclosed Fan Cooled (TEFC) motors have no vent openings.They are tightly enclosed to prevent the free exchange of air, but are not air tight. TENV motors have no cooling fan and rely on convection for cooling. They are suitable for use where exposed to dirt or dampness, but not for hazardous locations or applications having frequent hosedowns. motorsare the same as TENV except they have an external fan as an integral part of the motor to provide cooling by blowing air over the outside frame. Totally Enclosed Air Over motors are specifically designed...

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Basic Training -18

Class I (Gases, Vapors) Group AAcetylene Group B Butadiene, ethylene oxide, hydrogen, propylene oxideGroup C Acetaldehyde, cyclopropane, diethlether, ethylene, isopreneGroup D Acetone, acrylonitrile, ammonia, benzene, butane, ethylene dichloride, gasoline, hexane, methane, methanol, naphtha, propane, propylene, styrene, toluene, vinyl acetate, vinyl chloride, xylene Explosion Proof motors meet Under-writers Laboratories or CSA standards for use in the hazardous (explosive) locations shown by the UL/CSA label on the motor. The motor user must specify the explosion proof motor required. Locations...

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Basic Training -20

Contact FactoryContact Factory ATEX compliant motorsATEX compliant motors Class I Area ClassificationClass II Area Classification*Class I Area Classification Division 1 Explosion Proof/Zone 1 FlameproofDivision 2/Zone 2 Non-Sparking (Group C as noted), Sine wave Groups F & G, Sine waveor PWM poweror PWM power Explosion Proof - Class I, Group D(Group C as noted) Explosion Proof - Class I, Group DExplosion Proof - Class II, (Flammable Gases, Vapors or Mists)(Combustible Dusts)(Flammable Gases, Vapors or Mists) CODES TEMPERATURE CT4T4 O CT2AT2(280) CT2BT2(260)215 CT2DT2(215)200 CT3BT3(165) CT3CT3(160)...

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Basic Training -21

Frame numbers are not intended to indicate electrical characteristics suchas horsepower. However, as a frame number becomes higher so in general does the physical size of the motor and the horsepower. There are many motors of the same horsepower built in different frames. NEMA (National Electrical Manufacturers Association) frame size refers to mounting only and has no direct bearing on the motor body diameter.In any standard frame number designation there are either two or threenumbers. Typical examples are frame numbers 48, 56, 145, and 215. The frame number relates to the DӔ dimension (distance...

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.